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P68 Maintenance Manual
P68 Maintenance Manual
P68 Maintenance Manual
702-3
P.68R
MAINTENANCE MANUAL
- Applicable to P.68R aircraft from s/n 453 onwards -
INTRODUCTION
Page 1 2 3 4 5 6 7 8 9 10 11 12 13 14
Rev. - - 12 - 11 - - - 9 12 12 9 9 9
Rev. 12
DATE: 12 December 2019 Page 3
AMM10.702-3
Introduction
P.68R MAINTENANCE MANUAL
1 FOREWORD
This Manual contains recommended ground handling, servicing and maintenance procedures, and
mandatory and recommended instructions for the Continued Airworthiness of the P.68R aircraft
manufactured by Vulcanair S.p.A., Naples, Italy.
These maintenance instructions provide the aicraft operator with a precise guidance for establishing his
own Maintenance Program subject to the approval of his local Airworthiness Authority.
Operators shall refer to all technical publications provided by the aircraft manufacturer and to all
installed parts or appliances applicable documents.
NOTE
Read carefully this Manual prior to start whatever maintenance
activity.
NOTE
The discarded materials and fluids used during the maintenance
activities should be disposed of in accordance with applicable
regulations.
WARNING
Rev. 11
DATE: 01 March 2018 Page 5
AMM10.702-3
Introduction
P.68R MAINTENANCE MANUAL
The information contained in this Manual have been divided into the following 15 Sections, each with
its own index and list of effective pages, that provide the user with a quick reference:
SECTION 3 - SERVICING
SECTION 6 - STRUCTURES
SECTION 10 - POWERPLANT
Although the data in this Manual are correct at the time of issue, they will be supplemented and kept
current by revisions that shall be issued by Vulcanair as the need arises. Aircraft owners and operators
can download the revisions through appropriate registration to Vulcanair web-site www.vulcanair.com.
The material in the Maintenance Manual deals primarily with Vulcanair manufactured components,
and only secondary service information for vendor items are included. For detailed information
regarding the maintenance and or overhaul of installed OEM accessories and equipment, refer to the
relevant manufacturer documentation.
2 APPLICABILITY
This Maintenance Manual is applicable to P.68R aircraft from S/N 453 onwards.
NOTE
P.68R aircraft variants have their serial number composed of a
root of numerical digits plus a set of alphanumerical characters
beginning with ‘/’ character. Vulcanair wishes to clarify that the
aircraft serial number quoted on technical documentation refers
only to first numerical digits reported before the ‘/’ character.
For example:
Aircraft s/n: 999/FF On technical documentation: 999.
Wherever possible, this advance information and/or any outstanding service inspection shall be
subsequently embodied in an appropriate revision.
The amended information in both types of revision shall be indicated by a vertical black line situated in
the external margin, adjacent to the relevant text. In the event that an entire Section or Chapter is
revised, this black line shall be omitted.
Temporary revisions shall be printed on yellow coloured paper for easy reference purposes, and
should be inserted facing the page(s) as indicated on the Temporary Revision cover page.
Whenever a temporary revision is incorporated into the Manual, the relevant record page is to be
compiled accordingly. It is recommended to make a copy of the blank record page to be used for
additional insertions when the initial page is completed. Permanent revisions shall be accompanied by
an updated record sheet compiled by Vulcanair. Should a revision require substitution of a complete
page, this page must be inserted into the relevant section and the following guidelines adhered to:
a) Replace superseded pages with the substitute page having the same page number.
b) Insert pages having page numbers followed by a small letter in direct alpha-numerical
sequence.
4 SERVICE BULLETINS
Technical data may also be augmented or changed through the issue of Service Bulletins.
Whenever an applicable Service Bulletin is incorporated into the Manual, the relative record page must
be compiled accordingly. It is recommended to make a copy of the blank record page to be used for
additional insertions when the initial page is completed.
LOG OF REVISIONS
Rev. 9
DATE: 05 April 2017 Page 9
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Introduction
P.68R MAINTENANCE MANUAL
LOG OF REVISIONS
4-3; from 4-7 to 4-11; 4-14; 5-3; from 5-33 to 12 Jan. 28 Mar.
EASA No.10061439
5-36 2017 2017
3; 10; 5-3; 5-35; 6-3; from 6-26 to 6-33; 9-3;
from 9-5 to 9-9; 9-20; 9-21; from 9-23 to 9-48;
11-3; 11-23; 11-28; from 11-30 to 11-32; from Under Authority of DOA
14 Jul. 20 Jul.
10 11-37 to 11-40; 15-3; 15-11 EASA.21J.009
2017 2017
with No. AS-MM/17/034
Added pages:
from 9-49 to 9-54
3; 5; 10; 3-3; 3-5; 3-14; 3-21; 3-23; 8-3; 8-7; 8-8;
8-63; 8-68; 8-69; 8-70; 8-75; 8-76; from 8-85 to Under Authority of DOA
8-96 01 Mar. 19 Apr.
11 EASA.21J.009
2018 2018
Added pages: with No. AS-MM/18/004
8-97; 8-98
3; 10; 11; 3-3; 3-20; 5-3; 5-5; 5-6; from 5-27 to
5-44; 8-3; 8-18; 8-19; 8-51; 8-52; 8-91; 9-3; 9-5;
9-6; 9-8; from 9-24 to 9-26; from 9-47 to 9-49;
11-3; from 11-32 to 11-34; 13-3; 13-12; 13-13;
14-3; 14-5; 14-6; 14-25; 14-26; 14-30; 14-33; 14-
Under Authority of DOA
37; from 14-41 to 14-43; from 14-45 to 14-52; 12 Dec. 10 Jan.
12 EASA.21J.009
15-3; from 15-5 to 15-9; 15-11; 15-13; from 15-17 2019 2020
with No.
to 15-20; 15-59
AS-MM/19/008
Inserted TR-003, TR-004, TR-005, TR-006 and
TR-007
Section 12: complete reprint
Added pages: 14-53 and 14-54
Rev. 12
Page 10 DATE: 12 December 2019
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Rev. 12
DATE: 12 December 2019 Page 11
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Rev. 9
Page 12 DATE: 05 April 2017
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MAINTENANCE MANUAL P.68R
NOTE
An operating procedure, technique or maintenance practice
which is considered essential to emphasize.
CAUTION
WARNING
Rev. 9
DATE: 05 April 2017 Page 13
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Introduction
P.68R MAINTENANCE MANUAL
6 UNITS OF MEASUREMENT
On this Manual the basic units of measure are those of the Standard International (SI) system.
In order to better support the performing of the current maintenance activities all the numerical values
have been converted to U.S. system and reported within brackets beside the SI values.
On some illustrations the SI dimensional measures have not been converted for graphical reasons. A
table with the conversion factors for the most common units of measure is reported hereunder.
