FALCON 900EX

FALCON 900EX EASy

FALCON 900DX

No 305-R1

JANUARY 26, 2015

MANDATORY

ATA 33-10

LIGHTING

EXTERNAL LIGHTS

IMPROVED ELECTRICAL BONDING OF WHELEN ANTICOLLISION LIGHT TO THE S-DUCT COWL

FALCON SERVICE BULLETIN

Copyright © 2015 by Dassault Aviation

All rights reserved. No part of this work may be reproduced or copied

in any form or by any means without written permission

of Dassault Aviation.

573
LIGHTING

EXTERNAL LIGHTS

IMPROVED ELECTRICAL BONDING OF WHELEN ANTI-COLLISION LIGHT TO THE SDUCT COWL

Initial issuance September 19, 2007

List of effective pages :

1 to 13

Erratum November 21, 2008

List of effective pages :

1 to 13

List of modified pages :

3, 4 and 7

Revision 1 January 26, 2015

List of effective pages :

1 to 13

List of modified pages :

1 to 11

REASON:The Service Bulletin is now rendered mandatory.

This revision is not applicable to aircraft already modified per the initial issuance of

this Service Bulletin.

FALCON 900EX F900EX -305

F900EX -33-10
LIGHTING

EXTERNAL LIGHTS

IMPROVED ELECTRICAL BONDING OF WHELEN ANTI-COLLISION LIGHT TO THE SDUCT COWL

1. PLANNING INFORMATION

A. EFFECTIVITY

This Service Bulletin is applicable to:

• F900EX aircraft with serial numbers 1 through 195 (F900EX, F900EX EASy),

• F900EX aircraft with serial numbers 601 through 620 (F900DX),

equipped with a WHELEN anti-collision light on S-duct front upper fairing (353AT) (A/C with fin tip

SATCOM fairing).

B. REASON

The electrical bonding of the WHELEN anti–collision light installed on Engine No. 2 S–duct is currently

provided at the junction connector. The bonding value may not be sufficient in case of lightning strike.

The purpose of this Service Bulletin is to improve the anti-collision light bonding in order to make the

light installation more resistant to damage in case of a lightning strike.

C. DESCRIPTION

The operation consists in:

• removing S-duct front upper fairing (353AT),

• installing a bonding strip between the anti-collision light and a fuselage pick-up rib.

D. COMPLIANCE

Mandatory:

• This Service Bulletin is rendered mandatory by EASA Airworthiness Directive No. 2015-0006..

• As prescribed by the Airworthiness Authorities of the country of registration of the aircraft.

E. APPROVAL

This Service Bulletin covers DASSAULT AVIATION modification F900EX M5386 that has been

approved under the authority of DOA nr. EASA.21J.051.

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

F. LABOR

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

NOTE: These labor-hours only concern the work described in this Service Bulletin and do not include

other maintenance work that may be performed on this occasion.

G. MATERIAL - PRICE AND AVAILABILITY

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

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DASSAULT AVIATION Proprietary Data
Western hemisphere: DASSAULT FALCON JET CORP.

SPARES DISTRIBUTION CENTER

200 RISER ROAD

LITTLE FERRY, NJ 07643 U.S.A.

Telephone:

• CANADA and U.S.A.: 1-800-800-4036

• MEXICO: 001-800-800-4036

• Other countries: 1-201-541-4809

Fax:

• CANADA and U.S.A.: 1-800-800-4817

• MEXICO: 001-800-800-4817

• Other countries: 1-201-440-7021

Other continents: DASSAULT AVIATION

Falcon Spares

BOITE POSTALE N°101

AEROPORT DU BOURGET

93350 - LE BOURGET Cedex (FRANCE)

Please contact your Dassault Aviation

Account Representative

Telephone: 33 (0)1.48.35.56.78

Fax: 33 (0)1.48.35.56.00

E/H dafsorder@dassault-aviation.com

Price and availability on request.

H. TOOLING - PRICE AND AVAILABILITY

Normal maintenance tooling.

I. WEIGHT AND BALANCE

Change in weight: None.

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

J. REFERENCES

Aircraft Maintenance Manual:

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

• PRINCIPLES AND CHECK OF THE ELECTRICAL BONDING (Refer to TASK

20-20-00-910-801)

• OPERATIONAL TEST OF THE VHF COMMUNICATION SYSTEM (Refer to TASK

23-11-00-710-802)

• OPERATIONAL TEST OF THE EXTERIOR LIGHTING (Refer to TASK 33-40-00-710-801)

• REPLACEMENT OF UPPER ANTI-COLLISION LIGHT BULB (WHELEN) (Refer to TASK

33-40-09-960-801)

Structural Repair Manual:

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DASSAULT AVIATION Proprietary Data
• INSTALLATION OF SHUR-LOK BLIND TYPE INSERT (Refer to SRM 51-40-05)

K. OTHER PUBLICATIONS AFFECTED

The following publication is revised to account for the changes introduced by this Service Bulletin:

• Illustrated Parts Catalog.

