MD500 STC USA - Donaldson Company · MD500-IBF-KIT-MDL, Revision F Proprietary Information ... Thomas Newman Original Signed By 09/30/2004 Prepared By: Roger Wallis Original Signed

Document Number: MD500-IBF-KIT-MDLRevision: GDate: 7 FEBRUARY 2007

COPYRIGHT© 2002 Aerospace Filtration Systems, Inc.

UNPUBLISHED — ALL RIGHTS RESERVED

LIMITED and/or RESTRICTED RIGHTS NOTICE This document, along with its drawings and photographs, contains Trade Secrets and/or Commercial or Financial Information that is proprietary to Aerospace Filtration Systems, Inc. (AFS) under 5 USC 552 as amended, and is Prohibited from Public Disclosure by 18 USC 1905. Do not duplicate or disclose outside the U.S. Government without the express written permission of Aerospace Filtration Systems, Inc.

The Government's rights to use, modify, reproduce, release, perform, display, or disclose these technical data are restricted to the purpose of evaluating AFS’s design for FAA commercial certification and airworthiness consideration only. Any reproduction of technical data or portions thereof marked with this legend, or referring to this legend, must also reproduce the markings and legend. Any person, other than the Government, who has been provided access to such data must promptly notify: Aerospace Filtration Systems, Inc., Attn: Contracts Manager, 4 Research Park Drive, St. Charles, MO 63304-5685

The data subject to this limited/restricted rights notice is contained on all pages.

Master Data List

INLET BARRIER FILTER SYSTEM for the

MD Helicopters Inc. (MDHI) MD500 Series Helicopter

FAA STC No. SR01394LA

4 Research Park Drive, Suite 200 St. Charles, MO 63304-5685

Aerospace Filtration Systems, Inc. MD500-IBF-KIT-MDL, Revision F Proprietary Information

Use or disclosure of this material is subject Page i MD500 IBF Master Data Listto the restrictions on the title page

SIGNATURESRevision Date Name Signature Date

Prepared By: Roger Wallis Original Signed By 06/28/2002

Reviewed By: Daniel Flesher Original Signed By 06/28/2002 IR

Approved By: Mike Scimone Original Signed By 06/28/2002


Reviewed By: Daniel Flesher Original Signed By 07/31/2002 A



Reviewed By: Daniel Flesher Original Signed By 09/05/2002 B



Reviewed By: Daniel Flesher Original Signed By 05/13/2003C



Reviewed By: Daniel Flesher Original Signed By 09/30/2004D

Approved By: Thomas Newman Original Signed By 09/30/2004


Reviewed By: Thomas Newman Original Signed By 04/13/2006E

Approved By: Robert Stenberg Original Signed By 04/13/2006


Reviewed By: Thomas Newman Original Signed By 10/20/2006F

Approved By: Robert Stenberg Original Signed By 10/20/2006


Use or disclosure of this material is subject Page iii MD500 IBF Master Data Listto the restrictions on the title page

Log of Revisions Revision No. Revision Description Release Date

N/C Initial Submittal 06/28/2002

AFront cover page added signature block; MDL matrix deleted item stating “Special Conditions – Not Required”, and updated document list; Note 1 corrected typo; Note 3 revised; Note 4 corrected typos.

07/31/2002

B Updated document list for MDL, FMS, and FAT. 09/05/2002

C

Updated document references to latest revisions list for MDL, FMS, IP, and FAT modified to add the models 369H, HM, HS, & HE to list of applicable aircraft for kit no. 102200-101, and removed all Certification Documentation from the list.

05/13/2003

DTitle page updated company name/logo and added STC number; matrix updated to reflect current revision/date for MDL and DL modified to reflect minor changes for six month period of 01/04 to 06/04.

