# Dassault Mandatory Service Bulletin F2000EX-171: Revision 3 - Rights: © Dassault Aviation. Filed by the FAA in regulations.gov docket FAA-2012-1067; AD 2013-09-03 incorporates this document by reference. Not covered by OpenAirDocs’ CC0 dedication. - Document: [Dassault Mandatory Service Bulletin F2000EX-171](https://openairdocs.org/service-documents/dassault/f2000ex-171.md) - Title as filed: U.S. DOT/FAA - SB F2000EX-171 R3 - Pages: 86 - PDF: https://openairdocs.org/files/sha256/4d/fa/4dfae51bc7e0e6a973105a4ee4d23946ba05529377ea31441fd612b16d0e5a44 - Page: https://openairdocs.org/service-documents/dassault/f2000ex-171/file/4dfae51bc7e0 ## 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 SERVICE BULLETIN 671 641 FALCON 2000EX FALCON 2000EX EASy FALCON 2000DX No 171-R3 MARCH 10, 2010 MANDATORY MANDATORY Copyright © 2009 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. ATA 57-5 WING WING TANK MODIFICATION ### Page 2 FALCON 2000EX SERVICE BULLETIN F2000EX–171 F2000EX–57–5 WING WING TANK MODIFICATION ________________________________________________________________________________ INITIAL ISSUANCE date: July 6, 2009 List of effective pages: 1 to 6. ________________________________________________________________________________ COMPLETE ISSUANCE: REVISION 1 date: October 30, 2009 List of effective pages: 1 to 7. List of modified pages: 1 to 7. REASON: The Service Bulletin is updated to give precise details about compliance and training. This revision is not applicable to aircraft already modified per the original issue. ________________________________________________________________________________ COMPLETE ISSUANCE: REVISION 2 date: February 15, 2010 List of effective pages: 1 to 7. List of modified pages: 6 and 7. REASON: Addition/correction of information in appendix 1, 2, 5 following installations performed during training. This revision is not applicable to aircraft already changed per the original issue. ________________________________________________________________________________ COMPLETE ISSUANCE: REVISION 3 date: March 10, 2010 List of effective pages: 1 to 7. List of modified page: 3. REASON: Modification of paragraph “TRAINING”. This revision is not applicable to aircraft already changed per the original issue or revision 1 or revision 2. ### Page 3 DASSAULT AVIATION Proprietary Data SERVICE BULLETIN FALCON 2000EX F2000EX–171 March 10, 2010 F2000EX–57–5 Revision 3 Page 1 WING WING TANK MODIFICATION ________________________________________________________________________________ 1 . PLANNING INFORMATION A . EFFECTIVITY This Service Bulletin is applicable to: – FALCON 2000EX aircraft with serial numbers 1 through 600 (F2000EX, F2000EX EASy), – FALCON 2000EX aircraft with serial numbers 601 through 700 (F2000DX), which have not previously implemented DASSAUL T A VIATION modification F2000EX M3072. B . REASON An analysis of rare high-speed runway excursions has revealed that, in case of a main landing gear leg failure due to overloads, the subsequent wing damage may cause a potential fuel spill. The purpose of this Service Bulletin is to prevent such a fuel spill in the event of such an exceptional occurence by installing a sealed boundary between ribs No. 4 and 5 in front of the rear wing spar. C . DESCRIPTION The operation consists in: – removing the structural removable lower wing panel, – installing a drainage capability, – installing a boundary between ribs No 4 and 5, – applying a sealant around the boundary , – performing a test for leakage, – replacing the instruction placards on the wings and on the refueling door (186CR). The Accomplishment Instructions and the tests are included in the five Appendices to this Service Bulletin. ### Page 4 DASSAULT AVIATION Proprietary Data FALCON 2000EX SERVICE BULLETIN F2000EX–171 March 10, 2010 F2000EX–57–5 Revision 3 Page 2 D . COMPLIANCE Mandatory: Compliance with this Service Bulletin should be done no later than 12 years and 6 months of its release date. It is anticipated that this Service Bulletin will be rendered mandatory by an EASA Airworthiness Directive. The Airworthiness authorities of other countries may also elect to mandate compliance with this Service Bulletin and compliance timelines will be established by those authorities. Each person applying this Service Bulletin must have successfully completed a training program. For more details refer to the training section of paragraph F . E . APPROVAL This Service Bulletin covers DASSAULT AVIATION modifications F2000EX M3072 which has been approved by EASA and M3206 which have 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. ### Page 5 DASSAULT AVIATION Proprietary Data SERVICE BULLETIN FALCON 2000EX F2000EX–171 March 10, 2010 F2000EX–57–5 Revision 3 Page 3 F . LABOR Estimated labor–hours: – Access time: 300 hours – Modification: 300 hours – 40 hours for paint touch (including lower wing panels and upper wings reworked areas) 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. NOTE: The Service Bulletin instructions contained in the five APPENDICES constitute complex structural rework activity that should only be accomplished at Service Centers that have relevant experience working on Falcon aircraft and have a high level of competency in the following areas: – Work on primary structure. – Metal work. – Precision adjustment. – Non-destructive-Testing (NDT) for cracks. – Use of S-class screws and repair dimensions. Failure to utilize an experienced Service Center with a high level of proficiency in the above disciplines and specialized training in the operations covered hereby, could result in inadvertent damage during the Service Bulletin procedure, possibly requiring extensive aircraft repairs. TRAINING: Each person applying this Service Bulletin must have successfully completed a training program. This training program consists of applying this Service Bulletin in the person’s facility under the supervision of a trainer from Dassault Aviation, and/or Dassault Aircraft Services (DAS) personnel that have received training from Dassault A viation. Each facility applying this Service Bulletin must maintain capable individuals on staff that have successfully completed the Dassault training program prior to attempting this modification. However, it is acceptable that a person from a facility that has successfully completed the training program to be designated to serve as a trainer for that facility . As a consequence, it is the responsibility of each maintenance facility applying this Service Bulletin to