P.68 VARIANTS. SERVICE INSTRUCTION No. 76 Rev. 2

Transcription

1 vulcanair spa via g. pascoli, casoria (na) italia tel fax info@vulcanair.com P.68 VARIANTS SERVICE INSTRUCTION No. 76 Rev. 2 (Supersedes the previous issue dated 02 September 2004) Design Organisation Approval No. AS-SI/12/005 dated 10 December 2012 SUBJECT : INSTALLATION OF NEW FUEL LEVEL INDICATION SYSTEM CONSISTING OF ONE INDICATOR P/N NOR OR P/N NV A AND TWO TRANSMITTERS P/N NOR /-1A NOTE Revision 2 of this Service Instruction is a complete re-issue of the previous revision 1. It is being issued to supply instructions for the installation of a new dual fuel level indicator P/N NV A as an alternative item to the dual fuel level indicator P/N NOR Also please be advised that the Italian version of the present Service Instruction has been rendered inactive. 1. GENERAL 1.1 AIRCRAFT AFFECTED P.68C, P.68 Observer 2 and P.68TC Observer aircraft from S/N 411 up to S/N 422, plus S/N 424 and PURPOSE To supply instructions for the replacement of the existing Fuel Level Indication System manufactured by Electronics International Inc. P/N FL-2CA or by Vision Microsystems P/N , with a new Fuel Level Indication System as per SB 127 (latest applicable revision). 1.3 DESCRIPTION The new Fuel Level Indication System consists of a dual fuel level indicator P/N NOR or P/N NV A, depending upon their availability, and of two fuel level transmitters P/N NOR /-1A. First Issue dated 18/05/2004 Page 1 of 24

2 1. GENERAL (Cont.) 1.3 DESCRIPTION (Cont.) The instructions for the installation of the new Fuel Level Indication System are laid out in Paragraph 2 hereunder and divided into five sections as follows: PART A: REMOVAL OF THE FUEL LEVEL INDICATION SYSTEM MANUFACTURED BY ELECTRONIC INTERNATIONAL INC. OR BY VISION MICROSYSTEMS PART B: INSTALLATION OF THE NEW FUEL LEVEL INDICATION SYSTEM WITH APPLICATION OF KIT SB127/A OR SB127/B OR KIT SB127/C OR SB127/D, AS APPLICABLE PART C: RECONFIGURATION OF THE EXISTING WIRING HARNESS FOR THE NEW FUEL LEVEL INDICATION SYSTEM PART D: INSPECTION FOR LEAKAGE IN THE MODIFIED AREA OF THE FUEL TANKS PART E: CALIBRATION OF THE NEW FUEL LEVEL INDICATION SYSTEM 1.4 MANHOURS Refer to the relevant paragraph in the latest applicable revision of SB SPECIAL TOOLS Refer to the relevant paragraph in the latest applicable revision of SB VARIATION IN WEIGHT & BALANCE Negligible. 1.7 ELECTRICAL SYSTEM LOAD Negligible. 1.8 REFERENCE DOCUMENTS Latest applicable revision of Service Bulletin No. 127 Latest applicable revision of Service Instruction No. 77 Applicable Parts Catalogue for aircraft variant Applicable Maintenance Manual for aircraft variant 1.9 PUBLICATIONS AFFECTED Refer to the relevant paragraph in the latest applicable revision of SB MODIFICATION TO BE CARRIED OUT BY Vulcanair S.p.A. or other Certified Maintenance Facility. First Issue dated 18/05/2004 Page 2 of 24