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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 securing S-duct front upper fairing (353AT).

(3) Disengage S-duct front upper fairing (353AT) from the rib.

(4) If installed, disconnect VHF 1 antenna (L5RC) (connector 691P), located at the front on the LH

side.

(5) Disconnect upper anti-collision light (4LX).

(6) Remove S-duct front upper fairing (353AT).

(7) Protect the connectors with caps/lugs.

B. ELECTRICAL BONDING OF THE ANTI–COLLISION LIGHT

(1) As per Maintenance Manual (Refer to TASK 33-40-09-960-801):

• Remove the sealant embedding retainer (item 2) without removing the flexible seal located

under it.

• Remove the retainer, glass cover and seal (items 2, 3 and 4).

• Remove the anti–collision light housing.

NOTE: Discard the seal if installed between the housing and S-duct front upper fairing (353AT).

(2) As per fig. 1, fig. 2 and fig. 3:

(a) From S-duct front upper fairing (353AT) LH side, remove the two fittings attaching the anti–

collision light pick-up plate blending with strip (1-fig. 3).

(b) Install baseplate strip (item 1) on S-duct front upper fairing (353AT): drill a hole centered on

the hole drilled for the attachment of S-duct front upper fairing (353AT), and joggle to

abutment against the lower reinforcement.

(c) For A/C with Service Bulletin F900EX-19 (M1947) applied, slightly bend the strip at the plate

to allow the plate to fit flat against S-duct front upper fairing (353AT).

(d) Keep the strip applied against S-duct front upper fairing (353AT).

(e) Counterbore S-duct front upper fairing (353AT) to dia. 0.1 in (2.5 mm) in accordance with the

strip and pin-rig.

(f) Joggle strip (item 1) at the anti-collision light pick-up plate.

(3) For A/C with modification F900EX M3541 (F900EX S/N 141 through 195 and F900DX S/N 601

through 620) applied (riveted anti-collision light pick-up plate):

(a) Drill strip (item 1) to dia. 1/8 in (3.2 mm) in accordance with the two pick-up holes of the

plate.

(b) Remove the strip.

(c) Drill a new hole in the strip to dia. 0.1 in (2.5 mm) for additional attachment fitting (item 4).

(d) Pin the strip to the pick-up plate.

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DASSAULT AVIATION Proprietary Data
(e) Counterbore the new hole drilled in the strip, in the plate and S-duct front upper fairing

(353AT).

(f) Drill the three elements to dia. 0.157 in (4 mm).

(g) Remove strip (item 1).

(h) Countersink S-duct front upper fairing (353AT) for rivet (4-fig. 3).

(4) For A/C with Service Bulletin F900EX-19 (M1947) applied (attachment of anti-collision light pickup plate with screws and inserts):

(a) Draw the outline of strip (item 1) on the pick–up plate.

(b) Remove strip (item 1).

(c) Remove the pick–up plate and the sealant.

(d) In the plate, drill a new hole to dia. 0.1 in (2.5 mm) for the additional attachment fitting (item

6).

(e) Position the plate on S-duct front upper fairing (353AT) and mark the location of the new

hole.

(f) Place insert (item 6) (Refer to SRM 51-40-05).

(g) Drill the new hole to dia. 0.2 in (5 mm) in the pick-up plate.

(h) Position strip (item 1) on the pick-up plate in accordance with the previously drawn outline.

Drill the strip in accordance with the three holes drilled in the pick-up plate.

(i) Secure the pick-up plate, except at the three strip pick-up locations, with interlaying

sealant. Place bead sealant at the mating area with S-duct front upper fairing (353AT).

(5) As per fig. 3, fig. 4 and fig. 5:

(a) Pin strip (item 1) to the pick-up plate (screws or pins).

(b) Pin strip (item 1) to S-duct front upper fairing (353AT).

(c) One at a time, drill the pick-up holes of the strip and S-duct front upper fairing (353AT) to dia.

0.2 in (5 mm), at the location of screws (item 2), and pin-rig as the operation proceeds to

provide a satisfactory resting base.

(d) Remove the strip.

(e) Drill the lower hole of the strip to dia. 0.2 in (5 mm).

(f) Remove the honeycomb from each hole drilled in S-duct front upper fairing (353AT) over a

dia. of 0.71 in (18 mm).

(g) Completely fill the holes in S-duct front upper fairing (353AT) with epoxy resin. Allow to

cure.

(h) Re-drill and countersink for screws (2-fig. 4).

(6) As per fig. 3:

(a) Strip the paint from the upper surface of the anti-collision pick-up plate at the level of the

housing installation plane.

