GippsAero Mandatory Service Bulletin SB-GA8-2005-23

PO Box 881, Morwell, Victoria 3840, Australia Ph + 61 (0) 3 5172 1200 Fax + 61 (0) 3 5172 1201 www.gippsaero.com.au

MANDATORY Service Bulletin SB-GA8-2005-23 Issue 8 Date of Issue: 11th Oct 2023 Page 1 of 21

SB-GA8-2005-23 Issue 8 1 Subject:

Forward Cargo Door Slide 2 Applicability:

Table 1: Aircraft Applicability.

AIRCRAFT SERIAL NUMBER(s) GA8 & GA8-TC 320 All GA8 and GA8-TC 320 Aircraft.

3 Amendments:

Issue 1: Initial Issue.

Issue 2: Background amplified. 13 Sep 2005.

Issue 3: Service Bulletin was rewritten in total. GippsAero Reference GAE11#843.

Issue 4: Inspection of operating rod and requirement for handle with integrated stop added.

Template updated. GippsAero Reference GAE11#2371.

Issue 5: Door handle part number amended, Part C compliance date extended. Typos corrected.

GippsAero Reference GAE11#2483.

Issue 6: Service Bulletin rewritten in total and Part D added. GippsAero Reference GAE11#2415.

Issue 7: Part B Revised and formatting updated. GippsAero Reference GAE11#2808.

Issue 8: Revised to improve clarity & compliance schedule. Refer to change bars. GippsAero Reference GAE11#2816.

4 Background:

Following in-flight rear cabin door separation s from GA8 and GA8 -TC 320 aircraft, this Service Bulletin provides a programme of inspections and upgrades to the door tracks and latching mechanism.

PART A: Requires installation of a backing plate to forward door slider. Gives ongoing inspection and serviceability criteria of the forward cargo door slide.

PART B: Provides an inspection and upgrades for the door latch operating rod.

PART C: Requires installation of a door handle with an integral stop.

PART D: Requires installation of a physical stop to the forward cargo door slide.

SB-GA8-2005-23 Issue 8 Date of Issue: 11th Oct 2023 Page 2 of 21

5 Compliance:

Initial and recurring compliance requirements are given below.

Table 2: Compliance Requirements for SB-GA8-2005-23 Part Applicability Initial Compliance Recurring Compliance A1 All aircraft in Table 1. Within 50 Flight Hours or 2 calendar months, whichever is sooner. - A2 All aircraft in Table 1. At next scheduled 100-hourly or annual inspection. At each 100-hourly or annual inspection.

B1 All aircraft in Table 1. Within 50 Flight Hours or 2 calendar months, whichever is sooner. At each 100-hourly or annual inspection.

B2 All aircraft in Table 1. When required by PART B1. - B3 All aircraft in Table 1. When required by PART B1. - C All aircraft in Table 1. Within 150 Flight Hours or 4 calendar months, whichever is sooner. - D1 All aircraft in Table 1. Within 50 Flight Hours or 2 calendar months, whichever is sooner. - D2 All aircraft in Table 1. When required by PART D1. - 6 Weight and Balance:

There is negligible effect to the weight and balance of the aircraft.

7 Approval:

This Service Bulletin has been approved in accordance with the requirements of Australian Civil Aviation Safety Regulation 21.095 (1998).

8 Parts:

The materials required to complete PART A of this Service Bulletin are detailed in Table 3.

Table 3: PART A Kit Number SB-GA8-2005-23-01.

ITEM PART NUMBER DESCRIPTION QTY 1 GA8-521022-225 Notched Slide-Centre 1 2 GA8-521022-227 Notched Backing Plate 1 3 MS24694-S65 Structural Screw 2 4 AN3-11 Bolt 1 5 AN960-10L Washer thin 1 6 AN310-3 Castle nut 1 7 MS24665-132 Split pin 1 8 GA8-521022-153 Forward Slide Gauge 1

SB-GA8-2005-23 Issue 8 Date of Issue: 11th Oct 2023 Page 3 of 21

The materials required to complete PART B of this Service Bulletin are detailed in Table 4.

