ALERT

SERVICE BULLETIN
MODEL CL-600-2B16
ATA 73-00

ENGINE FUEL AND CONTROL

SPECIAL CHECK/MODIFICATION – INTEGRATED DRIVE GENERATOR (IDG)/FUEL

CONTROL UNIT - INSPECT IDG CABLE HARNESS FOR PROPER CLEARANCE
AND POSSIBLE CHAFING AND INSPECT THE FUEL MANIFOLD FOR PROPER
CLEARANCE WITH 10th STAGE BLEED AIR CHECK VALVE

1. PLANNING INFORMATION
A. Compliance
It is recommended that the special check in PART A and PART B is accomplished
within 50 flight hours from the Alert Service Bulletin release date.
NOTES: 1. This Alert Service Bulletin supercedes Alert Wire TA601-055,
dated March 31, 1999.
2. If Alert Wire TA601-055, was successfully accomplished then
this Alert Service Bulletin A604-73-001, is not required.
B. Approval
This special check/modification is approved by the Bombardier Inc., Canadair
Design Approval Designee(s) for Transport Canada Aviation (TCA).
This special check/modification is also FAA approved under the TCA/FAA bilateral
agreement.

COPYRIGHT  1998 BY BOMBARDIER INC. ALL RIGHTS RESERVED.

* CHALLENGER IS A TRADEMARK OF BOMBARDIER INC.
NO PART OF THIS WORK MAY BE REPRODUCED OR COPIED IN ANY FORM OR BY ANY MEANS WITHOUT WRITTEN PERMISSION OF BOMBARDIER INC.
REFER TO GOVERNMENT REGULATIONS AND USE ACCEPTABLE INDUSTRY STANDARDS TO DO THE WORK DESCRIBED IN THIS ALERT SERVICE BULLETIN.
BOMBARDIER INC. IS NOT RESPONSIBLE FOR THE RESULTS OF ANY WORK DONE OTHER THAN WORK DONE AT BOMBARDIER AVIATION SERVICES.

Apr 19/99 A604-73-001

Page 1 of 13
 MODEL CL-600-2B16
ALERT SERVICE BULLETIN

C. Effectivity
CL-600-2B16 (CL-604) aircraft, Serial No. 5301 to 5408.
NOTE: The instructions in this Alert Service Bulletin are only applicable to
the systems and parts installed at the time of delivery of the aircraft or
as changed by Bombardier Aerospace or Canadair Service Bulletin(s).
Before you do this bulletin, examine all STC, STA or equivalent
action changes to make sure this bulletin can be completed.
D. Reason
PART A:
An incident was reported of an Integrated Drive Generator (IDG) cable harness,
on the right engine, chafing against the adjacent fuel control unit (FCU) causing a
suspected flash fire on a Regional Jet aircraft. PART A of this Alert Service
Bulletin applies to the right hand engine only and gives instructions to inspect the
clearance between the IDG cable harness and the fuel control unit (FCU) with the
attaching fuel lines and the clearance between the IDG cable harness and the
adjacent structure. And, if necessary, in PART C, instructions are given to repair
a damaged IDG cable harness or to replace it.
PART B:
Two occurrences of chafing between the fuel manifold pigtails and the 10th stage
bleed air check valve were reported on a Regional Jet aircraft. PART B of this
Alert Service Bulletin gives instructions to inspect the clearance between the fuel
manifold and the 10th stage bleed air check valve. And, if necessary, instructions
are also given to repair a damaged fuel manifold pigtail and to obtain the proper
clearance.
E. Description
This Alert Service Bulletin gives instructions in:
PART A: IDG Cable Harness Special Check/Modification (Right Engine)
Special Check
 Inspect for a minimum clearance between the IDG cable harness and the
adjacent FCU and the attaching fuel lines,
 Inspect for a minimum clearance between the IDG cable harness and the
adjacent structure, and
 Inspect for possible damage to the IDG cable harness (chafing).
Modification
 A repair is given for the IDG cable harness,
 Re-route the IDG cable harness to get the proper clearance between the IDG
cable harness and the adjacent fuel control unit and the attaching fuel lines, and
 Re-route the IDG cable harness to get the proper clearance between the IDG
cable harness and the adjacent structure.