09/30/2004

E Title page updated; added signature page; matrix updated to reflect current revision/date for FMS, MDL and DL. 04/13/2006

F Title & signature pages updated; matrix updated to reflect current revision/date for Drawing – Top Assembly, MDL and DL. 10/20/2006

G Updated MDL to reflect revision of Installation Procedures to add clarity and information to help ease installation. 7 Feb 07


Use or disclosure of this material is subject Page 1 MD500 IBF Master Data Listto the restrictions on the title page

Kit/Top Assembly

MASTER DATA LIST

1022

00-1

01

Inlet Barrier Filter (IBF) Kit Document No. Revision Date

Master Data List MD500-IBF-KIT-MDL G 7 Feb 07 X

Drawings – Top Assembly 102200-101 E 10-11-06 X

Drawing List MD500-IBF-KIT-DL REVISION BY DATE ONLY 10-20-06 X

Operation & Maintenance Manual/ Illustrated Parts List1

MD500-IBF-KIT-OMM/IPL A 06-28-02 X

Kit - Installation Procedures1 MD500-IBF-KIT-IP D 26 Jan 07 X

Flight Manual Supplement2 MD500-IBF-KIT-FMS B 04-12-05 X

Aircraft Applicability3 Original T.C. No. Revision Date

MDHI-369H, 369HM, 369HS, 369HE H3WE 20 09-30-01 X

MDHI-369D, 369E, 369F, 369FF H3WE 20 09-30-01 X

Optional Ground Support Equipment Part Number Supplier Info

Environmental Protection Cover4 See Note 4 below See OMM/IPL, para. 2.5 X

NOTES: 1. These documents have been determined by the FAA LAACO to satisfy the FAR 27.1529 - Instruction for Continued Airworthiness and

must be filed in the appropriate aircraft manuals when this STC is incorporated. 2. The Flight Manual Supplement must be filed in the appropriate aircraft manuals when this STC is incorporated. 3. Those aircraft currently FAA approved and considered applicable for installation of the STC kit are indicated by an “X”. 4. No cover is included in the kit and, if required, must be procured separately. The cover is required anytime the aircraft is not kept in

covered storage, e.g. a hangar. The cover must be capable of protecting both the forward and upper filter assemblies and the static ports at the aft end of the fairing.

Aerospace Filtration Systems, Inc. SUPPLEMENT FOR MD Helicopters 4 Research Park Drive, Suite 200 Models 369H, HM, HS, HE, D, E, F, FF St. Charles, MO 63304-5685 RFMs CSP-HE/HS-1, CSP-D-1, CSP-E-1, CSP-FF-1 Supplement No. MD500-IBF-KIT-FMS STC No. SR01394LA

FAA Approved – April 12, 2005 ii

TABLE OF CONTENTS

SECTION TITLE PAGE

I General 1

II Limitations 2

III Emergency Procedures 3

IV Normal Procedures 4

V Performance Data 6

VI Weight and Balance Data 7

VII Handling, Servicing, and Maintenance 8

VIII Additional Operations and Performance Data 9

IX Optional Equipment 10


FAA Approved – April 12, 2005 3

SECTION I

GENERAL

Installation of the Inlet Barrier Filter (IBF) STC requires that the engine bleed air or scavenge air used by the Engine Air Particle Separator be capped and the SCAV AIR toggle breaker switch be removed.



SECTION II

LIMITATIONS

No Change.



SECTION III

EMERGENCY PROCEDURES

Paragraph 3-15 Other Malfunctions – Engine Air Particle Separator Filter Clogged (If installed)

All existing rotorcraft flight manual emergency/malfunction procedures and charts for operation of the aircraft with the Engine Air Particle Separator installed, apply when the Inlet Barrier Filter (IBF) System STC is installed as specified in Sections V and VIII of this RFMS. Modification of the rotorcraft from the particle separator configuration to the IBF configuration is therefore an invisible transition to the pilot/operator since there is no change in rotorcraft operation or emergency procedures.



SECTION IV

NORMAL PROCEDURES

Pre-Flight Inspection

Pre-flight inspection shall be made by the pilot to inspect the filters (forward and upper) for damage, excessive accumulation of debris (straw, leaves, insects, etc.) or snow/ice, missing or damaged fasteners, or the need for servicing or repair of the filters. After extended operation in precipitation (i.e., rain, or a combination of rain and sleet/snow), the sand and dust collected on the external side of the filter media (dirty side) may coagulate in the corners of the filter media pleats. If visual inspection indicates existence of any of the above conditions, the decision whether to service the filter assemblies will reside with the flight crew. Damaged or missing fasteners should be replaced to maintain maximum seal integrity.

NOTEOperation with either missing fasteners and/or filter damage can severely degrade IBF system separation efficiency and result in possible performance loss, wear, and/or damage to the engine. Damaged filter elements should be either repaired or replaced.

