FALCON SERVICE BULLETIN

Transcription

1 FALCON SERVICE BULLETIN FALCON 900EX FALCON 900EX EASy FALCON 900DX No 366 MARCH 10, 2010 ATA PASSENGER DOOR REDUCING GEAR MOTOR RELIABILITY IMPROVEMENT ed - VALIDATED - Certification Repository 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

2 FALCON 900EX F900EX 366 PASSENGER DOOR REDUCING GEAR MOTOR RELIABILITY IMPROVEMENT INITIAL ISSUANCE date: March 10, 2010 List of effective pages: 1 to 5. F900EX 52 17

3 FALCON 900EX F900EX 366 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 series or series with serial number lower than 395. B. REASON Several Falcon operators recently reported cancelling / delaying a flight due to difficulties in lifting and/or fully closing the electrical Main Entrance Door. Troubleshooting determined that the fault originated from an internal failure of the reducing gear motor P/N M01. Investigation showed that an incorrect installation of screw helical threads in the main box could, under certain tolerance conditions, prevent the screws that hold the reducing gear motor and the gear box housing together from being correctly preloaded, even though the recommended torque was applied. DASSAULT AVIATION Proprietary Data The purpose of this Service Bulletin is to improve the aircraft reliability by preventing failure of 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 during the 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. March 10, 2010 F900EX Initial issuance Page 1

4 FALCON 900EX F900EX 366 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 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: Western hemisphere: DASSAULT FALCON JET CORP. SPARES DISTRIBUTION CENTER 200 RISER ROAD LITTLE FERRY, NJ U.S.A. DASSAULT AVIATION Proprietary Data Other continents: Telephone: CANADA and U.S.A.: MEXICO: Other countries: Fax: CANADA and U.S.A.: MEXICO: Other countries: DASSAULT AVIATION Falcon Spares BOITE POSTALE N o 101 AEROPORT DU BOURGET LE BOURGET Cedex (FRANCE) Please contact your Dassault Aviation Account Representative Telephone: 33 (0) Fax: 33 (0) 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. March 10, 2010 F900EX Initial issuance Page 2

5 FALCON 900EX F900EX 366 J. REFERENCES SKF Service Bulletin. Standard Practices: Procedure Use of the aircraft maintenance procedures. Aircraft Maintenance Manual: Procedure Removal/installation of passenger door reducing gear motor. K. OTHER PUBLICATIONS AFFECTED None. DASSAULT AVIATION Proprietary Data March 10, 2010 F900EX Initial issuance Page 3

6 FALCON 900EX F900EX ACCOMPLISHMENT INSTRUCTIONS A. PRELIMINARY STEPS (1) The aircraft must be in the maintenance configuration (Refer to Standard Practices, Procedure ). B. PROCEDURE TESTING (1) Remove the passenger door reducing gear motor (13MC) (Refer to Maintenance Manual, procedure ). (2) Replace the 12 screws in accordance with SKF Service Bulletin. (3) Install the passenger door reducing gear motor (13MC) (Refer to Maintenance Manual, procedure ). C. RECORDING DASSAULT AVIATION Proprietary Data 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. March 10, 2010 F900EX Initial issuance Page 4

7 FALCON 900EX F900EX MATERIAL INFORMATION A. MODIFICATION KIT KIT P/N SBF A NEW P/N QTY KEY WORD 22221BC Screw, socket head DASSAULT AVIATION Proprietary Data March 10, 2010 F900EX Initial issuance END OF DOCUMENT Page 5

8 FIRST CLASS MAIL PERMIT NO HACKENSACK, NJ ATTENTION: FIELD SERVICE DEPARTMENT DASSAULT FALCON JET CORP. PO BOX 1946 SO HACKENSACK NJ A l attention de DSC DASSAULT AVIATION 78, Quai Marcel Dassault Cedex SAINT CLOUD Cedex FRANCE

9 S COMPLIANCE FALCON 900EX A/C S/N DASSAULT AVIATION Number F900EX 366 ATA Number F900EX Coding: C T complete compliance partial compliance Performed by: Remarks: Initial issuance 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: For Other Continents, mail card herebelow or fax to Dassault Aviation: 33 (0) 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 : Ou la carte réponse inférieure pour autres continents ou le fax pour Dassault Aviation : 33 (0) Eventuellement, si d autres Bulletins de Service ont été appliqués simultanément, vous pouvez les mentionner dans les cases vierges prévues à cet effet. SERVICE BULLETINS COMPLIANCE APPLICATION DES BULLETINS DE SERVICE DASSAULT AVIATION Number ATA Number Numéro DASSAULT AVIATION Numéro ATA Coding: F900EX 366 F900EX FALCON 900EX Avion N o C T complete compliance application totale partial compliance application partielle Remarks: Initial issuance Performed by: Fait par : Date : Signature : Remarques : Edition originale

10 F0222 SKF Fly-by-Wire SKF Aerospace France 1 avenue Marc Seguin Saint Vallier sur Rhône Cedex FRANCE Tel.: 33 (0) Telefax: 33 (0) SERVICE BULLETIN STANDARD DOOR-PASSENGER/CREW MAIN DOOR ACTUATOR PN SERIES RELIABILITY IMPROVEMENT 1. PLANNING INFORMATION A. EFFECTIVITY This Service Bulletin is applicable to SKF Fly-by-Wire (formerly SARMA) Main Door Actuators PN series and series, with serial number lower than 395 (excluded), fitted on DASSAULT AVIATION FALCON aircraft. B. CONCURRENT REQUIREMENTS C. REASON Not applicable (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). Initial Issue: Jun 15/09 Page 1 of 20

