Dassault SB F900-372: Revision 1

FALCON 900 No 372-R1 JANUARY 26, 2015

MANDATORY ATA 33-10

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 August 22, 2007 List of effective pages :

1 to 18 Revision 1 January 26, 2015 List of effective pages :

1 to 19 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 900 F900 -372 F900 -33-10

LIGHTING

EXTERIOR LIGHTING

ELECTRICAL BONDING OF WHELEN FIN TIP ANTI-COLLISION LIGHT

1. PLANNING INFORMATION A. EFFECTIVITY This Service Bulletin is applicable MYSTERE-FALCON 900 aircraft equipped with a WHELEN fin tip anti-collision light (without SATCOM fairing) per Service Bulletin F900-182 (M1682).

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 MYSTERE-FALCON 900 fin tip anti-collision light whose installation is similar to the F2000.

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,

• to reroute the wiring as required in accordance with the aircraft’s serial number.

D. COMPLIANCE Mandatory:

• 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 MF900 M5381 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.

FALCON 900 F900 -372 January 26, 2015 F900 -33-10 Revision 1 Page 1 / 19 DASSAULT AVIATION Proprietary Data

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: 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 DOORS,RIB05 TO RIB10C (Refer to IPC fig. 55-30-20-30)

• VERTICAL STABILIZER FIN TIP (Refer to IPC fig. 55-30-40-10) Service Bulletin F900-182 "Lights - Exterior lights - Replacement of fin anticollision light" FALCON 900 F900 -372 January 26, 2015 F900 -33-10 Revision 1 Page 2 / 19 DASSAULT AVIATION Proprietary Data

K. OTHER PUBLICATIONS AFFECTED The following publications will be revised at a later date to account for the changes introduced by this Service Bulletin:

• Illustrated Parts Catalog.

• Maintenance Manual.

• Wiring Manual.

FALCON 900 F900 -372 January 26, 2015 F900 -33-10 Revision 1 Page 3 / 19 DASSAULT AVIATION Proprietary Data

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) On aircraft with Service Bulletin F900-182 applied, remove door (323FL) (Refer to IPC fig.

55-30-20-30 , item 250).

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

• Remove the compound bead coating the retainer (item 342).

• Remove the retainer, glass cover and seal (items 342, 345 and 346).

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

NOTE: Remove and discard gasket (item 349) if installed.

B. PREPARING FAIRINGS F50B319, (A1), (A2) AND FGFB319, (A1) NOTE: If not concerned, go to step 2.C.

(1) Remove the contacts from connector (4LX).

(2) Extract the wiring from the feedthrough at the upper part of rib 3.

NOTE: The wiring will be re-routed in accordance with the instructions of paragraph 2.F.

(3) Machine the cutout in rib 3 in accordance with fig. 8.

C. ANTI-COLLISION LIGHT ELECTRICAL BONDING In accordance with fig. 1 or fig. 2 depending on the P/N of the existing fairing:

(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 shim (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.

FALCON 900 F900 -372 January 26, 2015 F900 -33-10 Revision 1 Page 4 / 19 DASSAULT AVIATION Proprietary Data

(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) Set the strip assembly and the light unit assembly into place in the fairing without making electrical connections and attach the light assembly to the fairing. Smooth out the PR in excess around the strips (items 2 and 3).

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

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

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

D. MODIFYING THE WIRING Modify the shield connection in accordance with instructions depicted hereafter and using fig. 3, fig. 4 and fig. 5 in accordance lights’ installation on the aircraft.

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.

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• 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.

• 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.

E. RE-ROUTING THE WIRING WITH WIRING ROUTED OVER RIB 2 In accordance with fig. 6:

(1) Remove the WHELEN light unit assembly.

(2) Drill a 0.19 in (4.9 mm) diameter hole through the rib of the fairing.

(3) Install new clamping stud (item 5) on rib 3.

(4) Unclamp the wiring from rib 2.

(5) Clamp the wiring to rib 3.

(6) Connect connector (4LX) to the WHELEN light.

(7) Attach the light unit assembly to the fairing.

