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DHC-8 (DASH 8) SERVICE BULLETIN 84-57-09 Fuel - Fuel Tank System Design Left and Right Side (SFAR 88) Retrofit
- ModSum 4-126330 This page transmits Revision 'B' of Service Bulletin 84-57-09, pages 1 thru 58 dated 03 Sep 2008.
This service bulletin is re- issued in its entirety for the reasons that follow:
- the References section is revised to convey the latest revision of this service bulletin and related engineering
- the MATERIAL INFORMATION section is revised as follows:
corrected the part number of a doubler, was 82811034-105, now 82822034-105 the part number of the Alodine 1132 is also revised, was 236049, now 592939
- the Procedure part of the ACCOMPLISHMENT INSTRUCTIONS section is revised as follows:
added new instruction (c) to existing step (20). The new instruction removes and discard an existing bonding jumper and related hardware
- existing step (2) in the Close Out section is revised to add new 'NOTE 1' and rename an existing NOTE to 'NOTE 2'.
The Compliance recommendation in the previous issue of this service bulletin is not affected by this revision. No additional rework to the aircraft is introduced by this revision.
Remove revision 'A' of Service Bulletin 84-57-09 dated 19 Mar 2007 and replace with attached.
Previous issues of Service Bulletin 84-57-09:
Initial issue - Pages 1 thru 58 dated 27 Jun 2006 Revision 'A' - Pages 1 thru 58 dated 19 Mar 2007 Revision 'B' 03 Sep 2008
de HAVILLAND BOMBARDIER DASIT8
SERVICE BULLETIN Customer.
Support ATA SYSTEM: 5700 NUMBER: 84-57-09
BOMBARDIER AEROSPACE REGIONAL AIRCRAFT CONSIDER THIS
SERVICE BULLETIN TO BE PARTICULARLY SIGNIFICANT AND
URGES OPERATORS TO PROMPTLY EVALUATE THE CONTENTS SUBJECT: Fuel - Fuel Tank System Design Left and Right Side (SFAR 88) Retrofit - ModSum 4-126330
1. PLANNING INFORMATION A. Effectivity Aircraft Affected:
In-Service: DHC-8 Aircraft Models 401 and 402 Serial Numbers 4003, 4004, 4006 and 4008 thru 4118.
Verification: ModSum 4-126330 has been installed on DHC-8 Aircraft Model 402 Serial Number 4006.
NOTE: The instructions in this Service Bulletin are only applicable to the systems and parts installed at the time of delivery on the aircraft or as changed by Bombardier Aerospace Service Bulletin(s). Before you do this bulletin, examine all STC or equivalent action changes to make sure this bulletin can be completed.
27 Jun 2006 S.B. 84-57-09 Revision 'B' 03 Sep 2008 Page 1 of 58 ELS
SERVICE BULLETIN 84-57-09 Spares Affected:
The following is a list of spares affected by this change. Review spares and procurement systems to determine the existence of any listed parts. See Paragraph 2.D., Existing Parts Accountability, for disposition.
B. Reason Problem: This service bulletin (ModSum 4- 126330) is issued as a result of FAA certification requirements conveyed by Special Federal Aviation Regulation 88 (SFAR 88). The regulations are set to enhance fuel tank system safety.
Certain fittings, couplings, o-rings, gaskets, fuel adapters and other related components in the fuel tanks may not comply with FAA certification requirements given in the SFAR 88 regulations (Special Federal Aviation Regulation). The regulations are set to enhance fuel tank system safety.
Solution: This service bulletin conveys ModSum 4-126330.
The ModSum replaces existing fittings, couplings, o-rings, gaskets, fuel adapters and other related components in the fuel tanks with redesigned fittings, couplings and adaptors that comply with SFAR 88 requirements. ModSum 4-126330 is designed to enhance fuel tank system safety.
