FALCON SERVICE BULLETIN 

207

FALCON 50

No 496-R2

MARCH 10, 2010

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 57-16

WING

WING TANK MODIFICATION
FALCON 50

SERVICE BULLETIN

F50–496

F50–57–16

WING

WING TANK MODIFICATION

________________________________________________________________________________

INITIAL ISSUANCE date: October 30, 2009

List of effective pages:

1 to 6.

________________________________________________________________________________

COMPLETE ISSUANCE: REVISION 1 date: February 15, 2010

List of effective pages:

1 to 6.

List of modified pages:

5 and 6.

REASON: Addition/correction of information in appendix 1, 2, 5 following installations

performed during training and replacement of instruction placards on the wings.

This revision is not applicable to aircraft already changed per the original issue.

________________________________________________________________________________

COMPLETE ISSUANCE: REVISION 2 date: March 10, 2010

List of effective pages:

1 to 6.

List of modified page:

2.

REASON: Modification of paragraph “TRAINING”.

This revision is not applicable to aircraft already changed per the original issue or revision 1.

________________________________________________________________________________
DASSAULT AVIATION Proprietary Data

SERVICE BULLETIN

FALCON 50 F50–496

March 10, 2010 F50–57–16

Revision 2 Page 1

WING

WING TANK MODIFICATION

________________________________________________________________________________

 1 . PLANNING INFORMATION

A . EFFECTIVITY

This Service Bulletin is applicable to MYSTERE–FALCON 50 aircraft with serial numbers

2 through 352.

 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.

The Accomplishment Instructions and the tests are included in the five Appendices to this

Service Bulletin.

 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.
DASSAULT AVIATION Proprietary Data

FALCON 50

SERVICE BULLETIN

F50–496

March 10, 2010 F50–57–16

Revision 2 Page 2

 E . APPROVAL

This Service Bulletin covers DASSAULT AVIATION modifications MF50 M3106 which has

been approved by EASA and M3140 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.

 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 Aviation.

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.
DASSAULT AVIATION Proprietary Data

SERVICE BULLETIN

FALCON 50 F50–496

March 10, 2010 F50–57–16

Revision 2 Page 3

 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 Aviation

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 : + 30 ft.lb (+ 4 m.daN) nose up moment.
DASSAULT AVIATION Proprietary Data

FALCON 50

SERVICE BULLETIN

F50–496

March 10, 2010 F50–57–16

Revision 2 Page 4

 J . REFERENCE

Aircraft Maintenance Manual:

– procedure 27-568,

– procedure 27-811,

– procedure 57-400.

Standard Practices:

– procedure 20-305,

– procedure 20-320,

– procedure 20-602,

– procedure 20-650.

Illustrated Parts Catalog:

– chapter 11-30-20, figure 60.

– chapter 52-40-30, figure 60.

AMM chap. 12, Ingredients and consumable products.

Airplane Flight Manual:

– F50B Airplane Flight Manual Temporary Change No. 68.

– F50EX Airplane Flight Manual FM318EX Rev. 8 or subsequent.

 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
DASSAULT AVIATION Proprietary Data

SERVICE BULLETIN

FALCON 50 F50–496

March 10, 2010 F50–57–16

Revision 2 Page 5

 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 20 as per Illustrated Parts Catalog,

Chap. 11-20-30, fig. 15.

– Install the new instruction placards FGFB090200003A4 at the same location as per

Procedure 20-306.

(2) Refueling access door

– Open the refueling door item 10 as per Illustrated Parts Catalog, Chap. 52-40-30,

fig. 60.

– Remove the instruction placard Item 10 as per Illustrated Parts Catalog,

Chap. 11-30-20, fig. 60.

– Install the new instruction placard F50B090100024A1 as per Procedure 20-305.

 C . DOCUMENTATION

Update, if not already done, the Airplane Flight Manual with:

– Airplane Flight Manual Temporary Change No. 68 for F50B.

– Airplane Flight Manual FM318EX Rev. 8 or subsequent for F50EX.

 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.
DASSAULT AVIATION Proprietary Data

FALCON 50

SERVICE BULLETIN

F50–496

March 10, 2010 F50–57–16

Revision 2 END OF DOCUMENT Page 6

 3 . MATERIAL INFORMATION

Refer to DRY BAY APPENDIX 5 REVISION 3.
DASSAULT FALCON JET CORP.

PO BOX 1946

SO HACKENSACK NJ 07606–9946

ATTENTION:

FIELD SERVICE DEPARTMENT

FIRST CLASS MAIL PERMIT NO. 3306 HACKENSACK, NJ 07602

DASSAULT AVIATION

78, Quai Marcel Dassault

Cedex 300

92552 SAINT–CLOUD Cedex

FRANCE

A l’attention de DSC
SERVICE BULLETINS COMPLIANCE

SERVICE BULLETINS COMPLIANCE

SERVICE BULLETINS COMPLIANCE

FALCON 50

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 50 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 :

496

496 F50

57

57 16

16

Revision 2

Revision 2

Révision 2

F50

F50 F50
ASSEMBLING DRY BAY AND DRAINING C

DRY BAY AP

This document is the intellectual property of DASSAULT AVIATION. It may not be used, reproduced, modified or disclosed without its authorization. DASSAULT A
HAZARDS OPERATIONS PROTEC

CHEMICAL HAZARDS ON WORKSTATION

Pickling 

Cleaning with solvent 

Sealant application

DRY BAY AP

This document is the intellectual property of DASSAULT AVIATION. It may not be used, reproduced, modified or disclosed without its authorization. DASSAULT A
Risks of clashes, fall of Handling with travelling craneobjects

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

HAZARDS OPERATIONS PROTECTIO

DRY BAY AP

This document is the intellectual property of DASSAULT AVIATION. It may not be used, reproduced, modified or disclosed without its authorization. DASSAULT A
F50 F900 F900EX F2000 F2000EX

27-811 27-811 27-811 27-811 27-81157-400 57-011 57-011 57-011 57-011

Extend the flaps see procedure

27-510 27-510 27-510

Remove the wing’s structural fuel tank removable panel see procedureRemove flap actuator (L25CF/R25CF) see procedure 27-568 27-521

PRELIMINARY STEPS

DRY BAY AP

CAUTION: Once panel is removed, ventilate with an air extractor to remove fuel vapors fro

