FALCON 900EX

FALCON 900EX EASy

FALCON 900DX

No 285-R1

JANUARY 26, 2015

MANDATORY

ATA 33-08

LIGHTING

EXTERIOR LIGHTING

ELECTRICAL BONDING OF WHELEN FIN TIP ANTICOLLISION 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.

573
LIGHTING

EXTERIOR LIGHTING

ELECTRICAL BONDING OF WHELEN FIN TIP ANTI-COLLISION LIGHT

Initial issuance July 18, 2007

List of effective pages :

1 to 15

Erratum September 09, 2007

List of effective pages :

1 to 15

List of modified pages :

8

Revision 1 January 26, 2015

List of effective pages :

1 to 14

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 -285

F900EX -33-08
LIGHTING

EXTERIOR LIGHTING

ELECTRICAL BONDING OF WHELEN FIN TIP ANTI-COLLISION LIGHT

1. PLANNING INFORMATION

A. EFFECTIVITY

This Service Bulletin is applicable to the following aircraft equipped with a WHELEN fin tip anticollision light (without SATCOM fairing):

• FALCON 900EX with serial numbers 1 through 195, equipped with a WHELEN fin tip anticollision light per Service Bulletin F900EX-25 (M1682), and (F900EX, F900EX-EASy), and

• FALCON 900EX with serial numbers 601 through 620 (F900DX).

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 FALCON 900EX and

FALCON 900DX 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 modify the routing of the wiring.

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 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.

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DASSAULT AVIATION Proprietary Data
G. MATERIAL - PRICE AND AVAILABILITY

The modification kit may be obtained from either address listed below:

Western hemisphere: DASSAULT FALCON JET CORP.

SPARES DISTRIBUTION CENTER

200 RISER ROAD

LITTLE FERRY, NJ 07643 U.S.A.

Telephone:

• CANADA and U.S.A.: 1-800-800-4036

• MEXICO: 001-800-800-4036

• Other countries: 1-201-541-4809

Fax:

• CANADA and U.S.A.: 1-800-800-4817

• MEXICO: 001-800-800-4817

• Other countries: 1-201-440-7021

Other continents: DASSAULT AVIATION

Falcon Spares

BOITE POSTALE N°101

AEROPORT DU BOURGET

93350 - LE BOURGET Cedex (FRANCE)

Please contact your Dassault Aviation

Account Representative

Telephone: 33 (0)1.48.35.56.78

Fax: 33 (0)1.48.35.56.00

E/H dafsorder@dassault-aviation.com

Price and availability on request.

H. TOOLING - PRICE AND AVAILABILITY

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)

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DASSAULT AVIATION Proprietary Data
• VERTICAL STABILIZER FIN TIP (Refer to IPC fig. 55-30-40-10)

Service Bulletin F200EX-25 "Lights - Navigation lights - Replacement of fin anti-collision light"

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.

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

• Remove the PR bead coating the retainer (item 150) without removing the flexible gasket

located underneath.

• Remove the retainer, glass cover and seal (items 150, 180 and 190).

• Remove the light unit assembly (screws item 110).

NOTE: Remove and discard gasket (item 210) if installed.

B. ANTI-COLLISION LIGHT ELECTRICAL BONDING

In accordance with fig. 1:

(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 plate (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.

(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) Connect and safety connector (4LX) to the light unit.

(16) Set the strip assembly and the light unit assembly into place in the fairing and attach the light

assembly to the fairing. Smooth out the PR in excess around the strips.

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DASSAULT AVIATION Proprietary Data
(17) Use a shim to wedge strip assembly (items 2 and 3) in contact against the fairing’s wall. Allow to

cure.

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

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

with alodine.

(20) Install the retainer, glass cover and sealthe gasket, the lens, and the retainer plate (Refer to IPC

fig. 33-40-10-50 , items 190, 180 and 150).

(21) Apply a bead sealant around the attaching plate.

C. MODIFYING THE WIRING

Modify the shield connection in accordance with instructions depicted hereafter and using:

• fig. 2 on aircraft with serial numbers 1, 12 and subsequent (modification F900EX M1682 factory

applied),

• fig. 3 on aircraft with serial numbers 2 through 11 if SB F900EX-25 if applied.

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.

• 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.

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DASSAULT AVIATION Proprietary Data
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.

D. RE-ROUTING THE WIRING WITH WIRING ROUTED OVER RIB 2

In accordance with fig. 4:

(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 180,

190, 260).

(9) Apply bead sealant around the retainer.

E. RE-ROUTING THE WIRING WITH WIRING ROUTED AROUND THE BACK OF FAIRING

In accordance with fig. 5:

(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. 5.

(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 180,

190, 260).

(11) Apply bead sealant around the retainer.

F. FINAL STEPS

(1) Use a permanent ink pen to record the number of this Service Bulletin on "Service Bulletin

Compliance" label (item 7).

(2) Use interlaying sealant to bond the "Service Bulletin Compliance" label (item 7) to the inner skin

of the fairing next to the P/N.

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

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DASSAULT AVIATION Proprietary Data
(4) 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.

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

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.

