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SPECIAL CHECK/MODIFICATION - RUDDER CONTROL SYSTEM - REPLACE THE
PILOT'S RUDDER PEDAL BAR ASSEMBLY OR RUDDER PEDAL ASSEMBLY The information below is provided for your reference. For full details, including labor and part coverage, please see corresponding paragraph contained within this bulletin.
RECOMMENDED
RELIABILITY/MAINTAINABILITY IMPROVEMENT
COMPLIANCE TIME See Paragraph 1.D.
EFFECTIVITY: AC Serial No. 5301 to 5665 MANPOWER: 8 man−hours for the removal/installation and testing of the pilot’s rudderpedal assy.
1 man−hour for the special check in PART A.
1 man−hour for the serialization in PART A.
2 man−hours for the modification in PART B.
CONTINUED AIRWORTHINESS (CAW)
FLEET CAMPAIGN NOYES TLMC, CH 5 AFFECTED NOYES KITS and/or PARTS YES NO
TOOLING/GSE NOYES PLANNING INFORMATION: See important information at the start of Paragraph 1. YES NO
DEDICATED SCHEDULE NOYES PREREQUISITE SERVICE BULLETINS: N/A To place an order for parts or kits, please call Bombardier Aerospace Parts Services at:
514−855−2999 or 1−866−538−1247
SERVICE BULLETIN SUMMARY www.cic.bombardier.com MODEL CL−600−2B16 ATA 27−21
FLIGHT CONTROLS Basic Issue: Mar 31/2016 604−27−037 Page 1 of 1 This Service Bulletin is available at:
SPECIAL CHECK/MODIFICATION - RUDDER CONTROL SYSTEM - REPLACE THE
PILOT'S RUDDER PEDAL BAR ASSEMBLY OR RUDDER PEDAL ASSEMBLY
1. PLANNING INFORMATION NOTES: 1. This Service Bulletin is applicable to the pilot’s rudder pedal bar assemblies only. Do not incorporate this Service Bulletin to the copilot’s rudder pedal bar assemblies.
2. If you incorporate PART B of this Service Bulletin, no further special check, in PART A, or replacement of tubes, in PART B, is necessary.
A. Effectivity CL−600−2B16 aircraft, Serial No. 5301 to 5665.
NOTE: The instructions given in this 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 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 Two rudder pedal mechanism incidents occurred on in−service aircraft.
Investigations determined that it is possible that there are cracks on the rudder pedal tubes, Part No. 600−90204−3, installed on the pilot’s rudder pedal assembly.
This Service Bulletin gives the procedures in PART A, to do a periodic Detailed Visual Inspection (DVI) or Eddy Current (EC) inspection for cracks on the pilot’s rudder pedal tubes, Part No. 600−90204−3, and to replace in PART B, the rudder pedal bar assembly or rudder pedal bar and pedal assembly.
SERVICE BULLETIN www.cic.bombardier.com MODEL CL−600−2B16 ATA 27−21
FLIGHT CONTROLS 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.
2016 Bombardier Inc. All rights reserved Learjet, Challenger, Global, are registered trademarks of Bombardier Inc. or its subsidiaries.
Basic Issue: Mar 31/2016 604−27−037 Page 1 of 21 This Service Bulletin is available at:
The DVI or the EC inspection on Part No. 600−90204−3 rudder pedal tubes and/or the replacement of the rudder pedal bar assemblies will prevent rudder pedal mechanism incidents.
Once you incorporate PART B of this Service Bulletin, no further special check, in PART A, or replacement of tubes, in PART B, is necessary.
C. Description This Service Bulletin gives instructions to:
− Remove the pilot’s rudder pedal assembly, and In PART A to:
− Perform a detail visual inspection (DVI) or an Eddy Current inspection (EC) on pilot’s rudder pedals tubes, − Mark the serial number of the inspected tube if you don’t find any crack on tube, − Re−install the old rudder pedal tubes assemblies, if no cracks are found and continue to repeat the inspection.
− If you find cracks on any of the tubes assembly, incorporate PART B.
In PART B to:
− Remove the rudder pedal bar (and pedal) assembly, − Install new rudder pedal bar (and pedal) assembly, and After PART A and PART B, as applicable:
− Do the operational test of the rudder control system.
MODEL CL−600−2B16 Basic Issue: Mar 31/2016 604−27−037 Page 2 of 21
D. Compliance
1. Recommended for PART A (DVI or EC inspection):
AIRCRAFT FLIGHT
CYCLES (FC)
FROM ENTRY IN
SERVICE
FIRST INSPECTION PERIODIC
INSPECTION Below 8250 FC at 9000 FC or Less Every 600 FC if you perform DVI, or Every 1000 FC if you perform EC Above 8250 FC and below 16625 FC Within 24 months or 750 FC, whichever comes first from this SB release date (Basic Issue) Above 16625 FC Within 12 months or 375 FC, whichever comes first from this SB release date (Basic Issue) If no cracks are found, a repeat inspection can be performed as per the table above, or PART B can be incorporated at any time to remove the requirement for the special check.
