Bell 206L1/C30, L-3, L-4 IBF Instructions for Continued Airworthiness

3.1 INSPECTION REQUIREMENTS ......................................................................................... 10 3.1.1 GENERAL REQUIREMENTS ...................................................................................... 10 3.1.2 FILTER ASSEMBLY INSPECTION .............................................................................. 10 3.1.3 STRUCTURAL COMPONENT INSPECTIONS............................................................ 10 3.1.4 SYSTEMS AND ELECTRICAL COMPONENT INSPECTIONS ................................... 11 3.1 OVERHAUL REQUIREMENTS ........................................................................................... 11 4 ACCESS PANELS .................................................................................................................... 12 4.1 GENERAL DESCRIPTION .................................................................................................. 12 4.2 ACCESS FOR FILTER SERVICING ................................................................................... 12 4.3 ACCESS FOR MAINTENANCE .......................................................................................... 12 4.3.1 ACCESS ABOVE BYPASS FLOOR ASSEMBLY ........................................................ 12 4.3.2 ACCESS BELOW BYPASS FLOOR ASSEMBLY........................................................ 12 5 STORAGE ................................................................................................................................ 14 5.1 STORAGE ........................................................................................................................... 14 6 PLACARDS, DATA PLATES, AND MARKINGS ..................................................................... 15 6.1 MARKING – Part Number / PMA / Serialization .................................................................. 15 6.2 DATA PLATE – FILTER ASSEMBLY .................................................................................. 15 6.3 PLACARDS / MARKINGS - Cockpit .................................................................................... 15 7 SERVICING .............................................................................................................................. 16 7.1 AUTHORIZED MATERIALS ................................................................................................ 16 7.2 FILTER SERVICE INTERVALS .......................................................................................... 16 7.2.1 GENERAL REQUIREMENTS ...................................................................................... 16 7.2.2 PREPARED FIELD OPERATIONS .............................................................................. 17 7.2.3 SEVERE ENVIRONMENT OPERATIONS ................................................................... 17 7.3 FILTER ASSEMBLY SERVICING ....................................................................................... 17 7.3.1 FILTER PRE-CLEANING ............................................................................................. 17 7.3.2 FILTER CLEANING ...................................................................................................... 18 AFS-BH206L3L4-IBF-KIT-ICA Aerospace Filtration Systems, Inc. Revision: D Proprietary Information Use or disclosure of this material is subject v AFS Bell 206L1/C30, L-3, L-4 IBF to the restrictions on the title page Instructions for Continued Airworthiness 7.3.3 FILTER DRYING .......................................................................................................... 19 7.3.4 FILTER OILING ............................................................................................................ 19 7.4 STRUCTURAL COMPONENT SERVICING ....................................................................... 20 7.5 SYSTEMS AND ELECTRICAL SERVICING ....................................................................... 20 7.6 ENGINE WATER WASH ..................................................................................................... 20 7.7 AIRCRAFT WASHING ........................................................................................................ 21 8 TROUBLESHOOTING AND MAINTENANCE ......................................................................... 22 8.1 MAINTENANCE GENERAL ................................................................................................ 22 8.2 COMPONENTS - GENERAL DESCRIPTION ..................................................................... 23 8.2.1 FILTER ASSY / ENGINE WASH TUBE ASSY / FILTER SEAL ................................... 23 8.2.2 STRUCTURAL COMPONENTS .................................................................................. 23 8.2.3 SYSTEMS AND ELECTRICAL COMPONENTS .......................................................... 23 8.3 FILTER ASSY / ENGINE WASH TUBE ASSY / FILTER SEAL .......................................... 24 8.3.1 FILTER ASSY / ENGINE WASH TUBE ASSY ............................................................. 24 8.3.2 FILTER SEAL ............................................................................................................... 29 8.4 STRUCTURAL COMPONENTS .......................................................................................... 30 8.4.1 BELL 206L1/C30, 206L-3, & 206L-4 AIR INLET COWL ASSEMBLY .......................... 30 8.4.2 BYPASS FLOOR ASSEMBLY ..................................................................................... 31 8.4.3 BYPASS DOOR ........................................................................................................... 33 8.4.4 BYPASS DOOR SEAL ................................................................................................. 35 8.4.5 FILTER FRAME ADAPTER ......................................................................................... 36 8.4.6 ACCESS DOOR / SEAL ............................................................................................... 37 8.5 SYSTEMS AND ELECTRICAL COMPONENTS ................................................................. 38 8.5.1 COCKPIT SWITCH / INDICATOR ............................................................................... 38 8.5.2 DIFFERENTIAL PRESSURE SWITCH ........................................................................ 40 8.5.3 FILTER MAINTENANCE AID ....................................................................................... 43 8.5.4 ACTUATOR .................................................................................................................. 45 8.5.5 WIRING, WIRING HARNESS, CONNECTORS, BACKSHELLS, CIRCUIT BREAKER, RELAY 49 8.6 FASTENER LISTING .......................................................................................................... 49 8.7 PROTECTIVE TREATMENT ............................................................................................... 50 8.8 TROUBLESHOOTING GUIDE ............................................................................................ 