Table 4: PART B items.

ITEM PART NUMBER DESCRIPTION QTY 9 GA8-521012-055 Actuating Rod Assy 1 9-A GA8-521022-231 Actuating Rod Fitting 2 9-B GA8-521022-233 Rear Door Rod End, ¼” 2 9-C NAS601-101 Screw, Machine, Pan Head 6 9-D MS21042-062 Nut, Self-Locking, Reduced Hex 6 9-E MS35338-43 Washer, Lock-Spring 3 9-F AN525-10R11 Screw, Washer Head 1

The materials required to complete PART C of this Service Bulletin are detailed in Table 5.

Table 5: PART C items.

ITEM PART NUMBER DESCRIPTION QTY 10 GA8-521012-0473 Door Handle 1 11 GA8-521022-159 Handle Bush 1

The materials required to complete PART D1 of this Service Bulletin are detailed in Table 6 and Table 7.

Table 6: PART D1 Kit Number SB-GA8-2005-23-04.

ITEM PART NUMBER DESCRIPTION QTY 12 GA8-521022-221 Centre Rail Aft Stop 1 13 GA8-521022-223 Radiused Washer 2 14 MS24694-S6 Structural Machined Screw 2 15 MS21042-08 Nut, Self-Locking 2 16 MS24665-132 Split pin 1 Table 7: Compounds

ITEM COMPOUND DESCRIPTION C1 Silicone Sealant, Silicone, General Purpose, Neutral Cure.

C2 Duralac Duralac Jointing Compound C3 Grease General Purpose Grease, MIL-PRF-81322 or equivalent: Aeroshell Grease 22, Mobil Grease 28, Rheolube 733.

C4 Loctite 222 Thread locking compound C5 Primer MIL-PRF-23377 Type I & II Class C2 C6 Topcoat Polyurethane topcoat, Colour “Horizon Grey”. MIL-PRF-85285 Type I Class H or equivalent.

1 Acceptable alternatives: MS51957-31, MS16995-19, NAS601-12.

2 Acceptable alternatives: MS21083-N06, AN364-632A 3 Acceptable alternative: P/No. GA8-521012-051.

SB-GA8-2005-23 Issue 8 Date of Issue: 11th Oct 2023 Page 4 of 21

The materials also required to complete PART D1 of this Service Bulletin, if not completing PART A or PART D2, are detailed in Table 8.

Table 8: PART D additional items.

ITEM PART NUMBER DESCRIPTION QTY 1 GA8-521022-225 Notched Slide-Centre 1 2 GA8-521022-227 Notched Backing Plate 1

9 Parts Availability:

New parts can be obtained directly from GippsAero.

Tel: +61 (0)3 5172 1200 Fax: +61 (0)3 5172 1201 Email: PARTS@gippsaero.com.au 10 Labour:

Table 9 details the approximate time that should be allocated for completing the requirements of each Part in this Service Bulletin.

Table 9: Allocated time for completing each Part.

PART APPROXIMATE TIME REQUIRED A1 30 minutes A2 15 minutes B1 60 minutes B2 60 minutes, if required.

B3 60 minutes, if required.

C 45 minutes D1 60 minutes D2 60 minutes, if required.

11 Warranty:

Aircraft under warranty may claim the direct cost of carrying this Service Bulletin via GippsAero Customer Service.

Tel: +61 (0)3 5172 1200 Fax: +61 (0)3 5172 1201 Email: Support@gippsaero.com.au

SB-GA8-2005-23 Issue 8 Date of Issue: 11th Oct 2023 Page 5 of 21

12 Accomplishment Instructions:

GENERAL NOTES:

Ensure the aircraft is prepared for maintenance and that appropriate safety precautions are taken when performing work outlined in this Service Bulletin.

