# Bombardier415 MODEL CL-215-6811 (415) ALERT SERVICE BULLETIN
NACELLES/PYLONS 

# BOMBARDIER

INSPECTION OF THE BUSHINGS IN THE NACELLE UPPER STRUT ASSEMBLIES
1 . Planning Information 

### A. Compliance This Service Bulletin is Mandatory. The inspection task described in this Service Bulletin must be performed prior to May 30th, 2013. If bushing 8541 0265-1 05 is installed and can only be repaired and not replaced at the time of the inspection , then it must be replaced at the next scheduled 5000 hours maintenance check or at the next engine removal , which ever comes first. NOTE : This Service Bulletin is applicable only to aircraft in the condition as originally delivered by Canadair and/or Bombardier Aerospace or as subsequently modified by Canadair and/or Bombardier Aerospace Service Bulletin(s) . Prior to incorporation of this Service Bulletin, the status of any related systems or structural modification(s) introduced by Supplementary Type Approval (STA) or equivalent action must be examined for compatibility with the modifications and test procedures (if applicable) detailed in this Service Bulletin. B. Approval The technical content of this Service Bulletin has been approved under the authority of the Design Approval Organization No : DAO #93-Q-02 . C. Effectivity CL-215-6B11 (415) turboprop aircraft Serial Nos. 2001 to 2067. D. Reason Bushings 85410265-105 have been found installed on some in-service aircraft in lieu of 85410265-103 , bushing 85410265-1 05 is shorter than the -1 03 and is not an acceptable replacement and is not intended for use on Bombardier 415 nacelles. Page 1 of 14 April 10/12 ATA Ref: 54- 10 Service Bulletin 215-A4453E . Description 

# Bombardier 415 MODEL CL-2 15-68 11 (415) ALERT SERVICE BULLETIN

This Service Bulletin gives instructions to do the following:

- Inspect the bushing

- Replace the bushing if necessary

- Repair the bushing if replacement is not possible. F. Manpower We estimate that it will take one technician approximately 4 hours to complete the inspection instructions of this Service Bulletin. We estimate that it will take one technician approximately 4 hours to complete the replacement instructions of this Service Bulletin. We estimate that it will take one technician approximately 4 hours to complete the repair instructions of this Service Bulletin . G. Material Availability Kit No. 215K4453 is necessary to do this Service Bulletin. Information on price and delivery is available from your Bombardier Specialized and Amphibious Spares Representative. Bushing 85410265-103 and repair bushing C415-3902-001 are available through your Bombardier Specialized and Amphibious Spares Representative. H. Tool Availability The following tools (refer to PSP 211) are required to do this inspection:

- Nacelle mounted engine hoist and sling , 08-0116-5000 (or equivalent) OR

- Engine sling, 08-0112-4000 (or equivalent)

- Dynamometer or Load cell of a 2500 lbs capacity. I. Weight and Balance Not affected. J. Electrical Load Data Not affected. K. References For Bombardier Aerospace Reference only: (Not Supplied with Kit) Bombardier Aerospace Restriction and/or Special Instruction (RSI) C-3902, Revision NC . Related document: All Operator Message 54-40-00-007, dated Dec 13/11 . Page 2 of 14 April 10/12 ATA Ref: 54-10 Service Bulletin 215-A4453L. Publications Affected None. M. Related Service Bulletin None. 2. AccQmQ]ishment_lnstructio[ls 