3 2. INSTALLATION INSTRUCTIONS SAFETY PRACTICE Where local regulations are not specified, the following safety precautions are recommended while de-fuelling and carrying out the modification: a) The aircraft must be placed in a designated fuelling or de-fuelling area b) Position a trestle under each wing in correspondence of rib No.16 bis c) All fuelling and de-fuelling equipment must be grounded and bonded to the aircraft. As bonding points, use the muffler tube protruding from the engine cowlings for aircraft equipped with IO-360-A1B(6) engines or the turbocharger exhaust tube protruding from the engine cowlings for aircraft equipped with TIO-360-C1A6D engines d) Fire fighting equipment must be readily available e) To avoid generating static electricity or causing sparks, do not wear nylon or synthetic fabrics, and/or shoes with metal heel taps f) Turn OFF all the electrical switches g) Remove baggage bulkhead and disconnect the battery connections (negative terminal first) h) Disconnect external power i) If artificial lighting is necessary, use only hermetically sealed lights j) Do not smoke or use a naked flame near aircraft tanks PART A : REMOVAL OF THE FUEL LEVEL INDICATION SYSTEM MANUFACTURED BY ELECTRONIC INTERNATIONAL INC. OR BY VISION MICROSYSTEMS - Referring to Figure 4 - Removal of the Fuel Level Probe P/N P-300C manufactured by Electronic International Inc. or - Referring to Figure 7 - Removal of the Fuel Level Probe P/N manufactured by Vision Microsystems The following instructions are applicable for the removal of the fuel level probes in both fuel tanks. 1. Drain fuel tanks completely 2. Open all the fuel tank inspection hatches on the upper wing 3. Allow fuel tanks to ventilate for at least 12 hours 4. Get access to the fuel level probe electrical connections opening the provided inspection hatch in proximity of rib No Disconnect the electrical connections from the fuel level probe manufactured by Electronic International Inc. or by Vision Microsystems, whichever is installed 6. Remove all fixing elements such as screws, nuts, washers, clamps and bushings from the fuel level probe manufactured by Electronic International Inc. or by Vision Microsystems, whichever is installed 7. Unscrew and remove the fuel level probe manufactured by either Electronic International Inc. P/N P-300C or by Vision Microsystems P/N , whichever is installed 8. Remove lubricating sealant from the adapter installed on rib No.10. Clean the area with Methyl-Ethyl-Ketone or equivalent cleaning solvent First Issue dated 18/05/2004 Page 3 of 24

4 2. INSTALLATION INSTRUCTIONS (Cont.) PART A (Cont.) 9. Apply a film of lubricating sealant P/N NOR to the threading of the plug P/N R and install this lat one on the adapter on rib No.10. Torque to the value of 230 lb.in 10. Allow the lubricating sealant to polymerize in accordance with the times indicated by the manufacturer 11. Reinstall the cover of the inspection hatch previously opened allowing the removal of the fuel level probe and subsequent installation of the plug P/N R Removal of the Fuel Level Indicator P/N FL-2CA manufactured by Electronic International Inc. or - Removal of the Fuel Level Indicator P/N NOR manufactured by Vision Microsystems - plus removal of the relative placards referring to Figures 2 and 3 For aircraft equipped with the Fuel Level Indicator P/N FL-2CA manufactured by Electronic International Inc.: 1. Referring to the Maintenance Manual applicable to the aircraft variant, get access to the rear of the instrument panel, remove the cover from the area concerned with the modification and disconnect the J125 connector (refer to Figures 9 and 10) 2. Carefully unscrew the four screws attaching the Fuel Level Indicator P/N FL-2CA manufactured by Electronic International Inc., to the instrument panel and remove the Indicator being especially careful not to damage any wiring and/or components of systems installed in the area concerned with the modification 3. Remove the CAUTION placard P/N and the U.S. GALLON placard P/N from the instrument panel (refer to Figures 1 and 3) 4. Remove the fuel level indicator "WARNING" placard P/N from the overhead panel in the cockpit area (refer to Figure 2) For aircraft equipped with the Fuel Level Indicator P/N NOR manufactured by Vision Microsystems: 1. Referring to the Maintenance Manual applicable to the aircraft variant, get access to the rear of the instrument panel, remove the cover from the area concerned with the modification and disconnect the electrical connections of the Fuel Level Indicator P/N NOR (refer to Figures 3, 11 and 12) 2. Disconnect the flat cable connector from the back of the Fuel Level Indicator (refer to Figures 3, 11 and 12) 3. Insulate and stow the previously disconnected connector in accordance with the aeronautical standard practices 4. Carefully unscrew the four screws attaching the Fuel Level Indicator P/N NOR manufactured by Vision Microsystems to the instrument panel and remove the indicator being especially careful not to damage any wiring and/or components of systems installed in the area concerned with the modification 5. Remove the fuel level indicator WARNING placard P/N from the overhead panel in the cockpit area (refer to Figure 2) First Issue dated 18/05/2004 Page 4 of 24