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DASSAULT AVIATION Proprietary Data
3. MATERIAL INFORMATION

A. MODIFICATION KIT

KIT P/N SBF900EX0285A

(1) Mechanical kit

KIT P/N SBF900EX0285A - Mechanical kit

NEW P/N

Q

T

Y

KEY WORD INSTRUCTIONS

DISPOSITION

ITEM

FIG

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. 4) - (5-fig. 5)

78750-02 1 Clamp - (6-fig. 4) - (6-fig. 5)

79160 1 "Service Bulletin

Compliance" label

- (7-fig. 1) -

(2) Electrical kit

KIT P/N SBF900EX0285A - Electrical kit

NEW P/N

Q

T

Y

KEY WORD INSTRUCTIONS

DISPOSITION FIG

01EQTC0S20-05-119-18 1 Lug Ground 322J - fig. 2 - fig. 3 -

01C0K302-16S01 1 Contact Ground 322J - fig. 2 - fig. 3 -

01CAN210-1-20 1 #20 gauge wire L= 3.3 ft (1 m) Ground 322J - fig. 2 - fig. 3 -

01C0A54143FC16 4 Blanking pin 322J/P - fig. 2 - fig. 3 -

01EQTRB23-2R 1 Self-soldering sleeve 4LX - fig. 2 - fig. 3 -

01CAN210-1-22 1 #22 gauge CF wire L = 1 ft (0.3 m) - See

NOTE 1

4LX - fig. 2 - fig. 3 -

01CAN203-1-22Y 1 #22 gauge KZ wire L = 1 ft (0.3 m) - See

NOTE 2

4LX - fig. 2 - fig. 3 -

01EQTC0S20A03-071-22 1 Lug 4LX - fig. 2 - fig. 3 -

01C0K345-16S01 2 Contact 4LX - fig. 2 - fig. 3 -

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DASSAULT AVIATION Proprietary Data
KIT P/N SBF900EX0285A - Electrical kit

NEW P/N

Q

T

Y

KEY WORD INSTRUCTIONS

DISPOSITION FIG

01EQTEC1-1 1 Insulating sleeve 322P - fig. 2 - fig. 3 -

01EQTEC1-1 4 Insulating sleeve - See NOTE 3

01EQTPRL08B01 1 Splice - See NOTE 3

GND322J-B 2 Black sleeve with white marking

01PR0TMS3-32BK

322J - fig. 2 - fig. 3 -

GND312J-B 2 Black sleeve with white marking

01PR0TMS3-32BK

312J - fig. 2 - fig. 3 -

A 1 Black sleeve with white marking

01PR0TMS3-32BK

4LX - fig. 2 - fig. 3 -

B 1 Black sleeve with white marking

01PR0TMS3-32BK

4LX - fig. 2 - fig. 3 -

78750-01 5 Clamp 4LX - fig. 2 - fig. 3 -

NOTE 1: Use on FALCON 900EX S/N 1 through 136 and 138 through 140.

NOTE 2: Use on FALCON 900EX S/N 137, 141 and subsequent, and FALCON 900DX.

NOTE 3: Do not use on FALCON 900EX and FALCON 900DX.

B. LOCAL PROCUREMENT

As indicated in Consumable Products Manual (CPM):

• alodine.

• interlaying sealant.

• bead sealant.

• MEK or equivalent.

• covering sealant.

• Green CELOMER varnish 6060B.

• Locking wire.

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DASSAULT AVIATION Proprietary Data
Figure 1: ELECTRICAL BONDING STRIPS INSTALLATION

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Figure 2: AIRCRAFT F900EX S/NS 1, 12 THROUGH 195 - AIRCRAFT F900DX 601 THROUGH 620

(MODIFICATION F900EX M1682 FACTORY APPLIED)

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Figure 3: AIRCRAFT F900EX S/NS 2 THROUGH 11 WITH SB F900EX-25 APPLIED GND322J–B

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Figure 4: RE-ROUTING THE WIRING - AIRCRAFT WITH WIRING ROUTED OVER RIB 2

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Figure 5: RE-ROUTING THE WIRING - AIRCRAFT WITH WIRING ROUTED AROUND THE BACK OF

FAIRING

END OF DOCUMENT

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SERVICE BULLETINS COMPLIANCE FALCON 900EX A/C S/N

DASSAULT AVIATION Number ATA Number

F900EX 285 F900EX 33 08 Coding: C complete compliance

T partial compliance

Performed by:

Remarks: Revision 1 Date: Signature:

SERVICE BULLETINS COMPLIANCE

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 applique ce Bulletin de Service sur votre avion, veuillez avoir l'amabilite de nous en informer:

- Utiliser la carte reponse superieure pour continent americain (Dispensee de timbrage pour postage depuis les U.S.A.) ou le fax pour

Dassault Falcon Jet : 1-201-541-4700.

- Ou la carte reponse inferieure pour autres continents ou le fax pour Dassault Aviation : 33 (0)1.47.11.65.21.

Eventuellement, si d'autres Bulletins de Service ont ete appliques simultanement, vous pouvez les mentionner dans les cases vierges

prevues a cet effet.

APPLICATION DES BULLETINS DE SERVICE

SERVICE BULLETINS COMPLIANCE FALCON 900EX A/C S/N

DASSAULT AVIATION Number

Numero DASSAULT AVIATION

ATA Number

Numero ATA

F900EX 285 F900EX 33 08 Coding: C

complete compliance

application totale

T

partial compliance

application partielle

Performed by:

Fait par:

Remarks: Revision 1 Date: Signature:

Remarques: Revision 1