Vulcanair V1 series Reference manual

First issue dated 09 October 2017
Rev.1 dated 08 January 2019
Page 1 of 19
Vulcanair S.p.A.
via G. Pascoli, 7
80026 Casoria (NA) –Italia
Tel [phone]
Fax [phone]
[email protected]m
www.vulcanair.com
V1 series
Approved by 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. VA-03 Rev. 1
(Supersedes the previous issue approved on 02 November 2017)
Design Organisation Approval No. AS-SB/19/002 dated 25 January 2019
INFORMATION
SUBJECT: AIRCRAFT CONVERSION FOR GLIDER TOWING
NOTE
This revision is being issued to add the new Kit
applicable to V1.0 aircraft from s/n 1020 onwards,
and to fix typing errors.
1. GENERAL
1.1 AIRCRAFT AFFECTED
Vulcanair V1.0.
1.2 PURPOSE
The purpose of this Service Bulletin is to supply information to convert aircraft for glider
towing.
1.3 DESCRIPTION
Compliance with this Service Bulletin requires the installation of the Kit SB_VA-03/A, or
SB_VA-03/B as applicable, to be carried out in accordance with the instructions in paragraph 2
hereunder:

Vulcanair S.p.A. Service Bulletin No. VA-03 Rev.1
First issue dated 09 October 2017
Rev.1 dated 08 January 2019
Page 2 of 19
Part A: Aircraft preparation
Part B: Installation of Kit SB_VA-03/A, or SB_VA-03/B, for glider towing
Part C: Restoring of aircraft’s airworthiness
Aircraft Flight Manual is affected by compliance with this Service Bulletin. Update Aircraft
Flight Manual at the latest revision and comply with Supplement B1 when the concerned
aircraft is converted for glider towing and used for tow-flight operation.
1.4 COMPLIANCE
At owner’s discretion.
1.5 MANHOURS
The time necessary for the application of this Service Bulletin is estimated as being 10 man-
hours (at least two people are required), including the time needed to access the parts and to
return the aircraft to an airworthy condition.
1.6 SPECIAL TOOLS
No special tools are required.
1.7 VARIATION IN WEIGHT & BALANCE
•Aircraft embodying Kit SB_VA-03/A, or SB_VA-03/B:
oWeight difference: +4.813kg
oMoment difference: +21.033 kg*m (with respect to datum, tangent to LE wing
section).
NOTE
It is responsibility of the pilot and aircraft owner to
ensure that the airplane is loaded properly before
flight.
1.8 ELECTRICAL SYSTEM LOAD
Negligible.
1.9 REFERENCE DOCUMENTS
•Applicable Aircraft Parts Catalogue
•Applicable Aircraft Maintenance Manual
•DWG R.0550 “Glider Tow Hook Installation”
1.10 PUBBLICATIONS AFFECTED
•Applicable Aircraft Parts Catalogue
•Applicable Aircraft Flight Manual

Vulcanair S.p.A. Service Bulletin No. VA-03 Rev.1
First issue dated 09 October 2017
Rev.1 dated 08 January 2019
Page 3 of 19
1.11 MODIFICATION TO BE CARRIED OUT BY
Vulcanair Part 145, or other Approved Maintenance Organisation.
Garmin Dealer Resource Center for Garmin Authorized Service Centers for enabling the
external video.

Vulcanair S.p.A. Service Bulletin No. VA-03 Rev.1
First issue dated 09 October 2017
Rev.1 dated 08 January 2019
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2. WORK PROCEDURE
WARNING
This work procedure calls for the use of
substances and/or procedures that may be
injurious to health if adequate precautions are not
taken. This document refers only to technical
suitability and in no way absolves the Operator
from statutory and other legal obligation relating
to health and safety at any stage of manufacture
or use.
WARNING
Carry out this work procedure in a FOD control
area.
•Practice “Clean as you go”.
•Monitor all your personal items. Personal
items should be accounted for upon exit of
FOD area.
•Keep and account for all your tools,
hardware, equipment.
•Dispose of trash properly.
•No food or beverage allowed.
Before finishing this work procedure, check that
all the area affected by this activity is FOD free.
CAUTION
Always follow the manufacturer’s instructions and
safety precautions during application and usage of all
the substances called out in this work procedure.

