PC-24 Service Bulletin Number 28-002

CCC, 19.1 - 946.33.22.004 4 4 N D 1 1 12 9 938.78.11.202 (See Note 1) Washer, supalloy, CD- PL, 4.3*1.5 - 938.77.11.110 24 - N D 1 1 13 10 932.35.10.070 (See Note 1) Screw, Hex, ST, CD-PL, 4.2*15.9 - 932.35.10.067/ 932.35.10.069 24 - N D 1 1 14 11 Disposition Codes: D - Discard / N - New / R - Return to Pilatus SERVICE BULLETIN Service Bulletin No: 28-002 Date: May 03/19 Rev. No. Date: Page 5 of 20 NOTE 1: The quantity given includes 4 spares. NOTE 2: The quantity given includes 2 spares. D. Operator supplied materials NOTE: Refer to AMM, PC24-A-A00-50-0000-00A-070A-A: E. Material necessary for each spare Not applicable. F. Re-identified parts Not applicable. G. Tools and equipment 946.91.30.015 (See Note 2) Seal, O-ring, FVMQ, 14.0*1.8 - 946.91.30.015 6 4 N D 1 1 5 5 946.91.30.218 (See Note 2) Seal, O-ring, FVMQ, 31.3*3.5 946.91.30.218 6 4 N D 1 1 4 4 Material No. Description Qty Remarks P04-030 Grease AR Nyco 65 (P/N 908.20.02.101) P04-041 Aeroshell grease 58 AR Threads of the screws Tools and equipment Recommended Pilatus part Tool kit, mechanic Local supply Shim (4,00 mm thick) or equivalent Local supply Air pressurization kit Local supply Air supply Local supply Blanking caps (or equivalent) Local supply New part No. Description Old part No. Qty Disp. code Fig Item Disposition Codes: D - Discard / N - New / R - Return to Pilatus Service Bulletin No: 28-002 Date: May 03/19 Rev. No. Date: Page 6 of 20 SERVICE BULLETIN 3. Accomplishment instructions WARNING: BE CAREFUL WHEN YOU DO WORK ON THE ELECTRICAL SYSTEM OR A SYSTEM THAT USES THE ELECTRICAL POWER. MAKE SURE THAT IT IS SAFE BEFORE YOU APPLY ELECTRICAL POWER TO THE AIRCRAFT OR ENERGIZE THE AIRCRAFT ELECTRICAL SYSTEMS. THE ELECTRICAL POWER CAN CAUSE DEATH OR INJURY TO PERSONNEL AND CAUSE DAMAGE TO EQUIPMENT. WARNING: MAKE SURE THAT THERE ARE NO SPARKS, FLAMES OR OTHER POSSIBLE IGNITION SOURCES AROUND THE WORK AREA. THE MIXTURE OF AIR AND FUEL VAPOR AND AN IGNITION SOURCE CAN CAUSE AN EXPLOSION. AN EXPLOSION CAN CAUSE DEATH OR INJURY TO PERSONNEL AND CAUSE DAMAGE TO EQUIPMENT. WARNING: USE THE APPLICABLE PERSONAL PROTECTIVE EQUIPMENT WHEN YOU WORK WITH FUEL. OBEY THE LOCAL REGULATIONS WHEN YOU DISCARD CONTAMINATED CLOTHING / EQUIPMENT. FUEL IS POISONOUS AND CAN CAUSE DEATH OR INJURY. WARNING: BE CAREFUL WHEN YOU USE THE CONSUMABLE MATERIALS. OBEY THE MANUFACTURERS’ HEALTH AND SAFETY INSTRUCTIONS. CAUTION: Make sure that all openings on the fuel system are covered. This will keep dirt, debris or other unwanted material out of the fuel system. A. Preparation (1) Obey the safe maintenance practices as necessary. Refer to AMM, PC24-A-E20-10-0003- 00A-913A-A. (2) De-energize the aircraft electrical system. Refer to AMM, PC24-A-E24-00-0000-00A- 913A-A. (3) Put a “DO NOT CONNECT ELECTRICAL POWER” placard on the overhead control panel. (4) Put "FUEL LINES OPEN" placards around the aircraft. (5) If installed, remove the Automatic Direction Finder (ADF) 1 antenna with the back-up plate. Refer to AMM, PC24-A-E34-45-0001-00A-520A-A. (6) Open/Remove the access panels/fairings in Table 1. Refer to AMM, PC24-A-A06-40- 0000-00A-040A-A and PC24-A-E53-10-0002-00A-520A-A. Table 1: Access panels/fairings to be closed/installed Panel number Panel name 143ABL Panel, wing fairing, MLG, FWD, LH 143ABR Panel, wing fairing, MLG, FWD, RH 143BBL Panel, MLG bay aft, wing fairing, LH 143BBR Panel, MLG bay aft, wing fairing, RH SERVICE BULLETIN Service Bulletin No: 