Bell 206B IBF Instructions for Continued Airworthiness

Use or disclosure of this material is subject DCI Bell 206B IBF Instructions for Continued Airworthiness to the restrictions on the title page vii THIS PAGE INTENTIONALLY LEFT BLANK Donaldson Company, Inc. AFS-BH206B-IBF-KIT-ICA, Revision A Proprietary Information Use or disclosure of this material is subject DCI Bell 206B IBF Instructions for Continued Airworthiness to the restrictions on the title page viii INSTRUCTIONS FOR CONTINUED AIRWORTHINESS For the Donaldson Company Engine Inlet Barrier Filter System Installed on the Bell Helicopter Textron Canada Model 206B series Helicopters TABLE OF CONTENTS ICA ATA Chapter Title Chapter 1 Introduction 1 2 Airworthiness Limitations 4 3 Inspection Requirements and Overhaul 5 4 Access Panels 6 5 Storage 10 6 Placards, Data Plates and Markings 11 7 Servicing 12 8 Troubleshooting and Maintenance 22 ICA Appendix Title A Illustrated Parts Breakdown Donaldson Company, Inc. AFS-BH206B-IBF-KIT-ICA, Revision A Proprietary Information Use or disclosure of this material is subject DCI Bell 206B IBF Instructions for Continued Airworthiness to the restrictions on the title page ix THIS PAGE INTENTIONALLY LEFT BLANK Donaldson Company, Inc. AFS-BH206B-IBF-KIT-ICA, Revision A Proprietary Information Use or disclosure of this material is subject DCI Bell 206B IBF Instructions for Continued Airworthiness to the restrictions on the title page 1-1 ICA CHAPTER 1 – INTRODUCTION TABLE OF CONTENTS Paragraph Page Number Title Number 1-1. SCOPE OF THIS MANUAL 1-2 1-2. USE OF THIS MANUAL 1-2 1-3. DEFINITIONS / TERMINOLOGY 1-2 1-4. ACRONYMNS 1-4 1-5. WARNINGS, CAUTIONS, AND NOTES 1-5 1-6. UNITS OF MEASURE 1-5 1-7. REFERENCE PUBLICATIONS 1-5 1-8. LIST OF APPLICABLE PUBLICATIONS 1-5 1-9. DISTRIBUTION OF CHANGES 1-6 1-10. INDICATION OF CHANGES 1-6 1-11. SYSTEM DESCRIPTION AND OVERVIEW 1-6 Figure Page Number Title Number 1-1. IBF SYSTEM AND ACCESS DOOR OPTION INSTALLATION 1-8 Donaldson Company, Inc. AFS-BH206B-IBF-KIT-ICA, Revision A Proprietary Information Use or disclosure of this material is subject DCI Bell 206B IBF Instructions for Continued Airworthiness to the restrictions on the title page 1-2 1-1. SCOPE OF THIS MANUAL These Instructions for Continued Airworthiness (ICA) provide the information required to do the maintenance and repair of the Donaldson Company, Inc. (DCI) Inlet Barrier Filter (IBF) system installation on the Bell Helicopter Textron Canada Limited (BHTCL) Model 206B series helicopters. The ICA should be used in conjunction with all pertinent BHTCL Model 206B series manuals and all publications listed in the List of Applicable Publications (LOAP). NOTE Thoroughly review and become familiar with the Appendix A – Illustrated Parts Breakdown section of this ICA before performing maintenance on the IBF system. 1-2. USE OF THIS MANUAL The instructions that are given in this manual and those that have been changed by revisions, bulletins and/or alerts issued by DCI, BHTCL or the Airworthiness Directives issued by the local Aviation Authority, shall be strictly followed. 1-3. DEFINITIONS / TERMINOLOGY Access door Allows access to the components mounted below the Bypass Floor Assembly. Actuator An electromechanical actuator used to open / close the bypass door. Air induction screen Screen installed in the engine inlet on baseline configuration aircraft in lieu of the EAPS or the IBF, to prevent engine foreign object damage. Air induction cowling This cowling houses the major kit components including the IBF filter assembly, adaptor frame, bypass floor assembly, associated wiring and, if elected the access door option as shown in Figure 1-1. Brownout A brownout condition is a zero visibility condition usually caused by hovering in a dusty environment. Bypass The bypass is an alternate air inlet used only when the main engine air inlet through the filter becomes clogged or blocked. Bypass door Door located in the Bypass Floor Assembly just aft of the filter that when opened by the actuator allows unfiltered air for the engine to be drawn from the aircraft transmission bay. Bypass floor assembly Floor is located just aft of the filter assembly and forward of the engine inlet/firewall that seals the bottom of the inlet plenum chamber. Donaldson Company, Inc. AFS-BH206B-IBF-KIT-ICA, Revision A Proprietary Information Use or disclosure of this material is subject DCI Bell 206B IBF Instructions for Continued Airworthiness to the restrictions on the title page 1-3 Mounted on the floor are the bypass door, actuator, filter maintenance aid, and differential pressure switch. Cockpit switch A toggle switch, labeled “IBF BYPASS”, is used to OPEN or CLOSE the bypass door. This switch is normally CLOSED and is toggled to the OPEN position only when the cockpit indicator, an amber caution “IBF FILTER” light on the aircraft caution/warning panel, illuminates. Cockpit indicator Cockpit indicator is an amber caution “IBF FILTER” light on the aircraft caution/warning panel that illuminates any time the differential pressure reaches or exceeds a preset limit. Differential pressure Drop in pressure across the filter assembly, which is measured by the differential pressure switch and the filter maintenance aid. Delta P switch Differential pressure switch. Filter Barrier type filter media made of multi-layers of cotton gauze saturated with specially formulated oil that forms a tack barrier that increases the capture efficiency of the filter. Filter assembly Filter media supported by pleated stainless steel screen on both sides and the filter assembly frame components around the perimeter of the filter media. Filter assembly frame Structure that frames, retains, and seals the outside edges of the filter