P68 VARIANTS SERVICE INSTRUCTION No. 84

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P68 VARIANTS
SERVICE INSTRUCTION
No. 84
SUBJECT: RETROFIT OF THE “KEITH” AIR CONDITIONING SYSTEM
1. GENERAL
1.1
AIRCRAFT AFFECTED
All P68 series aircraft from S/N 411 onwards on which the Keith Air Conditioning System is
to be retrofitted.
1.2
PURPOSE
To supply instructions for the installation of the Keith Air Conditioning System in accordance
with information in the latest applicable revision of Service Bulletin No. 141.
1.3
DESCRIPTION
The installation of Kit SB141/1 together with either Kit SB141/2 or Kit SB141-3 must be in
accordance with the instructions in Paragraph 2 hereunder and calls for the following
operations.
a) Opening of a hole in the baggage compartment bulkhead for the installation of a grid for
the recycling of air;
b) Opening of a hole on the skin on the LH side of the fuselage in the area between frame
numbers 11 and 12 and the installation of a conveyor for the discharge of air from the
Compressor/Condenser Unit;
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Service Instruction No. 84
1. GENERAL (Cont.)
1.3
DESCRIPTION (Cont.)
c) Opening of a hole on the skin on the RH side of the fuselage in the area between frame
numbers 11 and 12 and the installation of an air intake for an external air feed to the
Condenser;
d) Installation of three water drainage pipes under the fuselage between frame numbers 11
and 12;
e) Installation of the Compressor/Condenser and Evaporator/Fan units on an upper tray in
the area between frame numbers 11 and 12 immediately behind the baggage compartment;
f) Installation of the connecting hoses of the air conditioning system units;
g) Installation of a Plenum on the Condenser and the relative hoses for connection to the Air
Intake;
h) Installation of flexible drainage hoses;
i) Reconfiguration of the existing electric cables. Installation of a 100 Amp breaker on the
LH Power Panel located on the cabin ceiling between frame numbers 8 and 9;
j) Removal of the stickers “NOT USED” near the switches on the breaker panel and
installation on the ceiling panel on the pilot’s side of a placard stating “AIR
CONDITIONING – OPERATIONAL LIMITS”;
k) Filling of refrigerant;
l) Operational tests of the air conditioning system;
m) Ground tests for interference.
1.4
MANHOURS REQUIRED
The time necessary for the application of this Service Bulletin is estimated as being 130 manhours including the time required to access the parts and to release the aircraft back to service.
1.5
SPECIAL TOOLS
No special tools are required to install the air conditioning system.
Refer to the latest revision of the “Keith Service Manual TR-134” included in Kit SB141/1
for tools required for the filling and emptying of the refrigerant.
1.6
VARIATION IN WEIGHT AND BALANCE
The aircraft will have to be reweighed to determine the new empty weight and centre of
gravity.
1.7
ELECTRICAL SYSTEM LOAD
Maximum required load = 92 Amperes.
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Service Instruction No. 84
1. GENERAL (Cont.)
1.8
REFERENCE DOCUMENTS
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Latest applicable revision of the Service Bulletin No. 141;
Applicable Maintenance Manual for Aircraft Type;
Drawing No. R.0336;
Drawing No. R.0405-1 ;
Drawing No. R.0405-2 ;
Latest applicable revision of the “KEITH Service Manual TR-134”.
1.9 PUBLICATIONS AFFECTED
•
•
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Applicable Flight Manual for Aircraft Type;
Applicable Maintenance Manual for Aircraft Type;
Applicable Parts Catalogue for Aircraft Type.
1.10 MODIFICATION TO BE CARRIED OUT BY
Vulcanair S.p.A. or Certified Maintenance Facility.
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Service Instruction No. 84
2. WORK PROCEDURE
During the work procedure perform the following where required:
• Touch up all reworked metal areas with Alodine 1200 (MIL-C-5541) and then with
Epoxy Primer (MIL-PRF-23377);
•
Seal all unions in accordance with the indications in the latest applicable revision of
the Keith Service Manual TR-134;
•
Paint reference marks on all the high and low pressure lines and on the bolted
couplings.