28-002 Date: May 03/19 Rev. No. Date: Page 7 of 20 B. Modification (1) Disassemble the slider shroud and coupling on the LH and RH motive-flow fuel pipe. Refer to Figure 1 (Sheet 1, View B) NOTE: The procedure to disassemble the slider shroud and coupling on the LH and RH motive-flow fuel pipe is the same. (a) Put a container below the LH and RH motive-flow fuel pipe at the slider shroud (8) and coupling (7) installation position. (b) Remove the slider shroud nut (1) from the slider shroud (8). (c) Move the slider shroud (8) onto the motive-flow fuel pipe sufficiently to get access to the two O-rings (4) that are installed on the two large ferrules (2). (d) Release and remove the coupling (7) from the motive-flow fuel pipe. (e) Move the sleeve (6) onto the motive-flow fuel pipe sufficiently to get access to the two O-rings (5) that are installed on the two small ferrules (3). (f) Remove and discard the: • Two O-rings (5) (P/N 946.91.30.015) that are installed on the two small ferrules (3) • Two O-rings (4) (P/N 946.91.30.218) that are installed on the two large ferrules (2). CAUTION: Make sure that all openings on the fuel system are covered. This will keep dirt, debris or other unwanted material out of the fuel system. (g) Install blanking caps (or equivalent) on all openings. (h) Do the above procedure again to disassemble the slider shroud (8) and coupling (7) on the other motive-flow fuel pipe. (2) Replace the saddle clamps on the LH and RH motive-flow fuel pipe. Refer to Figure 1 (Sheet 2, View C) NOTE: The procedure to replace the two saddle clamps on the LH motive-flow fuel pipe and the two saddle clamps on the RH motive-flow fuel pipe is the same. Do the procedure below to replace the two saddle clamps on each side. (a) Hold the saddle clamp (9), remove the two screws (11) and the two washers (10). (b) Remove the two parts of the saddle clamp (9) from the structure and the motive-flow fuel pipe. 143DBL Panel, bottom, LH 143DBR Panel, bottom, RH Panel number Panel name Service Bulletin No: 28-002 Date: May 03/19 Rev. No. Date: Page 8 of 20 SERVICE BULLETIN (c) Discard the: • Two parts of the saddle clamp (9) (P/N 946.33.22.004) • Two screws (11) (P/N 932.35.10.067 / P/N 932.35.10.069) • Two washers (10) (P/N 938.77.11.110). WARNING: BE CAREFUL WHEN YOU USE THE CONSUMABLE MATERIALS. OBEY THE MANUFACTURERS’ HEALTH AND SAFETY INSTRUCTIONS. (d) If necessary, apply a thin layer of aeroshell grease 58 (Material No. P04-041) to the threads of two new screws (14) (P/N 932.35.10.070). (e) Put the two parts of the new saddle clamp (12) (P/N 946.33.21.933) in position on the structure and the motive-flow fuel pipe. NOTE: It is not necessary to torque the screws at this time. (f) Loosely install two new washers (13) (P/N 938.78.11.202) and the two new screws (14) (P/N 932.35.10.070). (g) Do the above procedure again to replace the two saddle clamps (9) on the other motive-flow fuel pipe. (3) Replace the screws and washers on the existing saddle clamps. Refer to Figure 1 (Sheet 2 and 3, View D, E and F) NOTE: The procedure to replace the screws and washers on each of the six existing saddle clamps is the same. (a) Hold the applicable saddle clamp (15), remove and discard the two screws (11) (P/N 932.35.10.069) and the two washers (10) (P/N 938.77.11.110). (b) Remove the two parts of the saddle clamp (15) from the structure and the motive- flow fuel pipe. Keep the two parts of the saddle clamp (15). WARNING: BE CAREFUL WHEN YOU USE THE