INLET BARRIER FILTER SYSTEM

Donaldson Company, Inc. Disclosure, reproduction, or use of this data for any purpose other than helicopter operation and/or maintenance is forbidden without prior written authorization from Donaldson Company, Inc. EFFECTIVITY Effectivity for this ICA is for all Leonardo Models A119 and AW119 MKII [including the AW119 G1000H and AW119 IDU-680P (TH-119) variants] with the Donaldson Company, Inc. (DCI) Inlet Barrier Filter (IBF) System installed. AFS-AA119-IBF-ICA Donaldson Company, Inc. Revision: K Proprietary Information Use or disclosure of this material is subject v DCI Leonardo A119 IBF to the restrictions on the title page Instructions for Continued Airworthiness THIS PAGE INTENTIONALLY LEFT BLANK AFS-AA119-IBF-ICA Donaldson Company, Inc. Revision: K Proprietary Information Use or disclosure of this material is subject vi DCI Leonardo A119 IBF to the restrictions on the title page Instructions for Continued Airworthiness INSTRUCTIONS FOR CONTINUED AIRWORTHINESS For the Donaldson Company Engine Inlet Barrier Filter System Installed on the Leonardo S.p.A Models A119 and AW119 MKII [including the AW119 G1000H and AW119 IDU- 680P (TH-119) variants] TABLE OF CONTENTS 1 INTRODUCTION ............................................................................................................................................... 1 1.1 SCOPE OF THIS MANUAL ....................................................................................................................... 1 1.2 USE OF THIS MANUAL ............................................................................................................................ 1 1.3 DEFINITIONS / TERMINOLOGY .............................................................................................................. 1 1.4 ACRONYMS ............................................................................................................................................. 3 1.5 WARNINGS, CAUTIONS, AND NOTES ................................................................................................... 3 1.6 UNITS OF MEASURE ............................................................................................................................... 3 1.7 REFERENCE PUBLICATIONS................................................................................................................. 4 1.8 LIST OF APPLICABLE PUBLICATIONS .................................................................................................. 4 1.9 DISTRIBUTION OF CHANGES ................................................................................................................ 4 1.10 INDICATION OF CHANGES ..................................................................................................................... 4 1.11 SYSTEM DESCRIPTION AND OVERVIEW ............................................................................................. 4 2 AIRWORTHINESS LIMITATIONS .................................................................................................................... 7 2.1 GENERAL ................................................................................................................................................. 8 2.2 FILTER RETIREMENT LIFE ..................................................................................................................... 8 2.3 LIFE LIMITED COMPONENTS ................................................................................................................. 8 3 INSPECTION REQUIREMENTS AND OVERHAUL ........................................................................................ 9 3.1 INSPECTION REQUIREMENTS .............................................................................................................. 9 3.1.1 GENERAL REQUIREMENTS .............................................................................................................. 9 3.1.2 FILTER ASSEMBLY INSPECTION ...................................................................................................... 9 3.1.3 STRUCTURAL COMPONENT INSPECTIONS ................................................................................. 10 3.1.4 SYSTEMS AND ELECTRICAL COMPONENT INSPECTIONS ........................................................ 10 3.2 OVERHAUL REQUIREMENTS .............................................................................................................. 12 3.3 SPECIAL INSPECTIONS (CONDITIONAL INSPECTIONS) .................................................................. 12 3.3.1 HARD LANDING................................................................................................................................. 13 3.3.2 LIGHTNING STRIKE .......................................................................................................................... 13 4 ACCESS PANELS .......................................................................................................................................... 14 4.1 GENERAL DESCRIPTION ..................................................................................................................... 14 4.2 ACCESS FOR MAINTENANCE .............................................................................................................. 14 4.2.1 ACCESS OF FMA AND DP SWITCH ASSEMBLIES ........................................................................ 14 4.2.2 ACCESS OF BYPASS ACTUATOR ASSEMBLY .............................................................................. 14 5 STORAGE ....................................................................................................................................................... 15 6 PLACARDS, DATA PLATES, AND MARKINGS ........................................................................................... 16 6.1 MARKING – PART NUMBER / PMA / SERIALIZATION ......................................................................... 16 6.2 DATA PLATE – FILTER ASSEMBLY ...................................................................................................... 16 6.3 PLACARDS / MARKINGS - COCKPIT .................................................................................................... 16 7 SERVICING ..................................................................................................................................................... 17 7.1 AUTHORIZED MATERIALS ................................................................................................................... 