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THIS PUBLICATION IS AVAILABLE AT: www.cic.bombardier.com 

### LEARJET 40 RT 40-56-03 

# Revision Transmittal Sheet

RT 40-56-03

Page 1 of 2

Oct 15/12 This page transmits Revision 1 to Service Bulletin No. 40-56-03, “Windshield Coupe Rail Inspection.” Rework: No rework is required for aircraft which have complied with previous i ssues of this document. Summary: This revision provides the following: Corrects the labor hours. Clarifies the expense coverage. Provides cautions about what facilities and personnel can pe rform the inspection. Provides additional cautions and instruct ions on how to perform the inspection. NOTE: Change bars are placed in the left margin of pages where significant changes are located. This revision incorporates the latest document format for Learjet service instructions. The general arrangement of this document may change from the previous issue. Description of Changes: In the Planning Information section: Added caution statement below serv ice bulletin title regarding facilit ies and personnel that are authorized to perform the service bulletin. Changed the Labor Hours information section as follows: Changed the total labor hours from 54 to 40. Added column showing hours for perimeter seal repair/replacement if required.Added note stating if black rubber perimeter seal is damaged to contact Learjet Support Engineering. In the Accomplishment Instructions section: Changed the Modification Instructions section as follows:Added note stating if black rubber perimeter seal is damaged to contact Learjet Support Engineering. Added caution stating not to tow, jack, down jack, or move the aircraft while the windshields are removed. Added note stating that black paint is not requ ired on the outboard surface of the coupe rail. In the Illustrations section Changed Figure 1 Sheet 2 as follows: Corrected Flagnote 1 from Frame Station 196.00 and Frame Station 204.00 to Frame Station 220.51 and Frame Station 228.51.

### LEARJET 40 Revision Transmittal Sheet

THIS PUBLICATION IS AVAILABLE AT: www.cic.bombardier.com RT 40-56-03 Page 2 of 2

Oct 15/12 Filing Instructions: This is a Complete revision. Remo ve and discard all pages of the prior issue and replace them with pages of Revision 1. Record of Revisions:
ISSUE DISTRIBUTION DATE Basic Apr 30/12 Revision 1 Oct 15/12

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THIS PUBLICATION IS AVAILABLE AT: www.cic.bombardier.com Refer to applicable government agency regulations and requi rements and make sure that the work described in this publication is performed in compliance with manufac turer’s recommendations and/or acceptable industry standards. This document is proprietary to Bombardi er Inc. and/or its affiliates and may not be reproduced or copied in any form or by any means without the prior wr itten consent of Bombardier Inc. and/or its affiliates. © 2012, Bombardier Inc. All rights reserved. Challenger*, Global Express*, Learjet* , are Trademarks of Bombardier Inc. SB 40-56-03 Recommended Page 1 of 9 Basic Issue: Apr 30/12 Revision 1: Oct 15/12 

### Contact Information Distribution Date Rev. No. Business Aircraft Learjet Inc. MS 53 P.O. Box 7707 Wichita, Kansas 67277

‐ 7707
Customer Response Center (CRC) 1

‐ 866

‐ 538

‐ 0247 (Toll Free) (316) 946

‐ 6100 (Tel) Push 2 for Parts Logistics. Push 4 then push 1 for Technical Publications. Push 3 for instructions on moving aircraft to a repair facility October 15, 2012 1 

### LEARJET 40

If you cannot complete the instructions in this publication because of an STC change to the aircraft, speak to the STC holder or the regional Federal Aviation Administration (FAA) office for information and disposition. 

# Service Bulletin

These commodities, technology or software were exported from the United States in accordance with the Export Administration Regulations. Divers ion contrary to United St ates law is prohibited. 

### SB 40-56-03 Recommended

WINDOWS- WINDSHIELD COUPE RAIL INSPECTION CAUTION: ONLY AUTHORIZED FACILITIES AND LEARJ ET TRAINED PERSONNEL CAN COMPLETE THESE INSTRUCTIONS. A LIST OF AUTHORIZED FACILITIES IS ATTACHED TO THIS DOCUMENT, OR CAN BE OBTAINED BY CONTACTING YOUR FIELD SERVICE REPRESENTATIVE OR THE CUSTOMER RESPONSE CENTER. 1. Planning Information A. Effectivity (1) Learjet 45-2000 thru 45-2120, 45-2122 thru 45-2130. B. Reason (1) To inspect the lower windshield coupe rails to det ermine if they meet specified design tolerances.THIS PUBLICATION IS AVAILABLE AT: www.cic.bombardier.com SB 40-56-03 Recommended Page 2 of 9 Basic Issue: Apr 30/12 Revision 1: Oct 15/12 

