INSTRUCTIONS FOR CONTINUED AIRWORTHINESS A120-1

Figure 1.1.2 Figure 1.1.3 AIRFILM CAMERA SYSTEMS INSTRUCTIONS FOR CONTINUED AIRWORTHINESS DOCUMENT No. AF120-005 Dated: Jan. 17, 2002 REVISION: 0 PAGE 4 1.3 SCOPE The scope of this document is limited to information, procedures, requirements and limitations for this Supplemental Type Certificate. When a requirement specified in the appendix to the regulations is not applicable to this Supplemental Type Certificate the requirement will not be included in the Instructions for Continued Airworthiness. 1.4 APPLICABILITY These Instructions for Continued Airworthiness are applicable to the Airfilm Camera Systems A120-1 Universal Mount installed on the Eurocopter EC120BHelicopter. 1.5 DOCUMENT CHANGE CONTROL Changes to this document will be distributed to registered owners of the A120-1 Universal Mount within 10 days after the revision is approved. Changes to this document will be indicated by a revision number in the footer, vertical lines adjacent to the change, and in the Record of Revisions. AIRFILM CAMERA SYSTEMS INSTRUCTIONS FOR CONTINUED AIRWORTHINESS DOCUMENT No. AF120-005 Dated: Jan. 17, 2002 REVISION: 0 PAGE 5 2.0 AIRWORTHINESS LIMITATIONS No airworthiness limitations associated with this type design change AIRFILM CAMERA SYSTEMS INSTRUCTIONS FOR CONTINUED AIRWORTHINESS DOCUMENT No. AF120-005 Dated: Jan. 17, 2002 REVISION: 0 PAGE 6 3.0 INSPECTION REQUIREMENTS Figure 3.0.1: Isometric View Table 3.0.1 Parts List ITEM QTY PART NUMBER DESCRIPTION 1 1 A120-10-10 Top Cap Bracket 2 1 A120-20 Drag Bracket Assembly 3 1 A120-10-11 Lower Bracket 4 1 A120-10-12 End Fitting 5 1 A120-5 Tube Assembly 6 10 AN960-616 Washer 7 5 AN365-624A Stop Nut 8 1 AN6-13A Hex Bolt 9 2 AB6-34A Hex Bolt 10 2 AN6-40A Hex Bolt 11 1 A120-20-5 Attach Pad 11 AIRFILM CAMERA SYSTEMS INSTRUCTIONS FOR CONTINUED AIRWORTHINESS DOCUMENT No. AF120-005 Dated: Jan. 17, 2002 REVISION: 0 PAGE 7 3.0 INSPECTION REQUIREMENTS Figure 3.0.2: Exploded View 3.1 SCHEDULED INSPECTIONS The scheduled inspections required by this ICA are contained on the following checklists. This checklist, when completed, is to become a permanent part of the A120-1 Universal Mount records. NOTE: There are no field repairs or overhaul allowed for the A120-1 Universal mount. If the mount fails the following inspections, the mount is to be removed from the helicopter and returned to Airfilm Camera Systems. 3.1.1 100 HOUR INSPECTION INTERVALS The 100 hour time in service inspections consist of visually inspecting the critical area of the A120-1 Universal Mount installation. Due to the simplicity of the mount structure, all scheduled 100 hour inspections consist of the same items since the mount is inspected while installed on the helicopter. The inspections per Table 3.1.1 are required while the A120-1 Universal Mount is installed on the helicopter at the time in service interval as specified. The inspection is to be performed by maintenance personnel. AIRFILM CAMERA SYSTEMS INSTRUCTIONS FOR CONTINUED AIRWORTHINESS DOCUMENT No. AF120-005 Dated: Jan. 17, 2002 REVISION: 0 PAGE 8 3.1.1 100 HOUR INSPECTION INTERVALS TABLE 3.1.1 100 HOUR TIME IN