GippsAero Service Bulletin SB-GA8-2017-174

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

MANDATORY Service Bulletin SB-GA8-2017-174 Issue 2 Date of Issue: 23-May-2018 Page 1 of 18 Issue 2 SB-GA8-2017-174 Issue 2 Subject Wing Strut and Strut Fitting Inspection and Replacement Applicability This Service Bulletin is applicable to the serial numbers listed for the part numbers identified in Table 1.

Critical part serial numbers can have five (5) or six (6) digits, with a prefix of either ‘00’ or ‘000’. Note Table 1 only lists the last three (3) or four (4) relevant numbers.

Table 1 – Applicability

PART NUMBER PART SERIAL NUMBERS GA8-570026-035 Strut Struts delivered on new aircraft: 350 thru 361, 363 thru 398, 402 thru 406, 409 thru 440, 442 thru 449, 451, 452, 459, 461, 462, 465, 466 thru 483, 486 thru 497, 500 thru 503, 506, 507, 510 thru 515, 520 thru 523, 526 thru 533, 552 thru 554, 559, 560, 562

Struts provided as replacement items: 362, 399, 400, 484, 498, 499, 512, 513, 524, 525, 527, 538, 539, 542, 543, 544, 545, 546, 547 GA8-570026-029 Strut Fitting – Fuselage End 718 thru 808, 889 thru 1022 GA8-570026-031 Strut Fitting – Wing End 716 thru 806, 967 thru 1020 GA8-571022-105 Forward Strut Fitting, RH 289, 290, 296, 297, 299, 300, 301, 308 thru 320, 322, 323, 325 thru 347 GA8-571022-106 Forward Strut Fitting, LH 288, 289, 290, 292, 295, 298, 303, 306 thru 314, 316 thru 319, 321 thru 326, 329 thru 333, 335 thru 345 GA8-571022-107 Aft Strut Fitting, LH 307 thru 346 GA8-571022-108 Aft Strut Fitting, RH 308 thru 347 GippsAero records show the aircraft serial numbers listed in Table 2 are affected, however all Operators must check the individual serial numbers identified in Table 1 as the following list may be incomplete.

Table 2 – Known Affected Aircraft

AIRCRAFT AIRCRAFT SERIAL NUMBERS GA8 and GA8-TC 320 Aircraft 139 Aircraft 158 thru 239 inclusive Amendments Issue 1: Initial Issue, released 26-Feb-2018 Issue 2: Amends requirement for strut removal for inspections to be a one-off only, inspection Part C1 and C2 are combined . Recurring o n-wing inspections introduced for Wing and Strut Fittings ;

outlined in Part C3 . Table 3 updated to include Part C3 . References to Service Letter SL-GA8- 2018-37 included where relevant. Rework of interfacing fuselage lug. Other minor changes highlighted by vertical change bars.

SB-GA8-2017-174 Issue 2 Date of Issue: 23-May-2018 Page 2 of 18 Issue 2 Background GippsAero has recently id entified that some P/N GA8 -570026-035 Struts, P/N GA8 -570026-029 Strut Fitting – Fuselage End, P/N GA8 -570026-031, Strut Fitting – Wing End, and P/N GA8571022 -105,-106,- 107 and -108 Strut Fittings cannot be assured as meeting their material specification requirements. This Service Bulletin introduces inspection requirements and replacement instructions for identified Wing Struts and Fittings. Safe flight with the identified Wing Strut Assemblies and Strut Fittings can continue as their certified strength is unaffected , however there ma y be a reduction in the Strut and Strut Fitting fatigue lives. As a precaution GippsAero is mandating replacement of Struts and Strut Fittings as detailed in this Service Bulletin.

Compliance This Service Bulletin requires an initial general visual inspection by 31 st August 2018; recurring general visual inspections are required at intervals not exceeding 110 hours. This Service Bulletin requires a oneoff detailed visual inspection, that involves the strut removal, by 31st August 2018; then recurring on-wing visual inspections are required at 1000 hours intervals. This Service Bulletin also introduces new mandatory replacement times for affected parts. More detail is provided under Continuing Airworthiness on Page 4.

Weight and Balance The inspections outlined herein do not impact the aircraft’s weight and balance.

A single replacement Strut Assembly, P/N GA8 -570016-041, adds 1.4 lbs to the aircraft 52 ” aft of the datum.

Approval The airframe inspection described in this Service Bulletin and part replacement intervals have been approved pursuant to Australian Civil Aviation Safety Regulation 21.098 (1998). GippsAero Reference GAE11#2215.