media. Filter downstream side Clean side of the filter media (i.e. the side of the filter facing aft) Filter media A wet media consisting of a multi-layered cotton gauze saturated with specially formulated oil. Filter pleats Stainless steel screen is used to form the pleats and hold the filter media in place. Filter upstream side Dirty side of the filter media (i.e. the side facing forward into the air stream on which the dirt collects). Inches of water Unit of measure used for the differential pressure measured across the filter, as measured with a water manometer or similar apparatus. Oiling Process used to apply a uniform amount of oil on filter media. OML covers Outer mold line covers used to block off the hole left on the outer skin of the Air Induction Cowling when the EAPS exhaust duct is removed. Donaldson Company, Inc. AFS-BH206B-IBF-KIT-ICA, Revision A Proprietary Information Use or disclosure of this material is subject DCI Bell 206B IBF Instructions for Continued Airworthiness to the restrictions on the title page 1-4 On-condition Indicates that servicing of the filter is based on a Filter Maintenance Aid (FMA) indication in the area marked in “RED”, Power Assurance Check (PAC) results (where a failed PAC is the result of a dirty Filter Assembly), and / or any “IBF FILTER” light indication on the cockpit indicator. Plenum chamber Space between the filter assembly and the engine inlet / firewall (fore and aft, respectively), and between the Air Induction Cowling and bypass floor assembly (top and bottom, respectively). Service cycle Period starting when a filter is cleaned, oiled and placed into service and ending when the filter is removed for its next cleaning and oiling. 1-4. ACRONYMS 14CFR = Title 14 of the Code of Federal Regulations AFS = Aerospace Filtration Systems, Inc. ATA = Air Transport Association of America, Inc. BHTCL = Bell Helicopter Textron Canada Limited DCI = Donaldson Company, Inc EAPS = Engine Air Particle Separator FAR = Federal Aviation Regulation FMA = Filter Maintenance Aid FMS = Flight Manual Supplement FOD = Foreign Object Damage IBF = Inlet Barrier Filter ICA = Instructions for Continued Airworthiness IP = Installation Procedures IPB = Illustrated Parts Breakdown LOAP = List of Applicable Publications MGT = Measured Gas Temperature OAT = Outside Air Temperature OML = Outer Mold Line PAC = Power Assurance Check RFM = Rotorcraft Flight Manual SAE = Society of Automotive Engineers TCDS = Type Certificate Data Sheet TIS = Time in Service Donaldson Company, Inc. AFS-BH206B-IBF-KIT-ICA, Revision A Proprietary Information Use or disclosure of this material is subject DCI Bell 206B IBF Instructions for Continued Airworthiness to the restrictions on the title page 1-5 1-5. WARNINGS, CAUTIONS, AND NOTES Warning, cautions and notes are used throughout this manual to emphasize important and critical instructions. WARNING IF YOU DO NOT FOLLOW THE INSTRUCTIONS THAT ARE GIVEN IN A WARNING, PERSONAL INJURY CAN OCCUR. CAUTION IF YOU DO NOT FOLLOW THE INSTRUCTIONS THAT ARE GIVEN IN A CAUTION, YOU CAN CAUSE DAMAGE TO THE HELICOPTER OR TO THE COMPONENTS. NOTE A note includes supplemental data about the procedure, the practice, the condition, etc. for the maintenance task. 1-6. UNITS OF MEASURE U.S. Standard units of measure have been used in preparation of this manual. Typical units used in this manual include - inches of water measuring differential pressure, inch-pounds of torque, etc. 1-7. REFERENCE PUBLICATIONS Reserved for future use. 1-8. LIST OF APPLICABLE PUBLICATIONS Bell Helicopter Textron 206B Series Technical Publications FAA FAA Advisory Circular, AC 43.13-1B, Acceptable Methods, Techniques, and Practices – Aircraft Inspection and Repair Donaldson Company, Inc. AFS-BH206B-IBF-KIT-ICA, Revision A Proprietary Information Use or disclosure of this material is subject DCI Bell 206B IBF Instructions for Continued Airworthiness to the restrictions on the title page 1-6 1-9. DISTRIBUTION OF CHANGES Changes shall be distributed by posting them on the DCI website www.donaldsonaerospace- defense.com. The ICA may also be found on https://ShopDonaldson.com. NOTE This webpage should be checked prior to the performance of any maintenance actions on the IBF system to confirm possession of the latest FAA approved revision. If access to the internet is not possible, contact DCI at (636) 300-5200 for assistance. 1-10. INDICATION OF CHANGES All changes will be complete revisions with all pages marked with the latest revision letter. All changes since the last revision shall be marked with a black vertical bar in the left side of the page. 1-11. SYSTEM DESCRIPTION AND OVERVIEW a. The Bell 206B IBF systems are offered to operators in two available kits. DCI Kit No. 109000-101 that includes the Inlet Barrier Filter (IBF) system only and DCI Kit No. 10900-103 that includes the Inlet Barrier Filter (IBF) system and a quick access door modification. b. The IBF provides a pair of forward-facing barrier type filter assemblies just aft of the aircraft’s bifurcated engine air inlet system in the same location and in lieu of the Engine Air Particle Separator (EAPS) or Air Induction Screen. The IBF installation requires no structural modifications to the existing Air Induction Cowling except for the installation of additional structure and the optional access door. The access door has been added on the top side of the Air Induction Cowling to allow the operator quick access to the filter for servicing, which is especially helpful during extensive desert type operations. The IBF provides aircraft owner/operators a high performance engine air filtration option that significantly improve filtration efficiency over the EAPS. The IBF will increase the life of the engine through