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D S.B. 84-28-15 Page 1 of 18 17 Aug 2012 MG
SERVICE BULLETIN Customer Support ATA SYSTEM: 2812 NUMBER: 84-28-15
BOMBARDIER AEROSPACE REGIONAL AIRCRAFT CONSIDER THIS
SERVICE BULLETIN TO BE PARTICULARLY SIGNIFICANT AND
URGES OPERATORS TO PROMPTLY EVALUATE THE CONTENTS SUBJECT: Fuel System - Center Wing - Engine Fuel Feed Installation - Introduction of New Tube to Eliminate Fouli ng Condition - ModSum 4-113762
1. PLANNING INFORMATION NOTE: This service bulletin supercedes Bombardier Service Bulletin 84-28-09 for operators who have not ordered ModKit 8MK4429-001.
A. Effectivity Aircraft Affected:
In-Service: DHC-8 Aircraft Models 401 and 402 Serial Numbers 4001, 4003, 4004, 4006, 4008 thru 4417.
Production: ModSum 4-113762 will be installed before delivery on applicable DHC-8 Aircraft Models 401 and 402 at Serial Number 4418 and subsequent.
Spares Affected:
None
SERVICE BULLETIN 84-28-15 S.B. 84-28-15 Page 2 of 18 17 Aug 2012 MG B. Reason Problem: Operators have reported a fouling condition between engine fuel feed line 82822143-003 and the wing structure at station Y-157.825 (right side fuel tank).
Other locations have been reported with inadequate clearance between the fuel pipe and structure. In the event of a lightning strike, a spark could be produced at the fouling interface between pipe and structure.
Solution: This service bulletin introduces ModSum 4-113762 which replaces five existing fuel lines (two in the left wing and three in the right wing and supporting brackets) with new fuel lines and supporting brackets.
The new fuel lines and brackets are designed to include different geometric angles to make sure contact with the wing structure is eliminated and adequate clearance is maintained. In addition, teflon tubing is wrapped around one motive flow line and scavenge lines in each fuel tank (left and right side) at specific locations as part of the modification.
C. Description The procedures in this service bulletin give the instructions to do the tasks that follow:
- aircraft is put into standard configuration for maintenance
- aircraft electrical power is removed
- the nose landing gear lock is engaged
- the main landing gear lock pins are installed thru each main gear and main gear door mechanism
- the fuel tanks are drained
- the engines are supported then specific fu el tank access panels (center and outer wing) are removed
- r e s i d u a lf u e li sm o p p e du pa n dt h et a n ki sv e n t e d
- five existing fuel feed tube assemblies, four existing brackets, cushion clamps and related hardware are removed
- five new fuel feed lines and new brackets are installed and secured using kept hardware
- the reworked ribs in each wing are re-identified with a new part number
- teflon sleeves are installed around a motive fuel line in each outer wing tank
- the new lines are pressure tested
SERVICE BULLETIN 84-28-15 S.B. 84-28-15 Page 3 of 18 17 Aug 2012 MG
- close out.
D. Compliance Bombardier Inc. highly recommend that ModSum 4-113762 be incorporated at the earliest opportunity unless otherwise directed by the operator’s airworthiness authority.
Transport Canada Airworthiness Directive Pending.
E. Approval The technical content of this service bulletin has been approved under the authority of the Transport Canada Civil Aviation (TCCA) Design Approval Organization No: DAO #93-Q-02.
This service bulletin does not affect Airworthiness Limitations (AWLs) or Damage Tolerance Inspections (DTIs).
F. Manpower It will take an estimated 35.00 man-hour s to complete this service bulletin. The breakdown of the man-hours is shown in the table that follows:
TASK MAN-HOURS MAN-HOURS TO
RWK LEFT WING
MAN-HOURS TO
RWK RIGHT WING Job Set-Up *2.00 n/a n/a Procedure /Test/ RTS n/a 14.00 15.00 Close-Out **4.00 n/a n/a * time required to defuel and vent fuel tank not included ** cure time for sealant not included.
