Bombardier Service Bulletin 40-71-02

SB 40-71-02 Page 1 of 28 b 2 THIS SERVICE BULLETIN IS AVAILABLE AT:

www.cic.bombardier.com Basic Issue: Feb 13/07 Refer to applicable government 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.

© 2007, Bombardier Inc. All rights reserved.

Challenger*, Global Express*, Learjet*, are Trademarks of Bombardier Inc.

LEARJET 40

RECOMMENDED SB 40-71-02

SERVICE BULLETIN If you cannot do all steps in this service bulletin 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.

POWER PLANT - MODIFICATION OF THE LEFT AND RIGHT ENGINE WIRE ROUTING AND

CLAMPING

1. Planning Information A. Effectivity

(1) Learjet 45-2001 thru 45-2069.

B. Reason

(1) The purpose of this modification is to improv e the routing and clamping of the left and right engine alternator wire harnesses and the starter/generator wire bundles to prevent chafing. An inspection to reveal possible chafing between the left engine hydraulic and fuel tubes is also necessary.

NOTE: Aircraft that have previously installed the left engine hydraulic pump case drain tube part number 4529101090-005 tube per Learjet Service Bulletin A40-29-03 are not required to replace the tube as instructed in this service bulletin.

CONTACT INFORMATION DISTRIBUTION DATE Business Aircraft Learjet Inc.

MS 53 P.O. Box 7707 Wichita, Kansas 67277-7707

(316) 946-2421 February 13, 2007

SB 40-71-02 Page 2 of 28 LEARJET 40

SERVICE BULLETIN THIS SERVICE BULLETIN IS AVAILABLE AT:

www.cic.bombardier.com Basic Issue: Feb 13/07 C. Description

(1) This service bulletin provides instructions to c hange the routing and clamping configuration of the engine and alternator wire harnesses, and the starter/generator wire bundles. Instructions are also provided to inspect specific hydr aulic tubes located within the left engine nacelle for chafing between the adjacent fuel tubes, to replace tubes damaged beyond acceptable limits, and to secure the hydraulic tubes with additional clamps.

D. Compliance

(1) Recommended - Bombardier Learjet Inc. recommend s that you do this service bulletin in less than 300 flight hours from the initial distribution date of this service bulletin.

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 cause the labor hours to change.

G. Expense Coverage

(1) Labor Coverage

(a) Aircraft in the new aircraft warranty period, labor coverage is provided.

NOTE: For labor coverage to apply, you must do this service bulletin at a Bombardier Business Aviation Service Fa cility or at a Bombardier Learjet Authorized Service Facility. You must do this service bulleti n within 24 months from the release date of this service bulletin, basic issue, February 13, 2007.

(b) Aircraft out of the new aircraft warranty period, no labor coverage is provided.

-801 KIT -802

KIT TASK

1.0 1.0 Labor hours to gain access.

3.5 4.0 Labor hours to do th e aircraft modification.

1.5 1.5 Labor hours to do a func tional test/operational check.

1.0 1.0 Labor hours to return the aircraft to airworthy status.

7.0 7.5 Total Labor Hours

SB 40-71-02 Page 3 of 28 LEARJET 40

SERVICE BULLETIN THIS SERVICE BULLETIN IS AVAILABLE AT:

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(2) Material Coverage

(a) Aircraft in the new aircraft warranty period, material coverage is provided.

NOTE: For material coverage to apply, this service bulletin kit must be placed on order from Bombardier within 12 months from the basic issu e distribution date of this service bulletin, February 13, 2007.

(b) Aircraft out of the new aircraft warranty period, no material coverage is provided.

(3) Smart Parts

(a) For those aircraft in the new aircraft warranty peri od at the time of service bulletin distribution, Smart Parts Plus does not pay for the kits at any time.

(b) For those aircraft out of the new aircraft warranty period at the time of service bulletin distribution, Smart Parts Plus pays for the kits for up to 12 months from the service bulletin distribution date.

H. Material Required to do this Service Bulletin NOTE: The above price can change.

To place an order for these kits, please call Bombardier Aerospace Parts Logistics Business Aircraft Customer Service at 1-888- 222-1428 in North America or 1-316-946-2377 outside North America for information.

Refer to paragraph 3.A. to know which kit is necessary.

(1) Other materials/parts necessary to do this service bulletin.

NOTE: To place an order for these materials, please call Bombardier Aerospace Parts Logistics Business Aircraft Customer Service at 1-888-222-1428 in North America or 1-316- 946-2377 outside North America for information.

