FALCON SERVICE BULLETIN -...

FALCON SERVICE BULLETIN

573

704

635

FALCON 900EX FALCON 900EX EASy

FALCON 900DX

No 366

MARCH 10, 2010

Copyright © 2010 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 52-17

PASSENGER DOOR

REDUCING GEAR MOTOR RELIABILITY IMPROVEMENT

0900

4000

8036

53ed

- V

ALI

DA

TE

D -

Cer

tific

atio

n R

epos

itory

FALCON 900EX

SERVICE BULLETIN

F900EX–366

F900EX–52–17

PASSENGER DOOR

REDUCING GEAR MOTOR

RELIABILITY IMPROVEMENT

________________________________________________________________________________

INITIAL ISSUANCE date: March 10, 2010

List of effective pages:1 to 5.

________________________________________________________________________________

DA

SS

AU

LT A

VIA

TIO

N P

ropr

ieta

ry D

ata

SERVICE BULLETIN

FALCON 900EX F900EX–366

March 10, 2010 F900EX–52–17

Initial issuance Page 1

PASSENGER DOOR

REDUCING GEAR MOTOR

RELIABILITY IMPROVEMENT

________________________________________________________________________________

1 . PLANNING INFORMATION

A . EFFECTIVITY

This Service Bulletin is applicable to:

– F900EX aircraft with serial numbers 1 through 600 (F900EX, F900EX EASy),– F900EX aircraft with serial numbers 601 and subsequent (F900DX),equipped with passenger door reducing gear motor part number 222200-1 series or222200-3 series with serial number lower than 395.

B . REASON

Several Falcon operators recently reported cancelling / delaying a flight due to difficulties inlifting and/or fully closing the electrical Main Entrance Door. Troubleshooting determined thatthe fault originated from an internal failure of the reducing gear motor P/N 222200–1M01.

Investigation showed that an incorrect installation of screw helical threads in the main boxcould, under certain tolerance conditions, prevent the screws that hold the reducing gearmotor and the gear box housing together from being correctly preloaded, even though therecommended torque was applied.

The purpose of this Service Bulletin is to improve the aircraft reliability by preventing failureof the passenger door reducing gear motor.

C . DESCRIPTION

The operation consists in:

– removing the passenger door reducing gear motor (13MC),– replacing the screws in the main box,– installing the passenger door reducing gear motor (13MC).

D . COMPLIANCE

If you choose to comply with this Service Bulletin, accomplishment is to be performed duringthe next “C” inspection or upon passenger door reducing gear motor removal/installation.

NOTE: This Service Bulletin is not applicable to failed passenger door reducing gear motor.Please note that failed units should be replaced.

E . APPROVAL

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

DA

SS

AU

LT A

VIA

TIO

N P

ropr

ieta

ry D

ata

FALCON 900EX

SERVICE BULLETIN

F900EX–366

March 10, 2010 F900EX–52–17


F . LABOR

Estimated labor–hours:

– Access (not included in “C” inspection): 6 hours.– Modification: 2 hours.

NOTE: These labor–hours only concern the work described in this Service Bulletin and donot 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:

Western hemisphere: DASSAULT FALCON JET CORP.SPARES DISTRIBUTION CENTER200 RISER ROADLITTLE FERRY, NJ 07643 U.S.A.

Telephone:CANADA and U.S.A.: 1–800–800–4036MEXICO: 001–800–800–4036Other countries: 1–201–541–4809

Fax:CANADA and U.S.A.: 1–800–800–4817MEXICO: 001–800–800–4817Other countries: 1–201–440–7021

Other continents: DASSAULT AVIATIONFalcon SparesBOITE POSTALE No 101AEROPORT DU BOURGET93352 – LE BOURGET Cedex (FRANCE)

Please contact your Dassault AviationAccount RepresentativeTelephone: 33 (0)1.48.35.56.78Fax: 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.

DA

SS

AU

LT A

VIA

TIO

N P

ropr

ieta

ry D

ata

SERVICE BULLETIN


March 10, 2010 F900EX–52–17


J . REFERENCES

SKF Service Bulletin 222200-52-004.

Standard Practices:

– Procedure 20-001 “Use of the aircraft maintenance procedures”.

Aircraft Maintenance Manual:

– Procedure 52-131 “Removal/installation of passenger door reducing gear motor”.

K . OTHER PUBLICATIONS AFFECTED

None.

