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FALCON 900EX FALCON 900EX EASy FALCON 900DX No 305-R1 JANUARY 26, 2015
MANDATORY ATA 33-10
LIGHTING
EXTERNAL LIGHTS
IMPROVED ELECTRICAL BONDING OF WHELEN ANTI-
COLLISION LIGHT TO THE S-DUCT COWL
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
EXTERNAL LIGHTS
IMPROVED ELECTRICAL BONDING OF WHELEN ANTI-COLLISION LIGHT TO THE S-
DUCT COWL Initial issuance September 19, 2007 List of effective pages :
1 to 13 Erratum November 21, 2008 List of effective pages :
1 to 13 List of modified pages :
3, 4 and 7 Revision 1 January 26, 2015 List of effective pages :
1 to 13 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 900EX F900EX -305 F900EX -33-10
LIGHTING
EXTERNAL LIGHTS
IMPROVED ELECTRICAL BONDING OF WHELEN ANTI-COLLISION LIGHT TO THE S-
DUCT COWL
1. PLANNING INFORMATION A. EFFECTIVITY This Service Bulletin is applicable to:
• F900EX aircraft with serial numbers 1 through 195 (F900EX, F900EX EASy),
• F900EX aircraft with serial numbers 601 through 620 (F900DX), equipped with a WHELEN anti-collision light on S-duct front upper fairing (353AT) (A/C with fin tip SATCOM fairing).
B. REASON The electrical bonding of the WHELEN anti–collision light installed on Engine No. 2 S–duct is currently provided at the junction connector. The bonding value may not be sufficient in case of lightning strike.
The purpose of this Service Bulletin is to improve the anti-collision light bonding in order to make the light installation more resistant to damage in case of a lightning strike.
C. DESCRIPTION The operation consists in:
• removing S-duct front upper fairing (353AT),
• installing a bonding strip between the anti-collision light and a fuselage pick-up rib.
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 F900EX M5386 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:
FALCON 900EX F900EX -305 January 26, 2015 F900EX -33-10 Revision 1 Page 1 / 13 DASSAULT AVIATION Proprietary Data
Western hemisphere: DASSAULT FALCON JET CORP.
SPARES DISTRIBUTION CENTER 200 RISER ROAD LITTLE FERRY, NJ 07643 U.S.A.
Telephone:
• CANADA and U.S.A.: 1-800-800-4036
• MEXICO: 001-800-800-4036
• Other countries: 1-201-541-4809 Fax:
• CANADA and U.S.A.: 1-800-800-4817
• MEXICO: 001-800-800-4817
• Other countries: 1-201-440-7021 Other continents: DASSAULT AVIATION Falcon Spares BOITE POSTALE N°101
AEROPORT DU BOURGET 93350 - LE BOURGET Cedex (FRANCE) Please contact your Dassault Aviation Account Representative Telephone: 33 (0)1.48.35.56.78 Fax: 33 (0)1.48.35.56.00 E/H dafsorder@dassault-aviation.com Price and availability on request.
H. TOOLING - PRICE AND AVAILABILITY Normal maintenance tooling.
I. WEIGHT AND BALANCE Change in weight: 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 VHF COMMUNICATION SYSTEM (Refer to TASK 23-11-00-710-802)
• OPERATIONAL TEST OF THE EXTERIOR LIGHTING (Refer to TASK 33-40-00-710-801)
• REPLACEMENT OF UPPER ANTI-COLLISION LIGHT BULB (WHELEN) (Refer to TASK 33-40-09-960-801) Structural Repair Manual:
FALCON 900EX F900EX -305 January 26, 2015 F900EX -33-10 Revision 1 Page 2 / 13 DASSAULT AVIATION Proprietary Data
• INSTALLATION OF SHUR-LOK BLIND TYPE INSERT (Refer to SRM 51-40-05) K. OTHER PUBLICATIONS AFFECTED The following publication is revised to account for the changes introduced by this Service Bulletin:
• Illustrated Parts Catalog.
FALCON 900EX F900EX -305 January 26, 2015 F900EX -33-10 Revision 1 Page 3 / 13 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 securing S-duct front upper fairing (353AT).
(3) Disengage S-duct front upper fairing (353AT) from the rib.
(4) If installed, disconnect VHF 1 antenna (L5RC) (connector 691P), located at the front on the LH side.
(5) Disconnect upper anti-collision light (4LX).
(6) Remove S-duct front upper fairing (353AT).
(7) Protect the connectors with caps/lugs.
B. ELECTRICAL BONDING OF THE ANTI–COLLISION LIGHT
(1) As per Maintenance Manual (Refer to TASK 33-40-09-960-801):
• Remove the sealant embedding retainer (item 2) without removing the flexible seal located under it.