(8) Install the gasket, the glass cover, and the retainer (Refer to IPC fig. 33-40-10-50 , items 346, 345, 342).

(9) Apply bead sealant around the retainer.

F. RE-ROUTING THE WIRING WITH WIRING ROUTED AROUND THE BACK OF FAIRING In accordance with fig. 7 (Fairing P/N F50B319BX or FGFB319A2, (A3)) or fig. 8 (Fairing P/N F50B319, (A1), (A2) or FGFB319, (A1))

(1) Remove the WHELEN light unit assembly.

(2) Drill a 0.19 in (4.9 mm) diameter hole through the rib 3 of the fairing.

(3) Install new clamping stud (item 5) on rib 3.

(4) Remove contacts from connector (4LX).

(5) Adjust the wiring length for proper re-routing in accordance with fig. 7.

(6) Fit the cut wires with new contacts and insert them into connector (4LX).

(7) Clamp the wiring to rib 3.

(8) Connect connector (4LX) to the WHELEN light.

(9) Attach the light unit assembly to the fairing.

(10) Install the gasket, the glass cover, and the retainer (Refer to IPC fig. 33-40-10-50 , items 346, 345, 342).

(11) Apply bead sealant around the retainer.

G. FINAL STEPS FALCON 900 F900 -372 January 26, 2015 F900 -33-10 Revision 1 Page 6 / 19 DASSAULT AVIATION Proprietary Data

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

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

(3) Place the fairing on the fin tip, connect connector (322P) and attach the fairing.

(4) Re-install the door (323FL) (Refer to IPC fig. 55-30-20-30 , item 250 ) (aircraft with Service Bulletin F900-182 applied).

(5) Measure the electrical bonding across the anti-collision light base 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.

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

H. 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.

FALCON 900 F900 -372 January 26, 2015 F900 -33-10 Revision 1 Page 7 / 19 DASSAULT AVIATION Proprietary Data

3. MATERIAL INFORMATION A. MODIFICATION KIT KIT P/N SBF900EX0285A APPLICABLE TO AIRCRAFT EQUIPPED WITH FAIRINGS F50B319BX OR FGFB319A2, (A3) 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 - (4-fig. 1) - 78753 1 Studded support - (5-fig. 6) - (5-fig. 7) - 78750-02 1 Clamp - (6-fig. 6) - (6-fig. 7) - 79160 1 "Service Bulletin Compliance" label

- (7-fig. 6) - (7-fig. 7) - 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. 3 - fig. 4 - fig. 5 01C0K302-16S01 1 Contact Ground 322J - fig. 3 - fig. 4 - fig. 5 01CAN210-1-20 1 #20 gauge wire L= 3.3 ft (1 m) Ground 322J - fig. 3 - fig. 4 - fig. 5 01C0A54143FC16 4 Blanking pin 322J/P - fig. 3 - fig. 4 - fig. 5 01EQTRB23-2R 1 Self-soldering sleeve 4LX - fig. 3 - fig. 4 - fig. 5 01CAN210-1-22 1 #22 gauge CF wire L = 1 ft (0.3 m) See NOTE 1 4LX - fig. 3 - fig. 4 - fig. 5 01CAN203-1-22Y 1 #22 gauge KZ wire L = 1 ft (0.3 m) FALCON 900 F900 -372 January 26, 2015 F900 -33-10 Revision 1 Page 8 / 19 DASSAULT AVIATION Proprietary Data

