Dassault SB 7X-042: Revision 1, text

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Page 1Open in PDF

FALCON 7X No 042-R1 MAY 03, 2016

MANDATORY ATA 53

FUSELAGE T5 LATERAL FUSELAGE PANELS

INSPECTION OF THE CHEMICALLY-MILLED PROFILES

FALCON SERVICE BULLETIN Copyright © 2016 by Dassault Aviation All rights reserved. No part of this work may be reproduced or copied in any form or by any means without written permission of Dassault Aviation.

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FUSELAGE T5 LATERAL FUSELAGE PANELS

INSPECTION OF THE CHEMICALLY-MILLED PROFILES Initial issuance January 03, 2011 List of effective pages :

1 to 28 Revision 1 May 03, 2016 List of effective pages :

1 to 32 List of modified pages :

1, 3, 5, 6, 7, 9, 14 to 27, 29, 31 and 32 REASON:The Service Bulletin is now rendered mandatory.

Extension of the Service Bulletin to aircraft with serial numbers 16 and 19:

Evaluation of the thickness and profile on the T5 fuselage lateral panels chemically milled.

This revision is not applicable to aircraft already modified per the initial issuance of this Service Bulletin.

FALCON 7X 7X -042 ATA 53

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FUSELAGE T5 LATERAL FUSELAGE PANELS

INSPECTION OF THE CHEMICALLY-MILLED PROFILES

1. PLANNING INFORMATION A. EFFECTIVITY This Service Bulletin is applicable to FALCON 7X aircraft with serial numbers 2, 4 through 17 and 19.

B. REASON The purpose of this Service Bulletin is to inspect 4 pockets of the T5 fuselage lateral panels in order to more accurately evaluate the profile obtained after the chemical milling performed during the manufacturing process.

During the development and qualification of the aircraft, it has been determined that this evaluation was necessary to confirm that all panels of the aircraft mentioned in the effectivity did not have a limited service life.

C. DESCRIPTION The operation consists in evaluating the thickness and the profile on different chemically milled pockets of the T5 fuselage lateral panels:

• for S/N 2, 4 through 6: 4 pockets with one chemical milling step,

• for S/N 7 through 15: 3 pockets with two chemical milling steps and 1 pocket with one chemical milling step,

• for S/N 16, 17 and 19: 3 pockets with two chemical milling steps and 1 pocket with one chemical milling step but on the forward pocket, the inspection is not possible because of a doubler.

Consequently, the operation consists in installing a stiffener instead of inspecting the forward pocket.

D. COMPLIANCE Mandatory:

• It is anticipated that this Service Bulletin will be rendered mandatory by an EASA Airworthiness Directive.

• As prescribed by the Airworthiness Authorities of the country of registration of the aircraft.

NOTE: THIS SERVICE BULLETIN MUST BE PERFORMED BY LEVEL-2 CERTIFIED PERSONNEL ACCORDING TO THE EN4179 OR NAS410 STANDARDS.

E. APPROVAL For aircraft with serial numbers 16, 17 and 19, this Service Bulletin covers DASSAULT AVIATION modification FALCON 7X R1024 that has been approved under the authority of DOA nr. EASA.21J.

051.

The technical content of this document is approved under the authority of DOA nr. EASA.21J.051.

FALCON 7X 7X -042 May 03, 2016 ATA 53 Revision 1 Page 1 / 32 DASSAULT AVIATION Proprietary Data

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F. LABOR Estimated labor-hours: Refer to Service Bulletin Commercial Summary.

NOTE: These labor-hours only concern the work described in this Service Bulletin and do not include other maintenance work which may be performed on this occasion.

G. MATERIAL - PRICE AND AVAILABILITY The modification kit may be obtained from either address listed below:

Western hemisphere: DASSAULT FALCON JET CORP.

SPARES DISTRIBUTION CENTER 200 RISER ROAD LITTLE FERRY, NJ 07643 U.S.A.

