P.68 VARIANTS. SERVICE BULLETIN No. 225 Rev. 1

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1 vulcanair spa via g. pascoli, casoria (na) italia Tel Fax info@vulcanair.com P.68 VARIANTS Approved by the Vulcanair Design Organisation The technical content of this document is approved under the authority of DOA No. EASA.21J.009. Operator obligations with regards to inspections, modifications and/or other technical directives and their times of compliance are laid out in the relative Airworthiness Directives. SERVICE BULLETIN No. 225 Rev. 1 (Supersedes the previous issue dated 21 November 2011) Design Organisation Approval No. AS-SB/14/006 dated 04 March 2014 INFORMATION SUBJECT: AERIAL SURVEY CONFIGURATION - WESCAM MX-15i AIRBORNE IMAGING SYSTEM INSTALLATION 1. GENERAL 1.1 AIRCRAFT AFFECTED P.68 Observer 2 s/n 446 P.68C s/n 471 NOTE This revision of the Service Bulletin is being issued to extend its applicability. No additional work is required for aircraft which have already embodied any of the previous revisions of this Service Bulletin. 1.2 PURPOSE The purpose of this Service Bulletin is to supply information for the installation of the Wescam MX-15i Airborne Imaging System. 1.3 DESCRIPTION The WESCAM MX-15i system on the aircraft provides long stand off range day/night surveillance capabilities. First Issue dated 21 November 2011 Page 1 of 14

2 1. GENERAL (Cont.) 1.3 DESCRIPTION (Cont.) The WESCAM MX-15i System consists of the following equipment (Refer to Figures 2 and 3 hereunder): Turret containing the imaging sensors and electronic controls Hand Controller providing: Turret steering controls Menu access and navigation controls Turret sensor controls Laser controls and indications GPS Antenna GPS Receiver and GPS Power Converter (if installed) Display The Wescam gimbal is mounted on a manually operated extension and retraction mechanism which allows the gimbal to be lowered and retracted during flight through the aircraft photogrammetric hatch located in the aircraft fuselage floor. The gimbal must be in the retracted position with the hatch outer doors closed during take-off and landing. A specially designed lift and support mechanism allows the gimbal operator to easily raise and lower the gimbal during surveillance operations. The monitor is mounted on a rack installed on the seat tracks in the area between the copilot seat and the photogrammetric hatch. The GPS receiver and the DC/DC converter, if installed, have been mounted on a support installed in the baggage compartment, behind the third row seats, using the cargo net attachments. For detailed description and operation of the system refer to the latest applicable revision of the relevant Manufacturer s technical documentation. The installation of the Wescam MX-15i requires that the aircraft must be pre-equipped with the following equipment: a) Two 130A alternators b) Photogrammetric hatch between the fuselage frames No.6 and 8 c) 28Vdc@30A max auxiliary power socket CAUTION For P.68C aircraft s/n 471, the change to type design for installation of 28Vdc@30A max auxiliary power socket is under direct responsibility of the aircraft owner. First Issue dated 21 November 2011 Page 2 of 14

3 1. GENERAL (Cont.) 1.3 DESCRIPTION (Cont.) The system is powered through the main bus at 28Vdc by means of the auxiliary power socket installed on the right side wall of the cabin near the photogrammetric hatch (refer to Service Bulletin No.223 for P.68 Observer 2 aircraft s/n 446). The circuit is protected by a 30A circuit breaker, which is located on the left power panel. The complete system is controlled by a switch located on the breaker panel labelled AUX PWR-OUT for P.68 Observer 2 aircraft s/n 446, or by a switch located on the master panel and labelled AUX PWR 28Vdc for P.68C aircraft s/n 471. For P.68 Observer 2 aircraft s/n 446, a Cut-off circuit allows the system to be powered up only when both engines are operating so to avoid overloading of the electrical generation system. The Cut-off is automatic whenever an alternator failure occurs, but manual Cut-off may be carried out by the pilot, whenever necessary, by turning OFF the AUX PWR- OUT switch installed on the breaker panel. For P.68C aircraft s/n 471, refer to the documentation of the change to type design, under direct responsibility of the aircraft owner, for installation of 28Vdc@30A max auxiliary power socket. Whenever a ground check of the system has to be carried out with engines OFF, an external power supply must be used. Compliance with this Service Bulletin requires the installation of the Kit SB225 to be carried out in accordance with the instructions laid out in the Part A through Part F of paragraph 2 hereunder. The installation of the Kit SB225 foresees the following operations: Part A: Installation of the Wescam MX-15i Turret on the photogrammetric hatch between the fuselage frames No.6 and 8 by means of the provided lift and support mechanism. Part B: Installation of the GPS Receiver and GPS Power Converter on the baggage floor just behind the third row seats by means of the provided support (if required). Part C: Installation of the GPS Antenna on the upper fuselage skin between the fuselage frames No.10 and 11. Part D: Installation of the Display on the seat tracks just forward the photogrammetric hatch by means of the provided rack. Part E: Installation of the Wescam wiring harnesses. Part F: Electromagnetic Interference Test. Part G: Return the aircraft to an airworthy condition. First Issue dated 21 November 2011 Page 3 of 14

