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© Dassault Aviation. Filed by the FAA in regulations.gov docket FAA-2018-0451; AD 2018-19-06 incorporates this document by reference. Not covered by OpenAirDocs’ CC0 dedication.

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Page 1Open in PDF

FALCON 900LX No 522 MARCH 08, 2017

ATA 27-20

FLIGHT CONTROLS FLAPS

PROTECTION AGAINST UNTIMELY RETRACTION OF FLAPS

FALCON SERVICE BULLETIN Copyright © 2017 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.

Page 2Open in PDF

FLIGHT CONTROLS FLAPS

PROTECTION AGAINST UNTIMELY RETRACTION OF FLAPS Initial issuance March 08, 2017 List of effective pages :

1 to 11 FALCON 900EX F900EX -522 F900EX -27-20

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FLIGHT CONTROLS FLAPS

PROTECTION AGAINST UNTIMELY RETRACTION OF FLAPS

1. PLANNING INFORMATION A. EFFECTIVITY This Service bulletin is applicable to FALCON 900LX aircraft with serial numbers 240, 242 through

273.

B. REASON Several aircraft experienced rejected take offs due to untimely inboard flap retraction upon take-off roll.

Investigation confirmed that the root cause was an improper adjustment of the outboard slat extended microswitch which could lead to flap retraction.

The purpose of this Service Bulletin is to prevent untimely flap retraction in case of outboard slat extended microswitch failure or improper adjustment.

C. DESCRIPTION The operation consists in modifying the flaps control logic by:

• replacing slats/flaps control box ( 2CG),

• modifying the aircraft electrical wiring between slats/flaps control box (2CG) and "7° FLAPS" control relay (8CG).

D. COMPLIANCE Compliance with this Service Bulletin should be done no later than the next "12 M" inspection.

E. APPROVAL This Service Bulletin covers DASSAULT AVIATION modification FALCON F900EX M6043 that has been approved under the authority of DOA nr. EASA.21J.051.

The technical content of this document is approved under the authority of DOA nr. EASA.21J.051.

F. LABOR Estimated labor-hours: Refer to Service Bulletin Commercial Summary.

NOTE: These labor-hours only concern the work described in this Service Bulletin and do not include other maintenance work that may be performed on this occasion.

G. MATERIAL - PRICE AND AVAILABILITY The modification kit may be obtained from either address listed below:

Western hemisphere: DASSAULT FALCON JET CORP.

SPARES DISTRIBUTION CENTER 200 RISER ROAD FALCON 900EX F900EX -522 March 08, 2017 F900EX -27-20 Initial issuance Page 1 / 11 DASSAULT AVIATION Proprietary Data

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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 54, AVENUE MARCEL DASSAULT B. P. 24 33701 - MERIGNAC Cedex (FRANCE) Please contact your Dassault Aviation Account Representative Telephone: 33 (0)1.48.35.56.78 E/H dafsorder@dassault-aviation.com Price and availability on request.

H. TOOLING - PRICE AND AVAILABILITY TOOL BOX (TO-20-008) I. WEIGHT AND BALANCE Change in weight: None.

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

J. REFERENCES Illustrated Parts Catalog:

• RH RELAY SUPPORT (Refer to FIG 24-61-10-51)

• RH COCKPIT CLOSET (Refer to FIG 25-15-10-41) Aircraft Maintenance Manual:

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

• USE OF THE AIRCRAFT MAINTENANCE PROCEDURES (Refer to TASK 20-00-00-910-803)

• INSERTION AND EXTRACTION OF A WIRE IN A CONNECTOR (Refer to TASK 20-95-00-910-801)

• ENERGIZATION / DE-ENERGIZATION OF THE AIRCRAFT SYSTEMS (Refer to TASK 24-00-00-860-801)

• ELECTRICAL SYSTEM MAINTENANCE AND SAFETY PRECAUTIONS (Refer to TASK 24-00-00-910-801)

• REMOVAL / INSTALLATION OF THE PILOT SEATS (Refer to TASK 25-11-01-900-801)

• REMOVAL / INSTALLATION OF THE LOWER COCKPIT LININGS (Refer to TASK 25-13-13-900-803) FALCON 900EX F900EX -522 March 08, 2017 F900EX -27-20 Initial issuance Page 2 / 11 DASSAULT AVIATION Proprietary Data

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• FLIGHT CONTROL SYSTEM MAINTENANCE AND SAFETY PRECAUTIONS (Refer to TASK 27-00-00-910-801)

• OPERATIONAL TEST OF THE FLAP CONTROL AND INDICATING SYSTEM (Refer to TASK 27-50-00-710-801)

• OPERATIONAL TEST OF THE SLATS IN NORMAL AND EMERGENCY MODES (Refer to TASK 27-80-00-710-804)

• OPERATIONAL TEST OF SLAT STALL 1 AND STALL 2 (Refer to TASK 27-80-00-710-809)

• PRESSURIZATION / DE-PRESSURIZATION OF THE HYDRAULIC SYSTEMS (Refer to TASK 29-00-00-860-801) Wiring Manual:

• FLAPS WD 27-51-00 K. OTHER PUBLICATIONS AFFECTED The following publication is revised to account for the changes introduced by this Service Bulletin:

• Airplane Flight Manual revision 14.