Vulcanair S.p.A. Service Bulletin No. VA-03 Rev.1
First issue dated 09 October 2017
Rev.1 dated 08 January 2019
Page 5 of 19
Part A - Aircraft preparation.
1. Place the aircraft in a suitable working area for the operations to be carried out.
2. Turn OFF all electrical switches, disconnect the battery cables (negative cable first) and the
external power unit (if connected), then ground the aircraft.
3. Carefully remove the pilot and co-pilot seats.
4. Remove the bench-seat.
5. Remove the cabin moquette.
6. Un-rivet and remove the LH cabin floor panel p/n 5750-001 near the rudder pedal.
7. Un-rivet and remove the remaining cabin floor panels in order to gain access at the working
area under the cabin floor.
8. Get access to the baggage compartment area and remove the inspection cover p/n 5754-001, and
the panel at fuselage frame No.2 (p/n 8203-016) to gain access to the internal fuselage rear
cone.
9. Get access to the bottom side of the fuselage rear cone, and remove the access panel p/n 5207-
003 of the inspection hatch located between the fuselage frames No.4 and 5.
10. Remove the tail fairings at the fuselage rear cone, after disconnecting the rear fuselage position
light.
11. Remove the fairing at the fin forward base.
12. Remove the fin rib nose no.0 p/n 5141-401 from the fin leading edge taking particular care to
not damage the flight control cables.
13. Remove the screws attaching the mooring hook at the fuselage frame No.6, then remove the
mooring hook from the aircraft.
14. Remove any trace of sealant and clean all the surfaces with Methyl-Ethyl-Ketone, or equivalent
cleaning solvent. If necessary, treat the surfaces with Alodine 1200 (MIL-C-5541) and then
with Epoxy Primer (MIL-PRF-23377).
15. Tag a store all the removed items in a reserved area for their subsequent reinstallation.
16. Proceed with the following Part B.
Part B - Installation of Kit SB_VA-03/A, or SB_VA-03/B, for glider towing.
1. Get access to the aircraft cabin and referring to DWG R.0550, fit the Lever Support Welded p/n
8393-406 (item 35) to the fuselage truss.
2. Fix the position of the Lever Support Welded on the fuselage truss as per instructions within
DWG R.0550, and tight by using bolt p/n AN4-12A, nut p/n MS21083N4 and washer p/n
NAS1149F0432P. Torque the nuts to [0.86÷0.94] kgm.
3. Install the Lever Assy p/n 8393-402 (item 28) to the Lever Support Welded p/n 8393-406 (item
35), by using bolt p/n AN4-7A, washer p/n NAS1149F0432P, nut p/n MS21083N4 and
interposing the spacer p/n 8395-010 (item 39). Torque the nuts to [0.86÷0.94] kgm.

Vulcanair S.p.A. Service Bulletin No. VA-03 Rev.1
First issue dated 09 October 2017
Rev.1 dated 08 January 2019
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4. Referring to DWG R.0550, fit the Bowden Support Welded p/n 8393-407 (item 26) to the
fuselage truss.
5. Fix the position of the Bowden Support Welded p/n 8393-407 on the fuselage truss as per
instructions within DWGR.0550, and tight by using bolt p/n AN4-12A, washer p/n
NAS1149F0432P and nut p/n MS21083N4. Torque the nuts to [0.86÷0.94] kgm.
6. Get access to the LH side of fuselage lower frame No.1 (ref. p/n 5186-001) of the internal
fuselage rear section, and put in place the bracket p/n NOR7.077-1 (item 41) as per instructions
within DWG R.0550.
7. Copy the holes from the bracket to the fuselage frame and then drill to Ø3.2mm diameter holes.
8. Deburr all the holes and clean all reworked surfaces with Methyl-Ethyl-Ketone or equivalent
cleaning solvent; treat them with Alodine 1200 (MIL-C-5541) and then with Epoxy Primer
(MIL-PRF-23377).
9. Install the bracket p/n NOR7.077-1 to the fuselage lower frame No.1 by using blind rivets p/n
1661-0410.
10. Get access to the LH rear side of fuselage frame No.2 (ref. p/n 5177-001) of the internal
fuselage rear section, and put in place the bracket p/n NOR7.077-1 (item 41) as per instructions
within DWG R.0550.
11. Copy the holes from the bracket to the fuselage frame No.2 and then drill to Ø3.2mm diameter
holes.
12. Deburr all the holes and clean all reworked surfaces with Methyl-Ethyl-Ketone or equivalent
cleaning solvent; treat them with Alodine 1200 (MIL-C-5541) and then with Epoxy Primer
(MIL-PRF-23377).
13. Install the bracket p/n NOR7.077-1 to the fuselage frame No.2 by using blind rivets p/n 1661-
0410.
14. Get access to the LH fuselage stringer (ref. p/n 5198-005), between fuselage frames No.2 and 3
of the internal fuselage rear section, and drill the stringer to Ø4.83mm diameter hole, as per
instructions within DWG R.0550.
15. Deburr the hole and clean the reworked surfaces with Methyl-Ethyl-Ketone or equivalent
cleaning solvent; treat them with Alodine 1200 (MIL-C-5541) and then with Epoxy Primer
(MIL-PRF-23377).
16. Get access to the LH fuselage stringer (ref. p/n 5204-001), between fuselage frames No.3 and 4
of the internal fuselage rear section, and drill the stringer to Ø4.83mm diameter hole, as per
instructions within DWG R.0550.
17. Deburr the hole and clean the reworked surfaces with Methyl-Ethyl-Ketone or equivalent
cleaning solvent; treat them with Alodine 1200 (MIL-C-5541) and then with Epoxy Primer
(MIL-PRF-23377).
18. Get access to the LH side of fuselage frame No.4 (ref. p/n 5181-001) of the internal fuselage
rear section, and put in place the bracket p/n NOR7.077-1 (item 41) as per instructions within
DWG R.0550.
19. Copy the holes from the bracket to the fuselage frame and then drill to Ø3.2mm diameter holes.

