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Service Bulletin 06 November 2018 Revision 02, 18 January 2019 2000−54−036 Page 1 of 18 ATA CHAPTER: 54 NACELLE/PYLONS − EMS STRUCTURE − REPAIR / REAM OF HOLE TOLERANCE AND
INSTALL NEW FASTENERS Mod No.
1. PLANNING INFORMATION A. EFFECTIVITY
(1) Aircraft:
Aircraft Mfg. Serial No’s SAAB 2000 − 004 thru − 063.
NOTE: Aircraft as stated in Table 1 below, could consider the performed repair via Saab Repair Statement as a terminating action for this Service Bulletin. Make a note in the logbook that SB 2000−54−036 has been implemented.
A/C Serial Number Related Repair Statement (Latest Revision) 006 2000SDS045679 043 2000SDS045888 056 2000SDS045859 061 2000SDS045159 Table 1 − Aircraft Affected by Repair Statement
(2) Spares: Not affected.
B. REASON Loose and irregular fasteners have been found at the forward extent of the nacelle upper longeron where the bulkhead frame and struts of the EMS structure attach.
Investigation results indicate potential risk for significant reduction of the safety margins.
Inspection and corrective actions will make sure the aircraft is repaired to the intended type design.
C. DESCRIPTION This Service Bulletin gives instructions for:
− Removal of the power plant − Removal of the upper struts − Removal of the horizontal struts − Removal of fasteners in the EMS fittings − Inspection of fasteners hole tolerance.
− If necessary ream the fastener holes to correct tolerance.
− If you can not get correct tolerance, Saab must be contacted for further repair instructions.
− Installation of fasteners − Installation of the horizontal struts − Installation of the upper struts − installation of the power plant NOTE: Applicable for L/H and R/H nacelle, inboard and outboard fittings.
D. COMPLIANCE Mandatory.
Service Bulletin 06 November 2018 Revision 02, 18 January 2019 2000−54−036 Page 2 of 18 Saab recommends this Service Bulletin to be performed within 24 month or 3000 flight hours, whichever occurs first, from release of this Service Bulletin.
This Service Bulletin is under EASA consideration for an Airworthiness Directive.
The final compliance terms will be set by the EASA Airworthiness Directive (AD) when issued.
E. APPROVAL The technical content of this Service Bulletin is approved under the authority of DOA nr.
EASA.21J.066.
F. MANPOWER Estimated time to complete this Service Bulletin is:
2 persons required.
Total manhours removal: 12 x 2 = 24 Total manhours modification: 100 x 2 = 200 Total manhours installation: 16 x 2 = 32 Total manhours: 256 Elapsed time (hours): 130 Labour cost at operators expense.
G. MATERIAL − COST AND AVAILABILITY Local supply.
H. TOOLING
(1) Access platform, 1.75 m (5.75 in.) height.
(2) Reamer for Hi −lok and Visu−lok nominal size and first and second step oversize (SRM 51−40−22, 51−40−25, 51−40−30).
(3) Visu −lok tool.
I. WEIGHT AND BALANCE None.
J. ELECTRICAL LOAD DATA Not affected.
Service Bulletin 06 November 2018 Revision 02, 18 January 2019 2000−54−036 Page 3 of 18 K. REFERENCES Aircraft Maintenance Manual (AMM) 26 −11−10−000−801 26−11−10−400−801 71−00−00−400−801 71−21−10−000−801 71−21−10−000−804 71−21−10−000−805 71−21−10−000−813 71−21−10−400−801 71−21−10−400−804 71−21−10−400−805 71−21−10−400−813 Structural Repair Manual (SRM) 51 −20−40 51−20−41 51−20−42 51−20−43 51−20−50 51−20−56 51−40−21 51−40−22 51−40−24 51−40−25 51−40−30 51−40−40 51−40−60 L. OTHER PUBLICATIONS AFFECTED Not affected.