Length Length
Surface Surface
Square meter [sq m] [sq m] x 10.7639 = [sq ft] Square feet [sq ft]
Square millimetre [sq mm] [sq mm] / 645.16 = [sq in] Square inch [sq in]
Weight/Mass Weight/Mass
Volume Volume
Torque Torque
Newton meter [Nm] [Nm] / 1.3558 = [lb ft] Pound foot [lb ft]
Pressure Pressure
Rev. 9
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Section 6
MAINTENANCE MANUAL P.68R
SECTION 6
STRUCTURES
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Rev. 10 10 10 - - - - - - 3 3 3 3 3 3
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Rev. 3 3 3 3 3 3 3 3 3 6 6 6 6 6 6
Page 61 62 63 64 65 66 67 68 69 70 71 72 73 74 75
Rev. 6 6 6 6 6 6 6 6 6 6 6 6 6 6 6
Page 76 77 78 79 80 81 82 83 84
Rev. - - - - - 1 1 1 1
Rev. 10
DATE: 14 July 2017 Page 6 - 3
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TABLE OF CONTENTS
DESCRIPTION PAGE
1 WING ........................................................................................................................................9
1.1 DESCRIPTION..................................................................................................................9
1.2 MAINTENANCE PRACTICES ..........................................................................................9
1.2.1 REMOVAL OF WING TIP .............................................................................................9
1.2.2 INSTALLATION OF WING TIP .....................................................................................9
1.2.3 REMOVAL OF WING LEADING EDGE ......................................................................12
1.2.4 INSTALLATION OF WING LEADING EDGE ..............................................................14
1.2.5 REMOVAL OF AILERON ............................................................................................15
1.2.6 INSTALLATION OF AILERON ....................................................................................15
1.2.7 REMOVAL OF WING FLAP ........................................................................................15
1.2.8 INSTALLATION OF WING FLAP ................................................................................15
1.2.9 REMOVAL OF WING ..................................................................................................18
1.2.10 INSTALLATION OF WING ..........................................................................................19
1.2.11 SPECIAL INSPECTION ON WING STRUCTURE ......................................................20
2 FUSELAGE .............................................................................................................................26
2.1 DESCRIPTION................................................................................................................26
2.2 MAINTENANCE PRACTICES ........................................................................................26
2.2.1 WING/FUSELAGE ATTACHMENT BOLTS AND BRACKETS ...................................26
2.2.2 REMOVAL OF WINDSHIELD .....................................................................................26
2.2.3 INSTALLATION OF WINDSHIELD .............................................................................27
2.2.4 REMOVAL OF PILOT SIDE WINDOW .......................................................................34
2.2.5 INSTALLATION OF A NEW PILOT SIDE WINDOW ..................................................34
2.2.6 REMOVAL OF ENTRANCE DOOR WINDOW ...........................................................36
2.2.7 INSTALLATION OF ENTRANCE DOOR WINDOW ...................................................36
2.2.8 REMOVAL OF SIDE WINDOWS ................................................................................37
2.2.9 INSTALLATION OF NEW SIDE WINDOWS ...............................................................37
2.2.10 CLEANING OF CLEAR PLASTIC WINDSHIELD AND WINDOWS ............................39
2.2.11 DESCRIPTION OF LATCH SYSTEM ASSY...............................................................40
2.2.12 REMOVAL OF ENTRANCE DOOR ............................................................................45
2.2.13 INSTALLATION OF ENTRANCE DOOR ....................................................................45
2.2.14 ADJUSTMENT OF ENTRANCE DOOR......................................................................45
2.2.15 REMOVAL OF ENTRANCE DOOR LATCH MECHANISM ........................................45
Rev. 3
DATE: 25 September 2013 Page 6 - 5
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TABLE OF CONTENTS
DESCRIPTION PAGE
Rev. 6
Page 6 - 6 DATE: 07 November 2014
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TABLE OF CONTENTS
DESCRIPTION PAGE
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P.68R MAINTENANCE MANUAL
1 WING
1.1 DESCRIPTION
Each wing is a full cantilever semi-monocoque type construction with removable aluminium leading
edge and tip. A fuel tank of the integral type is located in each wing outside the engine nacelle. An
aileron, flap, and power plant are attached to each wing. The wings are connected to each other at the
centre by means of steel plate joints and are connected to the fuselage with attachment brackets to
front and rear spars.
Major sub-assemblies and the wing may be removed individually or the wing may be removed as a
unit.
(1) Bring the wing tip near the wing to connect the ground lead fore terminal to the wing.
(2) Put in place the wing tip and install the screws around the tip.
(3) Connect the navigation light leads and install the navigation light.
(4) Connect the ground lead rear terminal to the wing.
(5) Install the screws around the tip.
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(1) Disconnect the aileron control rod at the center hinge by removing nut, washer and bolt.
(2) Support the aileron and disconnect the inboard, outboard and center aileron hinges by
removing nuts, washers and hinge bolts.
(1) Position the aileron in the wing and install bolts, washers and nuts at the hinges.
(2) Connect aileron control rod to the aileron at the centre hinge brackets with bolt, washer and
nut.
(3) Connect ground lead to the centre hinge bracket.
(1) Fully extend the flaps and remove bolt, washer and nut from the control rod end.
(2) Support the flap and disconnect the four flap hinges by removing nuts, washers and hinge
bolts.
(3) Pull the flap straight back off the wing.
(1) Place the wing flap into its proper position and insert hinge bolts, washers and nuts.
(2) With the flap control in the full flap position connect the flap control rod to the hinge brackets
with bolt, washer and nut.
(3) Connect the ground lead to the inboard hinge bracket.
(4) Operate the flap several times to ascertain it operates freely.
(6) Disconnect the fuel selector control cables from both RH and LH fuel selectors and unthread
them at grease nipples located alongside the girder between front spar and fuselage top.
(7) Unscrew the girder from the fuselage.
(8) Disconnect fuel flow, oil pressure and manifold pressure tubes.
CAUTION
CAUTION
In this paragraph are reported the instructions to perform special inspection on wing structure,
prescribed at 6000, 12000 and 18000 flight hours by an Airworthiness Limitation as per Section 4.
(1) Switch OFF all electrical loads, remove the baggage bulkhead and disconnect the battery
wires (negative wire first).
(2) Referring to removal procedures laid out in this Manual, remove:
(a) The cabin ceiling panel in the wing area and soundproof material if present.
(b) The wing to fuselage fillets and the upper centre fairing.
(c) The engine cowlings.
(d) The inboard and outboard wing leading edges.
(e) The inspection access covers under the wing skin, near the wing root.
(3) Position a trestle with height adjustable cradles under each left and right wing in
correspondence with ribs No.17.
(4) Referring to Figure 6-6 DETAIL A, one at time remove the two nearest wing centre line
fastening bolts from the front spar upper and lower caps joining plates and, with the aid of 10x
magnifying glass, carry out a visual inspection of the removed bolts for corrosion and cracks.
In any case discard the removed bolts to be replaced with new ones.
(5) Using a rigid boroscope of an appropriate diameter, positioned at a right angle with a visual
angle of 60 degrees, perform a visual inspection of the holes for corrosion and cracks.