4 1. GENERAL (Cont.) 1.4 COMPLIANCE At owner s discretion. 1.5 TIME REQUIRED The time necessary for the application of this Service Bulletin is estimated as being 60 man-hours, which includes the time required to access the parts and to return the aircraft to an airworthy condition. 1.6 SPECIAL TOOLS No special tools are required. 1.7 VARIATION IN WEIGHT & BALANCE The installation of the Kit SB225 involves some variations in Weight and Balance. Refer to the following table: ITEM BASIC EMPTY WEIGHT (as weighed) WEIGHT (KG) ARM (m) MOMENT (kgm) A=... G=. SUBTRACT WEIGHTS SEAT N SEAT N TOTAL B= 20 H= INSERT WEIGHTS GIMBAL (P/N ) MONITOR + RACK TOTAL NEW BASIC EMPTY WEIGHT D= A-B+C C= 61 I= D= L= G-H+I L=. Refer to Supplement T/2 included in the applicable Aircraft Flight Manual. C.G. variations during Gimbal extension and retraction are negligible. 1.8 ELECTRICAL SYSTEM LOAD Maximum required load = 36,5A. 1.9 REFERENCE DOCUMENTS Applicable Maintenance Manual for Aircraft Type Drawing R PUBLICATIONS AFFECTED Applicable Maintenance Manual for Aircraft Type Applicable Flight Manual for Aircraft Type 1.11 APPLICATION TO BE CARRIED OUT BY Vulcanair Part 145 or other Certified Maintenance Facility. First Issue dated 21 November 2011 Page 4 of 14

5 2. WORK PROCEDURE WARNING This work procedure calls for the use of substances and/or procedures that may be injurious to health if adequate precautions are not taken. This document refers only to technical suitability and in no way absolves the Operator from statutory and other legal obligation relating to health and safety at any stage of manufacture or use. Part A: Installation of the Wescam MX-15i Turret on the photogrammetric hatch between the fuselage frames No.6 and 8 by means of the provided lift and support mechanism (refer to the latest applicable revision of the relevant Manufacturer s technical documentation) IMPORTANT: Observe all warnings and cautions laid out in the latest applicable revision of the relevant Manufacturer s technical documentation during installation, troubleshooting, maintenance or operation of the Wescam MX-15i Airborne Imaging System. 1. Place the aircraft in a suitable working area for the operations to be carried out. 2. Turn all electrical switches OFF. Remove the baggage bulkhead and disconnect the battery cables (negative cable first). 3. Remove the 3 rd and 4 th seats (2 nd row). 4. Remove the carpet in the area between the fuselage frames No.6 to 8 of the cabin. 5. Remove the screws securing the cover of the photogrammetric hatch in the cabin and remove the cover P/N Tag and store in a reserved area all the previously removed items. 7. Referring to drawing R.0494 and copying from the perimetral existing holes on the photogrammetric hatch, drill 4.2 to 4.4 mm diameter 100 countersunk No.4 holes on the FWD of the frame of the Wescam MX-15 Turret Support Assy p/n , and drill 4.2 to 4.4 mm diameter No.17 holes on the other sides of the same frame. Deburr the holes. Clean all the reworked surfaces with Methyl-Ethyl-Ketone and touch up them with Alodine 1200 (MIL-C-5541), then with Epoxy Primer (MIL-PRF-23377) and after, where necessary, with grey polyurethane finish paint RAL On work bench, referring to drawing R.0494 and the installation instructions laid out in the latest applicable revision of the relevant Manufacturer s documentation, position the Wescam MX-15i Turret on the Support Assy p/n and install it using No.6 bolts p/n NAS and No.6 washers p/n NAS1149F0463P. Torque the bolts to 100 in.lb (1,15 Kgm). Take particular care during the above operation to avoid damage to the Wescam Turret. First Issue dated 21 November 2011 Page 5 of 14

