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FALCON 2000EX FALCON 2000EX EASy FALCON 2000LX FALCON 2000LXS FALCON 2000DX FALCON 2000S No 384-R1 MARCH 01, 2016
MANDATORY ATA 30-11
ICE AND RAIN PROTECTION
INSPECTION OF THE ANTI-ICE TUBE ASSEMBLY
FALCON SERVICE BULLETIN Copyright © 2016 by Dassault Aviation All rights reserved. No part of this work may be reproduced or copied in any form or by any means without written permission of Dassault Aviation.
ICE AND RAIN PROTECTION
INSPECTION OF THE ANTI-ICE TUBE ASSEMBLY Initial issuance January 27, 2016 List of effective pages :
1 to 19 Revision 1 March 01, 2016 List of effective pages :
1 to 19 List of modified pages :
6, 8, 12 and 18 REASON:Incorporation of a local procurement plastic tubing to perform the cleaning of the piccolo tube instead of the tubing provided through the tool kit.
The tubing from the tool kit was too stiff which made its insertion in the anti-ice tube assembly too difficult.
Incorporation of information to make sure that the NO-GO gauge is long enough before checking the anti-ice tube assembly inside diameter.
This revision is not applicable to aircraft already modified per the initial issuance of this Service Bulletin.
FALCON 2000EX F2000EX -384 F2000EX -30-11
ICE AND RAIN PROTECTION
INSPECTION OF THE ANTI-ICE TUBE ASSEMBLY
1. PLANNING INFORMATION A. EFFECTIVITY This Service Bulletin is applicable to:
• F2000EX aircraft with serial numbers 1 through 600 (F2000EX, F2000EX EASy, F2000LX, F2000LXS),
• F2000EX aircraft with serial numbers 601 through 604 (F2000DX),
• F2000EX aircraft with serial numbers 701 and subsequent (F2000S), equipped with Air Intake Assembly P/N 06ND71600-1.
B. REASON A quality review has revealed manufacturing deviations affecting the Engine air inlet “piccolo” tubes installed on FALCON 2000EX.
These deviations can possibly reduce the performance of the engine inlet anti-ice protection system.
The purpose of this Service Bulletin is to inspect the anti-ice tubes and modify them if necessary.
C. DESCRIPTION This Service Bulletin gives instructions to inspect the anti-ice “piccolo” tube assembly and to address the following two cases:
• the opening diameter of the anti-ice tube assembly is smaller than expected - instructions are given to ream and increase the inside diameter of the anti-ice tube assembly to restore the inlet anti-icing performance,
• perforation holes blocked by manufacturing residues - specific instructions to be provided by Dassault Aviation.
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 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.
FALCON 2000EX F2000EX -384 March 01, 2016 F2000EX -30-11 Revision 1 Page 1 / 19 DASSAULT AVIATION Proprietary Data
G. MATERIAL - PRICE AND AVAILABILITY The modification kit may be obtained from either address listed below:
Western hemisphere: DASSAULT FALCON JET CORP.
SPARES DISTRIBUTION CENTER 200 RISER ROAD LITTLE FERRY, NJ 07643 U.S.A.
Telephone:
• CANADA and U.S.A.: 1-800-800-4036
• MEXICO: 001-800-800-4036
• Other countries: 1-201-541-4809 Fax:
• CANADA and U.S.A.: 1-800-800-4817
• MEXICO: 001-800-800-4817
• Other countries: 1-201-440-7021 Other continents: DASSAULT AVIATION Falcon Spares BOITE POSTALE N°101
AEROPORT DU BOURGET 93350 - LE BOURGET Cedex (FRANCE) Please contact your Dassault Aviation Account Representative Telephone: 33 (0)1.48.35.56.78 Fax: 33 (0)1.48.35.56.00 E/H dafsorder@dassault-aviation.com Price and availability on request.
H. TOOLING - PRICE AND AVAILABILITY
• Modification kits 06ND71603-TOOLKIT and SBF2000X0384A.
• Normal maintenance tooling.
• Flexible borescope - 90˚ Field Of View (FOV) and straight FOV capable, photo capable, between
1.5 m (5 ft) and 3 m (10 ft) cable length, 4 mm (0.157 in) to 6 mm (0.236 in) cable diameter.
• Shop Vacuum.
• Shop air nozzle.
