INLET BARRIER FILTER SYSTEM

2.3 FILTER RETIREMENT LIFE .................................................................................................................... 10 2.4 LIFE LIMITED COMPONENTS ................................................................................................................ 10 3 INSPECTION REQUIREMENTS AND OVERHAUL................................................................................... 11 3.1 INSPECTION REQUIREMENTS .............................................................................................................. 11 3.1.1 GENERAL REQUIREMENTS ............................................................................................................... 11 3.1.2 FILTER ASSEMBLY INSPECTION ...................................................................................................... 11 3.1.3 STRUCTURAL COMPONENT INSPECTIONS .................................................................................... 12 3.1.4 SYSTEMS AND ELECTRICAL COMPONENT INSPECTIONS ........................................................... 12 3.1.5 IBF BYPASS COCKPIT SWITCH FUNCTION CHECK ...................................................................... 12 3.2 OVERHAUL REQUIREMENTS................................................................................................................ 13 4 ACCESS PANELS .............................................................................................................................................. 16 4.1 GENERAL DESCRIPTION ........................................................................................................................ 16 4.2 ACCESS FOR FILTER SERVICING ......................................................................................................... 16 4.3 ACCESS FOR MAINTENANCE ............................................................................................................... 16 5 STORAGE ........................................................................................................................................................... 17 5.1 STORAGE................................................................................................................................................... 17 6 PLACARDS, DATA PLATES, AND MARKINGS ......................................................................................... 18 6.1 MARKING – P ART N UMBER / PMA / S ERIALIZATION ................................................................................ 18 6.2 DATA PLATE – FILTER ASSEMBLY...................................................................................................... 18 6.3 PLACARDS / MARKINGS - COCKPIT .................................................................................................... 18 7 SERVICING ........................................................................................................................................................ 19 7.1 AUTHORIZED MATERIALS .................................................................................................................... 19 7.2 FILTER SERVICE INTERVALS ............................................................................................................... 19 7.2.1 GENERAL REQUIREMENTS ............................................................................................................... 19 7.2.2 PREPARED FIELD OPERATIONS ...................................................................................................... 20 7.2.3 SEVERE ENVIRONMENT OPERATIONS ............................................................................................ 21 7.3 FILTER ASSEMBLY SERVICING............................................................................................................ 21 AFS-AS350B-IBF-ICA Aerospace Filtration Systems, Inc. Revision: F Proprietary Information Use or disclosure of this material is subject v AFS Eurocopter AS350 IBF to the restrictions on the title page Instructions for Continued Airworthiness 7.3.1 FILTER PRE-CLEANING ..................................................................................................................... 21 7.3.2 FILTER CLEANING.............................................................................................................................. 21 7.3.3 FILTER DRYING .................................................................................................................................. 22 7.3.4 FILTER OILING.................................................................................................................................... 23 7.4 STRUCTURAL COMPONENT SERVICING ........................................................................................... 24 7.5 SYSTEMS AND ELECTRICAL SERVICING........................................................................................... 25 7.6 ENGINE WATER WASH ........................................................................................................................... 