Unless otherwise specified, reference to the GA8 Service manual as well as FAA AC43.13 -1B should be made when carrying out the procedure prescribed in this Service Bulletin. In case of discrepancy between the Service Manual and the AC, the Service Manual takes precedence.

When carrying out work outlined by this Service Bulletin, care is to be taken to ensure damage to surrounding structure and installations does not occur.

Torque all fasteners in accordance with the GA8 Service Manual unless stated otherwise. Values are for dry (unlubricated) threads unless shown otherwise.

WARNING:

IT IS THE RESPONSIBILITY OF ALL PERSONNEL TO ENSURE WORK HEALTH AND SAFETY REQUIREMENTS ARE MET AT ALL TIMES. ALL PERSONNEL MUST COMPLY

WITH ALL WORK HEALTH AND SAFETY REQUIREMENTS AS DEFINED OR RECOMMENDED BY:

- EQUIPMENT OEM INSTALLATION AND OPERATION MANUALS;

- AIRCRAFT MAINTENANCE AND OPERATION MANUALS;

- ASSOCIATED AIRCRAFT MODIFICATION INSTRUCTIONS;

- RELEVANT NAA REGULATIONS AND ADVISORY DOCUMENTATION;

- ORGANISATION MANUALS, INCLUDING NAA ENDORSED OPERATIONAL AND MAINTENANCE MANUALS; AND

- RELEVANT LOCAL, STATE AND FEDERAL GOVERNMENT REQUIREMENTS.

WARNING:

READ THE APPLICABLE MATERIAL SAFETY DATA SHEET (MSDS) FOR ANY

MATERIAL/CONSUMABLE USED DURING THE ACCOMPLISHMENT OF THIS S ERVICE

BULLETIN AND EMPLOY ANY RECOMMENDED PERSONAL PROTECTIVE EQUIPMENT (PPE) CONTAINED THEREIN.

NOTE:

Unless stated otherwise, hardware removed during the procedure below is be inspected and re-used if serviceable.

SB-GA8-2005-23 Issue 8 Date of Issue: 11th Oct 2023 Page 6 of 21

12.1 PART A1: SLIDER BACKING PLATE INSTALLATION

1. Open the door handle so that the door swings out to gain access to the Forward Cargo Door Slide Assembly, see Figure 1 below.

Figure 1: Forward Cargo Door Slide with door swung open.

2. Inspect the slide assembly. If the Backing Plate (Item 2 of Figure 4) is fitted, no further action is required. If the Backing Plate is NOT fitted, do the remaining steps of this part.

3. Remove the Forward Cargo Door Slide, by removing the vertical bolt and sliding the slider out of the track. On earlier versions of the GA8 aircraft it is necessary to remove the Nylon Track End as shown in Figure 2 to be able to remove the slider.

Figure 2: Nylon Track End.

4. Figure 3 shows how a worn part normally looks and where to measure the groove width. The TOP and BOTTOM profile differs on a worn part and as such both the top and bottom slide grooves are to be measured with a calliper.

Figure 3: A worn slider indicating where to measure.

FORWARD CARGO DOOR SLIDE

REMOVE THE VERTICAL BOLT AND DISCARD.

SB-GA8-2005-23 Issue 8 Date of Issue: 11th Oct 2023 Page 7 of 21

5. Measure the groove width and if the groove is wider than 0.145” at any point along the slider , or if the part is cracked or excessively worn, a new slider, Item 1, must be fitted.

6. Irrespective of Item 1, Items 2 to 7 MUST be fitted as shown in Figure 4 and listed in Table 3.

Figure 4: Old (left) and New (right) Forward Cargo Door Guide Assembly.

Table 10: Part numbers for the new assembly and the parts it is replacing.