Telephone:

• CANADA and U.S.A.: 1-800-800-4036

• MEXICO: 001-800-800-4036

• Other countries: 1-201-541-4809 Fax:

• CANADA and U.S.A.: 1-800-800-4817

• MEXICO: 001-800-800-4817

• Other countries: 1-201-440-7021 Other continents: DASSAULT AVIATION Falcon Spares BOITE POSTALE N°101

AEROPORT DU BOURGET 93350 - LE BOURGET Cedex (FRANCE) Please contact your Dassault Aviation Account Representative Telephone: 33 (0)1.48.35.56.78 Fax: 33 (0)1.48.35.56.00 Price and availability on request.

H. TOOLING - PRICE AND AVAILABILITY Normal maintenance tooling.

Ultrasonic equipment and local calibration standard.

Profile projector.

NOTE: Refer to Section 3 MATERIAL INFORMATION for more details.

I. WEIGHT AND BALANCE Change in weight: None.

Change in balance with respect to 25% MAC: None.

FALCON 7X 7X -042 May 03, 2016 ATA 53 Revision 1 Page 2 / 32 DASSAULT AVIATION Proprietary Data

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J. REFERENCES Structural Repair Manual:

• RIVETING (Refer to RPI 51-40-04)

• DRILLING (Refer to RPI 51-40-03)

• PAINTING (Refer to TASK 20-60-00-370-803) Maintenance Manual:

• GENERAL MAINTENANCE AND SAFETY PRECAUTIONS (Refer to TASK 20-00-00-910-801)

• REMOVAL / INSTALLATION OF THE AMSAC CHASSIS (Refer to TASK 21-61-09-900-801)

• REMOVAL / INSTALLATION OF THE BAGGAGE COMPARTMENT LININGS (Refer to TASK 25-52-01-900-801) K. OTHER PUBLICATIONS AFFECTED None FALCON 7X 7X -042 May 03, 2016 ATA 53 Revision 1 Page 3 / 32 DASSAULT AVIATION Proprietary Data

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2. ACCOMPLISHMENT INSTRUCTIONS A. PRELIMINARY STEPS fig. 2.

(1) The aircraft must be in the maintenance configuration (Refer to TASK 20-00-00-910-801).

(2) Remove the linings ( 272HZ), (272KZ), (272MZ) and (272NZ) (Refer to TASK 25-52-01-900-801).

(3) Remove the AMSAC chassis (103HN) (1-fig. 2) but do not disconnect it (Refer to TASK 21-61-09-900-801), and put it on the baggage compartment floor (fig. 2) .

(4) Remove the insulation blankets for the areas to be inspected.

(5) Clean the area to be inspected.

(6) Do a check of the inspection areas for any visible damage or discontinuities.

B. PROCEDURE NOTE: The procedure of the service bulletin is defined to fig. 1 . Do the Ultrasonic test only if moulding inspection value is out of criteria.

(1) Inspections and recording of the profile values according in fig. 1 (For S/N 2 and 4 through 6):

Refer to fig. 1, fig. 2, fig. 3, fig. 4, fig. 5, fig. 7, fig. 8, fig. 9, fig. 10, fig. 11, fig. 12 and fig. 21

(a) Use the modelling clay kit to measure the profile values (L, R, Ep and Hr) as described on fig. 4 at the critical areas (fig. 2 and fig. 5) for all the points identified in fig. 7 and fig. 8.

• Mix the green modelling clay and the white modelling clay in a proportion of 50% each.

• Apply the mixture on the critical areas in order to obtain an impression of minimum thickness 4 mm (0.16 in) (fig. 3).

• Let cure 10 to 15 min at ambient temperature.

• Identify the different points with the specific alpha-numeric codes in fig. 7 and fig. 8 before you remove the impression.

• Cut a 2 mm (0.08 in) thick strip in the impression for each point ( fig. 3).

• Measure the strip with the profile projector ( fig. 3).