# Bombardier 415 MODEL CL-2 15-681 1 (4 15) ALERT SERVICE BULLETIN

NOTES: 1. For this modification, it is assumed that standard maintenance and repair practices will be applied in accordance with applicable Product Support Publications (PSP). 2. For parts location, refer to the illustrations in this Service Bulletin. 3. If any deviation exists , contact your Amphibious Aircraft Technical Representative for further instructions. 4. This inspection is for both the LH and RH nacelle, and there are two bushings in each nacelle. A. Preparation WARNING: ENSURE PERSONNEL AND EQUIPMENT ARE CLEAR OF ALL HYDRAULICALLY OPERATED SYSTEMS PRIOR TO REMOVING AIRCRAFT ELECTRICAL POWER. (1) Isolate electrical power and observe all safety precautions (refer to PSP 492, Maintenance Manual , Chapter 24, ELECTRICAL POWER - MAINTENANCE PRACTICES). B. Access (1) Remove lower cowl panel assembly and forward upper cowl panel assembly, as per PSP 492, Maintenance Manual , Chapter 71 , POWER PLANT- ENGINE COWLINGMAINTENANCE PRACTICES. (2) On LH nacelle , remove access panels 412-1 , 412-2 , 412-3 , 412-4 , 412-5 , and 413-3 as per PSP 492 , Maintenance Manual , Chapter 6, ENGINE NACELLES- ACCESS PANELS. (3) On RH nacelle , remove access panels 422-1 , 422-2 , 422-3, 422-4, 422-5, and 423-3 as per PSP 492 , Maintenance Manual , Chapter 6, ENGINE NACELLES- ACCESS PANELS .

Page 3 of 14 April 10/12 ATA Ref: 54-10 Service Bulletin 215-A4453C_ Engine Support 

# Bombardier 415 MODEL CL-21 5-6811 ( 41 5) ALERT SERVI CE BULLETIN

The nacelle must be in the zero weight condition either by removing the engine from the nacel le (option 1) or by supporting the engine in the nacelle (option 2) as described below. CAUTION : ENSURE ENGINE SLING LIFT POINT IS POSITIONED TO BALANCE THE ENGINE AS CONFIGURED. USE EXTREME CAUTION WHEN SLINGING THE ENGINE TO AVOID DAMAGE TO THE HBV ELECTRICAL CONNECTOR AND FIRE/OVERHEAT SENSING ELEMENTS LOCATED IN NACELLE. 

### OPTION 1 -Engine is removed from Aircraft. Refer to Figure 1.1 NOTE: Use this option only if the engine is scheduled to be removed from the aircraft, if the engine is not scheduled to be removed from the aircraft, then use option 2 for the bushing inspection . (1) Attach sling to reduction gear box lifting brackets and to engine F flange lifting bracket, and remove the engine as shown in PSP 492, Maintenance Manual , Chapter 71 , POWER PLANT- TEAR DOWN/BUILD-UP- MAINTENANCE PRACTICES. 

### OPTION 2 - Engine is NOT removed from Aircraft. Refer to Figure 1.2 (2) Calculate total weight to be lifted by adding engine weight (1500 lbs) to weight of lifting equipment located under dynamometer or load cell . (3) Attach sling to reduction gear box lifting brackets and to engine F flange lifting bracket, as shown in PSP 492, Maintenance Manual, Chapter 71, POWER PLANT - TEAR DOWN/BUILD-UP - MAINTENANCE PRACTICES . (4) Slowly raise hoist until reading on dynamometer or load cell indicates total lifted weight to be± 50 lbs of calculated weight to be lifted. (5) Make sure the lifting equipment is locked in place and apply appropriate safety tags .

Page 4 of 14 April 10/12 ATA Ref: 54-10 Service Bulletin 215-A4453

# Bombardier 415 MODE L CL-2 15-68 1 1 (4 15) ALERT SERVICE BULLETIN
PART A - Inspection of the Bushing D. Inspection of the Nacelle Upper Strut Bushing Refer to Figure 2 Do the complete inspection on one strut assembly bushing before starting the other. (1) Remove the cotter pin and nut. (2) Remove and discard the PLI washer, and retain any washer that is installed between the PLI washer and the nut. NOTE: PLI (pre-load indicating) washers cannot be re-used and must be discarded once removed . (3) Remove the bolt 81812-8-30 and the countersunk washer. NOTES: 1 . Make sure that the strut does not move when the bolt is removed . 2. If the engine is in the zero weight condition , the bolt should remove with minimum resistance . (4) Measure the distance "A" as shown in the table on Figure 2 to determine the part number of the bushing installed . (5) If bushing 85410265-103 is installed, do the section PART A- cont'd, Installation of Bolt and PLI Washer, then continue with the inspection of the remaining bushings (both upper strut assemblies in both nacelles).