### LEARJET 40 Service Bulletin C. Description (1) This service bulletin provides instructions to perform ultrasound and eddy current inspections on the left and right lower coupe rails. If the coupe rails are found to be beyond acceptable limits per this service bulletin, the coupe rails must be replaced

. NOTE: Inspection and sheetmetal technicians mu st be trained/certified per Learjet ultrasound NDI inspection and material blending requirements

.This inspection may be performed only at a Bombardier Aircraft Services Facility or an authorized service facility that has received specific training in performing this inspection. D. Compliance (1) Recommended - Bombardier Learjet Inc. recommend s that you complete these instructions in less than 600 flight hours or 36 months from the initial distribution date of this publication. E. Approval (1) The Federal Aviation Administration (FAA) has ap proved the technical content in this publication that has an effect on the airplane type design. (2) The European Aviation Safety Agency (EASA) has accepted the technical content in this publication that has an effect on the airplane type design. F. Labor Hours - Estimated Accomplishment Time

NOTE: These labor hours are an estimate and ar e for planning purposes only. Facility and personnel capabilities may caus e the labor ho urs to change. When planning to complete these instructions, please contact Bombardier Aerospace, Learjet Inc. Business Aircraft Customer Service, Parts Logi stics for parts availability and shipping times as necessary. (Refer to the ti tle page of this document for contact information.) *If black rubber windshield retainer perimeter seal is damaged during windshield removal, contact Learjet Field Support Engineering for repair or replacement instructions. * ‐ 801 KIT WITH PERIMETER SEAL REPAIR/REPLACE ‐ MENT ‐ 801 KIT TASK

0.5 0.5 Labor hours to gain access. 43.0 One Windshield / 50.0 Both Windshields 36.0 Labor hours to do the aircraft modification.

3.0 3.0 Labor hours to do a functional test/operational check. 0.5 0.5 Labor hours to return the aircraft to airworthy status. 47.0 to 54.0 40.0 Total Labor HoursTHIS PUBLICATION IS AVAILABLE AT: www.cic.bombardier.com SB 40-56-03 Recommended Page 3 of 9 Basic Issue: Apr 30/12 Revision 1: Oct 15/12 

### LEARJET 40 Service Bulletin G. Expense Coverage (1) Labor Coverage - Labor coverage applies to all aircraft affected by this publication. NOTE: For labor coverage to apply, you must complete these instructions at a Bombardier Business Aviation Service Fa cility or at a Bombardier Learjet Authorized Service Facility. You must complete these instruct ions within 600 flight hours or 36 months from the Basic Issue distributi on date of this publication. (2) Material Coverage - - Material coverage applies to all aircraft affected by this publication. NOTE: For material coverage to apply, you must complete these instructions at a Bombardier Business Aviation Service Fa cility or at a Bombardier Learjet Authorized Service Facility. You must complete these instruct ions within 600 flight hours or 36 months from the Basic Issue distributi on date of this publication. H. Material Required

I. Tools and Equipment (1) Special tools and equipment necessary to complete these instructions.

J. Weight and Balance (1) Negligible. K. References (1) Learjet NDI Manual, Chapter 53 Parts 4 and 6. (2) Learjet Maintenance Manual, Chapters 20, 24, 25, 30 and 56. 2. Material Information A. The 4553130001-801 kit contains the following parts: PART NUMBER QTY NOMENCLATURE PRICING 4553130001

‐ 801 1 Service Bulletin Kit $77.52

PART NUMBER NOMENCLATURE SUPPLIER 12845

‐ 033

‐ 001 Learjet Ultrasound Kit Learjet

PART NUMBER QTY NOMENCLATURE S

‐ 912 2 Identification PlateTHIS PUBLICATION IS AVAILABLE AT: www.cic.bombardier.com SB 40-56-03 Recommended Page 4 of 9 Basic Issue: Apr 30/12 Revision 1: Oct 15/12 

### LEARJET 40 Service Bulletin B. Identification Tables

3. Accomplishment Instructions A. Gain Access (1) Disconnect external electrical power and the main and emergency batteries from the aircraft. (Refer to Chapter 24 of the Maintenance Manual .) (2) Remove windshields from the aircraft. (Refer to Chapter 56 of the Maintenance Manual .) NOTE: If black rubber windshield retainer perimeter seal is damaged during windshieldremoval, contact Learjet Field Support Engineering for repair or replacement instructions. TABLE 1 PART NUMBER NOMENCLA TURE IDENTIFY TO SPARES REPLACEMENT EFFECTIVITY
4556100007