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) FALCON 2000EX F2000EX -384 March 01, 2016 F2000EX -30-11 Revision 1 Page 2 / 19 DASSAULT AVIATION Proprietary Data
• OPERATIONAL TEST OF THE ENGINE AIR INTAKE ANTI-ICING SYSTEM (Refer to TASK 30-20-00-710-801)
• REMOVAL / INSTALLATION OF THE AIR INTAKE ANTI-ICING UPPER DUCT (Refer to TASK 30-20-17-900-801)
• REMOVAL / INSTALLATION OF THE ENGINE UPPER COWLINGS (Refer to TASK 54-11-01-900-801)
• REMOVAL / INSTALLATION OF THE ENGINE LOWER COWLINGS (Refer to TASK 54-11-05-900-801)
• REMOVAL / INSTALLATION OF THE ENGINE UPPER COWLING TIE-RODS (Refer to TASK 54-11-11-900-802) K. OTHER PUBLICATIONS AFFECTED None.
FALCON 2000EX F2000EX -384 March 01, 2016 F2000EX -30-11 Revision 1 Page 3 / 19 DASSAULT AVIATION Proprietary Data
2. ACCOMPLISHMENT INSTRUCTIONS A. INSPECT THE DATAPLATES
(1) The aircraft must be in the maintenance configuration (Refer to TASK 20-00-00-910-801).
(2) Open the lower engine cowls.
(3) Examine the dataplates on the LH and RH air intake assemblies:
(a) If NTR-RKFAL97 or NTR-RKFAL98 is marked on the dataplate, got to step 2.J. and close the lower engine cowls.
(b) If the serial number of the air intake assembly is listed below, perfom the following steps:
600-1-0025A 600-1-0027A 600-1-0033A 600-1-0034A 600-1-0064 600-1-0083A 600-1-0084A 600-1-0095A 600-1-0096A 600-1-0100A 600-1-0102A 600-1-0160A 600-1-0164A 600-1-0187A 600-1-0223 600-1-0234A 600-1-0265A 600-1-0266A 600-1-0269A 600-1-0271A 600-1-0296A 600-1-0308A 600-1-0309A 600-1-0312A 600-1-0331 600-1-0355A 600-1-0358A 600-1-0373 600-1-0374 600-1-0376A 600-1-0384A 600-1-0393A 600-1-0437A 600-1-0439A 600-1-0440A 71600-21T 71600-7TA 71600-8TA 71600-T4 1 Vibro-etch this Service Bulletin number on the dataplate of the air intake assembly.
2 Go to paragraph 2.J. and close the lower engine cowls.
(c) If NTR-RKFAL97 or NTR-RKFAL98 is not marked on the dataplate, and if the serial number is not listed in step 2.A.(3)(b), then go to paragraph 2.B. and following paragraphs.
FALCON 2000EX F2000EX -384 March 01, 2016 F2000EX -30-11 Revision 1 Page 4 / 19 DASSAULT AVIATION Proprietary Data
B. PRELIMINARY STEPS Refer to fig. 1
(1) Remove the upper engine cowl (Refer to TASK 54-11-01-900-801).
(2) Remove the air intake access panels ( 412AL)/(412AR).
(3) Remove the air intake anti-icing upper duct (Refer to TASK 30-20-17-900-801).
NOTE: Discard seals at each end of the duct (P/N AS1895/7-100 and P/N 13405-100).
(4) Remove the lockwire (2).
(5) Remove the four bolts (3) and washers (4) from the aft bulkhead.
(6) Remove the screw (11) and washer (12) from the clamp (13) on the anti-ice tube (5).
CAUTION: THE ANTI-ICE TUBE IS ATTACHED TO THE BULKHEAD WITH SEALANT. USE CARE WHEN REMOVING THE ANTI-ICE TUBE.
(7) Move the anti-ice tube (5) aft until it is removed from the air intake assembly.
(8) Remove the insulation (10) from the anti-ice tube as it is removed from the air intake assembly.
NOTE: If it is difficult to remove the insulation, clip the Panduit straps (1) necessary to remove the insulation.
(9) Place a protective covering over the cavity of the inlet to prevent tools and other items from falling into the inlet.
C. INSPECT THE ANTI-ICE TUBE ASSEMBLY OPENING INSIDE DIAMETER Refer to fig. 2 and fig. 5
(1) Check the inside diameter of the anti-ice tube assembly (6) opening with the GO/NO-GO gauge (P/N 06ND71603-TOOLKIT-01) (View B-fig. 2).