SERVICE INSPECTIONS ON HELICOPTER Inspect. Interval Hours Inspection Maintenance Personnel Initial 100 Visually inspect welds for cracks | Visually inspect aluminum brackets for cracks, nicks or deep scratches | Visually inspect tubes for dents, deep scratches, or cracks. | Visually inspect Drag Brace for cracks, dents, deep scratches or damage | Visually inspect drag brace fork ends for tightness and cracks 3.2 1000 HOUR TIME IN SERVICE INSPECTION INTERVAL The 1000 hour time in service inspection is to be performed every 1000 hours time in service. The mount must be removed from the helicopter and disassembled per Section 4.0. 3.2.1 Drag Brace Assembly, A120-20: 3.2.1.1 Fork Ends, A120-20-3 Inspect quantity 2 per Table 3.2.2 3.2.1.2 Torque Tube Assy. A120-40: Inspect per Table 3.2.3 3.2.2 Upper Top Cap Bracket: A120-10-10: Inspect Fitting per Table 3.2.1 3.2.4 Lower Attach Bracket, A120-10-11: Inspect Fitting per Table 3.2.1 3.2.5 End Fitting, A120-10-12: Inspect Fitting per Table 3.2.1 3.2.6 Tube Assembly, A120-5: Inspect per Table 3.2.3 3.2.7 Attach Pad fitting A120-20-5: Inspect per Table 3.2.1 AIRFILM CAMERA SYSTEMS INSTRUCTIONS FOR CONTINUED AIRWORTHINESS DOCUMENT No. AF120-005 Dated: Jan. 17, 2002 REVISION: 0 PAGE 9 TABLE 3.2.1 FITTING INSPECTIONS Inspect. Interval Hours Inspection Maintenance Personnel Initial 1000 Visually inspect bolt holes for damage | Visually inspect brackets for cracks, nicks or deep scratches TABLE 3.2.2 FORK END INSPECTIONS Inspect. Interval Hours Inspection Maintenance Personnel Initial 1000 Visually inspect bolt holes for damage Visually inspect threads for signs of damage Visually inspect body for cracks, nicks, and scratches TABLE 3.2.3 TUBE INSPECTIONS Inspect. Interval Hours Inspection Maintenance Personnel Initial 1000 Visually inspect welds for cracks | Visually inspect bolt holes for signs of cracks, elongation or damage. | Visually inspect tubes for dents, deep scratches, or cracks. | Visually inspect threads for signs of damage 3.3 INSPECTION LIMITS The A120-1 Universal Mount is to be removed from service and returned to Airfilm Camera Systems if the following inspection limits are exceeded. Cracks: Any indication Bolt hole elongation Any Indication Dents, scratches or nicks Greater than 0.010 inches Tube Dents: Greater than 0.020 inches Tube scratches: Greater than 0.010 inches AIRFILM CAMERA SYSTEMS INSTRUCTIONS FOR CONTINUED AIRWORTHINESS DOCUMENT No. AF120-005 Dated: Jan. 17, 2002 REVISION: 0 PAGE 10 4.0 REMOVAL, DISASSEMBLY, REASSEMBLY AND INSTALLATION Refer to Figures 3.0.1 and 3.0.2 and Table 3.0.1 for views and parts list. 4.1 REMOVAL Remove the A120-1 Universal Mount from the Helicopter as follows: 4.1.1 Remove two AN6-12A Bolts, AN365-624A nuts and two AN960-616L washers. Remove the A120-20 Drag Brace Assembly. Discard bolts. 4.1.2 Remove Eurocopter P/N 22125BC060024L screw and washer P/N 23111AG060LE in forward location and one P/N DHS411-101-3038 Screw and washer P/N 23111AG060LE in aft location. 4.1.3 At Upper bracket remove AN6-13A bolt, AN960-616 washer and AN365-624 nut. Remove mount from helicopter. 