DA

SS

AU

LT A

VIA

TIO

N P

ropr

ieta

ry D

ata

FALCON 900EX

SERVICE BULLETIN

F900EX–366

March 10, 2010 F900EX–52–17


2 . ACCOMPLISHMENT INSTRUCTIONS

A . PRELIMINARY STEPS

(1) The aircraft must be in the maintenance configuration (Refer to Standard Practices,Procedure 20-001).

B . PROCEDURE – TESTING

(1) Remove the passenger door reducing gear motor (13MC) (Refer to Maintenance Manual,procedure 52-131).

(2) Replace the 12 screws in accordance with SKF Service Bulletin 222200-52-004.

(3) Install the passenger door reducing gear motor (13MC) (Refer to Maintenance Manual,procedure 52-131).

C . 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 Aviationor Dassault Falcon Jet.

DA

SS

AU

LT A

VIA

TIO

N P

ropr

ieta

ry D

ata

SERVICE BULLETIN


March 10, 2010 F900EX–52–17

Initial issuance Page 5END OF DOCUMENT

3 . MATERIAL INFORMATION

A . MODIFICATION KIT

KIT P/N SBF2000-0384A

NEW P/N QTY KEY WORD

22221BC0500452 12 Screw, socket head

DASSAULT FALCON JET CORP.PO BOX 1946SO HACKENSACK NJ 07606–9946

ATTENTION:FIELD SERVICE DEPARTMENT

FIRST CLASS MAIL PERMIT NO. 3306 HACKENSACK, NJ 07602

DASSAULT AVIATION78, Quai Marcel DassaultCedex 30092552 SAINT–CLOUD CedexFRANCE

A l’attention de DSC

SERVICE BULLETINS COMPLIANCE



FALCON 900EX

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 900EX 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 SER VICELorsque vous aurez appliqué ce Bulletin de Service sur votre avion, veuillez avoir l’amabilitéde 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 :

366

366 F900EX

52

52 17

17

Initial issuance

Initial issuance

Edition originale

F900EX

F900EX F900EX

SERVICE BULLETIN

F0222 SKF Fly-by-Wire

SKF Aerospace France 1 avenue Marc Seguin

26240 Saint Vallier sur Rhône Cedex FRANCE

Tel.: 33 (0) 475 03 4040 Telefax: 33 (0) 475 03 4001

SERVICE BULLETIN STANDARD

DOOR-PASSENGER/CREW – MAIN DOOR ACTUATOR PN 222200 SERIES – RELIABILITY IMPROVEMENT

1. PLANNING INFORMATION

A. EFFECTIVITY

This Service Bulletin is applicable to SKF Fly-by-Wire (formerly SARMA) Main Door Actuators PN 222200-1 series and 222200-3 series, with serial number lower than 395 (excluded), fitted on DASSAULT AVIATION FALCON aircraft.

B. CONCURRENT REQUIREMENTS

Not applicable

C. REASON

(1) Background

On three occasions, Dassault FALCON Aircraft Operators have reported difficulties to operate the passenger door electrical actuator. Investigations on the actuators showed that internal screws were broken and, as a result, the housing flange had come loose from the main box. Further investigations showed that incorrect installation of the screw helicoils in the main box could, under certain tolerance conditions, prevent the screws from being correctly preloaded even though the recommended torque was applied.

(2) Purpose

The purpose of this Service Bulletin is to enable in-service modification of main door actuator units. The modification will make sure the screws (Figure 8 item 590) are correctly preloaded under all tolerance conditions, and therefore will prevent mechanical failure from happening between the housing flange (Figure 8 item 580) and the main box (Figure 8 item 850).

222200-52-004 Initial Issue: Jun 15/09 Page 1 of 20

SERVICE BULLETIN

(3) Action

- Obtain retrofit kit from SKF Fly-by-Wire approved source. Remove main door actuator from aircraft according to Aircraft Maintenance Manual procedures. Replace screws as described in this service bulletin. Re-identify the unit and re-install on aircraft.

- Alternatively, remove the main door actuator unit from aircraft and send it to SKF Fly-by-Wire authorized repair facilities for incorporation of this service bulletin.

- In case the main door actuator internal screws are found broken, send the unit to SKF Fly-by-Wire authorized repair facilities.

(4) Advantages

Compliance with this service bulletin will restore correct preload in housing flange attaching screws and improve mechanical reliability of the unit, avoiding in-service failures and unscheduled removals from aircraft.

D. DESCRIPTION

The present Service Bulletin gives instructions to:

- Identify main door actuator PN and the need for embodiment of this Service Bulletin.