17 7.2 FILTER SERVICE INTERVALS .............................................................................................................. 17 7.2.1 GENERAL REQUIREMENTS ............................................................................................................ 17 7.2.2 PREPARED FIELD OPERATIONS .................................................................................................... 18 7.2.3 SEVERE ENVIRONMENT OPERATIONS ......................................................................................... 18 7.3 FILTER ASSEMBLY SERVICING ........................................................................................................... 19 AFS-AA119-IBF-ICA Donaldson Company, Inc. Revision: K Proprietary Information Use or disclosure of this material is subject vii DCI Leonardo A119 IBF to the restrictions on the title page Instructions for Continued Airworthiness 7.3.1 FILTER PRE-CLEANING ................................................................................................................... 19 7.3.2 FILTER CLEANING ............................................................................................................................ 19 7.3.3 FILTER DRYING ................................................................................................................................ 20 7.3.4 FILTER OILING .................................................................................................................................. 20 7.4 STRUCTURAL COMPONENT SERVICING ........................................................................................... 22 7.5 SYSTEMS AND ELECTRICAL SERVICING........................................................................................... 22 7.6 AIRCRAFT WASHING ............................................................................................................................ 22 8 TROUBLESHOOTING AND MAINTENANCE ............................................................................................... 23 8.1 MAINTENANCE GENERAL .................................................................................................................... 23 8.2 COMPONENTS - GENERAL DESCRIPTION......................................................................................... 24 8.2.1 FILTER ASSY/FILTER SEAL ............................................................................................................. 24 8.2.2 FILTER HOUSING ASSEMBLY (STRUCTURAL COMPONENTS) .................................................. 24 8.2.3 SYSTEMS AND ELECTRICAL COMPONENTS................................................................................ 24 8.3 FILTER ASSY / FILTER SEAL ................................................................................................................ 25 8.3.1 FILTER ASSY ..................................................................................................................................... 25 8.3.2 FILTER SEAL ..................................................................................................................................... 29 8.4 STRUCTURAL COMPONENTS ............................................................................................................. 30 8.4.1 FILTER HOUSING ASSEMBLY ......................................................................................................... 30 8.4.2 LOWER SIDE FILTER SUPPORTS ................................................................................................... 32 8.5 SYSTEMS AND ELECTRICAL COMPONENTS..................................................................................... 34 8.5.1 CIRCUIT BREAKER ........................................................................................................................... 34 8.5.2 COCKPIT INDICATOR LIGHT ........................................................................................................... 35 8.5.3 DIFFERENTIAL PRESSURE SWITCH .............................................................................................. 36 8.5.4 FILTER MAINTENANCE AID ............................................................................................................. 39 8.5.5 ACTUATOR ........................................................................................................................................ 42 8.5.6 WIRING, WIRING HARNESS, CONNECTORS, BACKSHELLS, CIRCUIT BREAKER .................... 45 8.6 PROTECTIVE TREATMENT .................................................................................................................. 46 8.7 TROUBLESHOOTING GUIDE................................................................................................................ 48 8.8 SPECIAL TOOLS / SPECIAL EQUIPMENT............................................................................................ 49 8.9 CONSUMABLE MATERIALS, SUPPLIES, AND PROTECTIVE TREATMENT SPECIFICATIONS....... 49 APPENDIX A .............................................................................................................................................................. I AFS-AA119-IBF-ICA Donaldson Company, Inc. Revision: K Proprietary Information Use or disclosure of this material is subject viii DCI Leonardo A119 IBF to the restrictions on the title page Instructions for Continued Airworthiness TABLE OF FIGURES Figure 1: IBF SYSTEM AND INSTALLATION .......................................................................................... 6 Figure 2: FILTER MAINTENANCE AID .................................................................................................. 11 Figure 3: FILTER MAINTENANCE AID .................................................................................................. 11 Figure 4: COMPONENT ACCESS ......................................................................................................... 14 Figure 5: EXAMPLE OF FILTER ASSEMBLY DATA PLATE ................................................................. 16 Figure 6: IBF MARKINGS ....................................................................................................................... 16 Figure 7: OILING MEDIA ........................................................................................................................ 21 Figure 8: HAND SEAMER ...................................................................................................................... 27 Figure 9: FILTER MAINTENANCE AID ZONES..................................................................................... 