This document is the intellectual property of DASSAULT AVIATION. It may not be used, reproduced, modified or disclosed without its authorization. DASSAULT A
Strip the area prior to drilling the PR injection holesSee Standard practices 20-602 (Stripping and pickling)

L

UPPER SURFACE TOP VIEW

RIB 4

DRY AREA FRAME

FWD

FWD

RIB 5

Strip paintChemical pickling

DRY BAY AP

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 A
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 rive

 - Fit all nut gang channels to half-frames Item 1-2 and Item 3-4, and interlay sealant (see Stand

Cut-out

Half-frame Item 1-2FGFB112500011W1P01/FGFB122500011W1P01

FGFB112500027

Nut gang channel Item 2839600C102-04S

DRY BAY AP

This document is the intellectual property of DASSAULT AVIATION. It may not be used, reproduced, modified or disclosed without its authorization. DASSAULT A
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 screwDrill the angle (Item 11-12) dia. 0.1 in. ( 2.5 mm) hole in half-frameDisassemble angle, deburrAssemble angle with interlaying sealant (See Standard Practices 20-650) and rivet

Half-frame Item 1-2FGFB112500011W1P01/FGFB122500011W1P01

DRY BAY AP

This document is the intellectual property of DASSAULT AVIATION. It may not be used, reproduced, modified or disclosed without its authorization. DASSAULT A
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 hDrill both 2 x dia. 0.1 in. ( 2.5 mm) of a cup in the other one and drill both holes to Remove, deburr and install both nut plates Item 48 on cup Item 7-8Assemble the 2 cups with interlaying sealant between the two parts+ 2 x screws Ite

Pinning

Recess Item 7-8FGFB112500003/FGFB122500003

Cup Item 9-10FGFB112500004 / FGFB122500004

Fill with bead sealant See Standard Practices 20-650

DRY BAY AP

2 x screw Item 47 22201TX050003XF

Cup Item 7-8FGFB112500003/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 A
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-

DRY BAY AP

nut gang cItem 26

This document is the intellectual property of DASSAULT AVIATION. It may not be used, reproduced, modified or disclosed without its authorization. DASSAULT A
OMEGA STIFFENER REMOVAL + SEALING ON RIB 5

 1) Remove the omega stiffener 113005004 / 113005004 on rib 5 do not  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 no to remove the rivets to ease the PR injection

RIB 5

Omega stiffener holes

FGFB113005004

DRY BAY APP

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 SEALANTSealant beetween doublerand 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 A
REMOVING AND CLEANING SEALANT

DRY BAY AP

This document is the intellectual property of DASSAULT AVIATION. It may not be used, reproduced, modified or disclosed without its authorization. DASSAULT A
ATTACHMENT REMOVAL FOR REAR SPAR ANGLES

Remove the six fasteners and check the diameter of each screw (some may be oversize-dimensScrape and clean the sealant in the bent section aera

RIB 5

REAR SPAR

2 Screws 38472TX060

Dia. 0.236 in. (6 mm)

DRY BAY AP

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 A
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 bPerform paint touch-up on the dia. .63 in. (Dia. 16mm) hole and nut platesInstall 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),

Rib 5

Rib 4

Rear spar

Locating plug

Box structure - inside 

view

Box structure - ins

view

Rib 4 

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 AP

This document is the intellectual property of DASSAULT AVIATION. It may not be used, reproduced, modified or disclosed without its authorization. DASSAULT A
 INSTALLATION OF DRAIN PROVISION ON LOWER SURFACE PANEL

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 the shim and rib 4 for rivet 21215DE32Install anchor nut Item (NAS1473A3) on the angle with interlaying sealantProtect holes with alodine and touch-up with paint.

DRY ZONE

Rib 4

.24 in. min6 mm mini

Tool ME484001Z00-SBF2000-358

DRY BAY AP

Rear spar Rear sp

Rear spar

Ø .20 in. Ø 5 mm 

Ø .20 in. Ø 5 mm Ø .31 in. Ø 8 mm 

This document is the intellectual property of DASSAULT AVIATION. It may not be used, reproduced, modified or disclosed without its authorization. DASSAULT A
REINFORCING RIB 5

Back drill rib 5 holes into the shim (Item 22) to a diameter of 0.1 in.(Dia. 2.5 mm) with drill bush MA48401-01Back 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) wCleco the shim (item 24) and the angle bracket (item 25) to rib 5Enlarge 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 AP

Angle bracket Item 2

FGFB113005041 

Rib 5

Shim Item 22 

FGFB112500009

Rib 5 reinforcement

ATTACHME

DIRECTION

Remove this rivet, 

if necessary 

If this configuration is encountered, 

rework the shims (item 22 & 24) to fit 

with the stiffener’s shape.

Shim -Item 24

FGFB113005042

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DRILLING THE BENT SECTIONS

Have the bent sections Item 13-14 and Item 15-16 resting on rib 5 and rear sparDrill existing holes drilled in panels to bent sections using Dia. 0.1 in. (Dia. 2.5 mm) drill bushDrill the angle only to dia. 0.204 in. (5.2 D10) for vertical attachments, dia.0.244 in.(Dia. 6.2 D

and Dia. 0.244 in.(dia. 6.2D10) and 0.204 in. (5.2 D10) for upper surface attachment fittings

RIB 5 REAR 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 AP

Dia. 0.244 in (Dia. 6.2 

mm) D10 bore

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 DRILLING THE LOWER SURFACE PANEL STIFFENER

Using tool MA48402Z01-FGFB117/127000103, pre-drill the stiffener to a diameter of Dia. 0

Rib 4

Rib 5

Rear spar

Rib 5

DRY BAY AP

Tool MA48402Z01-FGFB117/127000103

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 DRILLING THE LOWER SURFACE PANEL STIFFENER

Rib 5

Rib 4

Pre-drilled stiffener (12 x Dia. .1 in. 