Vulcanair S.p.A. Service Bulletin No. VA-03 Rev.1
First issue dated 09 October 2017
Rev.1 dated 08 January 2019
Page 7 of 19
20. Deburr all the holes and clean all reworked surfaces with Methyl-Ethyl-Ketone or equivalent
cleaning solvent; treat them with Alodine 1200 (MIL-C-5541) and then with Epoxy Primer
(MIL-PRF-23377).
21. Install the bracket p/n NOR7.077-1 to the fuselage frame No.4 by using blind rivets p/n 1661-
0410.
22. Get access to the fuselage truss in the cabin. Referring to DWG R.0550, fit the clamp p/n 8395-
004 (item 16) to the fuselage truss and interpose the shim p/n 8395-005 (item 20) between the
clamp and the ventral skin. Temporarily fix them in place as per instructions within DWG
R.0550 and use the clamp with the shim as a drilling mask for the ventral skin.
23. Remove the clamp with the shim and drill the fuselage ventral skin to Ø4.82mm diameter holes
as per instructions within DWG R.0550.
24. Deburr all the holes and clean all reworked surfaces with Methyl-Ethyl-Ketone or equivalent
cleaning solvent; treat them with Alodine 1200 (MIL-C-5541) and then with Epoxy Primer
(MIL-PRF-23377).
25. Put in place the clamp p/n 8395-004 to the fuselage truss and interpose the shim p/n 8395-005
between the clamp and the ventral skin (onboard side).
26. Put in place the Cable Support Welded Assy p/n 8393-405 (item 15) to the fuselage ventral skin
(outboard side), then install it definitively to the fuselage and to the internal clamp and shim by
using 6 (six) screws p/n AN23-10A, washers p/n NAS1149F0332P and nuts p/n MS21042-3.
Torque the nuts to [0.48÷0.52] kgm.
NOTE
Interpose a film of Single-component polyurethane
sealant “POLIBOND” manufactured by SARATOGA
or other equivalent product between the faying
surfaces of the cable support welded and the fuselage
skin, then carry out the installation.
NOTE
During installation, impregnate the shank of the
bolts with a film of corrosion inhibitive compound
Mastinox D40 (Specification MIL-PRF-8116C), or
equivalent.
27. Referring to DWG R.0550, put temporarily in place the bracket p/n 8395-015 (item 13) at the
aircraft center line in correspondence of fuselage frame No.1, unriveting the existing two
attaching items.
28. Drill the ventral fuselage skin with the fuselage lower frame No.1 and the bracket to Ø3.2mm
diameter hole, as per instructions within DWG R.0550.
29. Deburr all the holes and clean all reworked surfaces with Methyl-Ethyl-Ketone or equivalent
cleaning solvent; treat them with Alodine 1200 (MIL-C-5541) and then with Epoxy Primer
(MIL-PRF-23377).
30. Referring to DWG R.0550, install the bracket p/n 8395-015 to the fuselage ventral skin by using
blind rivets p/n 4801-0407.

Vulcanair S.p.A. Service Bulletin No. VA-03 Rev.1
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Rev.1 dated 08 January 2019
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NOTE
Interpose a film of Single-component polyurethane
sealant “POLIBOND” manufactured by SARATOGA
or other equivalent product between the faying
surfaces of the bracket and the fuselage skin, then
carry out the installation.
31. Referring to DWG R.0550, put temporarily in place the bracket p/n 8395-015 (item 13) at the
aircraft center line in correspondence of fuselage frame No.3, unriveting the existing two
attaching items.
32. Drill the ventral fuselage skin with the fuselage lower frame No.3 and the bracket to Ø3.2mm,
as per instructions within DWG R.0550.
33. Deburr all the holes and clean all reworked surfaces with Methyl-Ethyl-Ketone or equivalent
cleaning solvent; treat them with Alodine 1200 (MIL-C-5541) and then with Epoxy Primer
(MIL-PRF-23377).
34. Referring to DWG R.0550, install the bracket p/n 8395-015 to the fuselage ventral skin by using
blind rivets p/n 4801-0407.
NOTE
Interpose a film of Single-component polyurethane
sealant “POLIBOND” manufactured by SARATOGA
or other equivalent product between the faying
surfaces of the bracket and the fuselage skin, then
carry out the installation.
35. Get access to the bottom-outboard side of the fuselage frame No.5 and remove the central rivet
and the two near ones (LH and RH) attaching the skin to the fuselage frame No.5, where the
doubler p/n 8395-003 (item 51) has to be installed.
36. Clean all reworked surfaces with Methyl-Ethyl-Ketone or equivalent cleaning solvent; treat
them with Alodine 1200 (MIL-C-5541) and then with Epoxy Primer (MIL-PRF-23377).
37. Referring to DWG R.0550, lock temporarily in place the angles p/n 8395-001/-002 with the
doubler p/n 8395-003, to the fuselage ventral skin.
38. Using the fuselage as a drilling mask, mark the LH/RH stringers p/n 8395-001/-002 (items 49
and 50) and the doubler p/n 8395-003 with the existing holes from the fuselage.
39. Lock temporarily in place the LH/RH stringers p/n 8395-001/-002 with the doubler p/n 8395-
003, to the fuselage ventral skin.
40. Using the LH/RH stringers p/n 8395-001/-002 with the doubler p/n 8395-003 as a drilling mask,
mark the fuselage ventral skin with all the holes required to install these items to the fuselage
ventral side.
41. Drill Ø2.5mm diameter pilot holes. After ensuring proper position of all the elements, drill to
Ø3.2mm diameter holes all the 49 (forty-nine) involved riveting holes and countersunk the hole
on the doubler p/n 8395-003 at the aircraft center line.
42. Remove the angles and the doubler.