a dramatic reduction in erosion resulting from the substantial increase in filtration efficiency without degrading engine performance. The DCI IBF system provides dust separation efficiencies exceeding 99% for Society of Automotive Engineers (SAE) AC Coarse and AC Fine dust as defined in specification SAE J726, Air Cleaner Test Code. c. The IBF system does not interfere with any of the commercial items installed in the Bell 206B series production aircraft. The IBF is a complete system in which safety, functionality and serviceability were major considerations in the design process. The major kit components include the filter assembly, cockpit switch/indicator, engine wash tube assembly, bypass floor assembly (which includes the bypass door assembly, actuator, differential pressure switch, filter maintenance aid and wiring harness), and an optional access panel. Figure 1-1, located at the end of this chapter, provides an exploded view of the major kit components with the exception of the cockpit switch, indicator light and wiring harness. For a detailed illustration of all kit components, see the Appendix A – Illustrated Parts Breakdown. Donaldson Company, Inc. AFS-BH206B-IBF-KIT-ICA, Revision A Proprietary Information Use or disclosure of this material is subject DCI Bell 206B IBF Instructions for Continued Airworthiness to the restrictions on the title page 1-7 d. The major components making up the bypass system include the bypass door, actuator, wiring harness, cockpit switch, indicator light, and differential pressure switch. e. The IBF system provides a means of monitoring the condition of the filter both in-flight and on the ground, and a bypass capability should flow through the filter become restricted. In-flight, when the differential pressure is too high, which means the filter is becoming too dirty for the engine to operate efficiently; the indicator light will illuminate alerting the pilot. At this point, the IBF is operating at approximately the same inlet differential pressure normally experienced with the EAPS installed. Upon illumination of the “IBF FILTER” caution light, the pilot must closely monitor the engine and if engine degradation is evident place the cockpit toggle switch, labeled IBF BYPASS, in the OPEN position to activate the actuator and open the bypass door. The electromechanically actuated bypass door permits unfiltered air to enter the engine inlet plenum chamber should the filter media become obstructed - and can be opened or closed as required. On the ground, a Filter Maintenance Aid, mounted under the bypass floor assembly, displays the maximum differential pressure across the filter reached during the last flight. It is accessible only on the ground, providing the pilot or mechanic the ability to visually gauge the current condition of the filter. This gives the mechanic the ability to forecast the timing of the next service cycle. The Filter Maintenance Aid can be reset by depressing the yellow button marked “PUSH TO RESET” located on the end of the Filter Maintenance Aid (See Pictures 3-1 & 3-2). f. The design of the bypass system allows the ground crew to cycle the bypass door with power on the aircraft. The switch can be flipped up to actuate the bypass door open, and then flipped down to actuate it closed. Full functional verification of the bypass system including all electromechanical components and the filter maintenance aid is possible during routine maintenance (see Chapter 8). g. Removal of the filter assemblies for servicing is easily achieved by removal of seven fasteners. Six of the fasteners are accessible through the engine air inlets, and then there is a single fastener that is common to the two filter assemblies that is accessible either through the access door on the top side of the Air Induction Cowling or by removal of the cowling. The two filter assemblies can then be removed. h. The nozzle on the engine water wash tube assembly provides the equivalent engine wash capability as currently provided by similar nozzles mounted on the EAPS and Air Induction Screen installations. Donaldson Company, Inc. AFS-BH206B-IBF-KIT-ICA, Revision A Proprietary Information Use or disclosure of this material is subject DCI Bell 206B IBF Instructions for Continued Airworthiness to the restrictions on the title page 1-8 Figure 1-1. IBF System Installation ITEM NO. ITEM NAME 1 Air Induction Cowling 2 Filter Assembly RH 3 Filter Assembly LH 4 Frame and Floor Assembly 5 L/H Floor closeout 6 R/H Floor closeout 7 EAPS Exhaust Port Cover 8 Seal - Filter Donaldson Company, Inc. AFS-BH206B-IBF-KIT-ICA, Revision A Proprietary Information Use or disclosure of this material is subject DCI Bell 206B IBF Instructions for Continued Airworthiness to the restrictions on the title page 2-1 ICA CHAPTER 2 – AIRWORTHINESS LIMITATIONS TABLE OF CONTENTS Paragraph Page Number Title Number AIRWORTHINESS LIMITATIONS/FAA APPROVAL BLOCK 2-2 2-1. GENERAL 2-3 2-2. FILTER RETIREMENT LIFE 2-3 2-3. LIFE LIMITED COMPONENTS 2-3 Donaldson Company, Inc. AFS-BH206B-IBF-KIT-ICA, Revision A Proprietary Information Use or disclosure of this material is subject DCI Bell 206B IBF Instructions for Continued Airworthiness to the restrictions on the title page 2-3 2-1. GENERAL The Airworthiness Limitations for the DCI Inlet Barrier Filtration system (IBF) as installed on Bell Helicopter Textron Canada Limited (BHTCL) model 206B series helicopters are FAA approved. NOTE The retirement life given or the failure to give a retirement life to a component does not constitute a warranty of any kind. The only warranty applicable to any component is the warranty included in the Purchase Agreement for the helicopter or the component. 