NOTE 1: The GO (green) diameter is 0.840 in. (21.34 mm) and the NO-GO (red) diameter is
0.900 in. (22.86 mm).
NOTE 2: When the GO end of the GO/NO-GO gauge fits in the anti-ice tube assembly, the edge of the bulkhead bracket must be within the two the scribed lines.
FALCON 2000EX F2000EX -384 March 01, 2016 F2000EX -30-11 Revision 1 Page 5 / 19 DASSAULT AVIATION Proprietary Data
NOTE: Record the inspection results on the Inspection Report (fig. 5).
(2) If the NO-GO end of the gauge fits in the anti-ice tube assembly (6) inside diameter, the inside diameter is too large and not acceptable. Contact Dassault Aviation at structure-repair@dassaultaviation.com (Europe, Middle East, Middle Asia, Africa) or structures@falconjet.com (North, South America, Pacific Rim) and provide the information for further instructions.
NOTE: : 1.5 in (38 mm) of the NO-GO gauge should be exposed. The length of the NO-GO gauge can be adjusted by loosening and tightening the red nut.
(3) If the GO end of the gauge fits in the anti-ice tube assembly (6) inside diameter, and the NO-GO end does not, the inside diameter is acceptable. Go to the 2.D. procedure.
(4) If the GO end of the gauge does not fit in the anti-ice tube assembly (6) inside diameter, the inside diameter is too small. Go to the 2.D. procedure.
D. INSPECT THE ANTI-ICE TUBE ASSEMBLY PERFORATION HOLES Refer to fig. 3, fig. 4 and fig. 5 NOTE: The full circumference of the anti-ice tube is approximately 3 m (10 ft).
(1) Inspect the full circumference of the anti-ice tube assembly (6) with a 90° FOV borescope.
FALCON 2000EX F2000EX -384 March 01, 2016 F2000EX -30-11 Revision 1 Page 6 / 19 DASSAULT AVIATION Proprietary Data
(2) Examine each perforation hole for caps and/or Foreign Object Debris (FOD) ( fig. 3).
(3) If two or more adjacent perforation holes have caps and/or FOD that are not acceptable ( fig. 4):
(a) Mark where the blockage is found on the Inspection Report ( fig. 5).
NOTE: Mark the distance on the borescope cable to use as an estimate of where the blockage is found.
(b) Take photographs of the perforation holes that are not acceptable.
NOTE: Acceptable limits are shown in fig. 4.
(c) Contact Dassault Aviation at structure-repair@dassault-aviation.com (Europe, Middle East, Middle Asia, Africa) or structures@falconjet.com (North, South America, Pacific Rim) and provide the information for further instructions.
(4) If perforation holes are confirmed acceptable and the opening inside diameter is too small, go to the 2.E. procedure.
(5) If perforation holes are confirmed acceptable and the opening inside diameter is confirmed acceptable, but a burr is found in the opening, go to step 2.E.(9) to remove the burr.
(6) If perforation holes are confirmed acceptable and the opening inside diameter is confirmed acceptable, go to the 2.G. procedure.
E. REAM THE ANTI-ICE TUBE ASSEMBLY Refer to fig. 2 and fig. 7
(1) Remove the lockwire (7) from the four bolts (8) on the forward bulkhead (View A-A-fig. 2).
(2) Remove the two bolts (8) and washers (9) from the forward bulkhead (View A-A-fig. 2).
(3) Install the drill block (P/N 06ND71603-TOOLKIT-02) with bolts ( fig. 7).
NOTE: Install the drill block so that the arrow points up.
(4) Torque the bolts from 2.0 to 2.3 Nm (18 to 20 lb.in).
(5) Determine the carbide reamer:
(a) Insert the 0.7500 in. (19.05 mm) drill guide tube (P/N 06ND71603-TOOLKIT-03) into the drill block (P/N 06ND71603-TOOLKIT-02) and twist into a locked position.
(b) Insert the 0.7500 in. (19.05 mm) carbide reamer (P/N 06ND71603-TOOLKIT-09) through the drill guide tube (P/N 06ND71603-TOOLKIT-03) and into the opening of the anti-ice tube assembly (6).
(c) If the carbide reamer fits in the opening of the anti-ice tube assembly (6) without resistance, then repeat the process using the next larger carbide reamer and matching drill guide tube.
(d) If the carbide reamer does not fit in the opening of the anti-ice tube assembly (6), then it is the correct carbide reamer to be used first for increasing the inside diameter.