52 8.9 SPECIAL TOOLS / SPECIAL EQUIPMENT ........................................................................ 53 8.10 CONSUMABLE MATERIALS, SUPPLIES, AND PROTECTIVE TREATMENT SPECIFICATIONS ......................................................................................................................... 53 ICA APPENDIX ................................................................................................................................. 54 AFS-BH206L3L4-IBF-KIT-ICA Aerospace Filtration Systems, Inc. Revision: D Proprietary Information Use or disclosure of this material is subject 1 AFS Bell 206L1/C30, L-3, L-4 IBF to the restrictions on the title page Instructions for Continued Airworthiness 1 INTRODUCTION 1.1 SCOPE OF THIS MANUAL These Instructions for Continued Airworthiness (ICA) provide the information required to do the maintenance and repair of the AFS Inlet Barrier Filter (IBF) system installation on the Bell Helicopter Textron Canada Limited (BHTC) Model 206L1/C30, 206L-3, & 206L-4 helicopters. The ICA should be used in conjunction with all pertinent BHTC Model 206L1/C30, 206L-3, & 206L-4 manuals and all publications listed in the List of Applicable Publications (LOAP). NOTE Thoroughly review and become familiar with the applicable Appendix (A or B) – Parts Figures section of this ICA before performing maintenance on the IBF system. NOTE Any references or depictions pertaining to the 4-bladed Bell 407 installation in this document are also applicable to the 2-bladed Bell 206L1/C30, 206L-3, and 206L-4 installations unless noted otherwise. 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 Aerospace Filtration Systems, Inc. (AFS), BHTC 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. AFS-BH206L3L4-IBF-KIT-ICA Aerospace Filtration Systems, Inc. Revision: D Proprietary Information Use or disclosure of this material is subject 2 AFS Bell 206L1/C30, L-3, L-4 IBF to the restrictions on the title page Instructions for Continued Airworthiness 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 This 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. Mounted on the floor are the bypass door, actuator, filter maintenance aid, and differential pressure switch. Cockpit switch / indicator Combination switch/indicator that appears as a square black button located on cockpit instrument panel within easy reach of the pilot and labeled “IBF”. The switch is used to activate the actuator by depressing the button once to open the bypass door and depressing it a second time to close the bypass door. The button also serves as a dual indicator. Normally black, the top half of the button illuminates an amber caution “FILTER” light any time the differential pressure reaches or exceeds a preset limit, and the bottom half displays an amber caution “BYPASS” light when the bypass door reaches the full open position. Differential pressure Drop in pressure across the filter assembly, which is measured by the differential pressure switch and the filter maintenance aid. 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 Multi-layered cotton gauze compressed between two layers of pleated stainless steel screen and saturated with specially formulated oil which allows the air to pass through with a very low drop in pressure but traps a high percentage of the dust/dirt particles. 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. IML covers Inner mold line covers used to block off the hole left on the inner skin of the Air Induction Cowling when the EAPS exhaust duct is removed. AFS-BH206L3L4-IBF-KIT-ICA Aerospace Filtration Systems, Inc. Revision: D Proprietary Information Use or disclosure of this material is subject 3 AFS Bell 206L1/C30, L-3, L-4 IBF to the restrictions on the title page Instructions for Continued Airworthiness 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. 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 “FILTER” light indication on the cockpit switch / 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 AFS = Aerospace Filtration Systems, Inc. ATA = Air Transport Association of America, Inc. BHTC = Bell Helicopter Textron Canada Limited 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 IML = Inner Mold Line 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 1.5 WARNINGS, CAUTIONS, AND NOTES Warning, cautions and notes are used throughout this manual to emphasize important and critical instructions. AFS-BH206L3L4-IBF-KIT-ICA Aerospace Filtration Systems, Inc. Revision: D Proprietary Information Use or disclosure of this material is subject 4 AFS Bell 206L1/C30, L-3, L-4 IBF to the restrictions on the title page Instructions for Continued Airworthiness 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 206L-1, 206L-3, & 206L-4 Series Technical Publications FAA FAA Advisory Circular, AC 43.13-1B, Acceptable Methods, Techniques, and Practices – Aircraft Inspection and Repair 1.9 DISTRIBUTION OF CHANGES Changes shall be distributed by posting them on the AFS webpage www.donaldsonaerospace- defense.com. Each customer will be registered and provided access to the webpage via a personalized log-in/password established at the time of kit purchase. 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 AFS at (636) 300-5200 for assistance. AFS-BH206L3L4-IBF-KIT-ICA Aerospace Filtration Systems, Inc. Revision: D Proprietary Information Use or disclosure of this material is subject 5 AFS Bell 206L1/C30, L-3, L-4 IBF to the restrictions on the title page Instructions for Continued Airworthiness 1.10 INDICATION OF CHANGES All changes will be complete revisions with all pages marked with the latest revision letter. 1.11 SYSTEM DESCRIPTION AND OVERVIEW a. The Bell 206L1/C30, 206L-3, & 206L-4 IBF systems are offered to operators in two kits; AFS Kit No. 106000-105 (for metal cowl) and AFS Kit No. 106000-111 (for composite cowl), each includes the Inlet Barrier Filter (IBF) system and a quick access door. b. The IBF provides a single forward-facing barrier type filter assembly 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 on the 206L-3 & 206L-4 requires no structural modifications to the existing Air Induction Cowling except for the installation of the access door. The IBF installation on the 206L1/C30 requires addition of Bell parts 206-064-819-123S, -135S, -136S, - 137S, -131S, -113S, and -091S be installed into the cowling to enable the attachment of the IBF system. The access door has been added on the right 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 improves 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 AFS 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. On the Bell 206L-3 & 206L-4, the IBF system does not interfere with any of the commercial items installed in the production aircraft. On the Bell 206L1/C30, the same statement is applicable after the modifications have been made in accordance with Air Services Intl’s STC SH296NM or Bell BHT-206- SI-2050 for installation of Rolls Royce 250-C30P engine. 