# Dassault Service Bulletin 7X-245: No revision named

- Rights: © Dassault Aviation. Filed by the FAA in regulations.gov docket FAA-2016-5466; AD 2016-24-07 incorporates this document by reference. Not covered by OpenAirDocs’ CC0 dedication.
- Document: [Dassault Service Bulletin 7X-245](https://openairdocs.org/service-documents/dassault/7x-245.md)
- Title as filed: FAA-2016-5466_SB 7X-245
- Pages: 18
- PDF: https://openairdocs.org/files/sha256/0f/01/0f012116baad42324570546c68248e5bfb5567b22924cc500f4e7e8c12601af3
- Page: https://openairdocs.org/service-documents/dassault/7x-245/file/0f012116baad

## Text

Some pages are OCR from a scan. OCR can misread letters and numbers. Each page's text from the PDF; open the PDF at a page with #page=N.

### Page 1

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.
785

### Page 2

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

### Page 3

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
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DASSAULT AVIATION Proprietary Data

### Page 4

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
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DASSAULT AVIATION Proprietary Data

### Page 5

• 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
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DASSAULT AVIATION Proprietary Data

### Page 6

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
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DASSAULT AVIATION Proprietary Data

### Page 7

• 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
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DASSAULT AVIATION Proprietary Data

### Page 8

(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),
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DASSAULT AVIATION Proprietary Data

### Page 9

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
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DASSAULT AVIATION Proprietary Data

### Page 10

• 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
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DASSAULT AVIATION Proprietary Data

### Page 11

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).
(c) Paint brush.
(d) Ultrasonic device.
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DASSAULT AVIATION Proprietary Data

### Page 12 (OCR)

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
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### Page 13 (OCR)

DASSAULT  SERVICE BULLETIN
AVIATION
FALCON 7X  7X -245
SECTION A-A (Applicable to all frames)
Bead of PR  (laid around patches)  (0.2 to 0.4 in.)
5 to 10 mm  Lateral panel
Bonding coat of PR  Bonding coat of PR
(Primer coat)  (Primer coat)
(Patch bonded to sticky primer coat)
Patch (thickness = 1mm (0.04 in.)) of PR  Overcoat of PR (Apply with paint brush)
(Patch bonded to sticky primer coat)
Overcoat of PR (Apply with paint brush)  Primer anti-corrosion coat
Primer anti-corrosion coat  Bead of PR
(laid around patches)
2 coats of PR
SECTION B-B (Applicable to all stringers)
SECTION C-C (Lateral panel with rivet)
Overcoat of PR  Primer anti-corrosion coat
Bonding coat of PR  (Apply with paint brush)
(Primer coat)
ss = 1mm (0.04 in.)) of PR
Lateral panel
Drill a hole to allow
the washer release
(laid around patches)  Bead of PR  STRINGER DATUM  Rivet
Rivet washer
Bonding coat of PR
(Primer coat)  Patch (thick  = 1mm (0.04 in.)) of PR
(Patch
Lateral panel
Overcoat of PR (Apply with paint brush)  Additional patch
thickness = 1mm (0.04 in.)) of PR
Patch bonded to sticky coat)
NOTE: SECTION A-A, SECTION B-B and SECTION C-C refer to figure 1.
Figure 2: PATCHES INSTALLATION
June 08, 2015  ATA 53
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### Page 14 (OCR)

DASSAULT  SERVICE BULLETIN
AVIATION
FALCON 7X  7X -245
EXAMPLE OF PATCHES INSTALLATION IN 6 STEPS
Lateral panel
SECTION A-A (Step 1)
1st STEP:  1st STEP:
Degreasing  Degreasing
Surface roughering  Surface roughening
Cleaning  Cleaning
(FR31)
SECTION A-A (Step 2)
Lateral panel  (0.2 to 0.4 in.)
5 to 10 mm
2nd STEP:
2nd STEP:  Application of PR
Application of PR  primer coat inside
primer coat inside  the milled recesses
the milled recesses
FR31
NOTE: These steps also apply to the stringers of the rear tank (refer to SECTION B-B-figure 2).
Figure 3: PATCHES INSTALLATION (STEPS 1 & 2)
June 08, 2015  ATA 53
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### Page 15 (OCR)

DASSAULT  SERVICE BULLETIN
AVIATION
FALCON 7X  7X -245
EXAMPLE OF PATCHES INSTALLATION IN 6 STEPS
SECTION A-A (Step 3)
Lateral panel
3rd STEP:  3rd STEP:
Installation of patches  Installation of patches
onto the primer coat,  onto the primer coat,
and immediatly after,  and immediatly after,
bead of PR applied  bead of PR applied
around each patch  FR31  around each patch
(4th step)  (4th step)
SECTION A-A (Step 4)
Lateral panel
4th STEP:  4th STEP:
Bead or PR laid around  Bead or PR laid around
patches to compensate  patches to compensate
for patch thickness at  for patch thickness at
the edges of recesses  the edges of recesses
(FR31)
NOTE: These steps also apply to the stringers of the rear tank (refer to SECTION B-B-figure 2).
Figure 4: PATCHES INSTALLATION (STEPS 3 & 4)
June 08, 2015  ATA 53
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### Page 16 (OCR)

DASSAULT  SERVICE BULLETIN
AVIATION
FALCON 7X  7X -245
EXAMPLE OF PATCHES INSTALLATION IN 6 STEPS
SECTION A-A (Step 5)
Lateral panel  5 to 10 mm  (0.2 to 0.4 in.)
5th STEP:  5th STEP:
Overcoat of PR  Overcoat of PR
applied over and  applied over and
around patch  around patch
FR31
For ref.: 2 coats of PR
SECTION A-A (Step 6 - final step)
Lateral panel
6th STEP:  6th STEP:
Overcoat of anti-corrosion  Overcoat of anti-corrosion primer
primer applied over and  applied over and around patch;
around patch; overflow on  overflow on adjacent frames and
adjacent frames and stringers  stringers
FR31)
NOTE: These steps also apply to the stringers of the rear tank (refer to SECTION B-B-figure 2).
Figure 5: PATCHES INSTALLATION (STEPS 5 & 6)
June 08, 2015  ATA 53
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### Page 17 (OCR)

DASSAULT  SERVICE BULLETIN
AVIATION
FALCON 7X  7X -245
26 PATCHES (for LH lateral panel)
26 Patches can
be installed on
the panel
(inside view)
DETAIL A
(Example for manufacture patch)
Plastic film (optional)
Patch
1 mm  (0.075 in.) °  Demolding  Tooling  26 PATCHES (for RH lateral panel)  Patch 1' will be obtained by recutting patch 1  (use the patch 1 form for moulding)
26 Patches can
be installed on
the panel
(inside view)
NOTE: According to the aircraft (and the LH & RH lateral panels of rear fuel tank), prepare patches to be installed.
Figure 6: PATCHES (LH & RH)
June 08. 2015  ATA 53
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### Page 18 (OCR)

DASSAULT  SERVICE BULLETIN
AVIATION
FALCON 7X  7X -245
2 mm (0.08 in.)
1mm (0.04 in.)
90 mm (3.54 in.)  TEFLON SPATULA
(to apply the primer coat)
55 mm (2.17 in.)
PAINTING ROLLER
(to apply PR over the patches)
and
HARD ROLLER
(to work out bubbles)
50 mm (1.98 in.)
25 mm (0.98 in.)
Figure 7: TOOLS
June 08, 2015  END OF DOCUMENT  ATA 53
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