ITEM

OLD ASSEMBLY NEW ASSEMBLY QTY

PART NUMBER DESCRIPTION PART NUMBER DESCRIPTION 1 GA8-521022-149 Slide-Centre GA8-521022-225 Notched Slide-Centre 1 2 - - GA8-521022-227 Notched Backing Plate 1 3 MS24694-S64 Structural Screw MS24694-S65 Structural Screw 2 4 AN3-10A Bolt AN3-11 Bolt 1 5 AN960-10 Washer AN960-10L Washer Thin 1 6 MS21042-3 Nut, Reduced Hexagon AN310-3 Castle Nut 1 7 - - MS24665-132 Split Pin 1

7. Reinstall the new slider assembly and refit the Nylon Track End if it was removed. Note that the notch in Item 1 and Item 2 must be facing aft, refer to Figure 22 of PART D 1 for the correct installed orientation.

SB-GA8-2005-23 Issue 8 Date of Issue: 11th Oct 2023 Page 8 of 21

12.2 PART A2: SLIDER WEAR INSPECTION

1. Open the Rear Cabin Door handle so that the door swings out to gain access to the slider (see PART A1, Step 1).

2. Try to insert the Forward Slide Gauge (Item 8 in Table 3) between the slider and the track as shown in Figure 5 and Figure 6 below. Standard Feeler gauges made up to 0.098”

(0.023”+0.024”+0.025”+0.026”) may also be used.

Figure 5: Checking with the Forward Slide Gauge. Note that all four corners require checking.

Figure 6: Forward Slide Gauge inserted between the slide and track, indicating a worn part. Note track in the image has been removed from the aircraft for clarity. Checking can be completed with the track installed on the aircraft.

3. If it is possible to fit the Forward Slide Gauge or feeler gauge between the track and slider (as shown in Figure 6 above) at any of the four corners carry out PART A1, Step 2 though 4.

OR

4. If Item 8 (or standard feeler gauge) is unavailable, carry out the inspection under PART A1, Step 2 through 4.

FORWARD SLIDE GAUGE

SB-GA8-2005-23 Issue 8 Date of Issue: 11th Oct 2023 Page 9 of 21

12.3 PART B1: DOOR MECHANISM INSPECTION NOTE:

PARTS B1, B2 and B3 may be done during a single inspection.

Section B1 inspection must be done on standard operating rods AND those reworked per Section B3.

1. Remove the Rear Mechanism Cover by removing the screws marked in Figure 7.

2. With the door handle held fully open / against the stop, check that the operating rod does not touch the rear door handle pivot post, refer to Figure 9. If the rod does touch the pivot post, do PART B2.

3. Inspect threaded studs and rod ends at both ends of the operating rod as shown in Figure 8. If there is any indication of bending:

i. For actuation rods fitted with female rod ends, do PART B3.

ii. For actuation rods fitted with male rod ends, replace the parts with new Item(s) 9-B, then repeat the inspections and necessary rectification actions detailed in PART B2 and B3.

4. Check door adjustment as detailed in Section 52-20-10 of the applicable aircraft service manual.

5. Check that the door ha ndle engages strongly with the catch when in the closed position ( Figure 7).

Weak engagement may be caused by wear to the handle bush or by damage (bending) of the handle and must be corrected by replacing the pivot bush (with Item 11 from Table 5) or the handle (Item 10 from Table 5) as appropriate.

6. After finishi ng inspection and required actions, reinstall the Rear Mechanism Cover as shown in Figure 7.

Figure 7: Rear Mechanism Cover (latch in closed position).

          AN525-832R6 x2 GA8-252024-155

REAR MECHANISM COVER

DOOR HANDLE MUST

ENGAGE STRONGLY

INTO CATCH WHEN

THE DOOR IS CLOSED AND LATCHED.

SB-GA8-2005-23 Issue 8 Date of Issue: 11th Oct 2023 Page 10 of 21

Figure 8: Rear Door Handle Mechanism - Inspection Areas.

