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P68 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. 134 Rev. 2
(Supersedes the Revision 1 dated 30 July 2008)
Design Organisation Approval No. AS-SB/10/006 dated 22 February 2010

INFORMATION

SUBJECT: FUEL TANKS RECONFIGURATION FROM STANDARD RANGE TO

LONG RANGE

NOTE
Revision 2 of this Service Bulletin is being issued to change the applicability of the
kits and relevant installation instructions, since also for P68R S/N 430 the existing
vent system provided for the STD fuel tank range will be left on board and
operative (refer to black vertical lines along the outer margin of the page to
individuate the revised material). Aircraft that have already embodied the first
issue or the previous revision of this Service Bulletin are dispensed with the
application of Rev. 2.

1. GENERAL

1.1 AIRCRAFT AFFECTED

All P68 aircraft variants from S/N 411 onwards equipped with the following Fuel Level
Indicator Systems:
a) Fuel Level Indicator System manufactured by “Farem” and consisting of a dual fuel level
indicator P/N NOR7.1037-3 and of two fuel level transmitters P/N NOR7.289-1/-1a as
delivered from the factory as per change No. MOD.P68/68 or embodying the Kit SB 127/A
or Kit SB 127/B as applicable, as per the Service Bulletin No. 127 first issue or subsequent
revisions.

First Issue dated November 08, 2004 Page 1 of 17

Rev. 2 dated 22 February 2010
Vulcanair S.p.A. Service Bulletin N°134

1. GENERAL (Cont.)
1.1 AIRCRAFT AFFECTED (Cont.)

b) Fuel Level Indicator System consisting of a dual fuel level indicator P/N NV7.002-59B
(Westberg P/N 2DA4-90) and of two fuel level transmitters P/N 7.3336-402 as per change
No. MOD.P68/116.

1.2 PURPOSE
To supply instructions for the Fuel Tanks Reconfiguration from Standard Range to Long
Range.

1.3 DESCRIPTION
This Service Bulletin requires the installation of the Kit SB 134 or Kit SB 134/A, as
applicable, to be carried out in accordance with the instructions in Paragraph 2 hereunder.
The installation of the above mentioned Kits foresee the following operations to be carried
out on each wing:

a) Removal of the two plug assemblies P/N 1.2329-18 from the fuel tanks interconnection
tubes between wing ribs Nos. 16 and No. 17 and consequently installation of the two rubber
float check valves P/N 1.2329-22;
b) Removal of the plug assembly P/N 1.2329-17 from the fuel tank interconnection vent tube;
c) Only for aircraft from S/N 446 onwards, the removal of the existing vent valve assembly
P/N 7.1059-1 on the wing rib No. 16 bis;
d) Removal of the hatch cover P/N 1.2381-4 on the wing skin between the wing rib No. 18 and
No. 19 and consequently installation of the fuel filler cap P/N NOR7.277-2;
e) Installation of the fuel tank vent line for the Long Range Configuration;
f) Removal of the placards relevant to the Standard Range Configuration and installation of
the new placards for the Long Range Configuration;
g) Inspection for leakage in the modified area of the fuel tank;
h) Calibration of the fuel level indicator system and Operational Test of the Fuel Control
System.

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 as 24 man-hours,
plus the time required for the ventilation of the tanks and the complete polymerization of the
sealant.

1.6 SPECIAL TOOLS

Calibration Gauge P/N 7.3336-402L.18E.

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Rev. 2 dated 22 February 2010
Vulcanair S.p.A. Service Bulletin N°134

1. GENERAL (Cont.)

1.7 VARIATION IN WEIGHT & BALANCE

Add 6 kg of unused fuel to the aircraft basic empty weight at 0.770 m from the DATUM.

1.8 ELECTRICAL SYSTEM LOAD

Not applicable

1.9 REFERENCE DOCUMENTS

• Applicable Maintenance Manual for aircraft variant;
• Applicable Parts Catalogue for aircraft variant;
• Latest applicable revision of the Service Instruction No. 79;
• Latest applicable revision of the Service Instruction No. 77.

1.10 PUBBLICATIONS AFFECTED

• Applicable Flight Manual for aircraft variant.

1.10 MODIFICATION TO BE CARRIED OUT BY

Vulcanair Part 145 or Certified Maintenance Facility.