RED ZoneYELLOWIndicator



SECTION V

PERFORMANCE DATA

Paragraph 5-1 General

All hover performance charts and power check charts, when the Inlet Barrier Filter (IBF) System STC is installed, should be used as indicated for the following conditions:

� Particle Separator installed � Scavenge Air OFF � Without Mist Eliminator



SECTION VI

WEIGHT AND BALANCE DATA

Paragraph 6-1 Weight and Balance Characteristics

Document weight and balance of the Inlet Barrier Filter (IBF) System in accordance with paragraph 6-3 of the IBF Kit Installation Procedures, MD500-IBF-KIT-IP when installing this STC. Additional information can be found in the IBF Kit Installation Procedures, MD500-IBF-KIT-IP.



SECTION VII

HANDLING, SERVICING, AND MAINTENANCE

Paragraphs 7-1 Helicopter Components 7-7 Servicing – General

7-11 Cleaning – General (Models 369D, E, F, FF) 7-12 Cleaning – General (Models 369H, HM, HS, HE) 7-16 Preservation and Storage (Models 369D, E, F, FF) 7-17 Flyable Storage – No Time Limit (Models 369D, E, F, FF) 7-18 Preservation and Storage (Models 369H, HM, HS, HE) 7-19 Flyable Storage – No Time Limit (Models 369H, HM, HS, HE)

All handling, servicing and maintenance of the Inlet Barrier Filter (IBF) System assemblies should be performed in accordance with the IBF Operations & Maintenance Manual/Illustrated Parts List (OMM/IPL), MD500-IBF-KIT-OMM/IPL. The OMM section defines IBF operational requirements, service limits/procedures, environmental requirements, repair procedures, and required materials. The IPL section provides a complete list of the IBF components/assemblies and associated illustrations.



SECTION VIII

ADDITIONAL OPERATIONS AND PERFORMANCE DATA

Paragraphs 8-1 Hover Ceiling – Out of Ground Effect (OGE)

All hover performance charts, when the Inlet Barrier Filter (IBF) System is installed, should be used as indicated for the following conditions:

� Particle Separator installed � Scavenge Air OFF � Without Mist Eliminator



SECTION IX

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Document Number: AFS-MD500-IBF-KIT-IPRevision: D Date: 26 JANUARY 2007

COPYRIGHT© 2006 Aerospace Filtration Systems, Inc. (AFS)


LIMITED and/or RESTRICTED RIGHTS NOTICE This document, along with its drawings and photographs, contains Trade Secrets and/or Commercial or Financial Information that is proprietary to Aerospace Filtration Systems, Inc. (AFS) under 5 USC 552 as amended, and is Prohibited from Public Disclosure by 18 USC 1905. Do not duplicate or disclose outside the U.S. Government without the express written permission of Aerospace Filtration Systems, Inc.

The Government's rights to use, modify, reproduce, release, perform, display, or disclose these technical data are restricted to the purpose of evaluating AFS's design for FAA commercial certification and airworthiness consideration only. Any reproduction of technical data or portions thereof marked with this legend, or referring to this legend, must also reproduce the markings and legend. Any person, other than the Government, who has been provided access to such data must promptly notify: Aerospace Filtration Systems, Inc., Attn: Business Manager, 4 Research Park Drive, St. Charles, MO 63304-5685


INSTALLATION PROCEDURES

INLET BARRIER FILTER SYSTEM for the

MD Helicopters Inc. (MDHI) MD500 Series Helicopters

FAA STC No. SR01394CH

4 Research Park Drive, Suite 200 St. Charles, MO 63304-5685

Aerospace Filtration Systems, Inc. MD500-IBF-KIT-IP, Revision: D Proprietary Information

Use or disclosure of this material is subject ii AFS MD500 Kit Installation Proceduresto the restrictions on the title page

LOG OF REVISIONS

Revision No. Revision Description Release Date

IR Initial Release 5 May 06

AAdd illustration from/references to aircraft manual, para 2.0

05-03-02

B

Corrected all references to “McDonnell Douglas Helicopter Incorporated” to read “MD Helicopters Inc.” and change references to “Westar” to new name “AFS”; Title pg - Added new logo & FAA project no.; pg i - add revision block page; pg ii - add Instructions for Continued Airworthiness message block; para 2.1.2 - add instructions for removal of extension fitting (surfboard) from structural fairing;

06-28-02

CAdded note for 369 series aircraft clarifying the air inlet screen removal and trim requirements. 05-13-03

D Added clarity to document for ease of installation 26 Jan 07


Use or disclosure of this material is subject iii AFS MD500 Kit Installation Proceduresto the restrictions on the title page

EFFECTIVITY

Effectivity for this IP is for all Bell MD500 series helicopters including models 369D, E, F, FF, H, HE, HM & HS series helicopters.