INTEGRATED STOP (Marked in Red) OPERATING ROD INSPECTION AREAS

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12.4 PART B2: DOOR PIVOT REWORK

1. Disconnect the rod ends from the handle and pivot arm. Remove the forward rod end and pull out the operating rod.

2. Rework the pivot post as detailed in Figure 9.

3. Install the operating rod through frame bush prior to installing forward Rod End. Install rod ends and connect to the handle and pivot arm.

NOTE:

Minimum thread engagement to not be less than the rod end check hole.

Perform functional check to ensure the door operates correctly

4. Adjust door mechanism as detailed in Section 52-20-10 of the applicable aircraft service manual.

5. After finishing inspection and required actions, reinstall the Rear Mechanism Cover as shown in Figure 7.

VIEW A (NOT TO SCALE)

Figure 9: Rear Door Handle Pivot Post – Rework Area.

   Notes:

1. Only Pivot post shown for clarity.

2. Rework using blending guidelines of AC43.13-1B Chapter 6 Section 7 and 10.

3. Ensure rod end and rod have a minimum clearance of 0.040in from pivot post.

4. Restore surface protection IAW Service Manual using compound C5 (Table 7).

CHECK FOR CLEARANCE

BETWEEN OPERATING ROD /

ROD END AND PIVOT POST Operating Rod

PIVOT POST

INTEGRATED STOP (Marked in Red)

SB-GA8-2005-23 Issue 8 Date of Issue: 11th Oct 2023 Page 12 of 21

12.5 PART B3: DOOR OPERATING ROD REWORK

1. Disconnect the existing rod ends from the handle and pivot arm. Remove the forward rod end and pull out the operating rod.

2. Replace with a new assembly, Item 9 of Table 4, OR, Ø0.313 rod assemblies may be reworked as detailed in the following steps.

i. Cut 0.625 inches (15.9 mm) from each end of the existing Operating Rod.

ii. Temporarily fit the Rod, Fittings (Item 9-A) and rod ends (Item 9-B) to the door as shown in Figure 10.

iii. Rotate the fittings so that the screws are vertical, as shown in Figure 10. Match-drill the rod to the Fittings (Item 9-A). Drill size #28 (0.1405 in).

iv. Install screws, trim any excess thread below nuts and de-burr. Ensure 1.5 full threads extend beyond the nut.

v. Remove Fittings (Item 9-A) from the rod. Apply compound C1 and do the final assembly of the AFT Fitting (Item 9-A) as shown in Figure 10.

3. Install the operating rod through frame bush. Do this before installing FWD Fitting (Item 9-A).

4. Assemble FWD Fitting (Item 9-A) and rod end (Item 9 -B) as shown in Figure 10, then connect the rod as detailed in Figure 11 and Figure 13. Check for clearance and make any required adjustments as detailed in Figure 14 to Figure 16.

5. If needed, the Pivot Arm may be modified in accordance with Figure 14.

6. If needed, the door skin may be modified in accordance with Figure 15.

7. If needed, increase cut-out size in interior trim as shown in Figure 16.

8. Once sufficient clearance is achieved, do the final assembly of the Fitting (Item 9-A), using compound C1 (Table 7) as shown in Figure 10.

9. Install rod ends (Item 9-B) and connect to the handle and pivot arm as shown in Figure 11 (for P/No.

GA8-521012-047 Door Handle) Figure 12 (for P/No. GA8-521012-051 Door Handle) and Figure 13, using the original hardware or Items 9-E and 9-F as required.

10. Do the inspection detailed in Section B2 and, if needed, rework the pivot post ( Figure 9).

11. Adjust door as detailed in Section 52-20-10 of the applicable aircraft service manual.

NOTE:

Minimum thread engagement to not be less than the rod end check hole.

Perform functional check to ensure the door operates correctly

12. After finishing inspection and required actions, reinstall the Rear Mechanism Cover as shown in Figure 7.

Figure 10: Rod End Fitting Installation FWD (Left) and AFT (Right). Some parts omitted for clarity.

EACH SCREW: ITEMS 9-C AND 9-D.

EACH ROD END: ITEM 9-B.