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Page 1Open in PDF

FALCON 7X No 245 JUNE 08, 2015

MANDATORY ATA 53

FUSELAGE

REAR FUEL TANK LATERAL PANELS

ADDITION OF PR PATCHES

FALCON SERVICE BULLETIN Copyright © 2015 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

REAR FUEL TANK LATERAL PANELS

ADDITION OF PR PATCHES Initial issuance June 08, 2015 List of effective pages :

1 to 16 FALCON 7X 7X -245 ATA 53

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FUSELAGE

REAR FUEL TANK LATERAL PANELS

ADDITION OF PR PATCHES

1. PLANNING INFORMATION A. EFFECTIVITY This Service Bulletin is applicable to FALCON 7X aircraft with serial numbers 17 to 21, 86 to 90, 115 to 119, 129 to 138 and 155 .

B. REASON On production line, several 7X rear fuselage tanks were assembled with a lateral panel that had suffered from excessive chemical milling in some areas.

The consequent remaining thickness has been assessed insufficient with regard to the certification requirements.

The purpose of this Service Bulletin is to restore lightning protection.

C. DESCRIPTION The operation consists in:

• locating the areas where thickness of lateral panels (LH and RH) of the rear fuselage fuel tank is insufficient (< 1.9 mm (0.075 in.)),

• restoring lightning protection of these areas by adding pre-polymerized PR patches on the internal side of the panel.

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.

E. APPROVAL This Service Bulletin covers DASSAULT AVIATION modification FALCON 7X M1557 that has been approved by EASA.

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

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:

FALCON 7X 7X -245 June 08, 2015 ATA 53 Initial issuance Page 1 / 16 DASSAULT AVIATION Proprietary Data

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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 E/H dafsorder@dassault-aviation.com Price and availability on request.

H. TOOLING - PRICE AND AVAILABILITY Normal maintenance tooling.

I. WEIGHT AND BALANCE Change in weight: Delta weight on aircraft depend on quantity of PR pads installed, from 0.07 kg to

4.14 kg per case.

Change in balance with respect to 25% MAC: Delta balance on aircraft depends on the quantity of PR pads installed, from 0.07 kg to 4.14 kg per case.

J. REFERENCES Aircraft Maintenance Manual:

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

• BASIC SEALANT METHODS (Refer to TASK 20-32-00-390-801).

• APPLICATION OF MAPAERO WATER-BASED PAINT SCHEME (Refer to TASK 20-60-00-370-821).

• APPLICATION OF PPG INTERIOR PAINT SCHEME (Refer to TASK 20-60-00-370-829).

• FUEL SYSTEM MAINTENANCE AND SAFETY PRECAUTIONS (Refer to TASK 28-00-00-910-801).

FALCON 7X 7X -245 June 08, 2015 ATA 53 Initial issuance Page 2 / 16 DASSAULT AVIATION Proprietary Data

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• QUICK TRANSFERT OF THE FUEL FROM ONE TANK TO ANOTHER (Refer to TASK 28-22-00-650-801).

• SUCTION DEFUELING (Refer to TASK 28-30-00-650-801).

• GRAVITY DEFUELING (Refer to TASK 28-30-00-680-801).

• DRAINING OF THE FUEL TANKS / FUEL SAMPLING (Refer to TASK 28-30-00-680-802).

• REMOVAL / INSTALLATION OF THE FUSELAGE FUEL GAUGING PROBES (Refer to TASK 28-41-05-900-801).

• PRESSURE REFUELING (Refer to TASK 28-50-00-650-801).

• DE-PRESSURIZATION / PRESSURIZATION OF THE FUEL TANKS (Refer to TASK 28-70-00-860-801).

• REMOVAL / INSTALLATION OF THE REAR FUEL TANK ACCESS DOORS AND PANELS (Refer to TASK 52-51-05-900-801).

• REMOVAL / INSTALLATION OF THE BODY FAIRINGS (Refer to TASK 53-60-00-900-801).

K. OTHER PUBLICATIONS AFFECTED None FALCON 7X 7X -245 June 08, 2015 ATA 53 Initial issuance Page 3 / 16 DASSAULT AVIATION Proprietary Data

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2. ACCOMPLISHMENT INSTRUCTIONS A. PRELIMINARY STEPS

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

B. PROCEDURE 1: AREAS CHECKING NOTE: The number and location of the areas to be checked are different according to the aircraft serial number.