2. If cracks are found during the special check in PART A, incorporate PART B before the next flight. PART B replaces both pilot rudder pedal bar assemblies with Part No. 600−90204−11/12 even if you find cracks on one tube. Refer to the table that follows:
AIRCRAFT FLIGHT
CYCLES (FC) FROM
ENTRY IN SERVICE
PART B INCORPORATION Below 8250 FC at 9000 FC or Less Above 8250 FC and below 16625 FC Within 24 months or 750 FC, whichever comes first from this SB release date (Basic Issue) Above 16625 FC Within 12 months or 375 FC, whichever comes first from this SB release date (Basic Issue) You can incorporate PART B of this Service Bulletin without incorporating the PART A, if the compliance table is respected.
If you incorporate PART B of this Service Bulletin, no further special check, in PART A is necessary.
PART B is the permanent repair and can be incorporated in accordance with the table above as an alternative to the PART A special check.
MODEL CL−600−2B16 Basic Issue: Mar 31/2016 604−27−037 Page 3 of 21
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 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 EASA in accordance with established procedures.
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 604−00−002.
2. This 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 Service Bulletin.
3. Labor hours are based on the fact that the modification will be done at the next scheduled maintenance task or inspection. Therefore no man−hours are allotted to prepare the aircraft for maintenance or to prepare for this Service Bulletin.
8 man−hours are necessary to do the removal/installation and testing of the pilot’s rudder pedal assembly.
1 man−hour is necessary to do the special check in PART A.
1 man−hour is necessary to do the serialization in PART A.
2 man−hours are necessary to do the modification in PART B.
Bombardier Aerospace does not pay for the labor required to do this Service Bulletin.
G. Material − Cost and Availability Kit 605K27−008 may be necessary to do this modification in PART B.
MODEL CL−600−2B16 Basic Issue: Mar 31/2016 604−27−037 Page 4 of 21
KIT NO. PRICE 605K27−008 Please contact Bombardier Aerospace Parts Services, in Montreal, for delivery lead times and confirmation of prices.
The parts listed in Paragraphs 3.B. are necessary to do the special check in PART A.
Sufficient kits and/or parts will be kept for the estimated amount of orders.
To ensure a timely and effective upgrade program, advance scheduling of this Service Bulletin is required. For parts availability and to schedule your aircraft, please contact your Regional Manager (RM).
Smart Parts Plus pays for the kit if cracks are found during the inspection in PART A and within the compliance time of the SB.
Bombardier Aerospace does not pay for the kit or parts to do this Service Bulletin.
H. Tooling No equipment or special tools are necessary.
I. Weight and Balance
WEIGHT MOMENT +0.45 pound(s) (+0.20 kg) +98.34 pound−inch(es) (+1.13 kgm) J. Electrical Load Data No change.
K. References − Bombardier Aerospace, Restriction and/or Special Instruction (RSI), C−4130, Rev. A.
− Bombardier Aerospace, Modification Summary, 600−6427, Rev. A1.
− Bombardier Aerospace, Standard Practices Manual (SPM), Chapter 20.
− Bombardier Aerospace, Kit Drawing K600−90200, Rev. −−.
− Appendix A − DVI and Eddy Current NDT Procedure (attached).
− CL−604 Aircraft Maintenance Manual (AMM), Chapters 6, 12, 20, 24, 27, and
51.
− CL−604 Aircraft Illustrated Parts Catalog (AIPC), Chapters 6, 12 and 27.
− CL−604 Structural Repair Manual (SRM), Chapter 51.
MODEL CL−600−2B16 Basic Issue: Mar 31/2016 604−27−037 Page 5 of 21
L. Other Publications Affected − None.
M. Equivalent Service Bulletins For the Challenger 600 aircraft use SB 600−0770.
For the Challenger 601 aircraft use SB 601−0643.
For the Challenger 605 aircraft use SB 605−27−008.
For the Challenger 650 aircraft, use SB 650−27−002.
2. ACCOMPLISHMENT INSTRUCTIONS NOTES: 1. All TASKs given in the procedures that follow are from the CL−604 Aircraft Maintenance Manual (AMM) unless otherwise specified.