- or - (6) If bushing 85410265-105 is installed , do one of the following:

- PART B - Replacement of the Bushing

- PART C - Repair of the Bushing PART B - Replacement of the Bushing E. If bushing 85410265-105 is installed and bushing 85410265-103 is readily available , then replace the bushing , as follows : (1) Remove the bushing 85410265-105 and discard. (2) Check the bushing housing for wear limits, refer to PSP 492 , Chapter 54 , STRUT MOUNTS- INSPECTION/CHECK. (3) Install the new bushing 85410265-103, refer to PSP 498, Chapter 20.
Page 5 of 14 ATA Ref: 54-10 April 10/12 Service Bulletin 215-A4453

# Bombardier 415 MODE L CL-215-6811 (4 15) ALERT SERVI CE BULLETIN (4) If necessary, apply a brush nickel plate coating to bare metal of machined area at each end of the strut. Refer to PSP 498 , Chapter 20 . (5) Coat the bushing with Mastinox 6856H. (6) Continue with PART A- cont'd, Installation of Bolt and PLI Washer PART C - Repair of the Bushing F. If bushing 85410265-105 is installed and bushing 85410265-103 is not readily available , then do the repair, as follows: Refer to Figure 4 (1) Fabricate the bushing C415-3902-001 and rework as per PSP 497 , Chapter 51 , REPAIR MATERIALS - STANDARD PRACTICES . (a) Material is 4130 BAR , AMS-S-6758 , heat treat to 125-145 KSI per MIL-H-6875. (b) Finish is cadmium plate per 00-P-416 Class 1 , Type II. (c) Required dimension is .220 

### ± .01 0. (d) The inside diameter is to be parallel and concentric with the outside diameter within

.0005 total indicator reading . (e) Break sharp edges .005" to .015". (f) Do a magnetic particle inspection as per ASTM-E1444, PSP 496 Part 7. (g) The surface texture to be 125RHR per ANSI/ASME B46.1. (h) Identify (ink stamp) as per PSP 497 , Chapter 51 , IDENTIFICATION OF REPAIR PARTS AND ASSEMBLIES. (2) Install bushing C415-3902-001 wet and transition fit per PSP 498 , Chapter 20-53-00 , PLAIN BUSHING- ASSEMBLY. (3) Continue with PART A- cont'd, Installation of Bolt and PLI Washer

Page 6 of 14 April 10/12 ATA Ref: 54-10 Service Bulletin 215-A4453

# Bombardier 415 MODEL CL-215-6811 (4 15) ALERT SERVICE BULLETIN


### PART A - cont'd G . Installation of Bolt and PLI Washer Refer to Figure 2 and PSP 492 , Maintenance Manual, Chapter 54, STRUT MOUNTSREMOVAL/INSTALLATION , 

### Upper Strut- Installation. (1) Coat the bolt 81812-8-30 with Mastinox 6856H. (2) Install the countersunk washer and the bolt. (3) Before fitting the PLI washers, determine the necessary gap for the correct pre-load for each PLI washer as follows: NOTE: If the bolt and bushing have not been replaced or repaired , then use the retained washer, if applicable , that was removed as part of the PLI washer assembly. (a) For PLI washer, measure and establish the required gap as follows: 

### 1 Measure the protrusion of the shank of bolt 81812-8-30. 

### 2 If protrusion is more than 0.21 inch (5,33 millimetres), add an MS 20002-8 washer between the PLI washer and the nut. (4) Install the PLI washer assembly and nut, then do as follows:

Page 7 of 14 April 10/12 Refer to Figure 3 (a) Tighten the nut until the outer washer of the PLI washer is against the inner centre ring with the outer center ring remaining loose. (b) Insert the shank of a drill into one of the test holes in the outer centre ring. (c) Rotate the outer center ring back and forth while tightening the nut or the bolt. (d) When the outer centre ring binds between the outer washers and can no longer rotate, stop tightening. Do not over tighten. The bolt has reached its required pre-load. (e) Check for gaps between the outer centre ring and both outer washers. A gap of 0.010 inch (0,25 millimetre) maximum at one of the outer washers or a combined total of 0.010 inch (0 ,25 millimetre) for both sides is acceptable . (f) If the slots in the castellated nut do not align sufficiently with either ofthe holes in the bolt to install the cotter pin , tighten the nut to align with the nearest hole. Do not tighten more than this. (g) Check at nuts that bolt threads are in safety. Refer to PSP 492, Maintenance Manual, Chapter 20. NOTE: If for any reason, the nut is backed off after the PLI washer assembly has been compressed , replace the PLI washer assembly. The PLI washer assembly is not re-usable. ATA Ref: 54-10 Service Bulletin 215-A4453