Labour

- 2 man hours should be allocated for completing the work detailed in Part B of this Service Bulletin.

- 3 man hours should be allocated for completing the work detailed in Part C1 and C2 of this Service Bulletin.

- 3 man hours should be allocated for completing the work detailed in Part C3 of this Service Bulletin.

- 5 man hours should be allocated for completing the work detailed in Part D of this Service Bulletin.

- 5 man hours should be allocated for completing the work detailed in Part E of this Service Bulletin.

These estimates do not include time required to do normal maintenance preparation or set up equipment.

Spare Parts and Warranty Replacement Wing Strut Assemblies and Wing Strut Fittings can be obtained by contacting GippsAero Customer Service:

Tel: +61 (0)3 5172 1200 Fax: +61 (0)3 5172 1201 Email: aircraft.parts@mahindraaerospace.com Aircraft covered by warranty may claim the direct cost of incorporating the requirements of this Service Bulletin by contacting GippsAero Customer Service:

Tel: +61 (0)3 5172 1200 Fax: +61 (0)3 5172 1201 Email: aircraft.warranty@mahindraaerospace.com

SB-GA8-2017-174 Issue 2 Date of Issue: 23-May-2018 Page 3 of 18 Issue 2 Part Identification The parts affected by this Service Bulletin are identified in Figure 1.

Figure 1 – Part Identification LHS Shown, RHS Opposite

SB-GA8-2017-174 Issue 2 Date of Issue: 23-May-2018 Page 4 of 18 Issue 2 Continuing Airworthiness The requirements of this Service Bulletin are shown in Table 3.

Table 3 – Service Bulletin Requirements

SERVICE

BULLETIN

APPLICABILITY See Table 1 for Serial Number effectivity ACTION and

DESCRIPTION STARTS INTERVAL TERMINATES

PART A All Identification of affected parts - - - PART B All General visual inspection by 31st August 2018 100 +/-10 hours when parts replaced by Part D or Part E PART C1 and PART C2 GA8-571022-105 Forward Strut Fitting, RH One-off detailed non-destructive inspection

by 31st August 2018

N/A

when inspection performed

GA8-571022-106 Forward Strut Fitting, LH

GA8-571022-107 Aft Strut Fitting, LH

GA8-571022-108 Aft Strut Fitting, RH

GA8-570026-029 Strut Fitting – Fuselage End

GA8-570026-031 Strut Fitting – Wing End

PART C3 GA8-571022-105 Forward Strut Fitting, RH Detailed nondestructive inspection by 31st August 2018 1000 +/- 10 hours when parts replaced by Part D

GA8-571022-106 Forward Strut Fitting, LH

GA8-571022-107 Aft Strut Fitting, LH

GA8-571022-108 Aft Strut Fitting, RH

GA8-570026-029 Strut Fitting – Fuselage End Detailed nondestructive inspection by 31st August 2018 1000 +/- 10 hours when parts replaced by Part E

GA8-570026-031 Strut Fitting – Wing End

PART D GA8-570026-035 Strut Replacement Not exceeding 9,000 part hours in service OR within 5 calendar years of date of issue of this Service Bulletin whichever occurs first

GA8-570026-029 Strut Fitting – Fuselage End Replacement Not exceeding 6,000 part hours in service nOR within 3 calendar years of date of issue of this Service Bulletin whichever occurs first

GA8-570026-031 Strut Fitting – Wing End

PART E GA8-571022-105 Forward Strut Fitting, RH Replacement Not exceeding 6,000 part hours in service OR within 3 calendar years of date of issue of this Service Bulletin whichever occurs first

GA8-571022-106 Forward Strut Fitting, LH

GA8-571022-107 Aft Strut Fitting, LH

GA8-571022-108 Aft Strut Fitting, RH

SB-GA8-2017-174 Issue 2 Date of Issue: 23-May-2018 Page 5 of 18 Issue 2 Table 4 shows the non -destructive inspection requirements for a typical block of 1000 flight hours after the date of issue of this Service Bulletin.

Table 4 – Inspection requirements Inspection Type Aircraft Hours in Service General Visual (Part B) One-Off Detailed Visual (Part C1 and C2) On Wing Detailed Visual (Part C3) By 31st August 2018     +100  +200  +300  +400  +500     +600     +700     +800     +900     +1000     Part B and Part C3 inspections must continue until any of the parts identified in Table 1 reach the replacement times shown in Table 3.

SB-GA8-2017-174 Issue 2 Date of Issue: 23-May-2018 Page 6 of 18 Issue 2 Parts The spare parts that may be required to do Parts C1 and C2 or C3 for one Strut Assembly are listed in Table 5.