KIT P/N SBF900EX0285A - Electrical kit

NEW P/N Q T Y

KEY WORD INSTRUCTIONSDISPOSITION FIG See NOTE 2 01EQTC0S20A03-071-22 1 Lug 4LX - fig. 3 - fig. 4 - fig. 5 01C0K345-16S01 2 Contact 4LX - fig. 3 - fig. 4 - fig. 5 01EQTEC1-1 1 Insulating sleeve 322P - fig. 3 - fig. 4 - fig. 5 01EQTEC1-1 4 Insulating sleeve - See NOTE 3 322J/P - fig. 4 - 01EQTPRL08B01 1 Splice - See NOTE 3 SP3LX-A - fig. 4 - GND322J-B 2 Black sleeve with white marking 01PR0TMS3-32BK 322J - fig. 3 - fig. 4 - fig. 5 GND312J-B 2 Black sleeve with white marking 01PR0TMS3-32BK 312J - fig. 3 - fig. 4 - fig. 5 A 1 Black sleeve with white marking 01PR0TMS3-32BK 4LX - fig. 3 - fig. 4 - fig. 5 B 1 Black sleeve with white marking 01PR0TMS3-32BK 4LX - fig. 3 - fig. 4 - fig. 5 78750-01 5 Clamp 4LX - fig. 3 - fig. 4 - fig. 5 NOTE 1: Use on MYSTERE-FALCON 900.

NOTE 2: Do not use on MYSTERE-FALCON 900.

NOTE 3: Use on MYSTERE-FALCON 900 with SB F900-182 applied.

KIT P/N SBF50-0481A APPLICABLE TO THOSE AIRCRAFT EQUIPPED WITH FAIRINGS F50B319, (A1), (A2) OR FGFB319, (A1) KIT P/N SBF50-0481A - Mechanical kit

NEW P/N Q T Y

KEY WORD INSTRUCTIONSDISPOSITION ITEMFIG FGFB319100010W1 1 Mounting-base bonding strip Supply already assembled

- (1-fig. 2) - FGFB319100038 1 Shim - (8-fig. 2) - FALCON 900 F900 -372 January 26, 2015 F900 -33-10 Revision 1 Page 9 / 19 DASSAULT AVIATION Proprietary Data

KIT P/N SBF50-0481A - Mechanical kit

NEW P/N Q T Y

KEY WORD INSTRUCTIONSDISPOSITION ITEMFIG FGFB319100036W1 1 Strip Supply already assembled

- (2-fig. 2) - FGFB319100037W2 1 Strip - (3-fig. 2) - NAS1919M04S02WU 3 Rivet - (4-fig. 2) - 78753 1 Studded support - (5-fig. 8) - 78750-02 1 Clamp - (6-fig. 8) - 79160 1 "Service Bulletin Compliance* label

- (7-fig. 6) - (7- fig. 7) - (7-fig. 8) - KIT P/N SBF50-0481A - Electrical kit

NEW P/N Q T Y

KEY WORD INSTRUCTIONSDISPOSITION FIG 01EQTC0S20-05-119-18 1 Lug Ground 322J - fig. 3 - fig. 4 - fig. 5 01C0K302-16S01 1 Contact Ground 322J - fig. 3 - fig. 4 - fig. 5 01CAN210-1-20 1 #20 gauge wire L= 3.3 ft (1 m) Ground 322J - fig. 3 - fig. 4 - fig. 5 01C0A54143FC16 4 Blanking pin 322J/P - fig. 3 - fig. 4 - fig. 5 01EQTRB23-2R 1 Self-soldering sleeve 4LX - fig. 3 - fig. 4 - fig. 5 01CAN210-1-22 1 #22 gauge CF wire L = 1 ft (0.3 m) - See NOTE 1 4LX - fig. 3 - fig. 4 - fig. 5 01CAN203-1-22Y 1 #22 gauge KZ wire L = 1 ft (0.3 m) - See NOTE 2 01EQTC0S20A03-071-22 1 Lug 4LX - fig. 3 - fig. 4 - fig. 5 01C0K345-16S01 2 Contact 4LX - fig. 3 - fig. 4 - fig. 5 01EQTEC1-1 1 Insulating sleeve 322P - fig. 3 - fig. 4 - fig. 5 01EQTEC1-1 4 Insulating sleeve - See NOTE 3 322J/P - fig. 4 - 01EQTPRL08B01 1 Splice - See NOTE 3 SP3LX-A - fig. 4 - FALCON 900 F900 -372 January 26, 2015 F900 -33-10 Revision 1 Page 10 / 19 DASSAULT AVIATION Proprietary Data