40 Figure 10: FILTER MAINTENANCE AID RESET ................................................................................... 40 Figure 11 ACTUATOR ADJUSTMENT................................................................................................... 44 TABLE OF FIGURES (APPENDIX A) Figure A-1: IBF System ............................................................................................................................ II Figure A-2: Major Assemblies.................................................................................................................. III Figure A-3: Side Filter Assembly ............................................................................................................. V Figure A-4: Upper Filter Assembly.......................................................................................................... VI Figure A-5: Actuator & Upper Filter/Bypass Door Instl (Superseded) ................................................... VII Figure A-6: Actuator & Upper Filter/Bypass Door Instl (Current) .......................................................... VIII Figure A-7: DP Switch & Maintenance Indicator Installation ................................................................... X Figure A-8: Wire Harness Assembly Instl (Superseded) ....................................................................... XII Figure A-9: Wire Harness Assembly Instl (Current).............................................................................. XIII Figure A-10: Side Filter Support Assembly............................................................................................ XV Figure A-11: Electrical Schematic for IBF S/N 0068 and Below ........................................................... XVI Figure A-12: Electrical Schematic for IBF S/N 0069 and Above.......................................................... XVII Figure A-13: Electrical Schematic for IBF AW119 G1000H ................................................................ XVIII Figure A-14: Electrical Schematic for IBF AW119 Genesys IDU-680P ................................................ XIX Figure A-15: Actuator Schematic ........................................................................................................... XX Figure A-16: Wire Routing .................................................................................................................... XXI Figure A-17: IBF Connector Location .................................................................................................. XXII Figure A-18: IBF Indicator/Switch and Circuit Breaker Location......................................................... XXIII Figure A-19: IBF Indicator/Switch and Circuit Breaker Location for AW119 G1000H ........................ XXIV Figure A-20: IBF Indicator/Switch and Circuit Breaker Location for AW119 Genesys IDU-680 .......... XXV Figure A-21: Circuit Breaker Locator ..................................................................................................XXVI Figure A-22: Circuit Breaker Locator for AW119 G1000H ................................................................. XXVII Figure A-23: Circuit Breaker Locator for AW119 Genesys IDU-680P .............................................. XXVIII TABLES Table 3- 1 Inspection Intervals................................................................................................................ 12 Table 8- 1 Protective Treatment for Components................................................................................... 47 Table 8- 2 Troubleshooting Guide .......................................................................................................... 48 Table 8- 3 Consumable Materials, Supplies and Protective Treatment Specifications .......................... 49 AFS-AA119-IBF-ICA Donaldson Company, Inc. Revision: K Proprietary Information Use or disclosure of this material is subject ix DCI Leonardo A119 IBF to the restrictions on the title page Instructions for Continued Airworthiness THIS PAGE INTENTIONALLY LEFT BLANK AFS-AA119-IBF-ICA Donaldson Company, Inc. Revision: K Proprietary Information Use or disclosure of this material is subject 1 DCI Leonardo A119 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 DCI Inlet Barrier Filter (IBF) system installation on the Leonardo S.p.A Models A119 and AW119 MKII [including the AW119 G1000H and AW119 IDU-680P (TH-119) variants]. This ICA should be used in conjunction with all pertinent Leonardo Model A119 and AW119 MKII manuals and all publications listed in the List of Applicable Publications (LOAP). NOTE Thoroughly review and become familiar with the Appendix A – Parts Figures 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 Donaldson Company, Inc. (DCI), Leonardo S.p.A. 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 EAPS or the IBF, to prevent engine foreign object damage. Air induction system This represents the major kit components including the IBF filter assemblies, plenums, 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 on the top of the IBF Filter housing assembly that, when opened by the actuator, allows unfiltered air from the environment around the aircraft to be drawn into the engine. Cockpit Indicator/switch Cockpit indicator/switch is a lighted push-button switch that is located in center console panel within easy reach of the pilot and labeled “IBF”. The switch is used to energize the actuator by depressing the switch to open the bypass door and depressing it to close the bypass door. When the filter has enough dirt/debris that causes the differential pressure reach or exceed a preset limit, the FILTER segment of the indicator will illuminate and when the bypass is fully employed, the BYPASS segment of the indicator will illuminate. AFS-AA119-IBF-ICA Donaldson Company, Inc. Revision: K Proprietary Information Use or disclosure of this material is subject 2 DCI Leonardo A119 IBF to the restrictions on the title page Instructions for Continued Airworthiness Differential pressure The difference between the ambient pressure and the pressure inside the plenum chamber, 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 downstream side Clean side of the filter media (i.e. the side of the filter facing toward the engine) 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 of the filter facing the incoming 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”, 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 light/switch indicator. Plenum chamber Area contained inside the IBF filter assembly. 