Apr 19/99 A604-73-001

Page 2 of 13
 MODEL CL-600-2B16
ALERT SERVICE BULLETIN

PART B: Fuel Manifold Special Check/Modification (Left and Right Engine)

Special Check
 Inspect for a minimum clearance between the fuel manifold pigtails (top and
bottom) and the adjacent 10th stage bleed air check valve, and
 Inspect for possible damage to the fuel manifold (chafing).
Modification
 To get the proper clearance, loosen the fuel manifold attachment brackets
and/or the 10th stage bleed air clamps/brackets and/or if required add spacers
on the left hand engine only, and
 A repair is given for the fuel manifold pigtails.
PART C: IDG Cable Harness Replacement (Right Engine) (if necessary)
 Replace the IDG cable harness.
F. Manpower
NOTE: The man-hours given are estimates to help you schedule the tasks.
Refer to Service Bulletin 604-00-002 for more detailed data.
For aircraft out of warranty, Bombardier Aerospace does not pay for the labor to
do this Special Check/ Modification.
For aircraft in the new aircraft warranty, labor is at no cost at Bombardier Aviation
Services or Recognized Service Facilities. For Bombardier to pay for the labor,
the Alert Service Bulletin must also be scheduled in less than 12 months from the
Service Bulletin release date.
(1) The man-hours that follow are necessary to do PART A of this Alert Service
Bulletin:
1 man-hour is necessary for access,
1 man-hour is necessary for the inspection,
2.5 man-hours are necessary for the repair.
(2) The man-hours that follow are necessary to do PART B of this Alert Service
Bulletin:
1 man-hour per engine is necessary for access,
2 man-hours per engine are necessary for the inspection,
2.5 man-hours per engine are necessary to obtain the proper clearance,
NOTE: In PART B, for the left engine only, add 5 hours for the addition
of the spacers (if necessary).
1 man-hour is necessary to fabricate one spacer,
5 man-hours per engine are necessary for the replacement of the fuel
manifold.

Apr 19/99 A604-73-001

Page 3 of 13
 MODEL CL-600-2B16
ALERT SERVICE BULLETIN

(3) The man-hours that follow are necessary to do PART C of this Alert Service
Bulletin (if necessary):
6 man-hours are necessary for the replacement of the IDG cable (per engine).
(4) The man-hours that follow are necessary for the testing required for PART B
and PART C of this Alert Service Bulletin:
1 man-hour is necessary for the testing for PART B (per engine).
1 man-hour is necessary for the testing for PART C (per engine).
G. Material - Cost and Availability
No kit is necessary to do this special check/modification. For material data, refer
to paragraph 3.
Bombardier Aerospace does not pay for the replacement part(s) given in
PART B and PART C of this Special Check/ Modification.
For aircraft in the new aircraft warranty, if a replacement part(s) is necessary as
given in PART B and PART C, the replacement part(s) will be available at no
cost if a no-charge purchase order is sent to Bombardier Aerospace in less than
12 months from the Alert Service Bulletin release date.
H. Tooling - Price and Availability
No equipment or special tools are necessary.
I. Weight and Balance
No change
J. Electrical Load Data
No change
K. References
 Bombardier Aerospace, Modification Summary, 600-5599, Issue A
 Bombardier Aerospace, Restriction Special and/or Instruction (RSI), C-1750, Rev. NC
 Bombardier Aerospace, Restriction Special and/or Instruction (RSI), C-1752, Rev. NC
 CL-604 Aircraft Maintenance Manual, Chapters 6, 24, 36 and 71
 CL-604 Illustrated Parts Catalog (IPC), Chapter 36
 GE TURBOFAN ENGINE, Service Manual (SEI 780), Chapter 72.
L. Other Publications Affected
 CL-604 Illustrated Parts Catalog (IPC), Chapter 36.
NOTE: It is recommended that you record the new part(s) added by this
Alert Service Bulletin in Chapter 36-11-00, Figure 1 of your IPC.
The IPC will include these changes in a future revision.
M. Equivalent Alert Service Bulletin
For the CL-600-2B16 (CL-601-3R) aircraft, use Alert Service Bulletin A601-0524.

Apr 19/99 A604-73-001

Page 4 of 13
 MODEL CL-600-2B16
ALERT SERVICE BULLETIN

2. ACCOMPLISHMENT INSTRUCTIONS
NOTES: 1. All TASKs referenced in the procedures that follow are from the
CL-604 Aircraft Maintenance Manual, unless otherwise specified.
2. All references made to zones, access panels and/or doors, are
from the CL-604 Aircraft Maintenance Manual, Chapter 6.
A. Aircraft Setup
(1) Obey all electrical/electronic safety precautions. Refer to TASK 24-00-00-
910-801.
(2) For the left and right engine, open and tag the circuit breakers that follow:

CB PANEL CB NO. LOCATION ZONE

CBP-1 L7 ENG IGN A 221
CBP-1 L8 ENG IGN B 221
CBP-3 C7 ENG IGN A 221
CBP-5 A1 ENG IGN B 311
CBP-1 L9 ENG START R 221
CBP-1 L10 ENG START L 221
CBP-4 A4 THRUST REV AUTO 222
STOW 1
CBP-4 A5 THRUST REV AUTO 222
STOW 2
CBP-4 A6 THRUST REV 1 222
CBP-5 A7 THRUST REV 2 222
(3) Open the upper translating cowl door on the left and right engine. Refer to
TASK 71-11-01-010-801.
(4) Open the lower translating cowl door on the left and right engine. Refer to
TASK 71-11-01-010-802.
(5) Open the upper core cowl door on the left and right engine. Refer to TASK
71-12-01-010-801.
(6) Open the lower core cowl door on the left and right engine. Refer to TASK
71-12-01-010-802.
(7) On the right engine remove the pylon access panel 422. Refer to Chapter 6,
Zoning.
NOTE: This panel is to be removed only if the IDG cable harness is
repaired or replaced or if you have to adjust the clearance
(applicable to PART A or PART C).

Apr 19/99 A604-73-001

Page 5 of 13
 MODEL CL-600-2B16
ALERT SERVICE BULLETIN

B. PART A: IDG Cable Harness Special Check/Modification (RH Engine)

NOTE: For logistic purposes and parts control, we suggest you do the
inspection before ordering any parts.
(1) Special Check (Refer to Figure1)
(a) Inspect the IDG cable harness for clearance.
 Inspect for the clearance between: (i) the IDG cable harness and
the adjacent FCU and the attaching fuel lines and (ii) the IDG cable
harness and the adjacent structure.
NOTE: If the clearance is not correct do step (2)(c) (Modification)
of this PART A.
(b) Inspect the IDG cable harness for evidence of chafing.
NOTE: If the IDG cable harness is chafed do step (2)(a) or (2)(b)
(Modification) of this PART A.
(2) Modification
(a) If the IDG cable jacket is damaged with no conductor damage, then
locally protect the IDG cable harness with insulation tape MIL-I-19166
for at least 1 inch (25.4 mm) on both sides of the damage.
NOTE: If the cable jacket is damaged it should be repaired before
the next flight.
 Secure the IDG cable in place using high temperature lacing cord,
Varglas # 46,
 Once the lacing cord is in place apply a layer of MIL-D-5549 (clear
dope or Glyptol G1201).
(i) If the IDG cable jacket is damaged but the cable core is not visible,
the above repair is permanent.
or
(ii) If the IDG cable jacket is damaged and the cable core is visible, the
repair is temporary. The cable must be replaced at the next
maintenance check or 300 hours from the date of the temporary
repair, whichever comes later. For the replacement of the IDG cable
harness, refer to PART C.
(b) If the cable core is damaged replace the IDG cable harness immediately.
Refer to PART C.

Apr 19/99 A604-73-001

Page 6 of 13
 MODEL CL-600-2B16
ALERT SERVICE BULLETIN

(c) To adjust the clearance of the IDG cable harness do the steps that follow:
(i) Loosen the IDG cable supports from the pylon to the attaching
points on the IDG.
(ii) Adjust the IDG cable harness to obtain (i) a minimum clearance of
0.5 inch (12.7 mm) between the IDG cable harness and the adjacent
fuel control unit and the attaching fuel lines, and (ii) a minimum
clearance of 0.2 inch (5.08 mm) between the IDG cable harness and
the adjacent structure.
(iii) Tighten the cable supports that have been loosened.
NOTE: Make sure the proper clearance exists after you tighten
all the supports.
(d) If the proper clearance exists and the cable is not damaged (chafed) then
no further action is required. Do the “Close-out” per section 2.F. of this
Alert Service Bulletin.
C. PART B: Fuel Manifold Special Check/Modification (Left and Right Engine)
NOTE: For logistic purposes and parts control, we suggest you do the
inspection before ordering any parts.
(1) Special Check (Refer to Figure 2)
(a) Make sure a minimum clearance of 0.15 inch (3.81 mm) exists between
the fuel manifold pigtails (top and bottom) and the adjacent 10th stage
bleed air check valve and attaching clamps.
NOTES: 1. If the clearance is not correct do step (2)(a) or (2)(c)
(Modification) of this PART B.
2. On the right engine, if you cannot get the minimum
clearance of 0.15 inch (3.81 mm), contact Bombardier
Aerospace, Customer Support for further instructions.
(b) Inspect the fuel manifold pigtails for evidence of chafing.
NOTE: If either fuel manifold pigtails (top or bottom) is chafed do
step (2)(d) (Modification) of this PART B.
(2) Modification
(a) To obtain the proper clearance, loosen the fuel manifold attachment
brackets. It may be necessary to also loosen the bleed air manifold
clamps/brackets. Adjust the connections so that the proper clearance
of 0.15 inch minimum (3.81 mm) is obtained.
NOTE: Adjustments to get the proper clearance should be done
before the next flight.
(b) Tighten all connections that have been loosened.
NOTE: Make sure that the proper clearance exists after you tighten
all the connections.