2-2. FILTER RETIREMENT LIFE After fifteen (15) cleaning and oiling cycles, the filter must be removed from service at the next servicing interval. The filter data tag is scribed after each cleaning and oiling cycle (see Paragraph 6-2). When all numerals (1-15) on the data tag have been scribed out, the filter shall be removed from service at the next service interval. No further cleaning cycles are authorized. 2-3. LIFE LIMITED COMPONENTS There are no fatigue life limited components on the IBF System. The only life limited component is the filter assembly. See Paragraph 2-2. Donaldson Company, Inc. AFS-BH206B-IBF-KIT-ICA, Revision A Proprietary Information Use or disclosure of this material is subject 3-1 DCI Bell 206B IBF Instructions for Continued Airworthiness to the restrictions on the title page ICA CHAPTER 3 –INSPECTION REQUIREMENTS AND OVERHAUL TABLE OF CONTENTS Paragraph Page Number Title Number 3-1. INSPECTION REQUIREMENTS 3-2 3-1.1. GENERAL REQUIREMENTS 3-2 3-1.2. FILTER ASSEMBLY INSPECTIONS 3-2 3-1.3. STRUCTURAL COMPONENT INSPECTIONS 3-3 3-1.4. SYSTEMS AND ELECTRICAL COMPONENT INSPECTIONS 3-3 3-1.5. IBF BYPASS COCKPIT SWITCH FUNCTION CHECK 3-4 3-2. OVERHAUL REQUIREMENTS 3-4 Picture Page Number Title Number 3-1. FMA OPERATION 3-5 3-2. FMA RESET LOCATION 3-5 Table Page Number Title Number 3-1. INSPECTION INTERVALS 3-6 Donaldson Company, Inc. AFS-BH206B-IBF-KIT-ICA, Revision A Proprietary Information Use or disclosure of this material is subject 3-2 DCI Bell 206B IBF Instructions for Continued Airworthiness to the restrictions on the title page 3-1. INSPECTION REQUIREMENTS 3-1.1. GENERAL REQUIREMENTS a. Inspection of the IBF system consists of, in general terms, inspection of the filter assembly, inspection of the structural components, inspection of electrical and system components, and a special inspection at three specified points based on hours after initial installation. The components of the system are divided, generally as a scope of work, into Filter Assembly / Water Wash Tube / Seal, Structural Components, and Systems and Electrical components as is done throughout the manual. b. Refer to the Appendix A - Illustrated Parts Breakdown for component illustrations that provide supplemental information relative to proper assembly configuration, orientation, and locations for all components to be inspected per Chapter 3 and Table 3-1. Refer to Appendix A, Figure A-1 & A-2 for the primary kit components. Refer to Appendix A, Figures A-2, A-3 and A-5 for filters, wash tube and filter seal components. Refer to Appendix A, Figures A-5, (items 2, 9, 27 & 34 plus associated tubes, hoses, clamps and brackets) and A-12 thru A-15 for items considered the primary systems and electrical components. Refer to Appendix A, Figures A-3 (less the filter assemblies and systems/electrical components) and A-11 for items considered structural components. c. Table 3-1 gives a recommended inspection schedule for the components of the system. The Trouble-Shooting Guide, Table 8-1 found near the end of Chapter 8, also gives additional guidance when performing inspections and encountering trouble with the system. Chapter 8 also provides specific inspection guidance and removal/installation procedures for each component and is structured in the same three major groups as discussed above. 3-1.2. FILTER ASSEMBLY INSPECTION a. The following inspections pertain to the barrier filter assembly and associated components, which include the filter assembly (i.e. filter frame and filter media), engine wash tube assembly, and all associated seals/fasteners. b. ON-CONDITION UP TO TIS LIMIT: Any FMA indication in the “RED”, “FILTER” light indication of the IBF cockpit indicator or failed PAC requires a conditional inspection in accordance with Table 3-1. c. VISUAL: All filter assembly components (plus engine wash tube assembly, seals and fasteners) are to be visually inspected at every annual in accordance with Table 3-1 checking for the following: filter media for tears, punctures, uneven or damaged pleats; seals for tears/damage; frame components for corrosion, cracks, distortions near holes, and check for missing or damaged fasteners. Donaldson Company, Inc. AFS-BH206B-IBF-KIT-ICA, Revision A Proprietary Information Use or disclosure of this material is subject 3-3 DCI Bell 206B IBF Instructions for Continued Airworthiness to the restrictions on the title page 3-1.3. STRUCTURAL COMPONENT INSPECTIONS VISUAL: All structural IBF components are to be inspected in accordance with Table 3-1 every 100 hours and annual. These components include the following: Bell 206B series Air Induction Cowling (OEM Equipment), Access Door (Optional Equipment), Filter Adapter Frame Assembly, Bypass Floor Assembly, OML Covers, and Close out Angles. 3-1.4. SYSTEMS AND ELECTRICAL COMPONENT INSPECTIONS a. VISUAL: The systems and electrical components are to be visually inspected in accordance with Table 3-1 every 100 hours and annual. These components include the following: Wiring, Wiring Harness, Connectors, Backshells, Circuit Breaker, Cockpit Switch, Cockpit Indicator, Differential Pressure Switch, Filter Maintenance Aid, and Actuator. b. FUNCTION CHECK: Certain systems and electrical components are also to be function checked in accordance with Table 3-1 every annual. These components include the following: Circuit Breaker, Cockpit Switch, Cockpit Indicator, Differential Pressure Switch, Filter Maintenance Aid, and Actuator. c. FMA CHECK: The FMA check is performed to ascertain the current condition of the filter or to gage the trend in accumulation of dirt. The FMA check is only a check of the indicator reading (See Picture 3-1). As such it is not considered an inspection of the FMA. The inspection Table 3-1 does not require a specific “inspection” interval of the