25 7.7 AIRCRAFT WASHING .............................................................................................................................. 25 8 TROUBLESHOOTING AND MAINTENANCE ............................................................................................ 26 8.1 MAINTENANCE GENERAL .................................................................................................................... 26 8.2 COMPONENTS - GENERAL DESCRIPTION .......................................................................................... 27 8.2.1 FILTER ASSY / FILTER SEAL .............................................................................................................. 27 8.2.2 STRUCTURAL COMPONENTS ........................................................................................................... 27 8.2.3 SYSTEMS AND ELECTRICAL COMPONENTS ................................................................................... 27 8.3 FILTER ASSY / FILTER SEAL.................................................................................................................. 28 8.3.1 FILTER ASSY ........................................................................................................................................ 28 8.3.2 FILTER SEAL ........................................................................................................................................ 32 8.4 STRUCTURAL COMPONENTS ............................................................................................................... 33 8.4.1 EUROCOPTER AS350 SERIES AIR INDUCTION COWLING ............................................................ 33 8.4.2 BYPASS DOOR ..................................................................................................................................... 34 8.4.3 BYPASS DOOR SEAL ........................................................................................................................... 35 8.4.4 UPPER FAIRING ASSEMBLY .............................................................................................................. 36 8.5 SYSTEMS AND ELECTRICAL COMPONENTS ..................................................................................... 38 8.5.1 COCKPIT SWITCH/INDICATOR ......................................................................................................... 38 8.5.2 DIFFERENTIAL PRESSURE SWITCH ................................................................................................ 39 8.5.3 FILTER MAINTENANCE AID .............................................................................................................. 43 8.5.4 ACTUATOR........................................................................................................................................... 46 8.5.5 WIRING, WIRING HARNESS, CONNECTORS, BACKSHELLS, CIRCUIT BREAKER, RELAY ......... 50 8.6 FASTENER LISTING................................................................................................................................. 51 8.7 PROTECTIVE TREATMENT .................................................................................................................... 51 8.8 TROUBLESHOOTING GUIDE ................................................................................................................. 53 8.9 SPECIAL TOOLS / SPECIAL EQUIPMENT ............................................................................................... 1 8.9.1 CONSUMABLE MATERIALS, SUPPLIES, AND PROTECTIVE TREATMENT SPECIFICATIONS .... 1 9 ICA APPENDIX A – ILLUSTRATED PARTS BREAKDOWN ................................................................. A-2 AFS-AS350B-IBF-ICA Aerospace Filtration Systems, Inc. Revision: F Proprietary Information Use or disclosure of this material is subject vi AFS Eurocopter AS350 IBF to the restrictions on the title page Instructions for Continued Airworthiness Table of Pictures Picture 1: FMA Operation ............................................................................................................... 14 Picture 2: FMA Reset Location ....................................................................................................... 14 Picture 3: Cockpit Switch/Indicator ................................................................................................. 18 Picture 4: Circuit Breaker ................................................................................................................ 18 Picture 5: Oiling Filter Media .......................................................................................................... 24 Picture 6: Hand Seamer Used to Straighten or Crimp Pleats........................................................... 30 Picture 7: Test Setup with Manometer............................................................................................. 