The following publication will be revised at a later date to account for the changes introduced by this Service Bulletin:

• Wiring Diagram Manual.

FALCON 900EX F900EX -522 March 08, 2017 F900EX -27-20 Initial issuance Page 3 / 11 DASSAULT AVIATION Proprietary Data

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2. ACCOMPLISHMENT INSTRUCTIONS A. GENERAL ELECTRICAL INSTRUCTIONS

(1) When mechanical retrofit and/or modification operations are performed on the aircraft, take special care to protect the wiring in order to prevent metal chips (or burrs) from penetrating into the wire bundles, since they could eventually damage the insulation sheathing of the wires.

Whenever possible, it is recommended that the wiring be removed from the work area. If that is not possible, it is absolutely necessary to protect the wiring.

(2) Due to the risk of damaging the wire insulation, it is prohibited to blindly drill holes through a box structure containing wiring.

(3) To allow passage through the pressure seal boxes, use one of the spare wires mounted in these boxes.

(4) New wires that are installed alongside existing wires should be secured by the existing clamp.

(5) Check that all connections are properly protected to ensure proper insulation, and that markings are visible and appropriate.

(6) Connector wires should be inserted and extracted as per the recommendations in Standard practices, (Refer to TASK 20-95-00-910-801).

(7) Electric and electronic equipment should be removed and installed as per the recommendations in Standard Practices, (Refer to TASK 20-00-00-910-801).

(8) Visually inspect the work area for particles or debris, then vacuum-clean. The blowing of compressed air is prohibited since it could move metal chips to inaccessible areas.

(9) Wiring diodes must be installed in the unbent sections of bundles, attached with moderately tightened lacing tape. Do not use self-tightening clamps or wire ties.

B. PRELIMINARY STEPS Refer to fig. 1

(1) The aircraft must be in the maintenance configuration (Refer to TASK 20-00-00-910-803).

(2) Obey the flight control system maintenance and safety precautions (Refer to TASK 27-00-00-910-801).

(3) Obey the electrical system maintenance and safety precautions (Refer to TASK 24-00-00-910-801).

(4) Connect the electrical Ground Power Unit (GPU) (Refer to TASK 24-00-00-860-801).

(5) Connect the hydraulic GPU to the hydraulic systems 1 and 2 (Refer to TASK 29-00-00-860-801).

(6) Remove the copilot seat ( R2MG) (Refer to TASK 25-11-01-900-801).

(7) For aircraft with new cockpit design, remove pedestal casing (Refer to TASK 25-13-13-900-803, paragraph "Removal / Installation Of The Pedestal Casing")

(8) For aircraft without new cockpit design, remove pedestal access panels ( 221CZ) and (222AZ).

(9) Remove cockpit floors ( 114FZ), (114DZ), (114EZ) and cabin floor (124AZ).

FALCON 900EX F900EX -522 March 08, 2017 F900EX -27-20 Initial issuance Page 4 / 11 DASSAULT AVIATION Proprietary Data

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(10) Remove RH panel between frames 4 and 5 (Refer to FIG 25-15-10-41) to gain access to the relay support (RH cabinet).

(11) Remove the relay support (Refer to FIG 24-61-10-51) to gain access to its rear side.

C. ELECTRICAL MODIFICATIONS Refer to fig. 1 and fig. 2

(1) Remove slats/flaps control box ( 2CG) as follows: (see fig. 1) NOTE: The slats/flaps control box (2CG) removed must be sent to one of the addresses listed in paragraph 1.G. of this Service Bulletin.

(a) Unscrew, remove and retain the four nuts.

(b) Disconnect the electrical connectors (2CG-A) and (2CG-B).

(c) Remove slats/flaps control box ( 2CG) from the pedestal.

(2) Perform the electrical modifications and electrical continuity checks in accordance with:

• Wiring general overview ( fig. 1),

• Wiring modification ( fig. 2).

(3) Install the new slats/flaps control box ( 2CG) as follws: (see fig. 1)

(a) Install slats/flaps control box ( 2CG) on the pedestal.

