Vulcanair V1 series Reference manual

First issue dated 30 April 2018
Rev.2 dated 30 July 2018
Page 1 of 48
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-02 Rev.2
(Supersedes the previous issue approved on 17 July 2018)
Design Organisation Approval No. AS-SB/18/018 dated 03 August 2018
INFORMATION
SUBJECT: PROCEDURE FOR AIRCRAFT RE-ASSEMBLING AND TESTING
1. GENERAL
1.1 AIRCRAFT AFFECTED
Vulcanair V1.0 from s/n 1003 onwards.
1.2 PURPOSE
The purpose of this Service Bulletin is to supply information for aircraft re-assembling and
testing for the aircraft shipped inside a container, once arrived to the final destination.
1.3 DESCRIPTION
The airplane, once arrived disassembled in container at the final destination, must be re-
assembled and tested (on-ground and in-flight) by a certified Maintenance Organisation of the
Importing State in order to release to service the airplane, in accordance with the procedures
laid out in paragraph 2 hereunder.
No change is needed about Operating Limitations, Emergency Procedures, Normal
Procedures, Performance and Weight and Balance Data.
No additional maintenance tasks are required when the aircraft embodies this Service
Bulletin, therefore the current aircraft maintenance program remains unchanged.

Vulcanair S.p.A. Service Bulletin No. VA-02 Rev.2
First issue dated 30 April 2018
Rev.2 dated 30 July 2018
Page 2 of 48
The instructions laid out in the paragraph 2 hereunder, are divided into seven Parts as
follows:
−Part A: DISASSEMBLED PARTS DISEMBARKING OPERATIONS
−Part B: HORIZONTAL EMPENNAGES INSTALLATION
−Part C: WING AND MOVABLE CONTROL SURFACES INSTALLATION
--- deleted ---
−Part D: PROPELLER INSTALLATION
−Part E: ON-GROUND TESTS
−Part F: IN-FLIGHT TESTS
1.4 COMPLIANCE
At owner’s discretion.
1.5 MANHOURS
The time necessaryfor the application of this Service Bulletin is estimated as being 30 man-hours.
1.6 SPECIAL TOOLS
Not applicable.
1.7 VARIATION IN WEIGHT & BALANCE
Not applicable.
1.8 ELECTRICAL SYSTEM LOAD
Not applicable.
1.9 REFERENCE DOCUMENTS
•Lycoming pertinent technical documentation
•Hartzell pertinent technical documentation
•Garmin pertinent technical documentation
•Aircraft Maintenance Manual AMM10.702-5
•Aircraft Flight Manual AFM10.701-7
•Parts Catalogue IPC10.703-7
1.10 PUBBLICATIONS AFFECTED
None.
1.11 MODIFICATION TO BE CARRIED OUT BY
Vulcanair Part 145 or other Approved Maintenance Organisation recognised also as
Garmin Dealer Resource Center for Garmin Authorized Service Centers.

Vulcanair S.p.A. Service Bulletin No. VA-02 Rev.2
First issue dated 30 April 2018
Rev.2 dated 30 July 2018
Page 3 of 48
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
SAFETY PRECAUTIONS
In addition to local requirements or where local
regulations are not specified, the following safety
precautions are recommended during fuelling and
de-fuelling activities:
1) Place the aircraft in a designated fuelling or
de-fuelling area (external area).
2) Ground the aircraft using designated
grounding cables.
3) Ground and bond all fuelling and de-fuelling
equipment to the aircraft. As bonding point
use the muffler tube protruding from the
engine cowlings.
4) Position a suitable firefighting equipment
near the aircraft. It must be readily available.
5) Use suitable plugs or caps to seal all opened
fuel lines.
6) Use only hermetically sealed lights, if an
artificial lighting is necessary.
7) Do not operate any avionics or electrical
equipment on the aircraft (all switches OFF).
8) Do not allow fire, sparks or heat near fuel.
Fuel burns violently and can cause injury to
persons and damage to the aircraft.
9) Do not wear nylon or synthetic fabrics,
and/or shoes with metal heel taps, to avoid
generating static electricity or causing sparks.
10) Do not smoke or use a naked flame in
proximity of the aircraft.
11) Do not get fuel on your skin. Fuel can cause
skin disease.
12) Fuelling and de-fuelling operations with
person on board are prohibited.

