Dassault SB F2000-337: Revision 1

FALCON 2000 No 337-R1 JANUARY 26, 2015

MANDATORY ATA 33-11

LIGHTING

EXTERIOR LIGHTING

ELECTRICAL BONDING OF WHELEN FIN TIP ANTI-

COLLISION LIGHT

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.

LIGHTING

EXTERIOR LIGHTING

ELECTRICAL BONDING OF WHELEN FIN TIP ANTI-COLLISION LIGHT Initial issuance July 25, 2007 List of effective pages :

1 to 11 Erratum September 09, 2007 List of effective pages :

1 to 11 List of modified pages :

7 Revision 1 January 26, 2015 List of effective pages :

1 to 11 List of modified pages :

1 to 11 REASON:The Service Bulletin is now rendered mandatory.

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

FALCON 2000 F2000 -337 F2000 -33-11

LIGHTING

EXTERIOR LIGHTING

ELECTRICAL BONDING OF WHELEN FIN TIP ANTI-COLLISION LIGHT

1. PLANNING INFORMATION A. EFFECTIVITY This Service Bulletin is applicable to FALCON 2000 aircraft equipped with a WHELEN fin tip anticollision light (without SATCOM fairing) per Service Bulletin F2000-44 (M331).

B. REASON The investigation conducted on a Falcon 2000 aircraft that had been struck by lightning has shown that the electrical bonding of the fin tip anti-collision light may not be sufficient under certain circumstances, potentially resulting in damaging the aircraft wiring.

The purpose of this Service Bulletin is to improve the electrical bonding of the WHELEN anti-collision light located on the fin tip.

C. DESCRIPTION After removing the fin tip fairing, the operation consists of the following:

• to install an electrical bonding strip in two parts between the anti-collision light and a rib of the fin,

• to modify the shield connection of the wiring.

D. COMPLIANCE

• This Service Bulletin is rendered mandatory by EASA Airworthiness Directive No. 2015-0006.

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

E. APPROVAL This Service Bulletin covers DASSAULT AVIATION modification F2000 M3036 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.

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 that 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 FALCON 2000 F2000 -337 January 26, 2015 F2000 -33-11 Revision 1 Page 1 / 11 DASSAULT AVIATION Proprietary Data

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: None.

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

J. REFERENCES Aircraft Maintenance Manual:

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

• PRINCIPLES AND CHECK OF THE ELECTRICAL BONDING (Refer to TASK 20-20-00-910-801)

• OPERATIONAL TEST OF THE EXTERIOR LIGHTING (Refer to TASK 33-40-00-710-801) Illustrated Parts Catalog:

• ANTI-COLLISION LIGHTS (Refer to IPC fig. 33-40-10-50)

• VERTICAL STABILIZER FIN TIP (Refer to IPC fig. 55-30-40-10) Service Bulletin F2000-44 "Lights - Navigation lights - Replacement of fin anti-collision light" K. OTHER PUBLICATIONS AFFECTED The following publications will be revised at a later date to account for the changes introduced by this Service Bulletin:

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• Illustrated Parts Catalog.

• Maintenance Manual.

• Wiring Manual.

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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).

(2) Remove the screws attaching upper fin tip fairing ( 322A) (Refer to IPC fig. 55-30-40-10 , item 10).

(3) Disengage upper fin tip fairing (322A), disconnect connector (322P) and remove upper fin tip fairing (322A).

(4) Removal of the light unit assembly (Refer to IPC fig. 33-40-10-50):

• Remove the PR bead coating the retainer (item 360) without removing the flexible gasket located underneath.

• Remove the retainer, glass cover and seal (items 380, 390 and 400).

• Remove the light unit assembly (screws item 130).

NOTE: Remove and discard gasket (item 420) if installed.

B. ANTI-COLLISION LIGHT ELECTRICAL BONDING In accordance with fig. 1:

(1) Cut out the run outs of the compound seal to obtain a plane mounting surface.

(2) Set the mounting-base bonding strip (item 1), equipped with plate (item 8), into place on the fairing. Attach with two screws.

(3) Fold the tab of the strip to a 90° angle with respect to the fairing’s rib.

(4) Pin the strip assembly (items 2 and 3) to the fairing.

(5) Position the strip assembly (items 2 and 3) in contact against the RH side panel of the fairing and on strip (item 1). If necessary, rework the shape of the strips to obtain proper contact.

(6) Remove the strip assembly (items 2 and 3).