5 2. INSTALLATION INSTRUCTIONS (Cont.) PART B : INSTALLATION OF THE NEW FUEL LEVEL INDICATION SYSTEM WITH APPLICATION OF KIT SB127/A OR SB127/B OR SB127/C OR SB127/D, AS APPLICABLE PART B/1 : Installation of the new Fuel Level Transmitter P/N NOR /-1A on the wing front spar The following instructions are applicable for both wings. Referring to the applicable Maintenance Manual for aircraft variant remove the outer leading edge and proceed with the following instructions, as applicable: PART B/1a : For aircraft without 120 mm diameter holes drilled in the front spars in the area between ribs No.13 and 14: 1. As indicated in Figure 6, drill 120 mm diameter holes in the front spar of both wings in the area between ribs No.13 and 14. Take particular care during drilling operation to avoid any imperfection. Also the hole must be smoothly finished to avoid the possibility of beginning of cracks in the future NOTE: Be especially careful to avoid damaging the aileron control cables that run through the area concerned with the modification. 2. Position the Fuel Level Transmitter Flange Support P/N over the hole drilled as indicated in Figure 6 3. Using the Transmitter Flange Support as a drilling template, drill fifteen 3,2 mm diameter holes on the wing front spar and the Transmitter Flange Support as indicated in Figure 6 4. Deburr all the holes. Clean the reworked area with Methyl-Ethyl-Ketone or equivalent cleaning solvent and touch up them with Alodine 1200 (MIL-C-5541). Finish with Epoxy Primer (MIL-PRF-23377) only the concerned area outer the fuel tank 5. Proceed with the instructions in PART B/1c hereunder PART B/1b : For aircraft with 120 mm diameter holes drilled in the front spars in the area between ribs No.13 and 14 and subsequently covered in accordance with drawing R.0363: 1. Referring to Figure 6, remove the sealant from the areas concerned with the modification through the inspection hatches on the upper wing skins NOTE: Be especially careful to avoid damaging the aileron control cables that run through the area which is concerned by the modification. 2. Unrivet and remove the covers P/N R /-3 from the wing front spar (LH and RH) 3. Clean the area with Methyl-Ethyl-Ketone or equivalent cleaning solvent First Issue dated 18/05/2004 Page 5 of 24

6 2. INSTALLATION INSTRUCTIONS (Cont.) PART B/1b (Cont.) 4. Position the Fuel Level Transmitter Flange Support P/N SP on the wing front spar as indicated in Figure 6 5. Copy the position of the holes on the wing front spar onto the Transmitter Flange Support and drill fifteen 3,2 mm diameter holes on it 6. Deburr all the holes. Clean the reworked area with Methyl-Ethyl-Ketone or equivalent cleaning solvent and touch up them with Alodine 1200 (MIL-C-5541). Finish with Epoxy Primer (MIL-PRF-23377) only the concerned area outer the fuel tank 6. Proceed with the instructions in PART B/1c below PART B/1c : For all the aircraft: 1. Install the Flange Support for the new Fuel Level Transmitter on the wing front spar with fifteen rivets P/N MS20470AD4-5. Interpose PR 1431 Type II sealant or equivalent between the Flange Support and the wing front spar; subsequently apply PR 1422 B2 sealant or equivalent around the edges and over the rivets. Allow the sealant to polymerize in accordance with the times indicated by the manufacturer 2. Install the new Fuel Level Transmitters P/N NOR on the Flange Support on the LH wing and P/N NOR A on the Flange Support on the RH wing with the gasket P/N NOR interposed between the Transmitter and the Flange, five screws P/N AN3-5A, five lock washers P/N MS , and five washers P/N NAS1149F0332P as indicated in Figure 6 3. Clean the tanks to eliminate any residual material PART B/2 : Installation of the new Fuel Level Indicator P/N NOR or P/N NV A, as applicable: Using 3 screws P/N MS24693-BB34 and 3 fast nuts P/N NOR H, install the new Fuel Level Indicator P/N NOR or P/N NV A on the instrument panel in the same location where the indicator manufactured by Electronic International Inc. or by Vision Microsystems, was previously installed. During this operation install also the instrument light P/N NOR and the relevant grounding cable to be made according to the indications reported in Figure 8. First Issue dated 18/05/2004 Page 6 of 24

