FALCON 7X

No 284-R1

APRIL 08, 2014

MANDATORY

ATA 53

FUSELAGE

INSPECTION OF THE FUEL BOXES

FALCON SERVICE BULLETIN

Copyright © 2014 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.

785
FUSELAGE

INSPECTION OF THE FUEL BOXES

Initial issuance September 12, 2013

List of effective pages :

1 to 9

Erratum October 16, 2013

List of effective pages :

1 to 9

List of modified pages :

9

REASON:Dimensions on figure 2 corrected.

Revision 1 April 08, 2014

List of effective pages :

1 to 11

List of modified pages :

4, 5, 6, 7 and 10

REASON:The purpose of this revision is to suppress a documentation discrepancy that may

cause an improper application of bead sealant.

This revision is applicable to aircraft which have already implemented the initial

issuance of this Service Bulletin, except aircraft with serial number 157.

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ATA 53
FUSELAGE

INSPECTION OF THE FUEL BOXES

1. PLANNING INFORMATION

A. EFFECTIVITY

This Service Bulletin is applicable to FALCON 7X aircraft with serial numbers from 2 through 140, 142

through 176, 178 to 181, 183, 184, 187, 188, 190, 194 and 200.

B. REASON

A fuel leak has been noted on one aircraft before delivery, in the area of the fuel box located in the

baggage compartment.

The purpose of this Service Bulletin is to check the installation and the sealing of the fuel boxes.

C. DESCRIPTION

This operation consists in:

• Removing a half shell from each fuel box,

• Checking for absence of fuel leak,

• Checking the draining hole,

• Renewing the sealant application when closing the half shell.

D. COMPLIANCE

Mandatory:

• It is anticipated that this Service Bulletin will be rendered mandatory by an EASA Airworthiness

Directive.

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

E. APPROVAL

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 which 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

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

Illustrated Parts Catalog:

• (Refer to IPC fig. 21-72-10-25)

• (Refer to IPC fig. 21-72-40-05)

• (Refer to IPC fig. 53-50-10-20)

• (Refer to IPC fig. 54-50-30-10)

Aircraft Maintenance Manual:

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

• ELIMINATION OF FUEL LEAKS (Refer to TASK 20-32-00-360-802)

• REMOVAL / INSTALLATION OF THE BAGGAGE COMPARTMENT LININGS (Refer to TASK

25-52-01-900-801)

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DASSAULT AVIATION Proprietary Data
• OPENING / CLOSING OF THE BAGGAGE COMPARTMENT DOOR (Refer to TASK

52-30-00-860-801)

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DASSAULT AVIATION Proprietary Data
2. ACCOMPLISHMENT INSTRUCTIONS FOR AIRCRAFT WHICH HAVE ALREADY IMPLEMENTED THE

INITIAL ISSUANCE OF THIS SERVICE BULLETIN

A. PRELIMINARY STEPS

(1) The aircraft must be in the maintenance configuration (Refer to TASK 20-00-00-910-801).

(2) Open the baggage compartment door (BAG) (Refer to TASK 52-30-00-860-801).

(3) Remove the pylon front lower access panel No.1 (431AB) and the pylon front lower access panel

No.1 (441AB) (Refer to IPC fig. 54-50-30-10 , items 10A et 20A).

(4) Remove the FR. 33 - FR. 36 lower lining (271CZ) and the FR. 33 - FR. 36 lining (272CZ) (Refer to

TASK 25-52-01-900-801) to gain access to the fuel boxes (Refer to IPC fig. 53-50-10-20 , items

420 and 500).

(5) Aircraft with humidifier system:

(a) Disconnect the draining pipe (Refer to IPC fig. 21-72-40-05 , item 330) from the pipe

receiver (Refer to IPC fig. 21-72-40-05 , item 310).

(b) Remove the humidifier receiver (Refer to IPC fig. 21-72-10-25 , item 150).

(c) Remove the pipe receiver (Refer to IPC fig. 21-72-40-05 , item 310).

(6) Remove the thermo-acoustic insulation around the fuel box working areas.

B. PROCEDURE

NOTE: This procedure is valid for the LH and the RH fuel boxes. The illustrations show either one or

the other.

(1) Half shell removal

CAUTION: RECORD THE LOCATION OF EACH ATTACHING PART BEFORE REMOVAL.

(a) Remove all the attaching parts following fig. 1.