(e) Go to the next step 2.E.(6).
(6) Ream the inside diameter of the anti-ice tube assembly.
NOTE 1: Lubricate the reamer with a small amount of cutting oil.
NOTE 2: Do not torque the reaming bit to more than 13.6 Nm (120 lb in).
FALCON 2000EX F2000EX -384 March 01, 2016 F2000EX -30-11 Revision 1 Page 7 / 19 DASSAULT AVIATION Proprietary Data
(a) Use the carbide reamer and matching drill guide tube to ream the inside diameter of the antiice tube assembly (6).
(b) Remove the carbide reamer and drill guide tube.
(c) Repeat the process with increasing carbide reamer and drill guide tube sizes until the largest carbide reamer has been used.
NOTE: Do not skip reamer sizes.
(7) Remove the carbide reamer.
(8) Remove the drill guide tube.
(9) Remove the drill block.
CAUTION: USE THE PENCIL GRINDER AND CARBIDE BITS ONLY TO REMOVE BURRS. BE
CAREFUL NOT TO INCREASE THE INSIDE DIAMETER OF THE ANTI-ICE TUBE OPENING. CONTACT DASSAULT AVIATION AT STRUCTURE- REPAIR@DASSAULT-AVIATION.COM (EUROPE, MIDDLE EAST, MIDDLE ASIA, AFRICA) OR STRUCTURES@FALCONJET.COM (NORTH, SOUTH AMERICA, PACIFIC RIM) IF THE INSIDE DIAMETER IS INCREASED.
(10) Use the pencil grinder (P/N CP9104Q) and carbide bits (P/N 85284149, 85284461) to remove burrs from the opening inside diameter of the anti-ice tube assembly (6).
(11) Check the inside diameter of the anti-ice tube assembly (6) with the GO/NO-GO gauge (P/N 06ND71603-TOOLKIT-01).
NOTE: The GO diameter is 0.840 in. (21.34 mm) and the GO/NO-GO diameter is 0.900 in.
(22.86 mm).
(12) If the NO-GO end of the gauge fits in the anti-ice tube assembly (6) opening, the inner diameter is too large and not acceptable. Contact Dassault Aviation at structure-repair@dassaultaviation.com (Europe, Middle East, Middle Asia, Africa) or structures@falconjet.com (North, South America, Pacific Rim) for further instructions.
(13) If the GO end of the gauge fits in the anti-ice tube assembly (6) opening, and the NO-GO end does not, go to the 2.F. procedure.
F. CLEANING Refer to fig. 6
(1) If FOD were found during borescope inspection, remove the FOD from the anti-ice tube assembly
(6).
(a) Insert one end of the plasting tubing (local procurement) through the vacuum hose adapter (PN 06ND71603-TOOLKIT-19).
(b) Insert the opposite end of the plastic tubing onto the end of the shop air nozzle.
(c) Tape the tubing to the shop air nozzle.
(d) Insert approximately 0.61 m (2 ft) of the tubing into the anti-ice tube assembly (6).
(e) Put the vacuum hose adapter (P/N 06ND71603-TOOLKIT-19) on the opening of the forward bulkhead of the air intake assembly.
(f) Attach a shop vacuum hose to the vacuum hose adapter (P/N 06ND71603-TOOLKIT-19).
FALCON 2000EX F2000EX -384 March 01, 2016 F2000EX -30-11 Revision 1 Page 8 / 19 DASSAULT AVIATION Proprietary Data
(g) Turn on both shop air and the shop vacuum for approximately 30 seconds.
(h) Remove the tubing and vacuum hose adapter.
(2) Insert a straight FOV borescope into the anti-ice tube assembly (6).
(3) Examine the anti-ice tube assembly (6) for FOD.
(a) If FOD is found, then do steps 2.F.(1) through 2.F.(3) again.
(b) If FOD is found after three cleaning attempts, then take a photograph of the FOD and contact Dassault Aviation at structure-repair@dassault-aviation.com (Europe, Middle East, Middle Asia, Africa) or structures@falconjet.com (North, South America, Pacific Rim) for further instructions.
(c) If FOD is not found, then go to the next step 2.F.(4).
(4) Inspect the full circumference of the anti-ice tube assembly (6) with a 90° FOV borescope.
(5) Examine each perforation hole for caps ( fig. 3).