(6) If during above inspections, severe corrosion and/or cracks are found, one at time remove all
the remaining bolts and inspect the bolts and holes as per the previous steps (4) and (5)
respectively. In any case discard the removed bolts to be replaced with new ones. Repair the
damaged wing structure in accordance with the Repair Procedures laid out in the FAA AC
43.13-1B para. 4-59.
(7) In absence of damage, referring to Figure 6-6, install new bolts in replacement of the
previously removed ones, interposing a film of corrosion inhibitive compound (Specification
MIL-PRF-8116). Torque to 27,91÷30,84 Nm (247÷273 lb.in).
(8) Referring to Figure 6-6 DETAIL B, one at time remove the two nearest wing centre line
fastening bolts, from the rear spar upper and lower caps joining plates and, with the aid of
10x magnifying glass, carry out a visual inspection of the removed bolts for corrosion and
cracks. In any case discard the removed bolts to be replaced with new ones.
(9) Using a rigid boroscope of an appropriate diameter, positioned at a right angle with a visual
angle of 60 degrees, perform a visual inspection of the holes for corrosion and cracks.
(10) If during above inspections, severe corrosion and/or cracks are found, one at time remove all
the remaining bolts and inspect the bolts and holes as per the previous step (8) and (9)
respectively. In any case discard the removed bolts to be replaced with new ones. Repair the
damaged wing structure in accordance with the Repair Procedures laid out in the FAA AC
43.13-1B para. 4-59.
(11) In absence of damage, referring to Figure 6-6, install new bolts in replacement of the
previously removed ones, interposing a film of corrosion inhibitive compound (Specification
MIL-PRF-8116). Torque to 27,91÷30,84 Nm (247÷273 lb.in).
(12) Carry out a detailed visual inspection of the front and rear spar caps and spar webs in the
Areas 1 and 3 in Figure 6-5. In particular, after to have cleaned the area from eventual dirty,
visually inspect the front and rear spar lower caps in the attachment to fuselage zone, for
corrosion and absence of fatigue crack, using a magnifying glass 5x and a powerful light
source (see Figure 6-7), positioning the light beam with an angle from 5° to 45° (see Figure 6-
8).
(13) If a cracks is detected, contact Vulcanair for the corrective action to be taken.
(14) In absence of damage, where necessary, clean the wing areas with Methyl-Ethyl-Ketone or
equivalent cleaning solvent and touch up them with epoxy primer (Specification MIL-PRF-
23377).
(15) In every case communicate to Vulcanair the results of the inspection performed.
(1) Using a suitable boroscope, through the lateral gaps between the engine firewall and the wing
front spar, inspect the wing spar web and spar caps for cracks and corrosion in the areas
behind the firewall.
(2) Open the two inspection access covers located at the rear and under the engine nacelles.
(3) Using a suitable boroscope, through the inspection holes under the engine nacelles,
previously opened, accurately inspect the areas of the front and rear spars on the inside of
the wing box for corrosion and cracks, as well as the relative wing rib attachments.
(4) With the aid of a powerful light source and 10x magnifying glass, visually inspect all the
accessible areas of the wing spars for cracks and corrosion.
(5) Should any damage be detected, as a result of the above inspections, repair in accordance
with the Repair Procedure laid out in the FAA AC 43.13-1B para. 4-59.
(6) Referring to installation procedures laid out in this Manual, reinstall the left and right inboard
and outboard wing leading edges, the engine cowlings and all the previously removed items.
Close all the opened inspection access holes.
2. Spar area near the nacelle firewall and its adjacent areas.
2 FUSELAGE
2.1 DESCRIPTION
The P.68R is a metal semi-monocoque structure. The fuselage consists of bulkheads, stringers and
stiffeners, to which all of the outer skin is riveted. Windows include an acrylic single formed windshield,
which meet ASTM-D4802 specifications, and six side windows. Cabin entrance door is located to the
LH of the fuselage. An access door to the baggage compartment is located just aft the right wing. A
crew door is provided on the RH side of the fuselage just aft of the windshield.
(1) Place a trestle with height adjustable cradles under each LH and RH wing rib No.17.
(2) One at a time remove the front and rear fuselage/wing attaching bolts and, using a rigid
boroscope of an appropriate diameter, properly positioned with a visual angle of 60 degrees,
perform a detailed visual inspection of the attaching holes for corrosion and cracks.
(3) In absence of damage, install new bolts as a replacement of the ones previously removed,
interposing a film of corrosion inhibitory compound (Specification MIL-PRF-8116).
(4) Torque to 6.17-6.82 Kgm (535-592 lb.in) the front attachments and to 3.80-4.19 Kgm (330-364
lb.in) the rear ones.
NOTE
All components removed from the aircraft and requiring
reinstallation, must be properly labelled and stored.
(1) Turn all electrical switches OFF and disconnect the battery cables (negative terminal first).
(2) Remove the instrument panel cover.
(3) Cover the instrument panel to prevent foreign material from entering radios and instruments
avoiding their damage.
(4) Position the fuel selector knobs in the “ENG. SHUT-OFF” position and remove them. Assure
during all the work the “ENG. SHUT-OFF” position of the fuel controls, for the subsequent
reinstallation of the fuel selector knobs.
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(5) Remove the overhead panel just enough to gain access to its back side and disconnect the
electrical connections and cockpit fresh air outlets/duct connection. Remove the overhead
panel.
(6) Remove all the cabin upholstery panels in the concerned areas.
(7) Remove all the screws, washers and nuts and all the internal and external and external
removable retainers securing the windshield in place. Remove the windshield.
(8) Remove the old sealant completely from the retainers and from the concerned areas of the
fuselage skins. Clean with Methyl-Ethyl-Ketone or equivalent cleaning solvent and where
necessary, touch up with Alodine 1200 (MIL-C-5541), then with Epoxy Primer (MIL-PRF-
23377).
2.2.3.2 Procedure
(1) Using the old windshield as a contour jig, trim the new windshield panel as required. To avoid
trimming of too much material, position the old windshield with its outer surface in contact with
the inner surface of the new windshield.
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(2) Position the new windshield panel on the aircraft adjusting it if necessary in order to assure a
clearance of about 3 through 6 mm (0.12 through 0.24 in) around all the contour of the
windshield so to allow for its expansion and contraction. Temporarily lock the new windshield
panel in place.
(3) Copying from the existing holes on the fuselage skins, mark the all the attachment holes on
the windshield panel. Mark the coupling area on the windshield panel from where protective
film is to be removed to allow the subsequent sealing procedure.
(4) Remove the new windshield panel and on work bench, drill 9 mm (0.35 in) diameter holes in
the marked position.
(5) Remove the protective film from all along the coupling area on both sides of the windshield
panel, and for 3 mm (0.12 in) more on the outer surface to allow the subsequent sealing
procedure.