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, and filter maintenance aid), wiring harness, and access panel. Figure 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 and wiring harness. For a detailed illustration of all kit components, see the Appendix A or B - Parts Figures. d. The major components making up the bypass system include the bypass door, actuator, wiring harness, cockpit switch/indicator, and differential pressure switch. The cockpit switch/indicator actually serves three functions: (1) a push button switch to energize the actuator to open/close the bypass door, (2) the top half of the button illuminates the word “FILTER” in amber any time the preset differential pressure limit is reached or exceeded, and (3) the bottom half illuminates the word “BYPASS” in amber when the bypass door reaches the full open position. The cockpit switch / indicator is also wired into the cockpit panel press-to-test system, and the aircraft lighting dimmer system. 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, a differential pressure switch continuously measures the drop in pressure across the filter, and triggers the cockpit switch/indicator displaying “FILTER” cautioning the pilot any time the differential pressure across the filter reaches or exceeds a preset limit. At this point, the IBF is operating at approximately the same inlet differential pressure normally experienced with the EAPS installed. The electromechanically actuated bypass door permits unfiltered air to enter the engine inlet plenum chamber should the filter media AFS-BH206L3L4-IBF-KIT-ICA Aerospace Filtration Systems, Inc. Revision: D Proprietary Information Use or disclosure of this material is subject 6 AFS Bell 206L1/C30, L-3, L-4 IBF to the restrictions on the title page Instructions for Continued Airworthiness 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. 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 depressed to actuate the bypass door open, and then depressed again 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 assembly for servicing is easily achieved by removal of seven fasteners, which are accessible through the engine air inlets, and then removal of the filter assembly through the access door on the right side of the Air Induction Cowling. 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. AFS-BH206L3L4-IBF-KIT-ICA Aerospace Filtration Systems, Inc. Revision: D Proprietary Information Use or disclosure of this material is subject 7 AFS Bell 206L1/C30, L-3, L-4 IBF to the restrictions on the title page Instructions for Continued Airworthiness Figure 1: IBF System and Access Door Installation ITEM NO. ITEM NAME 1 Adapter Frame Assembly 2 Filter Seal 3 Inlet Barrier Filter Assembly 4 Engine Wash Tube Assembly 5 Bypass Floor Assembly 6 Floor Closeout Angle Assembly (LH) 7 Floor Closeout Angle Assembly (RH) 8 Filter Access Door Installation 9 OML EAPS Ejector Cover 10 IML EAPS Ejector Cover Assembly 11 Screw 12 Screw AFS-BH206L3L4-IBF-KIT-ICA Aerospace Filtration Systems, Inc. Revision: D Proprietary Information Use or disclosure of this material is subject 8 AFS Bell 206L1/C30, L-3, L-4 IBF to the restrictions on the title page Instructions for Continued Airworthiness 2 AIRWORTHINESS LIMITATIONS AIRWORTHINESS LIMITATIONS FAA APPROVAL BLOCK The Airworthiness Limitations Section is FAA approved and specifies maintenance required under Secs. 43.16 and 91.403 of the Federal Aviation Regulations unless an alternative program has been FAA approved. AFS-BH206L3L4-IBF-KIT-ICA Aerospace Filtration Systems, Inc. Revision: D Proprietary Information Use or disclosure of this material is subject 9 AFS Bell 206L1/C30, L-3, L-4 IBF to the restrictions on the title page Instructions for Continued Airworthiness 2.1 GENERAL The Airworthiness Limitations for the AFS Inlet Barrier Filtration system (IBF) as installed on Bell Helicopter Textron Canada Limited model 206L1/C30, 206L-3, & 206L-4 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. 2.1 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. AFS-BH206L3L4-IBF-KIT-ICA Aerospace Filtration Systems, Inc. Revision: D Proprietary Information Use or disclosure of this material is subject 10 AFS Bell 206L1/C30, L-3, L-4 IBF to the restrictions on the title page Instructions for Continued Airworthiness 3 INSPECTION REQUIREMENTS AND OVERHAUL 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 / Seal, Structural Components, and Systems and Electrical components as is done throughout the manual. b. Refer to the Appendix A – For Bell 206L1/C30, 206L-3, & 206L-4 with metal cowing parts 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 1. Refer to Appendix A, for Kit No. 106000-105. c. Refer to the Appendix B – For Bell 206L1/C30, 206L-3, & 206L-4 with composite cowing parts 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 1. Refer to Appendix A, for Kit No. 106000-111. d. 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 switch / indicator or failed PAC requires a conditional inspection in accordance with Table 1. c. VISUAL: All filter assembly components (including engine wash tube assembly, seals and fasteners) are to be visually inspected at every annual in accordance with Table 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. 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 206L1/C30, 206L-3, & 206L-4 Air Induction Cowling (OEM Equipment), Access Door, Adapter Frame Assembly, Bypass Floor Assembly, OML / IML Covers, and Close out Angles. AFS-BH206L3L4-IBF-KIT-ICA Aerospace Filtration Systems, Inc. Revision: D Proprietary Information Use or disclosure of this material is subject 11 AFS Bell 206L1/C30, L-3, L-4 IBF to the restrictions on the title page Instructions for Continued Airworthiness 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 / 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 100 hours and annual. These components include the following: Circuit Breaker, Cockpit Switch / Indicator, Differential Pressure Switch, Filter Maintenance Aid, and Actuator. Table 1: Inspection Intervals Components Inspection 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, 8 Scheduled 2. Visual X 1, 2, 4, 7, 8 Structural Components as defined in para. 3- 1.3. Scheduled 1. Visual X X 1, 2, 4, 7 Systems and Electrical Components as defined in para. 3-1.4. Scheduled 1. Visual X X 1, 2, 4, 7 Scheduled 2. Function Check X X 1, 2, 4, 5 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. FILTER light or failed PAC. This inspection is required any time a FILTER light indication or failed PAC is reported by the pilot. 4. Reference Appendix A - Parts Figures. 5. Reference Trouble-Shooting Guide, Table 8-2 of this manual. 6. Removed 7. 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. 8. 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 “FILTER” light indication on the Cockpit Switch / Indicator, and / or upon a failed PAC (where the failed PAC is the result of a dirty Filter Assembly). 