FMA. The condition of the Filter Assembly and its accumulation of dirt will show up as an indication on the FMA. Thus, operational environment, more so than time in service, dictate how often the FMA should be checked in order to help determine the next Filter Assembly service requirement. It is an aid in scheduling the Filter Assembly servicing. At any time prior to an FMA indication in the “RED” (See Picture 3-1), a failed PAC, or a “IBF FILTER” indication on the cockpit indicator, when maintenance or flight personnel see a trend based on the FMA readings over time that would warrant servicing of the filter due to operational considerations, such as when the aircraft will be operated in a remote or off-site location without the ability to readily service the filter, the filter may be serviced, or replaced. See section 7-2 for a further description of the use of the FMA as it relates to the Filter Assembly service interval. See filter servicing Paragraph 7-3. NOTE The Filter Maintenance Aid is designed to hold the highest differential pressure across the filter assembly reached during the last flight and should be reset after servicing of the filter assembly by depressing the yellow button marked “PUSH TO RESET” located on the end of the filter maintenance aid (See Picture 3-2). The Filter Maintenance Aid (FMA) will not provide accurate readings when the engine air inlet snow deflector kit is installed, and therefore should not be used. Upon removal of the snow deflector kit the FMA should be reset by depressing the yellow button marked “PUSH TO RESET” located on the end of the filter maintenance aid (See Picture 3-2). Donaldson Company, Inc. AFS-BH206B-IBF-KIT-ICA, Revision A Proprietary Information Use or disclosure of this material is subject 3-4 DCI Bell 206B IBF Instructions for Continued Airworthiness to the restrictions on the title page 3-1.5. IBF BYPASS COCKPIT SWITCH FUNCTION CHECK FUNCTION CHECK: A function check of the IBF BYPASS Cockpit Switch is to be performed every 100 hours (See Table 3-1). Perform the function check as follows: (1) With aircraft power ON, place the IBF BYPASS switch in the OPEN position and visual check (through the engine air cowling RH access door) that the IBF bypass door is open. (2) Place the IBF BYPASS switch in the CLOSED position and visual check (through the engine air cowling RH access door) that the IBF bypass door is closed and ensure aircraft power is OFF. If conditions are not met refer to the Table 8-2 Troubleshooting Guide in the Instructions for Continued Airworthiness (ICA), AFS-BH206B-IBF-KIT-ICA. 3-2. OVERHAUL REQUIREMENTS There are no overhaul intervals or requirements applicable to this product at this time. Donaldson Company, Inc. AFS-BH206B-IBF-KIT-ICA, Revision A Proprietary Information Use or disclosure of this material is subject 3-5 DCI Bell 206B IBF Instructions for Continued Airworthiness to the restrictions on the title page GREEN Zone YELLOW RESET Button RED Zone YELLOW Indicator Picture 3-2: FMA RESET LOCATION - unit is mounted to bottom of IBF floor assembly and is accessed through RH access door on air induction cowling. PRESS YELLOW Button to RESET Picture 3-1: FMA OPERATION - “YELLOW Indicator” position relative to SAFE OPERATING ZONE (“GREEN Zone”) or SERVICE FILTER (“RED Zone”) markings defines current filter condition and pushing “YELLOW RESET Button” resets indicator. Donaldson Company, Inc. AFS-BH206B-IBF-KIT-ICA, Revision A Proprietary Information Use or disclosure of this material is subject 3-6 DCI Bell 206B IBF Instructions for Continued Airworthiness to the restrictions on the title page Table 3-1. Inspection Intervals Components Inspectio n Type Inspection Inspection Intervals Scheduled Time in Service Notes 100 Hrs. Annual Filter Assembly as defined in para. 3-1.2. Conditional 1. On-Condition up to TIS Limit 300 hrs. / 1 yr. 2, 3, 4, 5, 7 Scheduled 2. Visual X 1, 2, 4, 6, 7 Structural Components as defined in para. 3- 1.3. Scheduled 1. Visual X X 1, 2, 4, 6 Systems and Electrical Components as defined in para. 3-1.4. Scheduled 1. Visual X X 1, 2, 4, 6 Scheduled 2. Function Check X 1, 2, 4, 5 IBF Bypass Cockpit Switch as defined in para. 3-1.5. Scheduled 1. Function Check X 8 NOTES: 1. Refer to Chapter 8 for specific inspection requirements and functional check procedures. 2. Refer to Chapter 4 (Figure 4-1) for access information. 3. IBF FILTER light or failed PAC. This inspection is required any time an IBF FILTER light indication or failed PAC is reported by the pilot. 4. Reference Appendix A – Illustrated Parts Breakdown. 5. Reference Trouble-Shooting Guide, Table 8-2 of this manual. 6. Perform a visual inspection checking for deformation, buckling, corrosion, cracks, dents, tears, or other signs of damage and repair in accordance with the procedures in Chapter 8. 7. The maximum filter service interval between cleanings under any conditions is 300 flight hours or 1 year TIS, whichever comes first. Up to the TIS limit, the inspection of the Filter Assembly is “On-Condition” based on an FMA indication in the “RED”, any “IBF FILTER” light indication on the Cockpit Indicator, and / or upon a failed PAC (where the failed PAC is the result of a dirty Filter Assembly). 