PART NUMBER QTY NOMENCLATURE PRICING 4571530001-801 1 Service Bulletin Kit $108.00 4571530001-802 1 Service Bulletin Kit $80.45

PART NUMBER NAME QTY MANUFACTURER 361 Tape-Fiberglass 1 Roll 3-M Company, St. Paul, MN MIL-T-43435E or equivalent String Tie As Required Commercially Available Red GLPT Insulating Varnish As Required Commercially Available

SB 40-71-02 Page 4 of 28 LEARJET 40

SERVICE BULLETIN THIS SERVICE BULLETIN IS AVAILABLE AT:

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(2) Other materials/parts that may be necessary to do this service bulletin based on inspection results.

NOTE: * Required on aircraft that have not installed the 4529101090-005 left engine hydraulic pump case drain tube per Learjet Service Bulletin A40-29-03.

To place an order for these parts, please call Bombardier Aerospace Parts Logistics Business Aircraft Customer Service at 1-888-222-1428 in North America or 1-316- 946-2377 outside North America for information.

I. Tooling

(1) None.

J. Weight and Balance

(1) Change in basic weight and moment.

K. References

(1) Learjet Maintenance Manual, Chapters 12, 20, 24, 28, 29, 71 and 80.

2. Accomplishment Instructions A. Gain Access

(1) Disconnect the external electrical power and the main and emergency batteries from aircraft.

(Refer to Learjet Maintenance Manual, Chapter 24.)

(2) On aircraft 45-2001 thru 45-2026, remove the left and right engine upper and lower engine cowling. (Refer to Learjet Maintenance Manual, Chapter 71.)

(3) On aircraft 45-2027 thru 45-2069, remove the left engine lower cowling.

PART NUMBER QTY NOMENCLATURE EFFECTIVITY 4529101067-001 1 Tube-Hydraulic (Pressure) 45-2001 thru 45-2026 4529101071-001 1 Tube-Hydraulic (Pump Supply) 45-2001 thru 45-2026 4529101075-005 1 Tube-Hydraulic (Pump Case Drain) 45-2001 thru 45-2026 4529101090-005 1 Tube-Hydraulic (Pump Case Drain All * See Note Below 4573100000V13-001 1 Tube-Fuel (Motive Flow) 45-2001 thru 45-2026 4573100000V12-001 1 Tube-Fuel (Supply) 45-2001 thru 45-2026

CHANGE IN BASIC WEIGHT CHANGE IN BASIC MOMENT Plus (+) 1.21 pounds Plus (+) 629.2 inch-pounds

SB 40-71-02 Page 5 of 28 LEARJET 40

SERVICE BULLETIN THIS SERVICE BULLETIN IS AVAILABLE AT:

www.cic.bombardier.com Basic Issue: Feb 13/07 B. Modification of Aircraft

(1) On aircraft 45-2001 thru 45-2026, disconnect the left engine starter/generator wire bundles and remove the clamping as follows;

(a) Disconnect the starter/generator wire bundles (G1-B "+" and G1-E "-") from the starter/generator.

(b) Disconnect the engine wire harness (G 1 and G1P1) from the starter/generator.

(c) Disconnect alternator wire harness (G3P2) from the alternator.

(d) Remove the existing clamping configuration of the starter/ge nerator wire bundles at nacelle station 180.00. (See Figure 1, View C-C.)

(2) On aircraft that have not installed the 4529101090-005 left engine hydraulic pump case drain tube per Learjet Service Bu lletin No. A40-29-03, replace the 4529101090-001 left engine hydraulic pump case drain tube with a new 4529101090-005 tube. (See Figure 1, View L-L.)

(3) On aircraft 45-2001 thru 45-2026, inspect the remaining hydraulic tubing on the left engine for clearance as follows;

(a) Inspect the hydraulic tubing for clearance and chafing in the area shown. (See Figure 1, View K-K and Detail M.) (Refer to Learjet Maintenance Manual, Chapter 20 for damage tolerance on tubing.)

CAUTION: REVIEW THE SAFETY PRACTIC ES WHEN YOU WORK WITH OR AROUND THE AIRCRAFT HYDRAULIC SYSTEM. (REFER TO LEARJET MAINTE- NANCE MANUAL, CHAPTER 29.)

(b) On aircraft where chafing on the hydraulic tubes is beyond acceptable limits, do as follows;

1) Depressurize the hydraulic system. (Refer to Learjet Maintenance Manual, Chapter 12.)

