vulcanair spa via g. pascoli, 7 80026 Casoria (Na) Italy Tel +39 081 5918111 Fax +39 081 5918172 info@vulcanair.com www.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. 195 Rev. 1 (Supersedes the previous issue dated 19 February 2014) Design Organisation Approval No. AS-SB/14/007 dated 14 March 2014 INFORMATION SUBJECT: REPLACEMENT OF HALOGEN NAV AND STROBE LIGHTS WITH NEW LED LIGHTS NOTE Revision 1 of this Service Bulletin is being issued to extend its applicability. No additional work is required for aircraft which have already embodied the previous issue of this Service Bulletin. 1. GENERAL 1.1 AIRCRAFT AFFECTED P.68C-TC s/n 267 P.68R s/n 457 1.2 PURPOSE The purpose of this Service Bulletin is to supply information for the replacement of halogen NAV and STROBE lights with new LED lights. Rev. 1 dated 14 March 2014 Page 1 of 15
1. GENERAL (Cont.) 1.3 DESCRIPTION The application of this Service Bulletin requires the installation of the Kit SB195 or Kit SB195/A, as applicable, consisting of the replacement of the existing lights system (NAV and STROBE lights) with the new LED lights, as described below. The installation of the Kit SB195 or Kit SB195/A, as applicable, has to be carried out in accordance with the drawing R.0516 and the instructions laid out in the paragraph 2 hereunder. No change in aircraft Operating Limitations, Emergency Procedures, Normal Procedures, Performance and Weight and Balance data when the aircraft embodies the Kit SB195 or Kit SB195/A, as applicable. Only for P.68C-TC aircraft s/n 267 The replacement of the existing lights system (consisting of LH/RH wing tip NAV lights p/n NOR7.329-2/-3, NAV tail light p/n NOR7.329-1 and tail STROBE light p/n NOR7.3337-3) involves the installation of a new type of lights p/n 7.3291-5/-6 (LH/RH NAV & STROBE LED lights), p/n NV7.003-63A (tail NAV LED light) and p/n NV7.003-144A (tail STROBE LED light) on wing tips, rudder and vertical fin, respectively, and the addition, only for LED lights installed on wing tips, of a new wiring harness p/n R.0516-060 to the existing one. No change to wiring harnesses for all other LED lights installed on vertical fin and rudder (refer to electrical wiring diagram in drawing R.0516-040). Only for P.68R aircraft s/n 457 The replacement of the existing lights system (consisting of LH/RH wing tip NAV lights p/n p/n NV7.003-64A/-64B and tail STROBE light p/n NOR7.3337-3) involves the installation of a new type of lights p/n 7.3291-5/-6 (LH/RH NAV & STROBE LED lights) and p/n NV7.003-144A (tail STROBE LED light) on wing tips and vertical fin, respectively. No change to the existing wiring harnesses (refer to electrical wiring diagram in drawing R.0516-041). 1.4 COMPLIANCE At owner s discretion. 1.5 MANHOURS 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 in: - 10 man-hours for installation of Kit SB195-7 man-hours for installation of Kit SB195/A 1.6 SPECIAL TOOLS No special tool is required. Rev. 1 dated 14 March 2014 Page 2 of 15
1. GENERAL (Cont.) 1.7 VARIATION IN WEIGHT & BALANCE Negligible. 1.8 ELECTRICAL SYSTEM LOAD Negligible. 1.9 REFERENCE DOCUMENTS - Applicable Aircraft Maintenance Manual for aircraft variant - Applicable Parts Catalogue for aircraft variant - Drawing R.0516 Lights Installation Only for P.68C-TC aircraft s/n 267 - Drawing R.0516-040 NAV & STROBE LED Light EWD Only for P.68R aircraft s/n 457 - Drawing R.0516-041 NAV & STROBE LED Light EWD 1.10 PUBLICATION AFFECTED Applicable Parts Catalogue for aircraft variant. 1.11 MODIFICATION TO BE CARRIED OUT BY Vulcanair Part 145 or other Certified Maintenance Facility. Rev. 1 dated 14 March 2014 Page 3 of 15
