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AIRCRAFT SERVICE CHANGE

S U B J E C T

NUMBER 081

FLIGHT CONTROLS (ATA 27)

LATERAL CONTROL SYSTEM – AILERON CABLE SHROUD INSTALLATION

RECORD ONLY

DECEMBER 18, 2008

Gulfstream G550 Aircraft Service Change 081 “December 18, 2008”

Aircraft Service Change prepared by Gulfstream Aerospace, Savannah International Airport, PO Box 2206, Savannah Georgia, 31402-2206, USA. © 2008, Gulfstream Aerospace. All rights reserved, including the right to reproduce this publication. No part may be reproduced, stored in any retrieval system or transmitted in any part or form or by any means electronic, photocopying, microfilm, microfiche, mechanical or otherwise, without prior written permission of Gulfstream Aerospace. This technical data is controlled under the Export Administration Regulations by General License TSU. It may not be transferred to a third party without the prior written approval of the U.S. Department of Commerce.

PILOTS INFORMATION SHEET

LATERAL CONTROL SYSTEM –

AILERON CABLE SHROUD INSTALLATION

This aircraft service change is designed to eliminate aileron cable vibration in the lateral control system. Analysis has determined that airflow across the aileron cables at various operational speeds or during spoiler board deployment may cause the aileron control yoke to vibrate. The vibration is characterized as low-frequency “buzzing” in the range of 70-90 Hz.

There will be no cockpit procedural changes required as a result of this installation.

PLEASE DETACH AND GIVE TO FLIGHT DEPARTMENT PERSONNEL



PILOTS INFORMATION SHEET

LATERAL CONTROL SYSTEM –

AILERON CABLE SHROUD INSTALLATION

This aircraft service change is designed to eliminate aileron cable vibration in the lateral control system. Analysis has determined that airflow across the aileron cables at various operational speeds or during spoiler board deployment may cause the aileron control yoke to vibrate. The vibration is characterized as low-frequency “buzzing” in the range of 70-90 Hz.

There will be no cockpit procedural changes required as a result of this installation.

PLEASE RETAIN THIS COPY WITH THE ASC BOOKLET


Page 1 of 11

The design change effected by this Aircraft Service Change (ASC) has been classified as Minor. This modification is approved by the United States Federal Aviation Administration (FAA) and accepted by the European Aviation Safety Agency (EASA), European Union Directive, Decision No. 2004/04/CF.

The design of this ASC is approved by aircraft type design data for installation on aircraft registered for operation in accordance with applicable regulations of the FAA and EASA.

The design of an ASC is configured to a standard (“greenie”) production aircraft. If spare wires, pin connections or locations called out have been used for another modification, the installing agency must ensure the development, documentation and approval of any required deviations.

The following instructions, in step-by-step form, are written as a guide to perform this ASC. Compliance with safe maintenance practices as defined in the Aircraft Maintenance Manual and by the FAA and EASA is required.

Gulfstream considers this ASC a means to enhance aircraft capabilities to meet individual operator requirements. The modification is not related to any safety or airworthiness condition.

Subject: Flight Controls (ATA 27) – Lateral Control System – Aileron Cable Shroud Installation

Purpose/Discussion: This aircraft service change is designed to eliminate aileron cable vibration in the lateral control system. Analysis has determined that airflow across the aileron cables at various operational speeds or during spoiler board deployment may cause the aileron control yoke to vibrate. The vibration is characterized as low-frequency “buzzing” in the range of 70-90 Hz.

This service change is RECORD ONLY and can only be installed at Gulfstream or at a Gulfstream Authorized Warranty Repair Facility (AWRF).

Description/Man-Hours Required Per Aircraft:

This service change provides instructions for installing two cable shrouds and four brackets (two per wing) under the left and right wing cove panels, 581CT and 681CT. A clearance check will be required for return to service.

Approximately 24.5 man-hours will be required for this installation.

Approved Engineering Data: The source data for this aircraft service change is: • 1159ASC57081 REV “A”, Top Drawing Aileron Cable

Shroud Installation (ASC 081) • 1159SB50095 REV “A”, Lateral Control – Aileron

Cable Shroud Installation


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Prerequisites: None Associated Documents: Aircraft Maintenance Manual (AMM) Chapters 20 and

27 Flight Manual Revision/Supplement Required:

None

Publications Data: Data concerning this service change will be published in

a future revision of the affected manual(s). This booklet will provide technical data until the revision(s) are published.

Effectivity: This service change is applicable to aircraft, serial

numbers 5001-subsequent. Effect on Spares: None Special Equipment/Tools Required:

Drill Block Assembly, 1159GSE50711-01 and -03

Skill Type Required: Knowledge of the Gulfstream G550 Flight Control

systems will be required. Price: Prices are subject to change without notice.