C. Description The procedures in this service bulletin give the instructions to do the tasks that tollow:
- lock pins are installed thru each main gear and main gear door mechanism
- the nose gear ground lock is engaged
- the aircraft is pressure defueled
- all aircraft electrical power is selected to the OFF position
- electrically grounded work platforms or ladders are set-up around and/or under the left (and/or right) wing
- affected left and/or right side fuel tank access panels are removed
- assorted fittings, couplings, o-rings, gaskets, tuel adapters and other related components in the fuel tanks (left and right side) are removed and replaced
- the protective finish is removed from certain areas of affected structure and brackets. The reworked areas are treated with Alodine 1132 27 Jun 2006 S.B. 84-57-09 Revision 'B' 03 Sep 2008 Page 2 of 58 LS
SERVICE BULLETIN 84-57-09
- a bonding test of the reworked areas is done
- some parts are fillet profile sealed
- some fasteners are dome sealed
- an operational test of the Fuel System is done
- close-out D. Compliance Bombardier Inc. highly recommends that ModSum 4-126330 be incorporated at the earliest opportunity unless otherwise directed by the operator's airworthiness authority.
An Airworthiness Directive from Transport Canada is 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.
Manpower It will take an estimated 151.5 man-hours to complete this Service Bulletin. The breakdown of the man-hours is shown in the table that follows:
TASK MAN-HOURS Job Set-Up 15.00 Procedure 120.00 Test / RTS 1.50 Close-Out 15.00 All costs to incorporate this ModSum are the responsibility of the Operator Many man-hours would be saved if Service Bulletins 84-28-03 (MS 4- 126370), 84-28-04 (MS 4-126366) and 84-28-05 (MS 4-901425) are accomplished at the same time. Common access to affected rework areas is required.
27 Jun 2006 S.B. 84-57-09 Revision 'B' 03 Sep 2008 Page 3 of 58 ILS
SERVICE BULLETIN 84-57-09 G. Material - Price and Availability ModKit 8MK4316-001 is available through the Customer Accounts Service Team at Bombardier Aerospace Regional Aircraft division. Operators should submit a purchase order specifying aircraft serial numbers) 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 Price (US$) Delivery 8MK4316-001 Mod Kit - Fuel System Quoted at Will be given
- SFAR 88 Q400 time of order at time of order 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 27 Jun 2006 S.B. 84-57-09 Revision 'B' 03 Sep 2008 Page 4 of 58 ILS
SERVICE BULLETIN 84-57-09 References Revision 'B' of this service bulletin was prepared to the engineering drawings and related data that follows:
DRAWING SHEET REV 8MK4316 1 C 824483 1 D 824483 2 8Z4483 8Z4483 4 8Z4483 5 B 8Z4469 1 B 8Z4469 2 A 8Z4469 3 ModSum 4Q126330 Rev. 'D' ModSum 4- 126330 Rev. 'E' PCA 40933 issue 1 (for internal reference only) Transport Canada Airworthiness Directive Pending
2. MATERIAL INFORMATION A. Parts Required Per Aircraft
(1) Modification Kit 8MK4316-001
(2) Detailed Kit Content:
Quantity Per Kit Part Number Description Remarks
- 001 2 NAS1149D1216H Washer 27 Jun 2006 S.B. 84-57-09 Revision 'B' 03 Sep 2008 Page 5 of 58 I LS
SERVICE BULLETIN 84-57-09 Quantity Per Kit Part Number Description Remarks