42 Picture 8: FMA Operation ............................................................................................................... 44 Picture 9: FMA Location ................................................................................................................. 45 Table of Tables Table 1: Inspection Intervals ............................................................................................................ 15 Table 2: Protective Treatment for Components ............................................................................... 52 Table 3: Troubleshooting Guide ...................................................................................................... 53 Table 4: Consumable Materials, Supplies and Protective Treatment Specifications ........................ 1 Table of Figures Figure 1: IBF System Installation ...................................................................................................... 7 Figure 2: Filter Assembly Data Plate ............................................................................................... 18 Figure 3: Test Equipment Setup ...................................................................................................... 42 AFS-AS350B-IBF-ICA Aerospace Filtration Systems, Inc. Revision: F Proprietary Information Use or disclosure of this material is subject 1 AFS Eurocopter AS350 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 perform the maintenance and repair of the Aerospace Filtration Systems, Inc. (AFS) Inlet Barrier Filter (IBF) system installation on the Eurocopter Model AS350 series helicopters. The ICA should be used in conjunction with all pertinent Eurocopter Model AS350 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 AFS, Eurocopter or the Airworthiness Directives issued by the local Aviation Authority, shall be strictly followed. 1.3 DEFINITIONS / TERMINOLOGY 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 Sand Filter 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 door assembly and associated wiring. 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 is located just aft of the filter that when opened by the actuator allows unfiltered air to be drawn into the engine. AFS-AS350B-IBF-ICA Aerospace Filtration Systems, Inc. Revision: F Proprietary Information Use or disclosure of this material is subject 2 AFS Eurocopter AS350 IBF to the restrictions on the title page Instructions for Continued Airworthiness Cockpit switch/indicator A push button switch, labeled “IBF”, is used to OPEN or CLOSE the bypass door. This switch is normally CLOSED and is depressed to the OPEN position only when the cockpit indicator, an amber caution “FILTER” light in the switch, illuminates. The “FILTER” portion of the switch illuminates any time the differential pressure reaches or exceeds a preset value. The “BYPASS” portion of the switch illuminates when the door is completely open. 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 downward). 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 upward 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. On-condition Indicates that servicing of the filter is based on a Filter Maintenance Aid (FMA) indication in the area marked in “RED”, Engine Power Check (EPC) results (where a failed EPC is the result of a dirty Filter Assembly), and / or any “IBF FILTER” light indication on the cockpit indicator. AFS-AS350B-IBF-ICA Aerospace Filtration Systems, Inc. Revision: F Proprietary Information Use or disclosure of this material is subject 3 AFS Eurocopter AS350 IBF to the restrictions on the title page Instructions for Continued Airworthiness Plenum chamber Space between the filter assembly and the engine inlet, and the space between the Bypass Door and engine inlet. 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. EPC = Engine Power Check 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 OAT = Outside Air Temperature RFM = Rotorcraft Flight Manual SAE = Society of Automotive Engineers TCDS = Type Certificate Data Sheet TIS = Time In Service AFS-AS350B-IBF-ICA Aerospace Filtration Systems, Inc. Revision: F Proprietary Information Use or disclosure of this material is subject 4 AFS Eurocopter AS350 IBF to the restrictions on the title page Instructions for Continued Airworthiness 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 Eurocopter France AS350 Series Technical Publications FAA FAA Advisory Circular, AC 43.13-1B, Acceptable Methods, Techniques, and Practices – Aircraft Inspection and Repair AFS-AS350B-IBF-ICA Aerospace Filtration Systems, Inc. Revision: F Proprietary Information Use or disclosure of this material is subject 5 AFS Eurocopter AS350 IBF to the restrictions on the title page Instructions for Continued Airworthiness 1.9 DISTRIBUTION OF CHANGES Changes shall be distributed by posting them on the AFS webpage www.afsfilters.com. Each customer must register to receive access to the webpage via a personalized log-in/password. 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. 