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. AFS-AA119-IBF-ICA Donaldson Company, Inc. Revision: K Proprietary Information Use or disclosure of this material is subject 3 DCI Leonardo A119 IBF to the restrictions on the title page Instructions for Continued Airworthiness 1.4 ACRONYMS DCI = Donaldson Company, Inc. ATA = Air Transport Association of America, Inc. DP = Differential Pressure EAPS = Engine Air Particle Separator FAR = Federal Aviation Regulation FMA = Filter Maintenance Aid FMS = Flight Manual Supplement FOD = Foreign Object Damage IBF = Inlet Barrier Filter ICA = Instructions for Continued Airworthiness IP = Installation Procedures IPB = Illustrated Parts Breakdown LOAP = List of Applicable Publications ITT = Interturbine Temperature OAT = Outside Air Temperature 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. WARNING AN OPERATING PROCEDURE, PRACTICE, ETC., WHICH, IF NOT CORRECTLY FOLLOWED, COULD RESULT IN PERSONAL INJURY OR LOSS OF LIFE. CAUTION AN OPERATING PROCEDURE, PRACTICE, ETC., WHICH, IF NOT STRICTLY OBSERVED, COULD RESULT IN DAMAGE TO OR DESTRUCTION OF EQUIPMENT. NOTE An operating procedure, condition, etc., which it is essential to highlight. 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. AFS-AA119-IBF-ICA Donaldson Company, Inc. Revision: K Proprietary Information Use or disclosure of this material is subject 4 DCI Leonardo A119 IBF to the restrictions on the title page Instructions for Continued Airworthiness 1.7 REFERENCE PUBLICATIONS Reserved for future use. 1.8 LIST OF APPLICABLE PUBLICATIONS LEONARDO S.p.A Models A119 and AW119 MKII [including the AW119 G1000H and AW119 IDU-680P (TH-119) variants] Technical Publications FAA FAA Advisory Circular, AC 43.13-1B, Acceptable Methods, Techniques, and Practices – Aircraft Inspection and Repair FAA Advisory Circular, AC 27-1B, Certification of Normal Category Rotorcraft NOTE Unless otherwise specified use standard torque values when tightening bolts. (Refer to AC 43.13-1B, Chapter 7) 1.9 DISTRIBUTION OF CHANGES Changes shall be distributed by posting them on the DCI webpage www.donaldsonaerospace- defense.com. The ICA may also be found on https://ShopDonaldson.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 DCI at (636) 300-5200 for assistance. 1.10 INDICATION OF CHANGES All changes will be complete revisions with all pages marked with the latest revision letter. All changes since the last revision shall be marked with a black vertical bar in the left side of the page. 1.11 SYSTEM DESCRIPTION AND OVERVIEW a. The Leonardo IBF system is offered to operators which includes a filter housing assembly with three filter assemblies, a bypass door, and electrical hardware. b. The IBF system is located in the same location and in lieu of the OEM air induction screen or the Engine Air Particle Separator (EAPS). The IBF provides aircraft owner/operators a high performance engine air filtration option that significantly improve filtration efficiency over the EAPS. The IBF will increase the life of the engine through a dramatic reduction in erosion resulting from the substantial increase in filtration efficiency without degrading engine AFS-AA119-IBF-ICA Donaldson Company, Inc. Revision: K Proprietary Information Use or disclosure of this material is subject 5 DCI Leonardo A119 IBF to the restrictions on the title page Instructions for Continued Airworthiness performance. The DCI IBF system provides dust separation efficiencies exceeding 99% for Society of Automotive Engineers (SAE) AC Coarse and AC Fine dust as defined in specification SAE J726, Air Cleaner Test Code. c. The IBF system does not interfere with any of the commercial items installed in the Leonardo Models A119 and AW119 MKII [including the AW119 G1000H and AW119 IDU-680P (TH- 119) variants] 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 frame assembly, filter assemblies, cockpit indicator/switch, and bypass system (which includes the bypass door, actuator, differential pressure switch, and filter maintenance aid). Located at the end of this chapter is an exploded view of the major kit components with the exception of the cockpit hardware. For a detailed illustration of all kit components, see the Appendix A - Parts Figures. d. The major components making up the bypass system include the bypass door, actuator, electrical wire harness, cockpit indicator/switch, and differential pressure switch. The cockpit indicator/switch energizes the actuator to open and close the bypass doors and the “FILTER” light alerts the pilot that the differential pressure has reached or exceeded its preset limit. In the bypass mode, when the bypass door is fully extended, the “BYPASS” light will illuminate. 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 indicator/switch 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 doors permits unfiltered air to enter the engine inlet plenum chamber should the filter media become obstructed and can be opened or closed as required. On the ground, a Filter Maintenance Aid, mounted on the front of the forward filter housing frame, 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 Figures 2 & 3). f. The design of the bypass system allows the ground crew to cycle the bypass doors with power on the aircraft. The light/switch can be depressed to actuate the bypass doors 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 each filter assembly for servicing is easily achieved by removal of the forward and central aircraft cowlings, then loosening four bolts (side filters) and/or disconnecting the actuator and removing hinge rod (top filter). AFS-AA119-IBF-ICA Donaldson Company, Inc. Revision: K Proprietary Information Use or disclosure of this material is subject 6 DCI Leonardo A119 IBF to the restrictions on the title page Instructions for Continued Airworthiness Figure 1: IBF SYSTEM AND INSTALLATION AFS-AA119-IBF-ICA Donaldson Company, Inc. Revision: K Proprietary Information Use or disclosure of this material is subject 7 DCI Leonardo A119 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. Revision Date of FAA Signature FAA Signature Initial Release 11/13/06 Original Signed By Thadeus D. Krolicki A Superseded B Superseded C Superseded D 09/08/11 Original Signed By: Timothy Smyth E 06/14/12 Original Signed By: Chris Richards F 05/07/13 Original Signed By: Chris Richards G 12/04/13 Original Signed By: Timothy Smyth H N/A No changes to Airworthiness Limitations on this revision I N/A No changes to Airworthiness Limitations on this revision J N/A No changes to Airworthiness Limitations on this revision K N/A No changes to Airworthiness Limitations on this revision AFS-AA119-IBF-ICA Donaldson Company, Inc. Revision: K Proprietary Information Use or disclosure of this material is subject 8 DCI Leonardo A119 IBF to the restrictions on the title page Instructions for Continued Airworthiness 2.1 GENERAL The Airworthiness Limitations for the DCI Inlet Barrier Filtration system (IBF) as installed on Leonardo S.p.A. Models A119 and AW119 MKII [including the AW119 G1000H and AW119 IDU- 680P (TH-119) variants] are FAA approved. This STC does not impose any additional airworthiness limitations. 