define an internal training program of its technicians and maintain familiarization of the application of the SB to maintain the required knowledge over the years. ### Page 6 DASSAULT AVIATION Proprietary Data FALCON 2000EX SERVICE BULLETIN F2000EX–171 March 10, 2010 F2000EX–57–5 Revision 3 Page 4 G . MATERIAL – PRICE AND AVAILABILITY The modification kit will be delivered to the Service Centers approved 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 No 101 AEROPORT DU BOURGET 93352 – LE BOURGET Cedex (FRANCE) Please contact your Dassault A viation 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 The specific tooling are listed in the APPENDIX 5. I . WEIGHT AND BALANCE Change in weight: + 6.4 lb (+ 2.9 kg). Change in balance with respect to 25% MAC : + 32 ft.lb (+ 4,3 m.daN) nose up moment. ### Page 7 DASSAULT AVIATION Proprietary Data SERVICE BULLETIN FALCON 2000EX F2000EX–171 March 10, 2010 F2000EX–57–5 Revision 3 Page 5 J . REFERENCE Aircraft Maintenance Manual: – procedure 27-510, – procedure 27-811, – procedure 57-011. Standard Practices: – procedure 20-305, – procedure 20-306, – procedure 20-320, – procedure 20-602, – procedure 20-650. Illustrated Parts Catalog: – chapter 11-20-10, – chapter 11-20-20, – chapter 53-20-20. Airplane Flight Manual: – F2000EX Airplane Flight Manual (DGT84278) rev .7 or subsequent. – F2000EX Easy Airplane Flight Manual (DGT88898) rev .6 or subsequent. AMM chap. 12, Ingredients and consumable products. K . OTHER PUBLICATIONS AFFECTED The following publications will be revised at a later date to account for the changes introduced by this Service Bulletin: – AMM – IPC ### Page 8 DASSAULT AVIATION Proprietary Data FALCON 2000EX SERVICE BULLETIN F2000EX–171 March 10, 2010 F2000EX–57–5 Revision 3 Page 6 2 . ACCOMPLISHMENT INSTRUCTIONS A . ACCOMPLISHMENT INSTRUCTIONS ARE DESCRIBED IN THE FOLLOWING APPENDICES: (1) APPENDIX 1 DRY BAY – ASSEMBLY OF BOUNDARY AND DRAINING CAPABILITY REVISION 2 (2) APPENDIX 2 DRY BAY – SEALANT APPLICATION ON BOUNDARY REVISION 3 (3) APPENDIX 3 DRY BAY – LEAKAGE PRESSURE TEST FOR THE SEAL BOUNDARY REVISION 2 (4) APPENDIX 4 DRY BAY – REPORT OF DRILLING THE PR INJECTION HOLES REVISION 1 B . REPLACEMENT OF INSTRUCTION PLACARDS (1) LH and RH wings – Remove the instruction placards Item 50 as per Illustrated Parts Catalog, Chap. 11-20-20, fig. 10. – For F2000EX aircraft, install the new instruction placards F2MB090200003A3 at the same location as per Procedure 20-306. – For F2000DX aircraft, install the new instruction placards F2ME090200003A1 at the same location as per Procedure 20-306. (2) Refueling access door (186CR) – Open the refueling access door (186CR) as per Illustrated Parts Catalog, Chap. 53-20-20, fig. 35 for F2000EX aircraft or Illustrated Parts Catalog, Chap. 53-20-20, fig. 14 for F2000DX aircraft. – Remove the instruction placard Item 100 as per Illustrated Parts Catalog, Chap. 11-20-10, fig. 30. – For F2000EX aircraft, install the new instruction placard F2MB090100023A3 as per Procedure 20-305. – For F2000DX aircraft, install the new instruction placard F2ME090100024A1 as per Procedure 20-305. C . DOCUMENTATION Update, if not already done, the Airplane Flight Manual with: – Airplane Flight Manual (DGT84278) rev.7 or subsequent for a F2000EX – Airplane Flight Manual (DGT88898) rev.6 or subsequent for a F2000EX Easy ### Page 9 DASSAULT AVIATION Proprietary Data SERVICE BULLETIN FALCON 2000EX F2000EX–171 March 10, 2010 F2000EX–57–5 Revision 3 Page 7END OF DOCUMENT D . 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 Compliance Form on line on the Dassault Falcon website. 3 . MATERIAL INFORMATION Refer to DRY BAY APPENDIX 5 REVISION 3. ### Page 10 (OCR) NO POSTAGE NECESSARY FROM IF MAILED IN THE UNITED STATES ZIP CODE BUSINESS REPLY MAIL FIRST CLASS MAIL PERMIT NO. 3306 HACKENSACK, NJ 07602 POSTAGE WILL BE PAID BY ADDRESSEE: DASSAULT FALCON JET CORP. PO BOX 1946 SO HACKENSACK NJ 07606-9946 ATTENTION: FIELD SERVICE DEPARTMENT DASSAULT AVIATION 78, Quai Marcel Dassault Cedex 300 92552 SAINT-CLOUD Cedex FRANCE A l'attention de DSC ### Page 11 SERVICE BULLETINS COMPLIANCE SERVICE BULLETINS COMPLIANCE SERVICE BULLETINS COMPLIANCE FALCON 2000EX APPLICATION DES BULLETINS DE SERVICE DASSAULT AVIATION Number ATA Number Remarks: Coding: A/C S/N C T complete compliance partial compliance Date : Signature : Performed by: DASSAULT AVIATION Number ATA Number Remarks: Coding: C T complete compliance partial compliance Date : Signature : Performed by: FALCON 2000EX Avion No Numéro DASSAULT AVIATION Numéro ATA Fait par : application partielle application totale Would you be kind enough to inform us that this Service Bulletin is complied with: – For ”Western Hemisphere”, mail upper card (No postage necessary if mailed in the U.S.A.) or fax to Dassault Falcon Jet: 1–201–541–4700. – For ”Other Continents”, mail card herebelow or fax to Dassault Aviation: 33 (0)1.47.11.65.21. On the occasion, if other Service Bulletins have been simultaneously complied with could you complete the blank spaces provided for this purpose. APPLICATION DE BULLETINS DE SERVICE Lorsque vous aurez appliqué ce Bulletin de Service sur votre avion, veuillez avoir l’amabilité de nous en informer : – Utiliser la carte réponse supérieure pour continent américain (Dispensée de timbrage pour postage depuis les U.S.A.) ou le fax pour Dassault Falcon Jet : 1–201–541–4700. – Ou la carte réponse inférieure pour autres continents ou le fax pour Dassault Aviation : 33 (0)1.47.11.65.21. Eventuellement, si d’autres Bulletins de Service ont été appliqués simultanément, vous pouvez les mentionner dans les cases vierges prévues à cet effet. Remarques : 171 171 F2000EX 57 57 5 5 Revision 3 Revision 3 Révision 3 F2000EX F2000EX F2000EX ### Page 12 PAGE 1/49 ASSEMBLING DRY BAY AND DRAINING CAPABILITY Revision 2 February 15, 2010 DRY BAY APPENDIX-1 This document is the intellectual property of DASSAULT AVIATION. It may not be used, reproduced, modified or disclosed without its authorization. DASSAULT AVIATION Proprietary Data. ### Page 13 PAGE 2/49 Revision 2 February 15, 2010 PROTECTION EQUIPMENTOPERATIONSHAZARDS CHEMICAL HAZARDS ON WORKSTATION Pickling Vacuum cleaner+ Latex gloves Anti-dust mask Cleaning with solvent Latex gloves Sealant application Latex gloves Long sleeves clothes DRY BAY APPENDIX-1 This document is the intellectual property of DASSAULT AVIATION. It may not be used, reproduced, modified or disclosed without its authorization. DASSAULT AVIATION Proprietary Data. ### Page 14 PAGE 3/49 Revision 2 February 