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 on the side of the page. 1.11 SYSTEM DESCRIPTION AND OVERVIEW a. The Eurocopter AS350 IBF provides a barrier type filter assembly that mounts to the top of the Engine Air Induction Cowling in the same location and in lieu of the Air Induction Screen. The IBF installation requires only minor modifications to the existing Air Induction Cowling. The IBF provides aircraft owner/operators a high performance engine air filtration option that provide excellent filtration efficiency. 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. b. The IBF system does not interfere with any of the commercial items installed in the Eurocopter AS350 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, upper fairing assembly (which includes the bypass door assembly, actuator, differential pressure switch, filter maintenance aid and wiring harness), an engine interface assembly, a bottom cover and engine plenum extension. 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 light and wiring harness. For a detailed illustration of all kit components, see the Appendix A – Illustrated Parts Breakdown. c. The major components making up the bypass system include the bypass door, actuator, wiring harness, cockpit switch, indicator light, and differential pressure switch. d. 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 reaches the preset value the cockpit indicator light illuminates alerting the pilot that the filter is becoming restricted causing the engine to operate less AFS-AS350B-IBF-ICA Aerospace Filtration Systems, Inc. Revision: F Proprietary Information Use or disclosure of this material is subject 6 AFS Eurocopter AS350 IBF to the restrictions on the title page Instructions for Continued Airworthiness efficiently. At this point, the IBF is operating at approximately the same inlet differential pressure normally experienced with the Sand Filter installed. Upon illumination of the IBF “FILTER” caution light, the pilot must closely monitor the engine instruments and if engine performance degradation is evident the pilot should depress the cockpit switch, labeled IBF, to activate the actuator and open the bypass door. This will cause the bottom light, labeled “FILTER”, to extinguish and the top light, labeled “BYPASS”, to illuminate. 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. e. On the ground, a Filter Maintenance Aid, mounted inside the upper fairing assembly, which can be viewed through the transparent window, 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 1 & 2). f. The design of the bypass system allows the ground crew to cycle the bypass door only when power is applied to the aircraft. The switch can be pushed to actuate the bypass door open, and then pushed 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 fifteen Dzus or captive fasteners. The filter assembly can then be lifted out of the upper fairing. h. The engine wash can be accomplished easily by opening or removing the engine inlet cowling. AFS-AS350B-IBF-ICA Aerospace Filtration Systems, Inc. Revision: F Proprietary Information Use or disclosure of this material is subject 7 AFS Eurocopter AS350 IBF to the restrictions on the title page Instructions for Continued Airworthiness Figure 1: -101 IBF System Installation ITEM NO. ITEM NAME 1 Filter Assembly 2 Upper Fairing Assembly 3 Engine Interface Assembly 4 5 Cover Assembly Side Covers (optional) AFS-AS350B-IBF-ICA Aerospace Filtration Systems, Inc. Revision: F Proprietary Information Use or disclosure of this material is subject 8 AFS Eurocopter AS350 IBF to the restrictions on the title page Instructions for Continued Airworthiness Figure 2: -103 IBF System Installation ITEM NO. ITEM NAME 1 Filter Assembly 2 Upper Fairing Assembly 3 Engine Interface Assembly 4 Cover Assembly 5 Engine Plenum Extension AFS-AS350B-IBF-ICA Aerospace Filtration Systems, Inc. Revision: F Proprietary Information Use or disclosure of this material is subject 10 AFS Eurocopter AS350 IBF to the restrictions on the title page Instructions for Continued Airworthiness 2.2 GENERAL The Airworthiness Limitations for the AFS Inlet Barrier Filtration system (IBF) as installed on Eurocopter France model AS350B 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. 2.3 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 Section 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. 