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 filters 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 filters shall be removed from service at the next service interval. No further cleaning cycles are authorized. 2.3 LIFE LIMITED COMPONENTS The only life limited component features are the number of cleanings of the filter assemblies. See Section 2.2. AFS-AA119-IBF-ICA Donaldson Company, Inc. Revision: K Proprietary Information Use or disclosure of this material is subject 9 DCI Leonardo A119 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, and inspection of electrical and system components. These assembly/component inspection intervals are based on hours after initial installation or on condition as required. 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 - Parts Figures for component illustrations that provide supplemental information relative to proper assembly configuration, orientation, and locations for all components to be inspected per Chapter 3 and Table 3-1. Refer to Appendix A, Figure A-2 for the primary components included in Kit No. 119000-101 and 119000-105. c. Table 3-1 gives a recommended inspection schedule for the components of the system. The Trouble-Shooting Guide, Table 8-1 found near the end of Chapter 8, also gives additional guidance when performing inspections and encountering trouble with the system. Chapter 8 also provides specific inspection guidance and removal/installation procedures for each component and is structured in the same three major groups as discussed above. 3.1.2 FILTER ASSEMBLY INSPECTION a. The following inspections pertain to the barrier filter assembly and associated components, which include the filter assembly (i.e. filter frame and filter media), and all associated seals/fasteners. b. ON-CONDITION UP TO TIS LIMIT: Any FMA indication in the “RED”, “FILTER” light indication of the IBF cockpit indicator/switch light or failed PAC requires a conditional inspection in accordance with Table 3-1. c. VISUAL: All filter assembly components (including seals and fasteners) are to be visually inspected at every annual in accordance with Table 3-1 checking for the following: filter media for tears, punctures, uneven or damaged pleats; seals for tears/damage; frame components for corrosion, cracks, distortions near holes, and check for missing or damaged fasteners. AFS-AA119-IBF-ICA Donaldson Company, Inc. Revision: K Proprietary Information Use or disclosure of this material is subject 10 DCI Leonardo A119 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 3-1 every 300 hours/annual. These components include the following: Fore and Aft Frames, Filter Frames, FMA Bracket, Lower Supports, and Actuator Supports. 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 300 hours/annual. These components include the following: Wiring, Connectors, Backshells, Circuit Breaker, Cockpit Indicator/switch, Differential Pressure Switch, Filter Maintenance Aid, and Actuator. b. FUNCTION CHECK: Certain systems and electrical components are also to be function checked in accordance with Table 3-1 every annual inspection. These components include the following: Circuit Breaker, Cockpit Indicator/switch, 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 Figures 2 & 3). As such it is not considered an inspection of the FMA. The inspection Table 3-1 does not require a specific “inspection” interval of the FMA. The condition of the Filter Assembly and its accumulation of dirt will show up as an indication on the FMA. Thus, operational environment, more so than time in service, dictate how often the FMA should be checked in order to help determine the next Filter Assembly service requirement. It is an aid in scheduling the Filter Assembly servicing. At any time prior to an FMA indication in the “RED” (See Figure 2), a failed PAC, or a “FILTER” indication on the cockpit indicator/switch, 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 Figure 2 & 3). AFS-AA119-IBF-ICA Donaldson Company, Inc. Revision: K Proprietary Information Use or disclosure of this material is subject 11 DCI Leonardo A119 IBF to the restrictions on the title page Instructions for Continued Airworthiness Figure 2: FILTER MAINTENANCE AID “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. Figure 3: FILTER MAINTENANCE AID FMA unit is mounted to LH forward side of the Forward Frame Assembly and is accessed through the LH Engine Cowl Access Door (on the Forward Cowl). GREEN Zone YELLOW RESET Button RED Zone YELLOW Indicator PRESS YELLOW Button to RESET AFS-AA119-IBF-ICA Donaldson Company, Inc. Revision: K Proprietary Information Use or disclosure of this material is subject 12 DCI Leonardo A119 IBF to the restrictions on the title page Instructions for Continued Airworthiness Table 3- 1 Inspection Intervals Components Inspection Type Inspection Inspection Intervals Scheduled Time in Service Notes 300 Hrs. Annual Filter Assembly as defined in sec. 3.1.2. Conditional 1. On-Condition up to TIS Limit 300 hrs / 1 yr 2, 3, 4, 5,6 Scheduled 2. Visual X 1, 2, 4, 7 Structural Components as defined in sec. 3.1.3. Scheduled 1. Visual X X 1, 2, 4, 6, 7 Special 2. Visual 8 Systems and Electrical Components as defined in sec. 3.1.4. Scheduled 1. Visual X X 1, 2, 4, 7 Scheduled 2. Function Check X 1, 2, 4, 5 Notes. 1. Refer to Chapter 8 for specific inspection requirements and functional check procedures. 2. Refer to Chapter 4 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. 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 “FILTER” light indication on the Cockpit Indicator/switch, and/or upon a failed PAC (where the failed PAC is the result of a dirty Filter Assembly). 8. For IBF Serial Number 0002 ONLY, 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 for every 25 hours up to the first 100 hours, then resume normal 300 hour inspection intervals. 