15, 2010 Handling with travelling crane Risks of clashes, fall of objects + Authorized personnel Classic riveting, MGPL, FOBO, boring, reaming, broaching, countersinking, routing, trimming, pinning tightened Deburring, spot-facing Handling of bridges, spars, panels, drilling grids Risks of fall of objects NON-CHEMICAL HAZARDS ON WORKSTATION PROTECTION EQUIPMENTOPERATIONSHAZARDS DRY BAY APPENDIX-1 This document is the intellectual property of DASSAULT AVIATION. It may not be used, reproduced, modified or disclosed without its authorization. DASSAULT AVIATION Proprietary Data. ### Page 15 PAGE 4/49 F50 F900 F900EX F2000 F2000EX 27-811 27-811 27-811 27-811 27-811 57-400 57-011 57-011 57-011 57-011 Revision 2 February 15, 2010 Extend the flaps see procedure 27-510 27-510 27-510 Remove the wing’s structural fuel tank removable panel see procedure Remove flap actuator (L25CF/R25CF) see procedure 27-568 27-521 PRELIMINARY STEPS DRY BAY APPENDIX-1 CAUTION: Once panel is removed, ventilate with an air extractor to remove fuel vapors from the wing box. This document is the intellectual property of DASSAULT AVIATION. It may not be used, reproduced, modified or disclosed without its authorization. DASSAULT AVIATION Proprietary Data. ### Page 16 PAGE 5/49 Strip the area prior to drilling the PR injection holes See Standard practices 20-602 (Stripping and pickling) Revision 2 February 15, 2010 LOWER SURFACE BOTTOM VIEW UPPER SURFACE TOP VIEW RIB 4 DRY AREA FRAME FWD FWD RIB 5 Strip paint Chemical pickling Strip paint Chemical pickling DRY BAY APPENDIX-1 RIB 5 REAR SPAR Upper panel boundary REAR SPAR This document is the intellectual property of DASSAULT AVIATION. It may not be used, reproduced, modified or disclosed without its authorization. DASSAULT AVIATION Proprietary Data. ### Page 17 PAGE 6/49 ASSEMBLING HALF-FRAMES Fitting nut gang channels to half-frames: - On the workbench, cut out the nut gang channel 39600C332-13S (Item 26) - Mark the 2 gang channels: FGFB112500027 Secure with rivets 21218DB2408J (Item 54) February 15, 2010 - Fit all nut gang channels to half-frames Item 1-2 and Item 3-4, and interlay sealant (see Standard Pratices 20-650) Revision 2 Cut-out Half-frame Item 1-2 FGFB112500011W1P01/ FGFB122500011W1P01 Half-frame Item 3-4 FGFB112500012W1/FGFB12 2500012W1 FGFB112500027Nut gang channel Item 28 39600C102-04S Nut gang channel Item 27 39600C123-05S DRY BAY APPENDIX-1 This document is the intellectual property of DASSAULT AVIATION. It may not be used, reproduced, modified or disclosed without its authorization. DASSAULT AVIATION Proprietary Data. ### Page 18 PAGE 7/49 INSTALLATION OF DRY BAY STRUCTURE Installation of angle Item 11-12 on half-frame Attach the angle (Item 11-12) to half-frame (Item 1-2) using an assembly screw Drill the angle (Item 11-12) dia. 0.1 in. ( 2.5 mm) hole in half-frame Disassemble angle, deburr Assemble angle with interlaying sealant (See Standard Practices 20-650) and rivets 21218DE2408J Revision 2 February 15, 2010 Half-frame Item 1-2 FGFB112500011W1P01/ FGFB122500011W1P01 Angle Item 11-12 FGFB112500005W1EQU/ FGFB122500005W1EQU Rivet 21218DE2408J Item 54 DRY BAY APPENDIX-1 This document is the intellectual property of DASSAULT AVIATION. It may not be used, reproduced, modified or disclosed without its authorization. DASSAULT AVIATION Proprietary Data. ### Page 19 PAGE 8/49 INSTALLATION OF DRY BAY STRUCTURE - Assemble cups Item 7-8 and item 9-10 Cleco cups Item 7-8 and Item 9-10 through two dia. 0.1 in. ( 2.5 mm) predrilled holes Drill both 2 x dia. 0.1 in. ( 2.5 mm) of a cup in the other one and drill both holes to dia. 5.2 H9 Remove, deburr and install both nut plates Item 48 on cup Item 7-8 Assemble the 2 cups with interlaying sealant between the two parts+ 2 x screws Item 47 Pinning Revision 2 February 15, 2010 Recess Item 7-8 FGFB112500003/ FGFB122500003 Cup Item 9-10 FGFB112500004 / FGFB122500004 Fill with bead sealant See Standard Practices 20-650 Dia.5.2 H9 ( +0  Dia. 0,205 in. (+0 µin. +1.8 µin.) DRY BAY APPENDIX-1 2 x screw Item 47 22201TX050003XF Nut plates Item 48 5SF5009M Cup Item 7-8 FGFB112500003/ FGFB122500003 Cup Item 7-8 FGFB112500003/ FGFB122500003 Repeat both 2 x Ø 0.1 in ( 2.5 mm) This document is the intellectual property of DASSAULT AVIATION. It may not be used, reproduced, modified or disclosed without its authorization. DASSAULT AVIATION Proprietary Data. ### Page 20 PAGE 9/49 INSTALLATION OF DRY BAY STRUCTURE Fitting nut gang channels to cup assembly: Drill the cups to dia. 0.244 in. (6,2 mm) Secure with rivets 21218DB2408J (Item 54) - Fit 14ea nut gang channels to cups Item 7-8 and Item 9-10, and interlay sealant (see Standard Pratices 20-650) Revision 2 February 15, 2010 DRY BAY APPENDIX-1 nut gang channel 39600C332-13S Item 26 This document is the intellectual property of DASSAULT AVIATION. It may not be used, reproduced, modified or disclosed without its authorization. DASSAULT AVIATION Proprietary Data. ### Page 21 PAGE 10/49 OMEGA STIFFENER REMOVAL + SEALING ON RIB 5 1) Remove the omega stiffener 113005004 / 113005004 on rib 5 do not enlarge the rivet holes 2) Scrape and clean the sealant around the fastener doublers on rib 5 3) Check for presence of sealant between doubler and rib 5. If sealant is already applied, is not necessary to remove the rivets to ease the PR injection Revision 2 February 15, 2010 RIB 5 Scrape and clean sealant Omega stiffener holes FGFB113005004 DRY BAY APPENDIX-1 RIB 5 REAR SPAR Remove these rivets Item 57 to ease the PR injection Do not remove them if there is sealant between doubler and rib 5 Remove this rivet and replace with a 100°-countersunk head screw, INSPECT FOR SEALANT Sealant beetween doubler and rib 5 Remove this rivet if necessary only Remove the Omega stiffener FGFB113005004 Remove this screw RIB 5 NOTE: External wing skin top side This document is the intellectual property of DASSAULT AVIATION. It may not be used, reproduced, modified or disclosed without its authorization. DASSAULT AVIATION Proprietary Data. ### Page 22 PAGE 11/49 REMOVING AND CLEANING SEALANT Revision 2 February 15, 2010 DRY BAY APPENDIX-1 This document is the intellectual property of DASSAULT AVIATION. It may not be used, reproduced, modified or disclosed without its authorization. DASSAULT AVIATION Proprietary Data. ### Page 23 PAGE 12/49 ATTACHMENT REMOVAL FOR REAR SPAR ANGLES Remove the six fasteners and check the diameter of each screw (some may be oversize-dimension screws) Scrape and clean the sealant in the bent section aera Revision 2 February 15, 