2.4 LIFE LIMITED COMPONENTS The only life limited component features are the number of cleanings of the filter assembly. See Section 2.3. AFS-AS350B-IBF-ICA Aerospace Filtration Systems, Inc. Revision: F Proprietary Information Use or disclosure of this material is subject 11 AFS Eurocopter AS350 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 - 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 1. Refer to Appendix A, Figure A-1 for the primary kit components. Refer to Figures A-2 through A-8 for structural details. Refer to Figure A-9 for electrical components. c. Table 1 gives a recommended inspection schedule for the components of the system. The Trouble-Shooting Guide, Table 2 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) and all associated seals/fasteners. b. ON-CONDITION: Any FMA indication in the “RED”, “FILTER” light indication of the IBF cockpit indicator or failed EPC requires a visual inspection in accordance with Chapter 7. c. VISUAL: All filter assembly components are to be visually inspected at every annual inspection 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. AFS-AS350B-IBF-ICA Aerospace Filtration Systems, Inc. Revision: F Proprietary Information Use or disclosure of this material is subject 12 AFS Eurocopter AS350 IBF to the restrictions on the title page Instructions for Continued Airworthiness 3.1.3 STRUCTURAL COMPONENT INSPECTIONS VISUAL: All structural IBF components are to be inspected in accordance with Table 1 every 100 hours and annual inspection. These components include the following: Eurocopter AS350 series Air Induction Cowling (OEM equipment), Filter Assembly, Bypass Door Assembly, Upper Fairing Assembly, Engine Interface Assembly, and the Engine Plenum Extension. 3.1.4 SYSTEMS AND ELECTRICAL COMPONENT INSPECTIONS a. VISUAL: The systems and electrical components are to be visually inspected in accordance with Table 1 every 100 hours and annual inspection. 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 1 every annual inspection. These components include the following: Circuit Breaker, Cockpit Switch/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 1). As such it is not considered an inspection of the FMA. The inspection Table 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 1), a failed EPC, 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 Section 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 2). 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 1). Perform the function check as follows: (1) With aircraft power ON, push the IBF BYPASS switch in, the BYPASS light should illuminate AFS-AS350B-IBF-ICA Aerospace Filtration Systems, Inc. Revision: F Proprietary Information Use or disclosure of this material is subject 13 AFS Eurocopter AS350 IBF to the restrictions on the title page Instructions for Continued Airworthiness and the bypass door should open, visually verify this has happened. (2) Push the IBF BYPASS switch in, and the BYPASS light should go out and the bypass door should close, visually verify this has happened. Turn aircraft power OFF. If conditions are not met refer to Table 3 Troubleshooting Guide. 3.2 OVERHAUL REQUIREMENTS There are no overhaul intervals or requirements applicable to this product at this time. AFS-AS350B-IBF-ICA Aerospace Filtration Systems, Inc. Revision: F Proprietary Information Use or disclosure of this material is subject 14 AFS Eurocopter AS350 IBF to the restrictions on the title page Instructions for Continued Airworthiness Picture 1: FMA Operation Picture 2: FMA Reset Location GREEN Zone YELLOW RESET Button RED Zone YELLOW Indicator PRESS YELLOW Button to RESET “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. FMA Viewing Window AFS-AS350B-IBF-ICA Aerospace Filtration Systems, Inc. Revision: F Proprietary Information Use or disclosure of this material is subject 15 AFS Eurocopter AS350 IBF to the restrictions on the title page Instructions for Continued Airworthiness 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. Scheduled 1. Visual 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 for access information. 3. IBF FILTER light or failed EPC. This inspection is required any time an IBF FILTER light indication or failed EPC is reported by the pilot. 4. Reference Appendix A – Illustrated Parts Breakdown. 5. Reference Trouble-Shooting Guide, Table 3 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 EPC (where the failed EPC is the result of a dirty Filter Assembly). 8. If conditions are not met refer to the Table 3 Troubleshooting Guide in this manual. AFS-AS350B-IBF-ICA Aerospace Filtration Systems, Inc. Revision: F Proprietary Information Use or disclosure of this material is subject 16 AFS Eurocopter AS350 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 Filter servicing requires removal of the filter assembly. See Chapter 8 for filter assembly removal/installation procedures and Chapter 7 for filter servicing procedures. 4.3 ACCESS FOR MAINTENANCE Access for maintenance of the system components located below the bypass door assembly (i.e. actuator, delta p switch, filter maintenance aid, etc.) requires removal of the bypass door assembly. See Chapter 8 for component removal/installation procedures, inspection, troubleshooting guide, adjustment/calibration/repair procedures. AFS-AS350B-IBF-ICA Aerospace Filtration Systems, Inc. Revision: F Proprietary Information Use or disclosure of this material is subject 17 AFS Eurocopter AS350 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 is oiling of the filter media. Refer to filter servicing Section 7.3. AFS-AS350B-IBF-ICA Aerospace Filtration Systems, Inc. Revision: F Proprietary Information Use or disclosure of this material is subject 18 AFS Eurocopter AS350 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 (see Figure 3). 