6 2. WORK PROCEDURE (Cont.) Part A (Cont.) NOTE: Before installation, clean out the six mounting holes and the areas around the holes using a dry cloth, then inspect for corrosion inside and around the mounting holes. If corrosion is detected, do not install the Wescam MX-15i Turret on the aircraft without written approval from L-3 Wescam (Refer to the latest applicable revision of the relevant Manufacturer s documentation for the procedure to be performed). During installation, apply a film of Corrosion Inhibitive Jointing Compound CA 1000 (PRC-DESOTO AEROSPACE) or equivalent on the threads of the mounting bolts and around the mounting holes, paying special attention to apply it to areas where the Nickel Plating may have chipped off. For the application and usage method of the above Corrosion Inhibitive Compound refer to the Manufacturer's instructions. 9. In the cabin open the photogrammetric hatch doors and referring to drawing R.0494 and the installation instructions laid out in the latest applicable revision of the relevant Manufacturer s technical documentation, position and install the Wescam MX-15i Turret together with the previously pre-assembled Support Assy p/n on the photogrammetric hatch using No.4 screws p/n MS24693S51, No.2 screws p/n MS and No.15 screws p/n MS with No.15 washers p/n NAS1149FN816P. Tighten the screws just enough for a proper mounting. Take particular care during the above operation to avoid damage to the Wescam Turret. NOTE: During installation, apply a film of Corrosion Inhibitive Jointing Compound CA 1000 (PRC-DESOTO AEROSPACE) or equivalent on the shank of the mounting screws. For the application and usage method of the above Corrosion Inhibitive Compound refer to the Manufacturer's instructions. 10. Referring to drawing R.0494, install the Operative Mode placard p/n , the two Hatch Lock placards p/n and the Warning placard p/n on the Wescam MX-15i Support Assy. Part B: Installation of the GPS Receiver and GPS Power Converter on the baggage floor just behind the third row seats by means of the provided support, if required (refer to the latest applicable revision of the relevant Manufacturer s technical documentation) 1. On work bench, referring to drawing R.0494, perform the following: a) Position the GPS receiver bracket p/n and the DC/DC Converter bracket p/n in place and copying from their attaching holes, drill 4.81 to 4.86 mm diameter No.4 holes on the Support Assy p/n for each installation. b) Put in place the two angles p/n and copying from their attaching holes drill 4.2 to 4.4 mm diameter No.2 holes on the Support Assy p/n for each installation. c) Install the eight bolts p/n AN3-3A, the washers p/n NAS1149F0332P and the nuts p/n MS21083N3 on the Support Assy p/n First Issue dated 21 November 2011 Page 6 of 14