2. INSTALLATION INSTRUCTIONS
The following instructions are applicable for the modification of both left and right fuel tanks .

SAFETY PRACTICE

In addition to specific local requirements, the following safety precautions are recommended while
carrying out the modification:

a) Position the aircraft in a designated area for the maintenance of the fuel system;
b) Position a trestle under each wing in correspondence of rib n°16 bis;
c) Turn all electrical switches OFF;
d) Disconnect external power and battery connections (negative terminal first);
e) All maintenance equipment must be grounded and bonded to the aircraft. As a bonding points,
use the muffler tube protruding from the engine cowlings for aircraft equipped with IO-360-
A1B(6) engines or the turbocharger exhaust tube protruding from the engine cowlings for
aircraft equipped with TIO-360-C1A6D engines;
f) Fire fighting equipment must be readily available;
g) To avoid generating static electricity or causing sparks, do not wear nylon or synthetic fabrics,
and/or shoes with metal heel taps;
h) If artificial lighting is necessary, use only hermetically sealed lights;
i) Do not operate any avionics or electrical equipment on the aircraft;
j) Do not smoke or use a naked flame in the vicinity of the aircraft while fuelling.

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Rev. 2 dated 22 February 2010
Vulcanair S.p.A. Service Bulletin N°134

2. INSTALLATION INSTRUCTIONS (Cont.)

Instructions

1. Drain fuel tanks completely in accordance with the procedure in the latest applicable revision of
the Service Instruction No. 79;
2. Open all access hatches on the upper wing and allow fuel tanks to ventilate for at least 12 hours;
3. With reference to the applicable section of the Maintenance Manual, remove the outboard wing
leading edge. Tag and store the removed items in a reserved area for their subsequent
reinstallation;
4. With reference to Figure 1, access to the internal area of the wing skin between the rib No. 18
and No. 19 through the inspection hatch provided in this area and remove the sealant from the
installation area of the hatch cover P/N 1.2381-4. Un-rivet and remove the hatch cover P/N
1.2381-4;
5. Remove completely the sealant from the concerned area of the upper wing skin and clean with
Methyl Ethyl Ketone or Isopropylic Alcohol;
6. If the area concerned with the modification needs to be retreated, do so with Alodine 1200
(Specification MIL-C-5541) and finish only the external area of the fuel tank with Epoxy
Primer (Specification MIL-PRF-23377);
7. With reference to Figure 5, on workbench attach the chain P/N NOR7.277-2C to the attachment
plate P/N NOR7.277-6A with two washers P/N NAS1149FN616P and a cotter pin P/N
MS24665-132;
8. With reference to Figure 5, install the fuel filler cap coupling flange P/N NOR7.277-2A with 11
rivets P/N MS20470AD4-5 and install the chain/attachment plate assembly previously
performed, with 1 rivet P/N MS20470AD5-6. Use PR1431 G TYPE II sealant (Specification
ASN-A 4172) between the couplings and to impregnate the shanks of all the rivets before use.
For the safety precautions and method of usage of the aforementioned sealant follow the
manufacturer’s instructions;
9. Seal all the couplings with PR 1422 B2 sealant. For the safety precautions and method of usage
of the aforementioned sealant follow the manufacturer’s instructions;
10. Attach the fuel filler cap P/N NOR7.277-2 to the other end of the chain P/N NOR7.277-2C with
two washers P/N NAS1149FN616P and a cotter pin P/N MS24665-132 and install as shown in
Figure 5;
11. With reference to Figure 2, remove the two plug assemblies P/N 1.2329-18 from the fuel tank
interconnection tubes and the plug assembly P/N 1.2329-17 from the fuel tank vent
interconnection tube unscrewing completely the relevant tightening nuts and removing the
sealant around the coupling areas;
12. Only for aircraft from S/N 446 onwards, with reference to Figure 6a, access to the area between
the wing ribs Nos. 16 bis and 17 and remove the clamp securing the vent hose to the vent valve.
Disconnect the vent hose connected to the vent valve and remove the vent valve assembly P/N
7.1059-1 on the wing rib No. 16 bis unscrewing completely the relevant five attaching screws
and nuts;
13. Remove completely the sealant in the concerned area of the wing rib No. 16 bis and clean the
area with Methyl Ethyl Ketone or Isopropylic Alcohol;

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Rev. 2 dated 22 February 2010
Vulcanair S.p.A. Service Bulletin N°134