8. If conditions are not met refer to the Table 8-2 Troubleshooting Guide in the Instructions for Continued Airworthiness (ICA), AFS-BH206B-IBF-KIT-ICA. Donaldson Company, Inc. AFS-BH206B-IBF-KIT-ICA, Revision A Proprietary Information Use or disclosure of this material is subject 4-1 DCI Bell 206B IBF Instructions for Continued Airworthiness to the restrictions on the title page ICA CHAPTER 4 – ACCESS PANELS TABLE OF CONTENTS Paragraph Page Number Title Number 4-1. GENERAL DESCRIPTION 4-2 4-2. ACCESS FOR FILTER SERVICING 4-2 4-3. ACCESS FOR MAINTENANCE 4-2 4-3.1. ACCESS ABOVE BYPASS FLOOR ASSEMBLY 4-2 4-3.2. ACCESS BELOW BYPASS FLOOR ASSEMBLY 4-2 Figure Page Number Title Number 4-1. LOCATIONS OF (A) AIR INDUCTION COWLING, (B) IBF ACCESS DOOR OPTION AND (C) RH ACCESS DOOR 4-3 Donaldson Company, Inc. AFS-BH206B-IBF-KIT-ICA, Revision A Proprietary Information Use or disclosure of this material is subject 4-2 DCI Bell 206B IBF Instructions for Continued Airworthiness to the restrictions on the title page 4-1. GENERAL DESCRIPTION This chapter addresses how to access the IBF system installation for servicing or maintenance. 4-2. ACCESS FOR FILTER SERVICING Access for removal/installation of the filter assembly for filter servicing requires removal of the air induction cowling assembly (Figure 4-1, Item A) if the standard IBF system kit (DCI IBF Kit No. 109000-101) is installed, or removal of the optional access door (Figure 4-1, Item B) if the IBF system kit with access door option (DCI IBF Kit No. 109000-103) is installed. See Chapter 8 for filter assembly removal/installation procedures and Chapter 7 for filter servicing procedures. 4-3. ACCESS FOR MAINTENANCE 4-3.1. ACCESS ABOVE BYPASS FLOOR ASSEMBLY Access for maintenance of the system components located above the bypass floor assembly (i.e. filter assembly, engine water wash tube assembly, filter frame adapter, bypass door, etc.) requires removal of the air induction cowling assembly (Figure 4-1, Item A) if the standard IBF system kit (DCI IBF Kit No. 109000-101) is installed, or removal of the optional access door (Figure 4-1, Item B) if the IBF system kit with access door option (DCI IBF Kit No. 109000-103) is installed. See Chapter 8 for component removal/installation procedures, inspection, troubleshooting guide, adjustment/calibration/repair procedures. 4-3.2. ACCESS BELOW BYPASS FLOOR ASSEMBLY Access for maintenance of components located below the bypass floor assembly (i.e. filter maintenance aid, pressure differential switch, actuator, wiring harness/connectors) requires opening the RH access door (Figure 4-1, Item C) or the LH access door (located in the same location on the opposite side of the aircraft). Donaldson Company, Inc. AFS-BH206B-IBF-KIT-ICA, Revision A Proprietary Information Use or disclosure of this material is subject 4-3 DCI Bell 206B IBF Instructions for Continued Airworthiness to the restrictions on the title page Figure 4-1. Locations of (A) Air Induction Cowling, (B) IBF Access Door and (C) RH Access Door FORWARD Donaldson Company, Inc. AFS-BH206B-IBF-KIT-ICA, Revision A Proprietary Information Use or disclosure of this material is subject 5-1 DCI Bell 206B IBF Instructions for Continued Airworthiness to the restrictions on the title page ICA CHAPTER 5 – STORAGE TABLE OF CONTENTS Paragraph Page Number Title Number 5-1. STORAGE 5-2 Donaldson Company, Inc. AFS-BH206B-IBF-KIT-ICA, Revision A Proprietary Information Use or disclosure of this material is subject 5-2 DCI Bell 206B IBF Instructions for Continued Airworthiness to the restrictions on the title page 5-1. STORAGE CAUTION NEVER INSTALL A FILTER ASSEMBLY AND/OR OPERATE AN AIRCRAFT WITH A FILTER INSTALLED WHERE THE FILTER MEDIA HAS NOT BEEN PROPERLY OILED. Long-term storage has no effect on filter assembly reliability if stored unoiled (dry) in a cool, dry location to discourage possible fungus growth. After storage, the only maintenance to be performed on the filter before installation on the aircraft is oiling of the filter media. Refer to filter servicing Paragraph 7-3. Donaldson Company, Inc. AFS-BH206B-IBF-KIT-ICA, Revision A Proprietary Information Use or disclosure of this material is subject 6-1 DCI Bell 206B IBF Instructions for Continued Airworthiness to the restrictions on the title page ICA CHAPTER 6 – PLACARDS, DATA PLATES, AND MARKINGS TABLE OF CONTENTS Paragraph Page Number Title Number 6-1. MARKING – PART NUMBER / PMA / SERIALIZATION 6-2 6-2. DATA PLATE, FILTER ASSEMBLY 6-2 6-3. PLACARDS / MARKINGS - COCKPIT 6-2 Figure Page Number Title Number 6-1. EXAMPLE OF FILTER ASSEMBLY DATA PLATE 6-2 Picture Page Number Title Number 6-1. IBF MARKINGS 6-2 Donaldson Company, Inc. AFS-BH206B-IBF-KIT-ICA, Revision A Proprietary Information Use or disclosure of this material is subject 6-2 DCI Bell 206B IBF Instructions for Continued Airworthiness to the restrictions on the title page 6-1. MARKING – PART NUMBER / PMA / SERIALIZATION The IBF system is marked on the floor assembly to contain the top level part number, the serial number of the system, and the FAA PMA markings, if applicable. 6-2. DATA PLATE – FILTER ASSEMBLY After the filter assembly has been serviced an “X” is marked through one of the unmarked boxes on the serviceability tag (see Figure 6-1). When the last unmarked box is crossed through, the filter assembly will have to be replaced at the next servicing. See Chapter 7 for servicing procedures. Figure 6-1. Example of Filter Assembly Data Plate 6-3. PLACARDS / MARKINGS - COCKPIT a. The IBF uses a cockpit indicator in the aircraft caution/warning panel, which is amber and reads “IBF FILTER” when illuminated. See Picture 6-1(A) for markings b. The cockpit switch is a simple toggle switch located on the instrument panel, which is labeled “IBF BYPASS – OPEN/CLOSED”. See Picture 6-1(B) for markings. c. The IBF circuit breaker in the overhead console is marked “IBF”. See Picture 6-1(C) for markings. (A) (B) (C) Picture 6-1. IBF MARKINGS - (A) Cockpit Indicator, (B) Cockpit Switch & (C) Circuit Breaker Donaldson Company, Inc. AFS-BH206B-IBF-KIT-ICA, Revision A Proprietary Information Use or disclosure of this material is subject 7-1 DCI Bell 206B IBF Instructions for Continued Airworthiness to the restrictions on the title page ICA CHAPTER 7 – SERVICING