CONSUMABLE MATERIALS. OBEY THE MANUFACTURERS’ HEALTH AND SAFETY INSTRUCTIONS. (c) If necessary, apply a thin layer of aeroshell grease 58 (Material No. P04-041) to the threads of two new screws (14) (P/N 932.35.10.070). (d) Put the two parts of the saddle clamp (15) (that you kept) in position on the structure and the motive-flow fuel pipe. NOTE: It is not necessary to torque the screws at this time. (e) Loosely install two new washers (13) (P/N 938.78.11.202) and the two new screws (14) (P/N 932.35.10.070). (f) Do the above procedure again to replace the screws (11) and washers (10) on the other existing saddle clamps (15). SERVICE BULLETIN Service Bulletin No: 28-002 Date: May 03/19 Rev. No. Date: Page 9 of 20 (4) Align the LH and RH motive-flow fuel pipes (as necessary). Refer to Figure 1 (Sheet 2 and 3, View C, D, E and F) NOTE: Due to the installation of the four new saddle clamps (P/N 946.33.21.933), the position of the LH and RH motive-flow fuel pipes has moved by approximately 0.06 in (1,5 mm). It is possible that it will be necessary to install (or remove) shims and/or adjust the position of the existing saddle clamps to correctly align the LH and RH motive-flow fuel pipes. NOTE: This alignment procedure is very important. The permitted offset limits for the alignment of the LH and RH motive-flow fuel pipes are as follows: • Axial offset must be between 0.12 and 0.16 in (3,00 and 4,00 mm) • Radial offset must be a maximum of 0.02 in (0,50 mm). (a) On the LH motive-flow fuel pipe: Refer to Figure 1 (Sheet 1 and 2, View A, C and D). 1 Remove the blanking caps (or equivalent). 2 Put a shim (0.16 in thick (4,00 mm)) (or equivalent) in position between the two ends of the LH motive-flow fuel pipe. Make sure that the two ends of the fuel pipe are fully against the shim. 3 Torque the two screws (14) plus the run-down torque (refer to AMM, PC24-A- E20-20-0001-00A-040A-A) at the: • Saddle clamp (12) (between Frame 35 and Frame 36) • Saddle clamp (15) (between Frame 31 and Frame 32). 4 Remove the shim (or equivalent) from between the two ends of the LH motive-flow fuel pipe. 5 Torque the two screws (14) plus the run-down torque (refer to AMM, PC24-A- E20-20-0001-00A-040A-A) on each of the two saddle clamps (12) and (15) that are installed nearest to (fwd and aft of) the coupling (7) installation position. 6 Do a check (at the coupling installation position) to see if the two ends of the LH motive-flow fuel pipe are correctly aligned. 7 Determine if, and/or where, it is necessary to install shims (16). 8 If necessary: NOTE: The procedure to install shims is the same for each of the saddle clamps. i Hold the applicable saddle clamp, remove the two screws (14) and the two washers (13). Service Bulletin No: 28-002 Date: May 03/19 Rev. No. Date: Page 10 of 20 SERVICE BULLETIN NOTE: A maximum of two shims can be installed below each of the saddle clamps. ii Install one or two new shims (16) (P/N 528.22.24.105), as necessary, below the saddle clamp. iii Install the two washers (13) and the two screws (14). iv Torque all of the screws (14) plus the run-down torque. Refer to AMM, PC24-A-E20-20-0001-00A-040A-A. 9 Do a check again (at the coupling installation position) to make sure that the two ends of the LH motive-flow fuel pipe are correctly aligned. Refer to the permitted offset limits. 10 Do the above procedure again, as necessary: • For the other saddle clamp(s) • Until the alignment is within the permitted offset limits. (b) On the RH motive-flow fuel pipe: Refer to Figure 1 (Sheet 1, 2 and 3, View A, C, E and F). 