3.1 OVERHAUL REQUIREMENTS There are no overhaul intervals or requirements applicable to this product at this time. AFS-BH206L3L4-IBF-KIT-ICA Aerospace Filtration Systems, Inc. Revision: D Proprietary Information Use or disclosure of this material is subject 12 AFS Bell 206L1/C30, L-3, L-4 IBF to the restrictions on the title page Instructions for Continued Airworthiness 4 ACCESS PANELS 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 access door (Figure 2, Item B) when AFS IBF Kit No. 106000-105 or 106000-111 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 adaptor, bypass door, etc.), when AFS IBF Kit No. 106000-105 or 106000-111 is installed, requires removal of the access door (Figure 2, Item B). 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 2, Item C) and the LH access door (located in the same location on the opposite side of the aircraft). AFS-BH206L3L4-IBF-KIT-ICA Aerospace Filtration Systems, Inc. Revision: D Proprietary Information Use or disclosure of this material is subject 13 AFS Bell 206L1/C30, L-3, L-4 IBF to the restrictions on the title page Instructions for Continued Airworthiness Figure 2: Equipment Locations Locations of (A) Air Inlet Cowl Assembly, (B) IBF Access Door and (C) RH Access Door [Photo (above) & Line drawing (below)] C B C FORWARD B A A AFS-BH206L3L4-IBF-KIT-ICA Aerospace Filtration Systems, Inc. Revision: D Proprietary Information Use or disclosure of this material is subject 14 AFS Bell 206L1/C30, L-3, L-4 IBF to the restrictions on the title page Instructions for Continued Airworthiness 5 STORAGE 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 shall be oiling of the filter media. Refer to filter servicing Paragraph 7-3. AFS-BH206L3L4-IBF-KIT-ICA Aerospace Filtration Systems, Inc. Revision: D Proprietary Information Use or disclosure of this material is subject 15 AFS Bell 206L1/C30, L-3, L-4 IBF to the restrictions on the title page Instructions for Continued Airworthiness 6 PLACARDS, DATA PLATES, AND MARKINGS 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. 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 3: Example of Filter Assembly Data Plate 6.3 PLACARDS / MARKINGS - Cockpit a. The area on the instrument panel just above or below the cockpit switch / indicator is marked “IBF”. The actual cockpit switch / indicator is internally lit to display amber cautions marked “FILTER” and “BYPASS”. See Figure (A) below for marking and for location. (A) (B) Figure 4: IBF Markings (A) Cockpit Switch/Indicator & (B) Circuit Breaker b. The IBF circuit breaker in the overhead console is marked ”IBF”. See Figure (B) above for marking and for location. AFS-BH206L3L4-IBF-KIT-ICA Aerospace Filtration Systems, Inc. Revision: D Proprietary Information Use or disclosure of this material is subject 16 AFS Bell 206L1/C30, L-3, L-4 IBF to the restrictions on the title page Instructions for Continued Airworthiness 7 SERVICING 7.1 AUTHORIZED MATERIALS Service AFS Filter Assembly only with AFS Air Filter Oil, (14 oz. squeeze bottle – AFS P/N 100100-014, gallon container – AFS P/N 100101-000), AFS Air Filter Cleaner (gallon container – AFS P/N 100201- 000, 5 gallon container – AFS P/N 100205-000) or AFS authorized substitutes. 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 a FMA indication, a “Filter” light indication on the Cockpit Switch / Indicator, or upon a failed PAC (where the failed PAC is the result of a dirty Filter Assembly). b. Any “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. d. Any FMA indication in the area marked in “RED” requires servicing of the filter assembly. See filter servicing Paragraph 7-3. AFS-BH206L3L4-IBF-KIT-ICA Aerospace Filtration Systems, Inc. Revision: D Proprietary Information Use or disclosure of this material is subject 17 AFS Bell 206L1/C30, L-3, L-4 IBF to the restrictions on the title page Instructions for Continued Airworthiness e. At any time prior to a “FILTER” indication on the cockpit switch / 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 scribed 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. AFS 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. 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. If extended time is accumulated operating in brownout conditions, monitoring of the FMA between shut down and startup will give an indication of the differential pressure trend based on the severe environment being flown in. 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. 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. AFS-BH206L3L4-IBF-KIT-ICA Aerospace Filtration Systems, Inc. Revision: D Proprietary Information Use or disclosure of this material is subject 18 AFS Bell 206L1/C30, L-3, L-4 IBF to the restrictions on the title page Instructions for Continued Airworthiness 7.3.2 FILTER CLEANING CAUTION DO NOT CLEAN AFS 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 AFS FILTER ASSEMBLY. CAUTION ANY OF THESE PROCESSES WILL DAMAGE FILTER MEDIA AND/OR THE FILTER FRAMES. CAUTION USE ONLY AFS CLEANER OR AN AFS APPROVED SUBSTITUTE. a. Spray AFS 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 in the 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. d. Upon completion, adjust the filter to clean 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. AFS-BH206L3L4-IBF-KIT-ICA Aerospace Filtration Systems, Inc. Revision: D Proprietary Information Use or disclosure of this material is subject 19 AFS Bell 206L1/C30, L-3, L-4 IBF to the restrictions on the title page Instructions for Continued Airworthiness 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 AFS 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 AFS FILTER ASSEMBLY IN SERVICE WITHOUT OILING IT. CAUTION USE ONLY AFS FILTER OIL OR AN AFS APPROVED SUBSTITUTE. NOTE A squeeze bottle capable of accurately measuring out fourteen (14) fluid ounces should be used when applying the oil to the filter as directed below. a. The filter will not function properly if other types of oil are used. AFS 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 AFS filter. Do not use “WD-40,” “LPS,” or any other type of lightweight spray lubricants to oil the AFS 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 Figure 5). b. Apply approximately ¾ of the fourteen (14) fluid ounces that is to be applied to the 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. AFS-BH206L3L4-IBF-KIT-ICA Aerospace Filtration Systems, Inc. Revision: D Proprietary Information Use or disclosure of this material is subject 20 AFS Bell 206L1/C30, L-3, L-4 IBF to the restrictions on the title page Instructions for Continued Airworthiness c. Let the 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 14 fluid ounces from the squeeze bottle. Figure 5: 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. 7.5 SYSTEMS AND ELECTRICAL SERVICING There are no system and electrical components requiring periodic servicing. See Chapter 6 for inspection requirements and Chapter 8 for maintenance requirements. 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 Figure 10). 7.6 ENGINE WATER WASH NOTE It is not necessary to remove the IBF filter prior to conducting an engine wash. AFS-BH206L3L4-IBF-KIT-ICA Aerospace Filtration Systems, Inc. Revision: D Proprietary Information Use or disclosure of this material is subject 21 AFS Bell 206L1/C30, L-3, L-4 IBF to the restrictions on the title page Instructions for Continued Airworthiness It is recommended the engine water wash frequency be in accordance with the current Rolls-Royce requirements for operation in a standard environment, desert environment or salt-water environment. 