Instructions
1. Turn all electrical switches OFF and disconnect the battery cables (negative cable first);
2. As indicated in Drawing No. R.0405-2 included in Kit SB141/1, access the area of the fuselage
tail cone and remove the baggage compartment bulkhead from frame number 11;
3. On a work bench cut out a 204mm x 204mm opening and drill four 3.5mm diameter holes on the
upper bulkhead of the baggage compartment for the installation of the grid P/N NOR7.499-4 as
indicated in Drawing No. R.0405-2;
4. Install the grid P/N NOR7.499-4 on the upper bulkhead of the baggage compartment with four
screws P/N MS35206-230, four Washers P/N NAS1149FN616P and four Nuts P/N
MS21083N06 as indicated in Drawing No. R.0405-2;
5. Referring to Figure 1, access the upper tray between frame numbers 11 and 12 and remove the
Air Blower Vulcanair P/N NV7.001-14 (Keith P/N JBS 257-2) as follows:
•
•
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Disconnect the electrical wiring from the Air Blower;
Remove the clamps P/N NOR7.427-10 and the flexible hose P/N 7.9501-24
between the air distribution duct and the Air Blower;
Remove the screws, washers and nuts attaching the Air Blower to the upper tray;
Remove the Air Blower Assembly P/N 7.9571-11 and relative installation brackets;
6. On the LH fuselage skin in the area between frame numbers 11 and 12, trace and cut out a
210mm diameter hole for the installation of a tube P/N 7.9193-5 and the conveyor for the
discharge of condensed air P/N 7.9193-6 as indicated in Drawing No. R.0405-2;.
7. As indicated in drawing No. R.0405-2, position the conveyor P/N 7.9193-6, the tube P/N
7.9193-5 and the grid P/N 7.9193-2 in place and drill twenty-two 3.2mm holes and install the
conveyor, the tube and the grid with 22 Avex type blind rivets P/N 1661-0410. Seal the
couplings with Single-component polyurethane sealant “POLIBOND” manufactured by
Saratoga or other equivalent product. Allow the sealant to polymerize in accordance with the
time indicated by the manufacturer;
8. On the RH fuselage skin in the area between frame numbers 11 and 12, trace and cut out a
254x118mm slot for the installation of the Air Intake P/N 7.9504-401;
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Service Instruction No. 84
2. WORK PROCEDURE (Cont.)
9. As indicated in Drawing No. R.0405-2, position the flange P/N 7.9502-013, the grid P/N
7.9502-012 and the air intake P/N 7.9504-401in place and using the flange as a template, drill
twenty-two 3.2mm holes and install the air intake, the grid and the flange with 22 rivets P/N
AGS4717-410. Seal the couplings with Single-component polyurethane sealant “POLIBOND”
manufactured by Saratoga or other equivalent product. Allow the sealant to polymerize in
accordance with the time indicated by the manufacturer;
10. As indicated in detail “b” of Drawing No. R.0405-2 drill three 14mm diameter holes under the
fuselage and install the three drainage pipes P/N A-7.9809-1 riveting each pipe with three P/N
MS20470AD4-5 rivets;
