A605-57-004

Page 1 of 2 

ALERT SERVICE BULLETIN 

REVISION TRANSMITTAL SHEET 

MODEL CL-600-2B16 

Discard the Basic Issue of this Alert Service Bulletin dated Dec 20/2012, and replace in 

its entirety with this Revision 01. 

Service Bulletin No. A605-57-004

Date of Basic Issue Dec 20/2012

Revision No. 01 Dated Sep 26/2013

For action applicable to aircraft on which this Service Bulletin was done, refer to 

the retroactive action box on Page 1 of this Service Bulletin. 

This revision is a complete reissue, therefore revision bars were intentionally omitted. 

This revision is issued to provide instructions in PART B and PART C. The changes are 

as follows: 

1. Revise the Service Bulletin Summary Sheet, to add the manpower, the kit 

information and a note applicable to PART B. 

2. Revise the Service Bulletin Summary Sheet and Paragraph 1.A. to reflect the 

effectivity changes given in the Restriction and/or Special Instruction (RSI), C-4095, 

Rev. B. 

3. Add a Retroactive Action Box. 

4. Revise Paragraph 1.C., to add, PART B, PART C and the testing description. 

5. Add information to Paragraph 1.D. about PART B of the Service Bulletin. 

6. Revise Paragraph 1.F., to add the manpower applicable to PART B. 

7. Revise Paragraph 1.G., Paragraph 3.A. and Paragraph 3.B., to add the kit and part 

details applicable to PART B. 
MODEL CL-600-2B16 

 A605-57-004

Page 2 of 2 

8. Revise Paragraph 1.H., to add the additional tools applicable to PART B. 

9. Change, in Paragraph 1.K., the revision of the Restriction and/or Special Instruction 

(RSI), C-4095, to Rev. B. 

10. Add, in Paragraph 1.K., references to Structural Repair Manual (SRM), Standard 

Practices Manual (SPM), Repair Engineering Order (REO), 600-57-26-001, 

Repair Engineering Order (REO), 604-57-26-005, Appendix 1, Appendix 2 and 

add chapter references to the AMM. 

11. Add, in Paragraph 1.M., references to the 600 & 601 Service Bulletins. 

12. Revise Paragraph 2.A., to add additional instructions in the aircraft setup. 

13. Revise Paragraph 2.B., to add clarification for the special check. 

14. Revise Paragraph 2.C., to add the modification instructions applicable to PART B. 

15. Revise Paragraph 2.D., to add the instructions applicable to PART C. 

16. Revise Paragraph 2.E., to add the testing instructions applicable to PART B. 

17. Revise Paragraph 3.C., to add the consumables information applicable to this 

Service Bulletin. 

18. Add Appendix 1. 

19. Add Appendix 2. 

20. Make miscellaneous minor changes, as necessary, with no change of context. 
Basic Issue: Dec 20/2012 A605-57-004

Revision 01: Sep 26/2013 Page 1 of 1 

ALERT SERVICE BULLETIN SUMMARY 

This Service Bulletin is available at: 

www.cic.bombardier.com

MODEL CL-600-2B16

ATA 57-52 

WINGS 

SPECIAL CHECK/MODIFICATION – INBOARD FLAP HINGE BOX – 

FORWARD ATTACHMENT FITTINGS FASTENERS 

The information below is provided for your reference. For full details, please 

see corresponding paragraph contained within this bulletin. 

ALERT 

SPECIFIED TIME COMPLIANCE

COMPLIANCE TIME 

PART A is recommended within 100 

landings from this Alert Service Bulletin 

release date (Basic Issue) and must be 

repeated every 100 landings until 

modification in PART B is complied with 

or PART C is Completed. 

PART B is recommended no later than 

48 months from this Service Bulletin 

release date (Revision 01). 

EFFECTIVITY: A/C Serial No. 5701 to 5920 

MANPOWER: 1 man-hour for the special check in PART A 

58 man-hours for the modification in PART B 

CONTINUED AIRWORTHINESS (CAW) 

FLEET CAMPAIGN 

YES NO 

KITS and/or PARTS YES NO 

TOOLING/GSE YES NO 

PLANNING INFORMATION: See 

important information at the start of 

Paragraph 1.

YES NO 

DEDICATED SCHEDULE YES NO 

PREREQUISITE SERVICE BULLETINS: N/A 

NOTES 1. Defueling and venting of the fuel tanks must be done to do PART B of this 

Service Bulletin. 

2. To minimize aircraft downtime and cost, it is recommended to do Service 

Bulletin 605-57-005 in conjunction with PART B of this Service Bulletin. 

To place an order for parts or kits, please call Bombardier Aerospace Parts Services at: 

514-855-2999 or 1-866-538-1247
Refer to applicable governmental agency regulations and requirements and make sure that the work described in this 

Service Bulletin 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 - 2013 Bombardier Inc. All rights reserved 

Learjet, Challenger, Global, are registered trademarks of Bombardier Inc. or its subsidiaries. 