7.7 AIRCRAFT WASHING During aircraft washing the IBF system, including the filter assembly, should be protected or removed to avoid damaging the filter media with high pressure spray nozzles or to prevent solvents rinsing away the oil in the filter media. AFS-BH206L3L4-IBF-KIT-ICA Aerospace Filtration Systems, Inc. Revision: D Proprietary Information Use or disclosure of this material is subject 22 AFS Bell 206L1/C30, L-3, L-4 IBF to the restrictions on the title page Instructions for Continued Airworthiness 8 TROUBLESHOOTING AND MAINTENANCE 8.1 MAINTENANCE GENERAL CAUTION THOROUGHLY REVIEW AND BECOME FAMILIAR WITH THE APPENDIX A OR APPENDIX B - PARTS FIGURES BEFORE PERFORMING MAINTENANCE ON THE IBF SYSTEM. NOTE Except where otherwise indicated, all torque values shall be in accordance with Chapter 7 of FAA Advisory Circular AC 43.13-1B. a. The components of the system are divided, generally as a scope of work, into Filter Assembly / Seal / Engine Wash Tube, Structural Components, and Systems and Electrical components throughout the manual. Refer to Appendix A or B for items considered structural components. Refer to Appendix A or B for items considered electrical and systems components. Table 1 gives a recommended inspection schedule for the components of the system. The troubleshooting guide in Table 5 provides additional guidance for performing inspections when encountering trouble with the system. b. The maintenance chapter is organized by removal, inspection, troubleshooting, adjustment, calibration and / or repair, and installation for the major components noted above, as applicable to the particular component. For some components a functional check is included. Not all components will require adjustment, or calibration, or have any approved functional check or repair procedures. Contact AFS for possible repairs when not listed in this manual. In some cases defective components will require replacement. c. In general, visually inspect all structural components for oversized or elongated holes, deformation, cracks, corrosion, missing fasteners or components, fretting, galling, etc. Any component exhibiting these conditions requires repair or replacement. d. In general, visually inspect fasteners for damaged or missing threads, in both the bolt or screw and the nut or nut plate. If a self-locking fastener can be fully threaded by hand, replace the self-locking fastener. e. In general, visually inspect all electrical connections for security, corrosion, arcing, breakdown of insulation, and overheating. Repair or replace components exhibiting defects. Inspect and repair components per Bell Helicopter technical manuals or AC 43.13-1, Chapter 11. AFS-BH206L3L4-IBF-KIT-ICA Aerospace Filtration Systems, Inc. Revision: D Proprietary Information Use or disclosure of this material is subject 23 AFS Bell 206L1/C30, L-3, L-4 IBF to the restrictions on the title page Instructions for Continued Airworthiness 8.2 COMPONENTS - GENERAL DESCRIPTION 8.2.1 FILTER ASSY / ENGINE WASH TUBE ASSY / FILTER SEAL Figures A-1, A-4, and A-10) a. Filter Assembly - The Filter Assembly is composed of the filter media (stainless steel mesh covering cotton gauze) bonded into the aluminum alloy filter frame assembly. b. Engine Wash Tube Assembly - The engine wash tube is composed of formed aluminum tube, aluminum spray nozzle and associated “AN” fittings and attachment hardware. c. Seal - The Seal is expanded foam with adhesive backing. 8.2.2 STRUCTURAL COMPONENTS (Refer to Appendix A Figures or Appendix B Figures) a. Bell 206L1/C30, 206L-3, & 206L-4 Air Induction Cowling (OEM Equipment) - The Bell 206L1/C30, 206L-3, & 206L-4 Air Induction Cowling is part of the original equipment manufacturer supplied for the Bell 206L-1, 206L-3, & 206L-4 helicopters. For description see Bell 206L-1, 206L-3, & 206L-4 series technical manuals. b. Cowling Access Door - The cowling access door is formed and heat treated aluminum alloy with appropriate mounting holes providing access to the filter assembly and additional access inside the Air Induction Cowling. Chemical conversion coating and epoxy primer provide an organic protective coating. c. Filter Frame Adapter - The Filter Frame Adapter is sheet stock aluminum alloy providing structural support for the mounting of the Filter Assembly and the Bypass Floor Assembly. Chemical conversion coating and epoxy primer provide an organic protective coating. d. Bypass Floor Assembly / Bypass Door / Seal - The Bypass Floor Assembly consists of a machined aluminum alloy floor, a machined aluminum alloy actuator bracket, a military standard (MS) aluminum alloy hinge and steel pin, machined aluminum alloy bypass door, stainless steel mesh screen, aluminum sheet metal mounting brackets and provisions for mounting the Differential Pressure Switch and Filter Maintenance Aid, and associated MS hardware and other standard aircraft hardware for mounting and installation provisions. 8.2.3 SYSTEMS AND ELECTRICAL COMPONENTS (Refer to Appendix A Figures or Appendix B Figures) a. Cockpit Switch / Indicator - The cockpit switch / indicator provides both a switching function and indicating information to the pilot. The construction details of the component do not warrant field maintenance. Repair or servicing of this component requires the component to be sent back to AFS for disposition. b. Differential Pressure Switch - The Differential Pressure Switch provides a signal to the Cockpit Switch / Indicator for annunciation of the “FILTER” light to signal the differential pressure across the Filter Assembly has reached a preset limit. The construction details of the component do not warrant field maintenance. Repair of this component requires the component to be sent back to AFS for disposition. AFS-BH206L3L4-IBF-KIT-ICA Aerospace Filtration Systems, Inc. Revision: D Proprietary Information Use or disclosure of this material is subject 24 AFS Bell 206L1/C30, L-3, L-4 IBF to the restrictions on the title page Instructions for Continued Airworthiness c. Filter Maintenance Aid - The Filter Maintenance Aid provides an indication to maintenance personnel as to the trend of the differential pressure across the Filter Assembly. The construction details of the component do not warrant field maintenance. Repair of this component requires it to be sent back to AFS for disposition, or replaced. The FMA is an aid to help maintenance personnel and pilots to ascertain the current condition or trend in accumulation of dirt on the Filter Assembly. d. Actuator - The Actuator provides mechanical actuation of the Bypass Door should the pilot depress the cockpit switch / indicator. The construction details of the component do not warrant field maintenance. Repair of this component requires the component to be sent back to AFS for disposition or replaced. e. Wiring, Wiring Harness, Connectors, Backshells, Circuit Breaker – The wiring and wiring harness utilizes wire per Military Specification Mil-W-22759/41. The gauge and marking identification is specified on the wiring diagram. The connectors, backshells, and circuit breaker are military specification components, or where applicable, vendor designed components. The construction details of these components (other than wiring) do not warrant field maintenance. 