(Dia. 2.5mm))

DRY BAY AP

NOTE: For easier access, use tool MA48401Z01-FGFB122500003 on LH side and tool MA48401Z01-FGFB112500003 on RH Attach tool MA48401Z01-FGFB112/122500003 to the stiffener and pre-drill to a diameter of 0.1 in. (Dia. 2.5 mm)

Tool MA48401Z01-FGFB112/122500

Rib 4

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INSTALLATION OF DRY BAY STRUCTURE

DRY BAY AP

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 stiffenerUsing screw clamps, secure the cup assembly to the lower panel stiffener and check the position (0.06 in. - 1.5 mSpot drill the three dia. 0.1 in. ( Dia.2.5 mm) pre-drilled holes of the lower skin panel stiffener in the cup asssemAttach the cup assembly to the stiffener,NOTE: Verify the position of cup assembly with respect to the stiffener (.06 in.(1.5mm))

Rib 4

Cups FGFB112/122500003FGFB112/122500004Item 7-9/8-10

Cups

Stiffener

.06 in.1,5 m

m

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INSTALLATION OF DRY BAY STRUCTURE

In case of interference between the half-frame and rib 5 during installation: See page 47

Half-frame Item 1-2FGFB112500011W1P01 / FGFB122500011W1P01

DRY BAY AP

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 MA40301Z01Check 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-frameDisassemble and check the gap as per page 47

Rib 5

Cup assembly 

DETAIL A

Hole of the upper skin panel

Ga

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INSTALLATION OF DRY BAY STRUCTURE

In case of interference between the half-frame and rib 5 during installation: See page 47

DRY BAY AP

Inside the wing box assemble the half frame (Item1-2 and item 3-4) with the positioning template ME62001Z01-SBwith screwsResting on the cup assembly, position the assembly in contact to rib 5 and bearing on tool MA40301Z01-FGFB112/122Check 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

Rib 4

Half-frame Item 3-4112500012W1 / 122500012W1

Rib 5

Cup assembly 

Positioning template

ME62001Z01-SBF2000-358

Shim Item 23 (between Rib 4 and half-frame)

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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 skDrill both dia. 0.1 in. ( Dia. 2.5 mm) pre-drilled holes of the half-frames in the Rib 4Attach the half-frames to the upper surface skin and the rib 4 with shim item 23Drill rib 5 holes, dia. 0.1 in. (Dia. 2.5 mm) then dia. .161 in. (dia. 4,1 mm) into half-frame (Item  with drill bush MA48401-01

Rib 5

Drillhalf-frame/rib 5 link

Half-frame Item 1-2FGFB112500011W1P01 / FGFB122500011W1P01

DRY BAY AP

 Drill bushMA48401-01

Rib 5

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INSTALLATION OF DRY BAY STRUCTURE

Drill rib 4/half-frame link to dia. 0.158 in.(dia. 4mm) using tool MA48401Z01-FGFB112/122500010

Rib 4

Drill half-frame/rib 4 link

Half-frame Item 3-4FGFB112500012W1/FGFB122500012W1

DRY BAY AP

This document is the intellectual property of DASSAULT AVIATION. It may not be used, reproduced, modified or disclosed without its authorization. DASSAULT A
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 surfaceDisassemble and deburr the assemblyPreparation of shim Item 19-20On shim Item 19-20 mark and drill a dia 0.204 in.(dia. 5.2) hole

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 AP

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ASSEMBLING THE DRY BAY

Drill cup assembly on workbench

DRY BAY AP

NOTE: Use the same tool as that used to drill the lower panel stiffenerPin tool MA48401Z01-FGFB112/122500003 to the cup assembly (item 7-9/8-10) and pre-drill to a diametPin 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. (DiaPin the plug to tool MA48401Z01-FGFB112/122500003 and drill to a diameter of 0.158 in. (Dia. 4 mm)

Shim 0.06 in. (1.5 mm)

 Plug FGFB112/122500008Item 17-18

Tool MA48401Z01-FGFB112/122500003

Cup assembly

This document is the intellectual property of DASSAULT AVIATION. It may not be used, reproduced, modified or disclosed without its authorization. DASSAULT A
ASSEMBLING THE DRY BAY

Remove, deburr and reinstall the assemblyMEASUREMENT 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 4Half frame Item 1-2 and Item 3-4 and the upper wing surfaceCup assembly Item 7-8 and Item 9-10 with the stiffener of the lower wPlug Item 17-18 with the stiffener of the lower wing surface

Remove, clean and deburr the assemblyPut protections on the areas to be liquid shimmed: red adhesive tape reference CFR AVF HP or teflon tapeSand the areas to be liquid shimmedClean with authorized solventSpread filling compound (See Standard Practices 20-320)

RIB 5

UPPER WING SURFACE

PLUG ITEM 17-18

FGFB112500008 / 

FGFB122500008

HALF FRAME ITEM 1-2FGFB112500011W1P01 / FGFB122500011W1P01

Measure and inject liquid shim if => 0.05 mm < Clearance

DRY BAY AP

NOTE 1: Do not work on wing while liquid shNOTE 2: Apply Filleralu at the end of the day 

This document is the intellectual property of DASSAULT AVIATION. It may not be used, reproduced, modified or disclosed without its authorization. DASSAULT A
ASSEMBLING THE DRY BAY

Drill links half frame/cup assembly to final hole size

Disassemble, clean and deburr the assemblySee page 48 for boring tolerances

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 U9 Rib 5

Rib 4

Rib 5

Lower surface panel

DRY BAY AP

This document is the intellectual property of DASSAULT AVIATION. It may not be used, reproduced, modified or disclosed without its authorization. DASSAULT A
DETAIL OF RIB 5 SPLICE

RIB 5

DRY BAY 

RIB 5 REINFORCEMENT

CORDON DE PR A 

PAR L’INTERME

2 + 2 TROUS Ø2,3mm 

DRILLING THE PR INJECTION HOLES IN LOWER AND UPPER SURFACES AT RIB 5

DETAIL OF RIB 5 SPLICE

SEALANT BEAD 

2 + 2 INJECTION HO

DRY BAY AP

This document is the intellectual property of DASSAULT AVIATION. It may not be used, reproduced, modified or disclosed without its authorization. DASSAULT A
Record the dimensions between the attachments of rib 5 reinforcement and the edge of rib 5 reinforcement b

Draw the edge of rib 5 reinforcement baseplate on the skinDraw 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 marksDO NOT DRILL IF A CENTER-TO-CENTER DISTANCE OF .55 in, MIN (14 MM MIN.) CANNOMark the center point of each drilling position at the interface between rib 5 reinforcement and rib 5; check mm mini) from each attachment

1243

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 

FWD sealant

MIDDLE LINE

REAR SPAR

RIB 5

A/C CENTERLINE

UPPER SURFACE PANELthick,ness 0.16 in. (4 mm) 

Be 

DRY BAY AP

 Ø 0,09 in. 