2. INSTALLATION INSTRUCTIONS (Cont.)

14. Check the outboard fuel tank comprised between wing ribs No. 17 and No. 19, for evidence of
sealing damage. If necessary reseal using PR1422 B2 sealant (Specification MIL-S-8802 F
Class B). For the safety precautions and method of usage of the aforementioned sealant follow
the manufacturer’s instructions;
15. With reference to the Figure 4, install the two rubber float check valves P/N 1.2329-22 on the
wing rib No. 16 bis in correspondence with the fuel tank interconnection tubes. Install each
valve using No. 2 screws P/N MS35206-331 and the anchor nuts on the provided attachment
plate on the wing rib No. 16 bis;
16. With reference to the Figure 6 or Figure 6a, as applicable, install the vent tube P/N 7.1319-1 for
the left fuel tank and the vent tube P/N 7.1319-2 for the right fuel tank. Secure each vent tube to
the provided support on the wing front spar web using the clamp P/N MS21919WDG6 and the
bolt P/N AN3-3A and install two grommets P/N NOR7.219-3 on the provided crossing holes on
the wing front spar web;
17. Check the float vent valve installed on the wing rib. No. 19 for proper functionality blowing
low pressure of air into it through the relevant vent pipe on the outboard side of the wing rib
No. 19. If clicks will be heard, the float vent valve is properly working;
18. With reference to the Figure 6 or Figure 6a, as applicable, install the hose P/N 7.1317-2
connecting the aforementioned float vent valve to the vent tube previously installed. Secure the
hose to the piping using two clamps P/N NOR7.427-14;
19. Only for aircraft from S/N 411 up to and inclusive S/N 445, with reference to the Figure 6,
install the hose P/N 7.1317-1 connecting the provided vent pipe on the wing lower skin to the
previous installed vent tube. Secure the hose to the piping using two clamps P/N NOR7.427-14.
Secure the hose to the provided support on the wing rib No. 16 bis using the clamp P/N
MS21919WDG10 and the bolt P/N AN3-3A. Ensure that the vent hose is installed without
excessive slack to avoid possibility of siphoning;
20. Only for aircraft from S/N 446 onwards, with reference to the figure 6a, perform the following
steps:
a) Drill five 4.25 mm diameter holes on the plug P/N 7.1059-10 in accordance with the
existing holes on the wing rib No. 16 bis, where the vent valve has been previously
removed. Deburr the holes and treat them with Alodine 1200 (Specification MIL-C-5541).
b) Install the reworked plug P/N 7.1059-10 on the wing rib No. 16 bis, using five screws P/N
MS35206-244 and nuts P/N MS21083N08. Use PR1431 G TYPE II sealant between the
couplings and to impregnate the shanks of all the screws before use. After installation, seal
all the couplings with PR 1422 B2 sealant. For the safety precautions and method of usage
of the aforementioned sealants follow the manufacturer’s instructions;
c) Connect the existing vent hose located between the wing ribs Nos. 16 bis and 17 to the
previously installed vent tube P/N 7.1319-1/-2 and secure it with a clamp P/N NOR7.427-
14. Ensure that the vent hose is installed without excessive slack to avoid possibility of
siphoning;
21. Clean the tanks to eliminate any residual material;
22. With reference to the applicable section of the Maintenance Manual, reinstall the outboard wing
leading edge as previously;
23. Reinstall all the hatch covers previously removed using new gasket P/N NOR7.277-3;