Aerospace Filtration Systems, Inc. MD500–IBF-KIT-IP, Revision: D Proprietary Information

Use or disclosure of this material is subject iv AFS MD500 Kit Installation Proceduresto the restrictions on the title page

TABLE OF CONTENTS

1 OVERVIEW ................................................................................................................................................ 1

1.1 GENERAL INFORMATION AND PREPARATION. ......................................................................................... 11.1.1 General Information....................................................................................................................... 11.1.2 Helicopter Preparation................................................................................................................... 11.1.3 Kit Preparation............................................................................................................................... 1

2 REMOVING EXISTING COMPONENTS ................................................................................................... 4

2.1 REMOVAL OF FORWARD ENGINE INLET FAIRINGS AND PARTICLE SEPARATOR SYSTEM ............................ 42.2 REMOVAL OF EXISTING AFT FAIRING AND ANTENNAS............................................................................. 52.3 REMOVAL OF THE PARTICLE SEPARATOR SCAVENGE AIR VALVE AND LINES............................................ 7

3 AFS IBF INSTALLATION .......................................................................................................................... 9

3.1 REINSTALLATION OF ANTENNAS ............................................................................................................ 93.2 INSTALLATION OF THE AFT FAIRING, FORWARD FILTER, AND OIL COOLER COVER SCREEN ...................... 93.3 OILING FILTERS ................................................................................................................................. 15

4 MASTER TOOL LIST............................................................................................................................... 17

5 SPECIAL TOOLING, JIGS, AND FIXTURES ......................................................................................... 17

6 WEIGHT AND BALANCE DATA: ........................................................................................................... 17

7 RESTORATION ....................................................................................................................................... 17

8 MAINTENANCE TEST FLIGHT............................................................................................................... 18

Aerospace Filtration Systems, Inc. MD500–IBF-KIT-IP, Revision: D Proprietary Information

Use or disclosure of this material is subject v AFS MD500 Kit Installation Proceduresto the restrictions on the title page

TABLE OF FIGURES

Figure 1: Kit Installation Work Area .................................................................................................................... 2Figure 2: IBF System .......................................................................................................................................... 3Figure 3:Existing Faring Removal (Reference)................................................................................................... 4Figure 4: Control Rod Removal (Reference) ...................................................................................................... 4Figure 5: Closeout and Boot Removal (Reference)............................................................................................ 5Figure 6: Aft Fairing Assy. (Reference)............................................................................................................... 6Figure 7: Valve Assy. Components (Reference)................................................................................................. 7Figure 8: Line Removal (Reference)................................................................................................................... 7Figure 9: Breaker Removal (Reference) ............................................................................................................. 8Figure 10: Differential Press. Switch (Reference)............................................................................................... 9Figure 11: Differential Press. Switch and FMA (if installed) Operational Check (Reference) .......................... 19