3.2 OVERHAUL REQUIREMENTS There are no overhaul intervals or requirements applicable to this product at this time. 3.3 SPECIAL INSPECTIONS (CONDITIONAL INSPECTIONS) The following unscheduled special inspections/checks must be performed after encountering the following condition(s). AFS-AA119-IBF-ICA Donaldson Company, Inc. Revision: K Proprietary Information Use or disclosure of this material is subject 13 DCI Leonardo A119 IBF to the restrictions on the title page Instructions for Continued Airworthiness 3.3.1 HARD LANDING If a hard landing is suspected or has occurred, the following inspections/checks shall be complied with: a. Visually inspect filter assembly, lower supports, and filter housing structure for cracks, warping/distortion, and loose hardware. Refer to Sections 8.3 and 8.4 of this document for inspection guidance. If evidence of damage is found, contact DCI for disposition or replacement. b. Perform actuator function check to ensure the bypass door is not misaligned and that it operates and seals properly. Refer to Section 8.5 of this document for check/inspection guidance and troubleshooting procedures. 3.3.2 LIGHTNING STRIKE If a lightning strike is suspected or has occurred, the following inspections/checks shall be complied with: a. Visually inspect all external surfaces of the filter assembly, lower supports, and filter housing structure for damage. Refer to Sections 8.3 and 8.4 of this document for inspection guidance. If evidence of damage is found, contact DCI for disposition or replacement. b. Perform function check of all systems and electrical components. Refer to Section 8.5 of this document for check/inspection guidance and troubleshooting procedures. AFS-AA119-IBF-ICA Donaldson Company, Inc. Revision: K Proprietary Information Use or disclosure of this material is subject 14 DCI Leonardo A119 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 MAINTENANCE 4.2.1 ACCESS OF FMA AND DP SWITCH ASSEMBLIES Access for maintenance of the FMA (filter maintenance aid) and the DP (differential pressure) switch and related components (see Figure 4), is accomplished by removing the forward aircraft cowl. See Chapter 8 for component removal/installation procedures, inspection, troubleshooting guide, adjustment/calibration/repair procedures. 4.2.2 ACCESS OF BYPASS ACTUATOR ASSEMBLY Access for maintenance of the actuator assembly and related components (see Figure 4), is accomplished by opening the bypass door, removing either or both of the side filter assemblies and if required the top filter assembly. See Chapter 8 for component removal/installation procedures, inspection, troubleshooting guide, adjustment/calibration/repair procedures. Figure 4: COMPONENT ACCESS AFS-AA119-IBF-ICA Donaldson Company, Inc. Revision: K Proprietary Information Use or disclosure of this material is subject 15 DCI Leonardo A119 IBF to the restrictions on the title page Instructions for Continued Airworthiness 5 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 un-oiled (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 Section 7.3. AFS-AA119-IBF-ICA Donaldson Company, Inc. Revision: K Proprietary Information Use or disclosure of this material is subject 16 DCI Leonardo A119 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 forward frame assembly to contain the top level part number, the serial number of the system, and the FAA PMA markings. 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 5: EXAMPLE OF FILTER ASSEMBLY DATA PLATE 6.3 PLACARDS / MARKINGS - COCKPIT a. The Cockpit Indicator/Switch is labeled as shown below and is located in the center console in an open space. See Figure 6(A) for markings. (A) (B) Figure 6: IBF MARKINGS b. The IBF circuit breaker in the overhead console is marked “IBF”. See Figure 6(B) for markings. c. The area on the center console just below the indicator light maybe labeled as “IBF” if space is available. AFS-AA119-IBF-ICA Donaldson Company, Inc. Revision: K Proprietary Information Use or disclosure of this material is subject 17 DCI Leonardo A119 IBF to the restrictions on the title page Instructions for Continued Airworthiness 7 SERVICING 7.1 AUTHORIZED MATERIALS Service DCI Filter with only the following: a. Air Filter Oil x Squeeze bottle (11.2 oz) - DCI P/N 100100-112 x 1 qt. bottle - DCI P/N 100100-320 x 1 gal. container - DCI P/N 100101-000 x 5 gal. container - DCI P/N 100105-000 b. Air Filter Cleaner x 1 gallon container - DCI P/N 100201-000 x 5 gallon container - DCI P/N 100205-000 x 6.6 gallon container - ZOK Mfr. P/N ZOK 27 or Sky Geek P/N ZOK-27-6-6CON Contact DCI 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. 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 Indicator/switch, or upon a failed PAC (where the failed PAC is the result of a dirty Filter Assembly). AFS-AA119-IBF-ICA Donaldson Company, Inc. Revision: K Proprietary Information Use or disclosure of this material is subject 18 DCI Leonardo A119 IBF to the restrictions on the title page Instructions for Continued Airworthiness b. Any “FILTER” indication, where the pressure sensor and indicating system are working properly, requires monitoring of instruments during operation to ensure aircraft/engine limits are not exceeded. Service the filter as soon as practical. See filter servicing Section 7.3. c. The gradual increase in differential pressure across the IBF filter assembly causes an increase in the interturbine temperature (ITT) 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 Section 7.3. d. Any FMA indication in the area marked in “RED” it is recommended to service the filter as soon as practical. See filter servicing Section 7.3. e. At any time prior to a “FILTER” indication on the cockpit indicator/switch, 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 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 During typical operations in and out of prepared airfields and landing sites, the IBF filter assembly will not require frequent servicing. DCI recommends that the filter maintenance aid (FMA) be checked about every 25 aircraft operating hours following the first installation and operation of an IBF system on an aircraft. This should be done to gauge the rate of engine performance degradation due to changes in engine inlet differential pressure as the filters accumulate dirt in operations considered “prepared fields” operations. Once an interval of time in flight hours is determined that provided discrete changes in the FMA, this interval can be repeated as long as there is no change in the environmental operating conditions. a. This interval can be extended after sufficient flight data has been accumulated to establish a greater interval. Upon seeing increases in ITT 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. 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. 