First Issue dated November 08, 2004 Page 5 of 17

Rev. 2 dated 22 February 2010
Vulcanair S.p.A. Service Bulletin N°134

2. INSTALLATION INSTRUCTIONS (Cont.)

24. With reference to the Figure 1 remove the placard “Fuel Tank Capacity” (STD RANGE) P/N
8.2199-14 located on the wing skin near the fuel filler cap between the wing rib No. 16 and No.
16 bis;
25. Touch up, where necessary, the wing reworked external area with polyurethane paint to match
the existing livery;
26. With reference to the Figure 3, install the placard “Fuel Tank Capacity” (LONG RANGE) P/N
8.2511-4 near the fuel filler cap previously installed between the wing rib No. 18 and No. 19;
27. With reference to the Figure 3, install the placard “Fuel Level Inspection Cap” P/N 8.2512-10
near the existing fuel cap between the wing rib No. 16 and No. 16 bis;
28. Place the cockpit Fuel Selector Knob in the “ENG. SHUT OFF” position;
29. With reference to the applicable section of the Maintenance Manual, remove the two fuel
selector knobs on the overhead panel. Tag and store the removed items in a reserved area for
their subsequent reinstallation;
30. With reference to the Figure 7, remove the placard “FUEL SELECTOR CONTROL” (STD
RANGE) P/N 8.2101-32 from the overhead panel and install in the same location the placard
“FUEL SELECTOR CONTROL" (LONG RANGE) P/N 8.2511-57;
31. Reinstall the fuel selector knobs in the “ENG. SHUT OFF” position as previously;
32. With reference to the latest applicable revision of the Service Instruction No. 79, fill Left and
Right fuel tanks completely [348 Litres (92 U.S. gal)] and for a period of 4 hours, periodically
check for leaks in the area concerned with the modification. Eliminate eventual leaks;
33. Re-calibrate the Fuel Level Indicator System in accordance with the latest applicable revision of
Service Instruction N° 77;
34. Perform an Operational Test of the LH & RH Fuel Control System in accordance with the
following procedure:

a) Place the aircraft in a suitable engine test area;

b) Ensure that there is enough fuel in the tanks to guarantee at least thirty minutes of
continuous engine operation;
c) Position the aircraft upwind and place chocks under the main landing gear wheels;
d) Start both engines in accordance with the procedure in the Aircraft Flight Manual;
e) Run both engines at:
- 1500 RPM for aircraft equipped with IO-360-A1B6 engines;
- 1800 RPM for aircraft equipped with TIO-360-C1A6D engines.
f) Place the left Fuel Selector Knob in the “ENG SHUT OFF” position and verify that the LH
engine shuts down;
g) Place the left Fuel Selector Knob in the “LH TANK” position;
h) Restart the LH engine and run at 1500 RPM or 1800 RPM as applicable [Refer to step e) of
these instructions];
i) Place the left Fuel Selector Knob in the “ENG. SHUT OFF” position and when the left
engine begins to shut down, place the Fuel Selector Knob in the “RIGHT TANK” position.
Check that the engine runs normally; if necessary turn on the electrical fuel pump relative
to the tank in use. Allow engine to run at least 2 minutes in this regime;
j) Stop the left engine in accordance with the applicable procedure;
k) Repeat the above test procedure for the RH engine, inverting the selections as required.

First Issue dated November 08, 2004 Page 6 of 17

Rev. 2 dated 22 February 2010
Vulcanair S.p.A. Service Bulletin N°134

2. INSTALLATION INSTRUCTIONS (Cont.)

35. Install the self-adhesive placard “Long Range Reconfiguration” P/N R.0399 on the cover page
of the Aircraft Flight Manual as shown in Figure 8;
36. With reference to the previous paragraph 1.7, update the Figure 6.4 in Section 6, page 6-8, with
the new Basic Empty Weight and the relevant Moment;
37. Record the application of this Service Bulletin in the aircraft Log Book.

3. MATERIALS REQUIRED FOR THE MODIFICATION

Kit SB 134
Applicable for aircraft from S/N 411 up to and inclusive S/N 445

POS. P/N DESCRIZIONE Q.TÀ

1 1.2329-22 Float Check Valve 4
2 MS35206-331 Screw 8
3 7.1319-1 Vent Tube - Left 1
4 7.1319-2 Vent Tube - Right 1
5 NOR7.427-14 Clamp 8
6 MS21919WDG10 Clamp 2
7 AN3-3A Bolt 4
8 7.1317-1 Hose 2
9 NOR 7.219-3 Grommet 4
10 7.1317-2 Hose 2
11 MS21919WDG6 Clamp 2
12 8.2512-10 Placard “Fuel Level Inspection Cap” 2
13 8.2511-4 Placard “Fuel Tank Capacity” (LONG RANGE) 2
14 NOR7.277-2A Coupling Flange – Fuel Filler Cap 2
15 NOR7.277-2 Fuel Filler Cap 2
16 MS20470AD5-6 Rivet 2
17 MS20470AD4-5 Rivet 22
18 NOR7.277-2C Chain 2
19 NAS1149FN616P Washer 8
20 MS24665-132 Cotter Pin 4
21 NOR7.277-6A Attachment Plate 2
22 8.2511-57 Placard “Fuel Selector Control” (LONG RANGE) 1
23 R. 0399 Placard “Long Range Reconfiguration” 1