Vulcanair S.p.A. Service Bulletin No. VA-02 Rev.2
First issue dated 30 April 2018
Rev.2 dated 30 July 2018
Page 4 of 48
WARNING
Before performing any work in the propeller
areas, be sure that the magnetos and the master
switches are OFF, and that the mixture control
lever is in the IDLE CUT-OFF position, to avoid
bodily injury when the propeller is rotated during
installation.
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.
WARNING
Read the entire procedure and the latest
applicable revision of reference documents to
make sure you have a complete understanding of
the requirements.
WARNING
All the following procedures must be performed
by specific authorized personnel.
CAUTION
Always follow the manufacturer’s instructions and
safety precautions during application and usage of all
the substances called out in this work procedure.
NOTE
Refer, as applicable, to the Lycoming and/or Hartzell
pertinent technical documentation.
NOTE
The discarded materials and fluids used during the
maintenance activities should be disposed of in
accordance with applicable regulations.

Vulcanair S.p.A. Service Bulletin No. VA-02 Rev.2
First issue dated 30 April 2018
Rev.2 dated 30 July 2018
Page 5 of 48
Part A: DISASSEMBLED PARTS DISEMBARKING OPERATIONS
1) Perform an accurate visual inspection of the entrance door and external area of the container in
order to check its general condition and the possible presence of damages occurred on the
container during the shipment.
2) Verify the undamaged presence of all the security seals applied to the entrance door of the
container.
3) Gain access to the internal area of the container.
4) Get access to the aircraft cabin and identify the g-meter installed between the pilot and copilot
seats. Take note of the g-meter reading and transmit the load factor saved by the g-meter to
Vulcanair Customer Support by means of the online form at the address
http://support.vulcanair.com/ section “Support form” (a picture is appreciated): if g-meter
reading is less or equal than 4 (four), continue on performing this work instructions; if the
reading is greater than 4 (four), stop any kind of activities and wait for Vulcanair instructions.
5) Remove the g-meter together with its bracket and discard the bracket-to-aircraft attaching
screws.
6) Re-install the object holder attaching screws grouped in a bag next to the object holder.
7) Perform an accurate visual inspection of all the items inside the container in order to check
their general status and the possible evidence of damages occurred on the disassembled parts,
tools or security devices during the shipping (see Figure 1).
NOTE
Take care to extract opportunely the disassembled
parts out from the container.
8) Disengage the half-wings from the container, then carefully move them slowly forwards out of
the concerned container.
9) Disengage all the packing boxes from the container, then carefully move each of them slowly
forwards out of the container.
10) Disengage all embarked items from the container, then carefully move each of them slowly
forwards out of the container.
11) Carefully remove all the security devices used to assure all the aircraft disassembled parts and
tools to the container during the shipment.
12) Carefully remove all the protections and packaging used to avoid damages to the disassembled
parts.
13) Guarantee a correct disembarking of all aircraft disassembled parts arranged inside the
container.
14) Unmoor completely the aircraft fuselage from the container, maintaining it in the current
inclined position to permit its extraction.
15) Disengage the aft mooring hook from the container floor, then carefully move the aircraft
fuselage slowly forwards out of the container.
16) Handling the aircraft fuselage, install the NLG wheel in accordance with concerning
procedure laid out in the AMM and then lower the aircraft on its NLG wheel assembly.

Vulcanair S.p.A. Service Bulletin No. VA-02 Rev.2
First issue dated 30 April 2018
Rev.2 dated 30 July 2018
Page 6 of 48
WARNING
Assure that all the disassembled parts, previously
tagged as “EFFICIENT”, are still efficient after
the shipment (no damage found).
17) Place all the aircraft disassembled parts in a suitable working area for the operations to be
carried out.
18) Tow the aircraft fuselage on a compact and level surface.
19) Check that all electrical switches are in OFF position.
20) Maintain disconnected the battery cables and the external power unit.
21) Ground the aircraft using designated grounding cables.
22) Put in place a trestle under the aft mooring hook (tail of the airplane) in correspondence of the
fuselage frame No.6.
23) Proceed with the following Part B.
Figure 1 Parts predisposition inside the container