• Remove the retainer, glass cover and seal (items 2, 3 and 4).
• Remove the anti–collision light housing.
NOTE: Discard the seal if installed between the housing and S-duct front upper fairing (353AT).
(2) As per fig. 1, fig. 2 and fig. 3:
(a) From S-duct front upper fairing (353AT) LH side, remove the two fittings attaching the anti– collision light pick-up plate blending with strip (1-fig. 3).
(b) Install baseplate strip (item 1) on S-duct front upper fairing (353AT): drill a hole centered on the hole drilled for the attachment of S-duct front upper fairing (353AT), and joggle to abutment against the lower reinforcement.
(c) For A/C with Service Bulletin F900EX-19 (M1947) applied, slightly bend the strip at the plate to allow the plate to fit flat against S-duct front upper fairing (353AT).
(d) Keep the strip applied against S-duct front upper fairing ( 353AT).
(e) Counterbore S-duct front upper fairing ( 353AT) to dia. 0.1 in (2.5 mm) in accordance with the strip and pin-rig.
(f) Joggle strip (item 1) at the anti-collision light pick-up plate.
(3) For A/C with modification F900EX M3541 (F900EX S/N 141 through 195 and F900DX S/N 601 through 620) applied (riveted anti-collision light pick-up plate):
(a) Drill strip (item 1) to dia. 1/8 in (3.2 mm) in accordance with the two pick-up holes of the plate.
(b) Remove the strip.
(c) Drill a new hole in the strip to dia. 0.1 in (2.5 mm) for additional attachment fitting (item 4).
(d) Pin the strip to the pick-up plate.
FALCON 900EX F900EX -305 January 26, 2015 F900EX -33-10 Revision 1 Page 4 / 13 DASSAULT AVIATION Proprietary Data
(e) Counterbore the new hole drilled in the strip, in the plate and S-duct front upper fairing (353AT).
(f) Drill the three elements to dia. 0.157 in (4 mm).
(g) Remove strip (item 1).
(h) Countersink S-duct front upper fairing (353AT) for rivet (4-fig. 3).
(4) For A/C with Service Bulletin F900EX-19 (M1947) applied (attachment of anti-collision light pickup plate with screws and inserts):
(a) Draw the outline of strip (item 1) on the pick–up plate.
(b) Remove strip (item 1).
(c) Remove the pick–up plate and the sealant.
(d) In the plate, drill a new hole to dia. 0.1 in (2.5 mm) for the additional attachment fitting (item
6).
(e) Position the plate on S-duct front upper fairing (353AT) and mark the location of the new hole.
(f) Place insert (item 6) (Refer to SRM 51-40-05).
(g) Drill the new hole to dia. 0.2 in (5 mm) in the pick-up plate.
(h) Position strip (item 1) on the pick-up plate in accordance with the previously drawn outline.
Drill the strip in accordance with the three holes drilled in the pick-up plate.
(i) Secure the pick-up plate, except at the three strip pick-up locations, with interlaying sealant. Place bead sealant at the mating area with S-duct front upper fairing (353AT).
(5) As per fig. 3, fig. 4 and fig. 5:
(a) Pin strip (item 1) to the pick-up plate (screws or pins).
(b) Pin strip (item 1) to S-duct front upper fairing (353AT).
(c) One at a time, drill the pick-up holes of the strip and S-duct front upper fairing (353AT) to dia.
0.2 in (5 mm), at the location of screws (item 2), and pin-rig as the operation proceeds to provide a satisfactory resting base.
(d) Remove the strip.
(e) Drill the lower hole of the strip to dia. 0.2 in (5 mm).
(f) Remove the honeycomb from each hole drilled in S-duct front upper fairing (353AT) over a dia. of 0.71 in (18 mm).
(g) Completely fill the holes in S-duct front upper fairing (353AT) with epoxy resin . Allow to cure.
(h) Re-drill and countersink for screws (2-fig. 4).
(6) As per fig. 3:
(a) Strip the paint from the upper surface of the anti-collision pick-up plate at the level of the housing installation plane.
(b) Strip the paint from the lower surface of the anti-collision pick-up plate at the level of the mating plane of strip (item 1).
FALCON 900EX F900EX -305 January 26, 2015 F900EX -33-10 Revision 1 Page 5 / 13 DASSAULT AVIATION Proprietary Data
(c) Protect the stripped parts with alodine.
(7) Clean the resting faces of the housing, the strip and S-duct front upper fairing (353AT) with MEK.
(8) Apply interlaying sealant on the face of strip (item 1) resting on S-duct front upper fairing (353AT).
NOTE: Do not cover the part resting on the pick–up plate.
(9) As per (fig. 2) and (fig. 4), secure the strip to S-duct front upper fairing (353AT) with screws and nuts (items 2 and 3). Smooth the excess sealant at the periphery of the strip and cover the nuts with covering sealant.