• Record the values in the appropriate tables:

FIGURE AREA

- fig. 9 - Pocket Fr 37 - Fr 38, Str 11 - Str 12 (Detail A)

- fig. 10 - Pocket Fr 38 - Fr 39, Str 11 - Str 12 (Detail B)

- fig. 11 - Pocket Fr 39 - Fr 40, Str 11 - Str 12 (Detail C)

- fig. 12 - Pocket Fr 39 - Fr 40, Str 12 - Str 13 (Detail D)

(b) If Ep is out of value (Refer to the flow chart fig. 1), do the ultrasonic inspection:

CAUTION: THE ULTRASONIC MEASUREMENT MUST BE PERFORMED BY LEVEL-2 CERTIFIED PERSONNEL ACCORDING TO THE EN4179 OR NAS410 STANDARDS.

FALCON 7X 7X -042 May 03, 2016 ATA 53 Revision 1 Page 4 / 32 DASSAULT AVIATION Proprietary Data

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NOTE: Refer to Section 3 MATERIAL INFORMATION for requested characteristics of the ultrasonic equipment.

• Operate the equipment in accordance with the manufacturer’s instructions.

• Apply coupling gel on the area.

• Connect the transducer and verify the delay line.

• Adjust setting of the ultrasonic tool with local calibration standard ( fig. 21).

• If you must inspect the pocket between frame 38 and 39 and the stringer 11 and 12:

• Drill out the four rivets (3-fig. 2) in the frame 38 and 39 and remove them with a drift punch.

• Remove the bracket (2-fig. 2)

• Use the ultrasonic tool to measure the profile values (Et, Em1 and Em2) as described on fig. 21 at the critical areas (fig. 2 and fig. 5) for all the points identified in fig. 7 and fig. 8.

• Install the bracket (2-fig. 2) and the four rivets 21215DE40 (3-fig. 2) as applicable.

NOTE: For riveting methods (Refer to RPI 51-40-04).

• Compute Er value according to the fig. 21.

• Record the values in the appropriate tables ( fig. 9, fig. 10, fig. 11 and fig. 12).

(c) Send the completed tables to Dassault (Western : structures@dassault-falcon.com or Eastern : structure-repair@dassault-aviation.com).

(2) Inspections and recording of the profile values according to fig. 1 (For S/N 7 through 17 and 19):

Refer to fig. 1, fig. 2, fig. 3, fig. 4, fig. 13, fig. 15, fig. 16, fig. 17, fig. 18, fig. 19, fig. 20 and fig.

(a) Use the modelling clay kit to measure the profile values (L, R, Ep and Hr) as described on fig. 4 at the critical areas (fig. 2 and fig. 13) for all the points identified in fig. 15 and fig. 16.

• Mix the green modelling clay and the white modelling clay in a proportion of 50% each.

• Apply the mixture on the critical areas in order to obtain an impression of minimum thickness 4 mm (0.16 in) (fig. 3).

• Let cure 10 to 15 min at ambient temperature.

• Identify the different points with the specific alpha-numeric codes in fig. 15 and fig. 16 before you remove the impression.

• Cut a 2 mm (0.08 in) thick strip in the impression for each point ( fig. 3).

• Measure the strip with the profile projector ( fig. 3).

• Record the values in the appropriate tables:

FIGURE AREA

- fig. 17 - Pocket Fr 37 - Fr 38, Str 11 - Str 12 (Detail E)

- fig. 18 - Pocket Fr 38 - Fr 39, Str 11 - Str 12 (Detail F)

- fig. 19 - Pocket Fr 39 - Fr 40, Str 11 - Str 12 (Detail G)

- fig. 20 - Pocket Fr 39 - Fr 40, Str 12 - Str 13 (Detail H) FALCON 7X 7X -042 May 03, 2016 ATA 53 Revision 1 Page 5 / 32 DASSAULT AVIATION Proprietary Data

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(b) If Ep is out of value (Refer to the flow chart fig. 1), do the ultrasonic inspection:

CAUTION: THE ULTRASONIC MEASUREMENT MUST BE PERFORMED BY LEVEL-2 CERTIFIED PERSONNEL ACCORDING TO THE EN4179 OR NAS410 STANDARDS.