 ( Ø 2.3) 

1784 

1785 

1786 

1787 

1788 

1789 

1799 

1792 

1793 

1794 

1795 

1796 

1797 

1798 

NOTE.55 in. MIN14 mm MINI

This document is the intellectual property of DASSAULT AVIATION. It may not be used, reproduced, modified or disclosed without its authorization. DASSAULT A
Record the dimensions between the attachments of rib 5 reinforcement and the edge of rib 5 reinforcement b

Draw the edge of rib 5 reinforcement baseplate on the skinDraw 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 marksDO NOT DRILL IF A CENTER-TO-CENTER DISTANCE OF 14 MM MIN. CANNOT BE OBTAINMark the center point of each drilling position at the interface between rib 5 reinforcement and rib 5; check mm mini) from each attachment

1243

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

DRY BAY AP

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)

NOTE.55 in. MIN14 mm MINI

This document is the intellectual property of DASSAULT AVIATION. It may not be used, reproduced, modified or disclosed without its authorization. DASSAULT A
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 surr2) 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 43) Drill to final diameter with drill bit Ø .09 in. (Ø2.3 mm). 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 t(equal to the skin thickness)

DRILLING THE PR INJECTION HOLES

DRY BAY AP

NOTE: Lower skin .20 in. (5 mm) stop depth Upper skin .16 in. (4 mm) stop depth

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 INJECTING SEALANT INTO LOWER AND UPPER PANEL AND INTO RIB 5

PRIOR TO PR INJECTION1) Clean the dia. 0.09 in.bore (Ø2.3 mm) on lower and upper panel2) Inject authorized solvent (with a spout type container) in each doubler hole to clean the interface (double

DRY BAY AP

FIRST CLEAN AND DEGREASE CAREFULLY THE ASSEMBLY 

CAUTION : PRIOR TO STARTING SEALANT APPLICATION, ALL DRILLINGS PERFORMED, TO AVOID POLLUTING FRESH SEALANT WITH METAL SHAV

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RIB 5/DOUBLER INJECTION AND SEALANT

RIB 5 DOUBLER INJECTION SEALANT1) Sealant injection ((with a 1015 PSI (70 bars) extrusion gun fitted with a stiff end-piece)) in the doubler h

DRY BAY APP

- 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

BB

CC

DETAIL

INJECTION SCREW

Injection hole Drainage hole 

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 A
 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

DRY BAY APP

 S

Rib 5 doubler

RIB 5

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 A
 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 sp

CT Visual control of sealant application

DRY BAY AP

TOWARD WING ROO

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

Rear spar of 

upper wing 

surface

TOWARD WING ROOT

LOWER WING 

SURFACE

Thickness=4

UPPER WING 

SURFACE

Material: 2024 T351Protection: OACInstalled with PR

.008 in. (0.2 mm) CHAMFER AT 45°

PIN DETAIL

GRIP LE .4 μ in. to (10 μ to 2

2) Check for sealant flow at FWD/AFT end of upper/lower channels3) 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 A
INSTALLATION OF DRY BAY STRUCTURE

 Before tightening, apply interlaying sealant to the underside of the screw heads. - Final assembly of the lower and upper surface bent sections Item 13-14 and 15-16 of rib 5 fo

DRY BAY AP

1 x screw Item 39 38472TX060012XF1 x nut Item 38 6RH8035M

Upper surface angle Item 13-14FGFB11250006/FGFB122500006

Lower surface angle Item 15- 16FGFB11250007/FGFB122500007

Rib 5

2 x screw Item 31 22201TX050011XF

Rear spar 2 x nut Item 32 5RH8035M

1 x screw Item 40 38472TX060009X1 x nut Item 38 6RH8035M

1 x screw Item 44 Item38472TX050012XF1 x nut Item 32 5RH8035M

1 x screw Item 40 38472TX060009XF1 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 A
INSTALLATION OF DRY BAY STRUCTUREASSEMBLING 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 5Installation of 2 screws 38471BE044005ME (item 51) for attachment of reinforcement / rib 5Installation of 5 rivets 21215DE4011 (item 53) Installation of 2 screws 38460BE044006ME (Item 49) for attachment of bracket / reinforcement / rib 5Installation of 2 screws 38460BE044005ME (item 52) for attachment of reinforcement / rib 5Screws are installed with 4RH8035M nuts (item 35)

Rib 5

Shim -Item 24

FGFB113005042

Rib 5 reinforcement

DRY BAY APPE

REAR SPAR

Install rivets Item 57

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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 212

Rib 4

21215DE3208Item 55 

Item 61-62

Insert shim if 

necessary

DRY BAY AP

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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 stiffen

Lower surface panel

Rib 5

Cup assembly

11 x screw Item 36 22201TX050008XF11 x nut Item 32 5RH8035M

2 x screw Item 33 22201TX050010XF2 x nut Item 32 5RH8035M

Attachment direction

Plug Item 17-78FGFB112500008FGFB122500008

DRY BAY AP

NOTE: For easier access, screws item 33 and 36 can be installed in the reverse direc

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INSTALLATION OF DRY BAY STRUCTUREFilling the recess with bead sealant

DRY ZONE

Rib 4

Fill the recess with bead sealant

Fill the 2 holes with bead sealant Do not fill the anchor nuts

DRY BAY AP

REAR SPAR

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INSTALLATION OF DRY BAY STRUCTURE

DRY BAY AP

Apply sealant strips (See Appendix 2 page5: Sealant application for strips definition)

Apply a c

 Sealant strip

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INSTALLATION OF DRY BAY STRUCTURE

Assembling all parts with interlaying sealant: see Appendix 2

 - Final assembly of the half-frames

1 x screw Item 42 38471BE040008ME1 x nut Item 35 4RH8035M

Detail 1

15 x screw Item 41 22258TX050008XF

1 x Screw Item 43 15 x nut Item 32 5RH8035M22258TX050010XF1 x nut Item 32 5RH8035M

DRY BAY AP

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INSTALLATION OF DRY BAY STRUCTURE

 - Final installation of the half-framesFinal assembly check

Rib 4 Rib 5

Half-frame Item 3-4FGFB112500012W1/FGFB122500012W1

Shim Item 23FGFB112500015

7 x screw 22201TX050007XF7 x nut 5RH8035M

Attachment direction

CT

DRY BAY AP

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INSTALLATION OF DRY BAY STRUCTURE

DRY BAY AP

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 

Rib 5

Covering sealant on Rib 5 Covering 

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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 sealantSealing finish with sealant on door as per APPENDIX 2

CT

Rib 4

Door IFGFBFGFB

Rear spar

14 x screw Item 33 22201TX050010X14 x washer Item 46 23111DG050A

FUEL ZONE DRY ZONE

Rib 5

Rib 4

DRY BAY AP

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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.