2. ACCOMPLISHMENT INSTRUCTIONS CAUTION: BE CAREFUL WHEN YOU DO STRUCTURAL MODIFICATIONS NEAR ELECTRICAL HARNESSES AND/OR MECHANICAL COMPONENTS. MAKE SURE THAT YOU
COVER ELECTRICAL HARNESSES AND/OR MECHANICAL COMPONENTS ADJACENT TO THE WORK AREA. CLEAN AND INSPECT THE HARNESSES AND/OR THE MECHANICAL COMPONENTS WHEN THE MODIFICATION IS COMPLETED.
DAMAGES TO THE WIRES OR THE MECHANICAL COMPONENTS CAN CAUSE SYSTEM MALFUNCTION.
NOTE: This Service Bulletin gives instructions to ream fasteners hole to nominal size, or to first step oversize hole (at one location, second step oversize is approved without contact Saab). If the fastener holes are not within tolerance, after reaming to first or second step oversize hole, Saab must be contacted for further instructions.
NOTE: It is approved to perform actions in accordance with this SB on one nacelle at one occasion and on the other nacelle at another occasion. However, the SB must not be reported as fully implemented until actions are performed on both LH and RH side nacelle.
Service Bulletin 06 November 2018 Revision 02, 18 January 2019 2000−54−036 Page 4 of 18 A. JOB SET −UP
(1) Before you start the SB, make sure:
− The local supply items listed in the Service Bulletin are available − The documentation is available − The special tools are available − The fasteners are available.
CAUTION: IF FASTENERS HAS BEEN INSTALLED WITH STATEMENTS IN THIS AREA, THE FASTENERS SHALL NOT BE REMOVED AND THE HOLE NOT BE INSPECTED.
THESE HOLES SUPPOSED TO BE WITHIN LIMIT OF THE HOLE TOLERANCE.
(2) Put the access platforms in position.
B. REMOVAL
(1) Remove the power plant (Ref. AMM TASK 71−00−00−000−801).
(2) Remove the Engine Mounting Structure (EMS) LH Upper Strut (Ref. AMM TASK 71−21−10−000−801).
(3) Remove the Engine Mounting Structure (EMS) RH Upper Strut (Ref. AMM TASK 71−21−10−000−804).
(4) Remove the Engine Mounting Structure (EMS) LH/RH Horizontal Strut (Ref. AMM TASK 71−21−10−000−805).
(5) Remove the Aft Beam (Ref. AMM TASK 71−21−10−000−813).
(6) Remove / loose the sensor wire in the repair area of the inner skin (Ref. AMM TASK 26−11−10−000−801).
REF. FIG. 2 View A
(a) Loosen the screw (14).
(b) Lift the clamp cover (11).
(c) Carefully lift the bushing (13) and the sensor wire (12).
(d) Remove the screw (15) and keep.
(e) Remove the clamp (16) and keep.
C. MODIFICATION WARNING: BE CAREFUL WHEN YOU USE THE CONSUMABLE MATERIAL(S). YOU MUST OBEY THE OPERATOR,S AND MANUFACTURER,S HEALTH AND SAFETY INSTRUCTIONS.
THE CONSUMABLE MATERIAL (S) CAN CAUSE INJURY OR DEATH TO PERSONS.
CAUTION: MAKE SURE YOU DO NOT DAMAGE THE FIRE SENSOR WIRE WHEN YOU DO THIS REPAIR.
CAUTION: IF FASTENERS HAS BEEN INSTALLED WITH STATEMENTS IN THIS AREA, THE FASTENERS SHALL NOT BE REMOVED AND THE HOLE NOT BE INSPECTED.
THESE HOLES SUPPOSED TO BE WITHIN LIMIT OF THE HOLE TOLERANCE.
CAUTION: WHEN YOU REMOVE FASTENERS, REMOVE EVERY OTHER FASTENERS, SO THE ITEMS ARE CLOSE TOGETHER. IF NOT THE ITEMS CAN SEPARATE.
(1) Make a cut out in the inboard skin and make a doubler.
REF. FIG. 2 View A and B
(a) Remove the five screws (1), and keep them.
(b) Remove the door (2), and keep it.
Service Bulletin 06 November 2018 Revision 02, 18 January 2019 2000−54−036 Page 5 of 18
(c) Remove the four rivets (4), for the plate (3), with the anchor nuts.