For any on-site labor assistance, please speak with a Fleet Services representative for a quote. The Fleet Services group can be contacted via the Q Series Technical Help Desk by telephone at 416-375-4000 or email at:
thd.qseries@aero.bombardier.com G. Material - Price and Availability ModKit 8MK4497-001 is available through the Customer Accounts Service Team at
SERVICE BULLETIN 84-28-15 S.B. 84-28-15 Page 4 of 18 17 Aug 2012 MG Bombardier Aerospace Regional Aircraft division. Operators should submit a purchase order specifying aircraft serial number(s) to:
Bombardier Aerospace Customer Accounts Services Team (Mail Stop N11-32) 123 Garratt Blvd.
Toronto Ontario Canada M3K-1Y5 Facsimile: (416) 375-3060 Telephone: (416) 375-3920 Kit Number Description 8MK4497-001 Retrofit Kit - Engine Fuel Feed Line H. Tooling - Price and Availability None I. Weight and Balance None J. Electrical Load Data Not affected K. Publications Affected Maintenance Manual PSM 1-84-2................................
Dash 8 Illustrated Parts Catalogue PSM 1-84-4....................
ModSums Manual PSM 1-84-12..................................
L. References The initial issue of this service bulletin was prepared to the engineering drawings and related data that follows:
DRAWING SHEET REV
SERVICE BULLETIN 84-28-15 S.B. 84-28-15 Page 5 of 18 17 Aug 2012 MG
DRAWING REV SHEET 8MK4497 1 - 8Z9214 1 - 8Z9609 1 - 8Z6836 1 A ModSum 4Q113762 Rev. ‘B’ ModSum 4-113762 Rev. ‘B’ Bombardier Service Bulletin 84-28-09 (ModSum 4-113643) Bombardier Service Bulletin 84-28-13 (ModSum 4-113745) Bombardier Service Bulletin 84-28-14 (ModSum 4-113754) PCA 44006 Revision 0 (for internal reference only) Transport Canada Airworthiness Directive Pending.
2. MATERIAL INFORMATION A. Parts Required Per Aircraft
(1) Modification Kit 8MK4497-001, Retrofit Kit - Engine Fuel Feed Line
(2) Detailed Kit Content:
Quantity Per Kit -001 Part Number Description Remarks 1 8Z9214 Retrofit drawing 1 8Z9609 Retrofit drawing 1 8Z6836 Structural Provisions drawing 1 8Z6836-001 Rework-Structural Provisions 1 82822139-005 Tube Assembly 1 82822140-003 Tube Assembly
SERVICE BULLETIN 84-28-15 S.B. 84-28-15 Page 6 of 18 17 Aug 2012 MG Quantity Per Kit -001 RemarksDescriptionPart Number 1 82822142-005 Tube Assembly 1 82822143-003 Tube Assembly 1 82822144-005 Tube Assembly 12 MS29513-214 Packing, O-Ring 2 MS29513-215 Packing, O-Ring 4 DSC411-12-0032 Teflon Hose 2 DSC411-6-0026 Teflon Hose 4 B0305078-10 Clamp 4 B0305078-04 Clamp
(3) In addition to the above part(s), the following material(s) are required for the completion of this service bulletin and may be procured as single items from Bombardier Aerospace Regional Aircraft or purchased directly from industry sources.
Addresses of manufacturers and suppliers not shown below are listed in either Maintenance Manual Chapter 20 or in Structural Repair Manual Chapter 51 or, for 400 Series Aircraft, in Consumable Products Manual PSM 1-84-18.
Part Number Qty. Per Aircraft Description Remarks DHMS C4.06 10 oz. Coating, Corrosion Preventative for Aircraft Integral Fuel Tanks Type 1, Class A, Grade A or Grade B, B. Parts Required to Modify Spares None C. Special Tools and Equipment Required None D. Existing Parts Accountability The following parts may be affected by this service bulletin. Indented parts are
SERVICE BULLETIN 84-28-15 S.B. 84-28-15 Page 7 of 18 17 Aug 2012 MG components of the next higher assembly. The quantity (Qty.) column lists the quantity that may be affected per aircraft for non-indented parts and the quantity p e rn e x th i g h e ra s s e m b l yf o ri n d e n t e dp a r t s .