Basic Issue: Dec 20/2012 A605-57-004

Revision 01: Sep 26/2013 Page 1 of 20 

ALERT SERVICE 

BULLETIN 

This Alert Service Bulletin is available at: 

www.cic.bombardier.com 

MODEL CL-600-2B16

ATA 57-52 

WINGS 

SPECIAL CHECK/MODIFICATION – INBOARD FLAP HINGE BOX – 

FORWARD ATTACHMENT FITTINGS FASTENERS 

RETROACTIVE ACTION 

1. FOR THE AIRCRAFT WITH THE INCORRECTLY ORIENTED FORWARD 

FASTENERS HEADS (FIGURE 2 in PART A), PART A MUST BE REPEATED 

EVERY 100 LANDINGS UNTIL PART B IS COMPLIED WITH. 

– NO FURTHER ACTION IS REQUIRED, ONCE PART B IS INCORPORATED. 

OR 

2. FOR THE AIRCRAFT WITH THE CORRECTLY ORIENTED FORWARD 

FASTENERS HEADS (FIGURE 1 in PART A). 

– NO FURTHER ACTION IS REQUIRED, ONCE PART C IS COMPLETED. 

1. PLANNING INFORMATION 

NOTE: To minimize aircraft downtime and cost, it is recommended to do Service 

Bulletin 605-57-005 in conjunction with PART B of this Service Bulletin. 
MODEL CL-600-2B16

Basic Issue: Dec 20/2012 A605-57-004

Revision 01: Sep 26/2013 Page 2 of 20 

A. Effectivity 

CL-600-2B16 aircraft, Serial No. 5701 to 5920.

The intent of this Service Bulletin PART B was met on the aircraft that follow 

with the Repair Engineering Orders (REO) and Service Requests for Product 

Support Action (SRPSA) listed in the table that follows: 

AIRCRAFT SERIAL NO. DRAWING. SRPSA NO. 

5783 REO 600-57-26-001 31364 

5818 REO 600-57-26-001 31385 

5862 REO 600-57-26-001 32285 

A repair was carried out on the Right Side at WS 76.50 for aircraft, Serial No. 

5725 with the REO 604-57-26-005 and SRPSA 30876. , Perform this Service 

Bulletin only to the remaining 3 forward fittings, to meet the intent of this 

Service Bulletin. 

Aircraft, Serial No. 5921 and all other subsequent aircraft were scheduled for 

the modification in production (Ref.: Restriction and/or Special Instruction 

(RSI), C-4095). 

NOTE: The instructions given in this Alert Service Bulletin are only applicable 

to the systems and parts installed at the time of delivery of the aircraft 

or as changed by Bombardier Aerospace Alert Service Bulletin(s). 

Before you do this bulletin, examine all STC, STA or equivalent 

action changes to make sure that this bulletin can be completed. 

B. Reason 

On a Challenger 605 zonal inspection, one of the two forward fasteners 

attaching the inboard flap hinge box forward hinge fitting at Wing Station (WS) 

76.50 was found with its head missing. 

The investigation shows that when installed with their head outside, those 

fasteners will experience premature failure caused by higher pre-load due to 

clamping and alignment. 

This Alert Service Bulletin provides instruction to inspect and repair the forward 

fasteners attaching the forward fittings at WS 76.50 and WS 127.25 at both 

wings. 
MODEL CL-600-2B16

Basic Issue: Dec 20/2012 A605-57-004

Revision 01: Sep 26/2013 Page 3 of 20 

C. Description 

This Alert Service Bulletin gives instructions in: 

PART A. to: 

– Do the inspection of the forward inboard flap fasteners on the hinge box wing 

forward fitting. 

PART B, to: 

– Remove the forward and aft inboard flap hinge-fairings, 

– Remove the applicable upper and lower access panels, 

– Do the inboard flap fasteners modifications as per APPENDIX 1 on the hinge 

box wing forward fittings, 

– Install the removed wing upper and lower access panels, and 

– Re-install the forward and aft inboard flap hinge-fairings. 

PART C, to: 

– Confirm that the forward fasteners heads are correctly oriented. 

Testing, to: 

– Do the necessary testing to ensure that the inboard flaps operate correctly. 

D. Compliance 

PART A is recommended within 100 landings from this Alert Service Bulletin 

release date (Basic Issue) and must be repeated every 100 landings until 

PART B is complied with or until PART C is completed to confirm that the 

forward fasteners heads are correctly oriented. 

PART B is recommended no later than 48 months from this Service Bulletin 

release date (Revision 01). 

NOTES: 1. At any time, if any of the forward fasteners heads are found 

missing, PART B must be implemented before further flight. 

2. If the modification in PART B is incorporated or if the forward 

fasteners heads are correctly oriented as per PART C, no further 

action is required. 

E. Approval 

The technical content of this Service Bulletin has been approved under 

the authority of Transport Canada Civil Aviation (TCCA) Design Approval 

Organization (DAO) No. DAO #93-Q-02. 

NOTES: 1. The technical content of this Alert Service Bulletin is accepted 

by the FAA under the Canada/USA bilateral Aviation Safety 

Agreement. 

2. The technical content of this Service Bulletin is accepted by the 

JAA and by EASA in accordance with established procedures. 
MODEL CL-600-2B16

Basic Issue: Dec 20/2012 A605-57-004

Revision 01: Sep 26/2013 Page 4 of 20 

F. Manpower 

NOTES: 1. The man-hours given are estimates to help you schedule the tasks 

given in this bulletin. The estimates are for direct labor performed 

by an experienced crew and do not include the time for 

familiarization, planning, aircraft preparation in hangar such as 

towing and positioning of scaffolds, removal of interior furnishings, 

repainting, supervision and inspection. 