2) Replace the chafed tubing.

(c) Install additional clamping to the hydraulic tubing. (See Figure 1, Detail M.)

(d) Inspect the adjacent fuel tubing for interference with the hydraulic tubing.

CAUTION: REVIEW THE SAFETY PRACTIC ES WHEN YOU WORK WITH OR AROUND THE AIRCRAFT FUEL SYSTEM. (REFER TO LEARJET MAINTENANCE MAN- UAL, CHAPTER 28.)

(e) On aircraft where interference between the fu el tubing and hydraulic tubing is found, replace the fuel tubing as noted and shown. (See Figure 1, View K-K.)

(4) On aircraft 45-2027 thru 45-2069, inspect the remaining left engine hydraulic tubing for clearance with adjacent tubing, structure, and other components.

(5) On aircraft 45-2001 thru 45-2026, change the routing and clamping of the left engine starter/generator wire bundles as follows;

(a) Route the starter/generator wire bundles and the engine wire harness (G1 and G1P1) between the engine and the hydraulic pump. (See Figure 1, Detail B.)

NOTE: The starter/generator wire bundles should be next to the engine and inboard of the thrust reverser hydraulic plumbing coming through nacelle station 180.00.

SB 40-71-02 Page 6 of 28 LEARJET 40

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(b) Route and clamp the starter/generator wire bund les as shown. (See Figure 1, View A-A, Detail D, Detail E, View F-F and View G-G.)

(c) Route and clamp the starter/generator wire bund les at nacelle station 186.00 as shown. (See Figure 1, View H-H and View J-J.)

(d) Apply MIL-I-22129 spiral wrap or equivalent around the starter/generator wire bundles as necessary. (See Figure 1, Detail B and View C-C.)

NOTE: Make sure that the minimum clearance requirements are maintained between the spiral wrapped starter/generator wire bundles and adjacent tubing and components. (Refer to Learjet Maintenance Manual, Chapter 20 for clearance requirements.)

(e) Connect the starter/gen erator wire bundles (G1-B "+" and G1-E "-") to the starter/generator.

(f) Starting immediately forward of nacelle statio n 186.00, apply MIL-I-22129 or equivalent spiral wrap to engine wire harnesses (G1 and G1P1), and alternator wire harness (G3P2) as shown.

(See Figure 1, View H-H and View J-J.)

NOTE: At the location where alternator wire harness (G3P2) begins to route toward the alternator, discontinue spiral wrapping the engine wire harnesses (G1 and G1P1).

Continue the spiral wrap on alternator wire harness (G3P2) up to the alternator.

(g) Connect the engine wire harness (G1 and G1P1) to the starter/generator.

(h) Use MIL-T-43435E or equivalent string tie to secure the spiral wrap to the harnesses.

(6) On aircraft 45-2001 thru 45-2026, change the routing and clamping of the left engine alternator wire harnesses (G3P1 and G3P2) as follows;

(a) Route alternator wire harness (G3P2) along the starter/generator wire bundles and secure to starter/generator wire bundles as shown. (See Figure 1, View C-C, View H-H and View J-J.)

(b) Connect alternator wire harness (G3P2) to the alternator.

(c) Disconnect alternator wire harnesses (G3P1) from the alternator.

(d) Route the alternator wire harness (G3P1) as shown. (See Figure 1, View K-K.)

(e) Wrap alternator wire harness (G3P1) with fiberglass tape at bracket assemblies as shown.

(See Figure 1, View K-K.)

(f) Install new clamping configuration on alternator wire harness (G3P1) as shown. (See Figure 1, View K-K.)

(g) Connect alternator wire harness (G3P1) to the alternator.

(h) Apply MIL-I-22129 spiral wrap or equivalent around alternator wire harnesses (G3P1) as necessary. (See Figure 1, Detail B, View C-C and View K-K.)

NOTE: Make sure that the minimum clearance requirements are maintained between the spiral wrapped alternator wire harnesses and adjacent tubing and components.

(Refer to Learjet Maintenance Manual, Chapter 20 for clearance requirements.)

(i) Use MIL-T-43435E or equivalent string tie to secure the spiral wrap to the harnesses.

SB 40-71-02 Page 7 of 28 LEARJET 40

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(7) On aircraft 45-2001 thru 45-2026, change the routing and clamping configuration of the right engine starter/generator wire bundles and alternator wire harnesses as follows;

(a) Disconnect alternator wire harnesses (G3P1 and G3P2) from the alternator.