First Issue dated November 08, 2004 Page 7 of 17

Rev. 2 dated 22 February 2010
Vulcanair S.p.A. Service Bulletin N°134

3. MATERIALS REQUIRED FOR THE MODIFICATION (Cont.)

Kit SB 134/A
Applicable for aircraft from S/N 446 onwards

POS. P/N DESCRIZIONE Q.TÀ

1 1.2329-22 Float Check Valve 4
2 MS35206-331 Screw 8
3 7.1319-1 Vent Tube - Left 1
4 7.1319-2 Vent Tube - Right 1
5 NOR7.427-14 Clamp 6
6 AN3-3A Bolt 2
7 NOR 7.219-3 Grommet 4
8 7.1317-2 Hose 2
9 MS21919WDG6 Clamp 2
10 7.1059-10 Plug 2
11 MS35206-244 Screw 10
12 MS21083N08 Nut 10
13 8.2512-10 Placard “Fuel Level Inspection Cap” 2
14 8.2511-4 Placard “Fuel Tank Capacity” (LONG RANGE) 2
15 NOR7.277-2A Coupling Flange – Fuel Filler Cap 2
16 NOR7.277-2 Fuel Filler Cap 2
17 MS20470AD5-6 Rivet 2
18 MS20470AD4-5 Rivet 22
19 NOR7.277-2C Chain 2
20 NAS1149FN616P Washer 8
21 MS24665-132 Cotter Pin 4
22 NOR7.277-6A Attachment Plate 2
23 8.2511-57 Placard “Fuel Selector Control” (LONG RANGE) 1
24 R. 0399 Placard “Long Range Reconfiguration” 1

The following sealants are required to complete the modification but they are not included in the
Kits SB134 or 134/A, as couriers list them as hazardous material and will not carry them. They
should be acquired from the local market.

- PR1422 B-2 Sealant (Specification MIL-S-8802 F Class B) or equivalent;

- PR1431 G Type II Sealant (Specification ASN-A 4172) or equivalent.

First Issue dated November 08, 2004 Page 8 of 17

Rev. 2 dated 22 February 2010
Vulcanair S.p.A. Service Bulletin N°134

Figure 1 Premodification
- Fuel Tank STD Range Configuration -

First Issue dated November 08, 2004 Page 9 of 17

Rev. 2 dated 22 February 2010
Vulcanair S.p.A. Service Bulletin N°134

Figure 2 Premodification
- Fuel Tank STD Range Configuration -
(Detail “A” from Figure 1)

First Issue dated November 08, 2004 Page 10 of 17

Rev. 2 dated 22 February 2010
Vulcanair S.p.A. Service Bulletin N°134

Page to be considered as reference for spare parts.

Figure 3 Postmodification
- Fuel Tank Long Range Configuration -

First Issue dated November 08, 2004 Page 11 of 17

Rev. 2 dated 22 February 2010
Vulcanair S.p.A. Service Bulletin N°134

Page to be considered as reference for spare parts.

Figure 4 Postmodification
- Fuel Tank Long Range Configuration -
(Detail “B” from Figure 3)

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Rev. 2 dated 22 February 2010
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Figure 5 Postmodification
- Fuel Tank Long Range Configuration -
(Detail “C” from Figure 3)
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Figure 6 Postmodification
- Installation of the Fuel Tank Vent Line for the Long Range Configuration -
(Applicable for aircraft from S/N 411 up to and inclusive S/N 445)
First Issue dated November 08, 2004 Page 14 of 17
Rev. 2 dated 22 February 2010
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Figure 6a Postmodification
- Installation of the Fuel Tank Vent Line for the Long Range Configuration -
(Applicable for aircraft from S/N 446 onwards)
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Figure 7
- Replacement of the Fuel Selector Control Placard on the Overhead Panel -

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Rev. 2 dated 22 February 2010
Vulcanair S.p.A. Service Bulletin N°134

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Figure 8 (Typical)
- Registration of the application of this Service Bulletin on
the Cover Page of the Aircraft Flight Manual –

First Issue dated November 08, 2004 Page 17 of 17

Rev. 2 dated 22 February 2010