Vulcanair S.p.A. Service Bulletin No. VA-03 Rev.1
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Rev.1 dated 08 January 2019
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43. Deburr all the holes and clean all reworked surfaces with Methyl-Ethyl-Ketone or equivalent
cleaning solvent; treat them with Alodine 1200 (MIL-C-5541) and then with Epoxy Primer
(MIL-PRF-23377).
44. Install the RH stringer p/n 8395-001 (item 50) to the fuselage using blind rivets p/n 4801-407.
Do not rivet the area (three holes) where the doubler p/n 8395-003 is to be installed.
45. Install the LH stringer p/n 8395-002 (item 49) to the fuselage using blind rivets p/n 4801-407.
Do not rivet the area (three holes) where the doubler p/n 8395-003 is to be installed.
46. Put in place the doubler p/n 8395-003 (item 51) and install it to the:
a. LH/RH stringers using 4 (four) blind rivets p/n 4801-0407 and 2 (two) blind rivets p/n 4801-
0409 (in correspondence of fuselage frame No.5 riveting line).
b. Fuselage skin using 4 (four) blind rivets p/n 4801-0407.
c. Fuselage frame at aircraft center line hole by using countersunk rivet p/n MS20426AD4-5.
NOTE
Interpose a film of Single-component polyurethane
sealant “POLIBOND” manufactured by SARATOGA
or other equivalent product between the faying
surfaces of the installing parts and the fuselage skin,
then carry out the installation.
47. Get access to the bottom side of the fuselage frame No.6 and remove the rivets attaching the
skin to the fuselage frame No.6, where the Tow Hook Glider Welded Assembly p/n 8393-401
(item 1) has to be installed.
48. Clean all reworked surfaces with Methyl-Ethyl-Ketone or equivalent cleaning solvent; treat
them with Alodine 1200 (MIL-C-5541) and then with Epoxy Primer (MIL-PRF-23377).
49. Treat the holes previously used for mooring hook installation to fuselage frame No.6, with
Alodine 1200 (MIL-C-5541) and then with Epoxy Primer (MIL-PRF-23377), except the 2 (two)
holes to be used for following tow bar installation.
50. Raise the Tow Hook Glider Welded Assembly p/n 8393-401 (item 1) and lock it temporarily in
place.
51. Copy the attaching holes from the fuselage to the Tow Hook Glider Welded Assembly.
52. Remove the Tow Hook Glider Welded Assembly and drill to Ø4.82mm diameter hole, at the
location previously marked.
53. Deburr all the holes and clean all reworked surfaces with Methyl-Ethyl-Ketone or equivalent
cleaning solvent; treat them with Alodine 1200 (MIL-C-5541) and then with Epoxy Primer
(MIL-PRF-23377).
54. Install the Tow Hook Glider Welded Assembly p/n 8393-401 (item 1) to the fuselage frames
No.5 and 6, using bolts p/n AN3-5A, washers p/n NAS1149F0332P and nuts p/n MS21042-3.
Torque the nuts to [0.48÷0.52] kgm.

Vulcanair S.p.A. Service Bulletin No. VA-03 Rev.1
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Rev.1 dated 08 January 2019
Page 10 of 19
NOTE
During installation, impregnate the shank of the
bolts with a film of corrosion inhibitive compound
Mastinox D40 (Specification MIL-PRF-8116C), or
equivalent.
55. On workbench, referring to DWG R.0550, put in place the Bracket Quick Cam p/n 8395-016 to
the top tail fairing previously removed from the aircraft.
56. Using the Bracket Quick Cam as a drilling mask, copy the holes from the Bracket Quick Cam to
the top tail fairing.
57. Remove the Bracket Quick Cam and drill the top tail fairing to Ø3.5mm diameter holes.
58. Referring to DWG R.0550, drill to Ø14mm diameter hole the top tail faring to provide passage
of Cam W.H. and install the grommet p/n NOR7.219-3.
59. The Quick Cam p/n NV7.003-189A is provided with a mounting plate. Disconnect the Quick
Cam from mounting plate and put in place the cam mounting plate on the Support Quick Cam
p/n 8395-017 and copy the holes from the cam mounting plate to the Support Quick Cam p/n
8395-017.
60. Remove the cam mounting plate from the Support Quick Cam and drill to Ø2.5mm diameter 4
(four) places holes on the Support Quick Cam p/n 8395-017.
61. Referring to DWG R.0550, install 3 (three) anchor nuts p/n NOR9.183-1A to the Support Quick
Cam p/n 8395-017 using rivets p/n NAS1097AD3-3.
62. Install the cam mounting plate to the Support Quick Cam p/n 8395-017 by using blind rivets p/n
CCR264SS-3-02.
63. Install the Support Quick Cam p/n 8395-017 to the Bracket Quick Cam p/n 8395-016 by using
screws p/n MS35206-227.
64. Install the assy, composed by supports p/n 8395-016, p/n 8395-017 and quick cam mounting
plate, to the top tail fairing, by using screws p/n MS35206-227 and nuts p/n MS21083N06.
65. Referring to DWG R.0550, drill to Ø3.2mm diameter hole the top tail fairing and install the tie
mount p/n NV7.003-171A using rivet p/n 1661-0410 and washer p/n NAS1149FN632P.
66. Install the Quick Cam p/n NV7.003-189A to its mounting support and route its wiring harness
through the Ø14mm diameter hole previously drilled to the tail fairing (the Video cable
included in the Quick Cam kit, with two yellow jacks, is not to be used).
67. Referring to DWG R.0550, drill to Ø3.2mm diameter hole the fin at the rear spar.
68. Deburr the hole and clean all reworked surfaces with Methyl-Ethyl-Ketone or equivalent
cleaning solvent; treat them with Alodine 1200 (MIL-C-5541) and then with Epoxy Primer
(MIL-PRF-23377).
69. Referring to DWG R.0550, install the tie mount p/n NV7.003-171A (item 33) using rivet p/n
1661-0410 and washer p/n NAS1149FN632P.