(b) Remove the clamps and attaching hardware th at support alternator wire harnesses (G3P1 and G3P2) to nacelle station 180.00. (See Figure 2, View C-C.)

(c) Disconnect the engine wire harness (G 1 and G1P1) from the starter/generator.

(d) Install the new clamping configuration as shown, (See Figure 2, View D-D, View E-E, View F- F, View G-G, View H-H and View J-J.)

(e) Route alternator wire harnesses (G3P1 and G3P2) and engine wire harnesses (G1 and G1P1) as shown. (See Figure 2, Detail B and View C-C.)

NOTE: Wire harnesses routed between nacelle station 180.00 and 186.50 must be routed between the engine and the hydraulic pump.

(f) Apply MIL-I-22129 spiral wrap or equivalent to the alternator wire harnesses (G3P1 and G3P2) and engine wire harnesses (G1 and G1P1) as shown. (See Figure 2, View B-B and View C-C.)

NOTE: Make sure that the minimum clearance requirements are maintained between the spiral wrapped alternator and engine wire harnesses and adjacent tubing and components. (Refer to Learjet Maint enance Manual, Chapter 20 for clearance requirements.)

(g) Use MIL-T-43435E or equivalent string tie to secure the spiral wrap to the harnesses.

(h) Install new clamping configuration on alternator wire harness (G3P1) as shown. (See Figure 2, View C-C.)

(i) Route alternator wire harness (G3P2) along alternator wire harness (G3P1) and tie together with MIL-T-43435E string tie or equivalent. Apply insulating varnish to secure string ties. (See Figure 2, View C-C.)

(j) Connect alternator wire harnesses (G3P1 and G3P2) to the alternator.

(k) Connect engine wire harnesses (G1 and G1P1) to the starter/generator.

NOTE: It is permissible to fold and tie engine wire harness (G1P1) as necessary to take up excessive length.

(8) On aircraft 45-2001 thru 45-2026, do an inspection of the clearances between the wire harnesses and the hydraulic and fuel tubing on the left and right engines. (Refer to Learjet Maintenance Manual, Chapter 20.)

(9) On aircraft 45-2027 thru 45-2069, do an inspection of the clearances between the wire harnesses and the hydraulic and fuel tubing on the left engine. (Refer to Learjet Maintenance Manual, Chapter 20.)

(10) On aircraft that replaced hy draulic tubes due to chafing, service the hydraulic system reservoir.

(Refer to Learjet Maintenance Manual, Chapter 12.)

SB 40-71-02 Page 8 of 28 LEARJET 40

SERVICE BULLETIN THIS SERVICE BULLETIN IS AVAILABLE AT:

www.cic.bombardier.com Basic Issue: Feb 13/07 C. Functional Test/Operational Check

(1) Connect the main and emergency batteries to the aircraft. (Refer to Learjet Maintenance Manual, Chapter 24.)

(2) Connect external electrical power.

(3) Do the Automatic Engine Start for the left and ri ght engines. (Refer to Learjet Maintenance Manual, Chapter 80.)

(4) Do the Generator Voltage Adjustment and Current Test. (Refer to Learjet Maintenance Manual, Chapter 24.)

(5) On aircraft that replaced hydraulic or fuel tubes, check new tubes for leaks around fittings.

D. Return Aircraft to Airworthy Status

(1) Install the left and right engine upper and lowe r engine cowling. (Refer to Learjet Maintenance Manual, Chapter 71.)

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.

NOTE: To complete the aircraft maintenance records, refer to FAR/CFR 43.9.

SB 40-71-02 Page 9 of 28 LEARJET 40

SERVICE BULLETIN THIS SERVICE BULLETIN IS AVAILABLE AT:

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3. Material Information A. Parts Required

(1) The 4571530001-801 Kit is for the left engine and contains the parts that follow.

NOTE: Some hardware comes in pre-packaged quantities. When that occurs, the quantity in the kit will be more than the quantity in the parts list.

(2) The 4571530001-802 Kit is for the right engine and contains the parts that follow.