1 Remove the blanking caps (or equivalent). 2 Put a shim (0.16 in thick (4,00 mm)) (or equivalent) in position between the two ends of the RH motive-flow fuel pipe. Make sure that the two ends of the fuel pipe are fully against the shim. 3 Torque the two screws (14) plus the run-down torque (refer to AMM, PC24-A- E20-20-0001-00A-040A-A) at the: • Saddle clamp (12) (between Frame 35 and Frame 36) • Saddle clamp (15) (next to Frame 32). 4 Remove the shim (or equivalent) from between the two ends of the RH motive-flow fuel pipe. 5 Torque the two screws (14) plus the run-down torque (refer to AMM, PC24-A- E20-20-0001-00A-040A-A) on each of the two saddle clamps (12) and (15) that are installed nearest to (fwd and aft of) the coupling (7) installation position. 6 Do a check (at the coupling installation position) to see if the two ends of the RH motive-flow fuel pipe are correctly aligned. SERVICE BULLETIN Service Bulletin No: 28-002 Date: May 03/19 Rev. No. Date: Page 11 of 20 NOTE: The saddle clamp shown in View F already has a shim installed. It is possible that it will be necessary to remove or replace this shim. 7 Determine if, and/or where, it is necessary to: • Install shims (16) at the saddle clamps (12) as shown in View C • Adjust the position of the saddle clamps (15) as shown in View E • Remove or replace the shim (17) as shown in View F. 8 If necessary, to install shims (16) below the saddle clamps (12). Refer to View C: i Hold the applicable saddle clamp (12), remove the two screws (14) and the two washers (13). NOTE: A maximum of two shims can be installed below each of the saddle clamps. ii Install one or two new shims (16) (P/N 528.22.24.105), as necessary, below the saddle clamp (12). iii Install the two washers (13) and the two screws (14). iv Tighten the two screws (14). v Do the above procedure again, if necessary, for the other saddle clamp (12). 9 If necessary, to adjust the position of the saddle clamps (15) as shown in View E: NOTE: The adjust procedure is the same for each of the saddle clamps. i Loosen the two screws (14) sufficiently so that you can adjust the position of the saddle clamp (15). NOTE: It is possible that it will be necessary to adjust the position of the bracket (where the saddle clamp is installed) to get the correct alignment. ii Move the saddle clamp (15) up or down (as necessary) to correctly align the RH motive-flow fuel pipe. If necessary, adjust the position of the bracket that the saddle clamp is attached to. iii Tighten the necessary screws. iv Do the above procedure again, as necessary, for the other saddle clamps (15). Service Bulletin No: 28-002 Date: May 03/19 Rev. No. Date: Page 12 of 20 SERVICE BULLETIN 10 If necessary, to remove or replace the shim (17) as shown in View F: i Hold the saddle clamp (15), remove the two screws (14) and the two washers (13). NOTE: If necessary, a maximum of two shims can be installed below the saddle clamp. ii Remove the existing shim (17) or replace the existing shim (17) with one or two new shims (16) (P/N 528.22.24.105), as necessary, below the saddle clamp (15). iii Install the two washers (13) and the two screws (14). 11 Torque all of the screws (14) plus the run-down torque. Refer to AMM, PC24- A-E20-20-0001-00A-040A-A. 12 Do a check again (at the coupling installation position) to make sure that the two ends of the RH motive-flow fuel pipe are correctly aligned. Refer to the permitted offset limits. 