# Bombardier Recommended Service Bulletin 40-56-03

Copy: Revision 1 ("SB40-56-03 R 1"), 12 pages: PDF https://openairdocs.org/files/sha256/b1/2e/b12e0542afb2a1c6de6e2b530da77de6b69e3d000967cf72c2538c0dc2c751d4; text https://openairdocs.org/service-documents/bombardier/sb-40-56-03/file/b12e0542afb2.md. Rights: © Bombardier Inc. Filed by the FAA in regulations.gov docket FAA-2014-0249; AD 2015-12-06 incorporates this document by reference. Not covered by OpenAirDocs’ CC0 dedication.

## Details

- Manufacturer: [Bombardier](https://openairdocs.org/service-documents/bombardier.md)
- Type: Service bulletin (Recommended Service Bulletin)
- Number: 40-56-03
- Latest revision known: 40-56-03, Revision 1, dated October 15, 2012 (OpenAirDocs)
- Page: https://openairdocs.org/service-documents/bombardier/sb-40-56-03

## ADs that cite it (1) (OpenAirDocs)

Newest first, with the revision each names, as OpenAirDocs read it from the AD's text.

- [AD 2015-12-06](https://openairdocs.org/ad/2015-12-06.md), effective Jul 21, 2015: Revision 1

Also cited in [1 proposed AD](https://openairdocs.org/service-documents/bombardier/sb-40-56-03/proposed.md).

## Text (12 pages)

Rights: © Bombardier Inc. Filed by the FAA in regulations.gov docket FAA-2014-0249; AD 2015-12-06 incorporates this document by reference. Not covered by OpenAirDocs’ CC0 dedication. Each page's text from the PDF; open the PDF at a page with #page=N.

### Page 1

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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 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 serv ice bulletin title regarding facilit ies and personnel that are autho-
rized 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 Engineer-
ing.
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 Engineer-
ing.
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.

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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  1O c t  15/12

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THIS PUBLICATION IS AVAILABLE AT:
www.cic.bombardier.com
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.
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. Diversion contrary to United States law is prohibited.
SB 40-56-03
Recommended
WINDOWS- WINDSHIELD COUPE RAIL INSPECTION
CAUTION: ONLY  AUTHORIZED FACILITIES AND LEARJ ET TRAINED PERSONNEL CAN COM-
PLETE 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.

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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 Facil-
ity or an authorized service facility that has received specific training in per-
forming 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 publica-
tion 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 per-
sonnel 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 Logi stics for parts availability and
shipping times as necessary. (Refer to the title page of this document for contact informa-
tion.)
*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 TA SK
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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THIS 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 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 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 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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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 windshield
removal, contact Learjet Field Support Engineering for repair or replacement instruc-
tions.
TABLE  1
PART  NUMBER NOMENCLA TURE IDENTIFY  TO SPARESREPLACEMENT 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 SPARESREPLACEMENT 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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THIS 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 WIND-
SHIELDS. NO ENTRY THROUGH FORWARD ENTRY DOOR WHEN BOTH WIND-
SHIELDS 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 AIR-
CRAFT 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 dam-
age 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 Non-
Destructive 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.

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SB 40-56-03
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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 Identifica-
tion 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 re curring eddy current
inspection.
(8) If material thickness is below 0.166 in the "X" dimension (rail) and/or below 0.134 in the "Y" dimen-
sion (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 instructions on moving the aircraft 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 instructions on moving the aircraft to the repair facility.
(12) Mark new data plate with number using permanen t 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 mark-
ing be made permanent by coating with clear 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 Man-
ual.)
D. Return Aircraft to Airworthy Status
(1) Remove electrical power if no longer required, a nd return aircraft to normal operating condition.

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SB 40-56-03
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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 certification authority. Note if one or both coupe rail(s) will require the recurrent 5000
hour eddy current inspection.

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www.cic.bombardier.com
SB 40-56-03
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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)

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www.cic.bombardier.com
SB 40-56-03
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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)

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