2010 RIB 5 REAR SPAR 2 Screws 38472TX060 Dia. 0.236 in. (6 mm) DRY BAY APPENDIX-1 Scrape and clean the sealant in this area 1 Screw 38472TX060 Dia. 0.236 in. (6 mm) 2 Screws 22201TX050 Dia. 0.197 in. (5 mm) or MPGL’s 1 Screws 38472TX050 Dia. 0.197 in. (5 mm) This document is the intellectual property of DASSAULT AVIATION. It may not be used, reproduced, modified or disclosed without its authorization. DASSAULT AVIATION Proprietary Data. ### Page 24 PAGE 13/49 INSTALLATION OF BLANKING PLATE ON REAR SPAR After removal of the removable panel and of the locating plug, perform the following: Protect the dia. .63 in. (Dia. 16mm) hole with alodine and install the 2 nut plates (Item 30) on both sides of the hole Perform paint touch-up on the dia. .63 in. (Dia. 16mm) hole and nut plates Install the plate (item 21) on the spar, NOTE: DO NOT INSTALL UNTIL AFTER THE PRESSURE TEST (Appendix 3 page 5) Using tool MA48401Z01-FGFB112005A2 drill 2 bores to a diameter of .19 in. (Dia. 4.8E9) Drill the locating plug to a diameter of .39 in. to .63 in. (Dia. 10mm to 16mm), Revision 2 February 15, 2010 Rib 5 Rib 4 Rear spar Locating plug Box structure - inside view Nut MS21059L3 Locating plug to be removed Box structure - inside view Rib 4 Rib 5 Plate Item 21 FGFB112005003 (Installed outside the box structure) 2 nuts Item 30 MS21059L3 installed with rivets (Item 56) 21218DE2410J 2 screws Item 29 NAS1133V4A Dia,.63 in. (Dia.16mm) DRY BAY APPENDIX-1 Drilled dia..63 in. (dia. 16mm). hole This document is the intellectual property of DASSAULT AVIATION. It may not be used, reproduced, modified or disclosed without its authorization. DASSAULT AVIATION Proprietary Data. ### Page 25 PAGE 14/49 INSTALLATION OF DRAIN PROVISION ON LOWER SURFACE PANEL Revision 2 February 15, 2010 Install the drilling tool ME48401Z01-SBF2000-358 and check for the dimension of .24 in. min (6 mm min). NOTE: Install a shim (thickness .2 in. (5 mm)) under the tool to escape the radius of the risers. If the dimension is smaller than .24 in. (6 mm), use drilling tool ME48402Z01-SBF2000-358, Pre-drill the lower panel to a diameter of 0.1 in. (Dia. 2.5 mm) Enlarge the 3 holes (see figure) Set clocos to attach the angle (Item 61-62) (FGFB112500060W3/FGFB122500060W3) with the appropriate shim FGFB112500063W3 and counterdrill the shim and rib 4 for rivet 21215DE32 Install anchor nut Item (NAS1473A3) on the angle with interlaying sealant Protect holes with alodine and touch-up with paint. DRY ZONE Rib 4 .24 in. min 6 mm mini Tool ME484001Z00-SBF2000-358 DRY BAY APPENDIX-1 Rib 4 Item 61-62 Insert shim if necessary Rear sparRear spar Rear spar Ø .20 in. Ø 5 mm Ø .20 in. Ø 5 mm Ø .31 in. Ø 8 mm SECTION D-D Rear spar This document is the intellectual property of DASSAULT AVIATION. It may not be used, reproduced, modified or disclosed without its authorization. DASSAULT AVIATION Proprietary Data. ### Page 26 PAGE 15/49 REINFORCING RIB 5 Revision 2 February 15, 2010 Back drill rib 5 holes into the shim (Item 22) to a diameter of 0.1 in.(Dia. 2.5 mm) with drill bush MA48401-01 Back drill of rib 5 holes into the shim (Item 24) + angle bracket (item 25) to a diameter of Dia. .1 in.(Dia. 2.5 mm) with drill bush MA48401-01 Cleco the shim (item 24) and the angle bracket (item 25) to rib 5 Enlarge bores to dia.4,4 U9 ( Dia. 4,4U9 = 0.173 in. (-0,0009;-0,0020)) Countersink the 4 or 5 holes (CAUTION: contersunking is on Rib5 side) DRY BAY APPENDIX-1 Angle bracket Item 25 FGFB113005041 Rib 5 Shim Item 22 FGFB112500009 Rib 5 reinforcement ATTACHMENT DIRECTION Remove this rivet, only if necessary If this configuration is encountered, rework the shims (item 22 & 24) to fit with the stiffener’s shape. Shim -Item 24 FGFB113005042 This document is the intellectual property of DASSAULT AVIATION. It may not be used, reproduced, modified or disclosed without its authorization. DASSAULT AVIATION Proprietary Data. ### Page 27 PAGE 16/49 DRILLING THE BENT SECTIONS Have the bent sections Item 13-14 and Item 15-16 resting on rib 5 and rear spar Drill existing holes drilled in panels to bent sections using Dia. 0.1 in. (Dia. 2.5 mm) drill bushes Drill the angle only to dia. 0.204 in. (5.2 D10) for vertical attachments, dia.0.244 in.(Dia. 6.2 D10) for lower surface attachment fittings and Dia. 0.244 in.(dia. 6.2D10) and 0.204 in. (5.2 D10) for upper surface attachment fittings Revision 2 February 15, 2010 RIB 5REAR SPAR UPPER SURFACE BENT SECTION Item 15-16 FGFB11250006/FGFB122500006 LOWER SURFACE BENT SECTION Item 13-14 FGFB11250007/FGFB122500007 Dia. 0.204 in (Dia. 5.2 mm) D10 bore Dia. 0.244 in (Dia. 6.2 mm) D10 bore DRY BAY APPENDIX-1 Dia. 0.244 in (Dia. 6.2 mm) D10 bore DO NOT DRILL SKIN OR RIB 5 TO THESE MEASUREMENTS (JUST BENT SECTIONS) This document is the intellectual property of DASSAULT AVIATION. It may not be used, reproduced, modified or disclosed without its authorization. DASSAULT AVIATION Proprietary Data. ### Page 28 PAGE 17/49 DRILLING THE LOWER SURFACE PANEL STIFFENER Using tool MA48402Z01-FGFB117/127000103, pre-drill the stiffener to a diameter of Dia. 0.1 in. (Dia. 2.5 mm) Revision 2 February 15, 2010 Rib 4 Rib 5 Rear spar Rib 5 Rib 4 Pre-drilled stiffener (4 x Dia. .1 in. (Dia. 2.5mm)) DRY BAY APPENDIX-1 Tool MA48402Z01-FGFB117/127000103 Rib 5 This document is the intellectual property of DASSAULT AVIATION. It may not be used, reproduced, modified or disclosed without its authorization. DASSAULT AVIATION Proprietary Data. ### Page 29 PAGE 18/49 DRILLING THE LOWER SURFACE PANEL STIFFENER Revision 2 February 15, 2010 Rear spar Rib 5 Rib 4 Pre-drilled stiffener (12 x Dia. .1 in. (Dia. 2.5mm)) DRY BAY APPENDIX-1 NOTE: For easier access, use tool MA48401Z01-FGFB122500003 on LH side and tool MA48401Z01-FGFB112500003 on RH side. Attach tool MA48401Z01-FGFB112/122500003 to the stiffener and pre-drill to a diameter of 0.1 in. (Dia. 2.5 mm) Tool MA48401Z01-FGFB112/122500003 Rib 5 Rib 4 This document is the intellectual property of DASSAULT AVIATION. It may not be used, reproduced, modified or disclosed without its authorization. DASSAULT AVIATION Proprietary Data. ### Page 30 PAGE 19/49 INSTALLATION OF DRY BAY STRUCTURE Revision 2 February 15, 2010 DRY BAY APPENDIX-1 Inside the wing box, install the cup assembly (Item 7-9/8-10) against the lower panel stiffiner and Rib5 Position the cup assembly 0.06 in. (1,5 mm) from the top of the stiffener Using screw clamps, secure the cup assembly to the lower panel stiffener and check the position (0.06 in. - 1.5 mm) Spot drill the three dia. 0.1 in. ( Dia.2.5 mm) pre-drilled holes of the lower skin panel stiffener in the cup asssembly, Attach the cup assembly to the stiffener, NOTE: Verify the position of cup assembly with respect to the stiffener (.06 in.