- 001 2 MS35338-51 Lock Washer 2 AN924-8D Nut A/R MS20995C32 Lock Wire 4 MS29513-227 O-Ring 14 MS29513-224 O-Ring 34 MS29513-218 O-Ring 76 MS29513-214 O-Ring 2 MS29513-149 O-Ring 40 MS29513-117 O-Ring 2 MS29513-032 O-Ring 4 MS29513-020 O-Ring 4 MS29513-017 O-Ring 2 MS29513-014 O-Ring 2 MS29513-013 O-Ring 2 MS29512-12 O-Ring 1 MS29512-10 O-Ring 4 MS29512-08 O-Ring 2 MS29512-06 O-Ring 5 MS29512-04 O-Ring 7 B0305080A28 Coupling 17 B0305080A20 Coupling 36 B0305080A16 Coupling 22 B0305080A12 Coupling 4 AS3209-117 O-Ring 2 82822298-105 Elbow 2 82822256-101 Gasket 2 82822128-107 Fuel Adapter 2 82822105-103 Adapter 2 82822077-005 Shroud 1 82822076-105 Cap 4 82822075-007 Fitting Cap 2 82822074-009 Fitting Assembly 1 82822053-105 Manifold 27 Jun 2006 S.B. 84-57-09 Revision 'B' 03 Sep 2008 Page 6 of 58 LS
SERVICE BULLETIN 84-57-09 Quantity Per Kit Part Number Description Remarks
- 001 2 82822034-105 Doubler 2 82822032-101 Gasket 2 82822028-105 Fitting 2 82822027 - 107 Fitting 4 82820158-101 Gasket 4 72820141-103 Shroud 1 8Z4483 Retrofit Coupling dwg only 1 8Z4469 Retrofit Fitting dwg only In addition to the above parts), 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 592939 1 Tube Alodine 1132 Touch -N Prep Pen DHMS S3.01 2 Cartridges Sealant Temperature-Resistant Integral Fuel- Tanks, DHMS A6.09-2 2 Cartridges Sealant High Temperature Epoxy Adhesive, 04-14 AR Petroleum Jelly ¾ Petrolatum 27 Jun 2006 S.B. 84-57-09 Revision 'B' 03 Sep 2008 Page 7 of 58 LS
SERVICE BULLETIN 84-57-09 Alodine 1132 (Touch-N Prep Pen) is available from:
Henkel Surface Technologies 32100 Stephenson Highway Madison Heights, MI 48071 Telephone: 248-583-9300 Facsimile: 248-583-2976 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 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 per next higher assembly for indented parts.
Existing New Part Part Number Description Qty. IC DC Number PNC O-Ring 4 D DIS MS29513-227 Y O-Ring 14 D DIS MS29513-224 O-Ring 34 D DIS MS29513-218 O-Ring 76 D DIS MS29513-214 O-Ring 2 D DIS MS29513-149 O-Ring 40 D DIS MS29513-117 O-Ring 2 D DIS MS29513-032 O- Ring 2 D DIS MS29513-020 O-Ring 4 D DIS MS29513-017 O- Ring 2 D DIS MS29513-014 O-Ring 2 D DIS MS29513-013 O-Ring 2 D DIS MS29512-12 Y O- Ring 1 D DIS MS29512-10 27 Jun 2006 S.B. 84-57-09 Revision 'B' 03 Sep 2008 Page 8 of 58 ILS
SERVICE BULLETIN 84-57-09 Existing New Part Part Number Description Qty. DC Number PNC O-Ring 4 D DIS MS29512-08 Y O-Ring 2 D DIS MS29512-06 Y O-Ring 5 D DIS MS29512-04 Y O-Ring 4 D DIS AS3209-117 Y Gasket 2 D DIS 82822256-101 Y Gasket 2 D DIS 82822032-101 Y Gasket 4 D DIS 82820158-101 Y BO305025A28 Coupling 7 C DIS B0305080A28 S BO305025A20 Coupling 17 C DIS B0305080A20 S BO305025A16 Coupling 36 C DIS B0305080A16 S BO305025A12 Coupling 22 C DIS B0305080A12 S 82822298-103 Elbow 2 C DIS 82822298-105 S 82822128-105 Fuel Adapter 2 C DIS 82822128-107 S 82822105-101 Adapter 2 C DIS 82822105-103 S 82822077-003 Shroud 2 C DIS 82822077-005 S 82822076-103 Cap 1 C DIS 82822076-105 S 82822075-005 Fitting Cap 4 C DIS 82822075-007 S 82822074-007 Fitting 2 C DIS 82822074-009 S Assembly 82822074-005 Fitting 2 C IRWK 8Z4469-005 S Assembly 82822053-103 Manifold 1 C DIS 82822053-105 S 82822034-103 Doubler 2 C DIS 82822034-105 S 82822028-103 Fitting 2 C DIS 82822028-105 S 82822027-105 Fitting 2 C DIS 82822027-107 S 72820141-101 Shroud 4 C DIS 72820141-103 S IC Interchangeability Code A Not interchangeable.
