vulcanair spa via g. pascoli, 7 80026 casoria (na) italia Tel +39 081 5918111 Fax +39 081 5918172 info@vulcanair.com www.vulcanair.com P68 VARIANTS SERVICE INSTRUCTION No. 89 SUBJECT: MODIFICATION ON FRONT AND REAR SPARS IN LEFT AND RIGHT WINGS FOR SAFE LIFE LIMIT EXTENSION 1. GENERAL 1.1 AIRCRAFT AFFECTED All P.68 aircraft variants from S/N 01 up to and including S/N 356 affected by conditions reported in rows (a) or (c) on Table 1, paragraph 1.3 of the Service Bulletin No. 162. 1.2 PURPOSE According to the requirements stated in the Service Bulletin No. 162, the purpose of this Service Instruction is to supply the instructions necessary for: a. Modification to be carried out on the lower front and rear cap angles on the front spar in the left and right wing by installing the Kit SB162; b. Modification to be carried out on the front and rear spars in the left and right wings by installing the Kit SB162 plus Kit SB162/A. First Issue dated 01 March 2010 Page 1 of 8
1. GENERAL (Cont.) 1.3 DESCRIPTION The installation of Kit SB162 must be carried out in accordance with the drawing R.0441 and the instructions in Parts A, B and D of the paragraph 2 hereunder. The installation of Kit SB162/A must be carried out in accordance with the drawing R.0458 and the instructions in Parts A, C and D of the paragraph 2 hereunder. 1.4 MAN-HOURS REQUIRED The time necessary for the application of this Service Bulletin, including the time required to access the parts and return the aircraft to an airworthy condition, is estimated as follows: - Installation of the Kit SB162 only: 80 man-hours; - Installation of the Kit SB162 plus Kit SB162/A: 120 man-hours. 1.5 SPECIAL TOOLS No special tools are required. 1.6 VARIATION IN WEIGHT AND BALANCE Negligible. 1.7 ELECTRICAL SYSTEM LOAD Not applicable. 1.8 REFERENCE DOCUMENTS Latest applicable revision of the Service Bulletin No. 162; Applicable Maintenance Manual for Aircraft Type; Drawing No. R.0441; Drawing No. R.0458. 1.9 PUBLICATIONS AFFECTED Applicable Maintenance Manual for Aircraft Type; Applicable Parts Catalogue for Aircraft Type. 1.10 MODIFICATION TO BE CARRIED OUT BY Vulcanair Part 145 or Approved Maintenance Organisation. First Issue dated 01 March 2010 Page 2 of 8
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 Aircraft Preparation 1. Place the aircraft in a suitable working area for the operations to be carried out; 2. Switch OFF all electrical loads and disconnect the battery wires (negative wire first); 3. Position a trestle under the fuselage frame No. 16; 4. Position a trestle with height adjustable cradles under each left and right wing, in correspondence with rib No. 16; 5. Referring to Defuelling Procedure and Safety Precautions laid out in the Service Instruction No. 79, drain the fuel tanks completely; 6. Remove the cabin ceiling panels in the wing area; 7. Remove soundproof material if present; 8. Remove the wing to fuselage fillets and the upper centre fairing; 9. Remove the inboard left and right wing leading edge (between the fuselage and engine nacelle); 10. Open the inspection doors near the wing root; Note: The following tasks do not refer to a complete removal of the wing. They refer to the wing being lifted just enough to allow the repair to be carried out. 11. Remove the central seats, rear bench, carpets, fresh air outlets if installed, ADF antenna on the wing if installed and the engine cowlings; 12. Slacken aileron control cables acting on the turnbuckles located under the cabin floor; 13. In the area of the wing to fuselage fillets disconnect the following: a. Hot/Cool cabin air ventilation flexible hoses if installed; b. Sleeves on fuel selector control lines in the area of the grease fittings; c. Fuselage girder P/N 2.2039-1; d. Vacuum system hoses; e. De-ice system hoses if installed; Caution: To prevent damage and/or contamination of hydraulic, pneumatic and fuel hoses, protect the fittings and the terminals adequately and mark hoses and connections to facilitate their reinstallation. First Issue dated 01 March 2010 Page 3 of 8