2. All references made to zones, access panels and/or doors, are from the CL−604 AMM, Chapter 6.
A. Aircraft Setup Remove the pilot rudder pedal assembly. Refer to AMM 27−21−01−000−802.
B. PART A − Special Check − DVI or Eddy Current Inspection of Pilot’s Rudder Pedal Tubes, for Cracks
(1) Do the steps that follow to get access to the two aft tapered holes in the rudder pedal tubes (refer to Figure 1):
NOTE: The procedure that follows is applicable for one rudder pedal tube.
The procedure for the other tube is the same.
(a) Remove and discard the lockwire from the bolt (8). Refer to SPM20−50−00−000−801.
(b) Remove and keep the bolt (8) and the washer (9) that connect the control rod assembly (7) to the connecting rod fitting (6).
(c) Remove and discard the two cotter pins (1), nuts (2) , washers (3), and tapered pins (4) that connect the connecting rod fitting (6) to the rudder pedal tube (5) . Refer to Figure 1.
(d) Move the connecting rod fitting (6) along the rudder pedal tube (5) to expose the two aft tapered holes.
(e) Clean the area around the two aft tapered holes. Refer to Figure 1 and to SPM51−25−00−110−801.
(2) Do DVI or Eddy Current inspection for cracks around the two aft tapered holes in the rudder pedal tubes (5). Refer to Appendix A of this Service Bulletin.
MODEL CL−600−2B16 Basic Issue: Mar 31/2016 604−27−037 Page 6 of 21
(3) If a crack is found around the aft tapered holes in the rudder pedal tubes (5), do PART B of this Service Bulletin before the next flight.
(4) If any damage is found on the rudder pedal tube Part No. 600−90204−3 at another location than the inspected area, contact Bombardier Aerospace, Customer Support Engineering for a disposition.
(5) If no cracks are found around the aft tapered holes in the rudder pedal tubes
(5), mark the serial number of the inspected tube as follows:
(a) Determine the serial number of the inspected tube. Do the steps that follow:
(i) First number is 1 for LHS and 2 for RHS.
(ii) Add a dash “−”
(iii) The third number is aircraft serial number.
(iv) Add a dash ”−”.
(v) Add a letter in alphabetical order starting with A. If for any reason the rudder pedal tube Part No. 600−90204−3 is replaced by a new one that is not serialized, serialize the new part using the next availble alphabet to avoid the usage of the same serial number on a different part.
(vi) Example: On aircraft 5301, for the LHS, the number of the first tube will be: “1−5301−A”.
(vii) Use an indelible ink pen or equivalent and identify the serial number of the applicable rudder bar assembly as determined at previous step.
NOTE: Protect the marking with an overcoat of clear enamel or with solvent resistant tape 3M#853. Overlap marking 0.5 in minimum in all directions.
(6) Reinstall the rudder pedal tubes. Do the steps that follow:
NOTE: The inspection in PART A must be repeated every 600 flight cycles if you performed the DVI or every 1000 flight cycles if you performed the Eddy Current inspection.
(a) Use the new taper pins (4), washers (3) and nuts (2) and wet (with fluid resistant epoxy primer) install the connecting rod fitting (6) to the rudder pedal tube (5). Refer to SRM 51−43−00−00 and 51−23−04−00.
(b) Torque the nuts (2) from 20 to 28 lbf in (2.26 to 3.16 Nm).
(c) Safety the nuts with cotter pins (1). Refer to SPM 20−50−00−400−802.
(d) Install the control rod assembly (7) to connecting rod fitting (6) with washer
(9) and bolt (8). Torque the bolt (8). Refer to SPM 20−21−00−910−801.
(e) Safety bolt (8) with lockwire. Refer to SPM20−50−00−000−801.
(f) Remove the rigging pin P1 from the control lever L1. Refer to Figure 1.
MODEL CL−600−2B16 Basic Issue: Mar 31/2016 604−27−037 Page 7 of 21
SB604_27_01_005 1 23 4 LEGEND
1. Pin, cotter
2. Nut, self−locking
3. Washer
4. Pin, tapered
5. Tube, rudder pedal
6. Fitting, connecting rod.
7. Rod assembly, control.
8. Bolt.
9. Washer.
0.250 in.
(6.35 mm) RUDDER PEDAL (REF)
INSPECTION AREA
TYPICAL 5 6 9 8 7 P1A AC B B C MODEL CL−600−2B16 Rudder Pedal Tubes Tapered Holes − Inspection Figure 1 Basic Issue: Mar 31/2016 604−27−037 Page 8 of 21
(7) Go to Paragraph 2.D., Testing.
C. PART B− Modification − Replacement of Both Pilot Rudder Pedal Bar assemblies or Pilot Rudder Pedal and Bar Assemblies NOTE: Incorporate PART B of this Service Bulletin before next flight if you find cracks on tube, Part No. 600−90204−3, during PART A.