(1.5mm)) Rib 5 Rib 4 Cups FGFB112/122500003 FGFB112/122500004 Item 7-9/8-10 Cups Stiffener .06 in. 1,5 mm This document is the intellectual property of DASSAULT AVIATION. It may not be used, reproduced, modified or disclosed without its authorization. DASSAULT AVIATION Proprietary Data. ### Page 31 PAGE 20/49 INSTALLATION OF DRY BAY STRUCTURE In case of interference between the half-frame and rib 5 during installation: See page 47 Revision 2 February 15, 2010 Half-frame Item 1-2 FGFB112500011W1P01 / FGFB122500011W1P01 DRY BAY APPENDIX-1 Draw a line on the half frame (Item 1-2) at 0.39 in. (10mm ) of the edge (see detail A) Resting on the cup assembly, position the half frame (item 1-2) embedded in rib 5 and bearing on tool MA40301Z01-FGFB112/122500010 Check that the half-frame rests properly on the upper wing panel, Use bolt to assemble the half-frame to cup assembly. On half-frame, mark holes from rib 5 and the hole of the upper skin panel. Check for gaps between the upper panel attaching parts and and the half-frame Disassemble and check the gap as per page 47 Tool MA40301Z01- FGFB112/122500010 Rib 5 Cup assembly DETAIL A Hole of the upper skin panel Gap This document is the intellectual property of DASSAULT AVIATION. It may not be used, reproduced, modified or disclosed without its authorization. DASSAULT AVIATION Proprietary Data. ### Page 32 PAGE 21/49 INSTALLATION OF DRY BAY STRUCTURE In case of interference between the half-frame and rib 5 during installation: See page 47 Revision 2 February 15, 2010 DRY BAY APPENDIX-1 Inside the wing box assemble the half frame (Item1-2 and item 3-4) with the positioning template ME62001Z01-SBF2000-358 and attach the assembly with screws Resting on the cup assembly, position the assembly in contact to rib 5 and bearing on tool MA40301Z01-FGFB112/122500010 Check that the half-frames rest properly on the upper wing panel, Attach the assembly to cup assembly with screws, Insert shim (item 23) between half-frame (item 3-4) and rib 4, adjust shim thickness if necessary Tool MA40301Z01- FGFB112/122500010 Rib 4 Half-frame Item 1-2 FGFB112500011W1P01 / FGFB122500011W1P01 Half-frame Item 3-4 112500012W1 / 122500012W1 Rib 5 Cup assembly Positioning template ME62001Z01-SBF2000-358 Shim Item 23 (between Rib 4 and half-frame) This document is the intellectual property of DASSAULT AVIATION. It may not be used, reproduced, modified or disclosed without its authorization. DASSAULT AVIATION Proprietary Data. ### Page 33 PAGE 22/49 INSTALLATION OF DRY BAY STRUCTURE Drill both dia. 0.1 in. ( Dia. 2.5 mm) pre-drilled holes of the half-frames in the upper surface skin Drill both dia. 0.1 in. ( Dia. 2.5 mm) pre-drilled holes of the half-frames in the Rib 4 Attach the half-frames to the upper surface skin and the rib 4 with shim item 23 Drill rib 5 holes, dia. 0.1 in. (Dia. 2.5 mm) then dia. .161 in. (dia. 4,1 mm) into half-frame (Item 1-2) with drill bush MA48401-01 Revision 2 February 15, 2010 Rib 5 Drill half-frame/rib 5 link Half-frame Item 1-2 FGFB112500011W1P01 / FGFB122500011W1P01 DRY BAY APPENDIX-1 Drill bush MA48401-01 Rib 5 This document is the intellectual property of DASSAULT AVIATION. It may not be used, reproduced, modified or disclosed without its authorization. DASSAULT AVIATION Proprietary Data. ### Page 34 PAGE 23/49 INSTALLATION OF DRY BAY STRUCTURE Drill rib 4/half-frame link to dia. 0.158 in.(dia. 4mm) using tool MA48401Z01-FGFB112/122500010 Revision 2 February 15, 2010 Rib 4 Drill half-frame/rib 4 link Half-frame Item 3-4 FGFB112500012W1/ FGFB122500012W1 DRY BAY APPENDIX-1 Tool MA48401Z01- FGFB112/122500010 Rib 4 This document is the intellectual property of DASSAULT AVIATION. It may not be used, reproduced, modified or disclosed without its authorization. DASSAULT AVIATION Proprietary Data. ### Page 35 PAGE 24/49 ASSEMBLING THE DRY BAY Cleco the drilling template MA48401Z01-FGFB116/126 and bore to a diameter of 0.158 in. (Ø4mm) the linking half-frames / upper wing surface Disassemble and deburr the assembly Preparation of shim Item 19-20 On shim Item 19-20 mark and drill a dia 0.204 in.(dia. 5.2) hole Revision 2 February 15, 2010 Shim Item 19-20 FGFB112500016/ FGFB122500016 16 x dia. 0.158 in. (dia. 4 mm) 1 x dia. 0.1 in. (Ø2,5 mm) DRY BAY APPENDIX-1 Tool MA48401Z01- FGFB116/126 This document is the intellectual property of DASSAULT AVIATION. It may not be used, reproduced, modified or disclosed without its authorization. DASSAULT AVIATION Proprietary Data. ### Page 36 PAGE 25/49 ASSEMBLING THE DRY BAY Drill cup assembly on workbench Revision 2 February 15, 2010 DRY BAY APPENDIX-1 NOTE: Use the same tool as that used to drill the lower panel stiffener Pin tool MA48401Z01-FGFB112/122500003 to the cup assembly (item 7-9/8-10) and pre-drill to a diameter of 0.1 in. (Dia. 2.5 mm) Pin and position the plug (item 17-18) on the cup assembly (see DETAIL A) Drill dia 0.1 in. (Dia. 2.5 mm) pre-drill hole of cup assembly in the plug, Pin tool MA48401Z01-FGFB112/122500003 to the cup assembly and drill to a diameter of 0.158 in. (Dia. 4 mm) Pin the plug to tool MA48401Z01-FGFB112/122500003 and drill to a diameter of 0.158 in. (Dia. 4 mm) DETAIL A Shim 0.06 in. (1.5 mm) Plug FGFB112/122500008 Item 17-18 Tool MA48401Z01- FGFB112/122500003 Cup assembly Plug Cup assembly .03 in. 0.8 mm This document is the intellectual property of DASSAULT AVIATION. It may not be used, reproduced, modified or disclosed without its authorization. DASSAULT AVIATION Proprietary Data. ### Page 37 PAGE 26/49 ASSEMBLING THE DRY BAY Remove, deburr and reinstall the assembly MEASUREMENT OF FRAME CLEARANCES BETWEEN RIB 4 / RIB 5 AND BETWEEN THE CUP AND THE UPPER WING SURFACE Areas to check: Half frame Item 1-2 and rib 5 Half frame Item 3-4 and rib 4 Half frame Item 1-2 and Item 3-4 and the upper wing surface Cup assembly Item 7-8 and Item 9-10 with the stiffener of the lower wing surface Plug Item 17-18 with the stiffener of the lower wing surface Remove, clean and deburr the assembly Put protections on the areas to be liquid shimmed: red adhesive tape reference CFR AVF HP or teflon tape Sand the areas to be liquid shimmed Clean with authorized solvent Spread filling compound (See Standard Practices 20-320) Revision 2 February 15, 2010 RIB 4 HALF FRAME Item 3-4 FGFB112500012W1 / FGFB122500012W1 RIB 5 UPPER WING SURFACE STIFFENER LOWER WING SURFACE