(7) Install double-sided adhesive tape on the face coming in contact with bonding strip (item 1).

(8) Re-install strip assembly (items 2 and 3). Pin to hold in contact against the fairing.

(9) Install strip (item 1) over the strip assembly, pressing firmly at the contact area.

(10) Remove the strip assembly (items 1, 2 and 3).

(11) Counterdrill bonding strip (item 2) to a diameter of 0.1 in (2.5 mm). Disconnect the strips and discard the adhesive tape, remove all remaining adhesive.

(12) Enlarge the holes drilled in the strips to a diameter of 0.126 in (3.2 mm). Assemble bonding strips (items 1 and 2) using rivets (item 4). Coat the faces of the strips with covering sealant making a bead at the contour edge with bead sealant.

(13) Clean the contact surfaces of the light unit assembly, of the strips, and of the fairing using MEK.

(14) Coat the strip assembly (items 2 and 3) with interlaying sealant.

(15) Connect and safety connector (4LX) to the light unit.

(16) Set the strip assembly and the light unit assembly into place in the fairing and attach the light assembly to the fairing. Smooth out the PR in excess around the strips.

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(17) Use a shim to wedge strip assembly (items 2 and 3) in contact against the fairing’s wall. Allow to cure.

(18) Temporarily position the fairing at the fin tip and mark the location of strip (item 3).

(19) Strip the paint off the fin tip rib at the location marked for strip (item 3). Protect the stripped area with alodine.

(20) Install the seal, glass cover, and the retainer (Refer to IPC fig. 33-40-10-50 , items 400, 390 and

380).

(21) Apply bead sealant around the retainer plate.

C. MODIFYING THE WIRING Modify the shield connection in accordance with instructions depicted hereafter and using:

• fig. 2 on aircraft with serial numbers 1, 12, 16, 18, 22 and subsequent (modification F2000 M331 factory-applied),

• fig. 3 on aircraft with serial numbers 2 through 11, 13, 14, 15, 17 and 19 through 21 (with SB F2000-44, if applied), Dimension A:

• Connector with front extraction: 1.38 in (35 mm).

• Connector with rear extraction: 1.97 in (50 mm).

Self-soldering sleeves must be staggered at the extremity of the wiring assemblies so as to prevent a bulge on the bundle.

INSTALLING SELF-SOLDERING SLEEVES

• After stripping the shielded cable and the ground lead wire, unwind the shielding braid of cable without overlapping the shielding strands.

• Position the self-soldering sleeve on the stripped part of the cable.

• Insert the stripped part of the ground lead wire on the inside of the solder preform. Make sure that the ground lead wire is installed against the guide provided for this purpose.

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• With hot air or infrared generator equipped with an appropriate reflector, start heating the small diameter of the self-soldering sleeve, then move up to the solder preform until it melts and flows.

Complete the operation on the large side of the self-soldering sleeve. It is recommended to position the solder preform at a 90° angle maximum in relation to the heat source. The solder must always be visible to the operator.

• The insulating sheath of the shielded cable must not be blistered nor burnt.

D. FINAL STEPS

(1) Use a permanent ink pen to record the number of this Service Bulletin on "Service Bulletin Compliance" label (item 7).

(2) Use interlaying sealant to bond the "Service Bulletin Compliance" label (item 7) to the inner skin of the fairing next to the P/N.

(3) Connect connector (322P), place the fairing on the fin tip and attach the fairing.

(4) Measure the electrical bonding across the anti–collision light retainer plate and the reference point located in the mechanic’s servicing compartment (Refer to TASK 20-20-00-910-801).

The measured value must not exceed 2 mΩ

(5) Perform the operational test of the upper anti-collision light (Refer to TASK 33-40-00-710-801).

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

Fill out the card located at the end of the Service Bulletin and mail or fax it to Dassault Aviation or Dassault Falcon Jet, or fill out the electronic Service Bulletin reply form located in the ”Service Bulletin" page on the Falcon portal.

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3. MATERIAL INFORMATION A. MODIFICATION KIT KIT P/N SBF900EX0285A

(1) Mechanical kit KIT P/N SBF900EX0285A - Mechanical kit

NEW P/N Q T Y

KEY WORD INSTRUCTIONSDISPOSITION ITEMFIG FGFB319100010 1 Mounting-base bonding strip Supply already assembled

- (1-fig. 1) - FGFB319100038 1 Shim - (8-fig. 1) - FGFB319100036 1 Strip Supply already assembled

- (2-fig. 1) - FGFB319100037A1 1 Strip - (3-fig. 1) - NAS1919M04S02WU 3 Rivet See NOTE

- (4-fig. 1) - 78753 1 Studded support - (5-fig. 1) - 78750-02 1 Clamp - (6-fig. 1) - 79160 1 "Service Bulletin Compliance" label - (7-fig. 1) - NOTE: Not applicable to FALCON 2000.