Apr 19/99 A604-73-001

Page 7 of 13
 MODEL CL-600-2B16
ALERT SERVICE BULLETIN

(c) If unable to get the proper clearance, on the left engine, with the above
instructions add spacers as given in Figure 3.
NOTE: On the right engine the instructions in step (2)(a) should be
sufficient to get the proper clearance.
(d) If the fuel manifold is damaged refer to the GE TURBOFAN ENGINE,
Service Manual (SEI 780), Chapter 72-00-00, Maintenance Practices 57
(Hoses and Tubes Assembly – Cleaning, Inspection and Repair) for
disposition instructions.
NOTE: If the fuel manifold is damaged beyond repair it is to be
replaced immediately.
(e) If the proper clearance exists and the fuel manifold is not damaged
(chafed) then no further action is required. Do the “Close-out” per
section 2.F. of this Alert Service Bulletin.
D. PART C: IDG Cable Harness Replacement (Right Engine) (if necessary)
(1) Replace the IDG cable harness.
E. Testing
(1) For the aircraft that have replaced the IDG cable harness in PART C:
(a) Do an operational test of the IDG on the right engine. Refer to TASK
24-11-01-710-801.
(2) For the aircraft that have made adjustments to get the proper clearance or
added spacers to obtain the proper clearance or replaced the fuel manifold
pigtails(s) in PART B, do the following test(s):
(a) Do a test of the fuel manifold lines. Refer to the GE TURBOFAN
ENGINE, Service Manual (SEI 780), Chapter 72-00-00, Testing.
(b) Do an operational test of the 10th stage bleed air shutoff valve. Refer to
TASK 36-11-01-710-801.

Apr 19/99 A604-73-001

Page 8 of 13
 MODEL CL-600-2B16
ALERT SERVICE BULLETIN

F. Close-out
(1) For the left and right engine, remove tags and close the circuit breakers
that follow:

CB PANEL CB NO. NAME ZONE

CBP-1 L7 ENG IGN A 221
CBP-1 L8 ENG IGN B 221
CBP-3 C7 ENG IGN A 221
CBP-5 A1 ENG IGN B 311
CBP-1 L9 ENG START R 221
CBP-4 A4 THRUST REV AUTO 222
STOW 1
CBP-4 A5 THRUST REV AUTO 222
STOW 2
CBP-4 A6 THRUST REV 1 222
CBP-5 A7 THRUST REV 2 222
(2) Close the upper translating cowl door on the left and right engine. Refer to
TASK 71-11-01-410-801.
(3) Close the lower translating cowl door on the left and right engine. Refer to
TASK 71-11-01-410-802.
(4) Close the upper core cowl door on the left and right engine. Refer to TASK
71-12-01-410-801.
(5) Close the lower core cowl door on the left and right engine. Refer to TASK
71-12-01-410-802.
(6) On the right engine if pylon access panel 422 was removed install it. Refer to
Chapter 6, Zoning.
(7) Remove all tools, equipment and other unwanted materials from aircraft.
G. Recording
You can do each PART of this Alert Service Bulletin independently. When any
PART of this Alert Service Bulletin is completed, make an entry in the aircraft log
and send the attached Incorporation Notice to Bombardier Inc., Business Aircraft
Division.

Apr 19/99 A604-73-001

Page 9 of 13
 MODEL CL-600-2B16
ALERT SERVICE BULLETIN

3. MATERIAL INFORMATION
A. Parts
The parts that follow may be necessary to do PART A or PART C of this Alert
Service Bulletin and can be purchased from Bombardier, Service Parts Center,
Montreal:

ITEM PART NUMBER

IDG Cable Harness 604-57951-5/02(RH)

Fuel Manifold 6087T20P02

NOTE: If a replacement part is necessary you can order a new part from
Bombardier, Service Parts Center, Montreal. After the new part has
been installed, return the damaged part(s) to Bombardier, Service Parts
Center, Montreal at the address shown below:
Bombardier Aerospace
Distribution Center
2039 Cohen St.
St. Laurent, Quebec
Canada H4R 2N7

Apr 19/99 A604-73-001

Page 10 of 13
 MODEL CL-600-2B16
ALERT SERVICE BULLETIN

Inspect the IDG Cable Harness

Figure 1

Apr 19/99 A604-73-001

Page 11 of 13
 MODEL CL-600-2B16
ALERT SERVICE BULLETIN

Inspect Fuel Manifold Pigtails

Figure 2

Apr 19/99 A604-73-001

Page 12 of 13
 MODEL CL-600-2B16
ALERT SERVICE BULLETIN

Addition of Spacers
Figure 3

Apr 19/99 A604-73-001

Page 13 of 13