Installed Price: See Note 1

Kit Price only: Domestic: See Note 2

International: See Note 2

NOTE: This service change is RECORD ONLY and can only be installed at Gulfstream or at a Gulfstream Authorized Warranty Repair Facility (AWRF).

NOTE 1: This ASC will be installed at no charge for a period of 24 months from the release date noted on the cover of this Aircraft Service Change if installed at Gulfstream Aerospace or at an AWRF and the aircraft is still within the applicable labor warranty period. All other installations shall be subject to the prevailing labor rate of the installing agency.

NOTE 2: This ASC Kit will be provided at no charge for a period of 24 months from the release date noted on the cover of this Aircraft Service Change if the aircraft is still within the applicable warranty period. After the 24-month period has expired, this ASC Kit(s) will be priced and sold.


Page 3 of 11

MODIFICATION INSTRUCTIONS:

CAUTION: PROTECT WIRE BUNDLES, CONNECTORS AND SURROUNDING STRUCTURE DURING ANY MAINTENANCE PROCEDURE FROM SHAVINGS, DEBRIS AND CONTAMINATION. MAINTAIN A PROPERLY CLEANED WORK AREA THROUGHOUT THE PROCEDURE TO ENSURE THE INTEGRITY OF THE AFFECTED COMPONENT / SYSTEM. VISUALLY INSPECT WORK AREA USING ADDITIONAL LIGHT AS NECESSARY TO VERIFY ABSENCE OF ANY DEBRIS PRIOR TO COMPLETION OF PROCEDURE. FAILURE TO COMPLY MAY RESULT IN DAMAGE TO COMPONENTS AND / OR SYSTEMS.

A. Prepare aircraft for safe ground maintenance. Refer to AMM, Safe Ground

Maintenance Procedures, Chapter 20.

B. Extend flaps to 10 degrees. Refer to AMM, Flap System Operation, Chapter 27.

C. Remove all electrical power, turn all cockpit switches off and disconnect battery quick disconnects.

D. Remove left and right upper wing cove panels, 581CT and 681CT. Refer to Figure 1.

E. On a clean work table, modify the left wing cove panel as follows:

CAUTION: Prior to drilling, clamp in place and trial fit all tooling, shrouds and brackets to ensure proper alignment and orientation before installation. Do not permanently attach cable shrouds or brackets to cove panels at this time.

1. Verify drill block, P/N 1159GSE50711-1 matches the footprint of the nutpate

pattern on shroud assembly, P/N 1159SB50095-11. Refer to Figure 2, View A.

2. Verify drill block, P/N 1159GSE50711-3 matches the footprint of the nutpate pattern on shroud assembly, P/N 1159SB50095-13. Refer to Figure 2, View B.

3. Locate and clamp in place shroud drill blocks, P/N 1159GSE50711-1 (outboard) and -3 (inboard) onto the trailing edge of the cove panel web cavity. Refer to Figure 2, View C and Figure 3.

4. Match drill hole diameter to 0.166-0.172 (25 places) and countersink cove panel (near side) 0.262 x 100°. Refer to Figure 3.

5. Temporarily attach the shroud assemblies, P/N 1159SB50095 -11 and -13, to the left cove panel.

6. Join shroud assemblies, -11 and -13, to bracket assemblies, P/N 1159SB50095-3, -5, -7 and -9, using rivet, MS20470AD5-4 (2 places each), wet with sealant MIL-PRF-81733. Refer to Figure 3, as shown.

7. Orient the bracket assemblies, P/N 1159SB50095-3, -5, -7, and -9, to cove panel webbing as shown. Match drill hole diameter to 0.166-0.172. Refer to Figures 3 and 4.

8. Remove shroud assemblies and brackets. Set aside for final installation in Step H.


Page 4 of 11

F. On a clean work table, modify the right wing cove panel as follows:

CAUTION: Prior to drilling, clamp in place and trial fit all tooling, shrouds and brackets

to ensure proper alignment and orientation before installation. Do not permanently attach cable shrouds or brackets to cove panels at this time.

1. Verify drill block, P/N 1159GSE50711-1 matches the footprint of the nutpate

pattern on shroud assembly, P/N 1159SB50095-12. Refer to Figure 2, View A.

2. Verify drill block, P/N 1159GSE50711-3 matches the footprint of the nutpate pattern on shroud assembly, P/N 1159SB50095-14. Refer to Figure 2, View B.

3. Locate and clamp in place shroud drill blocks, P/N 1159GSE50711-1 (outboard) and -3 (Inboard) onto the trailing edge of the cove panel web cavity. Refer to Figure 2, View C and Figure 3.

4. Match drill hole diameter to 0.166-0.172 (25 places) and countersink cove panel (near side) 0.262 x 100°. Refer to Figure 3, opposite.