(b) Connect the electrical connectors (2CG-A) and (2CG-B).

(c) Install the four nuts.

D. TEST

(1) Energize the aircraft systems with the electrical GPU (Refer to TASK 24-00-00-860-801).

(2) Pressurize the hydraulic systems 1 and 2 with the hydraulic GPU (Refer to TASK 29-00-00-860-801).

(3) Perform an operational test of the flap control and indicating system (Refer to TASK 27-50-00-710-801).

(4) Perform only an operational test of the slats in emergency mode (Refer to TASK 27-80-00-710-804).

(5) Pressurize the hydraulic systems 1 and 2 with the hydraulic GPU (Refer to TASK 29-00-00-860-801).

(6) Check for slat/flap extension/retraction in normal mode from "SF0" to "SF2" and "SF0" to "SF3" as follows:

(a) Make sure that, on slats/flaps control box ( 2CG), the slat/flap control lever is set to "CLEAN",

(b) On slats/flaps control box ( 2CG), set slat/flap control lever to "SF2",

• Check that outboard slats extend,

• Check that extension of outboard slats causes inboard slats and flaps (20°) extension.

(c) On slats/flaps control box ( 2CG), set slat/flap control lever to "CLEAN",

• Check that flaps and inboard slats retract,

• Check that retraction of flaps and inboard slats causes outboard slats retraction.

FALCON 900EX F900EX -522 March 08, 2017 F900EX -27-20 Initial issuance Page 5 / 11 DASSAULT AVIATION Proprietary Data

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(d) On slats/flaps control box ( 2CG), set slat/flap control lever to "SF3",

• Check that outboard slats extend,

• Check that extension of outboard slats causes inboard slats and flaps (40°) extension.

(e) On slats/flaps control box ( 2CG), set slat/flap control lever to "CLEAN",

• Check that flaps and inboard slats retract,

• Check that retraction of flaps and inboard slats causes outboard slats retraction.

(7) Check of flaps non retraction after RH outboard slats position microswitch failure as follows:

(a) Make sure that, on slats/flaps control box ( 2CG), the slat/flap control lever is set to "CLEAN",

(b) On slats/flaps control box ( 2CG), set slat/flap control lever to "SF1",

(c) Check that outboard slats, flaps and inboard slats extend,

(d) Cut off and drop the pressure in hydraulic system 1 (Refer to TASK 29-00-00-860-801), NOTE: Wait for one minute to be sure that the hydraulic pressure is fully dropped in the slat system.

(e) Fully retract the RH inboard slat by hand with two operators.

(f) Slightly retract the RH outboard slat by hand with two operators until the RH outboard slat extended microswitch (R16CM) is released from the sliding angle,

(g) Check that the amber " OUTBD SLATS FAIL" CAS message is displayed.

NOTE: This CAS message is displayed after a time-delay of 5 seconds.

(h) Check that flaps remain in position (7 deg.).

(i) Slightly increase the pressure in hydraulic system 1 with the hydraulic GPU to extend the RH outboard slat.

(j) Check that the amber " OUTBD SLATS FAIL" CAS message is no longer displayed.

(k) Check that the RH outboard slat extends.

(l) Check that the RH inboard slat extends.

(m) On slats/flaps control box (2CG), set slat/flap control lever to "CLEAN".

(8) Check of flaps non retraction after LH outboard slats position microswitch failure as follows:

(a) Make sure that, on slats/flaps control box ( 2CG), the slat/flap control lever is set to "CLEAN",

(b) On slats/flaps control box ( 2CG), set slat/flap control lever to "SF1",

(c) Check that outboard slats, flaps and inboard slats extend,

(d) Cut off and drop the pressure in hydraulic system 1 (Refer to TASK 29-00-00-860-801), NOTE: Wait for one minute to be sure that the hydraulic pressure is fully dropped in the slat system.

(e) Fully retract the LH inboard slat by hand with two operators.

(f) Slightly retract the LH outboard slat by hand with two operators until the LH outboard slat extended microswitch (L16CM) is released from the sliding angle,

(g) Check that the amber " OUTBD SLATS FAIL" CAS message is displayed.

NOTE: This CAS message is displayed after a time-delay of 5 seconds.

FALCON 900EX F900EX -522 March 08, 2017 F900EX -27-20 Initial issuance Page 6 / 11 DASSAULT AVIATION Proprietary Data

Page 9Open in PDF

(h) Check that flaps remain in position (7 deg.).

(i) Slightly increase the pressure in hydraulic system 1 with the hydraulic GPU to extend the LH outboard slat.

