P68 VARIANTS SERVICE INSTRUCTION. No. 82. SUBJECT: INCREMENT OF MAXIMUM TAKE-OFF WEIGHT FROM 1990 Kg TO 2084 Kg.

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1 vulcanair spa via g. pascoli, casoria (na) italia Tel Fax info@vulcanair.com P68 VARIANTS SERVICE INSTRUCTION No. 82 SUBJECT: INCREMENT OF MAXIMUM TAKE-OFF WEIGHT FROM 1990 Kg TO 2084 Kg. 1. GENERAL 1.1 AIRCRAFT AFFECTED P68C-TC aircraft up to and including S/N TC delivered with TIO-360-C1A6D engines or whose engines were later converted by retrofitting Lycoming and Partenavia kits part numbers LW and respectively in accordance with the Partenavia Service Instruction N PURPOSE To supply instructions for the installation as applicable, of Kits SB 136, SB 136 Plus 1 and SB 136 Plus 2, to increase the maximum Take-off Weight from 1990 Kg to 2084 Kg and, where applicable, to increase the Maximum Landing Weight from 1890 Kg to 1980 Kg, in accordance with the latest applicable revision of Service Bulletin DESCRIPTION The instructions for the installation as applicable, of Kits SB 136, SB 136 Plus 1 and SB 136 Plus 2, are in Chapter 2 and divided in four sections as follows: PREPARATION OF AIRCRAFT FOR MODIFICATION INSTALLATION OF KIT SB 136 AND KIT SB 136 Plus 1. INSTALLATION OF KIT SB 136 Plus 2. COMPLETION OF MODIFICATION First Issue dated 13/04/2005 Page 1 of 13

2 1. GENERAL (Cont.) 1.4 MANHOURS The time necessary for the application of this Service Bulletin including the time required to access the parts and to return the aircraft to an airworthy condition: is estimated as follows: - 80 man-hours for the installation of Kit SB 136; - 10 man-hours for the installation of Kit SB 136 Plus 1; - 10 man-hours for the installation of Kit SB 136 Plus SPECIAL TOOLS - P/N NOR supplied with the aircraft at delivery, is required for the removal/installation of the main wheels; - Two centring pins P/N NOR included in Kit SB 136, for the positioning of the joists P/N / VARIATION IN WEIGHT & BALANCE Negligible. 1.7 ELECTRICAL SYSTEM LOAD Not applicable. 1.8 REFERENCE DOCUMENTS Latest applicable revision of Service Bulletin No.136; Aircraft Maintenance Manual; Illustrated Parts Catalogue. 1.9 PUBBLICATIONS AFFECTED Aircraft Flight Manual; Illustrated Parts Catalogue; Aircraft Maintenance Manual MODIFICATION TO BE CARRIED OUT BY Vulcanair S.p.A. or Certified Maintenance Facility. First Issue dated 13/04/2005 Page 2 of 13

3 2. INSTALLATION INSTRUCTIONS PREPARAZIONE VELIVOLO 1. Place the aircraft in a designated area to carry out the modification; 2. Place all switches in OFF position and disconnect battery connections (negative terminal first); 3. Remove all passenger seats and rear bench; 4. Remove the LH and RH cabin trim panels lower/lateral between fuselage frames No. 8 and No. 9; 5. Jack the aircraft as per instructions in the Section B of the Aircraft Maintenance Manual; 6. Position saddles at the front and rear of the fuselage under the frames; 7. Lower the jacks slowly to enable the aircraft to settle on the fuselage saddles without damages; 8. Position a trestle under each wing in correspondence of rib No. 11; Note: All the removed items to be reinstalled must be labelled and set aside in a reserved area. INSTALLATION OF KITS SB 136 AND SB 136 Plus 1. Note: In all areas to be coupled, interpose a film of corrosion inhibitive sealant Specification MIL-PRF between dissimilar metals to prevent galvanic corrosion. Before installation, impregnate the shank of the bolts with sealant. - Modification of Main Landing Gear (Refer to Figure 5 for the positions of the indicated items). The following instructions are applicable for the modification of both LH and RH Main Landing Gears. 1. Remove the Main Landing Gear Wheel as per instructions in Section E of the Aircraft Maintenance Manual; 2. Remove the screws (item 3) and remove the leaf spring/fuselage fairing (item 1); 3. Remove the rear leaf spring rubber shaping (item 14); 4. Remove the brake tube (item 5) and hose (item 8). Temporarily plug the opened lines to avoid pollution from foreign bodies; 5. Remove the four bolts (item 16) and remove the brake assembly (item 9), brake support (item 12) and wheel axle (item 11). Recover the reduction bushings (item 13); 6. Remove the bolt (item 29) attaching the leaf spring (item 4) to the joint (item 30); 7. Holding the leaf spring, remove the two bolts (item 37) retaining the channel (item 42). Remove the channel (item 42) and the spacer (item 41); 8. Remove the leaf spring (item 4), the rubber channel (item 40) and the two alignment spacers (item 39); 9. Remove the four bolts (item 33) and remove the side joist (item 38). Recover the ventral safety belt attachment (item 50); First Issue dated 13/04/2005 Page 3 of 13