5. Temporarily attach shroud assemblies, P/N 1159SB50095 -12 and -14, to right cove panel.

6. Join shroud assemblies, -12 and -14, to bracket assemblies, P/N 1159SB50095-4, -6, -8 and -10, using rivet, MS20470AD5-4 (2 places each), wet with sealant MIL PRF-81733. Refer to Figure 3, opposite.

7. Orient the bracket assemblies, P/N 1159SB50095-4, -6, -8 and -10 to cove panel webbing as shown. Match drill hole diameter to 0.166-0.172. Refer to Figures 3 and 4.

8. Remove shroud assemblies and brackets. Set aside for final installation in Step H.

G. Install the left and right wing cove panels, 581CT and 681CT. Refer to Figure 1.

NOTE: Wet install using sealant MIL PRF-81733 Type I or equivalent.

H. Align shroud assemblies with brackets over aileron cables and secure to cove panel using bolt, NAS8702-2 (25 places).

I. Secure the brackets to the cove panel webbing using bolts, P/N NAS7802-6, washer, P/N NAS620C8 and nuts, P/N NAS1291C08M.

NOTE: Permissible to align bolt, NAS7802-6 with direction of head facing forward. All

bolts must maintain uniformity.

J. Attach decal, P/N GAD12C-3-ASC081 to each shroud assembly as shown. Top coat with 3020 epoxy gloss clear. Refer to Figure 1.

K. Fillet seal cove panels using, MIL-PRF-81733 Type II or equivalent.

L. Touch up using epoxy primer, 3012 or equivalent.


Page 5 of 11

M. White top coat with epoxy gloss, 2012 or equivalent.

N. Comply with the following return to service procedure:

1. Rotate control yoke full deflection left and right and verify minimum clearance of 0.250 between aileron cable and shroud assemblies. Refer to Figure 5.

O. Ensure work area is clean and clear of foreign objects and debris (FOD).

P. Record compliance with this aircraft service change in the aircraft’s permanent maintenance records and return aircraft to flight status.

Q. Report compliance with this aircraft service change to Gulfstream CMP via electronic transmittal or fill out and fax the attached service reply card.

WEIGHT AND BALANCE DATA:

The effect of this service change is considered an appreciable increase to the aircraft’s basic weight and balance. Refer to the following table and update the aircraft’s weight and balance records.

MOD WEIGHT GVFS MOMENT

ASC 081 2.097 lbs 685.00 inches 1436.45 inch lbs

ELECTRICAL LOAD ANALYSIS DATA:

The effect of this change on the aircraft’s electrical loading is zero.


Page 6 of 11

Parts Required Per Aircraft

Item Part Number Nomenclature Kit Notes/Alt/Sub

1. 1159SB50095-3 Bracket Assy 1 -

2. 1159SB50095-4 Bracket Assy 1 -

3. 1159SB50095-5 Bracket Assy 1 -

4. 1159SB50095-6 Bracket Assy 1 -

5. 1159SB50095-7 Bracket Assy 1 -

6. 1159SB50095-8 Bracket Assy 1 -

7. 1159SB50095-9 Bracket Assy 1 -

8. 1159SB50095-10 Bracket Assy 1 -

9. 1159SB50095-11 Shroud Assy 1 -

10. 1159SB50095-12 Shroud Assy 1 -

11. 1159SB50095-13 Shroud Assy 1 -

12. 1159SB50095-14 Shroud Assy 1 -

13. NAS7802-6 Bolt 16 -

14. NAS8702-2 Bolt 50 -

15. NAS1291C08M Nut 16 -

16. MS20470AD5-4 Rivet 16 -

17. NAS620C8 Washer 16 -

18. GAD12C-3-ASC081 Decal 4 -

19. MIL-PRF-81733 Sealant A/R PR1776

20. 3012 Epoxy Primer A/R -

21. 2012 Top Coat Epoxy Gloss A/R -

22. 3020 Clear Epoxy Gloss A/R -

NOTE: All materials listed “As Required” are the responsibility of the installing facility.


Page 7 of 11

ASC 081

REF. SHROUD1159SB50095-11 SHN1159SB50095-12 OPP

ASC 081

REF. SHROUD1159SB50095-13 SHN1159SB50095-14 OPP

INSTALL DECALGAD12C-3-ASC081

INSTALL DECALGAD12C-3-ASC081

REF. BRACKET ASSY1159SB50095-3 1159SB50095-5

REF. BRACKET ASSY1159SB50095-7 1159SB50095-9

REF. COVE PANEL1159WM51535

VIEW LOOKING UP AND FORWARDLEFT WING SHOWN

RIGHT WING OPPOSITE

RIB STA 330.00

REMOVE UPPER COVE PANEL581CT (LEFT)681CT (RIGHT)