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. NOTE To simplify the following instructions for your convenience, the electrical wires to be added are identified with the proper labels as per electrical wiring diagram explained in the drawing R.0516-040 or R.0516-041, as applicable. NOTE Before performing any electrical connections, cutoff the excessive length of the wires. PART A: Aircraft preparation 1. Place the aircraft in a suitable working area for the operations to be carried out. 2. Turn OFF all the electrical switches. Remove the baggage bulkhead and disconnect the battery cables (negative cable first). 3. Ground the aircraft. 4. Jack the aircraft and place a trestle under the aft mooring hook. 5. Gain access to the baggage compartment. PART B: Installation of new LH/RH NAV & STROBE LED light on wing tips (Only for P.68R aircraft s/n 457 refer to Figure 1) NOTE The following tasks do not refer to a complete removal of the wing. They refer only to wing tips removal. Rev. 1 dated 14 March 2014 Page 4 of 15
2. WORK PROCEDURE (Cont.) PART B (Cont.) CAUTION Protect electrical connectors adequately to prevent any damage; mark them to facilitate the subsequent reinstallation. 1. Remove the existing LH/RH wing tip NAV lights p/n NOR7.329-2/-3 or p/n NV7.003-64A/-64B, as applicable, unscrewing their attaching screws; discard the removed screws. 2. Disconnect the ground lead at the connection near the aileron mass-balance weight. 3. Disconnect the existing electrical wire terminals or connectors behind the existing LH/RH wing tip NAV lights p/n NOR7.329-2/-3 or p/n NV7.003-64A/-64B, as applicable. 4. Remove the screws holding the LH/RH wing tips to the wing leading edge; bring them in evidence along the tip boundary line making the stucco crack by means of strokes. 5. Remove the LH/RH wing tips from the LH/RH wings as much as it is sufficient to disconnect the ground lead fore terminal, then remove the wing tip. 6. Only for P.68C-TC aircraft s/n 267, referring to drawing R.0516 detail b, manufacture a drilling template copying the position of the central attachment hole, relevant for the correct installation of the new LH/RH NAV & STROBE LED lights p/n 7.3291-5/-6 on the LH/RH wing tips. 7. Referring to drawing R.0516 detail b, rework the LH/RH wing tips, modifying the NAV lights cut-out; drill No.1 reamed hole including all the existing light holes and then sand with 180 gr paper internally the RH/LH wing tip considering a working area of 230 mm 2 (minimum). 8. Clean properly the concerned area for dust, before apply the repair. 9. Install a wooden waxed jig on the external plane side of the LH/RH wing tips, with reference to the concerned area. 10. Perform the repair on the internal plane side of the LH/RH wing tips using for the lamination: No.4 layers of chopped strand MAT 300 g/m 2 and No.1 layer of Woven ROVING 250 g/m 2 with resin NORPOL 844/730 (polyester). Only for P.68C-TC aircraft s/n 267 11a. Referring to drawing R.0516 detail b and using the above drilling template, drill 8 mm diameter No.1 reamed hole on the reworked LH/RH wing tips. Deburr the hole. NOTE Make a suitable drilling template for a correct positioning of the central attachment hole. CAUTION Before drilling the reworked LH/RH wing tips, take care to verify that the position of the central attachment hole is the same of the previous one. Rev. 1 dated 14 March 2014 Page 5 of 15