NOTE: Refer to Section 3 MATERIAL INFORMATION for requested characteristics of the ultrasonic equipment.

• Operate the equipment in accordance with the manufacturer’s instructions.

• Apply coupling gel on the area.

• Connect the transducer and verify the delay line.

• Adjust setting of the ultrasonic tool with local calibration standard ( fig. 21).

• If you must inspect the pocket between frame 38 and 39 and the stringer 11 and 12:

• Drill out the four rivets (3-fig. 2) in the frame 38 and 39 and remove them with a drift punch.

• Remove the bracket (2-fig. 2)

• Use the ultrasonic tool to measure the profile values (Et, Em1 and Em2) as described on fig. 21 at the critical areas ( fig. 2 and fig. 13) for all the points identified in fig. 15 and fig. 16.

• Install the bracket (2-fig. 2) and the four rivets 21215DE40 (3-fig. 2) as applicable.

NOTE: For riveting methods (Refer to RPI 51-40-04).

• Compute Er value according to the fig. 21.

• Record the values in the appropriate tables ( fig. 17, fig. 18, fig. 19 and fig. 20).

(c) Send the completed tables to Dassault (Western : structures@dassault-falcon.com or Eastern : structure-repair@dassault-aviation.com).

(3) Stiffener installation (For S/N 16, 17 and 19) Refer to fig. 22

(a) Removal of the rivets from the doubler

• Drill out the 12 rivets (A-fig. 22), (B-fig. 22), (C-fig. 22) and remove them with a drift punch (Refer to RPI 51-40-03).

• Clean the holes.

(b) Removal of the rivets from the lower pylon angle

• Drill out the two rivets (D-fig. 22) and remove them with a drift punch (Refer to RPI 51-40-03).

• Clean the holes.

• Drill out the two rivets (E-fig. 22) and remove them with a drift punch (Refer to RPI 51-40-03).

• Clean the holes.

(d) Stiffener installation

• Put stiffener SB7X0042 (1-fig. 22) in position on the lower pylon angle.

• Use the vices to hold stiffener SB7X0042 (1-fig. 22) from the holes (D-fig. 22).

FALCON 7X 7X -042 May 03, 2016 ATA 53 Revision 1 Page 6 / 32 DASSAULT AVIATION Proprietary Data

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• Counterdrill the holes (F-fig. 22) to Ø 4.16 mm (0.164 in.). Reaming tolerances -95/+105 (-3.7/+4.1) (Refer to RPI 51-40-03).

• Use the vices to hold stiffener SB7X0042 (1-fig. 22) from the holes (F-fig. 22).

• Counterdrill the holes (A-fig. 22) to Ø 4.16 mm (0.164 in.). Reaming tolerances -95/+105 (-3.7/+4.1) (Refer to RPI 51-40-03).

• Use the vices to hold stiffener SB7X0042 (1-fig. 22) from the holes (A-fig. 22).

• Counterdrill the holes (B-fig. 22) to Ø 3.35 mm (0.132 in.). Reaming tolerances -95/+105 (-3.7/+4.1) (Refer to RPI 51-40-03).

• Use the vices to hold stiffener SB7X0042 (1-fig. 22) from the holes (B-fig. 22).

• Counterdrill the holes (C-fig. 22) to Ø 4.16 mm (0.164 in.). Reaming tolerances -95/+105 (-3.7/+4.1) (Refer to RPI 51-40-03).

• Use the vices to hold stiffener SB7X0042 (1-fig. 22) from the holes (C-fig. 22).

• Counterdrill the holes (E-fig. 22) to Ø 4.16 mm (0.164 in.). Reaming tolerances -95/+105 (-3.7/+4.1) (Refer to RPI 51-40-03).