PART B is a permanent repair and no further inspection in PART A or replacement in PART B is necessary if you installed new Rudder Pedal Bar assembly Part No. 600−90204−11 and 600−90204−12.
(1) Do the steps that follow to remove the pilot’s rudder pedal and bar assembly (refer to Figure 2):
NOTE: The procedure that follows is applicable for one rudder pedal and one bar assembly. The procedure for the other rudder bar and pedal assembly is the same.
(a) At the pedal (2), remove and discard the cotter pin (5), nut (6) and the washer (7) that hold the pedal (2) to rudder bar assembly (1).
(b) Remove the pedal (2).
(c) At the brake control lever (4), remove the cotter pin (9), nut (10), washer
(11) and bolt (12) that hold the brake control rod (3) to the brake control lever (4). Discard the nut (10).
(d) Remove and keep the brake control rod (3) and pedal link (8).
NOTE: Do not remove pedal link (8) from brake control rod (3).
(e) At brake lever (4), remove the cotter pin (13), nut (14) and washer (15).
Discard nut (14).
(f) Remove the pivot bolt (16) and brake control lever (4).
(g) Remove and discard the rudder bar assembly (1).
MODEL CL−600−2B16 Basic Issue: Mar 31/2016 604−27−037 Page 9 of 21
SB604_27_00_001 5 6 7 8 1 16 3 109 4 12 15 13 14 2 17 LEGEND
1. Rudder bar assembly
2. Pedal
3. Control rod, rudder pedal brake
4. Lever, brake assembly
5. Pin, cotter
7. Washer
8. Link, pedal
9. Pin, cotter
10. Nut
11. Washer
12. Bolt
13. Pin, cotter
14. Nut
15. Washer
16. Bolt, pivot
17. Torque tube
6. Nut
ATTACHEMENT
LUG (REF)
11 A MODEL CL−600−2B16 Replacement of rudder bar assemblies Figure 2 Basic Issue: Mar 31/2016 604−27−037 Page 10 of 21
(2) Do the steps that follow to install the new pilot’s rudder bar assemblies Part No. 600−90204−11/12 on the pilot’s rudder assembly (refer to Figure 2):
NOTE: The procedure that follows is applicable for one rudder bar assembly.
The procedure for the other rudder bar assembly is the same.
(a) Align the inner bores of the inboard and outboard rudder bar assembly (1), the inboard and the outboard brake control levers (4), and the three attachment lugs on the torque tube assembly.
(b) Wet install the pivot bolt (16) through torque tube attachment lugs, inboard rudder bar assembly (1) and brake control levers (4).
NOTE: Use CA1000 corrosion inhibiting compound or Mastinox compound for installation of bolt (16).
(c) Install the washer (15) and the nut (14) on the bolt (16). Torque the nut from 200 to 300 lbf in (23 to 34 Nm).
(d) Safety the nut with cotter pin (13). Refer to SPM−MM 20−50−00−400−802.
(e) Install the brake control rod (3) to the brake control lever (4) with bolt (12), washer (11) and nut (10). Torque nut (10). Refer to SPM−MM 20−21−00−910−801.
(f) Safety the nut with cotter pin (9). Refer to SPM−MM 20−50−00−400−802.
(g) Connect pedal (2) to rudder bar assembly (1) and pedal link (8) with washer (7) and new nut (6). Torque the nut (6) from 150 to 200 lbf in (17 to 23 Nm).
(h) Safety the nut (6) with cotter pin (5). Refer to SPM−MM 20−50−00−400−802.
(3) Go to Paragraph 2.D., Testing.
D. Testing
(1) Install the pilot rudder pedal assembly. Refer to AMM 27−21−01−400−802.
(2) Remove the safety devices, pins, warning signs and warning placards from flight controls, flight control surfaces. Make sure that persons and equipment are not near the control surfaces. Flight control movement can cause injury to persons and damage to equipment.
NOTE: Make sure that you remove the rigging pin (P1) from the level (L1) of the forward pivot assembly on the left side. Refer to Figure 1, View A.
(3) Do the operational test of the rudder control system. Refer to AMM 27−21−00−710−801.
(4) At the pilot’s rudder pedal cover, turn the stature control crank to move the rudder pedals to the fully aft position. Push on the rudder pedals to move them through their full range of travel. Make sure that there is a minimum clearance of 0.250 in (6.35 mm) between the brake control lever (4) (and its attaching parts) and the adjacent brake control lever, other components, or structure.
Refer to Figure 2.
MODEL CL−600−2B16 Basic Issue: Mar 31/2016 604−27−037 Page 11 of 21