TABLE OF PICTURES

Picture 1: Existing Faring With Surfboard ........................................................................................................... 4Picture 2: Typical Particle Separator................................................................................................................... 5Picture 3: Removed Particle Separator Components ......................................................................................... 5Picture 4: Existing aft fairing with extension fitting (surfboard) ........................................................................... 5Picture 5: Static Line Disconnect Location.......................................................................................................... 5Picture 6: Removing rivets securing aft fairing.................................................................................................... 6Picture 7: Exposing edge of flange on aft fairing ................................................................................................ 6Picture 8: Loosening adhesive securing aft fairing ............................................................................................. 6Picture 9: Scavenge Air Valve to be removed .................................................................................................... 7Picture 10: Ejector Port Trimming ....................................................................................................................... 8Picture 11: Typical GPS Mount Installation......................................................................................................... 9Picture 12: Typical GPS Antenna Installation ..................................................................................................... 9Picture 13: Differential Pressure Switch Location............................................................................................... 9Picture 14: Static Port Location......................................................................................................................... 10Picture 15: Static Port Tubing ........................................................................................................................... 10Picture 16: Click Bond and Wire Strap Locations ............................................................................................. 10Picture 17: Fairing Location and Positioning..................................................................................................... 11Picture 18: Floor Plates Location and Installation............................................................................................. 11Picture 19: Scribing Floor Plates....................................................................................................................... 11Picture 20: Floor Plates Riveted to Fairing ....................................................................................................... 11Picture 21: Fairing Nut Plate Installation........................................................................................................... 11Picture 22: Fairing Installation........................................................................................................................... 12Picture 23: Control Rod Fairing Installation ...................................................................................................... 12Picture 24: Control Rod Boot Installation .......................................................................................................... 12Picture 25: Bypass Cable Installation ............................................................................................................... 12Picture 26: Bypass Cable Installation ............................................................................................................... 13Picture 27: Pressure Switch Connection........................................................................................................... 13Picture 28: Forward Filter Installation ............................................................................................................... 13Picture 29: Inlet Cooling Fan Installation .......................................................................................................... 13Picture 30: Upper Filter Installation................................................................................................................... 14Picture 31: FMA Installation .............................................................................................................................. 14Picture 32: FMA Tube Connection.................................................................................................................... 14Picture 33: Upper Filter Assembly (102400) ..................................................................................................... 15Picture 34: Forward Filter Assembly (102450).................................................................................................. 15Picture 35: Oil Bottle ......................................................................................................................................... 15Picture 36: Oiling Filter...................................................................................................................................... 16


Use or disclosure of this material is subject 1 AFS MD500 Kit Installation Proceduresto the restrictions on the title page

1 OVERVIEW

It is the responsibility of the installer to ensure that the interrelationship between this STC and any other previously approved modification will produce no adverse effect upon the airworthiness of the rotorcraft.

1.1 General Information and Preparation.

1.1.1 General Information

1. Items removed for access to work areas shall be tagged for identification and protected from damage until reinstalled. Save all attaching hardware unless otherwise noted.

2. When installing this kit, exercise care to prevent damage to adjacent structure and equipment.

3. Unless otherwise specified use standard torque values when tightening bolts. (Refer to AC 43.13-1B, Chapter 7)

4. When performing drilling, riveting, or cutting operations, exercise care to prevent damage to adjacent structure and equipment.

5. Following any cutting or drilling operation, remove burrs and metal particles. Apply epoxy primer coating to bare metal surfaces.

6. Refer to appropriate MDHI Manuals and Federal Aviation Administration (FAA) Advisory Circular (AC) 43.13-1B/2A for acceptable removal, installation, repairs, and maintenance procedures and practices of basic helicopter components and structures.

7. When installing either ground wires or components requiring grounding, clean structure surface to provide a good electrical bond.

8. Refer to applicable AFS manual (MD500-IBF-KIT-OMM/IPL) for additional information, for airworthiness information and applicable operational checks.

9. Fairing may be trimmed for fit to aircraft airframe (ref. Drawing. 102200-101 note 19).

10. Refer to AFS Installation Drawing (Drawing 102200-101) for approved configurations, installation information, and kit applications.

11. Wire sizes may be increased by one gauge if required.

12. Bolt/screw grip lengths may be increased or decreased by one size for fit. Ensure between one thread (min) to 2½ threads (max) are protruding.

1.1.2 Helicopter Preparation

1. Open battery access door and disconnect or remove battery.

2. Remove forward (clamshell) fairings per section 53 of CSP HMI-2.

3. Install engine inlet protection cover.

1.1.3 Kit Preparation

1. Inventory the components included in the IBF kit and determine if optional equipment will be installed.

2. For aircraft equipped with a differential pressure switch assembly (Item 18, Figure 2, Section 71-10-10, CSP-IPC-4), ensure the part number is a 369A8402-7, -13, or -15 switch assembly. If the part number is a 369A8402-3 or the aircraft does not have a switch assembly, it will be necessary to install a 369A8402-7, -13, or -15 switch assembly, per CSP-HMI-2, Section 71-10-10 and CSP-IPC-2, Section 71-10-10, Figure 2. If the aircraft has a 369A8402-7, -13, or -15 switch assembly, perform an Air Pressure Sensing Switch Calibration Check per CSP-HMI-2, Section 71-10-60.