NOTE: On the LH and RH sides, remove the screws (x-fig. 1) before screws (y-fig. 1).

(b) Note the orientation of the half shell using a soft-lead pencil.

(c) Remove the half shell (A-fig. 1).

(2) Removal of sealant

(a) Remove the sealant:

1 On the removed half shell (A-fig. 1), using a Plexiglas spatula,

2 On the other half shell (B-fig. 1), from areas (C-fig. 1), using a Plexiglas spatula.

3 Perform a dipping on each half shell (A-B-fig. 1), using scotch brite then clean the

areas with cleaner.

4 On each screw head using cleaner.

(3) Check the drain hole

(a) Make sure that the drain hole of each drain box (D-fig. 1) is not obstructed.

(b) Make sure that the LH and RH pylon drain holes are not obstructed.

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(4) Preparation of the fuel box

CAUTION: DO NOT OBSTRUCT THE DRAIN HOLE (D-FIG. 1) WHEN YOU APPLY SEALANT.

(a) Apply bead sealant on the joggling areas fig. 1.

(b) Let the bead sealant cure.

(c) Apply demolding agent on the areas (C-fig. 1) of the half shell (B-fig. 1).

(d) Let the demolding agent dry for 5 minutes minimum.

(e) Apply a second coat of demolding agent on the areas (C-fig. 1) of the half shell (B-fig. 1).

(f) Let the demolding agent dry for 5 minutes minimum.

(g) Apply bead sealant on the areas of the half shell (A-fig. 2).

(5) Half shell installation

(a) Position the half shell (A-fig. 2) on the other half shell (B-fig. 2).

(b) Apply bead sealant under each screw head.

(c) Install all the removed attaching parts following the recorded locations and fig. 1.

NOTE: On the LH and RH sides, install the screws (y-fig. 1) before screws (x-fig. 1).

(d) Torque each screw to 0.374 m.daN (33.10 lbf.in).

(e) Wipe the excess bead sealant around each fuel box.

C. FINAL STEPS

(1) Install the removed thermo-acoustic insulations.

(2) Aircraft with humidifier system:

(a) Install the pipe receiver (Refer to IPC fig. 21-72-40-05).

(b) Install the humidifier receiver (Refer to IPC fig. 21-72-10-25 , item 150).

(c) Connect the draining pipe (Refer to IPC fig. 21-72-40-05 , item 330) to the pipe receiver

(Refer to IPC fig. 21-72-40-05 , item 310).

(3) Install the FR. 33 - FR. 36 lower lining (271CZ) and the FR. 33 - FR. 36 lining (272CZ) (Refer to

TASK 25-52-01-900-801).

(4) Close the baggage compartment door (BAG) (Refer to TASK 52-30-00-860-801).

(5) Install the pylon front lower access panel No.1 (431AB) and the pylon front lower access panel

No.1 (441AB) (Refer to IPC fig. 54-50-30-10 , items 10A et 20A).

D. RECORDING

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

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. ACCOMPLISHMENT INSTRUCTIONS FOR AIRCRAFT WHICH HAVE NOT IMPLEMENTED THE INITIAL

ISSUANCE OF THIS SERVICE BULLETIN

A. PRELIMINARY STEPS

(1) The aircraft must be in the maintenance configuration (Refer to TASK 20-00-00-910-801).

(2) Open the baggage compartment door (BAG) (Refer to TASK 52-30-00-860-801).

(3) Remove the pylon front lower access panel No.1 (431AB) and the pylon front lower access panel

No.1 (441AB) (Refer to IPC fig. 54-50-30-10 , items 10A et 20A).

(4) Remove the FR. 33 - FR. 36 lower lining (271CZ) and the FR. 33 - FR. 36 lining (272CZ) (Refer to

TASK 25-52-01-900-801) to gain access to the fuel boxes (Refer to IPC fig. 53-50-10-20 , items

420 and 500).

(5) Aircraft with humidifier system:

(a) Disconnect the draining pipe (Refer to IPC fig. 21-72-40-05 , item 330) from the pipe

receiver (Refer to IPC fig. 21-72-40-05 , item 310).

(b) Remove the humidifier receiver (Refer to IPC fig. 21-72-10-25 , item 150).

(c) Remove the pipe receiver (Refer to IPC fig. 21-72-40-05 , item 310).

(6) Remove the thermo-acoustic insulation around the fuel box working areas.