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70. Get access to the fin front spar, if not already done, by removing the fin nose rib No.0, and
referring to DWG R.0550, drill the fin front spar to Ø3.2mm diameter hole.
71. Deburr all the holes and clean all reworked surfaces with Methyl-Ethyl-Ketone or equivalent
cleaning solvent; treat them with Alodine 1200 (MIL-C-5541) and then with Epoxy Primer
(MIL-PRF-23377).
72. Referring to DWG R.0550, install the tie mount p/n NV7.003-171A by using the rivet p/n 1661-
0410 and washer p/n NAS1149FN632P.
73. Referring to DWG R.0550, route the cam wiring harness p/n 8391-060 (item 34) through the
fin, fixing its position to the tie mount, previously installed, by using the tie wrap p/n
NOR7.701-1E.
74. Connect the CAM PWR JACK belonging to wiring harness p/n 8391-060, to the red colored
jack. Connect the CAM VIDEO JACK belonging to wiring harness p/n 8391-060, to the yellow
colored jack.
75. Route the cam wiring harness p/n 8391-060 throughout the fuselage up to the rear side of the
instrument panel, fixing it with the existing wiring harness running along the aircraft.
76. Referring to DWG R.0550, install the cam switch (provided with Cam Switch Wiring Harness
p/n 8391-061, item 55 of Kit SB_VA-03/A, item 56 of Kit SB_VA-03/B) to the instrument
panel in the position labelled “CAM”.
77. For V1.0 aircraft up to s/n 1019, referring to DWG R.0550, install the circuit breaker in the
position labelled “CAM”, and connect the cable P152A24 belonging to wiring harness p/n
8391-061 Rev.A to the CAM circuit breaker.
78. For V1.0 aircraft from s/n 1020 onwards, referring to DWG R.0550, install the fuse holder p/n
NV7.003-177A, and the fuse p/n NV7.003-177B-10, in the position labelled “CAM 1A”on the
bottom side of the breaker panel, and connect the cable P152A24 belonging to wiring harness
p/n 8391-061 Rev.B to the CAM fuse.
79. Connect the cable P153A24N belonging to wiring harness p/n 8391-061 to the nearest airframe
ground point.
80. Insert terminal belonging to cable T29B24SH into the existing connector J36 (located behind
the instrument panel), in accordance with the EWD p/n 8391-040 (inserted into DWG R.0550).
81. Connect wiring harness p/n 8391-060 to wiring harness p/n 8391-061 through connectors
J40/P40.
82. Ensure that wiring harness p/n 8391-060 and 8391-061 are properly routed and fixed.
83. Ensure that all the electrical connections have been properly carried out in accordance with
EWD p/n 8391-040 and 8391-041 (inserted into DWG R.0550).
84. Put in place the tail fairing, comprehensive of Quick Cam, and connect the cam wiring harness
p/n 8391-060 (item 34) to the quick cam wiring harness through the splices PWR CAM and
GND CAM. Re-connect the rear fuselage position light, as previously.
85. Install the tail fairing to the fuselage rear cone, as previously. Interpose a film of single-
component polyurethane sealant “POLIBOND” manufactured by SARATOGA, or other
equivalent product, during installation.

Vulcanair S.p.A. Service Bulletin No. VA-03 Rev.1
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Rev.1 dated 08 January 2019
Page 12 of 19
86. Route the Rear Cable Assy p/n 8393-409 (item 9) throughout the Tow Hook Glider Welded
Assembly p/n 8393-401, leaving the concerning terminal out of the tow bar for subsequent
installation to the Hook Support Welded Assembly p/n 8393-403 (item 2).
87. Route the Rear Cable Assy p/n 8393-409 (item 9) through the bracket previously installed in
correspondence of the fuselage frame No.3; install the grommet p/n MS35489-4 to the bracket
hole before routing the cable.
88. Install the Front Cable Assy p/n 8393-408 (item 11) to the Cable Support Welded Assy p/n
8393-405 (item 15, previously installed to the fuselage ventral skin), using screw p/n AN24-
11A, washer p/n NAS1149F0432P and nut MS21083N4. Torque the nut to [0.86÷0.94] kgm.
89. Route the Front Cable Assy p/n 8393-408 (item 11) through the bracket previously installed in
correspondence of the fuselage frame No.1; install the grommet p/n MS35489-4 to the bracket
hole before routing the cable.
90. Temporarily connect the front with the rear cables (respectively p/n 8393-408 and p/n 8393-
409) using the turnbuckle p/n MS21251-5S.
91. On workbench, drill the Hook Support Welded Assembly p/n 8393-403 (item 2) to Ø6.35H8
where the rear cable assy p/n 8393-409 is to be installed.
92. Put in place the Hook Support Welded Assembly p/n 8393-403 (item 2) and install the Rear
Cable Assy p/n 8393-409 (item 9) using the bolt p/n AN4-14A, the washer p/n
NAS1149F0432P and the nut p/n MS21083N4. Torque the nut to [0.86÷0.94] kgm.
93. On workbench, referring to DWG R.0550, carry out the cut-out on the access panel p/n 5207-
003, previously removed from the ventral side of fuselage rear cone.
94. Put in place the access panel p/n 5207-003 between the fuselage frames No.4 and 5, and install
the clamp p/n MS21919WDG5 at the afterward attaching screw.
95. Take the Bowden Cable Assy p/n 8395-401 (item 27), mark the external sleeve at the side
where the eye-end terminal is installed, and pull out the inner solid wire from the external
sleeve.
96. Accommodate the Bowden external sleeve in the fuselage rear cone, and then route the side
previously marked through the access panel cut-out, the clamp and throughout the Tow Hook
Glider Welded Assy.
97. Route the Bowden inner solid wire in the Bowden housing welded on the Hook Support Welded
Assembly p/n 8393-403 (item 2) and then push-in the Bowden inner solid wire throughout the
external sleeve, so to restore Bowden cable assy. Add grease, as required.
98. Fit the Bowden external sleeve in the Bowden housing welded on the Hook Support Welded
Assembly (item 2).
99. Get access onboard fuselage rear cone and fix the Bowden cable to the concerned bracket on the
fuselage frame No.4 using the clamp p/n MS21919WDG5, the spacer p/n 2.2539-6 and the bolt
p/n AN3-12A.
100. Fix the Bowden cable to the LH stringer between the fuselage frames No.3 and 4 at the hole
previously drilled, using the clamp p/n MS21919WDG5, the bolt p/n AN3-3A, the washer p/n
NAS1149F0332P and the nut p/n MS21083N3.