Table 5 – Parts C1 and C2 or C3 (KIT SB-GA8-2017-174-1)

ITEM PART NUMBER DESCRIPTION QTY ALTERNATE 1 NAS6610-38 BOLT, HEX HEAD, CLOSE TOLERANCE 2 - 2 AN960-1016 WASHER, PLAIN 2 NAS1149G1063P NAS1149F1063P 3 MS21245L10 NUT, SELF LOCKING, HEXAGON 2 MS21083N10 4 AN316-10R NUT, JAM 2 NASM316-10R

The spare parts required to do Part D for one Strut Assembly are listed in Table 6.

Table 6 – Part D (KIT SB-GA8-2017-174-2)

ITEM PART NUMBER DESCRIPTION QTY ALTERNATE 5 NAS6610-38 BOLT, HEX HEAD, CLOSE TOLERANCE 2 - 6 AN960-1016 WASHER, PLAIN 2 NAS1149G1063P NAS1149F1063P 7 MS21245L10 NUT, SELF LOCKING, HEXAGON 2 MS21083N10 8 AN316-10R NUT, JAM 2 NASM316-10R 9 GA8-570016-041 STRUT ASSEMBLY 1 -

The spare parts required to do Part E for one wing are listed in Table 7.

Table 7 – Part E (KIT SB-GA8-2017-174-3 and -4) ITEM PART NUMBER DESCRIPTION QTY – LH WING (-3) QTY – RH WING (-4) ALTERNATE 10 GA8-571022-106 FORWARD STRUT FITTING, LH 1 - - 11 GA8-571022-107 AFT STRUT FITTING, LH 1 - - 12 GA8-571022-105 FORWARD STRUT FITTING, RH - 1 - 13 GA8-571022-108 AFT STRUT FITTING, RH - 1 - 14 AN5-15A BOLT, MACHINE, AIRCRAFT 1 1 - 15 AN5-16A BOLT, MACHINE, AIRCRAFT 1 1 - 16 AN5-17A BOLT, MACHINE, AIRCRAFT 1 1 - 17 AN5-20A BOLT, MACHINE, AIRCRAFT 2 2 - 18 AN960-516 WASHER, PLAIN 9 9 NAS1149G0563P NAS1149F0563P 19 MS21042-5 NUT, SELF LOCKING 5 5 - 20 NAS6610-38 BOLT, HEX HEAD, CLOSE TOLERANCE 2 2 - 21 AN960-1016 WASHER, PLAIN 2 2 NAS1149G1063P NAS1149F1063P 22 MS21245L10 NUT, SELF LOCKING, HEXAGON 2 2 - 23 AN316-10R NUT, JAM 2 2 NASM316-10R

SB-GA8-2017-174 Issue 2 Date of Issue: 23-May-2018 Page 7 of 18 Issue 2 Approved Non-Destructive Inspections Parts C1, C2 and C3 of this Service Bulletin require mandatory visual inspections of primary aircraft structure. These visual inspections assess the condition of the parts and their paint or primer coatings.

They also look for corrosion, scratches, scoring, dents or cracks in machined parts and the wing strut.

All mandatory visual inspections require the use of at least 10x magnification and a strong supplementary source of light. A borescope (or Videoscope) is required for the On-Wing inspection in Part C3.

This Service Bulletin also identifies Eddy Current Inspection (ECI) or fluorescent Liquid Penetrant Inspection (LPI) as approved alternate procedures for the inspections. Where a non -destructive inspection is required by this Service Bulletin, GippsAero will identify general industry standards for either ECI or LPI if used as approved alternatives to the mandatory visual inspection. These industry standard s can be used by any local non -destructive testing provider to develop inspection techniques specific to the relevant parts.

Names of Features on Strut Fittings Examples of t he names of geometric features and locations on the Strut Fittings are shown in Figure 2.

When doing the visual inspections required by this Service Bulletin, all of these features and locations must be examined and these names should be used when communicating the results of any inspections to GippsAero.

Figure 2 – Strut Fitting Feature Names

SB-GA8-2017-174 Issue 2 Date of Issue: 23-May-2018 Page 8 of 18 Issue 2 Accomplishment Instructions All of the following accomplishment instructions are applicable to either the Left Hand Side (LHS) or the Right Hand Side (RHS) of the aircraft, unless noted 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:

- AIRCRAFT MAINTENANCE AND OPERATION MANUALS;

- 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

CONSUMABLE USED DURING THE ACCOMPLISHMENT OF THIS SERVICE

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

NOTE:

Unless otherwise specified, reference to the GA8 or GA8-TC 320 Service Manual and FAA Advisory Circular (AC) 43.13-1B & -2B should be made when carrying out the procedures prescribed in this Service Bulletin. In case of a discrepancy between the Service Manual and the AC, the Service Manual takes precedence.