(d) Carefully press the plate (3) inboard, and keep away from the inner skin.
(e) Make a cut −out in the inner skin.
1 Mark a cut−out line.
NOTE: Make sure you have a minimum radii of 13.0 mm (0.500 in) in the cut −out.
2 Make sure you have a distance of minimum 1 mm to the inner structure.
3 Make the cut−out.
4 Burr the edges.
(f) Remove the plate (3), with the anchor nuts.
1 Remove the anchor nuts, and keep them.
2 Keep the plate (3) as a template.
3 Use masking tape and cover the lightening holes in the nacelle.
(g) Make a doubler.
1 Make a doubler (5) from material Titan AMS 4911, T = 1.27 mm.
2 Measure the size of the doubler (5) is going to cover.
NOTE: Make sure you make the doubler (5) bigger than the final size, to get good edge distance.
3 Put the plate (3) on the doubler (5).
4 Mark the center hole, the five bolt holes.
5 Drill and ream the center hole, the five bolt holes.
6 Use the anchor nut as a template and drill for rivets.
7 Countersink for the anchor nuts rivets, ZCU3.
8 Deburr and chamfer the holes.
9 Clean the doubler (5) and the anchor nuts with MEK.
10 Use fay sealant and install the anchor nuts with rivets, ZCU3.
11 Do not remove fasteners for the doubler (5) at this moment.
(2) Repair of the inner skin area.
REF. FIG. 1 Sh 1 CAUTION: WHEN YOU REMOVE FASTENERS, REMOVE EVERY OTHER FASTENERS, SO THE ITEMS ARE CLOSE TOGETHER. IF NOT THE ITEMS CAN SEPARATE.
CAUTION: WHEN YOU INSPECT THE HOLES AFTER REAMING, AND A HOLE IS NOT WITHIN LIMIT, CONTACT SAAB.
(a) Remove every other fastener (10 plcs).
(b) Inspect the holes.
1 If the hole is within Hi−lok 6 limit, go to step (2)(f).
2 If the hole not is within Hi−lok 6 limit, go to step (2)(c).
(c) Ream to first step oversize for Hi −lok.
(d) Inspect the hole.
1 If the hole not is within limit, contact Saab.
Service Bulletin 06 November 2018 Revision 02, 18 January 2019 2000−54−036 Page 6 of 18 2 If the hole is within limit, go to step (2)(e).
(e) Chamfer the hole.
(f) Apply a thin layer of Bonderite 1200 in the hole.
(g) Apply a thin layer of FR −primer in the hole.
(h) Let the primer cure.
(i) Wet install Hi −lok (22 or 23) and washers with fay sealant.
(j) Install the nut on the Hi −lok.
(k) Torque the nut on the Hi −lok.
(l) Remove every other fastener, which not has bee removed in step (2)(a).
(m) Do step (2)(a) to (2)(k).
(n) Retorque all nuts.
(3) Repair of the outer skin area.
REF. FIG. 1 Sh 2 CAUTION: WHEN YOU REMOVE FASTENERS, REMOVE EVERY OTHER FASTENERS, SO THE ITEMS ARE CLOSE TOGETHER. IF NOT THE ITEMS CAN SEPARATE.
CAUTION: WHEN YOU INSPECT THE HOLES AFTER REAMING, AND A HOLE IS NOT WITHIN LIMIT, CONTACT SAAB.
(a) Remove every other fastener (10 plcs).
(b) Inspect the holes.
1 If the hole is within Hi−lok 6 limit, go to step (3)(f).
2 If the hole not is within Hi−lok 6 limit, go to step (3)(c).
(c) Ream to first step oversize for Hi −lok.
(d) Inspect the hole.
1 If the hole not is within limit, contact Saab.
2 If the hole is within limit, go to step (3)(e).
(e) Chamfer the hole.
(f) Apply a thin layer of Bonderite 1200 in the hole.
(g) Apply a thin layer of FR −primer in the hole.
(h) Let the primer cure.
(i) Wet install Hi −lok (24 or 25) and washers with fay sealant.
(j) Install the nut on the Hi −lok.
(k) Torque the nut on the Hi −lok.