11. As indicated in Drawing Number R.0405-2, drill one 21mm diameter hole, one 20mm diameter
hole and two 5mm diameter holes on the upper tray between frame numbers 11 and 12 of the
fuselage. Touch up the holes with Alodine 1200 (MIL-C-5541) and then with Epoxy Primer
(MIL-P-23377);
12. Install the grommet P/N MS35489-14 in the 21mm diameter hole on the tray:
13. On a work bench install the following components on the Evaporator/Fan Unit P/N NOR7.4993 as indicated in Drawing No. R.0336:
• Equip the conduit box P/N A-7.9807-6 with two self adhesive gaskets obtained from P/N
NOR7.419-5 and install it on the Evaporator/Fan with the two guide pins on the
Evaporator/Fan. Use a Washer P/N NAS1149F0363P with each pin;
• Install the Union Elbow P/N AN821-80 on the Evaporator/Fan unit as indicated in Drawing
No. R.0336;
14. Using the holes already drilled in the upper tray, install the Evaporator/Fan Unit on with 4 Bolts
P/N AN4-12A, 4 Washers P/N NAS1149F0332P, 4 Nuts P/N MS21042-3 and 4 Spacers P/N A7.9807-4 as indicated in drawing No. R.0336. Torque to 0.500Kgm (43.4 lb.in) ± 5%;
15. Referring to Drawing No. R.0336 and using the material in Kit SB141/1, on a work bench equip
the Compressor/Condenser Unit P/N NOR7.499-2 as follows:
• Remove the “T” Union, the pressure switch and the union reduction group;
• Remove the cap from the high pressure line on the Compressor and install the pressure
switch and the union reduction group in the same position;
• Remove the cap from the low pressure line on the Compressor and install the union
reduction P/N NOR7.499-11 in the same position. Install the filler valve P/N NV7.00142 on the union reduction;
• Disconnect the flexible hose from the “T” union on the compressor. Remove and
discard the “T” union. Reinstall the flexible hose on the compressor in the same position
where the “T” union was installed;
16. Using the holes already drilled in the upper tray, install the Compressor/Condenser Assembly
with 4 Bolts P/N AN4-21A, 4 Washers P/N NAS1149F0463P and 4 Spacers P/N A-7.9807-5 as
indicated in drawing No. R.0336. Torque to 0.900Kgm (78.1 lb.in) ± 5%;
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Service Instruction No. 84
2. WORK PROCEDURE (Cont.)
17. Between the Evaporator/Fan and the Compressor/Condenser, install the flexible hose P/N
NOR7.499-30 on the Low Pressure Line and the flexible hose P/N NOR7.499-13 on the High
Pressure Line as indicated in Drawing No. R.0336;
18. Connect the flexible hose P/N 7.9501-14 to the air discharge tube P/N 7.9193-5 and the
Compressor/Condenser P/N NOR7.499-2 and secure it in place with clamps P/N NOR7.427-32
as indicated in Drawing No. R.0405-2;
19. Connect the flexible hose P/N 7.9501-16 to the air discharge tube P/N 7.9193-5 and the drainage
pipe P/N A-7.9809-1 and secure with clamps P/N NOR7.427-25. Connect the flexible hose P/N
7.9501-15 to the Evaporator/Fan Unit P/N NOR7.499-3 and relative drainage pipe P/N A7.9809-1 securing with clamps P/N NOR7.427-25 as indicated in detail “b” of Drawing No.