Measure and inject filler if =>0.002 in. ( 0.05 mm ) 0.05 mm < Clearance DRY BAY APPENDIX-1 NOTE 1: Do not work on wing while liquid shim is drying. NOTE 2: Apply Filleralu at the end of the day so that it can dry during the night This document is the intellectual property of DASSAULT AVIATION. It may not be used, reproduced, modified or disclosed without its authorization. DASSAULT AVIATION Proprietary Data. ### Page 38 PAGE 27/49 ASSEMBLING THE DRY BAY Drill links half frame/cup assembly to final hole size Disassemble, clean and deburr the assembly See page 48 for boring tolerances Revision 2 February 15, 2010 13 x hole drilled to dia.5H9 7 x hole drilled to dia.5U9 16 x holes drilled to dia.5U9 + countersink 1 x hole drilled to dia.4U9 + countersink 8 x hole drilled to dia.4.4 U9Rib 5 Rib 4 Rib 5 Lower surface panel DRY BAY APPENDIX-1 This document is the intellectual property of DASSAULT AVIATION. It may not be used, reproduced, modified or disclosed without its authorization. DASSAULT AVIATION Proprietary Data. ### Page 39 PAGE 28/49 Revision 2 February 15, 2010 DETAIL OF RIB 5 SPLICE RIB 5 DRY BAY FRAME RIB 5 REINFORCEMENT CORDON DE PR A REALISER PAR L’INTERMEDIAIRE DE 2 + 2 TROUS Ø2,3mm D'INJECTION DRILLING THE PR INJECTION HOLES IN LOWER AND UPPER SURFACES AT RIB 5 DETAIL OF RIB 5 SPLICE SEALANT BEAD TO REALIZE WITH 2 + 2 INJECTION HOLES DIA. 0.09 in. (2,3mm) DRY BAY APPENDIX-1 This document is the intellectual property of DASSAULT AVIATION. It may not be used, reproduced, modified or disclosed without its authorization. DASSAULT AVIATION Proprietary Data. ### Page 40 PAGE 29/49 Record the dimensions between the attachments of rib 5 reinforcement and the edge of rib 5 reinforcement baseplate (.35 in. 9mm PM) Draw the edge of rib 5 reinforcement baseplate on the skin Draw the middle line at .79 in. (20 mm) from the edge of rib 5 reinforcement baseplate (This line represents the interface between rib 5 and rib 5 reinforcement) Locate the drilling positions with the attachment marks DO NOT DRILL IF A CENTER-TO-CENTER DISTANCE OF .55 in, MIN (14 MM MIN.) CANNOT BE OBTAINED February 15, 2010 Mark the center point of each drilling position at the interface between rib 5 reinforcement and rib 5; check that this point is located at 0.55 in. MIN (14 mm mini) from each attachment Revision 2 1 2 4 3 1 2 3 4 LOWER SURFACE BOTTOM VIEW L/H POSITIONING OF LOWER SURFACE HOLES DRILLED FOR PR INJECTION EDGE OF RIB 5 REINFORCEMENT BASEPLATE 2 DIA. 0.09 in. (Ø 2.3 mm) holes drilled for interlaying sealantFWD MIDDLE LINE REAR SPAR RIB 5 A/C CENTERLINE UPPER SURFACE PANELthick,ness 0.16 in. (4 mm) LOWER SURFACE PANEL thickness 0,20 in. (5 mm) SECTION A-A Be very careful when drilling here DRY BAY APPENDIX-1 Ø 0,09 in. ( Ø 2.3) 1784 1785 1786 1787 1788 1789 1799 1792 1793 1794 1795 1796 1797 1798 .79 in. 20 mm .35 in. 9 mm NOTE .55 in. MIN 14 mm MINI This document is the intellectual property of DASSAULT AVIATION. It may not be used, reproduced, modified or disclosed without its authorization. DASSAULT AVIATION Proprietary Data. ### Page 41 PAGE 30/49 Record the dimensions between the attachments of rib 5 reinforcement and the edge of rib 5 reinforcement baseplate (.35 in. 9 mm for ref.) Draw the edge of rib 5 reinforcement baseplate on the skin Draw the middle line at .79 in. (20 mm) from the edge of rib 5 reinforcement baseplate (This line represents the interface between rib 5 and rib 5 reinforcement) Locate the drilling positions with the attachment marks DO NOT DRILL IF A CENTER-TO-CENTER DISTANCE OF 14 MM MIN. CANNOT BE OBTAINED February 15, 2010 Mark the center point of each drilling position at the interface between rib 5 reinforcement and rib 5; check that this point is located at 0.55 in. MIN (14 mm mini) from each attachment Revision 2 1 2 4 3 1 2 3 4 UPPER SURFACE TOP VIEW L/H POSITIONING OF UPPER SURFACE HOLES DRILLED FOR PR INJECTION EDGE OF RIB 5 REINFORCEMENT BASEPLATE 2 x Ø .09 in.(Ø 2.3 mm) holes drilled for interlaying sealant FWD MIDDLE LINE REAR SPAR RIB 5 A/C CENTERLINE DRY BAY FRAME SECTION A-A Be very careful when drilling here DRY BAY APPENDIX-1 Ø 0,09 in. ( Ø 2.3) 1686 1687 1688 1689 1690 1692 1694 1696 1698 1691 1695 1697 1699 1693 .79 in. 20 mm .35 in. 9 mm LOWER SURFACE PANEL thickness 0,20 in. (5 mm) UPPER SURFACE PANELthick,ness 0.16 in. (4 mm) NOTE .55 in. MIN 14 mm MINI This document is the intellectual property of DASSAULT AVIATION. It may not be used, reproduced, modified or disclosed without its authorization. DASSAULT AVIATION Proprietary Data. ### Page 42 PAGE 31/49 1) Punch the 2 holes in the skin: depth = .02 in. MAX ( 0.5 mm MAX). Ask a checker to check for a margin of .55 in. MIN (14 mm MIN.) between the 2 punch marks and the surrounding attachment fittings 2) Pre-drill the PR injection holes at Ø .079 in. ( 2 mm) Before drilling, check that the flat-tip drill bit diameter is .09 in. (2.3 mm) and the adjustment of the drill bit stop height (equal to the skin thickness) Fill the table 2 in ANNEXE 4 3) Drill to final diameter with drill bit Ø .09 in. (Ø2.3 mm). Revision 2 February 15, 2010 Fill the table 1 in ANNEXE 4 Before pre-drilling, ask an inspector to check that the drill bit has a diameter of .079 in. (2 mm) and check the adjustment of the drill bit stop (equal to the skin thickness) DRILLING THE PR INJECTION HOLES DRY BAY APPENDIX-1 NOTE: Lower skin .20 in. (5 mm) stop depth Upper skin .16 in. (4 mm) stop depth This document is the intellectual property of DASSAULT AVIATION. It may not be used, reproduced, modified or disclosed without its authorization. DASSAULT AVIATION Proprietary Data. ### Page 43 PAGE 32/49 INJECTING SEALANT INTO LOWER AND UPPER PANEL AND INTO RIB 5 PRIOR TO PR INJECTION 1) Clean the dia. 0.09 in.bore (Ø2.3 mm) on lower and upper panel 2) Inject authorized solvent (with a spout type container) in each doubler hole to clean the interface (doubler / rib 5) ) Revision 2 February 15, 2010 DRY BAY APPENDIX-1 FIRST CLEAN AND DEGREASE CAREFULLY THE ASSEMBLY AREA CAUTION : PRIOR TO STARTING SEALANT APPLICATION, ALL DRILLINGS MUST HAVE BEEN PERFORMED, TO AVOID POLLUTING FRESH SEALANT WITH METAL SHAVINGS This document is the intellectual property of DASSAULT AVIATION. It may not be used, reproduced, modified or disclosed without its authorization. DASSAULT AVIATION Proprietary Data. ### Page 44 PAGE 33/49 RIB 5/DOUBLER INJECTION AND SEALANT RIB 5 DOUBLER INJECTION SEALANT 1) Sealant injection ((with a 1015 PSI (70 bars) extrusion gun fitted with a stiff end-piece)) in the doubler holes