# Bombardier 415 MODEL CL-215-6611 (41 5) ALERT SE RVI CE BULLETIN (5) Safety the nut with the cotter pin. (6) Torque stripe the heads and tails of bolts , nuts, and washers with a 1/8 inch witness mark which extends onto the adjacent structure. Refer to PSP 492, Maintenance Manual, Chapter 20. (7) Apply a coat of Mastinox 6856H to heads and tails of bolt assemblies. H. Completion (1) Gently release hoist and remove engine lifting brackets. (2) On LH nacelle, install access panels 412-1, 412-2, 412-3 , 412-4, 412-5, and 413-3 as per PSP 492 , Maintenance Manual, Chapter 6, ENGINE NACELLES - ACCESS PANELS. (3) On RH nacelle, install access panels 422-1, 422-2, 422-3, 422-4, 422-5, and 423-3 as per PSP 492 , Maintenance Manual, Chapter 6, ENGINE NACELLES- ACCESS PANELS. (4) Install lower cowl panel assembly and forward upper cowl panel assembly, as per PSP 492, Maintenance Manual, Chapter 71 , POWER PLANT- ENGINE COWLING - MAINTENANCE PRACTICES. WARNING: ENSURE PERSONNEL AND EQUIPMENT ARE CLEAR OF ALL HYDRAULICALLY OPERATED SYSTEMS PRIOR TO RESTORING AIRCRAFT ELECTRICAL POWER. (5) Restore electrical power and observe all safety precautions (refer to PSP 492 , Maintenance Manual , Chapter 24, ELECTRICAL POWER- MAINTENANCE PRACTICES) . I. Recording When this Service Bulletin is completed , make the entry in the aircraft log book and send back the attached Incorporation Notice to Amphibious Aircraft Technical Publications.

Page 8 of 14 April 10/12 ATA Ref: 54-10 Service Bulletin 215-A4453

# Bombardier 415

A. Kit No. 215K4453- Parts List PART NO. PLI-8-19.6 MODEL CL-215-6811 (415) ALERT SERVICE BULLETI N

QUANTITY 4 DESCRIPTION PLI washer B. The following materials, or equivalent, are necessary to do this Service Bulletin. You can buy them locally:

Page 9 of 14 April 10/12 DESCRIPTION High Temp. Grease White lacquer Sealing Compound Scotchbrite PART NO ./NAME TI-L-32 Mastinox No. 400 SPECIFICATION QUANTITY MIL-G-25013 A /R Fed. Std 595 A /R Colour 17875 6856H A /R A/R

ATA Ref: 54-10 Service Bulletin 215-A4453TRONAIR ENGINE HOIST AND SLING 08-0116-5000 OR EQUIVALENT

TRONAIR ENGINE SLING 08-0112-4000 OR EQUIVALENT 

# \ r·· ------ -' - 

# Bombardier 415 MODEL CL-215-6B11 (415) ALERT SERVICE BULLETIN

ENGINE HOISTING POINTS

ENGINE REMOVAL FIGURE 1.1

**~--------·- OVERHEAD**  HOIST ' 'I



# J_~)""

**,**

**I"~** 

### '\_ a'

**-----** DYNAMOMETER "'-,.._'-'-"-_;} OR LOAD CELL



# ..........I

m mmmmmmmmm m I NOTE Use this method if removing the engine is required .

ENGINE HOISTING -------. 