R.0405-2;
20. Connect the flexible hose P/N 7.9501-23 to the Evaporator/Fan Unit and the union on the
extremity of the air distribution duct securing with clamps P/N NOR7.427-23 as indicated in
Drawing No. R.0405-2 ;
21. Install the two halves of the Plenum RH P/N 7.9502-402 and LH P/N 7.9502-401 and attach
them to the upper tray between fuselage frame numbers 11 and 12 with 3 screws P/N MS35206246 and 3 washers P/N NAS1149FN832P. Attach the forward section of the two halves of the
Plenum to the Compressor/Condenser Unit with two existing screws as indicated in Drawing
No.R.0405-2,. Join the two halves together with 6 screws P/N MS35206-244, 1 screw P/N
MS35206-242 and 7 washers P/N NAS1149FN632P;
22. Install the flexible hose P/N 7.9501-14 between the air intake P/N 7.9504-401 and the right hand
half of the Plenum P/N 7.9502-402 and secure wit clamps P/N NOR7.427-32 as indicated in
Drawing No. R.0405-2;
23. Install 2 tube support collars P/N MS21919WDG8 under the upper tray between fuselage frame
numbers 11 and 12 as indicated in detail “f” of Drawing No. R.0405-2 ;
24. Install two flexible hoses P/N 7.9501-15 for the Plenum and the air intake respectively, securing
them with two clamps P/N NOR7.427-25. Route the hoses through the support collars previously
installed;
25. Install 2 clamp supports P/N NOR7.417-5D with a “Avex” type blind rivet P/N 1661-0410 on
the forward vertical support of the tray used for the installation of the “KEITH” components as
indicated in Drawing No. R.0405-2
26. Install the union P/N NOR7.101-4 between the two flexible hoses installed at step 24 and secure
them with two clamps P/N NOR7.427-25 as indicated in Drawing No. R.0405-2;
27. Install the drainage tube P/N NOR7.441-5 between the union P/N NOR7.101-4 and the relative
drainage pipe P/N A-7.9809-1 previously installed, with clamps P/N NOR7.427-25. Secure the
tube to the clamp supports P/N NOR7.417-5D with tie wraps P/N NOR7.701-1C as indicated in
Drawing No. R.0405-2
28. Paint the Air Discharge Conveyor P/N 7.9193-6 installed on the LH fuselage panel and touch up
the paint on reworked areas on the outer fuselage skins;
29. Using Kit SB141/2 or SB141/3 depending on the serial number of the aircraft, reconfigure the
electrical wiring making the necessary connections as indicated in Drawing R.0405-1 and
Figure 5;
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Service Instruction No. 84
2. WORK PROCEDURE (Cont.)
30. Remove the stickers “NOT USED” from the breaker panel as indicated in drawing No. R.04051 and install the placard “AIR CONDITIONING – OPERATIONAL LIMITS” P/N 7.9513-2 on
the pilot’s side of the cabin ceiling;
31. Reconnect the battery cables (positive cable first);
32. Fill the refrigerant in accordance with the instructions in the la test revision of the “Keith Service
Manual TR-134”;
33. Conduct operational tests in accordance with paragraph 2.1 hereunder;
34. Conduct tests on ground for interference in accordance with paragraph 2.2 hereunder;
35. Reinstall the upper bulkhead of the baggage compartment as sown in Drawing No. R.0405-2
2.1 OPERATIONAL TESTS
Conduct on ground operational tests on the air conditioner and the Cut-off System in accordance
with instructions la test revision of the Maintenance Manual Supplement P/N NOR 10.771-2B
for P68 C aircraft and P/N NOR 10.771-2A for P68 Observer 2 and P68TC Observer aircraft;
2.2 GROUND TESTS FOR INTERFERENCE
Make sure that the operational tests mentioned in Sub-paragraph 2.1 above do not generate any
type of interference with the equipment on board the aircraft. Verify on different frequencies
that when the air conditioner is functioning there is no interference with radio reception in the
headphones. Verify that there are no abnormal oscillations in the reading of the VOR, ADF,
magnetic compass , Gyroscope (HSI system ) and engine instruments.
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Service Instruction No. 84
Figure 1 Pre-modification
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Service Instruction No. 84
Figure 2 Post-modification
- Air Conditioning System Applicable for P68 Observer 2 and P68TC Observer Aircraft
(Ref. Drawing R.0336 and R.0405-2)
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Service Instruction No. 84
Figure 3 Post-modification
- Air Conditioning System Applicable for P68C Aircraft
(Ref. Drawing R.0336 and R.0405-2)
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Service Instruction No. 84
Figure 4 Post-modification
- Installation of a Plenum on the Compressor/Condenser Unit (Ref. Drawing R.0405-2)
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Service Instruction No. 84
Figure 5 Post-modification
- Reconfiguration of the Electrical System (Ref. Drawing R.0405-1)
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Service Instruction No. 84
Figure6 Post-modification
- Installation of 100 A. breaker on the power panel located on the LH side of the cabin ceiling
between fuselage frame numbers 8 and 9 (Ref. Drawing R.0405-1)
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