7 2. INSTALLATION INSTRUCTIONS (Cont.) PART C : RECONFIGURATION OF THE EXISTING WIRING HARNESS FOR THE NEW FUEL LEVEL INDICATION SYSTEM PART C/1 : Installation of Kit SB127/A or Kit SB127/C, as applicable, on aircraft equipped with the Fuel Level Indicator P/N FL-2CA manufactured by Electronic International Inc.: 1. Referring to Figure 1, remove the cabin furnishing panels to get access to the areas which are concerned by the modification 2. If installing Kit SB127/A, referring to the premodification and postmodification wiring diagrams shown in Figures 9 and 10, with the electrical material included in the above Kit, reconfigure the exiting wiring harness adapting it for the new fuel level indication system 3. If installing Kit SB127/C, referring to the premodification and postmodification wiring diagrams shown in Figures 9 and 10a, with the electrical material included in the above Kit, reconfigure the exiting wiring harness adapting it for the new fuel level indication system 4. Reinstall the wing leading edge and the cabin furnishing panels previously removed NOTE: In this phase, do not install the instrument panel cover. PART C/2 : Installation of Kit SB127/B or Kit SB127/D, as applicable, on aircraft equipped with the Fuel Level Indicator P/N NOR manufactured by Vision Microsystems: 1. Referring to Figure 1, remove the cabin furnishing panels to get access to the areas which are concerned by the modification 2. Referring to the Maintenance Manual applicable to the aircraft variant, get access to the back of the instrument panel in the area which is concerned by the modification and disconnect the Flat Cable from the back of the Left EC100 Unit 3. Carefully remove the four screws attaching the Left EC100 Unit to the instrument panel. Bring the Left EC100 Unit into view and drag it downwards for P.68 Observer 2 and P.68 TC Observer aircraft or drag it upwards for P.68C aircraft NOTE: During the above operation, be especially careful not to damage wiring and/or system components in the area which is concerned by the modification. 4. Unscrew and remove the cover from the Left EC100 unit and get access to the P1 connector which is concerned by the modification (refer to Figures 11 and 12) 5. Unscrew and disconnect the cables going from pin 1 to pin 6 of the P1 connector (refer to Figures 11 and 12) 6. Cut two adequately long pieces from the cable AWG20 P/N NOR included in the Kit and make a bridge between pins 1 and 3 and pins 4 and 6 on the connector P1, as shown in Figure 12 First Issue dated 18/05/2004 Page 7 of 24

8 2. INSTALLATION INSTRUCTIONS (Cont.) PART C/2 (Cont.) 7. Insulate and coil and stow all disconnected cables in accordance with aeronautical standard practices (refer to Figure 12) 8. Reinstall the left EC100 Unit on the Instrument Panel and reconnect the Flat Cable to the back of the Unit 9. Get access to the LH Fuel Level Transmitter and referring to wiring diagram in Figure 13, install the connector P/N NOR and two pins P/N NOR on the wires of the Fuel Level Transmitter, thereby making the connection P Get access to the RH Fuel Level Transmitter and referring to wiring diagram in Figure 13, install the connector P/N NOR and two pins P/N NOR on the wires of the Fuel Level Transmitter, thereby making the connection P Referring to Figure 13 or 13a, as applicable, install the Stand-alone wiring harness P/N connecting it to the P142 and P143 connectors and to the Fuel Level Indicator as follows: - If installing the Dual Fuel Level indicator P/N NOR (Kit SB127/B), tighten the ring nut of the J139 connector included in the wiring harness P/N (refer to Figures 8 and 13) - If installing the Dual Fuel Level indicator P/N NV A (Kit SB127/D), install the interface electrical wiring included in the instrument package using the connector P/N NOR and four pins P/N NOR (refer to Figures 8 and 13a) 12. Install the 2A Breaker P/N MS in the position SPARE on the Breaker Panel (refer to Figures 3 and 13) 13. Using the electrical material included in the Kit and, referring to Figure 13 or 13a, as applicable, connect the breaker to the wiring harness P/N Install the ground cables on the aircraft at the points indicated in Figure 13 or 13a, as applicable NOTE: Bind the electrical cables to the existing wiring harness with the tie wraps P/N NOR A included in the Kit. 15. Install the FUEL LEVEL INDICATOR placard P/N near the breaker previously installed 16. Reinstall the wing leading edge and the cabin furnishing panels previously removed NOTE: In this phase do not install the instrument panel cover. First Issue dated 18/05/2004 Page 8 of 24