DRY BAY AP

Identification pl

Intall this plate on

leak check has b

succesfully comp

NOTE:For FALCON 2000, 2000EX and 2000DX aircraft (refer to SB F2000-358 Page 5 or SB F2000EX-171 Page 5) ), replace the fuel doosurface 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 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 

This document is the intellectual property of DASSAULT AVIATION. It may not be used, reproduced, modified or disclosed without its authorization. DASSAULT A
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

DRY BAY AP

This document is the intellectual property of DASSAULT AVIATION. It may not be used, reproduced, modified or disclosed without its authorization. DASSAULT A
Check the tightening torque and re-tightening torque of fastenersCheck that all screws and MGPL (nuts, bushes) are properly installed, heads flush

8 141.6

17.7

31

66.4

SCREW

0.2360.276 106.2

SCREW 0.315SCREWSCREWSCREW

0.1580.205

4567

Ø inch Ø mm Torque lfb.in. To

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 

Dia. 0,2'LD

Dia. 0.2

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 AP

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FINAL STEPS

F50 F900 F900EX F2000 F2000EX

57-400 57-011 57-011 57-011 57-01127-811 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.

Install the flap actuator, (L25CF/R25CF)see procedure

27-568 27-521 27-510 27-510 27-510

Retract the flaps,see procedureInstall the wing’s structural fuel tank

removable panel,see procedure

 See DRY BAY APPENDIX-3 HYDROGEN PRESSURE TEST FOR D

DRY BAY AP

This document is the intellectual property of DASSAULT AVIATION. It may not be used, reproduced, modified or disclosed without its authorization. DASSAULT A
SEALANT APPLICATION DRY BAY W

DRY BAY AP

This document is the intellectual property of DASSAULT AVIATION. It may not be used, reproduced, modified or disclosed without its authorization. DASSAULT A
RISKS OPERATIONS MEANS OF PR

CHEMICAL RISKS LINKED TO WORK STATION

Pickling 

Cleaning with solvent 

Sealant application

DRY BAY AP

This document is the intellectual property of DASSAULT AVIATION. It may not be used, reproduced, modified or disclosed without its authorization. DASSAULT A
RISKS OPERATIONS MEANS OF 

Carrier handling Risk of injury, fall of objects.

 NON CHEMICAL RISKS LINKED TO WORK STATION

DRY BAY AP

This document is the intellectual property of DASSAULT AVIATION. It may not be used, reproduced, modified or disclosed without its authorization. DASSAULT A
DRY BAY ZONE

View detail following pages

Dry fence frame

made in 2 parts (FM)

Linking sheet metal angle mounted

with sealant interposition

Interstice filled with sealant

after mounting

Cups mounted with sealant interposition

Covering lay after fastening

3 lines of existing rivets covered by a sealant 

strip cemented with sealant on the fuel side

DRY BAY APP

This document is the intellectual property of DASSAULT AVIATION. It may not be used, reproduced, modified or disclosed without its authorization. DASSAULT A
INSTALLATION AND CEMENTING OF SEALANT BANDS WITH SEALANT ON 

Manufacture sealant strips with bead sealantOn flap vane, cement sealant strip with sealant

Sealant strip FGFB112005PR134 Qty : 1

Sealant strip FGFB112005PR118 Qty : 2Sealant strip FGFB112005PR042 Qty : 2

Sealan

Rib 5

5.3 in. (134 mm) .6 in.

16 mm

4.65 in. (118 mm)

F-F section

Covering sealant lay

Sealant strips cemented 

with sealant

Basic sealing methodsSee Standard Practices 20-650

DRY BAY AP

 .12 in. 

 3 mm 

.6 in.16 mm

 .12 in. 

 3 mm 

 .12 in. 

 3 mm 1.65 in. (42mm) .6 in. 16 mm

This document is the intellectual property of DASSAULT AVIATION. It may not be used, reproduced, modified or disclosed without its authorization. DASSAULT A
DETAIL 1

FUEL ZONE DRY ZO

RIB 5

DOOR MOUNTED WITH INTERLAYING SEALANT 

DRY BAY AP

This document is the intellectual property of DASSAULT AVIATION. It may not be used, reproduced, modified or disclosed without its authorization. DASSAULT A
DETAIL 1DETAIL 2

Shim Item 22

Shim Item 24

Stiffeni

R

RIB 4

Door Item 5-6

Half-frame Item 1-2

Half-frame Item 3-4 Shim Item 23 

DRY BAY AP

This document is the intellectual property of DASSAULT AVIATION. It may not be used, reproduced, modified or disclosed without its authorization. DASSAULT A
SECTION B-B

DETAIL 4

INTERLAYING SEALANT

COVERING SEALANT2 coating

BEAD SEALANT

FUEL

ZONE 

DRY Z

Recesses

Half frame

Door

Door

Half frame

Basic sealing methodsSee Standard Practices 20-650

DO NDRAI

DRY BAY AP

INSIDE PROTECWITH A COVER

FRAME / UPPER WING SURFACE

DOOR / FRAME / RECESSES

This document is the intellectual property of DASSAULT AVIATION. It may not be used, reproduced, modified or disclosed without its authorization. DASSAULT A
SEALANT BEADS BY INJECTION IN 

PANEL DRILLINGS ACCORDING TO 

PAGE 9

 + BEAD SEALANT ON TIPS

CT

DETAIL RIB 5 SPLICE

UPPER WI

LO

Visual control of sealant application

DRY BAY AP

This document is the intellectual property of DASSAULT AVIATION. It may not be used, reproduced, modified or disclosed without its authorization. DASSAULT A
SECTION C-C 

CT

VIEW G : RIB 5 SPLICE

Visual control of sealant application

 CLEANING OF THE INTERFACE : RIB 5 / RIB 5 DOUBLER + SEALANT INJECTION THROUGH THE 12 DRILLINGS AFTER REMOVAL OF THE HAT SECTIONSee page 33 APPENDIX 1

Bead sealant on joint of splice / rib 5+ covering sealant lay on all the fasteners in limit of sealant application zone, located on the back of the dry wall between rib 4 and rib 5.Beware not to blank off the stiffener access .