UP

FWD

VIEW LOOKING DOWNLEFT WING SHOWN

RIGHT WING OPPOSITE

FIGURE 1


Page 8 of 11

FIGURE 2


Page 9 of 11

INSTALLBRACKET ASSY

1159SB50095-3

INSTALLBRACKET ASSY

1159SB50095-5

INSTALLBRACKET ASSY1159SB50095-7

INSTALLBRACKET ASSY

1159SB50095-9INSTALL

SHROUD ASSY1159SB50095-11 SHN

1159SB50095-12 OPP

INSTALL SHROUD ASSY1159SB50095-13 SHN1159SB50095-14 OPP

INSTALLRIVETMS20470AD5-4(2 PLACES)

INSTALLRIVETMS20470AD5-4(2 PLACES) INSTALL RIVET

MS20470AD5-4(2 PLACES EA)

REFWING COVE PANEL

1159WM51535

MATCH DRILL HOLES TO COVE PANEL, SHROUD & NUTPLATES

DIA. 0.166 - 0.172CSK NS 0.262 x 1000

INSTALL SCREWSNAS8702-2

(25 PLACES)

SHROUD ASSY1159SB50095-11 REF

SHROUD ASSY1159SB50095-13 REF

SPOILER SEAL1159CS55480

REF

.89 1.43 REF1.38 REF .94 2.38 REF .32 REFAFT AILERON COMMAND CABLE REF

FWD AILERON COMMAND CABLE REF

FWD AILERON COMMAND CABLE REF

VIEW LOOKING UP LHS

AFT

INBD

VIEW LOOKING DOWN LHSAFT

OUTBD

RIB STA 347.000TRACE





1159WM51535 REFLEFT WING INSTL SHOWN

RIGHT WING INSTL OPPOSITE

SEE NOTE 2

SEE NOTE 1SEE NOTE 1 AND 2

NOTE:1. CLAMP IN PLACE DRILL BLOCK, P/N 1159GSE50711-1 (OUTBD)2. CLAMP IN PLACE DRILL BLOCK, P/N 1159GSE50711-3 (INBD)

FIGURE 3


Page 10 of 11

MATCH DRILL HOLES TO COVE PANEL & BRACKET ASSY

DIA. 0.166 - 0.172

INSTALL BOLT, NAS7802-6 (SEE NOTE)

WASHER, NAS620C8NUT, NAS1291C08M


DIA. 0.166 - 0.172




DIA. 0.166 - 0.172



.34 .34 .34 .34

SECT D-DVIEW LOOKIN AFT

INBD

UP

INSTALL BRACKET ASSY1159SB50095-3 SHN1159SB50095-4 OPP

INSTALL BRACKET ASSY

1159SB50095-5 SHN1159SB50095-6 OPP

AILERON COMMAND CABLE REF

RIB STA 333.000TRACERIB STA 347.000

TRACE


REFSHROUD ASSY1159SB50095-11 SHN1159SB50095-12 OPP

REFSHROUD ASSY1159SB50095-13 SHN1159SB50095-14 OPP



REF COVE PANEL1159WM51535

NOTE: PERMISIBLE TO ALIGN BOLT, NAS7802-6 WITH DIRECTION OF HEAD FACING FORWARD. ALL BOLTS MUST MAINTAIN UNIFORMITY.

FIGURE 4


Page 11 of 11

REFSPOILER SEAL1159CS55480

REFCABLE SHROUD1159SB50095-13

AILERON CABLE (SEE NOTE 1)

NOTE:1. ROTATE AILERON CONTROL YOKE FULL DEFLECTION LEFT & RIGHTAND VERIFY MINIMUM CLEARANCE OF 0.250 BETWEEN AILERON CABLEAND SHROUD ASSEMBLIES.2. PERMISSIBLE TO ALIGN BOLT, NAS7802-6 WITH DIRECTION OF HEAD FACING FORWARD. ALL BOLTS MUST MAINTAIN UNIFORMITY.

SECT C-C

REFBRACKET ASSY1159SB50095-7

REFWING COVE PANEL

1159WM51535

REFSPOILER BOARD

1159CS55480

REFRADIUS BLOCK1159SB50095-33

REFBOLT, NAS7802-6 (SEE NOTE 2)WASHER, NAS620C8NUT, NAS1291C08M

FIGURE 5



SERVICE REPLY CARD

PLEASE FAX THIS PAGE TO GULFSTREAM AEROSPACE CMP AT FAX # 912-965-3598 OR 866-827-7642.

THE FOLLOWING AIRCRAFT SERVICE CHANGE HAS BEEN COMPLIED WITH:

ASC NUMBER A/C AIRCRAFT TYPE COMPLIANCE DATE

970810 G550 AIRCRAFT HOURS: AIRCRAFT LANDINGS: PREVIOUSLY COMPLIED WITH (PCW):

DATE:

NOT APPLICABLE:

DATE:

NOMENCLATURE PART NUMBER SERIAL NUMBER CMP CODE

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