(l) Remove every other fastener, which not has bee removed in step (3)(a).
(m) Do step (3)(a) to (3)(k).
(n) Retorque all nuts.
(4) Repair of the upper area.
REF. FIG. 1 Sh 2 View A−A CAUTION: WHEN YOU REMOVE FASTENERS, REMOVE EVERY OTHER FASTENERS, SO THE ITEMS ARE CLOSE TOGETHER. IF NOT THE ITEMS CAN SEPARATE.
CAUTION: WHEN YOU INSPECT THE HOLES AFTER REAMING, AND A HOLE IS NOT WITHIN LIMIT, CONTACT SAAB.
(a) Remove every other fastener (18 plcs).
Service Bulletin 06 November 2018 Revision 02, 18 January 2019 2000−54−036 Page 7 of 18
(b) Inspect the holes.
1 Rivet hole.
a If the hole is within limit, install LM 5 rivet.
b If the hole not is within limit, drill for LM 6 rivet. Install LM 6 rivet.
2 Hi−lok hole.
a If the hole is within Hi−lok 6 limit, go to step (4)(f).
b If the hole not is within Hi−lok limit, go to step (4)(c).
(c) Ream to first step oversize for Hi −lok.
(d) Inspect the hole.
1 If the hole not is within limit, contact Saab.
2 If the hole is within limit, go to step (4)(e).
(e) Chamfer the hole.
(f) Apply a thin layer of Bonderite 1200 in the hole.
(g) Apply a thin layer of FR −primer in the hole.
(h) Let the primer cure.
(i) Wet install Hi −lok (22 or 23) and washers with fay sealant.
(j) Install the nut on the Hi −lok.
(k) Torque the nut on the Hi −lok.
(l) Remove every other fastener, which not has bee removed in step (4)(a).
(m) Do step (4)(a) to (4)(k).
(n) Retorque all nuts.
(5) Repair of the inner area.
REF. FIG. 1 Sh 2 View B−B CAUTION: WHEN YOU REMOVE FASTENERS, REMOVE EVERY OTHER FASTENERS, SO THE ITEMS ARE CLOSE TOGETHER. IF NOT THE ITEMS CAN SEPARATE.
CAUTION: WHEN YOU INSPECT THE HOLES AFTER REAMING, AND A HOLE IS NOT WITHIN LIMIT, CONTACT SAAB.
(a) Remove every other fastener(7 plcs).
(b) Inspect the hole.
1 If the hole is within Hi−lok 6 limit, go to step (5)(f).
2 If the hole not is within Hi−lok 6 limit, go to step (5)(c).
(c) Ream to first step oversize for Hi −lok.
(d) Inspect the hole.
1 If the hole not is within limit, contact Saab.
2 If the hole is within limit, go to step (5)(e).
(e) Chamfer the hole.
(f) Apply a thin layer of Bonderite 1200 in the hole.
(g) Apply a thin layer of FR −primer in the hole.
(h) Let the primer cure.
Service Bulletin 06 November 2018 Revision 02, 18 January 2019 2000−54−036 Page 8 of 18
(i) Wet install Hi −lok (22 or 23) and washers with fay sealant.
(j) Install the nut on the Hi −lok.
(k) Torque the nut on the Hi −lok.
(l) Remove every other fastener, which not has bee removed in step (5)(a).
(m) Do step (5)(a) to (5)(k).
(n) Retorque all nuts.
(6) Repair of the forward area.
REF. FIG. 1 Sh 2 View C−C CAUTION: WHEN YOU REMOVE FASTENERS, REMOVE EVERY OTHER FASTENERS, SO THE ITEMS ARE CLOSE TOGETHER. IF NOT THE ITEMS CAN SEPARATE.
CAUTION: WHEN YOU INSPECT THE HOLES AFTER REAMING, AND A HOLE IS NOT WITHIN LIMIT, CONTACT SAAB.
(a) Remove every other fastener (7 plcs).
(b) Inspect the hole.
1 If the hole is within Hi−lok 6 limit, go to step (6)(g).
2 If the hole not is within Hi−lok 6 limit, go to step (6)(c).
(c) Ream to first step oversize for Hi −lok.