For more information related to the manpower estimates, refer to 

SB 605-00-002. 

2. This Alert Service Bulletin may require consumable materials that 

have specific curing times (refer to Paragraph 3). The accumulated 

curing time is not included in the labor estimates and should be 

considered for planning purposes before you schedule this Alert 

Service Bulletin. 

1 man-hour is necessary to do the special check in PART A. 

58 man-hours are necessary to do this modification in PART B. 

Bombardier does not pay for the special check in PART A and the Fuel 

Disposal fee at any time. 

The 58 man-hours required to do the modification in PART B are at no cost 

for aircraft in new aircraft warranty at the time of release of this Service Bulletin 

(Revision 01) if: 

(i) the work is done at Bombardier Business Aviation Services 

(BBAS) or Authorized Service Facilities (ASF), and 

(ii) this Service Bulletin is scheduled in less than 48 months from 

its release date (Revision 01). 

For aircraft out of warranty at the time of release of this Service Bulletin (Revision 01), 

refer to the steps that follows for the labor covered to do the modification, if: 

(i) the work is done at Bombardier Business Aviation Services (BBAS) 

or Authorized Service Facilities (ASF), and 

(ii) the modification in PART B is carried out as per the table that follows: 

OUT-OF-WARRANTY COVERAGE 

LABOR COVERAGE COVERAGE PERIOD 

52 man-hours This Service Bulletin is carried out at The 

Next 96 Month Maintenance Inspection and 

within 48 months from the time of release of 

this Service Bulletin (Revision 01). 

58 man-hours This Service Bulletin is carried out after The 

96 Month Maintenance Inspection and within 

48 months from the time of release of this 

Service Bulletin (Revision 01). 
MODEL CL-600-2B16

Basic Issue: Dec 20/2012 A605-57-004

Revision 01: Sep 26/2013 Page 5 of 20 

G. Material - Cost and Availability 

No kits or parts are necessary to do the special check in PART A or to confirm 

that the forward fasteners heads are correctly oriented as per PART C. 

Kit 605K57-004 is necessary to do PART B of this modification: 

KIT NO. PRICE 

605K57-004 Please contact Bombardier 

Aerospace Parts Services, in 

Montreal, for delivery lead times and 

confirmation of prices. 

Sufficient kits will be kept for the estimated amount of orders. 

This kit for PART B is available at no cost if a no-charge purchase order is sent 

to Bombardier Aerospace in less than 48 months from this Service Bulletin 

release date (Revision 01). 

The bushings that may be necessary, to do PART B, are available at no cost 

for aircraft in new aircraft warranty at the time of release of this Service Bulletin 

(Revision 01), if: 

(i) a no-charge purchase order is sent to Bombardier Aerospace 

in less than 48 months from this Service Bulletin release date 

(Revision 01). 

Bombardier does not pay for the Fuel Disposal fee at any time. 

During or after the above free period, Smart Parts Plus does not pay for the kit. 

H. Tooling 

The tools that follow, or equivalent, are necessary to do PART A of this Alert 

Service Bulletin: 

GSE REFERENCE NO. PART NO. DESCRIPTION 

24-00-24 - Tag, Circuit Breaker 

Commercially Available - Borescope 

The tools that follow, or equivalent, are necessary to do PART B of this Alert 

Service Bulletin: 

GSE REFERENCE NO. PART NO. DESCRIPTION 

24-00-24 - Tag, Circuit Breaker 

Commercially Available - Torque Wrench 17 to 19 lbf 

in (1.92 to 2.14 Nm) 

Commercially Available - Torque Wrench 20 to 25 lbf 

in (2.26 to 2.82 Nm) 

Commercially Available - Torque Wrench 23 to 27 lbf 

in (2.60 to 3.05 Nm) 

Commercially Available - Torque Wrench 30 to 35 lbf 

in (3.39 to 3.95 Nm) 
MODEL CL-600-2B16

Basic Issue: Dec 20/2012 A605-57-004

Revision 01: Sep 26/2013 Page 6 of 20 

The tools listed below or commercially available equivalent tools are required 

for the removal of the bushings. 

REFERENCE NO. PART NO. DESCRIPTION 

Commercially Available - C-Clamp 

See Note 3 - Support Block 

NOTES: 1. Refer to the CL-605 Illustrated Tool and Equipment Manual (ITEM) 

to make sure that you use the correct equipment configuration. 

2. Refer to the Liability Statement in the ITEM for acceptable GSE 

equivalents. 

3. For the support block manufacturing details, refer to Appendix 2. 

I. Weight and Balance 

No change. 

J. Electrical Load Data 

No change. 

K. References 

– Bombardier Aerospace, Restriction and/or Special Instruction (RSI), 

C-4095, Rev. B. 

– CL-605 Aircraft Maintenance Manual (AMM), Chapters 6, 12, 24, 27, 28, 

51 and 57. 

– CL-605 Aircraft Illustrated Parts Catalog (AIPC), Chapter 57. 

– CL-605 Structural Repair Manual (SRM), Chapter 51. 

– CL-605 Standard Practices Manual (SPM), Chapter 51. 

– Bombardier Aerospace, Modification Summary IS600-57-0001, Rev. A. 

– Bombardier Aerospace, Repair Engineering Order (REO), 600-57-26-001. 

– Bombardier Aerospace, Repair Engineering Order (REO), 604-57-26-005. 