INTERLAYING SEALANT

COVERING SEALANT2 coating

BEAD SEALANT

Basic sealing methodsSee Standard Practices 20-650

DRY BAY AP

This document is the intellectual property of DASSAULT AVIATION. It may not be used, reproduced, modified or disclosed without its authorization. DASSAULT A
DRY BAY HYDROGEN PRESSURE 

DRY BAY AP

This document is the intellectual property of DASSAULT AVIATION. It may not be used, reproduced, modified or disclosed without its authorization. DASSAULT A
1) DRY BAY HYDROGEN PRESSURE TESTComposition of the gas to be used: 95

% of Nitrogen and 5% of Hydrogen

Hydrogen leak detector H2000-C including:

Main unit P/N AS90544 Probe P/N AS90232 Cable P/N AS90175

Leak Detector P/N AS90422 calibration tool 

Probe P/N AS90232

DRY BAY AP

Ce document est la propriété intellectuelle de DASSAULT AVIATION. Il ne peut être utilisé, reproduit, modifié, ou communiqué sans son autorisation . DASSAULT A
1) DRY BAY HYDROGEN PRESSURE TEST

LEAK DETECTOR START UP

Connect the probe to the main unitCAUTION : Always connect the probe to the unit prior to switching onSwitch the unit ONGreen indicator comes on and red indicator slowly flashes during warm-up phaseThe unit is used in Detection mode and the sensitivity must be set to 10.

TEST BEFORE USE

Before each use, test the probe using tool P/N AS90422Connect tool to Nitrogen cylinder (95% of Nitrogen and 5% of Hydrogen)Switch the unit ONOpen cylinder valve and bring the probe near the tool. If leak is not detected, replace the probe 

DRY BAY AP

The below procedure, allowing to determine if a leak is present or not, is applicable to the hydrogen leak dDassault . Equivalent tooling (should be capable of detecting an helium or 95% of Nitrogen and 5% of Hydmbar.l/sec) can be used under the responsability of the Service Station, with instructions to be defined by th

Ce document est la propriété intellectuelle de DASSAULT AVIATION. Il ne peut être utilisé, reproduit, modifié, ou communiqué sans son autorisation . DASSAULT A
1) DRY BAY HYDROGEN PRESSURE TESTSetting

Detector - gas cylinder

Main unit P/N AS90544 

DRY BAY- PRESSURE TEST AREA

Hose

PRESSU

SET T

DRY BAY AP

CAUTION : ADJUST THE VALUE OF PRESSURE REDUCING VALVE TO 

Ce document est la propriété intellectuelle de DASSAULT AVIATION. Il ne peut être utilisé, reproduit, modifié, ou communiqué sans son autorisation . DASSAULT A
1) Insert the seal plug into the drainage hole on the lower wing surface2) Connect the pressure gauge flexible line on the rear spar :

 - Close the valves of the pressure gauge and the gas bottle - Connect the flexible line of the detector gas on the pressure gauge - Open the pressure gauge valve to 5.1 psi (350 m.bars) pressure, then close the valve - Wait 30 minutes, time for the gas is spread inside the dry bay - Safety : disconnect the DETECTOR GAS bottle’s flexible line portion - Search for a leak see page 6

LOWER WING SURFACE

SEAL PLUG 

MA85202Z---F50B117

REAR SPAR

dia. 8 drainage hole

DRY BAY AP

Pressure gauge 

Pressure gauge : closed 

position

Gas cylinder hose

REAR SPAR

L

PRESSURMA85201

WARNING:Before re-injecting gas ventilate the dry bay

Ce document est la propriété intellectuelle de DASSAULT AVIATION. Il ne peut être utilisé, reproduit, modifié, ou communiqué sans son autorisation . DASSAULT A
3) Detection with Hydrogen leak detector H2000-C 

Probe

Rib 4 Rib 5

Probe

Switch the leak detector ONUsing the probe, search for a leak around the door and near rib 5 (between rib 5 and rib 6).If a leak is detected, the unit rings up and the red indicator comes on. The unit indicates "LEAK" where detected.Locate the leak and resume leak detection. Leak repair- Remove the PR arround the leak- Clean and degrease this area- Apply a new bead of PR or covering sealant- Make a new test.

DRY BAY AP

Door

Ce document est la propriété intellectuelle de DASSAULT AVIATION. Il ne peut être utilisé, reproduit, modifié, ou communiqué sans son autorisation . DASSAULT A
Install the plate (item 21) on the rear spar (see Appendix 1 page 13/49)

ZONE A

If there is a leak in zones A, contact DASSAULT AVIATION for specific repair solution.

DRY BAY AP

Ce document est la propriété intellectuelle de DASSAULT AVIATION. Il ne peut être utilisé, reproduit, modifié, ou communiqué sans son autorisation . DASSAULT A
REPORT OF DRILLING THE PR INJECTION HOLES

DRY BAY AP

Ce document est la propriété intellectuelle de DASSAULT AVIATION. Il ne peut être utilisé, reproduit, modifié, ou communiqué sans son autorisation . DASSAULT A
The technician and inspector must each fill-in the appropriate boxes of the table below

Lower 

surface

Upper 

surface

Lower 

surface

Upper 

surface

Signature

Check of margins

Name

Date

Pre-drilling bit dia.