7 2. WORK PROCEDURE (Cont.) Part B (Cont.) 2. Referring to drawing R.0494, position the Support Assy p/n on the baggage floor and copying from the existing holes on the frames No.9 and 11 cargo net attachments, drill 6.34 to 6.39 mm diameter No.4 holes at both ends of the beams of the Support Assy. 3. Deburr all the holes previously carried out. Clean all the reworked surfaces with Methyl- Ethyl-Ketone and touch up them with Alodine 1200 (MIL-C-5541), then with Epoxy Primer (MIL-PRF-23377) and finally, where necessary, with grey polyurethane finish paint RAL Referring to drawing R.0494, install the Support Assy p/n on the cargo net attachments, provided on the fuselage frames No.9 and 11, using No.2 bushings p/n , No.2 bolts p/n AN4-10A, No.2 washers p/n NAS1149F0432P and No.2 nuts p/n MS21083N4 for the frame No.9 attachments, and using No.2 bushings p/n , No.2 spacers p/n , No.2 bolts p/n AN4-7A, No.2 washers p/n NAS1149F0432P and No.2 nuts p/n MS21083N4 for the frame No.11 attachments. Torque the nuts to in.lb (0,8-0,9 Kgm). NOTE: During installation, apply a film of Corrosion Inhibitive Jointing Compound CA 1000 (PRC-DESOTO AEROSPACE) or equivalent on the shank of the mounting screws and inside the mounting holes. For the application and usage method of the above Corrosion Inhibitive Compound refer to the Manufacturer's instructions. 5. Referring to drawing R.0494, put in place the GPS Receiver and secure it installing the provided bracket p/n with interposition of the gasket p/n NV , using the relevant No.4 bolts p/n AN3-4A and No.4 washers p/n NAS1149F0332P. Torque the bolts to in.lb (0,475-0,525 Kgm). 6. Referring to drawing R.0494, position in place the DC/DC Converter and secure it installing the provided bracket p/n with the relevant No.4 bolts p/n AN3-4A and No.4 washers p/n NAS1149F0332P. Torque the bolts to in.lb (0,475-0,525 Kgm). 7. Referring to drawing R.0494, position in place and install the two angles p/n retaining the DC/DC Converter using No.2 screws p/n MS for each installation. Part C: Installation of the GPS Antenna on the upper fuselage skin between the fuselage frames No.10 and 11 Referring to drawing R.0494, carry out the installation of the GPS Antenna on the fuselage skin between the fuselage frames No.10 and 11, in accordance with the instructions laid out in the relevant applicable Manufacturer s documentation. First Issue dated 21 November 2011 Page 7 of 14

8 2. WORK PROCEDURE (Cont.) Part D: Installation of the Display on the seat tracks just forward the photogrammetric hatch by means of the provided rack 1. Unlock the copilot seat and its travel stop located just behind the seat, and slide them forward along the seat tracks just enough to be able to install the Display rack on the seat tracks just forward the photogrammetric hatch. 2. Referring to drawing R.0494, position the rack assy P/N for the display on the segment of seat tracks aftward the copilot seat and forward the photogrammetric hatch, and engage its rear attachments to the seat tracks through the slots provided on this last ones. Pull upward the release lever on the rack, then slide the rack rearward just enough to be able to engage its front attachments to the seat tracks also. Slide the rack positioning it just forward the photogrammetric hatch, then slide forward the rack just enough to be able to engage the locked mechanism into the one of the provided hole on the seat tracks. 3. Referring to drawing R.0494, put in place and install the Display on the rack, in accordance with the instructions laid out in the relevant applicable Manufacturer s documentation. Take particular care during the above operation to avoid damage to the display. Part E: Installation of Wescam wiring harnesses 1. For P.68 Observer 2 aircraft s/n 446, referring to Service Bulletin No.223, install the connector P/N MS3106A18-10P and the backshell P/N MS A included in the Kit SB223, as applicable, on the Wescam electrical wiring harnesses. 2. For P.68C aircraft s/n 471, with reference to the documentation of the change to type design, under direct responsibility of the aircraft owner, for installation of 28Vdc@30A max auxiliary power socket, connect appropriately the Wescam electrical wiring harnesses with the 28Vdc@30A max auxiliary power socket. 3. Route the Wescam electrical wiring harnesses in the aircraft cabin and adequately secure them in place in accordance with the standard aeronautical practices. 4. Mate the electrical connections to the various Wescam system components receptacles. 5. Connect the Wescam electrical wiring harnesses to the auxiliary power socket provided on the right side wall of the cabin near the photogrammetric hatch. Part F: Electromagnetic Interference Test 1. Feed the system with swift cycles ON/OFF and verify the absence of interferences on correct headset reception and of anomalous fluctuation on VOR, ADF, HSI, magnetic compass (max 10 allowable) and engines instruments. 2. Operate the system in all its functionalities and verify the absence of interferences on correct headset reception and of anomalous fluctuation on VOR, ADF, HSI, magnetic compass (max 10 allowable) and engine instruments. First Issue dated 21 November 2011 Page 8 of 14