8.3 FILTER ASSY / ENGINE WASH TUBE ASSY / FILTER SEAL (Refer to Figure 6 and Appendix A Figures or Appendix B Figures) 8.3.1 FILTER ASSY / ENGINE WASH TUBE ASSY 8.3.1.1 REMOVAL – FILTER ASSY / ENGINE WASH TUBE a. Remove the Access Door by removing the fasteners that retain the Access Door. Remove the Access Door (See Appendix A Figures or Appendix B Figures). b. Loosen the Engine Wash Tube from the fitting on the Bypass Floor Assembly (See Appendix A or Appendix B Figures). c. Remove the hardware attaching the Filter Assembly to the Filter Frame Adapter (See Appendix A or Appendix B Figures). Remove the fasteners from the air intake side of the cowling. d. Use a plastic scraper to gently break any seal between the Filter Assembly and the Seal itself. The Filter Assembly must be carefully removed so as not to damage the Filter Seal. Remove the Filter Assembly through the slot exposed when the Access Door is removed. e. Remove the hardware attaching the Engine Wash Tube to the Filter Assembly (See Appendix A or Appendix B Figures). AFS-BH206L3L4-IBF-KIT-ICA Aerospace Filtration Systems, Inc. Revision: D Proprietary Information Use or disclosure of this material is subject 25 AFS Bell 206L1/C30, L-3, L-4 IBF to the restrictions on the title page Instructions for Continued Airworthiness Figure 6: Engine Wash Tube Assembly Orientation to Filter Assembly (2) Engine Wash Tube Assy Clamp Locations (1) Filter Assy (4) Engine Wash Tube Nozzle (3) Engine Wash Tube Assy Fitting AFS-BH206L3L4-IBF-KIT-ICA Aerospace Filtration Systems, Inc. Revision: D Proprietary Information Use or disclosure of this material is subject 26 AFS Bell 206L1/C30, L-3, L-4 IBF to the restrictions on the title page Instructions for Continued Airworthiness 8.3.1.2 INSPECTION – FILTER ASSY / ENGINE WASH TUBE NOTE After servicing of the Filter Assembly or at any time the Filter Assembly is inspected, the pleats may require straightening or crimping. If you cannot see the bottom of the pleat, the airflow will be restricted and/or the pleats will adhere to one another when dirt loaded. Any restriction to the flow through the pleats will result in increased differential pressure and reduction in dirt loading capacity. In order to insure ideal flow characteristics through the filter media, the pleats must be straightened or crimped with a hand seamer. a. Visually inspect the pleats on both sides of the filter. If you cannot see the bottom of the pleat, when sighting the length, or depth of the pleat, straightening of the pleat is required. Refer to “Adjustment” for pleat straightening procedures. b. If this inspection is in response to a FILTER light indication or failed PAC, perform troubleshooting per Table 5. If troubleshooting indicates a dirty filter, service filter per paragraph 7.3. c. Inspect the Filter Assembly frame for cracks, gouges, distortion or deformation, corrosion, loose or missing fasteners, and missing or deteriorated protective coating. Refer to “Repair” for criteria / disposition. d. Inspect the Filter Seal. Refer to “Filter Seal” procedures. e. Inspect the engine wash tube for cracks, kinks, leaks, corrosion, deformation and security. Refer to “Repair” for criteria / disposition. 8.3.1.3 TROUBLESHOOTING – FILTER ASSY / ENGINE WASH TUBE See Table 5 for troubleshooting guide. 8.3.1.4 ADJUSTMENT - FILTER CAUTION HAND SEAMER MUST BE LIMITED TO A MAXIMUM JAW DEPTH OF 1 1/4 INCH. A DEEPER JAW DEPTH CAN RESULT IN DEFORMATION OR DAMAGE TO THE ADJOINING PLEATS. CAUTION DO NOT OVER CRIMP AND CRUSH PLEAT; CARE MUST BE TAKEN TO SQUEEZE THE PLEATS WITHOUT DAMAGING THE PLEATED SCREEN. THE RADIUS AT THE TOP OF THE PLEAT SHOULD REMAIN INTACT, NOT CREASED. a. If you cannot see the bottom of a pleat, use a hand seamer (See Special Tools / Special Equipment, Paragraph 8.9.a.) to crimp the pleat and to straighten the pleat. Sight down the length and depth of the pleat to confirm the pleat is straightened (See Figure 7). AFS-BH206L3L4-IBF-KIT-ICA Aerospace Filtration Systems, Inc. Revision: D Proprietary Information Use or disclosure of this material is subject 27 AFS Bell 206L1/C30, L-3, L-4 IBF to the restrictions on the title page Instructions for Continued Airworthiness b. Once one side is crimped, flip the filter over and crimp the other side as required following the guidance above. Use caution not to crush the pleats when straightening them. Use care to maintain the original radius, as much as possible, at the top of the pleat. Figure 7: Hand Seamer used to Straighten or Crimp Pleats 8.3.1.5 CALIBRATION Not applicable. 8.3.1.6 REPAIR - Filter Media, GENERAL WARNING ADHESIVE VAPORS (SUCH AS MAY BE CONTAINED IN SEALING MATERIAL AMS 3276 OR MIL-S-8802), MAY CAUSE IRRITATION OF EYES, NOSE, AND RESPIRATORY SYSTEM. EYE AND SKIN CONTACT WITH MATERIAL MAY CAUSE IRRITATION. IF INGESTED, MAY CAUSE GASTRIC DISTRESS. FLUSH EYES WITH WATER FOR 15 MINUTES. WASH SKIN WITH SOAP AND WATER. IF INHALED, MOVE TO FRESH AIR. IN ALL CASES GET IMMEDIATE MEDICAL ATTENTION. WORK IN A WELL-VENTILATED AREA. WEAR GLOVES AND SAFETY GLASSES. AFS-BH206L3L4-IBF-KIT-ICA Aerospace Filtration Systems, Inc. Revision: D Proprietary Information Use or disclosure of this material is subject 28 AFS Bell 206L1/C30, L-3, L-4 IBF to the restrictions on the title page Instructions for Continued Airworthiness NOTE Repair filter media damage after cleaning but prior to oiling of filters. 8.3.1.7 REPAIR - Filter Media, Small Ruptures, Tears, or Holes a. In the event of damage to the filter media, ruptures in the filter media may be repaired. Small ruptures defined as smaller than .500 inch diameter or length can be sealed shut without degradation of performance to the Filter Assembly. The up to 8 small ruptures in the filter media may be repaired on a single filter, but no repair may be within 1” of an adjacent repair. b. Prior to performing any of these repairs, the filter material must be cleaned of contamination and oil. Refer to Chapter 7 for cleaning of the Filter Assembly. Perform the repair to a cleaned and dry Filter Assembly. Each time the entire Filter Assembly is cleaned, repaired, and oiled, a mark shall be scribed on the Filter Assembly data plate in accordance with Paragraph 6-2 indicating a cleaning cycle was performed. c. Trim ruptures, tears, or holes in the filter media up to .500 inches in length or diameter to remove loose material (wire or cotton gauze). d. Seal the affected area using two-part Sealant, AMS 3276 or MIL-S-8802. Allow the Sealant to bleed into the filter material and cure. Follow manufacturer’s directions for proper mixing, application, and curing of the two-part Sealant. e. Proceed with oiling the filter. Refer to Chapter 7. 8.3.1.8 REPAIR - Filter Media, Large Ruptures, Tears, or Holes Larger ruptures exceeding .500 inch in size are not repairable in the field. Contact AFS for disposition and possible repair procedures, or discard the Filter Assembly. 