2. WORK PROCEDURE (Cont.) Part A Aircraft Preparation (Cont.) 14. Make sure that there are no other connections between the wing and the fuselage; 15. Position two hoists connected to the engines lifting points; 16. Remove the nuts and washers from the four wing to fuselage attachment bolts as shown in Figure 1; 17. Using the cradles and hoists, lift the wing just enough to allow removal of the wing-fuselage attachment bolts and access to the lower cap on the wing spar; Caution: Be very careful not to damage the wing to fuselage attachments during the removal of the bolts. 18. Remove all the bolts from the joining plates of the lower cap on the front spar and remove the front and rear joining plates; 19. Referring to relevant applicable revision of the Service Bulletin No. 65, remove the Kit 68-037 or Kit 68-037/B, as applicable, if one of the above Kits was embodied in the past. Part B Modification on the Lower Front and Rear Cap Angles on the Front Spar in the Left and Right Wings (installation of Kit SB162) 1. Referring to drawing R.0441, unrivet the required segment of the lower rear and front spar cap angles in the left and right wings. Partially unrivet the wing lower skin and ribs to gain access to the concerned area of the lower rear spar cap angle in the left and right wings and cut about 1080 mm off the lower front and rear spar cap angles. Pay particular attention during the above operation to avoid damage to the wing skins, ribs and the reinforcement straps under the lower rear and front spar cap angles; 2. Work the new lower rear spar cap angles item 1, P/N NOR7.521-4, and the new lower front spar cap angles item 11, P/N NOR7.521-5, as shown in Detail Q of the attached drawing R.0441. Clean all the reworked surfaces and the new angles with Methil-Ethyl-Ketone or equivalent cleaning solvent, and treat them with Alodine 1200 (Specification MIL-C-5541) then with Epoxy Primer (Specification MIL-PRF-23377); 3. Referring to drawing R.0441, position and install the new lower rear and front angles in the left and right wing as before using MS20470AD5 rivets of the required length on front side, while on lower side use MS20470AD5 rivets, MS20470AD4 rivets and NAS1097AD3 rivets as required. Wet the shank of the rivets with Epoxy Primer (Specification MIL-PRF-23377) then carry out the installation. Leave 6 rivets free at each joining edge of the new angles to install the doublers item 2; 4. Manufacture four 4 mm thick front doublers using the raw material P/N ALL-107 included in the Kit SB162 as per item 2 on the attached drawing R.0441; 5. Manufacture two 1.5 mm thick reinforcement plates using the raw material P/N ALL-018 included in the Kit SB162 as per item 3 on the attached drawing R.0441; 6. Clean all the reworked surfaces, the doublers and the reinforcement plates with Methil-Ethyl- Ketone or equivalent cleaning solvent, and treat them with Alodine 1200 (Specification MIL- C-5541) then with Epoxy Primer (Specification MIL-PRF-23377); First Issue dated 01 March 2010 Page 4 of 8
2. WORK PROCEDURE (Cont.) Part B Modification on the Lower (Cont.) 7. Referring to drawing R.0441, position and install the doublers item 2 using twelve AN3 bolts of the required length in the existing rivet holes that must be enlarged to the required diameter. Torque the nuts to 41 45 Lb.in. and mark them with safe reference marks; Note: Impregnate the shank of the bolts with a film of Corrosion Inhibitive Compound Specification MIL-PRF-8116C, then carry out the installation. For the application and usage method of the above Corrosion Inhibitive Compound, refer to the manufacturer's instructions. 8. Referring to drawing R.0441, position and install the reinforcement plates item 3 on the lower skin of the left and right wing in the joining area of the spar cap angle, using MS20470AD5 rivets of the required length. Adjust the reinforcement plates as required to perfectly fit on the 88 degrees spar cap angle; 9. Rivet, as previously, the portion of the left and right wing skins and ribs that were unriveted; Note: Do not rivet, in this phase, in the area affected by the installation of the left and right wing front spars reinforcements as per the relevant applicable revision of the Service Bulletin No. 65, or as per the Part C hereunder, as applicable. 10. In order to ensure a proper alignment with the existing holes, using a suitable bushing, drill the initial nine 1/8 diameter holes to be reamed to 0.312 0.313 mm diameter in accordance with the existing attachment holes on the lower wing spar cap in the wing centre joining; 11. Reinstall the front and rear spar lower cap joining plates in the wing centre joining using the removed bolts; torque the nuts to 247-273 Lb.in. Replace any damaged bolt with new one. Mark the nuts with safe reference marks; Note: Interpose a film of Corrosion Inhibitive Compound Specification MIL-PRF-8116C between the joining plates of the lower spar cap and the lower spar cap angle in the wing s centre joining to prevent galvanic corrosion. Impregnate the shank of the bolts for all the joinings with the same compound, then carry out the installation. For the application and usage method of the above Corrosion Inhibitive Compound, refer to the manufacturer's instructions. 