(6) Install the sealant tape p/n NV7.001-11 inside the windshield retainers and on concerned
areas of the fuselage skins as previously. Referring to Detail “a” in Figure 6-9, leave about 3
mm (0.12 in) free area inside the external retainer/fuselage skins which will be filled later on
with POLIBOND Polyurethane Sealant.
(7) Reposition the new windshield panel on the aircraft and lock it temporarily in place. Install new
rubber bushings p/n NOR7.035-5 and install the windshield retainers using the screws
previously removed. Tighten the screws to ensure a secure installation, then loosen the
screws one full turn to allow for windshield expansion and contraction.
(8) Mask the windshield area for about 2 mm (0.08 in) outer of the contour of the external
retainer/fuselage skins and, referring to Detail “a” in Figure 6-9, seal with POLIBOND
Polyurethane Sealant, filling 3 mm (0.12 in) free area inside the retainers/fuselage skins and 2
mm (0.08 in) area outer of the contour of the retainer/fuselage skins.
(9) Remove the masking tape and the protective film from the windshield panels and if necessary
clean in accordance with the instructions in paragraph 2.2.10 hereunder.
(10) Where necessary, touch up the external retainer/fuselage skins with final polyurethane paint
as per the existing livery.
(11) Remove the protective cover previously installed on the instrument panel and reinstall all the
removed cabin upholstery panels on the instrument panel cover as previously.
(12) Position the overhead panel in proximity of its cockpit installation area and restore all the
electrical connections and the cockpit fresh air outlets/duct connection on the back side of it,
as previously.
(13) Reinstall the fuel selector knobs positioning them to “ENG. SHUT-OFF” position as previously
and, referring to Section 9, check the fuel control for correct rigging. If necessary, carry out a
fuel control rigging.
(14) Reconnect battery connections (positive terminal first).
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NOTE
Should removal of the window panel prove difficult free by
inserting a flat blunt object between the window panel and the
aircraft retaining structure.
(5) Clean old tape and sealant from the window panel retainer channels and angles.
(1) Fit new panel and trim as required in order to obtain a correct fit.
(2) Apply black vinyl tape to the fuselage retaining edges. Do not detach paper protection strip.
(3) Install window panel and using the airplane retaining structure as a template drill 4 mm (0.16
in) diameter holes.
NOTE
Do not drill top of panel since this is a different kind of
attachment.
WARNING
(1) Apply black vinyl tape around the edge of the external retainer (Fuselage structure)
(2) Apply PR 365 sealing compound along the internal retainer corner.
(3) Remove excess of sealant or tape.
(4) Install the outer pane assembly into the frame and then the inner panel.
(5) Install all retainers together with the strip of black vinyl tape using rivets and screws.
(6) Install the upholstery panel.
NOTE
Since the windows of the baggage door and the crew door are
similar in construction to the entrance door, the same
instructions might be followed for removal and installation.
Plastics have many advantages over glass for aircraft use, but they lack the surface hardness of glass,
and care must be exercised while servicing the aircraft to avoid scratching or otherwise damaging the
surface.
The acrylic windshield should be kept clean and waxed at all times. Clean the windshield by washing
with plenty of water and mild soap, using a clean, soft, grit-free cloth, sponge, or bare hands. Do not
use gasoline, alcohol, benzene, acetone, carbon tetrachloride, fire extinguisher or de-icing fluids,
lacquer thinners, or window cleaning sprays because they will soften the plastic and cause crazing.
Plastics should not be rubbed with a dry cloth since this is likely to cause scratches, and also build up
an electrostatic charge which attracts dust particles to the surface. If after removing dirt and grease no
great amount of scratching is visible, finish the plastic with a good grade of commercial wax. Apply the
wax in a thin even coat and bring to a high polish by rubbing lightly with a soft cloth.
Do not attempt hand polishing or buffing until the surface is clean. A soft, open-type cotton or flannel
buffing wheel is suggested. Minor scratches may be removed by vigorously rubbing the affected area
by hand, using a soft clean cloth dampened with a mixture of turpentine and chalk, or by applying
automobile cleanser with a damp cloth. Remove the cleaner and polish with a soft, dry cloth. Acrylic
and cellulose acetate plastics are thermoplastic. Friction created by buffing or polishing too long in one
spot can generate sufficient heat to soften the surface. This will produce visual distortion and is to be
guarded against.
For aircraft from s/n 478 onwards, the latch system installation assy is listed below:
• The lock system of the mechanism has a double hook clinging to the latch stop on the door
frame, which makes the closing mechanism be safer, as the door stays in the closed position
even if the closing operation is not perfect.
• The latch stop on the door stanchion is horseshoe-shaped, so that it improves the reliability
and is not dangerous for persons entering the door.
• The link between the handle assy and the lock assy is represented by a proper interlock
mechanism, and it is reliable and precise.
• A reinforcement plate closes the part of the door structure to which the lock system is
connected, then creating a box which increases the structural strength of the door.
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(1) Remove nuts and washer from both upper and lower hinges.
(2) Remove clevis, bolts and bushings from the hinges while supporting the door.
(3) Remove door from airplane.
(1) Place door and line up holes of the male and female hinges
(2) Install bushing and secure hinges with clevis, bolt, washer and nut. Tighten as required.
(3) For adjustment of door refer to the instructions in paragraph 2.2.14.
(1) Normally the door does not require any adjustment. However when vertical adjustment would
be required, install thin washer between the cabin door hinge and the fuselage, hinge
assembly.
(2) Additional adjustment can be made by rotating the hinge to obtain a hinge center line location
which will provide a proper door fit.
(1) Remove the curtain and relative rail from border of window (Fig. 6-16 or 6-16a).
(2) Remove the housing handle (Fig. 6-16) or the cover handle (Fig. 6-16a), the main handle
and the leather pocket with relative fixing screws.
(3) Remove the ABS entrance door panel (Fig. 6-16 or 6-16a).
(4) Remove the latch mechanism metallic bracket (Fig. 6-17 or 6-17a).
(5) Remove the metallic external handle (Fig. 6-17 or 6-17a).
(6) Screw off the half clamp which links latch and interlock mechanism (Fig. 6-17 or 6-17a).
(7) Remove the latch system (Fig. 6-17 or 6-17a).
(8) Screw off from external the interlock mechanism (Fig. 6-17) or screw off the six interlock
mechanism screws (Fig. 6-17a), as applicable, to remove the complete assy.
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(3) Screw the half clamp which links latch and interlock mechanism.
(4) Install the metallic external handle.
(5) Install the latch mechanism metallic bracket.
(6) Install the ABS entrance door panel.
(7) Install the housing handle or cover handle (as applicable), the main handle and the leather
pocket with relative fixing screws.
(8) Install the curtain and relative rail from border of window.
(9) Without interlock mechanism applied, rig the door latch mechanism in order to guarantee the
handle full travel.
(10) Without interlock mechanism applied, rig the door latch mechanism in order to guarantee door
opening using handle half travel.
(11) With interlock mechanism applied, adjust travel stop in order to guarantee door locking
(Fig. 6-19) - Only for aircraft up to s/n 463.