Existing Part Number Description Qty. IC DC New Part Number PNC 82822139-003 Tube Assy Eng Feed (LH side) 1 A SAL 82822139-005 S 82822140-001 Tube Assy Eng Feed (LH side) 1 A SAL 82822140-003 S 82822142-003 Tube Assy Eng Feed (RH side) 1 A SAL 82822142-005 S 82822143-001 Tube Assy Eng Feed (RH side) 1 A SAL 82822143-003 S 82822144-001 Tube Assy Eng Feed (RH side) 1 A SAL 82822144-005 S IC Interchangeability Code A Not interchangeable.
B Removed Part. No direct replacement.
C Conditionally Interchangeable. Inst allation of superseded part negates the intent of this service bulletin.
DC Disposition DIS Discard Part.
MUI Multiple Usage Item: Return to stock if serviceable.
RWK Rework existing part in accordance with this service bulletin.
RWI Rework existing part per .....
SAL Salvage. Return to operator’s stores for salvage consideration.
PNC Part Number Code N No equivalent Bombardier Inc. part number for reworked part. Indicate on part that this service bulletin has been accomplished.
R Part number after rework.
S Superseding or equivalent part number.
X Reworked part and superseding part are functionally and physically equivalent but not identical.
SERVICE BULLETIN 84-28-15 S.B. 84-28-15 Page 8 of 18 17 Aug 2012 MG
3. ACCOMPLISHMENT INSTRUCTIONS NOTE: The operator has the option of reworking the left side and right side fuel tanks at different times or reworking bo th left side and right side fuel tanks at the same time.
A. Job Set-Up WARNING: MAKE SURE YOU INSTALL THE LOCKPINS ON THE MAIN LANDING GEAR. MAKE SURE YOU ENGAGE THE NOSE GEAR LOCK. IF YOU
DO NOT DO THIS, THE LANDING GEAR CAN ACCIDENTALLY RETRACT. THIS CAN CAUSE INJURIES TO PERSONS AND DAMAGE TO THE EQUIPMENT.
WARNING: MAKE SURE YOU INSTALL THE LOCKPINS ON THE LANDING GEAR DOORS. MAKE SURE YOU DISCONNECT THE LANDING GEAR DOORS. IF YOU DO NOT DO THIS THE LANDING GEAR DOORS WILL CLOSE WHEN YOU APPLY THE HYDRAULIC PRESSURE. THIS CAN CAUSE INJURIES TO PERSONS AND DAMAGE TO THE EQUIPMENT.
WARNING: OBEY ALL THE FUEL SAFETY PRECAUTIONS WHEN YOU DO WORK ON THE FUEL SYSTEM AND/OR A FUEL SYSTEM COMPONENT. IF
YOU DO NOT YOU CAN CAUSE INJURIES TO PERSONS AND/OR DAMAGE TO EQUIPMENT.
(1) Make sure that lock pins are installed through each main gear and main gear door mechanism.
(2) Make sure the nose gear ground lock is engaged.
WARNING: YOU MUST REMOVE THE FUEL FROM THE FUEL TANK IN AN OPEN AREA. IF YOU DO NOT DO THIS, YOU CAN CAUSE INJURIES TO PERSONS AND DAMAGE TO THE EQUIPMENT.
(3) Refer to AMM TASK 28-10-00-840-801 and prepare fuel tank for access. Make sure fuel or fuel vapors are not present before working on aircraft or in the fuel tanks.
SERVICE BULLETIN 84-28-15 S.B. 84-28-15 Page 9 of 18 17 Aug 2012 MG
(4) Refer to AMM TASK’ 24-00-00-861-802, TASK 24-00-00-910-801 and placard and select all aircraft electrical power to OFF. Obey all relevant WARNINGS and CAUTIONS.
(5) Set up work platforms and/or ladders to permit access to the fuel tank access panels between wing stations Y-42.000 and Y-317.019 left and right side wing.
Make sure that the work platforms or ladders are electrically grounded.
(6) Refer to AMM TASK 28-00-00-910-801 and make sure to obey the fuel system safety precautions.
(7) Refer to AMM TASK 24-00-00-910-801 and make sure to obey the electrical/electronic safety precautions.
(8) Refer to AMM TASK 24-00-00-910-802 and obey the electrostatic discharge safety precautions.
CAUTION: MAKE SURE THAT THE FUEL TANKS ARE DRAINED BEFORE YOU REMOVE THE ACCESS PANELS. IF YOU DO NOT DO THIS, YOU CAN CAUSE DAMAGE TO THE WING STRUCTURE.