Removed Part. No direct replacement.
C Conditionally Interchangeable. Installation of superseded part negates the intent of this service bulletin.
D Consumable item.
27 Jun 2006/ S.B. 84-57-09 Revision 'B' 03 Sep 2008 Page 9 of 58 LS
SERVICE BULLETIN 84-57-09 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 part number.
Reworked part and superseding part are functionally and physically equivalent but not identical.
Y Existing part number and new part number are the same.
3. ACCOMPLISHMENT INSTRUCTIONS A. Job Set-Up The procedures that follow give the instructions to rework components in the left side fuel tanks. The procedures to rework the components in the right side fuel tanks are almost the same. Differences will be shown.
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 thru each main gear and main gear door mechanism.
(2) Make sure the nose gear ground lock is engaged.
(3) Pressure defuel the aircraft (refer to TASK 12-10-28-650-802).
(4) Make sure to de-energize the aircraft electrical system (refer to AMM TASK 24-00-00-861-802).
27 Jun 2006 S.B. 84-57-09 Revision 'B' 03 Sep 2008 Page 10 of 58 LS
SERVICE BULLETIN 84-57-09
(5) Set up work platforms or ladders around and/or under the left (and/or right) wing to permit access to the fuel tanks. Make sure that the work platforms or ladders are electrically grounded.
(6) Make sure to obey the fuel system safety precautions (refer to TASK 28-00-00-910-801).
(7) Obey the electrical/electronic safety precautions (refer to TASK 24-00-00-910-801).
(8) Obey the electrostatic discharge safety precautions (refer to TASK 24-00-00-910-802).
(9) Remove the left and/or right wing panels that follow:
ACCESS 521BT (and/or 621BT right wing) 522AT (and/or 622AT right wing) 522BT (and/or 622BT right wing) 522CT (and/or 622CT right wing) 523AT (and/or 623AT right wing) 524AT (and/or 624AT right wing) 524BT (and/or 624BT right wing) 524CT (and/or 624CT right wing) 524DT (and/or 624DT right wing) 524ET (and/or 624ET right wing) 524FT (and/or 624FT right wing)
DESIGNATION Dry Bay Fuel Access Panels Wet Bay Fuel Access Panels Wet Bay Fuel Access Panels Wet Bay Fuel Access Panels Wet Bay Fuel Access Panels Outer Wing Fuel Access Panels Outer Wing Fuel Access Panels Outer Wing Fuel Access Panels Outer Wing Fuel Access Panels Outer Wing Fuel Access Panels Outer Wing Fuel Access Panels
(a) For removal of the dry bay fuel access panel 521BT (and/or 621BT right wing) refer to PSM 1-84-2 TASK 57-11-06-000-802.
CAUTION: DRAIN THE FUEL TANK BEFORE YOU REMOVE THE ACCESS PANELS. IF YOU DO NOT DO THIS, YOU CAN CAUSE DAMAGE TO THE WING STRUCTURE.
(b) For removal of the wet bay fuel access panel refer to PSM 1-84-2 TASK 57-11-01-000-801.
(c) For remove the outer wing fuel access panels refer to PSM 1-84-2 TASK 57-21-01-000-801.
27 Jun 2006 S.B. 84-57-09 Revision 'B' 03 Sep 2008 Page 11 of 58 LS