13 Do the above procedures again, as necessary: • For the other saddle clamps • Until the alignment is within the permitted offset limits. (5) Assemble the slider shroud and coupling on the LH and RH motive-flow fuel pipe. Refer to Figure 1 (Sheet 1, View B) NOTE: The procedure to assemble the coupling and slider shroud on the LH and RH motive-flow fuel pipe is the same. (a) If installed, remove the blanking caps (or equivalent). CAUTION: Do not lubricate the O-rings before you install them. (b) Dry install the: • Two new O-rings (4) (P/N 946.91.30.218) on the two large ferrules (2) • Two new O-rings (5) (P/N 946.91.30.015) on the two small ferrules (3). (c) Apply a thin layer of grease (Nyco 65) (Material No. P04-030) to the: • Outer surface only of the two new O-rings (3) that are installed on the two small ferrules (3) • Outer surface only of the two new O-rings (4) that are installed on the two large ferrules (2) • Inner surface of the sleeve (6) • Inner surface of the slider shroud (8). (d) Move the sleeve (6) in to position on the two O-rings (5). (e) Install and close the coupling (7) on the motive-flow fuel pipe. SERVICE BULLETIN Service Bulletin No: 28-002 Date: May 03/19 Rev. No. Date: Page 13 of 20 (f) Move the slider shroud (8) in to position on the two O-rings (4). (g) Install the slider shroud nut (1) on the slider shroud (8) and tighten with your hand. (h) Do the above procedure again to assemble the coupling (7) and slider shroud (8) on the other motive-flow fuel pipe. C. Test (leak check). Refer to Figure 2 (1) Make sure that no other work is being done on the aircraft and that the fuel system is fully assembled. NOTE: The procedure to do the leak check on the LH and RH motive-flow fuel pipe is the same. (2) On the LH/RH motive-flow fuel pipe (1)/(2), loosen the hose clamp (5) and disconnect the drain hose (4) from the drain fitting (6). (3) Connect the air pressurization kit to the drain hose (4) and tighten the hose clamp (5). (4) Connect an air supply to the air pressurization kit. CAUTION: Be careful when you apply air pressure to the motive-flow fuel pipes. Make sure that you do not apply more than 5.1 psig (0,35 bar) of air pressure. This will prevent structural damage and/or damage to equipment. (5) Slowly apply air pressure to the motive-flow fuel pipe until the indicator on the air pressurization kit shows between 4.9 and 5.1 psig (0,34 and 0,35 bar). (6) Close the air valve on the air pressurization kit. (7) Monitor the indicator on the air pressurization kit for 30 minutes. (8) After 30 minutes, do a check and make sure that the pressure has not decreased by more than 0.1 psig (0,01 bar): (a) If the pressure has decreased by more than 0.1 psig (0,01 bar), there is a leak. Do as follows: 1 Disconnect the air supply from the air pressurization kit and release the pressure from the motive-flow fuel pipe. 2 Disassemble the slider shroud and the coupling. Refer to Para. 3.B.(1). 3 Do a check to make sure that the: • Alignment of the motive-flow fuel pipe is correct • O-rings are correctly installed and not damaged. 4 Assemble the coupling and the slider shroud. Refer to Para. 3.B.(5). 