7.2.3 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 AFS-AA119-IBF-ICA Donaldson Company, Inc. Revision: K Proprietary Information Use or disclosure of this material is subject 19 DCI Leonardo A119 IBF to the restrictions on the title page Instructions for Continued Airworthiness 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 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 DCI FILTER ASSEMLBIES WITH GASOLINE, SOLVENTS, PARTS CLEANERS, STRONG DETERGENTS, OR CAUSTIC CLEANING SOLUTIONS. CAUTION DO NOT STEAM CLEAN OR USE HIGH-PRESSURE WASHERS TO CLEAN THE DCI FILTER ASSEMBLY. CAUTION ANY OF THESE PROCESSES WILL DAMAGE FILTER MEDIA AND/OR THE FILTER FRAMES. a. Spray DCI Air Filter Cleaner (DCI or ZOK 27) 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. In severe environmental conditions (high dirt/debris), the entire filter may be soaked in cleaner and repeated as necessary. Manufacturer’s instructions for dilution of cleaner should be followed if using concentrate. b. Let the cleaner soak into the contaminants and filter media for 20 minutes. AFS-AA119-IBF-ICA Donaldson Company, Inc. Revision: K Proprietary Information Use or disclosure of this material is subject 20 DCI Leonardo A119 IBF to the restrictions on the title page Instructions for Continued Airworthiness 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. h. If necessary, repeat cleaning procedure until filter is free from all contaminants. 7.3.3 FILTER DRYING CAUTION DO NOT USE COMPRESSED AIR TO DRY THE FILTER ASSEMBLY. IT MAY DAMAGE THE FILTER MEDIA. CAUTION DO NOT USE HEAT FROM ANY SOURCE TO DRY THE DCI FILTER ASSEMBLY. HEAT MAY SHRINK THE FILTER MEDIA AND MAY DAMAGE THE CORING MATERIAL WITHIN THE FILTER FRAMES. a. After rinsing, shake off the excess water and let the Filter Assembly dry at room or outside air temperature (above freezing). b. Ensure dirt or debris does not enter or contact the Filter Assembly while drying. c. After the Filter Assembly dries, mark the service cycle on data plate in accordance with the Section 6.2. 7.3.4 FILTER OILING CAUTION NEVER PUT AN DCI FILTER ASSEMBLY IN SERVICE WITHOUT OILING IT. AFS-AA119-IBF-ICA Donaldson Company, Inc. Revision: K Proprietary Information Use or disclosure of this material is subject 21 DCI Leonardo A119 IBF to the restrictions on the title page Instructions for Continued Airworthiness CAUTION USE ONLY DCI FILTER OIL OR AN DCI APPROVED SUBSTITUTE. NOTE A squeeze bottle capable of accurately measuring out the applicable fluid ounces that 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. DCI Air Filter Oil is a unique blend of mineral and organic oil base stocks and special polymers that form a very efficient “tack barrier.” Red dye is added to show areas of oil application. Do not use transmission fluid, any kind of motor oil, or diesel fuel to oil the DCI filter. Do not use “WD-40,” “LPS,” or any other type of lightweight spray lubricants to oil the DCI filter. Any of those products will damage the filter or degrade its filtering ability. A squeeze bottle allows for the controlled application of a specific amount of oil to the filter (See Figure 7). b. Using a total of 4.6 fl. Oz. for the Upper Filter Assembly and 6.6 fl oz. for each Side Filter Assembly, apply approximately ½ of the filter oil 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. c. Let the Filter Assembly sit for 20 minutes as the oil “wicks” into the surrounding filter media. Apply any remaining filter oil to any areas that are still white and to complete the application of the appropriate amount of oil from the squeeze bottle. Figure 7: OILING MEDIA AFS-AA119-IBF-ICA Donaldson Company, Inc. Revision: K Proprietary Information Use or disclosure of this material is subject 22 DCI Leonardo A119 IBF to the restrictions on the title page Instructions for Continued Airworthiness 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 8-3). 7.6 AIRCRAFT WASHING During aircraft washing the IBF system, including the filter assemblies, 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-AA119-IBF-ICA Donaldson Company, Inc. Revision: K Proprietary Information Use or disclosure of this material is subject 23 DCI Leonardo A119 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 IT IS STRONGLY SUGGESTED, THAT FOR ANY MAINTENANCE OTHER THAN ROUTINE INSPECTIONS, TROUBLESHOOTING OR REMOVAL OF THE FILTER ASSEMBLIES FOR CLEANING, THAT THE COMPLETE IBF ASSEMBLY BE REMOVED BEFORE PERFORMING MAINTENANCE AND/OR REPAIRS. 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 Housing Assembly (consisting of Forward, Aft, and Upper Frame Assemblies and Actuator Support Assembly), Filter Assembly, Lower Side Filter Supports, and Systems and Electrical components throughout the manual. Refer to Appendix A, Figures A-1 thru A-21. Table 3-1 gives a recommended inspection schedule for the components of the system. The troubleshooting guide in Table 8-2 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 DCI 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 Leonardo technical manuals or AC 43.13-1B, Chapter 11. AFS-AA119-IBF-ICA Donaldson Company, Inc. Revision: K Proprietary Information Use or disclosure of this material is subject 24 DCI Leonardo A119 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, Figures A-1 thru A-4) 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. Seal - The Seal is expanded foam with Dacron backing affixed to the Filter Assembly. 8.2.2 FILTER HOUSING ASSEMBLY (STRUCTURAL COMPONENTS) (Refer to Appendix A, Figures A-1, A-2, A-5 and A-8) a. Upper Frame Assembly – This assembly is a stainless steel and aluminum structure where the bypass door and upper filter assembly are located. The Upper Frame Assy is mounted to the forward and aft frame assemblies and the side filter frames. b. Forward Frame Assembly – The Forward Frame Assy is made up from machined aluminum and stainless steel sheet. The upper frame assembly, side filter frames, actuator supports, differential pressure switch, and filter maintenance aid assembly are secured to this assembly. c. Aft Frame Assembly – The Aft Frame Assy is made up from machined aluminum and stainless steel sheet. The upper frame assembly, side filter frames, and actuator supports are secured to this assembly. d. Lower Side Filter Supports (RH & LH) – The Lower Side Filter Supports are made from aluminum plate and are connected to the side filter frames and attach to the aircraft. e. Actuator Support Assembly – The Actuator Support Assembly is made from machined aluminum and is riveted to the Forward and Aft Frame Assemblies. 