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: Filter Assembly Data Plate 6.3 PLACARDS / MARKINGS - COCKPIT a. The IBF utilizes a cockpit switch/indicator labeled “IBF” on the aircraft instrument panel. The top half illuminates an amber “FILTER” message when the IBF differential pressure has reached a preset value. The bottom half illuminates an amber “BYPASS” message when the actuator has been energized and the bypass door is open. See Picture 3 for markings. b. The IBF circuit breaker in the circuit breaker panel (if applicable) is marked “IBF”. See Picture 4 for markings. Picture 3: Cockpit Switch/Indicator Picture 4: Circuit Breaker AFS-AS350B-IBF-ICA Aerospace Filtration Systems, Inc. Revision: F Proprietary Information Use or disclosure of this material is subject 19 AFS Eurocopter AS350 IBF to the restrictions on the title page Instructions for Continued Airworthiness 7 SERVICING 7.1 AUTHORIZED MATERIALS Service AFS Filter with only the following: a. Air Filter Oil  Squeeze bottle (11.2 oz) - AFS P/N 100100-112  1 qt. bottle - AFS P/N 100100-320  1 gal. container - AFS P/N 100101-000  5 gal. container - AFS P/N 100105-000 b. Air Filter Cleaner  1 gallon container - AFS P/N 100201-000  5 gallon container - AFS P/N 100205-000  Zok 27 Contact AFS for the products listed above. 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. AFS-AS350B-IBF-ICA Aerospace Filtration Systems, Inc. Revision: F Proprietary Information Use or disclosure of this material is subject 20 AFS Eurocopter AS350 IBF to the restrictions on the title page Instructions for Continued Airworthiness 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, an IBF “FILTER” light indication on the cockpit indicator, or upon a failed EPC (where the failed EPC 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 Section 7.3. c. The gradual increase in differential pressure across the IBF filter assembly causes an increase in the exhaust gas temperature (T4) required to produce a specified torque as measured during the EPC. A failed EPC due to an increase in differential pressure across the filter is cause for servicing of the filter assembly. See filter servicing Section 7.3. d. Any FMA indication in the area marked in “RED” requires servicing of the filter assembly. See filter servicing Section 7.3. e. At any time prior to an IBF “FILTER” indication on the cockpit indicator, an FMA indication in the “RED”, or a failed EPC, 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 Section 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 Section 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 provide 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 T4 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 Section 7.2.1 are followed. Refer to Section 7.3 for servicing of the filter assembly. AFS-AS350B-IBF-ICA Aerospace Filtration Systems, Inc. Revision: F Proprietary Information Use or disclosure of this material is subject 21 AFS Eurocopter AS350 IBF to the restrictions on the title page Instructions for Continued Airworthiness 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 provide 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 Section 7.2.1 are followed. Refer to Section 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 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. AFS-AS350B-IBF-ICA Aerospace Filtration Systems, Inc. Revision: F Proprietary Information Use or disclosure of this material is subject 22 AFS Eurocopter AS350 IBF to the restrictions on the title page Instructions for Continued Airworthiness a. Spray Air Filter Cleaner (Zok 27 or AFS) 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. In severe environmental conditions (high dirt/debris) the entire filter may be soaked in cleaner for an extended period of time as needed. 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. 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 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 the data plate in accordance with Section 6.2. AFS-AS350B-IBF-ICA Aerospace Filtration Systems, Inc. Revision: F Proprietary Information Use or disclosure of this material is subject 23 AFS Eurocopter AS350 IBF to the restrictions on the title page Instructions for Continued Airworthiness 7.3.4 FILTER OILING CAUTION NEVER PUT AN AFS FILTER ASSEMBLY IN SERVICE WITHOUT OILING IT. CAUTION USE ONLY AFS AIR FILTER OIL NOTE A squeeze bottle capable of accurately measuring out 11.2 fluid ounces should be used when applying the oil to the filter assembly 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 Picture 5). b. Apply approximately ¾ of the fourteen 11.2 fluid ounces that is to be applied to a 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 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. Apply all 11.2 ounces of the oil to the filter. AFS-AS350B-IBF-ICA Aerospace Filtration Systems, Inc. Revision: F Proprietary Information Use or disclosure of this material is subject 24 AFS Eurocopter AS350 IBF to the restrictions on the title page Instructions for Continued Airworthiness Picture 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. AFS-AS350B-IBF-ICA Aerospace Filtration Systems, Inc. Revision: F Proprietary Information Use or disclosure of this material is subject 25 AFS Eurocopter AS350 IBF to the restrictions on the title page Instructions for Continued Airworthiness 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 indicate 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 Pictures 1 & 2). 