(2) Electrical kit KIT P/N SBF900EX0285A - Electrical kit

NEW P/N Q T Y

KEY WORD INSTRUCTIONSDISPOSITION FIG 01EQTC0S20-05-119-18 1 Lug Ground 322J - fig. 2 - fig. 3 - 01C0K302-16S01 1 Contact Ground 322J - fig. 2 - fig. 3 - 01CAN210-1-20 1 #20 gauge wire L= 3.3 ft (1 m) Ground 322J - fig. 2 - fig. 3 - 01C0A54143FC16 4 Blanking pin 322J/P - fig. 2 - fig. 3 - 01EQTRB23-2R 1 Self-soldering sleeve 4LX - fig. 2 - fig. 3 - 01CAN210-1-22 1 #22 gauge CF wire L = 1 ft (0.3 m) - See NOTE 1 4LX - fig. 2 - fig. 3 - 01CAN203-1-22Y 1 #22 gauge KZ wire L = 1 ft (0.3 m) - See NOTE 2 01EQTC0S20A03-071-22 1 Lug 4LX - fig. 2 - fig. 3 - 01C0K345-16S01 2 Contact 4LX - fig. 2 - fig. 3 - FALCON 2000 F2000 -337 January 26, 2015 F2000 -33-11 Revision 1 Page 7 / 11 DASSAULT AVIATION Proprietary Data

KIT P/N SBF900EX0285A - Electrical kit

NEW P/N Q T Y

KEY WORD INSTRUCTIONSDISPOSITION FIG 01EQTEC1-1 1 Insulating sleeve 322P - fig. 2 - fig. 3 - 01EQTEC1-1 4 Insulating sleeve - See NOTE 3 01EQTPRL08B01 1 Splice - See NOTE 3 GND322J-B 2 Black sleeve with white marking 01PR0TMS3-32BK 322J - fig. 2 - fig. 3 - GND312J-B 2 Black sleeve with white marking 01PR0TMS3-32BK 312J - fig. 2 - fig. 3 - A 1 Black sleeve with white marking 01PR0TMS3-32BK 4LX - fig. 2 - fig. 3 - B 1 Black sleeve with white marking 01PR0TMS3-32BK 4LX - fig. 2 - fig. 3 - 78750-01 5 Clamp 4LX - fig. 2 - fig. 3 - NOTE 1: Use on FALCON 2000.

NOTE 2: Do not use on FALCON 2000.

NOTE 3: Do not use on FALCON 2000 B. LOCAL PROCUREMENT As indicated in Consumable Products Manual (CPM):

• alodine.

• interlaying sealant.

• bead sealant.

• covering sealant.

• MEK or equivalent.

• Green CELOMER varnish 6060B.

• Locking wire.

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DASSAULT SERVICE BULLETIN

AVIATION FALCON 2000 F2000 -337 Joggle Make a lay of bead sealant arround edge Coat the 2 faces of strips with covering sealant Base plate Light PR bead Light 90° unit assembly VIEW B (Inside fairing RH side) VIEW A Rib 3 * Clean strip mounting area on fin rib. Bond strips (items 2 and 3) to Protect with Alodine. RH side of fairing with interlaying sealant Figure 1: ELECTRICAL BONDING STRIPS INSTALLATION January 26, 2015 F2000 -33-11 Revision 1 Page 9 / 11

DASSAULT SERVICE BULLETIN

AVIATION FALCON 2000 F2000 -337

BEFORE SB 4LX 53FT L36SP 33420002 33420001 FLASH 33420074 33420063 150W RED

OO-ZE-EE WM 53FT AFTER SB 4LX

• 33420001 FLASH 33420074 150W RED 4LX 01CAB210-2-20 - R A — W B /22CF Figure 2: AIRCRAFT S/N 1, 12, 16, 18, 22 AND SUBSEQUENT (MODIFICATION F2000 M331 FACTORY

APPLIED) January 26, 2015 F2000-33-11 Revision 1 Page 10 / 11