– Bombardier Aerospace, Appendix 1 (attached). 

– Bombardier Aerospace, Appendix 2 (attached). 

L. Other Publications Affected 

None 

M. Equivalent Service Bulletins 

– For the Challenger 604 aircraft, use SB A604-57-006. 

– For the Challenger 601 aircraft, use SB A601-0627. 

– For the Challenger 600 aircraft, use SB A600-0763. 
MODEL CL-600-2B16

Basic Issue: Dec 20/2012 A605-57-004

Revision 01: Sep 26/2013 Page 7 of 20 

2. ACCOMPLISHMENT INSTRUCTIONS 

NOTES: 1. All TASKs given in the procedures that follow are from the CL-605 

Aircraft Maintenance Manual unless otherwise specified. 

2. All references made to zones, access panels and/or doors, are from 

the Aircraft Maintenance Manual, Chapter 6. 

A. Aircraft Setup 

(1) Install the safety devices and the warning signs in the applicable positions 

and the warning placard on the flap control lever. 

(2) Connect and energize the external AC power. Refer to TASK 12-00-07-861-801. 

(3) Set the flap control lever to 45 degrees and make sure that the flaps are 

fully extended. 

(4) Remove the external AC power. Refer to TASK 12-00-07-861-802. 

(5) Open and tag the circuit breakers that follow: 

CB PANEL CB NO. NAME ZONE 

CBP-2 B5 FLAP MOTOR 2 222 

CBP-3 B11 FLAP MOTOR 1 221 

B. PART A: Special Check − Inboard Flap Fasteners on the Hinge Box Wing 

Forward Fitting 

(1) Do a detailed borescope inspection of the inboard flap fasteners of the 

hinge box wing forward fitting of both wings. Refer to the steps that follow, 

Figure 1 and Figure 2. 

NOTE: If the fairing is already removed, a visual inspection can be carried 

out instead of a borescope inspection. 

(a) Examine the orientation of the forward attachments of the inboard flap 

hinge boxes at WS 76.50 and WS 127.25. Refer to Figure 1 and Figure 2. 

Figure 1 
MODEL CL-600-2B16

Basic Issue: Dec 20/2012 A605-57-004

Revision 01: Sep 26/2013 Page 8 of 20 

(i) If all of the forward fasteners heads of the inboard flap hinge boxes 

at WS 76.50 and WS 127.25 of both wings, are correctly oriented 

as per Figure 1, proceed to PART C in Paragraph 2.D. 

Figure 2 

(ii) If any of the forward fasteners heads are found missing as per 

Figure 2, proceed to PART B in Paragraph 2.C. 

(iii) If any of the forward fasteners heads are incorrectly oriented as 

per Figure 2 but no fasteners heads are found missing, then the 

borescope inspection of the forward inboard flap fasteners, hinge 

box wing forward fitting, must be repeated every 100 landings, until 

the modification, provided in PART B of this SB is complied with. 

Proceed to the Close-out in Paragraph 2.F. 

C. PART B: Modification − Incorrectly Oriented Inboard Flap Fasteners on 

the Hinge Box Wing Forward Fitting 

(1) Remove fillet seal from perimeter around the forward and aft inboard flap 

hinge-fairings, making contact with the wing surface and the inboard flap 

respectively. Refer to SPM TASK 51-23-00-100-801. 

(2) Remove the left and right forward and aft inboard flap hinge-fairings that 

follow: Refer to TASK 57-26-03-000-801. 

ACCESS DESIGNATION 

571AB (671AB) Fairing, Forward Inboard – Flap Hinge 

571EB (671EB) Fairing, Forward Inboard – Flap Hinge 

572DB (672DB) Aft Inboard – Flap Hinge Fairing 

572GB (672GB) Aft Inboard – Flap Hinge Fairing 
MODEL CL-600-2B16

Basic Issue: Dec 20/2012 A605-57-004

Revision 01: Sep 26/2013 Page 9 of 20 

(3) Obey the fuel system safety precautions. Refer to TASK 28-00-00-910-801. 

(4) Defuel the main fuel tank. Refer to TASK 12-11-28-650-803. 

(5) Gravity defuel the main fuel tank. Refer to TASK 12-11-28-650-804. 

(6) Remove the external ac power. Refer to TASK 12-00-07-861-802. 

(7) Remove the external dc power. Refer to TASK 12-00-07-861-804. 

(8) Disconnect the main battery. Refer to TASK 24-32-00-040-801. 

(9) Disconnect the auxiliary power unit (APU) battery. Refer to 

TASK 24-32-00-040-802. 

(10) Put a DO NOT CONNECT − FUEL TANK MAINTENANCE placard on the 

battery. 

(11) Put a DO NOT CONNECT − FUEL TANK MAINTENANCE placard on the 

ac and the dc ground power receptacles. 

(12) Remove the access panels that follow: 

ACCESS DESIGNATION TASK 

571BB (671BB) Wing Lower Surface – Access Panel 57−21−04−000−803 

541AT (641AT) Wing Upper Surface – Access Panel 57−21−01−000−802 

540EB (640EB) Fuel Tank – Access Panels 28−11−01−000−801 

540FB (640FB) Fuel Tank – Access Panels 28−11−01−000−801 

(13) Remove and replace each of the HI-LOK/Hi-LITE forward fasteners on the left 

and right wing at WS 76.50 and WS 127.25 as per Appendix 1, PART A, and 

Figure 3. 