5 Do Steps (4) thru (8) of this procedure again until the pressure is stable. (9) Disconnect the air supply from the air pressurization kit and release the pressure from the motive-flow fuel pipe. Service Bulletin No: 28-002 Date: May 03/19 Rev. No. Date: Page 14 of 20 SERVICE BULLETIN (10) Loosen the hose clamp (5) and disconnect the air pressurization kit from the drain hose (4). (11) Connect the drain hose (4) to the applicable drain fitting (6) and tighten the hose clamp (5). (12) Do the leak check procedure again for the motive-flow fuel pipe on the other side of the aircraft. Refer to the above Steps (2) thru (11). (13) Move the aircraft to an approved ground run area. (14) Energize the aircraft electrical system. Refer to AMM, PC24-A-E24-00-0000-00A-913A-A. (15) Start the RH and LH engines and let them run on idle for 10 minutes. Refer to AMM, PC24- A-E72-00-0000-00A-136A-A. (16) Examine the drain hole (3) for fuel leakage. (17) Stop the RH and LH engines. Refer to AMM, PC24-A-E72-00-0000-00A-136A-A. SERVICE BULLETIN Service Bulletin No: 28-002 Date: May 03/19 Rev. No. Date: Page 15 of 20 D. Requirements after job completion (1) De-energize the aircraft electrical system. Refer to AMM, PC24-A-E24-00-0000-00A- 913A-A. (2) Remove the containers from below the LH and RH motive-flow fuel pipe. Discard waste fuel in accordance with the local procedures. (3) Make sure that the work area is clean and clear of tools and other items. (4) Close/Install the access panels/fairings in Table 2. Refer to AMM, PC24-A-A06-40-0000- 00A-040A-A and PC24-A-E53-10-0002-00A-720A-A. Table 2: Access panels/fairings to be closed/installed (5) If removed, install the ADF 1 antenna with the back-up plate and do the operation test referenced in the procedure. Refer to AMM, PC24-A-E34-45-0001-00A-720A-A. (6) Remove all warning placards from the aircraft. E. Documentation (1) Make an entry in the Aircraft Logbook that this Service Bulletin has been incorporated. Panel number Panel name 143ABL Panel, wing fairing, MLG, FWD, LH 143ABR Panel, wing fairing, MLG, FWD, RH 143BBL Panel, MLG bay aft, wing fairing, LH 143BBR Panel, MLG bay aft, wing fairing, RH 143DBL Panel, bottom, LH 143DBR Panel, bottom, RH Service Bulletin No: 28-002 Date: May 03/19 Rev. No. Date: Page 16 of 20 SERVICE BULLETIN INTENTIONALLY BLANK SERVICE BULLETIN Service Bulletin No: 28-002 Date: May 03/19 Rev. No. Date: Page 17 of 20 Replacement of the saddle clamps and alignment of the motive-flow fuel pipes Figure 1 (Sheet 1 of 3) SB 3266 LH MOTIVE-FLOW FUEL PIPE FRAME 32 FRAME 33 FRAME 34 FRAME 36 FRAME 35 FRAME 30 FWD MOTIVE-FLOW FUEL PIPE AFT MOTIVE-FLOW FUEL PIPE 4 6 7 4 2 8 5 5 3 3 2 1 RH MOTIVE-FLOW FUEL PIPE A C C C D B B F E D D TYPICAL FRAME 31 E C Service Bulletin No: 28-002 Date: May 03/19 Rev. No. Date: Page 18 of 20 SERVICE BULLETIN Replacement of the saddle clamps and alignment of the motive-flow fuel pipes Figure 1 (Sheet 2 of 3) SB 3267 SB 3267 9 9 10 11 12 12 13 14 15 15 10 11 14 13 15 15 16 NOTE: INSTALL SHIMS AS NECESSARY PRE SB 28-002 POST SB 28-002 POST SB 28-002 PRE SB 28-002 TYPICAL TYPICAL TYPICAL TYPICAL 16 NOTE: INSTALL SHIMS AS NECESSARY SERVICE BULLETIN Service Bulletin No: 28-002 Date: May 03/19 Rev. No. Date: Page 19 of 20 Replacement of the saddle clamps and alignment of the motive-flow fuel pipes Figure 1 (Sheet 3 of 3) SB 3268 11 10 15 15 14 11 10 15 17 16 13 14 13 PRE SB 28-002 NOTE: ADJUST THE POSITION OF THE SADDLE CLAMPS (AS NECESSARY) NOTE: REMOVE / REPLACE EXISTING SHIM (AS NECESSARY) POST SB 28-002 PRE SB 28-002 TYPICAL POST SB 28-002 Service Bulletin No: 28-002 Date: May 03/19 Rev. No. Date: Page 20 of 20 SERVICE BULLETIN Motive-flow fuel pipes - Leak check Figure 2 SB 3256 3 TYPICAL C C B 1 2 INBOARD AFT SPAR 4 5 6 A