‐ 011 LH Coupe Rail 4556100007

‐ 011 4553190001

‐ 803 45

‐ 2000

‐ 45

‐ 2078 4556100007

‐ 012 RH Coupe Rail 4556100007

‐ 012 4553190001

‐ 804 45

‐ 2000

‐ 45

‐ 2078 4553002003V13

‐ 001 LH Coupe Rail 4553002003V13

‐ 001 4553190001

‐ 803 45

‐ 2079

‐ 45

‐ 2120 45

‐ 2122

‐ 45

‐ 2130 4553002003V13

‐ 002 RH Coupe Rail 4553002003V13

‐ 002 4553190001

‐ 804 45

‐ 2079

‐ 45

‐ 2120 45

‐ 2122

‐ 45

‐ 2130

TABLE 2 PART NUMBER NOMENCLATURE IDENTIFY TO SPARES REPLACEMENT EFFECTIVITY
4556100007

‐ 011 LH Coupe Rail 4553130001

‐ 806 4553190001

‐ 803 45

‐ 2000

‐ 45

‐ 2078 4556100007

‐ 012 RH Coupe Rail 4553130001

‐ 807 4553190001

‐ 804 45

‐ 2000

‐ 45

‐ 2078 4553002003V13

‐ 001 LH Coupe Rail 4553130001

‐ 808 4553190001

‐ 803 45

‐ 2079

‐ 45

‐ 2120 45

‐ 2122

‐ 45

‐ 2130 4553002003V13

‐ 002 RH Coupe Rail 4553130001

‐ 809 4553190001

‐ 804 45

‐ 2079

‐ 45

‐ 2120 45

‐ 2122

‐ 45

‐ 2130THIS PUBLICATION IS AVAILABLE AT: www.cic.bombardier.com SB 40-56-03 Recommended Page 5 of 9 Basic Issue: Apr 30/12 Revision 1: Oct 15/12 

### LEARJET 40 Service Bulletin CAUTION: CLOSE AND LOCK FORWARD ENTRY DO OR BEFORE REMOVING BOTH WINDSHIELDS. NO ENTRY THROUGH FORWARD ENTRY DOOR WHEN BOTH WINDSHIELDS ARE REMOVED. DO NOT OPEN FORWARD ENTRY DOOR UNTIL AT LEAST ONE WINDSHIELD HAS BEEN REINSTALLED. EGRESS AIRCRAFT THROUGH EMERGENCY EXIT DOOR. NO MORE THAN TWO PEOPLE IN AIRCRAFT WHILE BOTH WINDSHIELDS ARE REMOVED. DO NOT TOW, JACK, DOWN JACK OR OTHERWISE MOVE AIRCRAFT WHILE BOTH WINDSHIELDS ARE REMOVED. FOR EXAMPLE: IF AIRCRAFT IS ON JACKS, DO NOT DOWN JACK UNTIL WINDSHIELDS ARE INSTALLED. (3) Remove upper flight deck side walls from both pilot’s and copilot’s side to gain access to rear of coupe rails. (Refer to Chapter 25 of the Maintenance Manual .) B. Modification of Aircraft (1) Clean sealant and strip paint off coupe rails in pr eparation of NDI using scotch-brite pads. (Refer to Part 6, Chapter 53 of the Non-Destructive Inspection Manual .) NOTE: Clean sealant and strip paint using hand methods only, do not use power tools to avoid damaging the coupe rails. CAUTION: DO NOT REMOVE ANY BASE METAL. UNNECESSARY BASE METAL REMOVAL MAY RESULT IN INSPECTION FAILURE. (2) Inspect for gouging, scratches, or if radius has been removed. (See Figure 1 .) NOTE: Sheetmetal technicians must be trained/ certified per Learjet material blending requirements. (3) On coupe rails found with gouging or scratches, burnish/blend areas of gouges and scratches. NOTE: If damage is very minor, use burnishing tool supplied in NDI kit by rubbing tool back and forth across damaged area. Once most of the damage has been blended, apply a thin coat of petroleum jelly and use burnishin g tool to polish area for finishing. If damage is more severe, use 360 grit (or finer) sandpaper over spreader supplied in NDI kit and remove the damage. Polish as previously detailed. (4) On coupe rails found with the radius removed, restore radius in areas where it has been removed. (See Figure 1 .) NOTE: Wrap 360 grit (or finer) sandpaper over edge of spreader supplied in NDI kit twice to obtain proper radius of inspection area. Sand damaged areas making sure not to remove any more material than is required to restore radius. After sanding is complete finish using burnishing tool supplied in NDI ki t, apply a thin coat of petroleum jelly and use burnishing tool to polish the radius. (5) Perform ultrasound inspection of the lower coupe rails. (Refer to Part 4, Chapter 53 of the NonDestructive Inspection Manual .) Exempt area (See Figure 1 ) does not require inspection. NOTE: Inspection technicians must be traine d/certified per Learjet ultrasound NDI inspection requirements.THIS PUBLICATION IS AVAILABLE AT: www.cic.bombardier.com SB 40-56-03 Recommended Page 6 of 9 Basic Issue: Apr 30/12 Revision 1: Oct 15/12 