2. WORK PROCEDURE (Cont.) PART B (Cont.) 12a. Referring to drawing R.0516 detail b, put in place the new LH/RH NAV & STROBE LED lights p/n 7.3291-5/-6 and lock them temporarily by means the central attachment hole on the LH/RH wing tip respectively, then mark the other holes on the reworked LH/RH wing tips, copying from the existing holes on the new LH/RH NAV & STROBE LED lights. 13a. Remove the new LH/RH NAV & STROBE LED lights p/n 7.3291-5/-6, and drill 4 mm diameter No.1 reamed hole and drill 5 mm diameter No.1 reamed hole on the markings previously carried out on the reworked LH/RH wing tips (refer to drawing R.0516 detail b ). 14a. Deburr all the holes. Clean all the reworked surfaces with Methyl-Ethyl-Ketone or equivalent cleaning solvent and then touch up the whole concerned area of the LH/RH wing tips with finish polyurethane paint as per the existing livery of the aircraft. 15a. Open all LH/RH leading edge inspection hatches. 16a. Remove the concerned cabin furnishing panels necessary to allow the routing of the new addition electrical wiring harness p/n R.0516-060 (necessary for the installation of the new LH/RH NAV & STROBE LED lights p/n 7.3291-5/-6) and access to the relative area. 17a. Referring to drawing R.0516, route the new additional electrical wiring harness p/n R.0516-060 through the rear fuselage and each wing starting from the rear bulked. NOTE Consider the existing wiring harnesses as a guide wire in the aircraft. They serve as a guide for the new additional wiring harness p/n R.0516-060 routing. 18a. Taking particular care to avoid any damage to the other electrical components, install and lock the new additional electrical wiring harness p/n R.0516-060 routing along the LH/RH wing front spars near the lower spar cap angle and passing behind the firewall through the wing inspection hatches. 19a. Secure the new additional electrical wiring harness to the other existing wiring harnesses using specific tie wraps (wire supports or similar devices). 20a. Referring to drawing R.0516-040 replace the existing terminal with the new female connector p/n NOR7.619-9 (J115/J114 on LH/RH wing tips respectively), adding to the existing wiring harness the new one just routed (cables labelled L53C20SH and L54C20SH on LH/RH wing tips respectively). 21a. Bring the LH/RH wing tips near the LH/RH wings respectively to connect the ground lead for terminal to the wing. 22a. Put in place the LH/RH wing tips and install the screws around the tips. Rev. 1 dated 14 March 2014 Page 6 of 15
2. WORK PROCEDURE (Cont.) PART B (Cont.) 23a. Referring to drawing R.0516-040 connect the new electrical wire female connector p/n NOR7.619-9 (J115/J114) to the male connectors (P115/P114) behind the new LH/RH NAV & STROBE LED lights p/n 7.3291-5/-6 respectively. 24a. Referring to drawing R.0516 detail b, reposition the new LH/RH NAV & STROBE LED lights p/n 7.3291-5/-6 on the LH/RH wing tips respectively and install them using No.1 screw p/n MS24694-S69. 25a. Connect the ground lead rear connectors to the wings. 26a. Install the screws around the wing tips. 27a. Reinstall all inspection hatches and detachable parts, as previously. 28a. Reinstall the concerned cabin furnishing panels, as previously. Only for P.68R aircraft s/n 457 11b. Referring to drawing R.0516 detail b and Figure 1 below, drill 5 mm diameter No.1 reamed hole (installation hole) on the reworked LH/RH wing tips. Deburr the hole. CAUTION Before drilling the reworked LH/RH wing tips, take care to verify the correct positioning of the installation hole (ø5 hole), as per Figure 1. 12b. Referring to drawing R.0516 detail b, put in place the new LH/RH NAV & STROBE LED lights p/n 7.3291-5/-6 and lock them temporarily by means the installation hole on the LH/RH wing tip respectively, then mark the other holes on the reworked LH/RH wing tips, copying from the existing holes on the new LH/RH NAV & STROBE LED lights. 