8.3.1.9 REPAIR – Filter Assy/ Engine Wash Tube, Other Damage a. The repair procedures defined above are for damage resulting in ruptures, tears, or holes in the filter media. The following is for field repairable damage to the Filter Assembly frame. Field repairable damage to the Filter Assembly frame is limited to blending of scratches and gouges, and / or the re- application of protective coatings. See Table 4 for application of protective coatings. b. Any damage to the filter frames such as cracking requires the Filter Assembly to be returned to AFS for evaluation and disposition, or replacement. Any damage to the filter frames such as warping or distortion (to the extent that the Filter Frame, when installed against the Filter Frame Adapter and torqued, do not permit the Filter Assembly to sit flush against the Adapter Frame) requires the Filter Assembly be returned to AFS for evaluation and disposition, or be replaced. c. Any damage to the Engine Wash Tube Assembly that restricts the flow, allows leakage, or impacts security is cause for replacement. AFS-BH206L3L4-IBF-KIT-ICA Aerospace Filtration Systems, Inc. Revision: D Proprietary Information Use or disclosure of this material is subject 29 AFS Bell 206L1/C30, L-3, L-4 IBF to the restrictions on the title page Instructions for Continued Airworthiness 8.3.1.10 INSTALLATION – Filter Assy/ Engine Wash Tube CAUTION REMOVE COVER FROM THE ENGINE INLET PRIOR TO INSTALLING THE ACCESS DOOR. CAUTION OVER TIGHTENING OF THE FASTENERS MAY RESULT IN THE FASTENER BEING DAMAGED. a. Position the two clamps on the Engine Wash Tube Assembly to the bottom side of each of the two support brackets located on two of the three combs on the aft side of the Filter Assembly. (See Appendix A or Appendix B Figures). b. Install clamps using the associated hardware (See Appendix A or Appendix B Figures). c. Prior to installation of the Filter Assembly, the Seal shall be visually inspected for security and damage. The Filter Assembly must be carefully inserted through the access door and positioned against the mounting frame. Ensure the Filter Assembly seats properly (not cocked, i.e. fits flush) against the Filter Frame Adapter. d. Install fasteners from the air intake side of the cowling. Tighten all fasteners to 20-25 inch-pounds. e. Connect Engine Wash Tube to Bypass Floor Assembly. f. Install Access Door. 8.3.2 FILTER SEAL 8.3.2.1 REMOVAL a. Gain access to the Filter Frame Adapter Assembly by removing the Filter Assembly. Refer to Paragraphs 4.3.1 and 8.3.1. b. Carefully remove the Seal by peeling it away from the Filter Frame Adapter. Use a plastic scraper or other suitable tool that is softer than aluminum to peel the Seal from the Filter Frame Adapter. Discard the removed Seal. 8-3.2.2. INSPECTION Inspect the Filter Seal for any tears, nicks, gouges, missing pieces or a permanent set or flattening of the Seal. If the Seal exhibits any of these conditions, repair or replace the Seal. AFS-BH206L3L4-IBF-KIT-ICA Aerospace Filtration Systems, Inc. Revision: D Proprietary Information Use or disclosure of this material is subject 30 AFS Bell 206L1/C30, L-3, L-4 IBF to the restrictions on the title page Instructions for Continued Airworthiness 8.3.2.2 REPAIR WARNING ADHESIVE VAPORS (IN SEALANT SUCH AS RTV 736) MAY CAUSE IRRITATION OF EYES, NOSE, AND RESPIRATORY SYSTEM. EYE AND SKIN CONTACT WITH MATERIAL MAY CAUSE IRRITATION. IF INGESTED, MAY CAUSE GASTRIC DISTRESS. FLUSH EYES WITH WATER FOR 15 MINUTES. WASH SKIN WITH SOAP AND WATER. IF INHALED, MOVE TO FRESH AIR. IN ALL CASES GET IMMEDIATE MEDICAL ATTENTION. WORK IN A WELL- VENTILATED AREA. WEAR GLOVES AND SAFETY GLASSES. a. Small tears, nicks, or gouges in the Seal may be repaired using RTV 736 Sealant. Use a wooden tongue depressor, cotton swab, or similar tool to dab a small amount of Sealant on the damage to repair tears, nicks, or gouges in the Seal. Smooth over Sealant to create a smooth flush repair similar to the original Seal cross section. Allow to dry before re-installing filter. If the repair does not allow the Filter Assembly from sealing to the Adapter replace the Seal. b. If the Seal exhibits extensive tears, deep nicks or gouges, or missing pieces that would prevent the filter from properly sealing, replace the Seal. 8.3.2.3 INSTALLATION a. Gain access to the Filter Seal. Refer to Filter Assembly removal and Filter Seal removal. b. To install the Seal, remove the adhesive backing from the Seal. Locate and apply the Seal to a clean dry surface on Filter Frame Adapter and press in place. 8.4 STRUCTURAL COMPONENTS 8.4.1 BELL 206L1/C30, 206L-3, & 206L-4 AIR INLET COWL ASSEMBLY (Refer to Figure A-1, A-2 or B-1, B-2) 8.4.1.1 REMOVAL a. Disconnect electrical Bypass System Connector (See Appendix A or Appendix B Figures). b. Remove fasteners from Bypass Floor Assembly attaching to engine firewall. c. Remove Air Induction Cowling (See Figure 2, Item A and refer to Bell Helicopter Maintenance Manuals). 8.4.1.2 INSPECTION a. The AFS IBF interfaces the Air Induction Cowling at the Filter Assembly Adapter Frame, Bypass Floor Assembly, the Access Door, and IML / OML covers. See Appendix A or Appendix B. At these locations inspect for chafing or fretting, elongation of fastener holes, damage to nut plates and fasteners, corrosion, cracking, and deformation. b. Inspection for the above conditions and any other conditions that may be applicable are defined in the Bell Helicopter 206L-1, 206L-3 & 206L-4 technical manuals. AFS-BH206L3L4-IBF-KIT-ICA Aerospace Filtration Systems, Inc. Revision: D Proprietary Information Use or disclosure of this material is subject 31 AFS Bell 206L1/C30, L-3, L-4 IBF to the restrictions on the title page Instructions for Continued Airworthiness 8.4.1.3 TROUBLESHOOTING Not applicable. 8.4.1.4 ADJUSTMENT Not applicable. 8.4.1.5 CALIBRATION Not applicable 8.4.1.6 REPAIR For repairs see Bell Helicopter 206L-1, 206L-3 & 206L-4 technical manuals. 8.4.1.7 INSTALLATION a. Install Bell 206L1/C30, 206L-3 & 206L-4 Air Induction Cowling (See Figure 2, Item A and refer to Maintenance Manuals as applicable). b. Install hardware in the Bypass Floor Assembly to the Firewall. c. Connect Bypass System electrical disconnect. 