from rib 5 Revision 2 February 15, 2010 DRY BAY APPENDIX-1 - insert 2 x 2 item A screws - inject PR into item A holes until it flows out of item B holes - remove screws from item A holes and fit them into item B holes - inject PR into item B holes until it flows out of item C holes - remove screws from item B holes and fit them into item C holes - inject PR into item C holes - do the same for item D holes A B B C C D DETAIL INJECTION SCREW Drainage hole Injection hole PR injection gun MA29501Z00-1 or equivalent (see Appendix 5 page 6) Fit a stiff end-piece INJECTION SCREW Holes to be injected with interlaying sealant This document is the intellectual property of DASSAULT AVIATION. It may not be used, reproduced, modified or disclosed without its authorization. DASSAULT AVIATION Proprietary Data. ### Page 45 PAGE 34/49 INJECTING SEALANT INTO LOWER AND UPPER PANEL AND ON RIB 5 2) Set each doubler hole on rib 5 with clecos 3) Remove the excess sealant, then smooth it Revision 2 February 15, 2010 DRY BAY APPENDIX-1 Set each doubler hole with clecos Rib 5 doubler RIB 5 To rib 6 RIB 5 To RIB 4 REAR SPAR Remove the excess sealant, then smooth it This document is the intellectual property of DASSAULT AVIATION. It may not be used, reproduced, modified or disclosed without its authorization. DASSAULT AVIATION Proprietary Data. ### Page 46 PAGE 35/49 INJECTING SEALANT INTO LOWER AND UPPER PANEL AND ON RIB 5 1) Sealant injection => 1st time inject the sealant in the hole located next to the rear spar, then to the front spar Revision 2 February 15, 2010 CT Visual control of sealant application DRY BAY APPENDIX-1 TOWARD WING ROOT LOWER WING SURFACE Thickness=5 Rear spar of lower upper wing surface Sealant injection holes RIB 5 Rib 5 doubler 1st injection hole 2nd injection hole RIB 5 1st injection hole 2nd injection hole RIB 5 UPPER WING SURFACE Rear spar of upper wing surface TOWARD WING ROOT LOWER WING SURFACE Thickness=4 UPPER WING SURFACE Material: 2024 T351 Protection: OAC Installed with PR .008 in. (0.2 mm) CHAMFER AT 45° Theoretical thickness. -.004 in. , - .0078 in. (- 0.1 , -0.2) PIN DETAIL GRIP LENGTH: .4 µ in. to .78µ in. (10 µ to 20 µ) 2) Check for sealant flow at FWD/AFT end of upper/lower channels 3) Blank each injection hole with studs and fresh PR at a grip length of .4 µ in. to .78µ in. (10 µ to 20 µ) This document is the intellectual property of DASSAULT AVIATION. It may not be used, reproduced, modified or disclosed without its authorization. DASSAULT AVIATION Proprietary Data. ### Page 47 PAGE 36/49 INSTALLATION OF DRY BAY STRUCTURE Before tightening, apply interlaying sealant to the underside of the screw heads. February 15, 2010 - Final assembly of the lower and upper surface bent sections Item 13-14 and 15-16 of rib 5 foot with sealant (See Standard Practices 20-650) Revision 2 DRY BAY APPENDIX-1 1 x screw Item 39 38472TX060012XF 1 x nut Item 38 6RH8035M Upper surface angle Item 13-14 FGFB11250006/ FGFB122500006 Lower surface angle Item 15- 16 FGFB11250007/ FGFB122500007 Rib 5 2 x screw Item 31 22201TX050011XF 2 x nut Item 32 5RH8035MRear spar 1 x screw Item 40 38472TX060009XF 1 x nut Item 38 6RH8035M 1 x screw Item 44 Item38472TX050012XF 1 x nut Item 32 5RH8035M 1 x screw Item 40 38472TX060009XF 1 x nut Item 38 6RH8035M Attachment direction Attachment direction Attachment direction Attachment direction This document is the intellectual property of DASSAULT AVIATION. It may not be used, reproduced, modified or disclosed without its authorization. DASSAULT AVIATION Proprietary Data. ### Page 48 PAGE 37/49 INSTALLATION OF DRY BAY STRUCTURE ASSEMBLING ANGLE BACKET WITH RIB 5 Intall rivets 21215DE4009 (item 57) Installation of angle bracket (Item 25) + shim (Item 24) with interlaying sealant (See APPENDIX 2) Cleco shim (item 24)+ angle bracket (item 25) and reinforcement with interlay of sealant Installation of 3 screws 38471BE044006ME (Item 50) for attachment of angle bracket / reinforcement / rib 5 Installation of 2 screws 38471BE044005ME (item 51) for attachment of reinforcement / rib 5 Installation of 5 rivets 21215DE4011 (item 53) Installation of 2 screws 38460BE044006ME (Item 49) for attachment of bracket / reinforcement / rib 5 Installation of 2 screws 38460BE044005ME (item 52) for attachment of reinforcement / rib 5 Screws are installed with 4RH8035M nuts (item 35) Revision 2 February 15, 2010 Angle bracket Item 25 FGFB113005041 Rib 5 Shim -Item 24 FGFB113005042 Rib 5 reinforcement ATTACHMENT DIRECTION DRY BAY APPENDIX-1 REAR SPAR Install rivets Item 57 This document is the intellectual property of DASSAULT AVIATION. It may not be used, reproduced, modified or disclosed without its authorization. DASSAULT AVIATION Proprietary Data. ### Page 49 PAGE 38/49 INSTALLATION OF DRY BAY STRUCTURE INSTALLATION OF DRAIN PROVISION Install angle (item 61-62) and the shim (if you have used tool ME48401Z01-SBF2000-358 ) with rivet 21215DE32 and interlaying sealant, Revision 2 February 15, 2010 Rib 4 21215DE3208 Item 55 Item 61-62 Insert shim if necessary DRY BAY APPENDIX-1 This document is the intellectual property of DASSAULT AVIATION. It may not be used, reproduced, modified or disclosed without its authorization. DASSAULT AVIATION Proprietary Data. ### Page 50 PAGE 39/41 INSTALLATION OF DRY BAY STRUCTURE Assemble all parts with interlaying sealant see Appendix 2 - Final installation of the cup assembly and plug on the lower surface panel stiffener Revision 2 February 15, 2010 Lower surface panel Rib 4 Rib 5 Cup assembly 11 x screw Item 36 22201TX050008XF 11 x nut Item 32 5RH8035M 2 x screw Item 33 22201TX050010XF 2 x nut Item 32 5RH8035M Attachment direction Plug Item 17-78 FGFB112500008 FGFB122500008 DRY BAY APPENDIX-1 NOTE: For easier access, screws item 33 and 36 can be installed in the reverse direction. This document is the intellectual property of DASSAULT AVIATION. It may not be used, reproduced, modified or disclosed without its authorization. DASSAULT AVIATION Proprietary Data. ### Page 51 PAGE 40/49 INSTALLATION OF DRY BAY STRUCTURE Filling the recess with bead sealant Revision 2 February 15, 2010 DRY ZONE Rib 4 Fill the recess with bead sealant DO NOT BLANK OFF THE DRAINING HOLE Fill the 2 holes with bead sealant Do not fill the anchor nuts Basic sealing methods See Standard Practices 20-650 DRY BAY APPENDIX-1 INTERLAYING SEALANT COVERING SEALANT BEAD SEALANT REAR SPAR This document is the intellectual property of DASSAULT AVIATION. It may not be used, reproduced, modified or disclosed without its authorization. DASSAULT