- Get the retrofit kit from SKF approved source or send the unit to SKF Fly-by-Wire authorized repair facilities in case of internal damage.

- Retrofit the unit with the mechanical parts listed in the retrofit kit.

- Re-identify the retrofitted unit with new amendment.


SERVICE BULLETIN

Main Door Actuator before modification per this SB

FIGURE 1


SERVICE BULLETIN

Main Door Actuator after modification per this SB

FIGURE 2


SERVICE BULLETIN

E. COMPLIANCE

(1) Modification embodiment

- OEM units:

The latest Main Door Actuators manufactured by SKF part 21 facilities, serial number 395 and up, are delivered with different helical thread installation and will not require compliance with this service bulletin.

- In-service units:

The units with serial number lower than 395 must be modified per this Vendor Service Bulletin at first opportunity and no later than specified in corresponding DASSAULT Service Bulletins.

F. APPROVAL

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

G. MANPOWER

Once the unit has been removed from aircraft, an estimated half an hour is necessary to accomplish this service bulletin.

H. WEIGHT AND BALANCE

No impacts.

I. ELECTRICAL LOAD DATA

No impacts.

J. SOFTWARE ACCOMPLISHMENT SUMMARY

Not applicable.


SERVICE BULLETIN

K. REFERENCES

(1) References for Main Door Actuator documents (SKF vendor documents, formerly SARMA), vendor code F0222:

- SKF Equipment Evolution Sheet FEE 222200-1_04_issueA and FEE 222200-3_03_issueA approved by Dassault Aviation under the authority of DOA nr. EASA.21J.051.

- At aircraft level: Contact Dassault Aviation for corresponding DASSAULT Service Bulletins.

L. PUBLICATIONS AFFECTED

Not applicable.

M. INTERCHANGEABILITY AND MIXING

(1) Interchangeability

Prior to installation on any aircraft, refer to applicable DASSAULT AVIATION documentation.

(2) Mixing

Not applicable.


SERVICE BULLETIN

2. MATERIAL INFORMATION

A. MATERIAL - PRICE AND AVAILABILITY

(1) Material

Keyword Part Number Qty SCREW, SOCKET HEAD 22221BC050045L 12

(2) Price

Contact Dassault Aviation for information on this subject.

(3) Availability

Please contact DASSAULT AVIATION for information on availability timeframe.

B. INDUSTRY SUPPORT INFORMATION

(1) In conformance with SKF Fly-by-Wire quality policy, SKF will support FALCON aircraft operators by performing incorporation of this service bulletin in SKF Fly-by-Wire authorized repair facilities, or by providing retrofit kits for incorporation in DASSAULT service facilities and authorized service centers.

(2) For incorporation of this Service Bulletin, sourcing of retrofit kits, or for information on the subject, please contact the following SKF Fly-by-Wire authorized facilities:

Western Hemisphere: Eastern Hemisphere:

DERCO REPAIR SERVICES

8065 W. Fairlane Ave.

MILWAUKEE, WI 53223 - USA

Tel (1) (414) 355 30 66

Fax (1) (414) 355 26 48

[email protected]

CUSTOMER SERVICES

SKF Fly-by-Wire

1 Avenue Marc Seguin

26240 SAINT VALLIER cedex - FRANCE

Tel 33 (0) 475 03 40 40

Fax 33 (0) 475 03 40 07

[email protected]

AMERICAN CONTINENT: OTHER CONTINENTS:

DFJ TETERBORO:

DASSAULT FALCON JET

SPARES DISTRIBUTION CENTER

200 RISER ROAD

LITTLE FERRY, NJ07643 - USA

DAFS LE BOURGET:

DASSAULT FALCON SERVICE

BOITE POSTALE 10

AEROPORT DU BOURGET

93350 LE BOURGET - FRANCE


SERVICE BULLETIN

C. MATERIAL NECESSARY FOR EACH COMPONENT

(1) Material to be Purchased

The following vendor parts are to be obtained from SKF Fly-by-Wire approved sources.

NOTE: The new part number screws are manufactured with narrower tolerances compared to original screws. The shank length is compatible with existing main boxes (Fig 3 item 850) under all tolerance conditions. This allows correct preload in the new screw regardless how the helical thread was originally installed in the main box.