Refer to fig. 1 and table below

AIRCRAFT SN PANEL AREA NUMBERS TO BE CHECKED DEFECT TO IDENTIFY 17, 18, 19, 20 and 21 LH 22 Thickness < 1.9 mm (0.075 in.)

86, 87, 88, 89 and 90 RH 22 1 hole with rivet installation 115, 116, 117, 118 and 119 RH 13 and 24 Thickness < 1.9 mm (0.075 in.)

129 RH 2, 3, 4, 7, 8, 9, 11, 12, 13, 14, 16, 18, 20, 23, 24 and 25 Thickness < 1.9 mm (0.075 in.)

130 RH 2, 3, 4, 7, 8, 9, 11, 12, 13, 14, 16, 18, 20, 22, 23, 24 and 25 Thickness < 1.9 mm (0.075 in.)

131 and 132 RH 2, 3, 4, 7, 8, 9, 11, 12, 13, 14, 16, 18, 19, 20, 21, 22, 23, 24, 25 and 26 Thickness < 1.9 mm (0.075 in.) + 1 hole with rivet installation 133 and 134 RH 2 to 5 and 7 to 26 Thickness < 1.9 mm (0.075 in.) +1 hole with rivet installation 135 RH 2 to 5, 7 to 21 and 23 to 26 Thickness < 1.9 mm (0.075 in.) +1 hole with rivet installation 136 RH 2 to 5, 7 to 10, 12 to 21 and 23 to 26 Thickness < 1.9 mm (0.075 in.) +1 hole with rivet installation 137 RH 1 to 26 Thickness < 1.9 mm (0.075 in.)

138 RH 3, 7, 8, 12, 13, 23 and 24 Thickness < 1.9 mm (0.075 in.)

155 LH 20 1 hole with rivet installation

(1) Locate the areas to be checked.

(2) For each area, verify the presence of defect listed in the table using NDT:

CAUTION: THIS VERIFICATION MUST BE DONE BY AN OPERATOR HAVING PASSED A LEVEL II CERTIFICATION APPLICABLE TO ULTRASONIC TESTING.

(a) measure the panel thickness from the outside with an ultrasonic device,

(b) check the presence of hole with rivet installation.

(3) Record the area numbers where a defect is found.

(4) Inspection results:

• if no defect is found, no further action is required, FALCON 7X 7X -245 June 08, 2015 ATA 53 Initial issuance Page 4 / 16 DASSAULT AVIATION Proprietary Data

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• if some areas have been identified with defect, apply next paragraph ("PROCEDURE 2:

MANUFACTURE AND INSTALLATION OF PATCHES").

C. PROCEDURE 2: MANUFACTURE AND INSTALLATION OF PATCHES Refer to fig. 1, fig. 2, fig. 3, fig. 4, fig. 5, fig. 6 and fig. 7

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

(2) Apply recommendations and precautions during maintenance on the fuel system (Refer to TASK 28-00-00-910-801).

(3) Remove rear fuel tank access panel ( 161AB) (Refer to TASK 52-51-05-900-801):

• do a full suction defueling of the center tank group (Refer to TASK 28-30-00-650-801),

• or do a full gravity defueling of the center tank group (Refer to TASK 28-30-00-680-801),

• or do a quick transfer of the fuel from the center tank group to the LH or RH tank group (Refer to TASK 28-22-00-650-801),

• remove rear fuel tank fairing ( 167AL) (Refer to TASK 53-60-00-900-801),

• remove rear tank rear gauging probe ( 1503QJ) (Refer to TASK 28-41-05-900-801).

(4) If necessary, do a draining of the center tank group (Refer to TASK 28-30-00-680-802).

(5) After fully defueling, allow rear fuel tank to vent for 24 hours (minimum) (Refer to TASK 28-00-00-910-801).

WARNING: ONCE THE VENTING IS COMPLETED, CHECK WITH A FUEL VAPOR

ANALYZER THAT THE AMBIENT AIR INSIDE THE REAR FUEL TANK IS SAFE

FOR PERFORMING THE SUBSEQUENT MAINTENANCE OPERATIONS (DESCRIBED BELOW).