TABLE OF CONTENTS Paragraph Page Number Title Number 7-1. AUTHORIZED MATERIALS 7-2 7-2. FILTER SERVICE INTERVALS 7-2 7-2.1. GENERAL REQUIREMENTS 7-2 7-2.2. PREPARED FIELD OPERATIONS 7-3 7-2.3. SEVERE ENVIRONMENT OPERATIONS 7-3 7-3. FILTER ASSEMBLY SERVICING 7-4 7-3.1. FILTER PRE-CLEANING 7-4 7-3.2. FILTER CLEANING 7-4 7-3.3. FILTER DRYING 7-5 7-3.4. FILTER OILING 7-5 7-4. STRUCTURAL COMPONENT SERVICING 7-6 7-5. SYSTEMS AND ELECTRICAL SERVICING 7-7 7-6. ENGINE WATER WASH 7-7 7-7. AIRCRAFT WASHING 7-7 Picture Page Number Title Number 7-1. OILING FILTER MEDIA 7-6 Donaldson Company, Inc. AFS-BH206B-IBF-KIT-ICA, Revision A Proprietary Information Use or disclosure of this material is subject 7-2 DCI Bell 206B IBF Instructions for Continued Airworthiness to the restrictions on the title page 7-1. AUTHORIZED MATERIALS Service DCI Filter with only the following: a. Air Filter Oil Squeeze bottle (4.0 oz) - DCI P/N 100100-040 1 qt. bottle - DCI P/N 100100-320 1 gal. container - DCI P/N 100101-000 5 gal. container - DCI P/N 100105-000 b. Air Filter Cleaner 1 gallon container - DCI P/N 100201-000 5 gallon container - DCI P/N 100205-000 Zok 27 NOTE Refer to Chapter 8 for removal, inspection, repair and installation of filter assembly. Upon satisfactory inspection and any required maintenance of the filter assembly proceed with the rest of the servicing instructions for the filter assembly. 7-2. FILTER SERVICE INTERVALS The filter service interval is based on the specific aircraft operating environment. The filter service intervals section is broken up in three parts: general requirements pertaining to all operations, specific recommendations for operations on prepared fields, and for operations in severe environments. 7-2.1. GENERAL REQUIREMENTS NOTE The maximum filter service interval between cleanings under any conditions is 300 flight hours or 1 year TIS, whichever comes first. Up to the TIS limit, the filter is considered an “on-condition” item. NOTE The FMA is an aid to help maintenance personnel and pilots to ascertain the condition of the filter at any point in time or to trend the accumulation of dirt on the Filter Assembly over a period of time. a. Up to the 300 hour / 1 year TIS limit, the “on condition” requirement for servicing the Filter Assembly is based on an FMA indication, a “IBF Filter” light indication on the cockpit indicator, or upon a failed PAC (where the failed PAC is the result of a dirty Filter Assembly). b. Any “IBF FILTER” indication, where the pressure sensor and indicating system are working properly, requires servicing of the filter assembly. See filter servicing Paragraph 7-3. c. The gradual increase in differential pressure across the IBF filter assembly causes an increase in the measured gas temperature (MGT) required to produce a specified torque as measured during the PAC. A failed PAC due to an increase in differential pressure across the filter is cause for servicing of the filter assembly. See filter servicing Paragraph 7-3. Donaldson Company, Inc. AFS-BH206B-IBF-KIT-ICA, Revision A Proprietary Information Use or disclosure of this material is subject 7-3 DCI Bell 206B IBF Instructions for Continued Airworthiness to the restrictions on the title page d. Any FMA indication in the area marked in “RED” requires servicing of the filter assembly. See filter servicing Paragraph 7-3. e. At any time prior to a “IBF FILTER” indication on the cockpit indicator, an FMA indication in the “RED”, or a failed PAC, when maintenance or flight personnel see a trend on the FMA that would warrant servicing of the filter due to operational considerations, such as when the aircraft will be operating in a remote or off-site location without the ability to readily service the filter, the filter may be serviced, or replaced. See filter servicing Paragraph 7-3. f. The maximum number of service cycles for the filter assembly (i.e., cleaning / oiling) is limited to 15 for each filter assembly. The filter assembly includes a data plate that must be inscribed to track filter service cycles in accordance with Paragraph 6-2. 7-2.2. PREPARED FIELD OPERATIONS a. During typical operations in and out of prepared airfields and landing sites, the IBF filter assembly will not require frequent servicing. DCI recommends that the filter maintenance aid (FMA) be checked about every 25 aircraft operating hours following the first installation and operation of an IBF system on an aircraft. This should be done to gauge the rate of engine performance degradation due to changes in engine inlet differential pressure as the filters accumulate dirt in operations considered “prepared fields” operations. Once an interval of time in flight hours is determined that provided discrete changes in the FMA, this interval can be repeated as long as there is no change in the environmental operating conditions. b. This interval can be extended after sufficient flight data has been accumulated to establish a greater interval. Upon seeing increases in MGT and associated decreases in temperature margin / available power, the inspection interval should again be shortened to about every 25 hours or less to enable scheduling of filter servicing without interruption of normal operations. c. Ensure all filter servicing requirements defined in Paragraph 7-2.1 are followed. Refer to Paragraph 7-3 for servicing of the filter assembly. 