Part A – Preparation

1. Put the aircraft on a stable, level surface such as inside a maintenance hangar.

2. Make the aircraft safe for maintenance by at least electrically isolating the aircraft by disconnecting the aircraft battery.

3. Apply the aircraft park brake or otherwise chock at least the main landing gear wheels.

4. Remove Strut to Fuselage and Strut to Wing fairings. Retain fasteners if serviceable.

5. Slide fairing(s) away from Strut attachment joint(s).

CAUTION:

CROSS CHECK PHYSICAL PART IDENTIFICATION AND AIRCRAFT LOG

BOOK CAREFULLY IF STRUT ASSEMBLIES HAVE BEEN PREVIOUSLY REPLACED DURING AIRCRAFT SERVICE.

IF PHYSICAL PART IDENTIFICATION IS NOT POSSIBLE, OR A

DISCREPANCY EXISTS BETWEEN PHYSICAL PART AND AIRCRAFT

LOGBOOK, CONTACT GIPPSAERO

6. Identify and record the Wing Strut part number and serial number. Verify the aircraft’s log book contains the correct information.

7. Identify and record the Strut Fitting – Wing End and Strut Fitting – Fuselage End part numbers and serial numbers. Verify the aircraft’s log book contains the correct information.

8. Identify and record the Forward and Aft Strut Fitting part numbers and serial numbers. Verify the aircraft’s log book contains the correct information.

SB-GA8-2017-174 Issue 2 Date of Issue: 23-May-2018 Page 9 of 18 Issue 2 Part B – Directed Detailed Visual Inspection All of the following accomplishment instructions are applicable to either the Left Hand Side (LHS) or the Right Hand Side (RHS) of the aircraft, unless noted otherwise.

CAUTION:

THIS SECTION OF THE SERVICE BULLETIN DOES NOT AUTHORISE ANY REWORK. IF YOU THINK REWORK MAY BE REQUIRED, CONTACT

GIPPSAERO NOTE:

Removal of the Wing Strut Assembly from the aircraft will not be required

1. Clean the inspection areas identified in Figure 3 using a cleaning solvent or airframe cleaning compound.

2. Do a detailed visual inspection, using at least 10x magnification and a strong light source of the areas of the Strut, Strut Fittings (Wing End and Fuselage End) and Strut Fittings (Forward and Aft) in Figure 3. Look for cracked or damaged surface protection (primer and paint), corrosion or other damage.

Figure 3 – Directed Detailed Visual Inspection Areas

3. If any indications of cracking or corrosion are found, remove paint from the inspection area and do another detailed visual inspection.

4. If any indications of cracking or corrosion are found, replace all affected parts in accordance with Part D or Part E of this Service Bulletin. Contact GippsAero for assistance if required.

5. If no cracks or corrosion are found, do a torque check of all the fasteners connecting the Strut Fittings to the Strut using values from Chapter 20 of the GA8/GA8-TC 320 Service Manual. If any fasteners are found loose, contact GippsAero for assistance. Otherwise, continue.

6. If any areas of paint are removed for inspection, or found to be damaged, restore the surface protection. Apply a chemical conversion coating, Type 1, Class 1A per MIL-DTL-5541. Apply a coat of primer that conforms to MIL-PRF-23377 or FED-SPEC-TT-P-1757. Apply a topcoat of paint that conforms to MIL-PRF-85285 and matches the surrounding colour.

NOTE:

Surface protection is very important and helps prevent corrosion. Make sure to restore any removed or damaged surface protection.

use a mirror to inspect fitting and inside surfaces of the strut use a mirror to inspect fitting and inside surfaces of the strut

SB-GA8-2017-174 Issue 2 Date of Issue: 23-May-2018 Page 10 of 18 Issue 2

7. Install Strut to Fuselage and Strut to Wing fairings, inspection is complete.

Part C – Detailed Non-Destructive Inspection All of the following accomplishment instructions are applicable to either the Left Hand Side (LHS) or the Right Hand Side (RHS) of the aircraft, unless noted otherwise.