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INDEXNUMBER PART NUMBER ITEM NAME

UNITPERASSY

102200-101 IBF System 1

1 102300-101 Structural Assembly 1

2 102400-101/103 Filter Assembly – Upper 1

3 102450-101/103 Filter Assembly – Forward 1

4 102303-203 Floor Plate – L/H 1

5 102303-201 Floor Plate 1

6 102319-201 Fairing – Control Rod 1

7 102325-201 Cable 1

8 102380-103 Assembly – Indicator, Maintenance 1*

* Optional



2 REMOVING EXISTING COMPONENTS

Figure 1 shows the work area for installing the engine inlet barrier filter assembly kit.

CAUTIONWhenever the air inlet cowling is removed, ensure engine inlet is covered to prevent introduction of FOD into the engine.

NOTE:Refer to MDHI Maintenance Manual CSP HMI-2 and MDHI Illustrated Parts Catalog CSP-IPC-4 for identification, removal, and disposition of existing components and standard practices.

2.1 Removal of Forward Engine Inlet Fairings and Particle Separator System

2.1.1 Remove forward fairing assembly 369D293053 or 369D22025 (item 3, see figure 3 below) per CSP HMI-2, Section 53-30-30.

Figure 3: Existing Faring Removal (Reference) (Extract from CSP-IPC-4, Section 53-30-10, Figure 2)

2.1.2 If applicable, remove the extension fitting (surfboard) from the forward fairings per the following procedure:

2.1.2.1 Apply heat with a heating mechanism, controlling temperature to 160ºF maximum.

2.1.2.2 Apply heat along the bonded surfaces.

2.1.2.3 Remove the extensions (surfboard) utilizing a putty knife/hammer, by lightly tapping the knife between bonded surfaces to allow “surfboard” to separate from the fairings.

2.1.2.4 Remove residue (if any) by sanding lightly on the remaining fairings.

2.1.2.5 Touch-up paint as required.

Picture 1: Existing Faring With Surfboard

2.1.3 Disconnect the control rod (STA 120, Tail Rotor) from the mast base per section 67-20-10 of CSP HMI-2 (see figure 4).

Figure 4: Control Rod Removal (Reference) (Extract from CSP-HMI-2, Section 67-20-10, Figure 101)

Item 3

Control Rod (STA 120)



2.1.4 Remove the 369H90151 control rod boot and the fiberglass closeout (item 12, see figure 5 below) reference CSP-IPC-4, Section 71-10-10.

Figure 5: Closeout and Boot Removal (Reference) (Extract from CSP-IPC-4, Section 71-10-10, Figure 2)

2.1.5 Remove the 369H90148 Particle Separator (see Picture 2) per CSP-HMI-2 (also reference Figs. 2 and 4, Section 71-10-10, CSP-IPC-4)

Picture 2: Typical Particle Separator

Picture 3: Removed Particle Separator Components

2.2 Removal of Existing Aft Fairing and Antennas

2.2.1 Remove the bypass door cable and actuation handle.

2.2.2 Disconnect all antenna harnesses (as applicable) and existing static line per existing Technical Manuals, Service Bulletins, Technical Bulletins, and/or Service Letters.

Picture 4: Existing aft fairing with extension fitting (surfboard)

2.2.3 Disconnect the existing static line as shown below.

Picture 5: Static Line Disconnect Location

Fiberglass Closeout (Item 12)

ParticleSeparator

Static Line Disconnect



2.2.4 Remove the existing 369D293053 or 369A3053 Aft Engine Inlet Fairing (Item 1, Figure 1, Section 53-32-00, of CSP-IPC-4) and all associated hardware using acceptable aircraft methods or practices (ref. Federal Aviation Administration (FAA) Advisory Circular (AC) 43.13-1B/2A.

Figure 6: Aft Fairing Assy. (Reference) (Extract from CSP-IPC-4, Section 53-32-00, Figure 1)

2.2.5 Use a pneumatic drill or equivalent electrical drill to remove the existing rivets.

Picture 6: Removing rivets securing aft fairing

2.2.6 Use grinding wheel/putty knife to loosen adhesive from flange area and remove aft fairing.

Picture 7: Exposing edge of flange on aft fairing

Picture 8: Loosening adhesive securing aft fairing

2.2.7 Remove any sensors, power supplies, power amps, and GPS antenna (as applicable) from the removed fairing per existing Technical Manuals, Service Bulletins, Technical Bulletins, and Service Letters.

NOTEThe new AFS aft fairing does not include an integral antenna. If the built-in antenna on the removed (old) aft fairing was being used, an alternate antenna will be required.