7-2.3. SEVERE ENVIRONMENT OPERATIONS a. When operating in an environment of high sand and dust levels, frequent servicing of the filter assembly may be required based on the time exposure and severity of the environment. Any operations in an environment that can result in “brownout” conditions should therefore be minimized or avoided to the maximum extent possible within the constraints of the operation. During operations for extended periods of time in brownout conditions, monitoring of the FMA between shut down and start up will allow the maintainer or operator to trend the change in differential pressure. Once an interval of time in flight hours is determined that provided discrete changes in the FMA, this interval can be repeated as long as the initial readings remain typical of the current operations. Donaldson Company, Inc. AFS-BH206B-IBF-KIT-ICA, Revision A Proprietary Information Use or disclosure of this material is subject 7-4 DCI Bell 206B IBF Instructions for Continued Airworthiness to the restrictions on the title page b. Ensure all filter servicing requirements defined in Paragraph 7-2.1 are followed. Refer to Paragraph 7-3 for servicing of the filter assembly. 7-3. FILTER ASSEMBLY SERVICING The filter assembly servicing section defines the procedures for pre-cleaning, cleaning, drying, and oiling the filter media in the filter assembly. 7-3.1. FILTER PRE-CLEANING a. Servicing of the filter assembly is determined by the inspection requirements found in Chapter 3. b. Prior to any cleaning operation gently brush the dirty side of the filter with a soft bristle brush similar to a soft paintbrush. Remove as much debris as practical from the filter before proceeding to the cleaning procedure. 7-3.2. FILTER CLEANING CAUTION DO NOT CLEAN DCI FILTER ASSEMLBIES WITH GASOLINE, SOLVENTS, PARTS CLEANERS, STRONG DETERGENTS, OR CAUSTIC CLEANING SOLUTIONS. CAUTION DO NOT STEAM CLEAN OR USE HIGH-PRESSURE WASHERS TO CLEAN THE DCI FILTER ASSEMBLY. CAUTION ANY OF THESE PROCESSES WILL DAMAGE FILTER MEDIA AND/OR THE FILTER FRAMES. a. Spray DCI Air Filter Cleaner liberally onto the entire filter media (both sides) until the filter media is thoroughly soaked. If procured in bulk, transfer a smaller quantity to a spray bottle. A spray bottle provides a more uniform distribution of the cleaning agent. b. Let the cleaner soak into the contaminants and filter media for 10 minutes. c. Rinse the filter with low-pressure water. Use water out of a faucet or hose (without nozzle). Rinse opposite the direction of airflow, i.e., from the clean side to the dirty side. Arrange the filter so the pleats are vertical and begin to rinse in a gradual side-to-side motion starting at the top and working downward. Adjust the pace to correspond with the cleanliness of the water runoff. As long as the runoff is filled with debris and oil, do not proceed downward. Donaldson Company, Inc. AFS-BH206B-IBF-KIT-ICA, Revision A Proprietary Information Use or disclosure of this material is subject 7-5 DCI Bell 206B IBF Instructions for Continued Airworthiness to the restrictions on the title page d. Upon completion, adjust the filter to rinse from the dirty side to the clean side, pleats still vertical. e. Repeat the rinsing procedure once again, until there is no visible debris on the surface and the runoff water is relatively clean. f. When finished, flip the filter once again and repeat the rinse from clean side to dirty side. g. Finally, rotate the filter from top to bottom, and perform the final rinse until the runoff water is free of all debris and oil. 7-3.3. FILTER DRYING CAUTION DO NOT USE COMPRESSED AIR TO DRY THE FILTER ASSEMBLY. IT MAY DAMAGE THE FILTER MEDIA. CAUTION DO NOT USE HEAT FROM ANY SOURCE TO DRY THE DCI FILTER ASSEMBLY. HEAT MAY SHRINK THE FILTER MEDIA AND MAY DAMAGE THE CORING MATERIAL WITHIN THE FILTER FRAMES. a. After rinsing, shake off the excess water and let the Filter Assembly dry at room or outside air temperature (above freezing). b. Ensure dirt or debris does not enter or contact the Filter Assembly while drying. c. After the Filter Assembly dries, mark the service cycle on data plate in accordance with the Paragraph 6-2. 7-3.4. FILTER OILING CAUTION NEVER PUT AN DCI FILTER ASSEMBLY IN SERVICE WITHOUT OILING IT. CAUTION USE ONLY DCI FILTER OIL OR AN DCI APPROVED SUBSTITUTE. Donaldson Company, Inc. AFS-BH206B-IBF-KIT-ICA, Revision A Proprietary Information Use or disclosure of this material is subject 7-6 DCI Bell 206B IBF Instructions for Continued Airworthiness to the restrictions on the title page NOTE A squeeze bottle capable of accurately measuring out five (5) fluid ounces should be used when applying the oil to each filter assembly as directed below. a. The filter will not function properly if other types of oil are used. DCI Air Filter Oil is a unique blend of mineral and organic oil base stocks and special polymers that form a very efficient “tack barrier.” Red dye is added to show areas of oil application. Do not use transmission fluid, any kind of motor oil, or diesel fuel to oil the DCI filter. Do not use “WD-40,” “LPS,” or any other type of lightweight spray lubricants to oil the DCI filter. Any of those products will damage the filter or degrade its filtering ability. A squeeze bottle allows for the controlled application of a specific amount of oil to the filter (See Picture 7-1). b. Apply approximately ¾ of the five (5) fluid ounces that is to be applied to each clean, dried Filter Assembly. Gently squeeze a small stream of oil along the entire length of each pleat peak, then flip the filter over and repeat this on the backside. Apply sparingly to ensure coverage of the entire filter. c. Let each Filter Assembly sit for 20 minutes as the oil “wicks” into the surrounding filter media. Apply the remaining filter oil to any areas that are still white and to complete the application of the 5 fluid ounces from the squeeze bottle. Picture 7-1: OILING FILTER MEDIA 7-4. STRUCTURAL COMPONENT SERVICING There are no structural components requiring periodic servicing. See Chapter 6 for inspection requirements and Chapter 8 for maintenance requirements.