7.6 ENGINE WATER WASH NOTE It is not necessary to remove the IBF filter prior to conducting an engine wash. It is recommended the engine water wash frequency be in accordance with the current Honeywell 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 from rinsing away the oil in the filter media. AFS-AS350B-IBF-ICA Aerospace Filtration Systems, Inc. Revision: F Proprietary Information Use or disclosure of this material is subject 26 AFS Eurocopter AS350 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 - 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, Structural Components, and Systems and Electrical components throughout the manual. Refer to Appendix A for a breakdown of the kit components. The troubleshooting guide in Table 3 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 Eurocopter technical manuals or AC 43.13-1, Chapter 11. AFS-AS350B-IBF-ICA Aerospace Filtration Systems, Inc. Revision: F Proprietary Information Use or disclosure of this material is subject 27 AFS Eurocopter AS350 IBF to the restrictions on the title page Instructions for Continued Airworthiness 8.2 COMPONENTS - GENERAL DESCRIPTION 8.2.1 FILTER ASSY / FILTER SEAL (Refer to Appendix A, Figure A-8) 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. Filter Seal - The Filter Seal is a silicon sponge that is held in place with adhesive. 8.2.2 STRUCTURAL COMPONENTS (Refer to Appendix A, Figure A-1) a. Eurocopter AS350 Series Air Induction Cowling (OEM Equipment) - The AS350 Air Induction Cowling is part of the original equipment manufacturer supplied for the AS350 series helicopters. For description see Eurocopter AS350 series technical manuals. b. Upper Fairing Assembly / Bypass Door / Seal - The Bypass Door Assembly consists of a machined aluminum door, a machined aluminum alloy actuator bracket, a military standard (MS) aluminum alloy hinge and steel pin. The Upper Fairing Assembly consists of a composite fairing, 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, Figure A-11) a. Cockpit Switch/Indicator – This switch serves a dual purpose, it activates the bypass door as well as indicates that the filter is dirty. The switch is a push button type used to open or close the bypass door. The indicator is a split light that when the filter becomes dirty the top half will illuminate “FILTER” and as soon as the bypass door is fully opened the bottom will illuminate “BYPASS”. 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 Indicator for annunciation of the IBF “FILTER” light to signal that the differential pressure across the Filter Assembly has reached a preset value. 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 replacement. 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 replacement. The FMA is an AFS-AS350B-IBF-ICA Aerospace Filtration Systems, Inc. Revision: F Proprietary Information Use or disclosure of this material is subject 28 AFS Eurocopter AS350 IBF to the restrictions on the title page Instructions for Continued Airworthiness aid to help maintenance personnel and pilots to ascertain the current condition or trend accumulation of dirt on the Filter Assembly. d. Actuator - The Actuator is an electro-mechanical device that provides mechanical actuation of the Bypass Door when the cockpit switch is pushed to open or close the bypass door. 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 replacement. 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 / FILTER SEAL (Refer to Appendix A, Figure A-8) 8.3.1 FILTER ASSY 8.3.1.1 Removal – Filter Assy CAUTION UPON REMOVAL OF THE FILTER ASSEMBLY, COVER THE ENGINE INLET TO ENSURE IT IS PROTECTED FROM FOREIGN OBJECT DAMAGE (FOD). a. For the 112300-101 Filter Assembly, remove the fifteen (15) Dzus fasteners securing the Filter Assembly to the Upper Fairing Assembly. For the 112300-103 Filter Assembly, remove the fifteen (15) captive fasteners securing the Filter Assembly to the Upper Fairing Assembly. NOTE The Filter Assembly must be carefully removed so as not to damage the Filter Seal. b. Use a plastic scraper to gently break any seal between the Filter Assembly and the Seal itself. c. Carefully remove the Filter Assembly from the Upper Fairing Assembly. d. Inspect the Filter Seal. Refer to “Filter Seal” procedures. AFS-AS350B-IBF-ICA Aerospace Filtration Systems, Inc. Revision: F Proprietary Information Use or disclosure of this material is subject 29 AFS Eurocopter AS350 IBF to the restrictions on the title page Instructions for Continued Airworthiness 8.3.1.2 Inspection – Filter Assy 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 ensure 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 an IBF “FILTER” light indication or failed EPC, perform troubleshooting per Table 3. If troubleshooting indicates a dirty filter, service filter per Section 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. 