Vulcanair S.p.A. Service Bulletin No. VA-03 Rev.1
First issue dated 09 October 2017
Rev.1 dated 08 January 2019
Page 13 of 19
101. Referring to DWG R.0550, route the Bowden cable through the existing cut-out on the fuselage
frame No.3 up to the stringer between the fuselage frames No.2 and 3.
102. Fix the Bowden cable to the LH stringer between the fuselage frames No.2 and 3 at the hole
previously drilled, using the clamp p/n MS21919WDG5, the spacer p/n 2.2539-5, the bolt p/n
AN3-6A, the washer p/n NAS1149F0332P and the nut p/n MS21083N3.
103. Fix the Bowden cable to the concerned bracket on the fuselage frame No.2 using the clamp p/n
MS21919WDG5, the spacer p/n 2.2539-6 and the bolt p/n AN3-12A.
104. Referring to DWG R.0550, route the Bowden cable through the lightning holes of the fuselage
frames No.2 and 1.
105. Route the Bowden cable through the LH side of the fuselage up to the bracket previously
installed on the fuselage frame No.1.
106. Fix the Bowden cable to the concerned bracket on the fuselage frame No.1 using the clamp p/n
MS21919WDG5, the spacer p/n 2.2539-6 and the bolt p/n AN3-12A.
107. Fit the Bowden inner solid wire in the special bolt hole of Bowden Support Welded Assy p/n
8393-407 (item 26) previously installed to the fuselage truss near the pilot entrance door. Trim
the Bowden external sleeve as required. Pull the Bowden inner solid wire up to the lever assy.
108. Put in place the Tow Release p/n NV7.003-247A (item 19) on the Hook Support Welded Assy
p/n 8393-403 (item 2), let the Bowden inner solid wire passing in the pulley groove, and install
the Bowden cable eye-end terminal to the concerning lever, of Tow Release p/n NV7.003-
247A, using the bolt p/n AN3-5A, the washer p/n NAS1149F0332P and the nut p/n MS21042-
3. Torque the nut to [0.48÷0.52] kgm. Keep the Tow Release lever in neutral position.
109. Referring to DWG R.0550, install the Tow Release p/n NV7.003-247A (item 19) to the Hook
Support Welded Assy p/n 8393-403 (item 2) using the bolt p/n AN4-14A, the washer p/n
NAS1149F0432P and the nut p/n MS21083N4. Torque the nuts to [0.86÷0.94] kgm.
110. Install definitively the Hook Support Welded Assy p/n 8393-403 (item 2) to the Tow Hook
Glider Welded Assembly (item 1) by tightening the turnbuckle (item 10) connecting aft and fwd
cables to 45.36±1.80 kg (100±4 lb) of tension, then install securing clips p/n MS21256-1.
NOTE
Ensure that the aft cable is in the pulley groove.
111. Referring to DWG R.0550, put the cabin lever in the neutral position.
112. Referring to DWG R.0550, fit the special bolt p/n 5429-019 (item 29) in the lever assy and then
install the nut p/n AN316-3R, and washer p/n NAS1149F0332P; fit the Bowden inner solid wire
in the special bolt and then complete the installation with the washer p/n NAS1149F0332P and
the nut p/n MS21083N3. Torque the nut to [0.48÷0.52] kgm. Bend the Bowden inner solid wire
and trim, as required, during the installation.
113. On workbench, cut out the floor panel p/n 5750-001 in accordance with DWG R.0555.
114. Apply reference red marks on all the couplings.
115. Reinstall the access panel at the bottom side of fuselage rear cone.