CAUTION: MAKE SURE THAT YOU DO NOT MOVE THE AIRCRAFT BEFORE YOU INSTALL THE FUEL ACCESS PANELS. THIS IS NECESSARY TO PREVENT DAMAGE TO THE WING AND THE WING BOX STRUCTURE.
(9) Refer to Figure 1, the applicable instructions in AMM TASK 57-11-01-000-801 and the table below and remove the left and/or right wing wet bay fuel tank access panels.
ACCESS DESIGNATION 523AT (left wing) and/or 623AT (right wing) Wet Bay Fuel Access Panels 522BT (left wing) and/or 622BT (right wing) Wet Bay Fuel Access Panels 522CT (left wing) and/or 622CT (right wing) Wet Bay Fuel Access Panels
(10) Refer to Figure 1, the applicable instructions in AMM TASK 57-21-01-000-801 and the table below and remove the outer wing fuel tank access panels.
ACCESS DESIGNATION 524AT (left wing) and/or 624AT (right wing) Outer Wing Fuel Access Panels 524CT (left wing) and/or 624CT (right wing) Outer Wing Fuel Access Panels
SERVICE BULLETIN 84-28-15 S.B. 84-28-15 Page 10 of 18 17 Aug 2012 MG
(11) Use cotton cloths or a natural sponge to soak up the remaining fuel.
(12) Refer to the applicable instructions in AMM TASK 28-10-00-840-802 and remove fuel fumes from tank(s).
CAUTION: KEEP A CONTINUOUS FLOW OF VENTILATING AIR THROUGH A FUEL TANK WHEN WORK IS BEING DONE INSIDE THE TANK.
B. Procedure NOTE: The Procedure section is divided into two parts. PART 1 gives the instructions to rework the left side fuel tanks. PART 2 gives the instructions to rework the right side fuel tanks.
Part 1 - Rework of the Left Side Fuel Tank
(1) Refer to applicable instructions in AMM TASK 28-21-06-000-801 and Figure 3 and locate and remove engine fuel feed line 82822139-003 and 82822140-001 (including related cushion clamps and h ardware). Keep related cushion clamps and related hardware.
(2) Remove and discard the preformed O-rings from the fuel line couplings.
(3) Cap all open fuel lines. Send the removed fuel lines to stores to determine disposition.
(4) Install new replacement bracket 85714430-003 to rib at station Y-136.300 in the left fuel tank as follows:
(a) Refer to Figure 3-Flag Note 1 and locate, carefully remove and discard one existing bracket from rib 85713370-001 at station Y-136.300.
(a) Deburr the vacated rivet holes and treat with a layer of alodine and touch up with a layer of DHMS C4.06 Type 1, Class A, Grade A or Grade B, (Coating, Corrosion Preventative for Aircraft Integral Fuel Tanks).
(b) Refer to drawing 8Z6836, VIEW LOOKING RIB ASSY INBD AT Y102D-Y136.30 LH and VIEW A and install new replacement bracket 85714430-003 to rib at station Y-136.300 using two solid rivets B0205016AD5-7S.
(c) In a suitable area next to new bracket 85714430-003 re-identify rib 85713370-001 as 8Z6836-1 using an indelible marker.
SERVICE BULLETIN 84-28-15 S.B. 84-28-15 Page 11 of 18 17 Aug 2012 MG
(5) Install new replacement bracket 85714527-001 to rib at station Y-157.825 in the left fuel tank as follows:
(a) Refer to Figure 3-Flag Note 2 and at station Y-157.825 locate, carefully remove and discard one existing bracket from rib 85713380-001.
(b) Deburr the vacated rivet holes and treat with a layer of alodine and touch up with a layer of DHMS C4.06 Type 1, Class A, Grade A or Grade B, (Coating, Corrosion Preventative for Aircraft Integral Fuel Tanks).
(c) Refer to drawing 8Z6836, VIEW LOOKING RIB ASSY INBD AT Y102D-Y157.825 LH and VIEW C and install new replacement bracket 85714527-001 to rib at station Y-157.825 using two solid rivets B0205016AD5-8S.
(d) In a suitable area next to new bracket 85714527-001 re-identify rib 85713380-001 as 8Z6836-3 using an indelible marker.