Figure 3 
MODEL CL-600-2B16

Basic Issue: Dec 20/2012 A605-57-004

Revision 01: Sep 26/2013 Page 10 of 20 

(14) For each wing, disconnect one flap hinge box at a time from the forward 

attachment fitting and aft attachment fitting. Refer to the steps that follow: 

CAUTION: ONLY ONE FLAP HINGE BOX IS TO BE DISCONNECTED AT A 

TIME. THE FLAP HINGE BOX MUST BE SUPPORTED DURING 

THE MODIFICATION SO AS NOT TO DAMAGE THE FLAPS AND 

ATTACHED COMPONENTS. 

NOTES: 1. The flap will be supported by the other attached flap hinge 

box/arm and both actuators. 

 2. To reduce the load on the other attached flap hinge box/arm 

and actuators, the flaps should also be supported per best 

shop practice or with a bench and padding. Refer to Figure 4. 

Figure 4 

(a) Disconnect the inboard flap hinge box (1) at location WS 76.50 and 

WS 127.25 as follows: Refer to Figure 5 and Figure 6. 

(i) If necessary, remove and keep the hardware that attach the 

bonding jumpers to the flap hinge box (1). 

(ii) For the flap hinge box (1) located at WS 76.50 only, do as follows: 

(aa) If necessary, disconnect the electrical connector wire from 

any attached location on the structure, to allow downward 

movement of the flap hinge box. 

(bb) Remove and discard the cotter pin (4). Refer to SPM-MM 

20-50-00-000-802. 

(cc) Remove and keep the nut (5), washer (6) and bolt (7) and 

disconnect the control rod (2) from the lever (8) of the flap 

position transmitter. 

(dd) If necessary, put protective covers on the open ends of the 

electrical connector (3) and on the electrical connection of 

the position transmitter. 
MODEL CL-600-2B16

Basic Issue: Dec 20/2012 A605-57-004

Revision 01: Sep 26/2013 Page 11 of 20 

(iii) For the flap hinge box (1) located WS 76.50 and WS 127.25, 

remove and keep the nuts (9), washers (10) and (11), bolts (12), 

and hinge bushings (13), to disconnect the flap hinge box (1) from 

the forward attachment fitting. Refer to Figure 5 and Figure 6. 

 

CAUTION: TO REMOVE AND INSTALL THE HINGE 

BUSHINGS USE A C-CLAMP METHOD WITH 

THE SUPPORT BLOCK. USE LIGHT ANTISEIZE LUBRICANT (WD-40 OR SIMILAR) IF 

THE BUSHINGS ARE SEIZED OR DIFFICULT 

TO REMOVE, MAKE SURE THAT THE 

LATERAL FORCE DOES NOT EXCEED 

200 LBS AND DO NOT USE A HAMMER TO 

REMOVE THE BUSHINGS, THIS CAN CAUSE 

DAMAGE. 

 BEFORE YOU INSTALL THE C-CLAMP, MAKE 

SURE YOU INSTALL A SUPPORT BLOCK 

BETWEEN THE FITTINGS, SHIMS IN ALL 

GAPS AS REQUIRED TO AVOID BENDING 

AND DAMAGE FROM THE CLAMP FORCE. 

 OTHER METHOD THAN C-CLAMP COULD BE 

USED, PROVIDED LUGS ARE SUPPORTED 

AND LATERAL FORCE DOES NOT EXCEED 

200 LBS TO AVOID DAMAGE. 

Figure 5 

(aa) Inspect the hinge bushings, Part No. 600-10300-611 (13) for 

damage and/or corrosion, if applicable, replace any damaged 

or corroded hinge bushings. 

(iv) For the flap hinge box (1) located WS 76.50 and WS 127.25, 

remove and keep the nuts (14), washers (15) and (16), bolts (17), 

and hinge bushings (18), to disconnect the hinge box (1) from the 

aft attachment fitting. Refer to Figure 5 and Figure 6. 

Install the support block,

manufactured as per 

Appendix 2 or an 

equivalent commercially 

available tool between 

the fittings. 

Shim all gaps as 

required. 
MODEL CL-600-2B16

Basic Issue: Dec 20/2012 A605-57-004

Revision 01: Sep 26/2013 Page 12 of 20 

(aa) Inspect the hinge bushings, Part No. 600-10300-609 (18) for 

damage and/or corrosion, if applicable, replace any damaged 

or corroded hinge bushings. 

(b) Carefully pull the flap hinge box (1) downward to allow access to the 

forward attachment fitting. 

Figure 6 
MODEL CL-600-2B16

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Revision 01: Sep 26/2013 Page 13 of 20 

(15) Remove and replace each of the HI-LOK/Hi-LITE AFT fasteners on the left 

and right wing at WS 76.50 and WS 127.25 as per Appendix 1, PART B, 

and Figure 7. 

Figure 7 

(16) Attach the inboard flap hinge box (1) at locations WS 76.50 and WS 127.25. 

Refer to the steps that follow, Figure 5 and Figure 6: 

(a) Apply one layer of Mastinox 6856K to the hinge bushings (13) and 

hinge bushings (18) on installation. 

(b) Put the flap-hinge-box (1) in position. 

(c) Install the bushings (18) on the flap hinge box (1) and aft attachment 

fitting. 