8.3.1.3 Troubleshooting – Filter Assy See Table 3 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. AFS-AS350B-IBF-ICA Aerospace Filtration Systems, Inc. Revision: F Proprietary Information Use or disclosure of this material is subject 30 AFS Eurocopter AS350 IBF to the restrictions on the title page Instructions for Continued Airworthiness 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, Section 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 Picture 6). 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. Picture 6: 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-AS350B-IBF-ICA Aerospace Filtration Systems, Inc. Revision: F Proprietary Information Use or disclosure of this material is subject 31 AFS Eurocopter AS350 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 without degradation of performance to the Filter Assembly. 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 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 Section 6.2 indicating a cleaning cycle has been 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, 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 2 for application of protective coatings. b. Any damage to the filter frame such as cracking requires the Filter Assembly 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 Upper Fairing Assembly do not permit the Filter Assembly to sit flush against the Upper Fairing) requires the Filter Assembly be returned to AFS for evaluation and disposition or replacement. AFS-AS350B-IBF-ICA Aerospace Filtration Systems, Inc. Revision: F Proprietary Information Use or disclosure of this material is subject 32 AFS Eurocopter AS350 IBF to the restrictions on the title page Instructions for Continued Airworthiness 8.3.1.10 Installation – Filter Assy CAUTION REMOVE COVER FROM THE ENGINE INLET PRIOR TO INSTALLING THE FILTER ASSEMBLY. CAUTION OVER TIGHTENING OF THE FASTENERS MAY RESULT IN THE FASTENER BEING DAMAGED. a. Prior to installation of the Filter Assembly, the Filter Seal on the Upper Fairing Assembly shall be visually inspected for security and damage. Carefully position the Filter Assembly in the Upper Fairing Assembly with the two holes forward. Ensure the Filter Assembly seats properly (not cocked, i.e. fits flush) against the Upper Fairing Assembly. b. For the 112300-101 Filter Assembly, install the fifteen (15) Dzus fasteners securing the Filter Assembly to the Upper Fairing Assembly. For the 112300-103 and 112300-105 Filter Assembly, install the fifteen (15) captive fasteners securing the Filter Assembly to the Upper Fairing Assembly. 8.3.2 FILTER SEAL 8.3.2.1 Removal a. Gain access to the Filter Seal by removing the Filter Assembly. Refer to Sections 4.3.1 and 8.3.1. b. Carefully remove the Seal by peeling it away from the Upper Fairing Assembly. Use a plastic scraper or other suitable tool that won’t damage the Upper Fairing to peel the Seal from the Upper Fairing Assembly. 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. 8.3.2.3 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 AFS-AS350B-IBF-ICA Aerospace Filtration Systems, Inc. Revision: F Proprietary Information Use or disclosure of this material is subject 33 AFS Eurocopter AS350 IBF to the restrictions on the title page Instructions for Continued Airworthiness 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 or equivalent. 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 to properly seal against 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. 8.3.2.4 Installation a. Gain access to the Filter Seal. Refer to Sections 4.3.1 and 8.3.1. b. To install the Seal, clean bottom surface of Filter Frame, locate and bond Seal in place using Dow Corning RTV 736 or equivalent. 8.4 STRUCTURAL COMPONENTS 8.4.1 EUROCOPTER AS350 SERIES AIR INDUCTION COWLING 8.4.1.1 Removal a. Release Air Induction Cowling tiedowns and open cowling. b. Disconnect electrical Bypass System Connector. c. Remove hinge pin. d. Remove Air Induction Cowling from aircraft. 8.4.1.2 Inspection a. The AFS IBF interfaces the Air Induction Cowling where the Upper Fairing Assembly is sandwiched between the Upper Fairing and the Engine Interface and the where the Upper Fairing is sealed to the Cowling. At these locations inspect for chafing or fretting, elongation of fastener holes, damage to nut plates and fasteners, corrosion, cracking, deformation, and check the seal around the Upper Fairing. b. Inspection for the above conditions and any other conditions that may be applicable are defined in the Eurocopter AS350 series technical manuals.