(12) Apply torque value 0,47÷0,52 Kgm [41÷45 lb.in] on the half-clamp (Fig. 6-20).
(1) Remove the knob of latch mechanism, the main handle and the leather pocket with relative
fixing screws (Fig. 6-21).
(2) Remove the ABS baggage door panel (Fig. 6-21).
(3) Remove the latch mechanism plastic cover and metallic bracket (Fig. 6-21 and 6-22).
(4) Remove the metallic external handle (Fig. 6-21).
(5) Remove the latch system (Fig. 6-22).
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(8) Install the lever guard and knob of the emergency right engine turn-off switch.
(9) Rig the door latch mechanism in order to guarantee the handle full travel.
(10) Rig the door latch mechanism in order to guarantee door opening using handle half travel.
(11) Apply torque value 0,47÷0,52 Kgm [41÷45 lb.in] on the half-clamp (Fig. 6-20).
(12) Perform unlock pin functional test.
(13) Perform “Emergency Right Engine Turn-Off Switch” operational test.
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Figure 6-18 Entrance Door Internal and External Complete Installation Assy
(Applicable to aircraft up to s/n 463)
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Figure 6-18a Entrance Door Internal and External Complete Installation Assy
(Applicable to aircraft from s/n 478 onwards)
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Figure 6-21 Baggage Door Internal and External Complete Installation Assy
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Figure 6-24 Crew Door Latch and Interlock Mechanism Installation Assy
(Applicable to aircraft up to s/n 463)
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Figure 6-24a Crew Door Latch and Interlock Mechanism Installation Assy
(Applicable to aircraft from s/n 478 onwards)
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3 EMPENNAGE GROUP
3.1 DESCRIPTION
The metal empennage group is a full cantilever design consisting of a vertical stabilizer (fin), rudder
and stabilator. The rudder and the stabilator are provided with trim tabs. The stabilator incorporates
also one torque tube that is hinged to the aft bulkhead assembly of the fuselage.
The stabilator (Refer to Figures 6-26 and 6-27) consists of two metal semi-monocoque halves coupled
with a hinge torque tube assembled to the rear bulkhead of the fuselage. The stabilator is provided
with trim tab in two halves, one for each half-stabilator.
(2) Install the attaching bolts, washer, nuts and keys without tightening the bolts.
(3) Connect one half-stabilator to the other by means of the bolt to be installed in the coupling
links of the rear spars.
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(4) Check for a full engagement of the tie-clamp on the major diameter of the torque tube: for this
check a full engagement of the only outboard tie-clamps, noting that no more than 1,5 mm
(0,06 in), of the major diameter of the torque tube be engaged.
(5) Tighten the attaching bolt assemblies at a torque of 9,38-10,51 Nm (83-93 lb.in).
(6) Ascertain that the two keys are neither blocked nor too much free. If a keys is found blocked,
remove it and reduce its thickness of 0,1 mm (0,04 in), then repeat this until the key is found
just free to be rotated with the strength of a finger. If a key is found too much free, replace it
with a 0,1 mm (0,04 in) thicker key and repeat this until the key is found just free to be rotated
with the strength of a finger.
(7) If de-icer is installed, connect de-icer hoses (access panels in the lower skin of the stabilator).
(8) Connect the trim tab halves to each other by means of the bolt assembly.
(9) Connect the trim tab control rod to the trim tab by installing bolt, washer and nut.
(10) Install the plugs on the holes at the attaching bolts, and access panels.
(11) Check for stabilator control adjustment (see Section 7).
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In this paragraph are reported the instructions to perform the inspection on stabilator structure,
prescribed at first 8500 flight hours and every 500 flight hours thereafter by an Airworthiness Limitation
as per Section 4.
(1) Referring to paragraph 3.2.1, remove the two half stabilator structures.
(2) On bench, with the aid of a suitable boroscope, inspect the inside structural parts of the both
half stabilator structures for corrosion and cracks. Should any damage be detected as a result
of the above inspections, repair in accordance with the Repair Procedure laid out in the FAA
AC 43.13-1B, paragraph 4-59.
(3) In absence of damage, reinstall the two half stabilator structures according with the
installation procedure laid out in paragraph 3.2.2.
(4) No stabilator backlash is permissible. Referring to Figure 6-27, check the stabilator for
horizontal and vertical backlash as follows: acting on the tip of left or right half stabilator,
lightly shake the half stabilator longitudinally, up and down and along its hinge bearings axis
and check for absence of backlash. Repeat above check for the other remaining half
stabilator.
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NOTE
If there is doubt that the stops could have been altered, the
connection at the deicer hose shall be made after performing the
stabilator adjustment according to Section 7.
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3.2.6 REMOVAL OF TORQUE TUBE
(Refer to Figures 6-28 and 6-29)
(1) Remove the stabilator according to the instructions given in paragraph 3.2.1.
(2) Remove the tail cone.
(3) Disconnect, if installed, the de-ice hose (fuselage line) from the “T” fitting on the torque tube.
Remove the “T” fitting together connected de-ice hoses from the torque tube.
(4) Disconnect the stabilator control rod from the torque horn.
(5) Remove the safety screw from the torque horn and visually inspect this one for absence of
scoring as specified in Figure 6-29. In presence of damage, replace the safety screw with one
of the same type and advise Vulcanair on the inspection result.
(6) Remove the bolts securing the torque horn to the stabilator tube. To avoid damages to the
torque tube during its removal, insert a proper spacer in the gap of the torque horn clamp.
(7) Remove the bolts securing the RH flanged ball bearing, the control stop pad and the ground
lead to the attaching flange.
(8) Remove the bolt securing the control stop sector and the RH flanged ball bearing to the
torque tube.
(9) Remove the bolt securing the LH flanged ball bearing to the torque tube.
(10) Withdraw the torque tube from the LH flanged ball bearing by taping lightly against the LH end
of the tube by using a wooden hammer or similar suitable tool by supporting this one on the
RH side.
NOTE
If difficulties are found, increase the action of the hammer after
to have installed a metal heavy wall tube between the attaching
flanges by utilizing the attaching bolt holes of the trim tab control
rod bracket.
(11) Remove the torque tube together the flanged ball bearing by withdrawing them trought the
RH attaching flange by supporting the torque horn and the control stop sector.
(12) Withdraw the flanged ball bearing from the nearest end of the torque tube by taping lightly on
the internal bearing thrust with a suitable tool.
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(2) Insert the torque tube through the RH attaching flange, the control stop sector and the torque
horn.
(3) Push the torque tube through the LH flanged ball bearing and the RH one in the attaching
flange by tapping lightly, by means of wooden hammer, against the RH end of the tube until
the mounting hole are lined up with the LH flanged ball bearing hole. Secure the LH flanged
ball bearing to the torque tube by using the relevant bolt, washer and nut.
NOTE
Install the bolt securing the flanged ball bearing to the torque
tube with the head facing forward after the safety screw hole of
the torque tube is positioned rearward.