13b. Remove the new LH/RH NAV & STROBE LED lights p/n 7.3291-5/-6, and drill 8 mm diameter No.1 reamed hole and drill 4 mm diameter No.1 reamed hole on the markings previously carried out on the reworked LH/RH wing tips (refer to drawing R.0516 detail b and Figure 1 below). 14b. Deburr all the holes. Clean all the reworked surfaces with Methyl-Ethyl-Ketone or equivalent cleaning solvent and then touch up the whole concerned area of the LH/RH wing tips with finish polyurethane paint as per the existing livery of the aircraft. 15b. Cut off the existing electrical wire female connectors of the LH/RH NAV lights. 16b. Referring to drawing R.0516-041, add the two cut wires ( L28B20 and L26B20 ) to the existing electrical wire female connectors of LH/RH STROBE lights (J115/J114 pin 4 on LH/RH wing tips respectively). 17b. Bring the LH/RH wing tips near the LH/RH wings respectively to connect the ground lead for terminal to the wing. 18b. Put in place the LH/RH wing tips and install the screws around the tips. Rev. 1 dated 14 March 2014 Page 7 of 15
2. WORK PROCEDURE (Cont.) PART B (Cont.) 19b. Referring to drawing R.0516-041, connect the existing electrical wire female connectors (J115/J114) to the male connectors (P115/P114) behind the new LH/RH NAV & STROBE LED lights p/n 7.3291-5/-6 respectively. 20b. Referring to drawing R.0516 detail b, reposition the new LH/RH NAV & STROBE LED lights p/n 7.3291-5/-6 on the LH/RH wing tips respectively and install them using No.1 screw p/n MS24694-S69. 21b. Connect the ground lead rear connectors to the wings. 22b. Install the screws around the wing tips. PART C: Installation of new NAV tail LED light on rudder NOTE The following tasks are applicable only to P.68C- TC aircraft s/n 267. The P.68R aircraft s/n 457 has already installed the new NAV tail LED light on the rudder. CAUTION Protect electrical connectors adequately to prevent damages; mark them to facilitate the reinstallation. 1. Remove the existing NAV tail light p/n NOR7.329-1 and its adapter flange p/n NOR7.025-3, unscrewing its attaching screws; discard the removed screws. 2. Cut off the existing electrical wire behind the existing NAV tail light p/n NOR7.329-1 and install on it the new terminal p/n NOR7.611-5. 3. Referring to drawing R.0516 replace the existing connector of the new NAV tail LED light p/n NV7.003-63A with two new terminals p/n NOR7.601-3 (on negative wire) and p/n NOR7.611-5 (on positive wire). 4. Referring to drawings R.0516-040 and R.0516 detail c connect the new electrical wire terminal p/n NOR7.611-5 with the existing positive electrical wire terminal p/n NOR7.611-5. 5. Connect the new electrical wire terminal (ground lead terminal) p/n NOR7.601-3, as shown in drawing R.0516 detail c. 6. Referring to drawing R.0516 detail c, put in place the new NAV tail LED light p/n NV7.003-63A on the rudder and install it using a specific adapter flange p/n 7.9610-001 and No.2 special screws p/n 7.9610-002. 7. Touch up the whole concerned area of the rudder with finish polyurethane paint as per the existing livery of the aircraft. Rev. 1 dated 14 March 2014 Page 8 of 15
2. WORK PROCEDURE (Cont.) PART D: Installation of new tail STROBE LED light on vertical fin CAUTION Protect electrical terminals adequately to prevent damages; mark them to facilitate the reinstallation. 1. Remove the existing tail STROBE light p/n NOR7.3337-3 and its adapter flange p/n NOR7.337-3A, unscrewing its attaching screws; discard the removed screws. 2. Disconnect the existing electrical wire connector behind the existing tail STROBE light p/n NOR7.3337-3. 3. Referring to drawing R.0516-040 or R.0516-041, as applicable, replace the existing connector of the new STROBE LED light p/n NV7.003-144A with the new one p/n NOR7.619-1 (male connector P117). 