AVIATION Proprietary Data. ### Page 52 PAGE 41/49 INSTALLATION OF DRY BAY STRUCTURE Revision 2 February 15, 2010 DRY BAY APPENDIX-1 Apply sealant strips (See Appendix 2 page5: Sealant application for strips definition) Apply a coat of covering sealant in dry bay Sealant strips This document is the intellectual property of DASSAULT AVIATION. It may not be used, reproduced, modified or disclosed without its authorization. DASSAULT AVIATION Proprietary Data. ### Page 53 PAGE 42/49 INSTALLATION OF DRY BAY STRUCTURE Assembling all parts with interlaying sealant: see Appendix 2 - Final assembly of the half-frames Revision 2 February 15, 2010 1 x screw Item 42 38471BE040008ME 1 x nut Item 35 4RH8035M Detail 1 Detail 1 Shim Item 19-20 FGFB112500016/ FGFB122500016 Attachment direction 15 x screw Item 41 22258TX050008XF 15 x nut Item 32 5RH8035M1 x Screw Item 43 22258TX050010XF 1 x nut Item 32 5RH8035M DRY BAY APPENDIX-1 This document is the intellectual property of DASSAULT AVIATION. It may not be used, reproduced, modified or disclosed without its authorization. DASSAULT AVIATION Proprietary Data. ### Page 54 PAGE 43/49 INSTALLATION OF DRY BAY STRUCTURE - Final installation of the half-frames Final assembly check Revision 2 February 15, 2010 Rib 4 Rib 5 Half-frame Item 3-4 FGFB112500012W1/ FGFB122500012W1 Shim Item 23 FGFB112500015 7 x screw 22201TX050007XF 7 x nut 5RH8035M 8 x screw Item 49 38460BE044006ME + 8 x nut Item 35 4RH8035M Attachment direction Attachment direction Attachment direction CT Half-frame Item 1-2 FGFB112500011W1P01 / FGFB122500011W1P01 DRY BAY APPENDIX-1 This document is the intellectual property of DASSAULT AVIATION. It may not be used, reproduced, modified or disclosed without its authorization. DASSAULT AVIATION Proprietary Data. ### Page 55 PAGE 44/49 INSTALLATION OF DRY BAY STRUCTURE Revision 2 February 15, 2010 DRY BAY APPENDIX-1 Make all sealant beads as per Appendix 2: Sealant application, Once all sealant beads are dry, apply a coat of covering sealant in the dry bay, on Rib 5 and on sealant strips Rib 5 Covering sealant on Rib 5 Covering sealant on sealant strips This document is the intellectual property of DASSAULT AVIATION. It may not be used, reproduced, modified or disclosed without its authorization. DASSAULT AVIATION Proprietary Data. ### Page 56 PAGE 45/49 INSTALLATION OF DRY BAY STRUCTURE After sealing of dry bay box structure with sealant as per APPENDIX 2 Check for cleanliness of dry bay box structure before closing Install door with interlaying sealant Sealing finish with sealant on door as per APPENDIX 2 Revision 2 February 15, 2010 CT Rib 5 Rib 4 Lower surface panel Door Item 5-6 FGFB112500002/ FGFB122500002 Rear spar 25 x screw Item 45 22201TX050007XF 25 x washer Item 46 23111DG050A 14 x screw Item 33 22201TX050010XF 14 x washer Item 46 23111DG050A FUEL ZONE DRY ZONE Rib 5 Rib 4 DRY BAY APPENDIX-1 This document is the intellectual property of DASSAULT AVIATION. It may not be used, reproduced, modified or disclosed without its authorization. DASSAULT AVIATION Proprietary Data. ### Page 57 PAGE 46/49 IDENTIFICATION OF SERVICE BULLETIN 1) In the landing gear compartment, clean and degrease the area above the wing identification plate (2) Write the number of this Service Bulletin on the “SERVICE BULLETIN COMPLIANCE” labels and bond them with PR to each wing, above the identification plate. Revision 2 February 15, 2010 DRY BAY APPENDIX-1 Identification plate, Intall this plate once the leak check has been succesfully completed NOTE: For FALCON 2000, 2000EX and 2000DX aircraft (refer to SB F2000-358 Page 5 or SB F2000EX-171 Page 5) ), replace the fuel door placard. The placards on the wing upper surface must be replaced with the "New Fuel Quantity" placards. For FALCON 50 aircraft (refer to SB F50-496 Page 5), replace the fuel door placard. The placards on the wing upper surface must be replaced with the new ones (No Fuel Quantity). For some FALCON 900 aircraft (refer to SB F900-388 Page 5), the placards on the wing upper surface must be replaced with the new ones (No Fuel Quantity). This document is the intellectual property of DASSAULT AVIATION. It may not be used, reproduced, modified or disclosed without its authorization. DASSAULT AVIATION Proprietary Data. ### Page 58 PAGE 47/49 Revision 2 February 15, 2010 0.39 in. 10 mm Frame machining allowed in order to increase the gap between the fasteners rib 5 / wing upper panel and the frame + alodine protection, PPR + PAC + finishing paint Spot facing Ø12-R2 allowed if required + alodine protection, PPR + PAC DRY BAY APPENDIX-1 This document is the intellectual property of DASSAULT AVIATION. It may not be used, reproduced, modified or disclosed without its authorization. DASSAULT AVIATION Proprietary Data. ### Page 59 PAGE 48/49 Check the tightening torque and re-tightening torque of fasteners Check that all screws and MGPL (nuts, bushes) are properly installed, heads flush 8 141.6 0.2 0.35 0.75 1.2 1.6 17.7 31 66.4 SCREW 0.236 0.276 106.2 0.315SCREW SCREW SCREW SCREW 0.158 0.205 4 5 6 7 Ø inch Ø mm Torque lfb.in. Torque mdaN Revision 2 February 15, 2010 TIGHTENING TORQUE METRIC FASTENER (as per STD 30908) CT Dia. 4U9 (-23µ , -53µ) Dia. 0.158 in. (-0.9 µin.; -2.1 µin.) Dia. 4,4U9 (-23µ , -53µ) Dia. 0.173 in. (-0.9 µin.; -2.1 µin.) Dia. 5U9 (-23µ , -53µ) Dia. 0.197 in. (-0.9 µin. - 2.1 µin) Dia. 6.2 D10 ( +40  Dia. 0,244 in. (+1.5 µin. +3.9 µin.) ’LD’   Dia. 0.205 in. (+1.2 µin. +3.1 µin.) Dia. 5.2 H9 ( +0  Dia. 0,205 in. (+0 µin. +1.8 µin.) ’LD+   Dia. 0,197 in. (+0 µin. +1.8 µin.) BORING TOLERANCES DRY BAY APPENDIX-1 This document is the intellectual property of DASSAULT AVIATION. It may not be used, reproduced, modified or disclosed without its authorization. DASSAULT AVIATION Proprietary Data. ### Page 60 PAGE 49/49 FINAL STEPS F50 F900 F900EX F2000 F2000EX 57-400 57-011 57-011 57-011 57-011 27-811 27-811 27-811 27-811 27-811 Paint the pickling area in accordance with the paint scheme used for the exterior of the aircraft. Revision 2 February 15, 2010 Install the flap actuator, (L25CF/R25CF) see procedure 27-568 27-521 27-510 27-510 27-510 Retract the flaps, see procedure Install the wing’s structural fuel tank removable panel, see procedure See DRY BAY APPENDIX-3 HYDROGEN PRESSURE TEST FOR DRY BAY DRY BAY APPENDIX-1 This document is the intellectual property of DASSAULT AVIATION. It may not be used, reproduced, modified or disclosed without its authorization. DASSAULT AVIATION Proprietary Data. 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