11 (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. Initial Issue: Jun 15/09 Page 2 of 20

12 Main Door Actuator before modification per this SB FIGURE 1 Initial Issue: Jun 15/09 Page 3 of 20

13 Main Door Actuator after modification per this SB FIGURE 2 Initial Issue: Jun 15/09 Page 4 of 20

14 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. Initial Issue: Jun 15/09 Page 5 of 20

15 K. REFERENCES (1) References for Main Door Actuator documents (SKF vendor documents, formerly SARMA), vendor code F0222: - SKF Equipment Evolution Sheet FEE _04_issueA and FEE _03_issueA approved by Dassault Aviation under the authority of DOA nr. EASA.21J 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. Initial Issue: Jun 15/09 Page 6 of 20

16 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: DERCO REPAIR SERVICES 8065 W. Fairlane Ave. MILWAUKEE, WI USA Tel (1) (414) Fax (1) (414) repairgeneralmanager@dercoaerospace.com AMERICAN CONTINENT: DFJ TETERBORO: DASSAULT FALCON JET SPARES DISTRIBUTION CENTER 200 RISER ROAD LITTLE FERRY, NJ USA Eastern Hemisphere: CUSTOMER SERVICES SKF Fly-by-Wire 1 Avenue Marc Seguin SAINT VALLIER cedex - FRANCE Tel 33 (0) Fax 33 (0) daniel.constant@skf.com OTHER CONTINENTS: DAFS LE BOURGET: DASSAULT FALCON SERVICE BOITE POSTALE 10 AEROPORT DU BOURGET LE BOURGET - FRANCE Initial Issue: Jun 15/09 Page 7 of 20

17 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 BC050045L SCREW, SOCKET HEAD CHCM5-45, REJECTED/ REPLACED (2) Consumables DESIGNATION PART NUMBER AND SPECIFICATION MASTINOX 6856K ZINC POWDER AS < 100 Mu OR GZ200TV MANUFACTURER OR SUPPLIER (NAME ADDRESS CODE) PPG / CELOMER 7 ALLEE DE LA PLAINE F GONFREVILLE FRANCE (F1419) OR LOCAL SUPPLIER ECKART POUDMET 26 RUE DU MOULIN SENECOURT BAILLEVAL FRANCE OR LOCAL SUPPLIER CODE MB008 MB009 (3) Material supplied by the Operator Complete Main Door Actuator PN M01amdtA, PN M01amdtB, PN M01amdtC or PN M00. (4) Material necessary for each spare Not applicable. Initial Issue: Jun 15/09 Page 8 of 20

18 D. REIDENTIFIED PARTS (1) Main Door Actuator IPL ITEM NEW PN QTY DESCRIPTION OLD PN A M01amdtMA 1 MAIN DOOR ACTUATOR M01amdtA B M01amdtMB 1 MAIN DOOR ACTUATOR M01amdtB C M01amdtMC 1 MAIN DOOR ACTUATOR M01amdtC D M00amdtMC 1 MAIN DOOR ACTUATOR M00 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 QTY 1 REQUIRED) Initial Issue: Jun 15/09 Page 9 of 20

19 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 Flyby-Wire repair facility in Saint-Vallier, France, for a thorough disassembly and inspection before the service bulletin can be embodied. Initial Issue: Jun 15/09 Page 10 of 20

20 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 small shoulder NOT inserted into hole (T1) special tool 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 Initial Issue: Jun 15/09 Page 11 of 20

21 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. Initial Issue: Jun 15/09 Page 12 of 20

22 Illustrated Parts List fully exploded view FIGURE 8 Initial Issue: Jun 15/09 Page 13 of 20

23 Screw assembly/disassembly sequence FIGURE 9 Initial Issue: Jun 15/09 Page 14 of 20

24 C. REWORK AND/OR INSPECTION AND/OR REPAIR D. ASSEMBLY E. TEST Not applicable. Not applicable. See 3.B. (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 M00 series according to the table below. IPL ITEM P/N ROOT OLD AMENDMENT NEW AMENDMENT A M01 amdta amdtma B M01 amdtb amdtmb C M01 amdtc amdtmc D M00 N/A amdtmc Initial Issue: Jun 15/09 Page 15 of 20

25 Location of Main Door Actuator identification and amendment plates FIGURE 10 Initial Issue: Jun 15/09 Page 16 of 20

26 1. FAMILY TREE CHARTS APPENDIX A MAIN DOOR ACTUATOR MAIN DOOR ACTUATOR MAIN DOOR ACTUATOR M01amdtA M01amdtB M01amdtC Service Bulletin Reliability improvement MAIN DOOR ACTUATOR a MAIN DOOR ACTUATOR MAIN DOOR ACTUATOR M01amdtMA M01amdtMB M01amdtMC MAIN DOOR ACTUATOR M00 Service Bulletin Reliability improvement MAIN DOOR ACTUATOR M00amdtMC APPENDIX A Initial Issue: Jun 15/09 Page 17 of 20

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28 APPENDIX B 1. (T1) SPECIAL TOOL MANUFACTURING DRAWING 8 ( 0.315) 85 (3.346) , ,5 (1.850 ) (0.236 ) - R0,3 R0,3 5 0,1 ( 0.197±0.004) break edges 60 POINT hole DE for CENTRE lathe center ADMI permitted 3,5 ( 0.138) DIMENSIONS: MILLIMETERS (INCHES) LINEAR TOLERANCES: ±0,25 (±0.010) UNLESS OTHERWISE SPECIFIED MATERIAL: STEEL OR STAINLESS APPENDIX B Initial Issue: Jun 15/09 Page 19 of 20

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