(d) Inspect the hole.
1 If the hole not is within limit, go to step (6)(e).
2 If the hole is within limit, go to step (6)(f).
(e) Ream to second step oversize for Hi −lok.
1 If the hole not is within limit, contact Saab.
2 If the hole is within limit, go to step (6)(f).
(f) Chamfer the hole.
(g) Apply a thin layer of Bonderite 1200 in the hole.
(h) Apply a thin layer of FR −primer in the hole.
(i) Let the primer cure.
(j) Wet install Hi −lok (22 or 23) and washers with fay sealant.
(k) Install the nut on the Hi −lok.
(l) Torque the nut on the Hi −lok.
(m) Remove every other fastener, which not has bee removed in step (6)(a).
(n) Do step (6)(a) to (6)(l).
(o) Retorque all nuts.
(7) Modification of the doubler and installation.
REF. FIG. 2 View C and D CAUTION: WHEN YOU REMOVE FASTENERS, REMOVE EVERY OTHER FASTENERS, SO THE ITEMS ARE CLOSE TOGETHER. IF NOT THE ITEMS CAN SEPARATE.
CAUTION: WHEN YOU INSPECT THE HOLES AFTER REAMING, AND A HOLE IS NOT WITHIN LIMIT, CONTACT SAAB.
(a) Remove every other fastener (23 plcs).
Service Bulletin 06 November 2018 Revision 02, 18 January 2019 2000−54−036 Page 9 of 18
(b) Pin the holes.
NOTE: This keep the structure together.
(c) Remove the rest of the fasteners.
(d) Remove the pins.
(e) Put the doubler (5) in position.
(f) Use a hole finder and drill holes in the doubler (5).
(g) Deburr the holes in nacelle structure and the doubler (5).
(h) Pin the doubler to the nacelle structure.
(i) Mark the new fastener holes (11 plcs).
(j) Drill and ream the new holes for Visu −lok (27) (11 plcs).
(k) Drill and ream the old holes for Visu −lok (28) (4 plcs).
(l) Ream the existing holes to first step oversize for Hi −lok (23).
(m) Inspect the hole.
1 If the hole not is within limit for Hi−lok 6 oversize, or Visu−lok (08 and 3), contact Saab.
2 If the hole is within limit for Hi−lok 6 oversize, or Visu−lok (08 and 3), go to step
(7)(n).
(n) Remove the doubler (5).
(o) Drill and ream the two holes for the sensor wire clamp in the doubler (5).
(p) Chamfer the holes in the doubler (5) and the nacelle structure.
(q) Use a vacuum cleaner and clean in the nacelle and the repair area.
(r) Remove the masking tape from the nacelle lightening holes.
(s) Clean the doubler (5) and the nacelle structure with MEK.
(t) Wet install Hi −loks (23), and if necessary washer under the head with fay sealant.
NOTE: The Hi −loks shall be installed from the inner area, so you easily install the nuts.
(u) Press the Hi −loks (23) into the holes, so it does not turn.
(v) Apply fay sealant on the doubler (5).
(w) Put the doubler (5) in position on to the Hi −loks threads (23).
(x) Push the doubler (5) carefully in position.
(y) Install washer and nut on the Hi −lok (23).
(z) Torque the nuts on the Hi −loks.
(aa) Pin every other Visu −lok hole.
(ab) Wet install the Visu −loks (27 and 28) and washers with fay sealant.
(ac) Remove the pins.
(ad) Wet install the rest of the Visu −loks (27 and 28) and washers with fay sealant.
(ae) Retorque all nuts on the HI −loks.
(af) Apply FR −primer on the Visu−luk pin.
(8) Install the door (2).
REF. FIG. 2 View D
Service Bulletin 06 November 2018 Revision 02, 18 January 2019 2000−54−036 Page 10 of 18
(a) Clean the door (2) and doubler (5) with MEK.
(b) Apply firewall sealant, DC 730, on the doubler at the door (2) position.
(c) Apply promoter, DC 1200 on door (2).
(d) Let the promoter dry.