(j) Check that the amber " OUTBD SLATS FAIL" CAS message is no longer displayed.

(k) Check that the LH outboard slat extends.

(l) Check that the LH inboard slat extends.

(m) On slats/flaps control box (2CG), set slat/flap control lever to "CLEAN".

(9) Check of outboard slat automatic extention

(a) Pressurize hydraulic systems 1 and 2 with the hydraulic GPU (Refer to TASK 29-00-00-860-801).

(b) Make sure that, on slats/flaps control box ( 2CG), the slat/flap control lever is set to "CLEAN".

(c) On airbrake/tailplane/trim control box ( 2CF), move airbrake control lever from "0" to "2".

(d) Make sure that the three pairs of airbrakes extend.

(e) Press and hold the "STALL 1" soft key.

NOTE: The test of "STALL 1" is run by selecting the corresponding soft key on the "TEST" synoptic page on the Multi-Function Display (MFD) (R22FV), using the pilot or the copilot Cursor Control Device (CCD) (L44FV)/(R44FV).

(f) Make sure that:

• the "STALL" voice warning is triggered,

• the outboard slats extend,

• the three pairs of airbrakes retract and the airbrake symbol displayed on PFDs goes off, when all airbrakes are retracted.

(g) On airbrake/tailplane/trim control box ( 2CF), set airbrake control lever to "0".

(10) Perform operational tests of the slat "STALL" function (Refer to TASK 27-80-00-710-809).

E. FINAL STEPS

(1) Reverse the remaining operations described in paragraph 2.B. to return the aircraft to initial configuration.

(2) On RH lateral overhead panel lighting face ( R15LC), rotate "PANEL" rheostat (R2LK) clockwise.

(3) Check illumination and brightness variation control of slats/flaps control box ( 2CG).

(4) Rotate "PANEL" rheostat ( R2LK) counterclockwise.

(5) Cut off and drop the pressure in hydraulic systems 1 and 2 (Refer to TASK 29-00-00-860-801).

(6) De-energize the aircraft systems (Refer to TASK 24-00-00-860-801).

F. DOCUMENTATION Check that the Airplane Flight Manual is updated with revision 14 pages.

Incorporate fig. 2 into the Wiring Manual chapter 27-51-00-XX.

FALCON 900EX F900EX -522 March 08, 2017 F900EX -27-20 Initial issuance Page 7 / 11 DASSAULT AVIATION Proprietary Data

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G. 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 -522 March 08, 2017 F900EX -27-20 Initial issuance Page 8 / 11 DASSAULT AVIATION Proprietary Data

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3. MATERIAL INFORMATION NOTE: Compliance with this Service Bulletin by substituting the part numbers below with interchangeable subsequent part numbers (as per the Master List or Dassault-approved supply list) is acceptable, provided that subsequent part numbers have the same effectivity as the original ones.

A. MODIFICATION OF SLATS/FLAPS CONTROL BOX PART NUMBER

NEW P/N QTY KEY WORD OLD P/N 7-7061 1 slats/flaps control box (2CG) 6-7061 NOTE: The slats/flaps control box (2CG) removed must be sent to one of the addresses listed in paragraph 1.G. of this Service Bulletin.

B. MODIFICATION KIT ELECTRICAL CIRCUIT Kit P/N SBF900EX0522A

NEW P/N QTY KEY WORD 01C0K302-20S01 3 Contact 01EQTSR03-16S01 1 Contact 01C0A54148FC16 1 Dummy Contact 01CAN211-1-20 15 m (49 ft) Cable 2CGA-J/SP8CG-1 2 Identification sleeve (01PROTMS1G1-8) 2CGA-K/SP8CG-2 2 Identification sleeve (01PROTMS1G1-8) 2CGA-P/8CG-A1 2 Identification sleeve (01PROTMS1G1-8) 01EQTPRL08R1 2 Red Extension Cables SP8CG-1 1 Identification sleeve (01PROTMS1G3-32) SP8CG-2 1 Identification sleeve (01PROTMS1G3-32) 78750-02 20 Cable clamp C. LOCAL PROCUREMENT None FALCON 900EX F900EX -522 March 08, 2017 F900EX -27-20 Initial issuance Page 9 / 11 DASSAULT AVIATION Proprietary Data

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DASSAULT SERVICE BULLETIN

AVIATION FALCON 900EX F900EX -522 2CG EWO 2CG-A 2CG-B Fr 4 FWD Relay location, RH Cabinet Fr 4-5 8CG Figure 1: WIRING - GENERAL OVERVIEW March 08, 2017 F900EX -27-20 Initial issuance Page 10 / 11

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