4. Referring to drawing R.0516-040 or R.0516-041, as applicable, replace the existing connector of the existing electrical wire coming from the power supply in the rear bulkhead with the new one p/n NOR7.619-9 (female connector J117). 5. Referring to drawing R.0516-040 or R.0516-041, as applicable, connect the new electrical wire female connector p/n NOR7.619-9 (J117) to the male connector p/n NOR7.619-1 (P117) behind the new tail STROBE LED light p/n NV7.003-144A. 6. Referring to drawing R.0516 detail c, put in place the new tail STROBE LED light p/n NV7.003-144A on the vertical fin and install it using a specific flange p/n 3.2049-002, and No.2 screws p/n MS35206-219. 7. Touch up the whole concerned area of the rudder with finish polyurethane paint as per the existing livery of the aircraft. Rev. 1 dated 14 March 2014 Page 9 of 15
2. WORK PROCEDURE (Cont.) PART E: Removing STROBE power supply and performing system electrical connections 1. Access to battery compartment (rear bulkhead) 2. Referring to drawing R.0516, disconnect input and output connectors (existing power connector and existing electrical wire connector coming from the existing tail STROBE light p/n NOR7.337-3 respectively) from the power supply p/n NOR7.337-8 (for aircraft s/n 267) or p/n NOR7.337-10 (for aircraft s/n 457), located in the rear bulkhead. 3. Referring to drawing R.0516, remove the existing power supply p/n NOR7.337-8 or p/n NOR7.337-10, as applicable, and its mounts unscrewing its attaching screws. Only for P.68C-TC aircraft s/n 267 4a. Referring to drawing R.0516-040 regroup all the concerned electrical wires located in the rear bulkhead (coming from wing tips, rudder and vertical fin lights system) and connect them (all input and output connectors) through the new female connector p/n NOR7.619-12 (J116). 5a. Create the new male connector p/n NOR7.619-4 (P116) to performing system electrical connections. 6a. Connect the ground wire to one of the four existing screws before used for fixing the existing power supply. 7a. Referring to drawing R.0516-040 connect the new electrical wire female connector p/n NOR7.619-12 (J116) to the male connector p/n NOR7.619-4 (P116) and complete the electrical connections. Only for P.68R aircraft s/n 457 4b. Referring to drawing R.0516-041, disconnect the existing electrical wire female connector J33 from the male connector P33. 5b. Cut off the existing electrical wire female connector of the tail STROBE light. 6b. Referring to drawing R.0516-041, add the three cut wires (RED, BLACK and WHITE) to the existing electrical wire female connector J33 pin 8, pin 11 and pin 12 respectively; if necessary, add an extension cord wire (p/n NOR7.625-9) to reach the female connector J33. 7b. Referring to drawing R.0516-041, install a jumper AWG 20 (p/n NOR7.623-5) on existing electrical wire male connector P33. 8b. Connect the ground wire to one of the four existing screws before used for fixing the existing power supply. 9b. Referring to drawing R.0516-041, reconnect the existing electrical wire female connector J33 to the male connector P33 and complete the electrical connections. 10b. Install on the Select Strobe Light Switch located on the breaker panel (refer to Figure 2) the self adhesive placard NOT USED p/n 8.2512-70. Rev. 1 dated 14 March 2014 Page 10 of 15