(d) Install the bushings (13) on the forward lugs of the flap hinge box (1) 

and forward attachment fitting. 
MODEL CL-600-2B16

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Revision 01: Sep 26/2013 Page 14 of 20 

(e) Install bolts (17), washers (15) and (16), and nuts (14) to attach the 

flap hinge box (1) to the aft attachment fitting. 

NOTE: Make sure the sum of the gap measurement between the 

aft attachment fitting and lower surface of bolt head (17), 

and between the aft attachment fitting and the lower surface 

of washer (15), is 0.020 in to 0.105 in (0.508 mm 

to 2.667 mm). 

(f) Install the bolts (12), washers (10) and (11), and nuts (9) to attach the 

flap hinge box (1) to the forward attachment fitting. 

NOTE: Make sure the sum of the gap measurement between the 

forward attachment fitting and lower surface of bolt head 

(12), and between the forward attachment fitting and the 

lower surface of washer (10), is 0.015 in to 0.060 in 

(0.381mm to 1.524 mm). 

(g) Torque the nuts (9), and (14) from 30 to 35 lbf in (3.39 to 3.95 Nm). 

Refer to SPM-MM 20-21-00-910-801. 

(h) Attach the control rod (2) and electrical connector (3) to the flap 

position transmitter as follows: 

(i) Align the eye of the control rod (2) with the lever (8). 

(ii) Install the bolt (7), washer (6) and the nut (5). 

(iii) Torque the nut (5), from 20 to 25 lbf in (2.26 to 2.82 Nm). Refer to 

SPM-MM 20-21-00-910-801. 

(iv) Install the cotter pin (4). Refer to SPM-MM 20-50-00-400-802. 

(v) Remove the protective covers from the open ends of the electrical 

connector (3) and from the electrical connection of the position 

transmitter. 

(vi) Connect the electrical connector (3) to the flap position transmitter. 

NOTE: If detached, attach the electrical connector wire to the 

necessary locations on the structure. 

(i) Install the bonding jumper on the flap hinge box (1). Refer to 

SPM 51-80-00-400-801. 

(j) Do the electrical bonding test for the applicable flap hinge box (1). 

Refer to SPM-MM 51-80-00-760-801. 

(17) Install the access panels that follow: 

ACCESS DESIGNATION TASK 

571BB (671BB) Wing Lower Surface – Access Panel 57−21−04−400−803 

541AT (641AT) Wing Upper Surface – Access Panel 57−21−01−400−802 

540EB (640EB) Fuel Tank – Access Panels 28−11−01−400−801 

540FB (640FB) Fuel Tank – Access Panels 28−11−01−400−801 
MODEL CL-600-2B16

Basic Issue: Dec 20/2012 A605-57-004

Revision 01: Sep 26/2013 Page 15 of 20 

(18) Remove the DO NOT CONNECT − FUEL TANK MAINTENANCE placard 

from the battery. 

(19) Remove the DO NOT CONNECT − FUEL TANK MAINTENANCE placard 

from the ac and the dc ground power receptacles. 

(20) Connect the main battery. Refer to TASK 24-32-00-440-801. 

(21) Connect the APU battery. Refer to TASK 24-32-00-440-802. 

(22) Proceed to the Testing in Paragraph 2.E. 

D. PART C: Correctly Oriented Inboard Flap Fasteners on the Hinge Box 

Wing Forward Fitting 

If the forward fasteners heads are correctly oriented as per Figure 1, you 

already meet the intention of this Service Bulletin and no further action is 

required, proceed to the Close-out in Paragraph 2.F. 

E. Testing 

(1) Remove the tags and close the circuit breakers that follow: 

CB PANEL CB NO. NAME ZONE 

CBP-2 B5 FLAP MOTOR 2 222 

CBP-3 B11 FLAP MOTOR 1 221 

(2) Connect and energize the external AC power. Refer to TASK 12-00-07-861-801. 

(3) Do an operational test of the inboard flaps to make sure the flap hinge box 

assemblies move freely, before installing the flap hinge-fairings. Refer to 

TASK 27-54-00-710-801. 

(4) Remove the external AC power. Refer to TASK 12-00-07-861-802. 

(5) Open and tag the circuit breakers that follow: 

CB PANEL CB NO. NAME ZONE 

CBP-2 B5 FLAP MOTOR 2 222 

CBP-3 B11 FLAP MOTOR 1 221 

(6) Install the left and right forward and aft inboard flap hinge-fairings that follow: 

Refer to TASK 57-26-03-400-801. 

ACCESS DESIGNATION 

571AB (671AB) Fairing, Forward Inboard – Flap Hinge 

571EB (671EB) Fairing, Forward Inboard – Flap Hinge 

572DB (672DB) Aft Inboard – Flap Hinge Fairing 

572GB (672GB) Aft Inboard – Flap Hinge Fairing 
MODEL CL-600-2B16

Basic Issue: Dec 20/2012 A605-57-004

Revision 01: Sep 26/2013 Page 16 of 20 

(7) Apply a filet of sealant around the forward and aft inboard flap hinge fairings. 

Refer to SPM-MM 51-23-00-390-805. 

(8) Remove the tags and close the circuit breakers that follow: 

CB PANEL CB NO. NAME ZONE 

CBP-2 B5 FLAP MOTOR 2 222 

CBP-3 B11 FLAP MOTOR 1 221 

(9) Connect and energize the external AC power. Refer to TASK 12-00-07-861-801. 