(10) Attachment of strip (item 1) to the pick–up plate (fig. 3):
(a) Remove any sealant seeping in between the two elements.
(b) For A/C with Service Bulletin F900EX-19 (M1947) applied, secure the assembly on S-duct front upper fairing (353AT) with removed screws and washers (items 6 and 7).
(c) For A/C with modification F900EX M3541 (F900EX S/N 141 through 195 and F900DX S/N 601 through 620) applied, secure the assembly to S-duct front upper fairing (353AT) with rivets (item 4) and interlaying sealant under the rivet heads.
(d) Apply bead sealant to the periphery of the strip.
(11) Modification of the fuselage rib (fig. 2):
(a) Mark the location of the hole picking up the strip on the rib.
(b) Remove the sealant and the paint from the marked area.
(c) Protect the stripped area with alodine.
C. FINAL STEPS
(1) Secure the anti-collision light housing to S-duct front upper fairing (353AT).
(2) Install the seal, the glass cover and the retainer.
(3) Apply bead sealant around the attachment plate.
(4) Using indelible ink, inscribe “SB 305” on "Service Bulletin Compliance" label (8-fig. 1).
(5) Using interlaying sealant, bond the "Service Bulletin Compliance" label to the internal skin of S- duct front upper fairing (353AT) in the vicinity of the reference (fig. 1).
(6) Position S-duct front upper fairing (353AT) on the fuselage.
(7) Connect and safety upper anti-collision light (4LX) to the housing.
(8) If installed, connect VHF 1 antenna (L5RC).
(9) Install S-duct front upper fairing (353AT).
(10) Measure bonding value between the anti–collision light baseplate and the reference test point in the mechanic’s servicing compartment (Refer to TASK 20-20-00-910-801).
The value should be equal to 2.5 mΩ max.
(11) Perform the operational test of the upper anti-collision light (4LX) (Refer to TASK 33-40-00-710-801).
FALCON 900EX F900EX -305 January 26, 2015 F900EX -33-10 Revision 1 Page 6 / 13 DASSAULT AVIATION Proprietary Data
(12) Perform the operational test of the VHF1 system (Refer to TASK 23-11-00-710-802 ) if VHF1 antenna installed on S-duct front upper fairing (353AT) 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 electronic Service Bulletin reply form located in the ”Service Bulletin" page on the Falcon portal.
FALCON 900EX F900EX -305 January 26, 2015 F900EX -33-10 Revision 1 Page 7 / 13 DASSAULT AVIATION Proprietary Data
3. MATERIAL INFORMATION A. MODIFICATION KIT KIT P/N SBF900EX0305A
NEW P/N QTY KEY WORD ITEM FIG FGFB823675330A1 1 Bonding strip FGFB823675330A1 1 Bonding strip Refer to (1-fig. 1) NAS1153V4A 5 Screw Refer to (2-fig. 4) HW17-3DF 5 Nut Refer to (3-fig. 4) NAS1921M05S03WU 3 Rivet Refer to (4-fig. 3) SL644M5-3 1 Insert Refer to (5-fig. 3) 22208TX050006XA 1 Screw Refer to (6-fig. 3) 23111DG050A 1 Washer Refer to (7-fig. 3) 79160 1 "Service Bulletin Compliance" label Refer to (8-fig. 1) B. LOCAL PROCUREMENT As indicated in Consumable Products Manual (CPM):
• alodine
• bead sealant
• covering sealant
• interlaying sealant
• MEK
• epoxy resin FALCON 900EX F900EX -305 January 26, 2015 F900EX -33-10 Revision 1 Page 8 / 13 DASSAULT AVIATION Proprietary Data
DASSAULT SERVICE BULLETIN
AVIATION FALCON 900EX F900EX -305 ENGINE No. 2
AIR INTAKE Upper anti-collision light (4LX) VHF1 antenna (if installed) (L5RC) 353AT 353AT REMOVED
INSIDE VIEW
LH SIDE
RH SIDE See figure 3 Connector See figure 2 691P Figure 1: GENERAL VIEW January 26, 2015 F900EX -33-10 Revision 1 Page 9 / 13
DASSAULT SERVICE BULLETIN
AVIATION FALCON 900EX F900EX -305 View A (see figure 1) Fr30 Fr29 Bead sealant on baseplate periphery 4444 ***** Cross-section CC see figure 4 Interlaying sealant on 353AT Cross-section DD see figure 5 Joggling
(701) (161) (704) (701) (X0() Remove sealant and strip paint from rib Cross-section EE
1.46 in 1.46 in (37 mm) (37 mm) Figure 2: VIEW A January 26, 2015 F900EX -33-10 Revision 1 Page 10 / 13