(4) Secure the RH flanged ball bearing and the control stop sector to the torque tube by using the
relevant bolt, washer and nut.
(5) Secure the RH flanged ball bearing, the control stop pad and the ground lead to the attaching
flange.
(6) Place the torque horn in the middle of the torque tube and line up the safety screw holes.
NOTE
Check for absence of grease and/or oil between the mater
surfaces of the torque horn-torque tube joint. In presence of
grease and/or oil, clean accurately by using Methyl-Ethyl-Ketone.
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WARNING
(1) Remove the stabilator torque tube according to the instructions given in paragraph 3.2.6.
(2) Locate the not painted areas for the subsequent repainting of the stabilator torque tube.
(3) Remove paint completely from the inner and outer areas of the stabilator torque tube using a
paint-stripper in accordance with Specification MIL-R-81294 and clean with Methyl-Ethyl-
Ketone MEK TT-M-261.
(4) Place the stabilator torque tube on a surface plate and rolling it, check it for absence of
distortion.
(5) If a distortion is found, report officially the results to Vulcanair at e-mail address
continued.airworthiness@vulcanair.com and then replace the stabilator torque tube with a
new one, according to the installation instructions given in paragraph 3.2.9.
(6) Using a 10x magnifying glass, inspect the outer surfaces of the stabilator torque tube for
absence of cracks and corrosion.
(7) Using a boroscope or in alternative a spot light and a mirror, inspect the inner surfaces of the
stabilator torque tube for absence of cracks and corrosion.
(8) Using a 10x magnifying glass, inspect all the holes and slots on the stabilator torque tube, for
absence of cracks, ovalization and corrosion.
(9) If a damage is found, report officially the results to Vulcanair at e-mail address
continued.airworthiness@vulcanair.com and then replace the stabilator torque tube with a
new one, according to the installation instructions given in paragraph 3.2.9.
(10) If no damage is found, carry out a magnetic particle inspection on the stabilator torque tube in
accordance with Specification ASTM-E-1444.
(11) In case of damage is found by means of magnetic particle inspection, report officially the
results to Vulcanair at e-mail address continued.airworthiness@vulcanair.com and then
replace the stabilator torque tube with a new one, according to the installation instructions
given in paragraph 3.2.9.
(12) If no damage is found during the magnetic particle inspection, carry out the demagnetization
and cleaning of the stabilator torque tube in accordance with Specification ASTM-E-1444.
(13) Treat the inner and outer surfaces of the stabilator torque tube with epoxy primer, in
accordance with Specification MIL-PRF-23377, except the outer not painted areas located in
the previous step (2).
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(14) Reinstall the removed stabilator torque tube, in accordance with paragraph 3.2.7.
(15) Perform rigging of stabilator control system in accordance with procedure laid out in the
Section 7.
Figure 6-30 Positioning scheme of the stop collar for a correct drilling work
3.2.9.1 Preliminary
In case of replacement of flanged ball bearings (item 9), on work bench drill 4,80÷4,81 mm
(0,1890÷0,1895 in) diameter No.2 reamed opposite holes on the flanged ball bearings for the
installation of the bolts P/N AN3-30A (LH) and AN3-32A (RH), assuring a perfect ortogonality during
all the drilling phase so to obtain a correct alignment between the opposite holes. Drill using a special
drill bit for hard steel. Deburr carefully the holes to avoid scratches on the torque tube that could be
cause of beginning of corrosion and cracks.
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(2) Rotate the torque tube up to reaching the parallelism between the safety screw (item 2) axis
and the top face of the attaching flanges (item 8) and temporarily lock it in place.
(3) Rotate the stop collar (item 6) up to reaching the position indicated in Figure 6-30, that is 16
mm (0,63 in) forward and 27 mm (1,06 in) rearward the stop pad, and temporarily lock it in
place.
(4) Rotate the RH flanged ball bearing (item 9) up to reaching the alignment between the two
attaching holes on the stop collar (item 6) and the two attaching holes on the RH flanged ball
bearing (item 9).
(5) Rotate the LH flanged ball bearing up to reaching the parallelism between the its attaching
hole axis and the attaching hole axis on the RH flanged ball bearing.
(6) Using the flanged ball bearings as drilling jigs, drill 4,80÷4,81 mm (0,1890÷0,1895 in) diameter
No.2 reamed attaching holes on the stabilator torque tube assuring a perfect ortogonality
during all the drilling phase. Insert two suitable centring pins to assure the alignment between
the holes.
(7) Remove the stop pad (item 10) and rotate 180° the stabilator torque tube together with the
flanged ball bearings.
(8) Using the flanged ball bearings as drilling jigs, drill 4,80÷4,81 mm (0,1890÷0,1895 in)
diameter No. 2 reamed attaching holes opposite to the same ones previously carried out on
the stabilator torque tube as per the step 6. Assure a perfect ortogonality during all the drilling
phase so to obtain a correct alignment between the opposite holes on the stabilator torque
tube.
(9) Perform a dimensional check of the holes previously carried out.
(10) Blow compressed air into the stabilator torque tube to remove all the residual material due to
drilling work.
(11) Referring to Figures 6-28 and 6-30, insert the two provided bolts P/N AN3-32A and P/N AN3-
30A respectively into the RH and LH attachment points. Replace every damaged bolt with a
new one.
(12) Rotate 180° the stabilator torque tube together with the flanged ball bearings.
(13) Install the proper washers and nuts on the attaching bolts previously inserted. Torque the
nuts to 4,63-5,08 Nm (41-45 lb.in), then apply reference red marks on the coupling bolts.
(14) Check the stabilator torque tube for absence of play in the couplings.
(15) Reinstall the stop pad (item 10) as previously.
(16) Complete the reinstallation of all the disassembled items in accordance with the applicable
installation procedure laid out in paragraphs 3.2.5 and 3.2.7.
(17) Record the replacement of the stabilator torque tube in the Aircraft Log Book.
(18) Perform rigging of stabilator control system in accordance with Section 7.
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3.2.10 REMOVAL OF STABILATOR TRIM TAB
(Refer to Figure 6-26)
(1) Disconnect the trim tab control rod from the tab.
(2) Disconnect the trim tab halves from each other.
(3) Remove the three trim tab hinge pins by cutting one end of the wire pins while supporting the
half-tab.
In this paragraph are reported the instructions to perform the check the stabilator trim tab free play,
prescribed every 100 flight hours by an Airworthiness Limitation as per Section 4.
(1) Referring to Section 7, place the stabilator to its neutral position and stabilator trim tab to its
minimum down position.
(2) Keeping the stabilator in its neutral position, apply a light force toward the top at about mid
span of the stabilator trim tab trailing edge and check for absence of backlash. The perception
of a backlash indicates the presence of a free play. If a backlash is perceived:
a) Keep fixed the stabilator.
b) Measure and record the mismatch existing between stabilator and stabilator trim tab at
trailing edge in both extreme position of stabilator trim tab during its backlash (applying
light force).
c) The difference of two recorded values must be no greater than 2,54 mm (0,1 in).