(10) Do an operational test of the inboard and outboard flaps. Refer to 

TASK 27-54-00-710-801. 

F. Close-out 

(1) If not already done, remove the tags and close the circuit breakers that 

follow: 

CB PANEL CB NO. NAME ZONE 

CBP-2 B5 FLAP MOTOR 2 222 

CBP-3 B11 FLAP MOTOR 1 221 

(2) Remove all tools, equipment and unwanted materials from the aircraft. 

G. Recording 

You can do each PART of this Alert Service Bulletin independently. When any 

PART of this Alert Service Bulletin is completed, make an entry in the aircraft 

log and send the attached Incorporation Notice to Bombardier Business Aircraft 

Customer Services (BBACS). 

This Alert Service Bulletin can only be closed when: 

- The modification in PART B is completed. 

or 

- PART C is completed to confirm that the forward fasteners heads are 

correctly oriented. 

In an effort to improve the quality of our technical communications, we are 

requesting your feedback. Please take a moment to fill out our easy on-line 

Alert Service Bulletin survey: 

http://csefeedback.aero.bombardier.com
MODEL CL-600-2B16

Basic Issue: Dec 20/2012 A605-57-004

Revision 01: Sep 26/2013 Page 17 of 20 

3. MATERIAL INFORMATION 

A. Kit 

Kit 605K57-004 is necessary to do PART B of this Alert Service Bulletin and 

contains the parts that follow: 

NEW 

PART NO. 

QTY ITEM USED 

PART NO. 

INSTRUCTIONS - 

DISPOSITION 

600-57-26-001-001 1 Shim - - 

600-57-26-001-002 1 Shim - - 

600-57-26-001-003 1 Shim - - 

600-57-26-001-004 1 Shim - - 

600-57-26-001-005 1 Shim - - 

600-57-26-001-006 1 Shim - - 

600-57-26-001-007 1 Shim - - 

600-57-26-001-008 1 Shim - - 

HST54AG8-11 

or 

HST54AC8-11 

or 

HST54AP8-11 

or 

HST54AZ8-11 

(See NOTE 3) 

4 Pin (HI-LITE)

HL912AP-8-11 

or 

HST54AG8-11 

Discard 

HST54AG8-12 

or 

HST54AC8-12 

or 

HST54AP8-12 

or 

HST54AZ8-12 

(See NOTE 3) 

12 Pin (HI-LITE)

HL912AP-8-12 

or 

HST54AG8-12 

Discard 

HST154AG8-11 

or 

HST154AC8-11 

or 

HST154AP8-11 

or 

HST154AZ8-11 

(See NOTE 4) 

1 Pin (HI-LITE)

HL912AP-8-11 

or 

HST54AG8-11 

Discard 
MODEL CL-600-2B16

Basic Issue: Dec 20/2012 A605-57-004

Revision 01: Sep 26/2013 Page 18 of 20 

NEW 

PART NO. 

QTY ITEM USED 

PART NO. 

INSTRUCTIONS - 

DISPOSITION 

HST154AG8-12 

or 

HST154AC8-12 

or 

HST154AP8-12 

or 

HST154AZ8-12 

(See NOTE 4) 

2 Pin (HI-LITE)

HL912AP-8-12 

or 

HST54AG8-12 

Discard 

KFN674-4 

or 

B0203015-4 

16 Self Locking 

Nuts 

HL75-8AW 

or 

B0203015-4 

Discard 

MS24665-71 2 Cotter Pin MS24665-71 Discard 

NOTES: 1. In case of discrepancy between this list and the “Alert Service 

Bulletin Kit Parts List” contained in the respective kit, then the latter 

list prevails. 

2. The actual quantity for some of the hardware contained in the kit 

can be greater than the amount shown in the table as these items 

are supplied in prepackaged quantities. 

3. Require for nominal size holes. 

4. If Required for First (1st) oversize holes. 

B. Parts 

The parts that follow may be necessary, to do PART B of this Alert Service Bulletin 

if found damaged or corroded when removed and are available from Bombardier 

Aerospace Parts Services, Montreal: 

NEW 

PART NO. 

QTY ITEM USED 

PART NO. 

INSTRUCTIONS -

DISPOSITION 

600-10300-609 0 to 8 Bushing, 

AFT Attachment Fitting 

600-10300-609 Discard 

600-10300-611 0 to 8 Bushing, 

FWD Attachment Fitting 

600-10300-611 Discard 

NOTE: The part numbers for the items listed above are subject to change without 

revision to this Service Bulletin. In case of discrepancy between this list and 

any other list, the Illustrated Parts Catalog prevails and shall be used to 

determine the latest part number. 
MODEL CL-600-2B16

Basic Issue: Dec 20/2012 A605-57-004

Revision 01: Sep 26/2013 Page 19 of 20 

C. Material 

The materials that follow, or equivalent, are necessary to do PART B of this Alert 

Service Bulletin. These can be purchased from a local supplier. Bombardier 

Aerospace does not pay for these consumables.