FIG 3 ITEM

NEW PN KEYWORD OLD PN QTY INSTRUCTION

590 22221BC050045L SCREW, SOCKET HEAD

CHCM5-45,8.8 12 REJECTED/ REPLACED

(2) Consumables

DESIGNATION PART NUMBER AND SPECIFICATION

MANUFACTURER OR SUPPLIER (NAME ADDRESS CODE)

CODE

MASTINOX 6856K

PPG / CELOMER 7 ALLEE DE LA PLAINE F-76700 GONFREVILLE FRANCE (F1419) OR LOCAL SUPPLIER

MB008

ZINC POWDER AS < 100 Mu OR GZ200TV

ECKART – POUDMET 26 RUE DU MOULIN SENECOURT 60140 BAILLEVAL FRANCE OR LOCAL SUPPLIER

MB009

(3) Material supplied by the Operator

Complete Main Door Actuator PN 222200-1M01amdtA, PN 222200-1M01amdtB, PN 222200-1M01amdtC or PN 222200-3M00.

(4) Material necessary for each spare

Not applicable.


SERVICE BULLETIN

D. REIDENTIFIED PARTS

(1) Main Door Actuator

IPL ITEM NEW PN QTY DESCRIPTION OLD PN 01-001A 222200-1M01amdtMA 1 MAIN DOOR ACTUATOR 222200-1M01amdtA

01-001B 222200-1M01amdtMB 1 MAIN DOOR ACTUATOR 222200-1M01amdtB

01-001C 222200-1M01amdtMC 1 MAIN DOOR ACTUATOR 222200-1M01amdtC

01-001D 222200-3M00amdtMC 1 MAIN DOOR ACTUATOR 222200-3M00

E. TOOLING-PRICE AND AVAILABILITY

(1) Standard tools

- Torque wrench with 4mm male hex driver bit for M5-size socket head screws.

- Hammer used to break helicoil tangs.

(2) Specific tools

The following tool is to be obtained from SKF Fly-by-Wire or manufactured locally according to dimensions shown in appendix B:

S

FIGURE 3 (T1) SPECIAL TOOL (P/N 3999-0028 QTY 1 REQUIRED)


SERVICE BULLETIN

3. ACCOMPLISHMENT INSTRUCTION

A. GENERAL

This section describes in detail steps required for the modification. Note that standard maintenance practices such as cleaning, inspection or check upon disassembly are not detailed in this Service Bulletin but shall not be omitted.

B. DISASSEMBLY

NOTE: the following only details the disassembly steps required to incorporate the service bulletin. Further actions may be required by the equipment condition, but are not detailed in this Service Bulletin.

(1) Visually inspect the unit. Make sure there is no gap between the housing flange (Figure 8 item 580) and the main box (Figure 8 item 850). Make sure the 12 screws (Figure 8 item 590) are not damaged or loose, and the housing flange (Figure 8 item 580) is in good condition near the three smaller locating pins (Refer to Figure 9). Units showing any evidence of damage should be returned to SKF Fly-by-Wire repair facility in Saint-Vallier, France, for a thorough disassembly and inspection before the service bulletin can be embodied.

NOTE: the following gives instructions to replace the screws (Figure 8 item 590) without separating the housing flange (Figure 8 item 580) from the main box (Figure 8 item 850).

(2) Prepare a mixture of MASTINOX (MB008) with ZINC POWDER (MB009) according to the instructions below:

i. Mix an homogenous mixture of:

- 58 % weight of material (MB008),

- 42 % weight of material (MB009).

ii. Keep the resulting product in a sealed container.

(3) Refer to Figure 9 for information on the disassembly sequence for the screws (Figure 8 item 590).

(4) For each screw in the sequence, perform the following steps before proceeding with the next screw:

i. Un-tighten and remove the original screw (Figure 8 item 590) and washer (Figure 8 item 600). Before discarding the screw, inspect it for evidence of stretching or shearing. In case the screw is damaged, send the complete door actuator to SKF Fly-by-Wire repair facility in Saint-Vallier, France, for a thorough disassembly and inspection before the service bulletin can be embodied.


SERVICE BULLETIN

ii. Install special tool (T1) into the threaded hole and make sure the tip is not resting on the edge of the threaded insert. The small shoulder of (T1) tool should be into the hole, refer to figure 4 and 5 of this SB.

small shoulder inserted into hole (T1) special tool

FIGURE 4 (T1) TOOL CORRECTLY INSTALLED

(T1) special toolsmall shoulder

NOT inserted into hole

FIGURE 5 (T1) TOOL INCORRECTLY INSTALLED

iii. Inspect the large shoulder of (T1) tool as shown in figure 6 of this SB. If there is a gap between the large shoulder and the housing flange, use a hammer to break the helicoil tang and allow the special tool to go deeper into the hole (refer to figure 6 and 7 of this SB).