The inspections required by this section of the Service Bulletin are:

- one-off inspection that removes the Strut and performs detailed visual inspections of Part C1 and C2

- recurring On-Wing detailed visual inspections in Part C3 that removes the Strut bolts at 1000 hour intervals CAUTION:

THIS SECTION OF THE SERVICE BULLETIN AUTHORISES LIMITED REWORK. IF

ADDITIONAL REWORK IS REQUIRED, CONTACT GIPPSAERO Part C1 and Part C2 – Preparation

1. Shore aircraft wing by placing on trestles or similar supporting device in accordance with Chapter 7-20-00 of the GA8/GA8-TC 320 Service Manual. Service Letter SL-GA8-2018-37 also provides additional guidance on how to shore the wing, remove the bolts and remove the Strut.

2. Remove upper and lower Strut bolts, nuts and washers.

3. Remove Wing Strut from aircraft.

4. Clean bolts, nuts and washers using a cleaning solvent. Inspect the bolts, nuts and washers for serviceability.

Look for corrosion, scores, scratches or any other damage. Look for damaged surface protection (Cadmium plating). Check that the locknut has a minimum prevailing torque of 1 8 in-lbs.

Bolt hole diameter standard value: 0.623” – 0.624” If corrosion is evident or Cadmium plating is compromised, or if the hardware is not within above limits, replace the affected hardware with new parts as listed in Table 5.

Part C1 – Forward and Aft Strut Fittings (Wing) Inspection

1. Clean wing Forward and Aft Strut Fittings attached to the wing identified in Figure 4 using a cleaning solvent or airframe cleaning compound.

2. Do a detailed visual inspection using at least 10x magnification and a strong light source of the lug faces, inner surfaces of the Strut Fitting bolt holes, fastener lands and Fitting shank.

Look for corrosion, cracks, scores, scratches or any other damage. Look for cracked or damaged surface protection (primer and paint). Check lug bolt holes for any evidence of elongation, damage or corrosion.

Bolt hole diameter standard value: 0.6245” – 0.6255” If corrosion or cracks are found, or if the bolt hole is not within the standard value, replace all affected parts in accordance with Part E of this Service Bulletin. Contact GippsAero for assistance if required.

Otherwise, continue.

NOTE:

Doing an Eddy Current Inspection of the bolt holes in accordance with SAE-ARP-4402 is an approved alternative method of inspection for these parts Doing a fluorescent liquid penetrant inspection in accordance with ASTM E-1417 is an approved alternative method of inspection for these parts

3. If any areas of paint are removed for inspection, or found to be damaged, restore the surface protection. Apply a chemical conversion coating, Type 1, Class 1A per MIL-DTL-5541. Apply a coat of primer that conforms to MIL-PRF-23377 or FED-SPEC-TT-P-1757. Where required, apply a topcoat of paint that conforms to MIL-PRF-85285 and matches the surrounding colour.

NOTE:

Surface protection is very important and helps prevent corrosion. Make sure to restore any removed or damaged surface protection.

SB-GA8-2017-174 Issue 2 Date of Issue: 23-May-2018 Page 11 of 18 Issue 2

Figure 4 – Inspection areas in Strut Fittings (Forward and Aft)

Part C2 - Wing Strut Fittings and Fuselage Attachment Inspection

1. Clean the inspection areas of the Strut and all Strut Fittings identified in Figure 5 and interfacing parts on the fuselage using a cleaning solvent or airframe cleaning compound.

2. Do a detailed visual inspection using at least 10x magnification and a strong light source of the lug faces, inner surfaces of the Strut Fitting bolt holes, lug clevis and fastener lands and interfacing parts on the fuselage.

Look for corrosion, cracks, scores, scratches or any other damage. Look for cracked or damaged surface protection (primer and paint). Check lug bolt holes for any evidence of elongation, damage or corrosion.

Bolt hole diameter standard value: 0.625” – 0.627” If corrosion or cracks are found, or if the Strut Fitting bolt hole/s is/are not within the standard value, replace the Strut Assembly in accordance with Part D of this Service Bulletin. Contact GippsAero for assistance if required.

NOTE:

Doing an Eddy Current Inspection of the bolt holes in accordance with SAE-ARP-4402 is an approved alternative method of inspection for these parts Doing a fluorescent liquid penetrant inspection in accordance with ASTM E-1417 is an approved alternative method of inspection for these parts

SB-GA8-2017-174 Issue 2 Date of Issue: 23-May-2018 Page 12 of 18 Issue 2

Figure 5 – Wing Strut and Strut Fittings inspection areas

3. If there is evidence of foul on the strut fitting lug inner face and fuselage lug outer faces, remove material from the fuselage lug by blending as shown in Figure 6.

Figure 6 – Allowable Rework to Fuselage Lug

RIB 5/6 Note:

Finish the blended edge s with an abrasive pad or similar to achieve a maximum surface roughness of 63 Ra