(e) Install the door (1) with the five bolt (1).
(f) Torque the bolts.
(9) Apply firewall sealant.
REF. FIG. 2 View D
(a) Remove redundant fay sealant around the doubler (5).
(b) Clean edge around the doubler (5) with MEK.
(c) Apply promoter, DC 1200, on the edge.
(d) Let the promoter dry.
(e) Apply firewall sealant, DC 730, on the edge.
D. JOB CLOSE −UP
(1) Close the access.
(a) Remove all the tools and equipment from the work area. Make sure the work area is clean.
(b) Install the sensor wire in the repair area of the inner skin (Ref. AMM TASK 26−11−10−000−801).
NOTE: Make sure that the sensor wires for the Fire Detection System have distance to fasteners in the repaired area.
REF. FIG. 2 View A 1 Put the clamp (16) in position.
2 Install the screw (15).
3 Put the bushing (13) and the sensor wire (12) in position.
4 Put the clamp cover (11) in position.
5 Install the screw (14).
6 Clean the head of the screw (15) with MEK.
7 Apply promoter, DC 1200, on the head of the screw (15).
8 Let the promoter dry.
9 Apply firewall sealant, DC 730, on the head of the screw (15).
(c) Install the Aft Beam (Ref. AMM TASK 71−21−10−400−813).
(d) Install the Engine Mounting Structure (EMS) LH/RH Horizontal Strut (Ref. AMM TASK 71−21−10−400−805).
(e) Install the Engine Mounting Structure (EMS) RH Upper Strut (Ref. AMM TASK 71−21−10−400−804).
(f) Install the Engine Mounting Structure (EMS) LH Upper Strut (Ref. AMM TASK 71−21−10−400−801).
(g) Install the power plant (Ref. AMM TASK 71−00−00−400−801).
Service Bulletin 06 November 2018 Revision 02, 18 January 2019 2000−54−036 Page 11 of 18
(h) Remove the access platforms.
3. MATERIAL INFORMATION A. Local supply Item Part Number Qty Nomenclature Designation Remarks 5 4 Doubler − Make from Titan AMS 4911, alt.
AISI 301 ¼ Hard, T = 1.27 mm 21 HL10VAP −5−xx Alternative:
HL10VAZ−5−xx AR Hi −Lok − Length as required 22 HL10VAP −6−xx Alternative:
HL10VAZ−6−xx AR Hi −Lok − Length as required, oversize for size 5 23 HL110 −6−xx AR Hi −Lok − Length as required, oversize for size 6, step 1 24 HL11VAP −6−xx Alternative:
HL11VAZ−6−xx AR Hi −Lok − Length as required, oversize for size 5 25 HL111 −6−xx AR Hi −Lok − Length as required, oversize for size 6, step 1 26 MS20613C AR Rivet LM 5 or 6 − AN960C8L AR Washer − Thin washer under protrouding head, if needed − AN960C8 AR Washer − − AN960C10L AR Washer − Thin washer under protrouding head, if needed − AN960C10 AR Washer − _ MS21042 −08 AR Nut − _ MS21042 −3 AR Nut − AF184C3 AR Rivet − ZCU3 27 NAS 1671 −08 AR Visu −lok − − 0224994−045 AR Visu −lok Washer − 28 NAS 1671 −3 AR Visu −lok −
Service Bulletin 06 November 2018 Revision 02, 18 January 2019 2000−54−036 Page 12 of 18 Item RemarksDesignationNomenclatureQtyPart Number − 0224994−041 AR Visu −lok Washer − 29 HL410 −6−xx AR Hi −Lok − Length as required, oversize for size 6, step 2 − Methyl Ethyl Ketone AR Cleaning agent − TT−M−261 or equivalent − Bonderite M−CR 1200S AR Surface Treatment − MIL−DTL−81706 Class 1A − PS 870 A AR Fay sealant − MIL-PRF-81733 Type I − Aerudur S15/90 AR FR −Primer −− DC 730 RTV AR Firewall sealant − DC 1200 AR Promoter − MIL−A−46106 A Type I NOTE: Equivalent materials can be used for listed items, Ref. SRM 51 −33−00.