9 2. WORK PROCEDURE (Cont.) Part G: Return the aircraft to an airworthy condition 1. Connect the battery cables (positive cable first) and reinstall the baggage bulkhead. 2. Reposition and lock in place the co-pilot seat and the relevant travel stop to their initial status. 3. Referring to drawing R.0494, install the Operational Limits placard P/N on the pilot overhead panel and ensure that all the placards on the MX-15i Turret Support Assy are installed and clear. 4. Be sure that the AUX PWR-OUT breaker located on the left power panel is engaged. 5. Place the aircraft in a suitable engine test area. 6. Place all the other utilities OFF. 7. Ensure that there is enough fuel in the tanks to guarantee at least 30 (thirty) minutes of continuous engine operation. 8. Position the aircraft upwind and place chocks under the main landing gear wheels. 9. Start both engines in accordance with the procedure laid out in the Aircraft Flight Manual and accelerate to 1800 RPM. 10. Turn ON the AUX PWR-OUT switch on the breaker panel (for P.68 Observer 2 aircraft s/n 446) or the AUX PWR 28Vdc switch on the master panel (for P.68C aircraft s/n 471), and perform an operational test of the Wescam MX-15i Airborne Imaging System in accordance with the Manufacturer s procedures. 11. Turn OFF the AUX PWR-OUT switch on the breaker panel (for P.68 Observer 2 aircraft s/n 446) or the AUX PWR 28Vdc switch on the master panel (for P.68C aircraft s/n 471), and shutdown the engines. 12. Update the aircraft maintenance program and procedures in accordance with information laid out in the latest applicable revision of the Maintenance Manual Supplement p/n NOR A to be downloaded by Vulcanair web-site Update the Aircraft Flight Manual inserting the current revision to be downloaded by Vulcanair web-site (AFM Supplement T/2 is required). 14. If required, reweigh the aircraft to determine the new Empty Weight and Centre of Gravity or use the weight and balance data in the relevant applicable Aircraft Flight Manual Supplement in accordance with the Local Airworthiness Regulations. 15. Record installation of the Wescam MX-15i Airborne Imaging System as per this Service Bulletin in the Aircraft Log Book. First Issue dated 21 November 2011 Page 9 of 14

10 3. MATERIAL REQUIRED FOR THE MODIFICATION Kit SB 225 (Mechanical interface items for the Wescam MX-15i Airborne Imaging System Installation) Item P/N Description Q.ty MX-15i Camera Support Assy 1 2. NAS Bolt 6 3. NAS1149F0463P Washer 6 4. MS24693S51 Screw 4 5. MS Screw 2 6. MS Screw NAS1149FN816P Washer Operative Mode Placard Hatch Lock Placard Warning Placard GPS Receiver Bracket DC/DC Converter Bracket Wescam Equipment Support Assy Angle Bushing AN4-10A Bolt NAS1149F0432P Washer MS21083N4 Nut Bushing Spacer AN4-7A Bolt NAS1149F0332P Washer AN3-3A Bolt MS21083N3 Nut AN3-4A Bolt MS Screw Display Rack assy Operational Limits Placard NV Gasket 0,3 mt First Issue dated 21 November 2011 Page 10 of 14

11 3. MATERIAL REQUIRED FOR THE MODIFICATION (Cont.) Kit SB 225 (Cont.) (Mechanical interface items for the Wescam MX-15i Airborne Imaging System Installation) Item P/N Description Q.ty 30. MS21919WDG32 Clamp R.0494 Drawing MX-15i WESCAM SYSTEM INSTALL. 1 NOTE: The Wescam MX-15i system components and all the electrical wiring harnesses required to supply power to the system must be ordered directly to the Manufacturer. Commercially available material required but not included in the Kit: - Alodine 1200 (Specification MIL-C-5541) - Epoxy Primer (Specification MIL-PRF-23377) - Corrosion Inhibitive Compound CA 1000 (PRC-DESOTO AEROSPACE) or equivalent First Issue dated 21 November 2011 Page 11 of 14

12 Figure 1 PREMODIFICATION First Issue dated 21 November 2011 Page 12 of 14

13 Figure 2 POSTMODIFICATION (P.68 Observer 2 aircraft) - WESCAM MX-15i AIRBORNE IMAGING SYSTEM LAYOUT - First Issue dated 21 November 2011 Page 13 of 14

14 Figure 3 POSTMODIFICATION (P.68C aircraft) - WESCAM MX-15i AIRBORNE IMAGING SYSTEM LAYOUT - First Issue dated 21 November 2011 Page 14 of 14