NOTE: Make sure that the fuel lines installed in the step below have a minimum clearance of no less that 0.125 inch from adjacent structure.
(6) Refer to AMM TASK 28-21-06-400-801 and drawing 8Z9609-ASSY -001 and install / route new fuel feed lines 82822139-005 and 82822140-003. Secure the fuel feed lines using kept clamps, screws and washers. Make sure to install new preformed O-rings MS29513-214 at each coupling B030508A16 during assembly.
(7) If any discrepancy exists record the condition then contact the ‘‘Toronto Help Desk at telephone number (416) 375-4000 or facsimile (416) 375-4539’’ or E-mail: thd.qseries@aero.bombardier.com for a corrective action .
NOTE: Fuel lines designed with a protective teflon sleeve installed around the tube adjacent to wing structure are not required to achieve the minimum clearance requirement of no less that 0.125 inch from adjacent structure.
(8) Refer to drawing 8Z9214-ASSY-001 SHN-VIEW LKG DOWN and DETAIL A and install and secure one teflon hose DSC411-12-0032 and one clamp B0305078-10 around scavenge fuel line adjacent to rib 85713802 at approx.
station Y-245.019. Install clamp 1.50 inches from the end of the teflon hose.
Refer to AMM TASK 20-10-01-430-801 and tighten the clamp fastener.
(9) Refer to drawing 8Z9214-ASSY-001-VIEW LKG DOWN and DETAIL A and install and secure one teflon hose DSC411-12-0032 and one clamp B0305078-10 around scavenge fuel line adjacent rib 85713806 at approx. station Y-317.019.
Install clamp 1.50 inches from the end of the teflon hose. Refer to AMM TASK 20-10-01-430-801 and tighten the clamp fastener.
SERVICE BULLETIN 84-28-15 S.B. 84-28-15 Page 12 of 18 17 Aug 2012 MG
(10) Refer to drawing 8Z9609-ASSY -001-VIEW B and install and secure one teflon hose DSC411-6-0026 and two clamps B0305078-04 to motive flow line 82822065 at approx. station Y-117.500 as shown.
(11) Refer to the applicable instructions in AMM TASK 28-21-00-780-801 and do a pressure test of the left side fuel feed lines. Make sure a 0.125 inch (1/8 inch) clearance between fuel line and wing structure is kept during pressure test.
(12) Go to the Close Out section and install the left wet bay and outer wing fuel tank access panels OR go to PART 2 and rework the right side fuel tanks.
Part 2 - Rework of the Right Side Fuel Tank
(1) Refer to Figure 4 and remove and discard cushion clamps and related hardware that secures existing fuel feed line 82822143-001 to adjacent scavenge line at approx. Y-150.00.
(2) Refer to applicable instructions in AMM TASK 28-21-06-000-801 and Figure 4 and locate and remove engine fuel feed lines 82822142-003, 82822143-001 and 82822144-001 (including related cushion clamps and hardware). Keep related cushion clamps and related hardware.
(3) Cap all open fuel lines. Send the removed fuel lines to stores to determine disposition.
(4) Install new replacement bracket 85714428-003 to rib at station Y-136.300 in the right side fuel tank as follows:
(a) Refer to Figure 4-Flag Note 1 and locate, carefully remove and discard one existing bracket from rib p/n 85713370-002 at station Y-136.300.
(b) Deburr the vacated rivet holes and treat with a layer of alodine and touch up with a layer of DHMS C4.06 Type 1, Class A, Grade A or Grade B (Coating, Corrosion Preventative for Aircraft Integral Fuel Tanks).
(c) Refer to drawing 8Z6836-VIEW LOOKING RIB ASSY INBD AT Y102D-136.30 LH and VIEW B and install new bracket 85714428-003 to rib 85713370-002 at station Y-136.300 using solid rivets B0205016AD5-7S.
(d) In a suitable area next to new bracket 85714428-003 re-identify rib 85713370-002 as 8Z6836-2 using an indelible marker.
(5) Install new replacement bracket 85714426-003 to rib at station Y-157.825 in the right side fuel tank as follows:
(a) Refer to Figure 4-Flag Note 2 and locate, carefully remove and discard one existing bracket from rib 85713380-002 at station Y-157.825.