Vulcanair S.p.A. Service Bulletin No. VA-02 Rev.2
First issue dated 30 April 2018
Rev.2 dated 30 July 2018
Page 7 of 48
Part B: HORIZONTAL EMPENNAGES INSTALLATION
WARNING
Be careful not to damage both halves-stabilator
during their reinstallation.
NOTE
During re-assembling procedure apply MIL-PRF-
8116C (Mastinox D40, or equivalent) anticorrosive
compound to all bolt shanks.
NOTE
During re-assembling procedure install the safety
wires as applicable, using stainless steel wires with
0.8mm (0.03in) diameter.
NOTE
During re-assembling procedure install the ground
leads as applicable.
1) Refer to Figure 2 for horizontal empennages installation.
2) Gently withdraw from the container and from the concerned packing boxes, if not already
done, all the items necessary to perform the horizontal empennages re-installation. Discard
and replace the damaged items, as appropriate.
3) Ascertain that the fuselage is solidly positioned.
4) Carefully raise each half-stabilator and push it onto the torque tube, checking a clearance of
approximately 12mm to 3mm (0.47in to 0.12in) between the root chord (set in the horizontal
attitude) and the fuselage.
5) Install the attaching bolts, washers and nuts through stabilator, tie-clamp and torque tube,
without tightening the nuts (use new provided attaching items).
6) Connect half-stabilators to each other by means of the bolt to be installed coupling link-plates
at the rear spar with the plate for tail surface gust lock. Torque to 0.47÷0.52 Kgm
(40.79÷45.13 lb.in).
7) Check for a full engagement of tie-clamps on the external diameter of the torque tube and then
torque the nuts to 2.565÷2.835 Kgm (222.63÷246.07 lb.in).
8) Check for absence of horizontal and vertical backlash of the stabilator: for this check, shake
lightly each half-stabilator longitudinally, up and down and along its hinge bearings axis.
WARNING
No stabilator backlash is permissible.
9) Connect the trim tab halves to each other by means of bolt, washer and nut, interposing the
spacer. Torque the nuts to 0.47÷0.52 Kgm (40.79÷45.13 lb.in).
10) Connect the 2 (two) trim tab control rods to trim tab brackets by means of bolts, washers and
nuts, interposing, if necessary, washer p/n NAS1149F0332P or NAS1149F0316P as shims
between bracket and control rod head. Torque to 0.5±5% kgm.
11) Check that trim tab control rods are set to proper length ensuring that both ball joint ends have
the same number of engaged threads.

Vulcanair S.p.A. Service Bulletin No. VA-02 Rev.2
First issue dated 30 April 2018
Rev.2 dated 30 July 2018
Page 8 of 48
12) Ascertain that all stabilator surfaces operate freely.
13) Apply reference red marks on all the coupling bolts.
14) Lock temporarily the stabilator surfaces with suitable locking device p/n 8903-401.
15) Proceed with the following Part C.
Figure 2 Stabilator installation

Vulcanair S.p.A. Service Bulletin No. VA-02 Rev.2
First issue dated 30 April 2018
Rev.2 dated 30 July 2018
Page 9 of 48
Part C: WING AND MOVABLE CONTROL SURFACES INSTALLATION
NOTE
The following is applicable to both LH and RH
wing.
NOTE
During re-assembling procedure install the safety
wires as applicable, using stainless steel wires with
0.8mm (0.03in) diameter.
NOTE
During re-assembling procedure install the ground
leads as applicable.
1) Refer to Figure 3 for LH/RH wing installation to the fuselage, and to Figure 4 for wing struts
installation.
Figure 3 Wing installation

Vulcanair S.p.A. Service Bulletin No. VA-02 Rev.2
First issue dated 30 April 2018
Rev.2 dated 30 July 2018
Page 10 of 48
Figure 4 Wing struts installation
2) Gently withdraw from the container and from the concerned packing boxes, if not already
done, all the items necessary to perform the wing and movable control surfaces re-installation.
Discard and replace the damaged items, as appropriate.
3) Ascertain that the fuselage is solidly positioned.
WARNING
Be careful not to damage the wing and the other
components therein installed during the wing re-
installation.
4) Raise the LH/RH wing to allow its installation on the fuselage.
5) Place the LH/RH wing near the fuselage.
6) Put in place the trestle with height adjustable padded cradles under the LH/ RH wing.
7) Open the most inboard inspection hatches at the bottom of wing leading edge.
8) Unfix the fresh cabin air hoses from the fuselage, by removing the tie wraps.
9) Insert the air flexible hoses in the lightning hole of the leading edge rib (see Figure 5).