2. WORK PROCEDURE (Cont.) PART F: Restoring aircraft Airworthiness 1. Connect the battery cables (positive cable first) and reinstall the baggage bulkhead. 2. Perform a Functional Test: put in ON the relative switch and verify that the light works properly. 3. Perform an EMI Test: ON-OFF-ON for each switch (NAV and STROBE) and verify if there are interferences on the primary flight system indicators and compass. Only for P.68C-TC aircraft s/n 267 4a. Update the Equipment List reported in Section 6 of applicable AFM, removing the items RE-56, RE-57, RE-58, RE-60 and RE-61, and inserting the following new data: Item No. RE-56 RE-57 RE-58 RE-60 Mark if Instl. ----------- ----------- ----------- ----------- Description Part Number Q.ty Weight (Lbs) Arm (Inches) Navigation light NV7.003-63A 1 0.20 249.21 LH Nav & strobe light 7.3291-5 1 0.18 21.65 RH Nav & strobe light 7.3291-6 1 0.18 21.65 Anti-collision strobe light NV7.003-144A 1 0.11 222.44 5a. Record compliance with this Service Bulletin in the Aircraft Log-Book. Only for P.68R aircraft s/n 457 4b. Update the aircraft Equipment List by marking the appropriate items installed. 5b. Record compliance with this Service Bulletin in the Aircraft Log-Book. Rev. 1 dated 14 March 2014 Page 11 of 15
3. MATERIALS REQUIRED FOR THE MODIFICATION Kit SB195 (Applicable only to P.68C-TC s/n 267) Item P/N Description Q.ty 1 NV7.003-144A Anti-Collision Led Light 1 2 MS35206-219 Screw 2 3 3.2049-002 Flange 1 4 1604-0412 Blind rivet 4 5 MS24694-S69 Screw 2 6 7.3291-5 LH NAV+STROBE Led Light 1 7 7.3291-6 RH NAV+STROBE Led Light 1 8 NOR9.181-1D Anchor Nut 2 9 MS20426AD3-4 Rivet 4 10 NV7.003-63A Navigation light 1 11 7.9610-001 Adapter Flange 1 12 7.9610-002 Special Screw 2 13 NOR7.601-3 Terminal (on negative wire) 1 14 NOR7.611-5 Terminal (on positive wire) 2 15 R.0516-060 Wiring Harness 1 16 NOR7.619-12 Electrical Connector Female [J116] 1 17 NOR7.619-4 Electrical Connector Male [P116] 1 18 NOR7.619-1 Electrical Connector Male [P117] 1 19 NOR7.619-9 Electrical Connector Female [J114; J115; J117] 3 20 NOR7.613-1 Splice AWG 22/18 6 21 NOR7.637-3 Backshell connector 2 22 NOR7.639-1 Electrical Terminal Male (Large) 6 23 NOR7.639-2 Electrical Terminal Male (Medium) 8 24 NOR7.639-4 Electrical Terminal Female (Medium) 22 25 NOR7.625-9 Tripolar Electrical Shielded Wire 20 AWG 23 m 26 NOR7.635-1 Wire Identification Sleeve 4 27 NOR7.647-9 Protective Tape 0.2 m 28 NOR7.641-1 Pig Tail 6 29 Dwg R.0516 Lights Installation 1 30 Dwg R.0516-040 NAV & STROBE LED Light EWD 1 31 NOR7.701-1C Tie Wrap 10 Rev. 1 dated 14 March 2014 Page 12 of 15
3. MATERIALS REQUIRED FOR THE MODIFICATION (Cont.) Kit SB195/A (Applicable only to P.68R s/n 457) Item P/N Description Q.ty 1 NV7.003-144A Anti-Collision Led Light 1 2 MS35206-219 Screw 2 3 3.2049-002 Flange 1 4 1604-0412 Blind rivet 4 5 MS24694-S69 Screw 2 6 7.3291-5 LH NAV+STROBE Led Light 1 7 7.3291-6 RH NAV+STROBE Led Light 1 8 NOR9.181-1D Anchor Nut 2 9 MS20426AD3-4 Rivet 4 10 NOR7.619-1 Electrical Connector Male [P117] 1 11 NOR7.619-9 Electrical Connector Female [J117] 1 12 NOR7.613-1 Splice AWG 22/18 10 13 NOR7.701-1C Tie Wrap 4 14 NOR7.639-1 Electrical Terminal Male (Large) 8 15 NOR7.639-2 Electrical Terminal Male (Medium) 7 16 NOR7.639-4 Electrical Terminal Female (Medium) 7 17 NOR7.625-9 Tripolar Electrical Shielded Wire 20 AWG 1.5 m 18 NOR7.623-5 Unipolar AWG 20 1.5 m 19 NOR7.647-9 Protective Tape 0.2 m 20 Dwg R.0516 Lights Installation 1 21 Dwg R.0516-041 NAV & STROBE LED Light EWD 1 22 8.2512-70 Placard NOT USED 1 Commercially available material required but not included in the Kit SB195 and Kit SB195/A: 1. Methyl-Ethyl-Ketone or equivalent cleaning solvent AR 2. Polyurethane enamels as per the aircraft livery. AR Rev. 1 dated 14 March 2014 Page 13 of 15
Figure 1 Positioning of new LH/RH wing tip NAV & STROBE LED lights (Applicable only to P.68R s/n 457) Rev. 1 dated 14 March 2014 Page 14 of 15
Figure 2 Location of Select Strobe Light Switch (Applicable only to P.68R s/n 457) Rev. 1 dated 14 March 2014 Page 15 of 15