8.4.2 BYPASS FLOOR ASSEMBLY (Refer to Appendix A or B; Figure A-1, A-6, A-8, A-9 and A-10 or Figure B-1, B-6, B-8, B-9, and B-10) 8.4.2.1 REMOVAL a. Disconnect the wiring harness from the Bypass System Disconnect (See Appendix A or Appendix B Figures) b. Remove the hardware attaching the Bypass Floor Assembly to the Firewall from the Engine side of the Firewall. c. Gain access to the Bypass Floor by removing the Bell 206L1/C30, 206L-3 & 206L-4 Air Induction Cowling (See Figure 2, Item A and refer to Maintenance Manual as applicable). d. Disconnect the Engine Wash Tube (See Appendix A or Appendix B Figures) from the adapter on the Bypass Floor Assembly. e. Remove the Filter Assembly (See Appendix A or Appendix B Figures) with the Engine Wash Tube attached. f. Remove the hardware attaching the Bypass Floor Assembly to the Filter Frame Adapter (See Appendix A or Appendix B Figures). g. Remove the hardware attaching the Floor Closeout Angles to the Bell 206L1/C30, 206L-3 & 206L-4 Air Induction Cowling (See Appendix A or Appendix B Figures). h. Remove the Bypass Floor Assembly (See Appendix A or Appendix B Figures). AFS-BH206L3L4-IBF-KIT-ICA Aerospace Filtration Systems, Inc. Revision: D Proprietary Information Use or disclosure of this material is subject 32 AFS Bell 206L1/C30, L-3, L-4 IBF to the restrictions on the title page Instructions for Continued Airworthiness 8.4.2.2 INSPECTION a. Cracking. Visually inspect the Bypass Floor Assembly and related parts for cracking using 10x magnification at the corners, radiuses, and transitions in part thickness. Any fretting of faying surfaces, such as those at a crack may emit a black or grey dust or soot like material indicative of a crack. Inspect suspect areas carefully using the 10x magnification. Refer to adjustment / calibration / repair for disposition of cracks in the Bypass Floor Assembly or parts. b. Reserved. c. Protective Coatings. Visually inspect the Bypass Floor Assembly and related parts for missing, damaged, or “scratched through” protective coatings. Re-apply protective coatings per Table 4 of this chapter. d. Corrosion. Visually inspect the Bypass Floor Assembly and related parts for corrosion in accordance with AC 43.13-1, Chapter 6 and Table 4. e. Missing, damaged or loose associated components. Visually inspect the Bypass Floor Assembly for missing damaged or loose components. 8.4.2.3 TROUBLESHOOTING Not applicable. 8.4.2.4 CALIBRATION / ADJUSTMENT Not applicable. 8.4.2.5 REPAIR a. Cracks. No un-repaired cracks are allowed in the Bypass Floor Assembly. Contact AFS for disposition and possible repairs. b. Warping or distortion. Contact AFS for disposition and possible repairs. c. Protective Coatings. Re-apply protective coatings per Table 4 of this chapter. d. Corrosion. Treat corrosion in accordance with AC 43.13-1, Chapter 6 and Table 4. e. Missing, damaged or loose associated components. Replace missing or damaged components. Secure loose components. 8.4.2.6 INSTALLATION a. Position the Bypass Floor Assembly (See Appendix A or Appendix B Figures) to the Bell 206L1/C30, 206L-3 & 206L-4 Air Induction Cowling (See Figure 2, Item A). b. Install the hardware attaching the Bypass Floor Assembly to the Filter Frame Adapter (See Appendix A or Appendix B Figures). AFS-BH206L3L4-IBF-KIT-ICA Aerospace Filtration Systems, Inc. Revision: D Proprietary Information Use or disclosure of this material is subject 33 AFS Bell 206L1/C30, L-3, L-4 IBF to the restrictions on the title page Instructions for Continued Airworthiness c. Install the hardware attaching the Floor Closeout Angles to the Bell 206L1/C30, 206L-3 & 206L-4 Air Induction Cowling (See Appendix A or Appendix B Figures). d. Install the Filter Assembly (See Appendix A or Appendix B Figures) with the Engine Wash Tube attached. e. Connect the Engine Wash Tube (See Appendix A or Appendix B Figures) to the adapter on the Bypass Floor Assembly. f. Install the Bell 206L1/C30, 206L-3 & 206L-4 Air Induction Cowling (See Figure 2, Item A and refer to Maintenance Manual as applicable). g. Install the hardware attaching the Bypass Floor Assembly to the Firewall from the Engine side of the Firewall. h. Connect the wiring harness to the Bypass System Disconnect (See Appendix A or Appendix B Figures) 8.4.3 BYPASS DOOR (Ref. Appendix A or B, Figures A-1, A-6, A-8, A-9, and A-10 or B-1, B-6, B-8, B-9, or B-10) 8.4.3.1 REMOVAL a. Gain access to the Bypass Floor Assembly (See Paragraph 4.3). b. Remove the Bypass Floor Assembly from the Bell 206L1/C30, 206L-3 & 206L-4 Air Induction Cowling (Refer to Paragraph 8.4.2.1). c. Remove the bolt attaching the Actuator to the Bypass Door Clevis Plate (See Figure 11 and Appendix A or Appendix B Figures). d. Carefully open the flattened end of one end of the hinge (See Appendix A or Appendix B Figures). e. Remove the hinge pin (See Appendix A or Appendix B Figures). f. Remove the Bypass Door (See Appendix A or Appendix B Figures). 8.4.3.2 INSPECTION a. Cracking. Visually inspect the Bypass Door and related parts for cracking using 10x magnification at the corners, radiuses, and transitions in part thickness. Any fretting of faying surfaces, such as those at a crack may emit a black or grey dust or soot like material indicative of a crack. Inspect suspect areas carefully using the 10x magnification. No cracks are allowed in the Bypass Door. If cracks are found, Bypass Door must be replaced. b. Warping or distortion. Visually inspect the Bypass Door and related parts for warping or distortion. Any warping or distortion that keeps the Bypass Door from creating a seal to the Bypass Floor requires disposition instructions from AFS or replacement of the door. c. Protective Coatings. Visually inspect the Bypass Door and related parts for missing, damaged, or “scratched through” protective coatings. Re-apply protective coatings per Table 4 of this chapter. AFS-BH206L3L4-IBF-KIT-ICA Aerospace Filtration Systems, Inc. Revision: D Proprietary Information Use or disclosure of this material is subject 34 AFS Bell 206L1/C30, L-3, L-4 IBF to the restrictions on the title page Instructions for Continued Airworthiness d. Corrosion. Visually inspect the Bypass Door and related parts for corrosion in accordance with AC 43.13-1, Chapter 6, and Table 4. e. Missing, damaged or loose associated components. Visually inspect for missing, damaged, or loose components. 8.4.3.3 TROUBLESHOOTING See Table 5. 8.4.3.4 ADJUSTMENT Refer to Actuator / Bypass Door Adjustment (See paragraph 8.5.4.4). 8.4.3.5 CALIBRATION Not applicable. 8.4.3.6 REPAIR a. Cracks. No cracks are allowed in the Bypass Door. Cracks are not repairable. If cracks exist, Bypass Door must be replaced. b. Warping or distortion. Visually inspect the Bypass Door for warping or distortion. With the Bypass Door in the closed position the Bypass Door Seal should be uniformly compressed. If there are gaps refer to Bypass Door Adjustment. After adjustments are performed if the gaps still exist, the door is warped or distorted beyond limit. Replace Bypass Door. c. Protective Coatings. Visually inspect the Bypass Door for missing, damaged, or “scratched through” protective coatings. Re-apply protective coatings per Table 4 of this chapter. d. Corrosion. Treat corrosion in accordance with AC 43.13-1, Chapter 6 and Table 4. e. Missing, damaged or loose associated components. Replace missing or damaged components. Secure loose components. 8.4.3.7 INSTALLATION a. Locate the Bypass Door to the Bypass Floor Assembly (See Appendix A or Appendix B Figures). b. Install the Bypass Door to the Bypass Floor Assembly by installing the hinge pin (See Appendix A or Appendix B Figures). Crimp both ends of hinge to prevent pin from backing out (See Appendix A or Appendix B Figures). c. Temporarily install the Bolt attaching the Actuator to the Bypass Door Clevis Plate (See Figure 11, and See Appendix A or Appendix B Figures). d. Perform functional check per Actuator / Bypass Door Adjustment procedures (Refer to Paragraph 8.5.4.7). CAUTION