NOTE: it is acceptable to leave the broken tang into the bottom of the threaded hole.

gap Large shoulder

HAMMER

FIGURE 6 (T1) TOOL BOTTOMING ON HELICOIL TANG


SERVICE BULLETIN

No gap

FIGURE 7 CORRECT DEPTH ALLOWING SCREW INSTALLATION

iv. Apply the mixture prepared at step 3.B.(2) onto the threads of the new screw (Figure 8 item 590, refer to section 2.C.1 for information on new part number).

v. Remove the special tool (T1) and install the new screw (Figure 8 item 590) with washer (Figure 8 item 600).

vi. Tighten the new screw (Figure 8 item 590) to a torque of 5 ± 0.5 N.m (44.25 ± 4.42 Lbf.in).

(5) Repeat the above steps until all the screws in the sequence shown in Figure 9 have been replaced.


SERVICE BULLETIN

Illustrated Parts List – fully exploded view FIGURE 8


SERVICE BULLETIN

Screw assembly/disassembly sequence

FIGURE 9


SERVICE BULLETIN

C. REWORK AND/OR INSPECTION AND/OR REPAIR

Not applicable.

D. ASSEMBLY

Not applicable. See 3.B.

E. TEST

(1) Provided that the disassembly/assembly procedure described in section 3.B is followed step by step with no further disassembly, the release to service does not require performing any bench testing or any off-aircraft acceptance test procedure.

F. RE-IDENTIFICATION

(1) Refer to section 2.D of this service bulletin for information on the new amendment required for the unit.

(2) Refer to Figure 10 of this service bulletin for details on identification plate (item 920) and amendment plate (item 930).

(3) Using a power engraving tool, scribe the new amendment on the existing identification plate (item 920) or amendment plate (item 930). M letter must be added to all units, and C letter must also be added to P/N 222200-3M00 series according to the table below.

IPL ITEM P/N ROOT OLD AMENDMENT NEW AMENDMENT 01-001A 222200-1M01 amdtA

amdtMA

01-001B 222200-1M01 amdtB

amdtMB

01-001C 222200-1M01 amdtC

amdtMC

01-001D 222200-3M00 N/A

amdtMC


SERVICE BULLETIN

Location of Main Door Actuator identification and amendment plates

FIGURE 10


SERVICE BULLETIN

APPENDIX A 1. FAMILY TREE CHARTS

222200-52-004

a

MAIN DOOR ACTUATOR 222200-1M01amdtA

MAIN DOOR ACTUATOR 222200-1M01amdtB

MAIN DOOR ACTUATOR 222200-1M01amdtC

MAIN DOOR ACTUATOR 222200-1M01amdtMA

Reliability improvement

Service Bulletin 222200-52-004

MAIN DOOR ACTUATOR 222200-1M01amdtMB

MAIN DOOR ACTUATOR 222200-1M01amdtMC

Reliability improvement

Service Bullet222200-52-0

in 04

MAIN DOOR ACTUATOR 222200-3M00

MAIN DOOR ACTUATOR 222200-3M00amdtMC

APPENDIX A Initial Issue: Jun 15/09 Page 17 of 20

SERVICE BULLETIN

THIS PAGE INTENTIONALLY LEFT BLANK

222200-52-004 BLANK

Initial Issue: Jun 15/09 Page 18 of 20

SERVICE BULLETIN

APPENDIX B 1. (T1) SPECIAL TOOL MANUFACTURING DRAWING

222200-52-004

DIMENSIONS: MILLIMETERS (INCHES) LINEAR TOLERANCES: ±0,25 (±0.010) UNLESS OTHERWISE SPECIFIED MATERIAL: STEEL OR STAINLESS

47 0 -0,

5

85

3,5

6 0 -0,5

8

5 0,1R0,3

R0,3

POINT DE CENTRE ADMI60° hole for lathe center permitted

(∅0.315)

(∅0.197±0.004)

(∅0.138)

(3.3

46)

(1.8

50

) 0 -

(0.2

36

) 0 -0

.020

0.02

0

break edges

APPENDIX B Initial Issue: Jun 15/09 Page 19 of 20

SERVICE BULLETIN

THIS PAGE INTENTIONALLY LEFT BLANK

222200-52-004 BLANK

Initial Issue: Jun 15/09 Page 20 of 20

FALCON SERVICE BULLETIN -...

Documents

Transcript of FALCON SERVICE BULLETIN -...