DESCRIPTION PART 

No./NAME 

SPECIFICATION QUANTITY SUPPLIER

(See Note)

Corrosion 

inhibitor 

Compound 

Mastinox 6856K - As 

Necessary Code: A 

Integral Fuel 

Tank Sealant 

CT: (9 hours) B1/2 

(20 hours) B2

P/S 870B MIL-PRF-81733 

Type II 

As 

Necessary Code: A 

Sealant 

CT: (12 hours) B1/2 

(24 hours) B2 

PR1776M B1/2 

or 

PR1776M B2 

- As 

Necessary Code: A 

Durathane High 

Gloss Enamel 

CT: (12 hours)

7600 line BAMS 565-002 As 

Necessary Code: B 

Epoxy Primer 

Grey 

CT: (2 hours)

4500-P-40B 

(16473, FS 595B) BAMS 565-001 As Necessary Code: B 

Conversion 

Coating Alodine 1201 MIL-DTL81706B Type II 

As 

Necessary Code: C 

Epoxy Resin 

CT: (24 hours)

Hysol 

EA9309.3NA AS9354002 As Necessary Code: C 

Fuel Tank 

Coatings 

(Primer Yellow) 

CT: (24 hours)

20P1-10 BAMS 565-010 As 

Necessary Code: D 

Anti-Seize 

lubricant WD-40 - As 

Necessary Code: E 

Brush, Natural or 

Synthetic Bristle - - As 

Necessary Code: E 

Scraper, 

Non-Metallic - - As 

Necessary Code: E 

NOTES: 1. Refer to the table that follows for each supplier’s address listed by codes. 

2. The Curing Time (CT), if applicable, for each consumable material 

is indicated with the description of each product. 

3. At time of release of this Alert Service Bulletin, the information on 

the supplier was valid and accurate. In the event that this 

information has changed, the operator is encouraged to use the 

World Wide Web to find a local supplier. 
MODEL CL-600-2B16

Basic Issue: Dec 20/2012 A605-57-004

Revision 01: Sep 26/2013 Page 20 of 20 

SUPPLIERS ADDRESSES BY CODES 

Code: A 

PRC – Desoto International 

5430 San Fernando Road, 

PO Box 1800, Glendale, 

CA, U.S.A. 91209 

Tel.: 1-800-228-5635 

Fax: (818)-549-7790 

Web Site: www.ppg.com/prc-desoto

Code: B 

Tempo Aerospace Inc 

205 Fenmar Drive, 

Toronto, Ontario, Canada 

M9L 2X4 

Tel.: 1-416-746-2233 

Fax.: 1-416-746-2235 

E-mail: sales@tempo-aerospace.com

Web Site: www.tempo-aerospace.com

Code: C 

Henkel Corporation 

2850 Willow Pass Road 

Bay Point, California 94565 

Tel.: 1-925-458-8000 

Fax: 1-925-458-8030 

Web Site: www.henkelna.com

Code: D 

AkzoNobel Aerospace Coatings. 

1 East Water Street 

Waukegan, IL 60085 

USA 

Tel.: 1-847-623-4200 

Fax.: 1-847-625-3200 

E-mail: customer.service@akzonobel.com

Web Site: www.akzonobel.com 

Code: E 

Commercially Available 

D. Publications 

No publications required. 
ALERT SERVICE BULLETIN EVALUATION FORM 

(Your ideas will help us provide better bulletins) 

SERVICE BULLETIN: A605-57-004 ISSUE: Rev. 01 DATED: Sep 26/2013 

 

TITLE: Special Check/Modification – Inboard Flap Hinge Box – Forward Attachment Fittings 

Fasteners 

In an effort to improve the quality of our technical communications, we are replacing 

the standard Service Bulletin Evaluation Form with an on-line Service Bulletin 

Survey and we are requesting your feedback. Please take a moment to fill out our 

easy on-line Service Bulletin survey: 

http://csefeedback.aero.bombardier.com
ALERT SERVICE BULLETIN INCORPORATION SHEET – 

“A605-57-004” 

BOMBARDIER 

SUBMISSION

Upon completion of the Service Bulletin, please fill-in, fax to 

(514) 855-8798 or e-mail to Fracas at fracas.montreal@aero.bombardier.com

If your aircraft is registered on CAMP and you are reporting to them, 

please do not send the incorporation sheet to Bombardier. If your aircraft 

is on another tracking system, please contact Bombardier to make 

arrangements for automated data submission. 

 COMPLIED WITH

 Alert Service 

Bulletin Number 

 Rev. * Parts 

Completed 

YES NO N/A Remarks/Reason 

 A605-57-004 01 PART A 

 “ “ PART B 

 “ “ PART C 

Actual hours to accomplish Service Bulletin: 

1. Where the Service Bulletin is divided into a number of parts (e.g., PARTS A, B, 

C, D, etc.) which can be carried out separately, indicate only those parts 

completed at this time. 

2. For repetitive checks (usually PART A) only the initial check should be reported 

unless otherwise stated in the Service Bulletin. 

* NOTES: 

 

 3. When more than one part is carried out at the same time, each part should be 

reported. 

 Aircraft Serial No. Aircraft Reg. No. 

 Airframe Hours: Airframe Landings 

 S.B. Incorporation date Service Order No. 

 (dd/mm/yy) 

 Facility Incorporating S.B. 

 Name Signature Date 

 (dd/mm/yy) Signature not required if sent by E-Mail
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Bombardier Business Aircraft Customer Services (BBACS) 

P.O. Box 6087, Station Centre-ville 

Montreal, Québec, Canada H3C 3G9 

Attention: Customer Support Department, Maintenance Engineering 

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