4 2. INSTALLATION INSTRUCTIONS (Cont.) INSTALLATION OF KITS SB 136 AND SB 136 Plus 1 (Cont.) 10. Position the new side joist (item 38) P/N for the LH installation and P/N for the RH installation between the fuselage frame Nos. 8 and 9 as per the previous installation. Align the holes on the joist (item 38) with the holes on the attachments (item 36) and hold in place with the two centring pins P/N NOR in the lower front and upper rear attachment holes; 11. With the holes on the attachment (item 36) aligned, enlarge the two free holes on the new joist (item 38) reaming them to 3/8 H7; 12. In the reworked holes, install the new bolts P/N NAS (item 33), washers P/N NAS1149F0663P (item 34) and nuts P/N MS21042L6 (item 35). Torque to in. Lb ( Kgm); 13. Remove the two centring pins P/N NOR previously installed; 14. Maintaining the alignment with the holes on the attachment (item 36), enlarge the two free holes on the new joist (item 38) reaming them to 3/8 H7; 15. Reposition the attachment for the seat belt on the bench seat (item 50) previously removed and reinstall in the reworked holes of the new joist (item 38) with the new bolts P/N NAS (item 33), washers P/N NAS1149F0663P (item 34) and nuts P/N MS21042L6 (item 35). Torque to in. Lb ( Kgm); 16. Install the new leaf spring P/N (item 4) and attach it to the joint (item 30) with the new bolt P/N NAS (item 29), washer P/N NAS1149F0632P (item 31) and nut P/N MS21042L6 (item 32). Torque to in. Lb ( Kgm); 17. Install the new rubber channel P/N NOR B (item 40), new spacer P/N (item 41) and new channel P/N (item 42) with the new bolts AN5-27A (item 37), new washers NAS1149F0532P (item 43) and new nuts P/N MS21042L5 (item 44). Do not tighten the nuts at this stage since the main landing gear will have to be aligned and the alignment spacers (item 39) will have to be installed; 18. Unplug the brake lines that were temporarily plugged and reinstall the brake tube (item 5) and the hose (item 8) previously removed; 19. Install the new wheel axle P/N (item 11) and the brake support (item 12), the reduction bushings (item 13) and the brake assembly (item 9) previously removed using the new bolts P/N MS (item 16), washers P/N MS20002-C5 (item 17), P/N NAS1149F0532P (item 27) and nuts P/N MS21042L5 (item 28). Torque to in.lb ( Kgm); 20. Unplug the brake lines that were temporarily plugged and connect the hose (item 8) to the brake assembly (item 9). Bleed air from the brake system in accordance with the procedure laid out in the applicable section of the Aircraft Maintenance Manual; 21. Using type EC-1300 L glue manufactured by 3M or equivalent, and following the manufacturer s procedures and precautions, install the new front shaping P/N (item 7). Lodge the rigid brake tube (item 5) in the new rear shaping P/N (item 14) and install. 22. As per instructions in Section E of the Aircraft Maintenance Manual, remove the tyre and tube from the wheel previously removed and install the new tyre P/N NOR and new tube P/N NOR Inflate the tyre to 50 p.s.i.; 23. Install the new wheel assembly ( item 18) as per instructions in the Section E of the Aircraft Maintenance Manual; First Issue dated 13/04/2005 Page 4 of 13

5 2. INSTALLATION INSTRUCTIONS (Cont.) INSTALLATION OF KITS SB 136 AND SB 136 Plus 1 (Cont.) 24. Jack the aircraft and remove the fuselage saddles; 25. Lower the jacks slowly until the aircraft is safely settled on the ground ; 26. Level the aircraft as per instructions in Section B of the Aircraft Maintenance Manual; 27. With reference to Detail A in Figure 5, align main wheels, bearing in mind that the distance between the main wheel axis and the wing leading edge must be in. +/ in. (818 mm +/- 25 mm). With the leaf spring aligned, measure the gap between the leaf spring and the front and rear shoulders of the joist. Rework the new alignment spacer P/N (item 39) as required by the measurement of the gaps; 28. Holding the channel (item 42) and spacer (item 41), remove the two bolts AN5-27A (item 37), insert the new reworked alignment spacers P/N (item 39) and reinstall. Torque to in. Lb ( Kgm); 29. Check the wheel camber and toe-in as per instructions in the Section E of the Aircraft Maintenance Manual. If necessary install as applicable, the shims (item 24 ) P/N for the toe-in correction and shims P/N for the camber correction; 30. Make reference marks on all coupling bolts and brake line connections; 31. Position the new leaf spring/fuselage fairing (item 1) in place, P/N for the LH side and P/N for the RH side. Copy the positions of the existing attachment holes on the fuselage on to the fairing. Drill and countersink the trace marks on the fairing to in. diameters. Install the new reworked fairing with the new screws P/N MS24693S50 (item 3) and washers P/N NOR (item 2); 32. Reinstall all lateral panels and flooring from the cabin interior between frame Nos. 8 and 9; 33. Reinstall all passenger seats and rear bench; - Installation of new upturned wing tips (Refer to Figure 6) The following instructions are applicable for the installation of both LH and RH wing tips. 1. Remove the attachment screws and pull the existing wing tip as far outward as allowed by the ground lead cables and navigation light wiring. Disconnect the ground lead cables and navigation light electrical connections and remove the existing wing tip. Remove the navigation light from the old wing tip and store it for later installation on the new upturned wing tip; 2. Place the aileron in the neutral position as per instructions in Section D of the Aircraft Maintenance Manual; NOTE: Only for aircraft up to S/N TC equipped with fiberglass wing leading edges, before proceeding further, must install Kit SB 136 Plus 1 as per modification drawing R.0260 and in accordance with the following instructions: a) Cut out the outboard area of the existing wing leading edge as shown in the modification drawing R.0260; b) Install the rib nose P/N for the LH wing and P/N for the RH wing and the strip for the attachment of the upturned wing tip P/N with blind rivets P/N Adjust as necessary; First Issue dated 13/04/2005 Page 5 of 13