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(5) Remove nuts and washers from the rudder hinge bolts and while supporting the rudder
remove the hinge bolts.
(6) Withdraw rudder from airplane, taking care to retain the bushings from the hinge fittings on
the horizontal stabilizer.
(1) The installation of the rudder can be performed by reversing the removal instructions in para.
3.2.13.
(2) After the installation has been completed, check rudder for full, free and unobstructed travel.
(3) Check for rigging and adjustment of rudder and trim tab in accordance with the instructions
given in Section 7.
(1) Remove the screws attaching the fuselage/tail fairing assembly to the airframe structure and
remove the top and bottom fairings.
(2) Carefully clean the upper and lower rudder hinges with Methyl-Ethyl-Ketone or equivalent
cleaning solvent and leave them to dry at air.
(3) Visually inspect the upper and lower rudder hinges for looseness, security and safety. Check
travel.
(4) With the aid of a powerful light source and 10x magnifying glass, perform a detailed visual
inspection of the upper and lower rudded hinges for corrosion, cracks and general condition.
(5) In presence of every damage, report officially the inspection results to Vulcanair via e-mail at
continued.airworthiness@vulcanair.com. Vulcanair will supply you a suitable repair
suggestion.
WARNING
No damage is permissible.
(6) In case of doubts, referring to procedure laid out in paragraph 3.2.13, remove the rudder and
inspect more accurately the hinges, with particular care to their pivot/attachment holes, using
a non destructive method.
(7) In absence of damage, if the rudder has been previously removed, reinstall it according to
procedure laid out in paragraph 3.2.14, then hand lubricate the hinges as per the Lubrication
Chart in Section 3 and reinstall the top and bottom fuselage/tail fairings as previously.
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(11) Remove the anticollision light assembly and disconnect the positive lead, and attach a line
prior to removal.
(12) Remove the bolts connecting the forward attaching flange of the fin to the fuselage.
(13) Remove the bolts connecting the rear attaching flange of the fin to the fuselage.
(14) Remove the fin upwards.
(1) Position the vertical fin and install bolts, washer, and nuts that secure the fin attaching flanges
to the bulkheads.
(2) Install the stabilator trim tab actuator.
(3) Install the pulley assembly to the rear bulkhead.
(4) Install the rudder trim tab control cable (refer to Section 7).
(5) Install the rudder as per paragraph 3.2.14.
(6) Install the trim tab as per paragraph 3.2.17.
(7) Install the rudder control (refer to Section 7).
(8) Pull the electrical and antenna leads through the vertical fin with the attached lines.
(9) Connect the antenna leads to the proper terminals.
(10) Connect the electrical leads at the disconnects and insulate.
(11) Rig and adjust the rudder and trim controls according to Section 7.
(12) Check the operation of radios and electrical lights.
(13) Replace all the fairings and access plates and secure them with attaching screws.
However weight and balance alterations may occur when any control surface undergoes repair,
repainting or modification. Therefore all replacement control surfaces or surfaces that have been
repaired, repainted or modified should be re-balanced according to the procedures given in the
following paragraphs.
It should be noted that spare control surfaces are delivered unpainted and the static balance will not
necessarily fall within the limits provided. This is more pronounced on the stabilator and rudder.
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4.1 STABILATOR BALANCING
(Refer to Figure 6-32)
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NOTE
Lead mass balance weights of the correct weight to balance the
stabilator are fitted at the factory.
(2) Should additional mass balance weights be found to exist, these should be removed as
follows:
a) Remove all the additional mass balance weight attachment bolts.
b) Place and retain the stabilator in its full rose down attitude while removing the additional
mass balance weights (including nuts and washers) through the lower gap between the
fuselage and stabilator root.
c) Proceed to check for balance as per STEP 2. The newly required additional mass
balance weights should be put in place using all the existing bolts. If only a part of these
bolts are used, it necessary to plug the holes in the skin with the remaining bolts or with
rivets.
(3) If there are no additional mass balance weights in the trailing edge position in the case of a
stabilator with de-icing boots, this should be considered an unusual case and contact should
be made with the factory.
(1) Check that no additional mass balance weights are present in the T.E. mass balance weight
housing as a result of a previous balancing. The presence of any additional mass balance
weights in the housing is easily checked.
(2) If there are any additional mass balance weights, remove them.
(3) Check balance as per STEP 2.
(4) If a new mass balance weight is to be placed in the L.E. mass balance weight housing, this
should be attached by small bolts instead of rivets (see Figure 6-32).
(5) If a new mass balance weight is to be placed in the T.E. mass balance weight housing, this
should be put in place using all the bolts of the previous mass balance. If only a part of these
bolts are used, it is necessary to plug the holes in the skin with the remaining bolts or with
rivets.
(6) If there is no additional mass balance, this should be considered an unusual case that may
occur only when the surface has been improperly repainted. Therefore strip and repaint.
(7) Repeat STEP 2 and items (4) and (5) of this sub-paragraph.
NOTE
Each half stabilator, including factory paint antistatic kit, fibre-
glass parts, trim-tab (half) without its actuating rod, but excluding
additional mass balance weights, torque tube, bolts and de-icing
weighs 14,74 Kg (32.5 lb). The tolerance to the above weight is
±0,68 Kg (±1,5 lb).
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4.1.4 STEP 4 - PROCEDURE FOR FITMENT OF ADDITIONAL BALANCING WEIGHT FOR
TAIL HEAVY STABILATOR
(1) Estimate the additional balance weight required.
(2) Make four balance weight strips of approximately 9,52 x 19,05 mm (3/8 x 3/4 in) cross section
and length as required to cater for the balancing weight. Each balance weight may weigh
approximately 1/4 of the total balance weight required.
(3) The material required for making the balance weight is lead of best commercial quality.
(4) The balance weight may be attached to the inboard nose ribs (LH and RH) symmetrically on
top and bottom flange. The maximum additional balance weight permissible is 0,8 Kg (1,76
lb).
NOTE
In order to reduce the additional balance weight a leading edge
rubber protection P/N 3.3047 could be installed along spanwise
of tailplane.
The existing rivets may be de-rivetted and replaced with screws for the attachment of balance
weight.
(5) In case only a small quantity of additional balance weight is required, the location may be
selected in the following order progressively:
(a) LH inboard rib bottom flange.
(b) RH inboard rib bottom flange.
(c) LH inboard rib top flange.
(d) RH inboard rib top flange.
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The procedure for checking the balance of the rudder should be carried out in three steps:
(1) Place the rudder on a suitable support, the two arms of which should have ball bearings to
which the rudder hinges can be attached as shown in Figure 6-33. Pins could be used instead
of ball bearings but this requires a more delicate balancing, taking into account friction in the
hinge pins. The rudder should be installed with the trim control side facing upwards (see
Figure 6-33). The hinge axis should be correctly aligned and lie in a horizontal plane.