Vulcanair S.p.A. Service Bulletin No. VA-03 Rev.1
First issue dated 09 October 2017
Rev.1 dated 08 January 2019
Page 14 of 19
116. Reinstall the fin rib nose No.0 p/n 5141-401 to the fin leading edge, as previously.
117. Reinstall the fairing at the fin forward base, as previously. Interpose a film of single-component
polyurethane sealant “POLIBOND” manufactured by SARATOGA, or other equivalent
product, during installation.
118. Reinstall all the cabin floor panels, as previously.
119. Reinstall the inspection cover and the panel at the fuselage frame No.2, in the baggage
compartment area, as previously.
120. Reinstall the moquette, the bench seat, the pilot and co-pilot seats.
121. Touch up all the external surfaces with finish polyurethane paint as per the existing livery of the
aircraft.
122. Proceed with the following Part C.
Part C - Restoring of aircraft’s airworthiness
1. Check the release mechanism, as following:
a. Attach a rope to the tow hook of Tow Release p/n NV7.003-247 (item 19).
b. Pull the rope with a reasonable force and allow an operator in the cabin to activate the
release.
c. Check that the rope is released successfully.
WARNING
The following steps can be performed only by a
Garmin Dealer Resource Center for Garmin
Authorized Service Centers.
WARNING
This work procedure requires the Unlock Loader
Card Garmin p/n 010-00769-60, available only on
the Garmin Dealer Resource Center for Garmin
Authorized Service Centers.
NOTE
It is required the Video Enablement Card Garmin
p/n 010-00769-61 in order to enable Garmin G500
MFD to display external video from Quick Cam.
2. Power supply the aircraft with an External Power Unit.
3. Push-in the CAM circuit breaker (valid only up to s/n 1019).
4. Pull-out the PFD circuit breaker.
5. Insert the Video Enablement SD Card p/n 010-00769-61 in the upper slot of PFD.

Vulcanair S.p.A. Service Bulletin No. VA-03 Rev.1
First issue dated 09 October 2017
Rev.1 dated 08 January 2019
Page 15 of 19
6. Insert the Installer Unlock Card p/n 010-00769-60 in the lower slot of PFD.
7. Keeping pushed the ENT softkey of PFD, push-in the PFD circuit breaker.
8. Garmin System will turn on in configuration mode. Wait few seconds.
9. By operating with the larger FMS KNOB on MFD, select the page SYS GROUP and press
ENT.
10. By operating with the smaller FMS KNOB on MFD, select the page FEATURE
CONFIGURATION and press ENT.
11. Select and enable the External Video feature.
12. Press ENT and check that “ENABLED” is shown in the ACTIVE column near “External
Video”.
13. Pull-out PFD breaker.
14. Wait few seconds, then push-in the PFD circuit breaker and set the aircraft Master Switch to ON.
15. Garmin System will turn on in normal mode. Wait few seconds.
16. Turn the larger FMS KNOB on MFD to the Aux page group. The External Video page is the
first page in the Aux page group.
17. Check that Quick Cam video is shown.
NOTE
Refer to the latest revision of Garmin G500 Pilot’s
Guide p/n 190-01102-02 for additional information
about zooming, panning and external video setups.
18. Tag and store in a reserved area the mooring hook removed from the aircraft.
19. Update the Aircraft Flight Manual at the latest revision.
20. Record compliance with this Service Bulletin in the Aircraft Log-Book.

Vulcanair S.p.A. Service Bulletin No. VA-03 Rev.1
First issue dated 09 October 2017
Rev.1 dated 08 January 2019
Page 16 of 19
3. MATERIALS REQUIRED FOR THE MODIFICATION
Kit SB_VA-03/A
(applicable to V1.0 aircraft up to s/n 1019)
ITEM
P/N
DESCRIPTION
Q.TY
1
8393-401
TOW HOOK GLIDER WELDED
ASSEMBLY
1
2
8393-403
HOOK SUPPORT WELDED ASSEMBLY
1
3
AN4-14A
BOLT
3
4
NAS1149F0432P
WASHER
8
5
MS21083N4
NUT
8
6
AN3-5A
BOLT
5
7
NAS1149F0332P
WASHER
16
8
MS21042-3
NUT
11
9
8393-409
REAR CABLE ASSY
1
10
MS21251-5S
TURNBUCKLE
1
11
8393-408
FRONT CABLE ASSY
1
12
MS21256-1
CLIP
2
13
8395-015
BRACKET
2
14
MS35489-4
GROMMET
REF
15
8393-405
CABLE SUPPORT WELDED ASSY
1
16
8395-004
CLAMP
1
17
AN23-10A
SCREW
6
18
MS21266-1N
PLASTIC GROMMET
500mm
19
NV7.003-247A
TOW RELEASE
1
20
8395-005
SHIM
1
21
AN24-11A
SCREW
1
22
8393-024
SPACER
1
23
NAS1149FN632P
WASHER
2
24
AN4-12A
BOLT
3
25
NOR7.701-1E
TIE WRAP
3
26
8393-407
BOWDEN SUPPORT WELDED ASSY
1
27
8395-401
CABLE ASSEMBLY -BOWDEN
1
28
8393-402
LEVER ASSY
1
29
5429-019
SPECIAL BOLT
1
30
AN316-3R
NUT
1
31
MS21083N3
NUT
3
32
MS20426AD4-5
RIVET - CSK
1
33
NV7.003-171A
TIE MOUNT
3
34
8391-060
CAM WIRING HARNESS
1
35
8393-406
LEVER SUPPORT WELDED ASSY
1
36
AN4-7A
BOLT
1
37
CCR264SS-3-02
BLIND RIVET
4