(6) If two or more adjacent perforation holes have caps that are not acceptable ( fig. 3):
(a) Mark where the blockage is found on the Inspection Report ( fig. 5).
(b) Take photographs of the perforation holes that are not acceptable.
(c) Contact Dassault Aviation at structure-repair@dassault-aviation.com (Europe, Middle East, Middle Asia, Africa) or structures@falconjet.com (North, South America, Pacific Rim) and provide the information for further instructions.
(7) Install the two washers (9) and bolts (8).
(8) Torque the bolts (8) from 2.0 to 2.3 Nm (18 to 20 lb in).
(9) Install the lockwire (7).
(10) Apply torque stripe to the bolts (8).
(11) Go to the 2.G. procedure.
G. INSTALL THE ANTI-ICE TUBE Refer to fig. 1
(1) Use a plastic spatula to remove the remaining sealant from the aft bulkhead.
WARNING: SOLVENT IS CLASSIFIED AS A HAZARDOUS MATERIAL WHICH MAY CAUSE INJURY OR ILLNESS IF NOT PROPERLY USED. THIS PRODUCT SHOULD BE
USED ONLY IN ACCORDANCE WITH THE MANUFACTURER'S MATERIAL SAFETY DATA SHEET.
(2) Use a clean cloth moistened with MEK to remove all sealant.
(3) Wipe the surface with a dry, clean cloth before the MEK evaporates.
WARNING: SEALANT IS CLASSIFIED AS A HAZARDOUS MATERIAL WHICH MAY CAUSE INJURY OR ILLNESS IF NOT PROPERLY USED. THIS PRODUCT SHOULD BE
USED ONLY IN ACCORDANCE WITH THE MANUFACTURER'S MATERIAL SAFETY DATA SHEET.
(4) Apply a thin layer of high temperature sealant to the mating surfaces of the aft bulkhead and the anti-ice tube (5).
FALCON 2000EX F2000EX -384 March 01, 2016 F2000EX -30-11 Revision 1 Page 9 / 19 DASSAULT AVIATION Proprietary Data
(5) Slide the anti-ice tube (5) into the aft bulkhead of the air intake assembly.
(6) Slide the insulation (10) over the anti-ice tube (5) as the tube enters the air intake assembly.
(7) Attach the anti-ice tube (5) to the aft bulkhead with four washers (4) and bolts (3).
(8) Torque the bolts (3) from 2.0 to 2.3 Nm (18 to 20 lb in).
(9) Install the lockwire (2).
(10) Apply torque stripe to the bolts (3).
(11) Attach the anti-ice tube (5) to a bracket (1) with a clamp (13), washer (12) and screw (11).
WARNING: SEALANT IS CLASSIFIED AS A HAZARDOUS MATERIAL WHICH MAY CAUSE INJURY OR ILLNESS IF NOT PROPERLY USED. THIS PRODUCT SHOULD BE
USED ONLY IN ACCORDANCE WITH THE MANUFACTURER'S MATERIAL SAFETY DATA SHEET.
(12) Apply hot section bead sealant along the edge of the anti-ice tube (5).
(13) If necessary, install Panduits straps (1) on the insulation (10).
(14) Go to the 2.H. procedure.
H. RECORD THE SERVICE BULLETIN ON THE DATAPLATE
(1) Vibro-etch this Service Bulletin number and date of incorporation on the air intake assembly dataplate.
(2) Go to the 2.I.procedure.
I. FINAL STEPS
(1) Install the air intake anti-icing upper duct (Refer to TASK 30-20-17-900-801).
NOTE: Use the seals included in kit P/N SBF2000X0384A (P/N AS1895/7-100 and P/N 13405-100).
(2) Install the air intake access panels ( 412AL)/(412AR).
(3) Install the upper engine cowl (Refer to TASK 54-11-01-900-801).
(4) Install the lower engine cowl (Refer to TASK 54-11-05-900-801).
(5) Perform an operational test of the engine air intake anti-icing system (Refer to TASK 30-20-00-710-801).
J. RECORDING
(1) Complete and return fig. 5 Inspection Report to structure-repair@dassault-aviation.com (Europe, Middle East, Middle Asia, Africa) or structures@falconjet.com (North, South America, Pacific Rim) .
(2) 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.
FALCON 2000EX F2000EX -384 March 01, 2016 F2000EX -30-11 Revision 1 Page 10 / 19 DASSAULT AVIATION Proprietary Data