(6) After sufficient venting, remove equipment and components hampering access to working areas.

(7) Preparing the patches:

(a) use the set of shaping templates:

• with the shaping templates, each patch can be manufactured by respecting the form and dimensions.

(b) manufacture the patch ( fig. 6):

1 apply demolding agent on the shaping template, 2 wait until demolding agent is dry, 3 apply bead sealant (PR1440MB2 or equivalent) on the shaping template:

• patch thickness 1 mm (0.075 in.),

• respect the form of patch,

• and await the drying of PR,

• a protective film (non-adhering plastic film) can be installed on patch to allow easy handling, 4 demold patch with precaution and install it on a flat area without deteriorating it, 5 repeat this procedure for each patch to install.

(8) Thoroughly protect all surrounding equipment against ingress of dust and foreign material.

(9) Preparing the areas to be worked ( fig. 1 and (STEP 1-fig. 3)):

FALCON 7X 7X -245 June 08, 2015 ATA 53 Initial issuance Page 5 / 16 DASSAULT AVIATION Proprietary Data

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(a) using white cloth and MEK, degrease the milled recess areas, the stringers and the frames where patches are to be installed,

(b) check for corrosion, NOTE: If corrosion is found, please contact one of the addresses provided in paragraph

1.G.

(c) using Scotch Brite pads, roughen the surface of the previously degreased milled recess areas, stringers and frames, NOTE: Eliminate all traces or runs of PR in the milled recess areas to obtain a surface with sufficient grip for the interlaying sealant (PR1440MA2/MB2 or equivalent) primer coat.

(d) Vacuum out all PR debris and dust from inside the lateral panel of rear fuel tank,

(e) using white cloth slightly soaked with MEK, clean the previously roughened areas.

(10) Manufacture spatulas and rollers in accordance with fig. 7.

(11) Installing the patch(es) (fig. 1, fig. 2, fig. 3, fig. 4, fig. 5 and fig. 6):

(a) Prepare the sets of patches (side to be coated facing up) in accordance with fig. 6 and to table of paragraph 2.B.:

NOTE 1: Patches must be installed while PR primer coat is still sticky (refer to characteristics of PR used).

NOTE 2: To make the installation of patches easier, it is recommended to have one technician assigned to coating the patches with PR on a work bench while another technician works inside the feeder tank.

NOTE 3: Whenever the procedure calls for applying PR, a PR test specimen must also be prepared for checking the PR quality and curing properties.

(b) Using a serrated spatula ( fig. 7 ) apply a primer coat of interlaying sealant (PR1440MA2/MB2 or equivalent) inside the milled recess areas (STEP 2-fig. 3), NOTE: Proceed in sequence as per the patch numbering (1, 2, 3, ... or/and 26).

(c) installation of patches (operation described for one patch) to be repeated for each patch to install (1, 2 , 3, ..... or/and 26):

1 Patch previously installed on a flat area (example: on a work bench), 2 use a painting roller ( fig. 7 ) to apply a thin coat of interlaying sealant (PR1440MA2/MB2 or equivalent) over the face of the patch that is to come in contact with the milled recess area, 3 install the patch in its assigned recess area and use a hard roller ( fig. 7) to work out the air pockets (bubbles) that may have formed between the patch and the primer coat (STEP 3-fig. 4), 4 remove the protective film (if previously installed) remaining on the installed patch, 5 smooth out the PR that ran out from under the patch to form a bead around the patch and provide an even thickness of PR in the milled recess area (fill the gaps with more PR as required) (STEP 4-fig. 4), FALCON 7X 7X -245 June 08, 2015 ATA 53 Initial issuance Page 6 / 16 DASSAULT AVIATION Proprietary Data

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6 repeat these operations for the other patches.

(d) particular case with rivet (SECTION C-C-fig. 2):

1 locate the rivet position on the panel, 2 mark the rivet position on the patch and drill a hole on this position, 3 manufacture an additional patch (refer to paragraph 2.C.(7)(b)) that will be applied to the hole previously drilled, 4 apply previous paragraph 2.C.(11)(c), 5 when patch is installed and that interlaying PR is dry, install the additional patch following the same procedure of paragraph 2.C.(11)(c),

(e) wait until PR is no longer sticky,

(f) applying PR covering coat (STEP 5-fig. 5):

1 using the painting roller ( fig. 7) and the paint brush, cover with a thin coat of covering sealant (PR1440MA2 or equivalent):

• the patches and the edges of the patches installed,

• the PR beads (around patches),

• the flanges of the adjacent frames or stringers (overflow of coat applied to the patches), NOTE: 2 coats of PR will be applied on stringer or frame fixing.