### LEARJET 40 Service Bulletin (6) If coupe rail(s) pass the ultrasound inspection with an "X" dimension of 0.246 or greater and a "Y" dimension of 0.148 or greater (See Figure 1 ), identify coupe rail(s) in accordance with Identification Table 1. (Refer to Mate rial Information Section B.) (7) If coupe rail(s) pass ultrasound inspection with an "X" dimension of between 0.246 to 0.166 and/or a "Y" dimension of between 0.148 to 0.134 (See Figure 1 ), reidentify coupe rail(s) in accordance with Identification Table 2. (Refer to Material Information Section B.) NOTE: All coupe rails identified in Table 2 will require a 5000 hour re curring eddy current inspection. (8) If material thickness is below 0.1 66 in the "X" dimension (rail) and/or below 0.134 in the "Y" dimension (flange), replace the coupe rail. NOTE: If one or both coupe rails are below th e limits specified, co ntact Learjet Customer Response Center (CRC) for inst ructions on moving the airc raft to the repair facility. (9) Perform flange and radius eddy current inspecti on of the LH (RH) lower coupe rail(s). (See Part 6, Chapter 53 of the Non-Destructive Inspection Manual .) Exempt area (See Figure 1 ) does not require inspection. (10) On aircraft with no cracks in either coupe rail , proceed to Step (12) to mark the new data plate with the applicable number per the identification tables. (11) On aircraft with cracks in one or both coupe rails , the coupe rail(s) must be replaced. NOTE: If one or both coupe rails are below th e limits specified, co ntact Learjet Customer Response Center (CRC) for inst ructions on moving the airc raft to the repair facility. (12) Mark new data plate with number using permanen t marking pen. Mark N/A for serial number. Markcomplied with SB 40-56-03 near the identification plate when installed. It is required that the marking be made permanent by coating with cl ear polyurethane protective coating. (13) Apply alodine 1132 anti-corrosion chemical f ilm treatment on all exposed surfaces of the coupe rail. (Refer to Chapter 20 of the Maintenance Manual .) After completion of chemical film, apply epoxy primer on exposed aluminum surfaces. (Refer to Chapter 20 of the Maintenance Manual .) NOTE: Black paint is not required on the outboard surface of the coupe rail and under the windshield retainer. (14) Install new data plate on the aft side of the coupe rail(s). (See Figure 1 .) (15) Reinstall windshields in aircraft. (Refer to Chapter 56 of the Maintenance Manual .) Do not perform functional test at this time. (16) Reinstall both upper sidewall panels. (Refer to Chapter 25 of the Maintenance Manual .) (17) Reconnect main and emergency batteries and apply electrical power to aircraft. (Refer to Chapter 24 of the Maintenance Manual .) C. Functional Test/Operational Check. (1) Perform Functional Test of Windshields. (Refer to Chapter 30 of the Maintenance Manual .) (2) Perform the Windshield Return to Service Check. (Refer to Chapter 56 of the Maintenance Manual .) D. Return Aircraft to Airworthy Status (1) Remove electrical power if no longer required, a nd return aircraft to normal operating condition.THIS PUBLICATION IS AVAILABLE AT: www.cic.bombardier.com SB 40-56-03 Recommended Page 7 of 9 Basic Issue: Apr 30/12 Revision 1: Oct 15/12 

### LEARJET 40 Service Bulletin E. Compliance Response Form (1) Complete the compliance response form. (2) Send the compliance response form to Learjet Inc. as soon as possible. F. Aircraft Maintenance Records (1) Complete the Aircraft Maintenance Records in accordance with the regulatory requirements of your aircraft certificatio n authority. Note if one or both coupe rail(s) will require the recurrent 5000 hour eddy current inspection.THIS PUBLICATION IS AVAILABLE AT: www.cic.bombardier.com SB 40-56-03 Recommended Page 8 of 9 Basic Issue: Apr 30/12 Revision 1: Oct 15/12 

### LEARJET 40 Service Bulletin

Coupe Rail Inspection Figure 1 (Sheet 1 of 2)THIS PUBLICATION IS AVAILABLE AT: www.cic.bombardier.com SB 40-56-03 Recommended Page 9 of 9 Basic Issue: Apr 30/12 Revision 1: Oct 15/12 

### LEARJET 40 Service Bulletin

Coupe Rail Inspection Figure 1 (Sheet 2 of 2)