B. PROCEDURE

NOTE: This procedure is valid for the LH and the RH fuel boxes. The illustrations show either one or

the other.

(1) Half shell removal

CAUTION: RECORD THE LOCATION OF EACH ATTACHING PART BEFORE REMOVAL.

(a) Remove all the attaching parts following fig. 1.

NOTE: On the LH and RH sides, remove the screws (x-fig. 1) before screws (y-fig. 1).

(b) Note the orientation of the half shell using a soft-lead pencil.

(c) Remove the half shell (A-fig. 1).

(2) Check for fuel leak

(a) Make sure that there is no fuel in the box.

(b) Make sure that there is no leak at the wig-o-flex coupling.

(c) In case of fuel leak, repair it (Refer to TASK 20-32-00-360-802).

(3) Removal of sealant

(a) On the removed half shell (A-fig. 1), remove sealant, using a Plexiglas spatula.

(b) On the other half shell (B-fig. 1), remove sealant from areas (C-fig. 1), using a Plexiglas

spatula.

(c) Perform a dipping on each half shell (A-B-fig. 1), using scotch brite then clean the areas

with cleaner.

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DASSAULT AVIATION Proprietary Data
(4) Check the drain hole

(a) Make sure that the drain hole of each drain box (D-fig. 1) is not obstructed.

(b) Make sure that the LH and RH pylon drain holes are not obstructed.

(5) Preparation of the fuel box

CAUTION: DO NOT OBSTRUCT THE DRAIN HOLE (D-FIG. 1) WHEN YOU APPLY SEALANT.

(a) Apply a thin coat of bead sealant in the bottom of each half shell as per fig. 2.

(b) Make sure that the drain hole (D-fig. 1) is not obstructed.

(c) Let the bead sealant cure.

(d) Apply bead sealant on the joggling areas fig. 1.

(e) Let the bead sealant cure.

(f) Apply demolding agent on the areas (C-fig. 1) of the half shell (B-fig. 1).

(g) Let the demolding agent dry for 5 minutes minimum.

(h) Apply a second coat of demolding agent on the areas (C-fig. 1) of the half shell (B-fig. 1).

(i) Let the demolding agent dry for 5 minutes minimum.

(j) Apply bead sealant on the areas of the half shell (A-fig. 2).

 ̈

(6) Half shell installation

(a) Position the half shell (A-fig. 2) on the other half shell (B-fig. 2).

(b) Apply bead sealant under each screw head.

(c) Install all the removed attaching parts following the recorded locations and fig. 1.

NOTE: On the LH and RH sides, install the screws (y-fig. 1) before screws (x-fig. 1).

(d) Torque each screw to 0.374 m.daN (33.10 lbf.in).

(e) Wipe the excess bead sealant around each fuel box.

C. FINAL STEPS

(1) Install the removed thermo-acoustic insulations.

(2) Aircraft with humidifier system:

(a) Install the pipe receiver (Refer to IPC fig. 21-72-40-05).

(b) Install the humidifier receiver (Refer to IPC fig. 21-72-10-25 , item 150).

(c) Connect the draining pipe (Refer to IPC fig. 21-72-40-05 , item 330) to the pipe receiver

(Refer to IPC fig. 21-72-40-05 , item 310).

(3) Install the FR. 33 - FR. 36 lower lining (271CZ) and the FR. 33 - FR. 36 lining (272CZ) (Refer to

TASK 25-52-01-900-801).

(4) Close the baggage compartment door (BAG) (Refer to TASK 52-30-00-860-801).

(5) Install the pylon front lower access panel No.1 (431AB) and the pylon front lower access panel

No.1 (441AB) (Refer to IPC fig. 54-50-30-10 , items 10A et 20A).

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DASSAULT AVIATION Proprietary Data
D. RECORDING

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

Fill out the electronic Service Bulletin reply form located in the ”Service Bulletin" page on the Falcon

portal.

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4. MATERIAL INFORMATION

A. LOCAL PROCUREMENT

As indicated in Consumable Products Manual (CPM):

• bead sealant (AC 350 B2)

• cleaner (Diestone)

• demolding agent (QZ 5111)

• scotch brite

Miscellaneous

• Cloths

• Plexiglas spatula

• Soft-lead pencil

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DASSAULT AVIATION Proprietary Data
Figure 1: LOCATION OF FUEL BOXES

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Figure 2: SEALANT PROTECTION

END OF DOCUMENT

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