8.2.3 SYSTEMS AND ELECTRICAL COMPONENTS (Refer to Appendix A, Figures A-5, A-6, A-7, and A-9 thru A-21) a. Cockpit Indicator/Switch - The cockpit indicator/switch provides the lighting/switching function for the bypass door. The cockpit indicator light illuminates when the differential pressure between ambient and the plenum chamber has reached its preset limit. 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 DCI for disposition. b. Differential Pressure Switch - The Differential Pressure Switch provides a signal to the Cockpit Indicator/Switch 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 DCI for disposition. AFS-AA119-IBF-ICA Donaldson Company, Inc. Revision: K Proprietary Information Use or disclosure of this material is subject 25 DCI Leonardo A119 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 DCI for disposition or replacement. 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 indicator/switch. The construction details of the component do not warrant field maintenance. Repair of this component requires the component to be sent back to DCI for disposition or replacement. e. Wiring, Connectors, Backshells, Circuit Breaker – The wiring 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, Figures A-1 thru A-4) 8.3.1 FILTER ASSY 8.3.1.1 REMOVAL – SIDE FILTER ASSY CAUTION UPON REMOVAL OF ANY FILTER ASSEMBLY OR THE COMPLETE IBF SYSTEM, COVER THE ENGINE INLET (AS SOON AS THERE IS ACCESS TO THE INLET), TO PREVENT FOREIGN OBJECT DAMAGE (FOD). a. Remove the aircraft forward and central cowls. b. To remove side filters – Loosen the two (2) upper and two (2) lower captive bolts that retain each Side Filter Assembly to the Upper Frame Assembly and the Lower Side Filter Supports. (Refer to Appendix A, Figures A-2 and A-3) c. Use a plastic scraper to gently break any seal between the filter housing structure and the seal itself. The filter assembly must be carefully removed so as not to damage the filter seal. 8.3.1.2 REMOVAL – UPPER FILTER ASSY a. To remove upper filter – Open the Bypass door, cover engine inlet and remove the safety wire and bolt (with washers) that connects the filter assembly to the actuator. (Refer to Appendix A, Figures A-2, A-4 and A-5) AFS-AA119-IBF-ICA Donaldson Company, Inc. Revision: K Proprietary Information Use or disclosure of this material is subject 26 DCI Leonardo A119 IBF to the restrictions on the title page Instructions for Continued Airworthiness b. Loosen the captive bolt on the upper LH side of the filter housing until the hinge rod can be removed. c. Remove the hinge rod. d. The upper filter assembly may now be removed. e. Inspect the filter seals. Refer to “Filter Seal” procedures. 8.3.1.3 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 a FILTER light indication or failed PAC, perform troubleshooting per Table 8-2. 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. 8.3.1.4 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-AA119-IBF-ICA Donaldson Company, Inc. Revision: K Proprietary Information Use or disclosure of this material is subject 27 DCI Leonardo A119 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 Figure 8). 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 8: HAND SEAMER 8.3.1.5 CALIBRATION Not applicable. AFS-AA119-IBF-ICA Donaldson Company, Inc. Revision: K Proprietary Information Use or disclosure of this material is subject 28 DCI Leonardo A119 IBF to the restrictions on the title page Instructions for Continued Airworthiness 8.3.1.6 REPAIR - FILTER MEDIA, GENERAL WARNING ADHESIVE VAPORS (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. 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. Each filter assembly may have up to 3 small ruptures that may be repaired, 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 Section 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 DCI for disposition and possible repair procedures, or discard the filter assembly. AFS-AA119-IBF-ICA Donaldson Company, Inc. Revision: K Proprietary Information Use or disclosure of this material is subject 29 DCI Leonardo A119 IBF to the restrictions on the title page Instructions for Continued Airworthiness 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 8-1 for application of protective coatings. b. Any damage to the filter frames such as cracking requires the filter assembly to be returned to DCI for evaluation and disposition or replacement. Any damage to the filter frames such as warping or distortion (to the extent that a good seal of the filter frame, when installed and/or torqued, do not permit the filter assembly to sit flush against the forward, aft, and/or the upper frame assembly) requires the filter assembly be returned to DCI for evaluation and disposition, or be replaced. 8.3.1.10 INSTALLATION a. SIDE FILTER – Locate and install the filter into the side of the filter housing. (Refer to Appendix A, Figures A-2 and A-3) b. Tighten the two (2) upper and two (2) lower captive bolts that retain each Side Filter Assembly to the Upper Frame Assembly and the Lower Side Filter Supports. c. Install the aircraft forward and central cowls. d. UPPER FILTER – Locate the filter and align the filter hinge and the hinge on the filter housing. (Refer to Appendix A, Figures A-2, A-4 and A-5) e. Install the hinge rod (insert until the retainer will capture the hinge rod) f. Tighten the captive bolt to retain the hinge rod. g. Connect the actuator to the filter (re-using the bolt and washers) and safety wire the bolt. 8.3.2 FILTER SEAL 8.3.2.1 REMOVAL a. Gain access to the filter seal by removing the filter assembly(s). Refer to Section 8.3.1.1. b. Carefully remove the seal by peeling it away from the filter assembly(s) (See Appendix A, Figures A-3 and A-4, Item 2). Use a plastic scraper or other suitable tool that is softer than aluminum to peel the seal from the filter assembly(s). Discard the removed seal. AFS-AA119-IBF-ICA Donaldson Company, Inc. Revision: K Proprietary Information Use or disclosure of this material is subject 30 DCI Leonardo A119 IBF to the restrictions on the title page Instructions for Continued Airworthiness 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 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(s) from sealing to the forward, aft, and/or upper frame assembly 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 filter assembly removal and filter seal removal. b. To install the seal, apply RTV 736 sealant to the foam side of the seal. Locate and apply the seal to the clean dry surface on the filter frame and press in place. 8.4 STRUCTURAL COMPONENTS NOTE: THE IBF SYSTEM SHOULD BE REMOVED FROM THE AIRCRAFT PRIOR TO ANY MAINTENANCE OR REPAIR OF THE STRUCTURAL COMPONENTS. 8.4.1 FILTER HOUSING ASSEMBLY (Refer to Appendix A, Figures A-1, A-2, A-3 and A-13)