6 2. INSTALLATION INSTRUCTIONS (Cont.) INSTALLATION OF KITS SB 136 AND SB 136 Plus 1 (Cont.) c) Copy the attachment holes on the strip P/N , drill them to in. diameters and install the anchor nuts P/N K with rivets P/N MS20426AD-3 as shown in the modification drawing R Position the new wing tip P/N on the LH wing and P/N on the RH wing aligning them with the aileron trailing edge. If necessary, rework the wing tip for a proper fit with the wing; 4. Copy the existing attachment holes on the wing onto the new wings tips. Drill the markings to in. diameters; and countersink 100 ; 5. With reference to Figure 5, position the navigation light previously removed on the new wing tip and copy the attachment holes on the wing tip. Drill 3 holes to in. diameters and install the anchor nuts P/N K with rivets P/N MS20426AD3-4; 6. With the new screws P/N MS24693S51, reinstall the green navigation light on the RH wing tip and the red navigation light on the LH wingtip; 7. Position the new upturned wing tip near enough to the wing to enable the connection of the ground leads and the electrical connections of the navigation lights, fit wing tip on the wing and secure with the new screws P/N MS24694S7. - Installation of new airspeed indicator and new Operational Limits placard 1. Referring to the removal/installation procedure in the applicable section of the aircraft Maintenance Manual, replace the airspeed indicator P/N NOR currently installed, with the new airspeed indicator P/N NOR If installed, also replace the second optional airspeed indicator if installed; 2. Replace the Operational Limits placard currently installed with the new placard P/N ; 3. Referring to the applicable section of the aircraft Maintenance Manual, carry out an air leakage test on the pitot-static system. First Issue dated 13/04/2005 Page 6 of 13

7 2. INSTALLATION INSTRUCTIONS (Cont.) INSTALLATION OF KIT SB 136 Plus 2 (Refer to Figure 5 for the positions of the indicated items). The following instructions are applicable for the installation of both LH and RH main wheel fairings. 1. The new wheel fairings (item 100) have a pilot hole in correspondence to the attachment bolt of the wheel axle (item 101). Drill this hole to a 1/4 in. diameter; 2. Temporarily install the new reworked fairing P/N for the LH wheel and P/N for the RH wheel, attaching it to the wheel axle with the spacer P/N (item 104), nut P/N (item 105), washer P/N (item 103) and bolt P/N AN4-5A (item 101); 3. Mark the positions of the existing attachment holes on the bracket (item 10) onto the new wheel fairing. Check for interference between the wheel and the fairing. Adjust if necessary; 4. Remove the new fairing and drill the markings made to in. diameters; 5. Install the new reworked wheel fairing on board attaching it to the wheel axle with the spacer P/N (item 104), nut P/N (item 105), washer P/N (item 103), lock washer P/N MS (item 102) and bolt P/N AN4-5A (item 101) while the screws P/N MS (item 25) and washers P/N NAS1149FN816P (item 26) are used to attach the wheel airing to the bracket (item 10); COMPLETION OF MODIFICATION 1. Reconnect battery connections (positive terminal first); 2. Verify that the navigation lights on the wings are functioning properly; 3. Check that the brake system is operating correctly. First Issue dated 13/04/2005 Page 7 of 13

8 Figure 1 Three view - PREMODIFICATION - First Issue dated 13/04/2005 Page 8 of 13

9 Figure 2 Three view - POSTMODIFICATION - First Issue dated 13/04/2005 Page 9 of 13

10 Figure 3 Main Landing Gear - PREMODIFICATION - First Issue dated 13/04/2005 Page 10 of 13

11 Figure 4 Main Landing Gear - POSTMODIFICATION - First Issue dated 13/04/2005 Page 11 of 13

12 Figure 5 INSTALLATION OF LARGER LEAF SPRING AND WHEEL (Take as reference for the instructions in the paragraph 2) First Issue dated 13/04/2005 Page 12 of 13

13 Figure 6 INSTALLATION OF NEW UPTURNED WING TIP First Issue dated 13/04/2005 Page 13 of 13

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