12. Only for aircraft affected by condition reported in row (c) on Table 1, in paragraph 1.3 of the Service Bulletin No. 162, referring to relevant revision of the Service Bulletin No. 65, reinstall the previously removed Kit 68-037 or the Kit 68-037/B, as applicable, and proceed with the Part D hereunder; 13. Only for aircraft affected by condition reported in row (a) on Table 1, in paragraph 1.3 of the Service Bulletin No. 162, referring to drawing R.0458 and instructions in Part C hereunder, carry out the modification on wing front and rear spars by installing the Kit SB162/A. First Issue dated 01 March 2010 Page 5 of 8
2. WORK PROCEDURE (Cont.) Part C Modification on the Front and Rear Spars in the Left and Right Wings (installation of Kit SB162/A) 1. Referring to drawing R.0458, unrivet the affected two rivets on the lower rear spars in the left and right wings, to allow the installation of the wing rear spar reinforcements P/N 1.4145-002; 2. Referring to drawing R.0458, position in place the front spar reinforcements P/N 1.4145-001 on the left and right wings, and copying from the affected existing holes on the front spars and from the pilot holes on the reinforcements, drill to required diameter, then deburr the holes; 3. Referring to drawing R.0458, position in place the rear spar reinforcements P/N 1.4145-002 on the left and right wings, and copying from the affected existing holes on the rear spars and from the pilot holes on the reinforcements, drill to required diameter, then deburr the holes; 4. Clean all the reworked surfaces with Methyl-Ethyl-Ketone or equivalent cleaning solvent, and treat them with Alodine 1200 (MIL-C-5541) then with epoxy primer (MIL-PRF-23377); 5. Referring to drawing R.0458, position and install the front spar reinforcements P/N 1.4145-001 in the left and right wings using, for each installation, No. 20 rivets P/N MS20470AD5-8. Before installation, impregnate the shank of rivets with epoxy primer (MIL-PRF-23377), then carry out the installation; 6. Referring to drawing R.0458, position and install the rear spar reinforcements P/N 1.4145-002 in the left and right wings using, for each installation, No. 5 rivets P/N MS20470AD5-6 and No. 1 rivet P/N MS20426AD5-7. Before installation, impregnate the shank of rivets with epoxy primer (MIL-PRF-23377), then carry out the installation. Part D Restore the Airworthiness of the Aircraft 1. Referring to Figure 1 hereunder, reposition the wing on the fuselage and insert wing-fuselage attachment bolts and washers as previously, by adjusting saddles and hoists as necessary. Replace any damaged bolt with a new one; 2. Tighten nuts of the wing-fuselage attachment bolts according to the values indicated in Figure 1. Mark the nuts with safe reference marks; 3. Restore all the disconnected systems and reinstall all the removed items as before; 4. Referring to drawing R.0441, to avoid interference between the wing leading edge and the doublers item 2 on the front spar in the left and right wing, adjust the left and right wing leading edge as shown on the sheet 2 of the same drawing R.0441. Cut off the concerned segment of the gang channel as necessary and install the anchor nuts P/N NOR9.181-1C using countersunk rivets P/N MS20426AD3 of required length. In the area which is concerned by the repair, install the left and right wing leading edges using bolts P/N NAS1132-5 for metallic wing leading edges or bolts P/N NAS1132 of required length and washers P/N NAS1149FN816P for fibreglass wing leading edges (refer to drawing R.0441); 5. Referring to applicable section of the aircraft Maintenance Manual, restore the tension of the aileron control cables and check for free travel of the aileron control system; 6. Referring to applicable section of the aircraft Maintenance Manual, check for free travel of the flaps control system; First Issue dated 01 March 2010 Page 6 of 8
2. WORK PROCEDURE (Cont.) Part D Restore the Airworthiness of the Aircraft (cont.) 7. Carry out a functional test on all the systems disassembled and, if necessary, regulate them in accordance with the procedure in the latest issue of the applicable documentation issued by Vulcanair. First Issue dated 01 March 2010 Page 7 of 8
Figure 1. Wing to Fuselage Attachments First Issue dated 01 March 2010 Page 8 of 8