9 2. INSTALLATION INSTRUCTIONS (Cont.) PART D : INSPECTION FOR LEAKAGE IN THE MODIFIED AREA OF THE FUEL TANKS Fill fuel tanks completely and for a period of 4 hours periodically inspect for leakage of fuel each wing in proximity of the Fuel Level Transmitter and plug P/N R (on rib No.10). Eliminate any eventual leak. PART E : CALIBRATION OF THE NEW FUEL LEVEL INDICATION SYSTEM 1. Restore the battery electrical connections (positive terminal first) and reinstall the baggage bulkhead 2. Calibrate the Fuel Level Indicator in accordance with the latest applicable revision of Service Instruction No Close all the open inspection hatches. When closing the inspection hatches on the upper wing, use new gaskets P/N NOR included in the Kit 4. Install the cover on the instrument panel First Issue dated 18/05/2004 Page 9 of 24

10 Figure 1 - PREMODIFICATION - Fuel Level Indication System Electronics International Inc. or Vision Microsystems to be removed First Issue dated 18/05/2004 Page 10 of 24

11 Figure 2 - PREMODIFICATION - Fuel Level Indication System Electronics International Inc. or Vision Microsystems to be modified First Issue dated 18/05/2004 Page 11 of 24

12 Page to be considered as reference for spare parts. Figure 3 - PRE/POSTMODIFICATION - Fuel Level Indication System Electronics International Inc. or Vision Microsystems to be modified First Issue dated 18/05/2004 Page 12 of 24

13 Figure 4 - PREMODIFICATION - Fuel Level Indication System Electronics International Inc. to be removed First Issue dated 18/05/2004 Page 13 of 24

14 Page to be considered as reference for spare parts. Figure 5 - POSTMODIFICATION - New Fuel Level Indication System installation First Issue dated 18/05/2004 Page 14 of 24

15 Page to be considered as reference for spare parts. Figure 6 - POSTMODIFICATION - New Fuel Level Indication System installation First Issue dated 18/05/2004 Page 15 of 24

16 Figure 7 - PREMODIFICATION - Fuel Level Indication System Vision Microsystems to be removed First Issue dated 18/05/2004 Page 16 of 24

17 Page to be considered as reference for spare parts. Figure 8 - POSTMODIFICATION - New Fuel Level Indication System installation First Issue dated 18/05/2004 Page 17 of 24

18 Figure 9 - PREMODIFICATION - Fuel Level Indication System Electronics International Inc. Wiring Diagram to be reconfigured First Issue dated 18/05/2004 Page 18 of 24

19 Figure 10 - POSTMODIFICATION - Fuel Level Indication System Electronics International Inc. Wiring Diagram reconfigured for New Dual Fuel Level Indicator P/N NOR First Issue dated 18/05/2004 Page 19 of 24

20 Figure 10a - POSTMODIFICATION - Fuel Level Indication System Electronics International Inc. Wiring Diagram reconfigured for New Dual Fuel Level Indicator P/N NV A First Issue dated 18/05/2004 Page 20 of 24

21 Figure 11 - PREMODIFICATION - Fuel Level Indication System Vision Microsystems Wiring Diagram to be modified First Issue dated 18/05/2004 Page 21 of 24

22 Figure 12 - POSTMODIFICATION - Fuel Level Indication System Vision Microsystems Wiring Diagram modified First Issue dated 18/05/2004 Page 22 of 24

23 Figure 13 - POSTMODIFICATION - Wiring Diagram for New Fuel Level Indication System including Dual Fuel Level Indicator P/N NOR Applicable only to aircraft previously equipped with Vision Microsystems Fuel Level Indication System First Issue dated 18/05/2004 Page 23 of 24

24 Figure 13a - POSTMODIFICATION - Wiring Diagram for new Fuel Level Indication System including Dual Fuel Level Indicator P/N NV A Applicable only to aircraft previously equipped with Vision Microsystems Fuel Level Indication System First Issue dated 18/05/2004 Page 24 of 24