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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 issues 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 perform the inspection.

Provides additional cautions and instructions 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 service bulletin title regarding facilities 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 required 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

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Filing Instructions:

This is a Complete revision. Remove 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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Refer to applicable government agency regulations and requirements and make sure that the work described 

in this publication is performed in compliance with manufacturer’s recommendations and/or acceptable industry standards. 

This document is proprietary to Bombardier Inc. and/or its affiliates and may not be reproduced or copied in any form or by any means without the prior written consent of Bombardier Inc. and/or its affiliates. 

© 2012, Bombardier Inc. All rights reserved. Challenger*, Global Express*, Learjet*, are Trademarks of Bombardier Inc.

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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. Diversion contrary to United States law is prohibited.

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WINDOWS- WINDSHIELD COUPE RAIL INSPECTION

CAUTION: ONLY AUTHORIZED FACILITIES AND LEARJET 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 determine if they meet specified design tolerances.
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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 must 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. recommends 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 approved 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 are for planning purposes only. Facility and personnel capabilities may cause the labor hours to change.

When planning to complete these instructions, please contact Bombardier Aerospace,

Learjet Inc. Business Aircraft Customer Service, Parts Logistics for parts availability and

shipping times as necessary. (Refer to the title 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 Hours
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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 Facility or at a Bombardier Learjet Authorized Service

Facility. You must complete these instructions within 600 flight hours or 36 months

from the Basic Issue distribution 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 Facility or at a Bombardier Learjet Authorized Service

Facility. You must complete these instructions within 600 flight hours or 36 months

from the Basic Issue distribution 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 Plate
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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 windshield

removal, contact Learjet Field Support Engineering for repair or replacement instructions.

TABLE 1

PART NUMBER NOMENCLATURE 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

45‐2122‐45‐2130
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Service Bulletin

CAUTION: CLOSE AND LOCK FORWARD ENTRY DOOR 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 preparation 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 burnishing 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 kit, 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 trained/certified per Learjet ultrasound NDI

inspection requirements.
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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 Material 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 recurring eddy current

inspection.

(8) If material thickness is below 0.166 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 the limits specified, contact Learjet Customer

Response Center (CRC) for instructions on moving the aircraft to the repair facility.

(9) Perform flange and radius eddy current inspection 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 the limits specified, contact Learjet Customer

Response Center (CRC) for instructions on moving the aircraft to the repair facility.

(12) Mark new data plate with number using permanent marking pen. Mark N/A for serial number. Mark

complied with SB 40-56-03 near the identification plate when installed. It is required that the marking be made permanent by coating with clear polyurethane protective coating.

(13) Apply alodine 1132 anti-corrosion chemical film 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, and return aircraft to normal operating condition.
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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 certification authority. Note if one or both coupe rail(s) will require the recurrent 5000

hour eddy current inspection.
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LEARJET 40

Service Bulletin

Coupe Rail Inspection

Figure 1 (Sheet 1 of 2)
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Service Bulletin

Coupe Rail Inspection

Figure 1 (Sheet 2 of 2)