# I POINTS ----.... j 

# L--------

**~~~~~** HOISTING

Page 10 of 14 April 10/12 ZERO WEIGHT COND ITION IS WHEN INDICATED READING (in LBS) =W+X ±50 (in LBS) Where. "W" is approximate weight of the engine (in lbs) . = 1500 NOTE ·x-is weight of the engine sling assembly before setup (in lbs) . Use this method if engine is not to be removed . ZERO WEIGHT CONDITION OF NACELLE FIGURE 1.2
ATA Ref: 54-10 Service Bulletin 215-A4453Page 11 of 14 April 10/12 

# Bombardier 415 MODEL CL-215-6811 (415) ALERT SERVICE BULLETIN

ACCESS BOLT AND BUSHING THROUGH THIS AREA

OUTBOARD ON LH NACELLE SHOWN INBOARD ON LH NACELLE OPPOSITE INSPECTION OF THE BUSHINGS IN THE NACELLE STRUT ASSEMBLIES FIGURE 2
ATA Ref: 54-10 Service Bulletin 215-A4453Page 12 of 14 April 10/12 

# Bombardier 415 MODEL CL-2 15-6811 (415) ALE RT SERVI CE BULLETIN



# 0-0
GAP "A"- PART NUMBER CORRESPONDENCE A (in.) PART NUMBER Disassembled view of Bushing is shown for clarity. do not remove from assembly.

------------ ..................- ..--·---·------- 0.040 +/- 0.010 85410265-103 0.260 +I- 0.010 85410265-105 INSPECTION OF THE BUSHINGS IN THE NACELLE STRUT ASSEMBLIES FIGURE 2
ATA Ref: 54-10 Service Bulletin 215-A4453

# Bombardier 415

OUTER WASHERS

NOTE MODEL CL-215-6B11 (415) ALERT SE RVI CE BULLET IN

BEFORE TIGHTENING

,_ INNER CENTRE / RING

**....--""""'+--+'~**

**::---.**_______ "'-- OUTER CENTRE RING Washer assembly comprises two concentric steel rings sandwiched between two close tolerance plain steel washers. 2 The PLI-8-19.6 washer has its center ring coloured blue (180 KSI) , a 1 /2-inch internal diameter, and 19,600 LBS nominal preload. AFTER TIGHTENING

_________ BOLT

.--'-"4----f-"-"-'-" -,'-..-....____'--.., TEST HOLE (3 PLACES)

PRELOAD INDICATING WASHERS
AT LOWER LONGERON



# // **BUSHING** STRUT/ / 

# //] / / BOLT/ / [0.25 INCH (6,3 MM) / MAXIMUM COUNTERSUNK WASHER AT HORSE COLLAR AND SLOPING LONGERON STRUT BUSHING 

# "

**~//**



# ~ 1111111111 

# j L0.21 INCH (5,3 MM) MAXIMUM GAP MEASUREMENT
Page 13 of 14 April 10/12 FIGURE 3 ATA Ref: 54-1 0 Service Bulletin 215-A4453DIA 0.6875 in. DIA 0.6885 in .

SLNO NUMBER 1 C415-3902-001

Page 14 of 14 April 10/12 

## I DIA 0.500 in. DIA 0.505 in . 

## I 

# Bombardier 415 MODEL CL-215-6811 (415) ALERT SERVICE BULLETIN



# \ \ 0 0.015 in .x45 CHAMFER 4 PLACES BUSHING C415-3902-001 REPAIR MATERIAL TABLE DESCRIPTION I MATERIAL SPECIFICATION BUSHING t 4130 BAR. AMS-S-6758 , HEAT TREAT TO 125-145 KSI PER MIL-H-6875

AFTER REPAIR NOTE Use bushing C415-3902-001 with shear bushing 8541 0265-1 05 to maintain the gap of 0.040 +/- 0.010 in . BUSHING C415-3901-001 DETAILS USED IN REPAIR FIGURE 4
ATA Ref: 54-10 Service Bulletin 215-A4453

# SERVICE BULLETIN INCORPORATION NOTICE REPLY FAX 

# BOMBARDIER

Upon completion of Service Bulletin(s), please fill in and return by fax to:

Service Bulletin Number(s)

Customer/Operation Aircraft Serial No. Airframe Hours Name 

### Technical Publication, Dept. 649-DBF-(9) Bombardier Aerospace Specialized & Amphibious Aircraft St. Laurent, Quebec Fax No.: (514) 855-7602

Rev. Remarks

_ Aircraft Reg. No. Date of Incorporation (Please Print)