(b) Strip the paint from the lower surface of the anti-collision pick-up plate at the level of the

mating plane of strip (item 1).

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DASSAULT AVIATION Proprietary Data
(c) Protect the stripped parts with alodine.

(7) Clean the resting faces of the housing, the strip and S-duct front upper fairing (353AT) with MEK.

(8) Apply interlaying sealant on the face of strip (item 1) resting on S-duct front upper fairing

(353AT).

NOTE: Do not cover the part resting on the pick–up plate.

(9) As per (fig. 2) and (fig. 4), secure the strip to S-duct front upper fairing (353AT) with screws and

nuts (items 2 and 3). Smooth the excess sealant at the periphery of the strip and cover the nuts

with covering sealant.

(10) Attachment of strip (item 1) to the pick–up plate (fig. 3):

(a) Remove any sealant seeping in between the two elements.

(b) For A/C with Service Bulletin F900EX-19 (M1947) applied, secure the assembly on S-duct

front upper fairing (353AT) with removed screws and washers (items 6 and 7).

(c) For A/C with modification F900EX M3541 (F900EX S/N 141 through 195 and F900DX S/N

601 through 620) applied, secure the assembly to S-duct front upper fairing (353AT) with

rivets (item 4) and interlaying sealant under the rivet heads.

(d) Apply bead sealant to the periphery of the strip.

(11) Modification of the fuselage rib (fig. 2):

(a) Mark the location of the hole picking up the strip on the rib.

(b) Remove the sealant and the paint from the marked area.

(c) Protect the stripped area with alodine.

C. FINAL STEPS

(1) Secure the anti-collision light housing to S-duct front upper fairing (353AT).

(2) Install the seal, the glass cover and the retainer.

(3) Apply bead sealant around the attachment plate.

(4) Using indelible ink, inscribe “SB 305” on "Service Bulletin Compliance" label (8-fig. 1).

(5) Using interlaying sealant, bond the "Service Bulletin Compliance" label to the internal skin of Sduct front upper fairing (353AT) in the vicinity of the reference (fig. 1).

(6) Position S-duct front upper fairing (353AT) on the fuselage.

(7) Connect and safety upper anti-collision light (4LX) to the housing.

(8) If installed, connect VHF 1 antenna (L5RC).

(9) Install S-duct front upper fairing (353AT).

(10) Measure bonding value between the anti–collision light baseplate and the reference test point in

the mechanic’s servicing compartment (Refer to TASK 20-20-00-910-801).

The value should be equal to 2.5 mΩ max.

(11) Perform the operational test of the upper anti-collision light (4LX) (Refer to TASK

33-40-00-710-801).

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DASSAULT AVIATION Proprietary Data
(12) Perform the operational test of the VHF1 system (Refer to TASK 23-11-00-710-802) if VHF1

antenna installed on S-duct front upper fairing (353AT)

D. RECORDING

Record compliance with this Service Bulletin in the appropriate aircraft documents.

Fill out the card located at the end of the Service Bulletin and mail or fax it to Dassault Aviation or

Dassault Falcon Jet, or fill out the electronic Service Bulletin reply form located in the ”Service Bulletin"

page on the Falcon portal.

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DASSAULT AVIATION Proprietary Data
3. MATERIAL INFORMATION

A. MODIFICATION KIT

KIT P/N SBF900EX0305A

NEW P/N QTY KEY WORD

ITEM

FIG

FGFB823675330A1 1 Bonding strip

FGFB823675330A1 1 Bonding strip Refer to (1-fig. 1)

NAS1153V4A 5 Screw Refer to (2-fig. 4)

HW17-3DF 5 Nut Refer to (3-fig. 4)

NAS1921M05S03WU 3 Rivet Refer to (4-fig. 3)

SL644M5-3 1 Insert Refer to (5-fig. 3)

22208TX050006XA 1 Screw Refer to (6-fig. 3)

23111DG050A 1 Washer Refer to (7-fig. 3)

79160 1 "Service Bulletin Compliance" label Refer to (8-fig. 1)

B. LOCAL PROCUREMENT

As indicated in Consumable Products Manual (CPM):

• alodine

• bead sealant

• covering sealant

• interlaying sealant

• MEK

• epoxy resin

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DASSAULT AVIATION Proprietary Data
Figure 1: GENERAL VIEW

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Figure 2: VIEW A

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Figure 3: VIEW B

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Figure 4: CROSS-SECTION CC

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Figure 5: CROSS-SECTION DD

END OF DOCUMENT

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

DASSAULT AVIATION Number ATA Number

F900EX 305 F900EX 33 10 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 305 F900EX 33 10 Coding: C

complete compliance

application totale

T

partial compliance

application partielle

Performed by:

Fait par:

Remarks: Revision 1 Date: Signature:

Remarques: Revision 1