• Use the vices to hold stiffener SB7X0042 (1-fig. 22) from the holes (E-fig. 22).

• Remove the vices from the holes (D-fig. 22).

• Counterdrill the holes (D-fig. 22) to Ø 4.16 mm (0.164 in.). Reaming tolerances -95/+105 (-3.7/+4.1) (Refer to RPI 51-40-03).

• Remove the vices (A-fig. 22), (B-fig. 22), (C-fig. 22), (E-fig. 22) and (F-fig. 22) and stiffener SB7X0042 (1-fig.22).

• Clean the area.

• Install the stiffener (1-fig. 22) in position with interlaying sealant (Refer to TASK 20-32-00-390-801).

• Install rivets P/N 35656C04006XF (2-fig. 22) with interlaying sealant under the rivet heads (Refer to RPI 51-40-04).

• Install rivets P/N MS14218D5-7 (3-fig. 22) with interlaying sealant under the rivet heads (Refer to RPI 51-40-04).

• Install rivets P/N MS14218D4-6 (4-fig. 22) with interlaying sealant under the rivet heads (Refer to RPI 51-40-04).

• Install rivets P/N 35067-40-12 (5-fig. 22) with interlaying sealant under the rivet heads (Refer to RPI 51-40-04).

(e) Make touch-up of paint on the fasteners with wash primer, anti-corrosion primer and top coat PU66 (Refer to TASK 20-60-00-370-803).

C. IDENTIFICATION OF THE SERVICE BULLETIN Refer to fig. 23

(1) If necessary, bond the new “Service Bulletin Compliance” label (1-fig. 23) with high-temperature sealant on lower frame 42.

(2) With non-removable ink, write the reference SB 042 on the identification plate (1-fig. 23).

D. FINAL STEPS Refer to fig. 2 FALCON 7X 7X -042 May 03, 2016 ATA 53 Revision 1 Page 7 / 32 DASSAULT AVIATION Proprietary Data

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(1) Make sure that the work area is clean and clear of tools and other items.

(2) Install the insulation blankets.

(3) Install the AMSAC chassis ( 103HN) (1-fig. 2) (Refer to TASK 21-61-09-900-801).

(4) Install the linings ( 272HZ), (272KZ), (272MZ) and (272NZ) (Refer to TASK 25-52-01-900-801).

E. RECORDING Record compliance with this Service Bulletin in the appropriate aircraft documents.

Fill out the electronic Service Bulletin reply form located in the ”Service Bulletin" page on the Falcon portal.

FALCON 7X 7X -042 May 03, 2016 ATA 53 Revision 1 Page 8 / 32 DASSAULT AVIATION Proprietary Data

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3. MATERIAL INFORMATION A. MODIFICATION KIT Kit P/N SBF7X0042A

NEW P/N QTY KEY WORD ITEM FIG SBF7X0042ALAT including :

- SBF7X0042 1 Stiffener 1 22

- 35656C04006XF 2 Rivet 2 22

- MS14218D5-7 8 Rivet 3 22

- MS14218D4-6 8 Rivet 4 22

- 35067-40-12 2 Rivet 5 22

- 79160 1 SB identification plate 1 23 B. LOCAL PROCUREMENT As indicated in Consumable Products Manual (CPM):

• cleaner,

• wash primer,

• anti-corrosion primer,

• top coat PU66,

• interlaying sealant.

FALCON 7X 7X -042 May 03, 2016 ATA 53 Revision 1 Page 9 / 32 DASSAULT AVIATION Proprietary Data

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DASSAULT SERVICE BULLETIN

AVIATION FALCON 7X 7X -042 Do the moulding inspection

NO YES Ep ≥ 0.05 mm (Ep ≥0.002 in) Do the ultrasonic inspection for critical points Complete the inspection report Send the inspection report to DASSAULT Figure 1: INSPECTION PROCESS FLOW CHART May 03, 2016 ATA 53 Revision 1 Page 10 / 32

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