• and filling the gaps with more PR as required,

(g) await complete curing of PR,

(h) apply a coat of primer P60-A and top coat F70-A (Refer to TASK 20-60-00-370-821) or a coat of primer CA7045 and top coat CA8391 (Refer to TASK 20-60-00-370-829) (STEP 6- fig. 5):

1 on the patches installed, 2 on the PR beads, 3 on the flanges of the adjacent frames or stringers (overflow of coat applied to the patches).

(12) Allow a minimum of 72 hours to cure.

(13) Remove protection installed at the beginning of procedure (in particular to paragraph 2.C.(8)).

(14) Check for remaining foreign matter inside the rear tank, and thoroughly clean the inside of this tank.

(15) Install all the equipment and components removed at the beginning (or during) this procedure ("PROCEDURE 2: MANUFACTURE AND INSTALLATION OF PATCHES").

D. CHECK - TEST

(1) Install rear fuel tank access panel ( 161AB) (Refer to TASK 52-51-05-900-801):

• install rear tank rear gauging probe ( 1503QJ) (Refer to TASK 28-41-05-900-801),

• perform a pressurization and de-pressurization of the fuel tanks (Refer to TASK 28-70-00-860-801), FALCON 7X 7X -245 June 08, 2015 ATA 53 Initial issuance Page 7 / 16 DASSAULT AVIATION Proprietary Data

Page 10Open in PDF

• fill the center tank group (Refer to TASK 28-22-00-650-801 ) or (Refer to TASK 28-50-00-650-801).

E. FINAL STEPS

(1) Install rear fuel tank fairing ( 167AL) (Refer to TASK 52-51-05-900-801).

F. 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 -245 June 08, 2015 ATA 53 Initial issuance Page 8 / 16 DASSAULT AVIATION Proprietary Data

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3. MATERIAL INFORMATION A. MODIFICATION KIT Kit P/N SBF7X0245A

REFERENCE QTY KEY WORD F7XCSBF7X245 including: 1 Set of shaping templates F7XCSBF7X245-01 1 Shaping template F7XCSBF7X245-02 1 Shaping template F7XCSBF7X245-03 1 Shaping template F7XCSBF7X245-04 1 Shaping template F7XCSBF7X245-05 1 Shaping template B. LOCAL PROCUREMENT

(1) Ingredients

(a) As indicated in Consumable Products Manual (CPM):

• bead sealant (PR1440MB2 or equivalent),

• interlaying sealant (PR1440MA2/MB2 or equivalent),

• covering sealant (PR1440MA2 or equivalent),

• MEK or equivalent,

• demolding agent.

• primer P60-A and top coat F70-A or primer CA7045 and top coat CA8391.

(2) Tooling

(a) (Teflon) serrated spatula ( fig. 7).

(b) Painting roller ( fig. 7).

(d) Ultrasonic device.

FALCON 7X 7X -245 June 08, 2015 ATA 53 Initial issuance Page 9 / 16 DASSAULT AVIATION Proprietary Data

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DASSAULT SERVICE BULLETIN

AVIATION FALCON 7X 7X -245 REAR FUEL TANK Frame 30 Frame 29 Frame 28 LH lateral panel VIEW B (RH lateral panel) Frame 33 Stringer 17 FWD Stringer 1 Rear fuel tank acess panel (161AB) FWD (inside view) RH lateral panel VIEW A (LH lateral panel) (FR33) FR32) FR31) FR30) FR29) FWD Stringer 17 Stringer 18 Stringer 19 Stringer 20 Stringer 22 Stringer 21 (inside view) NOTE: SECTION A-A, SECTION B-B and SECTION C-C refer to figure 2 Figure 1: LATERAL PANELS AND PATCHES LOCATION June 08. 2015 ATA 53 Initial issuance Page 10 / 16

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