(2) Check for free pivoting of the rudder. Every stiffness can be due either to excessive friction in
the hinge pins, if used instead of ball bearings, or to an imperfect alignment of the hinge axis.
(3) Make sure that there is no grease on the surface.
(4) Make sure that the rudder incorporates position light, anti-static kit, paint, fibre-glass parts
and trim-tab.
(5) The trim-tab should be left in the L.E. down attitude it assumes.
(6) The rudder is balanced if it is manually adjustable in the horizontal attitude on placing a
balance check weight of 0,71± 0,11 Kg (1.5625 ± 0,25 lb) at point "A" (see Figure 6-33).
(7) If the rudder remains out-of-balance, the following action should be taken.
The reasons for a heavy trailing edge could be excessive painting of the rudder or structural repairs.
(1) In case of absence of any repair, proceed with stripping the rudder.
(2) Repeat item (6) of STEP 2.
(3) Should the rudder still have a heavy trailing edge (which is a remote possibility), the
Manufacturer should be consulted.
(4) Should a light trailing edge be found to exist, correct balance with paint.
(5) Repeat item (6) of STEP 2.
(6) In case of presence of every structural repair, ascertain that the repair is the possible cause of
the out-of-balance condition.
(7) If so, an improved repair scheme should be carried out.
(8) Repeat item (6) of STEP 2.
(9) Should an out-of-balance condition remain, repeat item (1), (2) and (3) of this sub-paragraph.
(1) In case of absence of any signs of repair, paint the rudder correctly and then repeat item (6)
of STEP 2.
(2) If the light trailing edge condition is still found, the mass balance weight fixed in its housing
should be reduced by drilling the areas shown in Figure 6-33, until the out-of-balance
condition disappeard.
NOTE
The drilling of the mass balance weights,from the point of view
of position and depth, should always be carried outsymmetrically
in respect to the centre plane of the mass balance weight itself
and care should be taken to avoid drilling the attachment bolts.
NOTE
An alternative way to balance the rudder could be to add more
paint.
(3) Should evidence of a structural repair be present, ascertain that the repair is the possible
reason for the out-of-balance condition.
(4) If so, an improved repair scheme should be carried out.
(5) Repeat item (6) of STEP 2.
(6) If the rudder is still out-of-balance, repeat item (2) of this sub-paragraph.
NOTE
The rudder, including factory paint, position light, anti-static kit,
fibre-glass tip and trim tab, weighs 6,76 Kg (14,9 lb). The
tolerance to the above weight is ± 0,23 Kg (± 0,5 lb).
(1) Place the aileron on a suitable support at the two hinge points as shown in Figure 6-33. The
aileron should be installed with the hinge axis correctly aligned and in a horizontal plane.
(2) Check for free pivoting of the aileron. Every stiffness will be due to an imperfect alignment of
the hinge axis or to defective bearings.
(3) Make sure that there is no grease on the surface.
(4) Make sure that the aileron incorporates the anti-static kit and is painted.
(5) The aileron is balanced in the horizontal attitude (with reference to the axis of the arm of the
mass balance) on placing a balance check weight of 0,54 ± 0,085 Kg (1.1875 ± 0,1875 lb) at
point "B" (see Figure 6-33).
(6) If the aileron is out-of-balance, the following action should be taken.
The reasons for a too heavy trailing edge could be excessive painting of the aileron or structural
repairs.
(1) In case of absence of any repair, proceed with stripping the aileron.
(2) Repeat item (5) of STEP 2.
(3) Should the aileron still have a heavy trailing edge (which is a remote possibility), the
Manufacturer should be consulted.
(4) Should a light trailing edge be found to exist, correct balance with paint.
(5) Repeat item (5) of STEP 2.
(6) In case of presence of every structural repair, ascertain that the repair is the possible cause
of the out-of-balance condition.
(7) If so, an improved repair scheme should be carried out.
(8) Repeat item (5) of STEP 2.
(9) Should an out-of-balance condition remain, repeat item (1), (2), (3) and (4) of this sub-
paragraph.
(1) In the case of absence of any signs of repair, paint the aileron correctly.
(2) Repeat item (5) of STEP 2.
(3) If a light trailing condition is still found, the mass balance weight of the aileron (see Figure 6-
33) should be reduced by drilling the sides of the mass balance until the out-of-balance
condition disappears. An alternative way to balance the aileron could be to add more paint.
(4) Should a structural repair be present, ascertain that the repair is the possible cause of the
out-of-balance condition.
(5) If so, an improved repair scheme should be carried out.
(6) Repeat item (5) of STEP 2.
(7) If the aileron is still out-of-balance, repeat item (3) of this sub-paragraph.
NOTE
The aileron, including factory paint, mass balance weights and
anti-static kit, weighs 6,67 Kg (14,7 lb). The tolerance to the
above weight is ± 0,23 Kg (± 0,5 lb).
The fairings on P.68 aircraft were manufactured using polyester resin system and glass coat including
mats. Polyester resin system has limited pot life, moreover it is not possible to apply vacuum during
curing therefore it is not possible to remove resin in excess applied during the lamination process. As
per consequence an excess of weight is included in each item manufactured. This excess is
constituted by resin with limited mechanical properties.
In order to improve manufacturing process, qualities of parts and strength of the fairings, an epoxy
resin system with carbon fiber cloths is introduced to manufacture the fairings listed in this
Supplement.
The above improvements have been applied introducing the following new fairings:
In order to realize the new items, the following general rules have been applied:
(1) The external shape of the items are not changed.
(2) The mechanical interfaces with the airplane structure are not changed (i.e. local thickness to
guarantee alignment of external surfaces or minimal gap).
(3) In areas of contact with airplane structure glass cloths are utilized to improve galvanic
corrosion resistance of metallic structures.
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All the components can be removed by common tools and practices. Removal and replacement of
components should be only required as a result of a failure (cracks, delamination, debonding).
The general visual inspection performed during pre-flight is sufficient for major damage detection
(cracks).
To discover any possible internal delamination or debonding, the new fairings should be inspected
utilizing NDT coin-tapping methods as per FAA AC 43.13-1B, Chapter 5, Section 8.
The tap testing procedure consists of lightly tapping the surface of the part with a coin, light special
hammer with a maximum of 56 g (2 ounces), as per Figure 6-35, or any other suitable similar object.
The acoustic response is compared with that of a known good area.
A “flat” or “dead” response is considered unacceptable. The acoustic response of a good part can vary
dramatically with changes in geometry, in which case a standard of some sort is required. The entire
area of interest must be tapped. The surface should be dry and free of oil, grease and dirt.
Tap testing is limited to finding relatively shallow defects in skins with a thickness less than 2 mm
(0.080 in).
WARNING
In case of cracks or delamination, relevant repairs may be conducted in accordance with FAA AC
43.13-1B change 1 (or subsequent revisions), otherwise the aircraft owner/operator may contact
Vulcanair to order an ad-hoc repair procedure.
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