Location of injection holes Technician Inspector

Skin

The adjustment of the drill bit stop height (equal 

to the skin thickness)

Check of drilling location

DRILLING THE PR INJECTION HOLES 

TABLE 1

DRY BAY AP

Ce document est la propriété intellectuelle de DASSAULT AVIATION. Il ne peut être utilisé, reproduit, modifié, ou communiqué sans son autorisation . DASSAULT A
Lower 

surface

Upper 

surface

Lower 

surface

Upper 

surface

The adjustment of the drill bit stop height (equal 

to the skin thickness)

Drilling bit dia.

The technician and inspector must each fill-in the appropriate boxes of the table below

Location of injection holes Technician Inspector

Skin

Signature

Name

Date

DRILLING THE PR INJECTION HOLES 

TABLE 2

DRY BAY AP

Ce document est la propriété intellectuelle de DASSAULT AVIATION. Il ne peut être utilisé, reproduit, modifié, ou communiqué sans son autorisation . DASSAULT A
SERVICE BULLETIN

DRY BAY – APPENDIX 5

February 15, 2010

Revision 3 Page 1

A . MODIFICATION KIT

(1) KIT P/N SBF2000-0358A

Structural parts

NEW P/N QTY KEY WORD INSTRUCTIONS

DISPOSITION ITEM

F

I

G

FGFB112500011W1P01 1 Half–frame LH 1

FGFB112500012W1 1 Half–frame LH 3

FGFB112500002 1 Door LH 5

FGFB112500003 1 Recess LH 7

FGFB112500004 1 Recess LH 9

FGFB112500005W1EQU 1 Angle assy LH 11

FGFB112500007 1 Bent section LH 13

FGFB112500006 1 Bent section LH 15

FGFB112500008 1 Plug LH 17

FGFB112500016 1 Shim LH 19

FGFB112500060W3 1 Angle LH 61

FGFB122500011W1P01 1 Half–frame RH 2

FGFB122500012W1 1 Half–frame RH 4

FGFB122500002 1 Door RH 6

FGFB122500003 1 Recess RH 8

FGFB122500004 1 Recess RH 10

FGFB122500005W1EQU 1 Angle assy RH 12

FGFB122500007 1 Bent section RH 14

FGFB122500006 1 Bent section RH 16

FGFB122500008 1 Plug RH 18

FGFB122500016 1 Shim RH 20

FGFB122500060W3 1 Angle RH 62

FGFB112005003 2 Plate LH/RH 21

FGFB112500009 2 Shim LH/RH 22

FGFB112500015 2 Shim LH/RH 23

FGFB113005042 2 Shim LH/RH 24

FGFB113005041 2 Angle bracket LH/RH 25

39600C332-13S 4 Gang-channel LH/RH 26

39600C123-05S 2 Gang-channel LH/RH 27

39600C102-04S 2 Gang-channel LH/RH 28
SERVICE BULLETIN

DRY BAY – APPENDIX 5

February 15, 2010

Revision 3 Page 2

Tool kit

NEW P/N QTY KEY WORD

ME48401Z01-SBF2000-358 1 Drill tool

ME48402Z01-SBF2000-358 1 Drill tool

Hardware part

NEW P/N QTY KEY WORD INSTRUCTIONS

DISPOSITION ITEM FIG

NAS1133V4A 4 Screw 29

MS21059L3 4 Nut 30

22201TX050011XF 6 Screw 31

5RH8035M 78 Nut 32

22201TX050010XF 32 Screw 33

38145BE040006ME 16 Screw 34

4RH8035M 36 Nut 35

22201TX050008XF 22 Screw 36

22201TX050006XF 14 Screw 37

6RH8035M 6 Nut 38

38472TX060012XF 2 Screw 39

38472TX060009XF 4 Screw 40

22258TX050008XF 30 Screw 41

38471BE040008ME 2 Screw 42

22258TX050010XF 2 Screw 43

38472TX050012XF 2 Screw 44

2201TX050007XF 64 Screw 45

23111DG050A 78 Washer 46

22201TX050003XF 4 Screw 47

5SF5009M 4 Nut 48

38145BE044006ME

or

38460BE044006ME

20 Screw

Screw used instead of rivet

49

38471BE044006ME 6 Screw 50

38471BE044005ME 4 Screw 51

38460BE044005ME 4 Screw 52

21215DE4011 10 Rivet 53

21218DB2408J 20 Rivet 54

21218DE3208 8 Rivet 55

21215DE2410J 8 Rivet 56

21215DE4009 30 Rivet 57

79160 2

“SERVICE BULLETIN

COMPLIANCE” label 58
SERVICE BULLETIN

DRY BAY – APPENDIX 5

February 15, 2010

Revision 3 Page 3

(2) KIT P/N SBF2000-0358B

Tool kit to be made available in Service Center.

P/N

Q

T

Y

KEY WORD TOOL BOX

ITEM

MA95101Z00-FGFB112500001 1 Tool box

Comprising:

MA48402Z00-FGFB117000103 1 Lower panel stiffener drilling tool (LH) 1

MA48401Z00-FGFB112500003 1 Recess/Stiffener drilling tool (LH) 2

MA40301Z00-FGFB112500010 1 Frame maintaining tool (LH) 3

MA48401Z00-FGFB112500010 1 Rib 4/half-frame drilling tool (LH) 4

MA48401Z00-FGFB116 1 Lower-panel Rib 4/Rib 5 drilling grid (LH) 5

MA48402Z00-FGFB112500010 1 Rib 5/half-frame drilling tool (LH) 6

MA48402Z00-FGFB127000103 1 Lower panel stiffener drilling tool (RH) 7

MA48401Z00-FGFB122500003 1 Recess/Stiffener drilling tool (RH) 8

MA40301Z00-FGFB122500010 1 Frame maintaining tool (RH) 9

MA48401Z00-FGFB122500010 1 Rib 4/half-frame drilling tool (RH) 10

MA48401Z00-FGFB126 1 Lower-panel Rib 4/Rib 5 drilling grid (RH) 11

MA48402Z00-FGFB122500010 1 Rib 5/half-frame drilling tool (RH) 12

MA48401Z00-FGFB112005A2 1

Blanking plate rear spar boring tool (L/H

and R/H) 13

MA61101Z00-F50B101001 8 Washer, pinning 14

MA61101Z00-F50B101002 8 Washer, pinning 15

MA48401Z00-FGFB116001 3 Drill–bush, template 16

MA48401Z00-FGFB116002 3 Drill–bush, template 17

MA48401Z00-FGFB112500003051 10 Drill–bush, shouldered, dia. 2.5 18

MA48401Z00-FGFB112500003052 10 Drill–bush, shouldered, dia. 4 19

MA48401Z00-FGFB112500003053 10 Drill–bush, shouldered, dia. 5 20

MA48401Z00-FGFB112500003054 10 Drill–bush, shouldered, dia. 4.2 21

MA48401Z00-FGFB112500003055 10 Drill–bush, shouldered, dia. 4.4 22

MA48401Z00-FGFB112500003031 10 Pin, knurled dia 2.5 23

MA48401Z00-FGFB112500003041 10 Nut, dia 2.5 23

MA48401Z00-FGFB112500003032 10 Pin, knurled dia 4 24

MA48401Z00-FGFB112500003042 10 Nut, dia 4 24

MA48401Z00-FGFB112500003033 10 Pin, knurled dia 5 25

MA48401Z00-FGFB112500003043 10 Nut, dia 5 25

MA60401-01-DIA4U9 8 Pin, centering, dia. 4 U9 26

MA60401-01-DIA42U9 4 Pin, centering, dia. 4.2 U9 27

MA60401-01-DIA44U9 4 Pin, centering, dia. 4.4 U9 28

MA48401-01 3Drill–bush, with handle, int. dia. 2.5, ext.

dia 4 29
SERVICE BULLETIN

DRY BAY – APPENDIX 5

February 15, 2010

Revision 3 Page 4

P/N

Q

T

Y

KEY WORD INSTRUCTIONS

DISPOSITION

MA95101Z00-FGFB112 1 Tool box

Comprising:

MA85202Z00-F50B117 2 Seal plug L/H and R/H

MA85201Z00-FGFB112 1 Presssurization tool applicable

ME62001Z00-SBF2000-358 2 Positioning template

ME29501Z00-38460BE040SB1 16 Screw

NOTE: In the tool reference 00 stand for the serial number.

(3) KIT P/N SBF2000-0358F

This kit is to be orded for each SB application

NEW P/N

Q

T

Y

KEY WORD

MA29501Z00-F50B101001 1 Nozzle

ME29502Z00-SBF2000-358 2 Injection hose

(4) KIT FOR APPLICATION OF SB F2000-358 ONLY

KIT P/N SBF2000-0358C for aircraft without BS F2000-202 or without M1903

NEW P/N

Q

T

Y

KEY WORD OLD P/N

INSTRUCTIONS

DISPOSITION

F2MA090200003A6 2 Instruction placard F2MA090200003XX Discard

F2MA090100024A6 1 Instruction placard F2MA090100024XX Discard

KIT P/N SBF2000-0358D for aircraft with BS F2000-202 or with M1903

NEW P/N

Q

T

Y

KEY WORD OLD P/N

INSTRUCTIONS

DISPOSITION

F2MA090200003A7 2 Instruction placard F2MA090200003XX Discard

F2MA090100024A7 1 Instruction placard F2MA090100024XX Discard
SERVICE BULLETIN

DRY BAY – APPENDIX 5

February 15, 2010

Revision 3 Page 5

(5) KIT FOR APPLICATION OF SB F2000EX 171 ONLY

KIT P/N SBF2000X0171A for F2000EX aircraft

NEW P/N

Q

T

Y

KEY WORD OLD P/N

INSTRUCTIONS

DISPOSITION

F2MB090200003A3 2 Instruction placard F2MB090200003XX Discard

F2MB090100024A3 1 Instruction placard F2MB090100024XX Discard

KIT P/N SBF2000X0171B for F2000DX aircraft

NEW P/N

Q

T

Y

KEY WORD OLD P/N

INSTRUCTIONS

DISPOSITION

F2ME090200003A1 2 Instruction placard F2ME090200003 Discard

F2ME090100024A1 1 Instruction placard F2ME090100024 Discard

(6) KIT FOR APPLICATION OF SB F50-496 ONLY

KIT P/N SBF50–0496AR1

NEW P/N

Q

T

Y

KEY WORD OLD P/N

INSTRUCTIONS

DISPOSITION

F50B090100024A1 1 Instruction placard F50B800499012XX Discard

FGFB090200003A4 2 Instruction placard F50B800501002XX Discard

(7) KIT FOR APPLICATION OF SB F900-388 ONLY DFOR AIRCRAFT S/N 1 THROUGH 20

KIT P/N SBF900-0388A

NEW P/N

Q

T

Y

KEY WORD OLD P/N

INSTRUCTIONS

DISPOSITION

FGFB090200003A4 2 Instruction placard FGFB090200003A1 Discard
SERVICE BULLETIN

DRY BAY – APPENDIX 5

February 15, 2010

Revision 3 END OF DOCUMENT Page 6

 B . LOCAL PROCUREMENT

As per chapter12, ingredients and consumable product

– Interlaying sealant PS 892C2.

– Covering sealant PR 1776A AS or AC350.

– Bead sealant PR 1776B2 or PR 1422B2.

– Filleralu.

– Alodine 1200.

– PU 66 CELOMER paint scheme.

– Stripper MIL-R-81294.

Specific tool:

(1) Hydrogen leak detector

– Dassault validated hydrogen leak detector comprising:

 Main unit P/N AS90544

 Probe P/N AS90232

 Cable P/N AS90175

 Leak detector calibration tool P/N AS90422

 To be used with a 95% of Nitrogen and 5% of Hydrogen gas

– Or an equivalent tool under the responsability of the Service Station

(2) PR injection gun

– Injection gun capable of an injection pressure of at least 1015 psi (70 bars)

– If your gun does not feature these characteristics, order kit SBF2000-0358E or hire gun

RB1140-04 and adapter ME29501Z00-SBF2000-358, otherwise using your gun implies to

manufacture the adapter locally for connecting the injection hose provided in the kit

SBF2000-0358F.

KIT P/N SBF2000-0358E

NEW P/N QTY KEY WORD

MA29501Z00-1VALISE 1 Tool case

comprising: 1

 MA29501Z00-1 1 PR injection gun

 MA29502Z00-F50B101001 1 Union

 MA29502Z00-F50B101002 1 Union nut