Vulcanair S.p.A. Service Bulletin No. VA-03 Rev.1
First issue dated 09 October 2017
Rev.1 dated 08 January 2019
Page 17 of 19
38
NOR9.183-1A
ANCHOR NUT (K2000-06)
3
39
8395-010
SPACER
1
40
MS21919WDG5
CLAMP
5
41
NOR7.077-1
BRACKET ASSY
3
42
2.2539-6
SPACER
3
43
2.2539-5
SPACER
1
44
AN3-12A
BOLT
2
45
1661-0410
BLIND RIVET
7
46
AN3-3A
BOLT
1
47
NAS1097AD3-3
RIVET
6
48
AN3-6A
BOLT
1
49
8395-002
LH STRINGER
1
50
8395-001
RH STRINGER
1
51
8395-003
DOUBLER
1
52
4801-0409
BLIND RIVET AVDEL
2
53
4801-0407
BLIND RIVET AVDEL
50
54
MS3320-1
BREAKER 1A
1
55
8391-061 REV.A
CAM SWITCH WIRING HARNESS
1
56
8395-016
BRACKET –QUICK CAM
1
57
NV7.003-189A
QUICK CAM
1
58
8395-017
SUPPORT –QUICK CAM
1
59
MS35206-227
SCREW
7
60
MS21083N06
NUT
4
61
NOR7.219-3
GROMMET
1
62
010-00769-61
GARMIN SD CARD
1
63
DWG R.0550
GLIDER TOW HOOK INSTALLATION
1

Vulcanair S.p.A. Service Bulletin No. VA-03 Rev.1
First issue dated 09 October 2017
Rev.1 dated 08 January 2019
Page 18 of 19
Kit SB_VA-03/B
(applicable to V1.0 aircraft from s/n 1020 onwards)
ITEM
P/N
DESCRIPTION
Q.TY
1
8393-401
TOW HOOK GLIDER WELDED
ASSEMBLY
1
2
8393-403
HOOK SUPPORT WELDED ASSEMBLY
1
3
AN4-14A
BOLT
3
4
NAS1149F0432P
WASHER
8
5
MS21083N4
NUT
8
6
AN3-5A
BOLT
5
7
NAS1149F0332P
WASHER
16
8
MS21042-3
NUT
11
9
8393-409
REAR CABLE ASSY
1
10
MS21251-5S
TURNBUCKLE
1
11
8393-408
FRONT CABLE ASSY
1
12
MS21256-1
CLIP
2
13
8395-015
BRACKET
2
14
MS35489-4
GROMMET
REF
15
8393-405
CABLE SUPPORT WELDED ASSY
1
16
8395-004
CLAMP
1
17
AN23-10A
SCREW
6
18
MS21266-1N
PLASTIC GROMMET
500mm
19
NV7.003-247A
TOW RELEASE
1
20
8395-005
SHIM
1
21
AN24-11A
SCREW
1
22
8393-024
SPACER
1
23
NAS1149FN632P
WASHER
2
24
AN4-12A
BOLT
3
25
NOR7.701-1E
TIE WRAP
3
26
8393-407
BOWDEN SUPPORT WELDED ASSY
1
27
8395-401
CABLE ASSEMBLY -BOWDEN
1
28
8393-402
LEVER ASSY
1
29
5429-019
SPECIAL BOLT
1
30
AN316-3R
NUT
1
31
MS21083N3
NUT
3
32
MS20426AD4-5
RIVET - CSK
1
33
NV7.003-171A
TIE MOUNT
3
34
8391-060
CAM WIRING HARNESS
1
35
8393-406
LEVER SUPPORT WELDED ASSY
1
36
AN4-7A
BOLT
1
37
CCR264SS-3-02
BLIND RIVET
4
38
NOR9.183-1A
ANCHOR NUT (K2000-06)
3
39
8395-010
SPACER
1
40
MS21919WDG5
CLAMP
5

Vulcanair S.p.A. Service Bulletin No. VA-03 Rev.1
First issue dated 09 October 2017
Rev.1 dated 08 January 2019
Page 19 of 19
41
NOR7.077-1
BRACKET ASSY
3
42
2.2539-6
SPACER
3
43
2.2539-5
SPACER
1
44
AN3-12A
BOLT
2
45
1661-0410
BLIND RIVET
7
46
AN3-3A
BOLT
1
47
NAS1097AD3-3
RIVET
6
48
AN3-6A
BOLT
1
49
8395-002
LH STRINGER
1
50
8395-001
RH STRINGER
1
51
8395-003
DOUBLER
1
52
4801-0409
BLIND RIVET AVDEL
2
53
4801-0407
BLIND RIVET AVDEL
50
54
NV7.003-177B-10
FUSE 1A
1
55
NV7.003-177A
FUSE HOLDER
1
56
8391-061 REV.B
CAM SWITCH WIRING HARNESS
1
57
8395-016
BRACKET –QUICK CAM
1
58
NV7.003-189A
QUICK CAM
1
59
8395-017
SUPPORT –QUICK CAM
1
60
MS35206-227
SCREW
7
61
MS21083N06
NUT
4
62
NOR7.219-3
GROMMET
1
63
010-00769-61
GARMIN SD CARD
1
64
DWG R.0550
GLIDER TOW HOOK INSTALLATION
1
Commercially available materials required but not included in the Kit:
ITEM
DESCRIPTION
Q.TY
1
POLIBOND polyurethane sealant manufactured by “SARATOGA”
or equivalent
AR
2
SIKAFLEX-221 sealing compound or equivalent
AR
3
MASTINOX D40
AR
4
Methyl-Ethyl-Ketone or equivalent cleaning solvent
AR
5
Alodine 1200 (MIL-C-5541)
AR
6
Epoxy Primer (MIL-PRF-23377)
AR
7
Polyurethane paint as per aircraft livery
AR