4.2 DISASSEMBLY 4.2.1 Disassemble the A120-10 Drag brace by loosening the AN364-624A Nuts and removing the two A120-20-3 Fork Ends from the drag brace A120-40 Torque Tube. 4.2.2 Remove the two AN 6 Bolts.at the upper fitting location. Remove upper A120-10-10 Top Cap Bracket from the A120-05 Tube Assembly. Discard bolts. 4.2.3 Remove the two AN 6 Bolts.at the lower fitting location. Remove lower A120-10-11 Lower Attach Bracket from the A120-5 Tube Assembly. 4.2.4 Remove the two AN 6 Bolts.at the middle fitting location. Remove middle A120-10-12 End Fitting from the A120-5 Tube Assembly. Discard bolts. 4.3 REASSEMBLY Consumable Products: Mastinox 6856K (Mil-P-8116B) or equivalent 4.3.1 Install middle A120-10-12 End Fitting (coat contacting surfaces with Mastinox) into the A120- 5 Tube Assembly. Install two AN 6-40A Bolts, two AN960-616 washers and one AN365- 624A nut through the existing holes at the middle fitting location. Torque AN365-624A nut to 200-230 in-lbs. 4.3.2 Install A120-10-11 Lower Attach Bracket (coat contacting surfaces with Mastinox into the A120-5 Tube Assembly. Install the two AN 6-40A Bolts, two AN960-616 washers and one AN365-624A nut through the existing holes at the lower fitting location. Torque AN365-624A nuts to 200-230 in-lbs. AIRFILM CAMERA SYSTEMS INSTRUCTIONS FOR CONTINUED AIRWORTHINESS DOCUMENT No. AF120-005 Dated: Jan. 17, 2002 REVISION: 0 PAGE 11 4.3.3. Install upper A120-10-10 Top Cap Bracket (coat contacting surfaces with Mastinox) into the A120-05 Tube Assembly. Install the two AN 6-34A Bolts, two AN960-616 washers and two AN365-624A nuts through the existing holes. Torque AN365-624A nuts to 200-230 in-lbs. 4.4 INSTALLATION Install the A120-1 Universal Mount onto the Helicopter as follows: 4.4.1 Align A120-10-11 Lower Bracket with the holes at the left aft cargo swing location. Install Eurocopter P/N 22125BC060024L screw and washer P/N 23111AG060LE in forward location, Torque to 100-110 in-lbs. Install one Eurocopter P/N DHS411-101-3038 Screw and washer P/N 23111AG060LE in aft location. Torque to 200-230 in-lbs. 4.4.2 Align Upper bracket clevis hole with helicopter upper shoulder hard point (EC P/N C533C 7342203 Fitting Jack) shown on Figure 1.1.1. Install AN6-13A bolt, An960-616 washer and AN365-624 nut. Torque AN365-624A nuts to 200-230 in-lbs. 4.4.3 Install two A120-20-3 Fork Ends with AN 364-624A nuts into A120 Drag Brace. 4.4.4 Install A120-20 Drag Brace onto the clevis in the A120-5 Tube Assembly leaving approx 0.50 inches of thread showing. Install the AN 6-12A Bolt, one AN960-616 washer and one AN365- 624A nut through the existing hole. Torque AN365-624A nut to 200-230 in-lbs. 4.4.5 Adjust A120-20 Drag Brace clevis to align with hole in the A120-20-5 Attach Pad. Align holes to at least one thread turn. Insure that no more than 3/8 inches of thread show on clevis. Align holes and install AN 6-12A Bolt, one AN960-616 washer and one AN365-624A nut through the existing hole. Torque AN365-624A nut to 200-230 in-lbs. Torque AN364-624A nuts on each clevis to 100 to 110 in-lbs 5.0 WEIGHT AND BALANCE The weight and center of gravity location for the A120-1 Universal Mount is: Wt = 21.5 lbs Station: 183.3 inches BL: -28.75 inches (left)