PART NUMBER QTY NOMENCLATURE MS9592-014 1 Bracket MS9592-387 1 Bracket MS21919WCH4 2 Clamp MS21919WCH5 2 Clamp MS21919WCH10 1 Clamp MS21919WCH11 5 Clamp M85052/3-6 1 Clamp M85052/3-8 1 Clamp NAS1802-3-7 1 Screw NAS1802-3-8 4 Screw MS21042-3 4 Nut NAS1149C0316R 1 Washer SWT1/2Natural 15 ft. Spiral Wrap (MIL-I-22129)

PART NUMBER QTY NOMENCLATURE MS9592-010 3 Bracket MS9592-022 1 Bracket AN743-C12 1 Bracket MS21919WCH5 1 Clamp MS21919WCH9 3 Clamp MS21919WCH11 4 Clamp NAS1802-3-8 3 Screw MS21042-3 3 Nut SWT1/2Natural 15 ft. Spiral Wrap (MIL-I-22129)

SB 40-71-02 Page 10 of 28 LEARJET 40

SERVICE BULLETIN THIS SERVICE BULLETIN IS AVAILABLE AT:

www.cic.bombardier.com Basic Issue: Feb 13/07 NOTE: Some hardware comes in pre-packaged quantities. When that occurs, the quantity in the kit will be more than the quantity in the parts list.

B. Parts Removed List

PART NUMBER QTY NOMENCLATURE DISPOSITION EFFECTIVITY MS9592-010 2 Bracket Destroy 45-2001 thru 45-2026 (Both Engines) MS21919WH4 2 Clamp Destroy 45-2001 thru 45-2026 (RH Engine) MS21919WH5 2 Clamp Destroy 45-2001 thru 45-2026 (RH Engine) MS21919WH7 2 Clamp Destroy 45-2001 thru 45-2026 (RH Engine) MS21919WH8 2 Clamp Destroy 45-2001 thru 45-2026 (RH Engine) MS21919WH10 1 Clamp Destroy 45-2001 thru 45-2026 (LH Engine) MS21919WH12 4 Clamp Destroy 45-2001 thru 45-2026 (RH Engine) MS21919WH12 5 Clamp Destroy 45-2001 thru 45-2026 (LH Engine) NAS1802-3-8 2 Screw Destroy 45-2001 thru 45-2026 (RH Engine) NAS1802-3-9 2 Screw Destroy 45-2001 thru 45-2026 (LH Engine) NAS43DD3-64FC 1 Spacer Destroy 45-2001 thru 45-2026 (LH Engine) MS21042-3 1 Nut Destroy 45-2001 thru 45-2026 (LH Engine) 4529101067-001 1 Tube-Hydraulic (Pressure) Destroy 45-2001 thru 45-2026 * See Note Below (LH Engine) 4529101071-001 1 Tube-Hydraulic (Pump Supply) Destroy 45-2001 thru 45-2026 * See Note Below (LH Engine)

SB 40-71-02 Page 11 of 28 LEARJET 40

SERVICE BULLETIN THIS SERVICE BULLETIN IS AVAILABLE AT:

www.cic.bombardier.com Basic Issue: Feb 13/07 NOTE: * On aircraft 45-2001 thru 45-2026, replace hydraulic tubes as necessary that have chafing beyond acceptable limits.

* * On aircraft 45-2001 thru 45-2026, replace fuel tubes as necessary to correct or prevent an interference condition with the adjacent hydraulic tubes.

* * * Aircraft that have not installed the 4529101090-005 left engine hydraulic pump case drain tube per Learjet Service Bulletin No. A40-29-03.

4529101075-005 1 Tube-Hydraulic (Pump Case Drain) Destroy 45-2001 thru 45-2026 * See Note Below (LH Engine) 4529101090-001 1 Tube-Hydraulic (Pump Case Drain) Destroy 45-2001 thru 45-2069 * * * See Note Below (LH Engine) 4528200044-001 1 Tube-Fuel (Motive Flow) Destroy 45-2001 thru 45-2026 * * See Note Below (LH Engine) 4573100005-013 1 Tube-Fuel (Supply) Destroy 45-2001 thru 45-2026 * * See Note Below (LH Engine)

PART NUMBER QTY NOMENCLATURE DISPOSITION EFFECTIVITY

LEARJET 40

SERVICE BULLETIN

• F • G

NAC NAC NAC FS 3 I FS FS

180.00 200.00 209.15 NAC WL

100.00 — F G NOTE View A-A Notes information is found on the last sheet of this figure.

K40-407102-001-01 Left Engine Wire Harness Routing and Clamping Figure 1 (Sheet 1 of 9) Basic Issue: Feb 13/07 THIS SERVICE BULLETIN IS AVAILABLE AT: SB 40-71-02 www.cic.bombardier.com Page 12 of 28