2.2.8 Clean inlet area thoroughly to remove any foreign objects/debris.

2.2.9 For most installations the existing pressure switch will be retained and reused. (If removal is required, remove the existing differential pressure switch per the note below.) If the ambient side of the differential pressure switch is vented forward of the Particle Separator, remove the venting line.

NOTEFor aircraft equipped with the Donaldson particle separator, replace the 369A8402-3 pressure switch with a 369A8402-7 switch assembly (Item 18, Figure 2, Section 71-10-

Aft Fairing



10, CSP-IPC-4). For aircraft with only a FOD screen installed it will be necessary to install a 369A8402-7 (see Para 3.2.1 for installation information).

2.2.10 Remove the 369D25640 air inlet cooling fan screen assembly (Item 43, Figure 2, Section 71-10-10, CSP-IPC-4), if installed.

NOTENot all 369 series aircraft have the air inlet cooling fan screen installed. Disregard the above instruction if the screen is not installed.

2.3 Removal of the Particle Separator Scavenge Air Valve and Lines

2.3.1 To access scavenge air valve and associated components, remove the left hand passenger compartment quarter panel assy. P/N 369D26568-3 (Item 11, Figure 9, Section 25-30-00, CSP-IPC-4).

2.3.2 Remove particle separator scavenge air valve assembly and associated tube that is connected to elbow 369A8094 (do not remove mounting bracket). Cap elbow 369A8094 where tube was removed. (Reference CPS-IPC-4, Section 71-10-10, Figure 5, Item 28).

Figure 7: Valve Assy. Components (Reference) (Extract from CSP-IPC-4, Section 71-10-10, Figure 5)

Picture 9: Scavenge Air Valve to be removed

2.3.3 Remove the associated plumbing from air valve that leads to elbow AN833-6 (CPS-IPC-4, Section 71-10-10, Item 45, Fig. 2 or Item 1, Fig. 5).

2.3.4 Remove the line inside the plenum leading from the particle separator to the AN833-6 elbow on the plenum wall. Cap elbow AN833-6 (both ends of elbow) where tubes were removed (see note below).

Figure 8: Line Removal (Reference) (Extract from CSP-IPC-4, Section 71-10-10, Figure 2)

NOTEIf Filter Maintenance Aid (FMA) is to be installed do not cap Elbow AN833-6 (see Section 3.2.26 for FMA Installation). (Ref. CPS-IPC-4, Section 71-10-10, Figs. 2 and 5).

AN833-6

369A8094

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Air Valve

Line to be removed

Particle Separator

Plenum Wall



2.3.5 Remove the cockpit scavenge air circuit breaker, switch, and nameplate (reference CSP-IPC-4, Section 71-10-10, Figure 3); plug hole, and remove breaker wires (wires may be capped and stowed as an option).

Figure 9: Breaker Removal (Reference) (Extract from CSP-IPC-4, Section 71-10-10, Figure 3)

2.3.6 Trim the existing IPS ejector hole port approximately ¼ inch above the bottom of the hole.

Picture 10: Ejector Port Trimming

Circuit Breaker Optional Location A

Circuit Breaker Optional Location B



3 AFS IBF INSTALLATION

3.1 Reinstallation of Antennas

NOTEThe new AFS aft fairing does not include an integral antenna. If the built-in antenna on the removed (old) aft fairing was being used, an alternate antenna will be required.

3.1.1 Install the GPS mount and antenna mount (as applicable) in the aft end of the 102300-101 fairing structural assembly (Ref. Page 3 of this document, Figure 2, Item 1) using existing Technical Manuals, Service Bulletins, Technical Bulletins, and Service Letters.

Picture 11: Typical GPS Mount Installation

Picture 12: Typical GPS Antenna Installation

3.1.2 Attach remaining antennas and electrical hardware to the 102300-101 fairing structural assembly per existing Technical Manuals, Service Bulletins, Technical Bulletins, and Service Letters.

3.2 Installation of the Aft Fairing, Forward Filter, and Oil Cooler Cover Screen

3.2.1 Retain the existing differential pressure switch assembly. If not equipped with the switch, install the differential pressure switch (369A8402-7) per CSP-HMI-2, Section 71-10-10 and CSP-IPC-2, Section 71-10-10, Figure 2. (Ref. Note in Para. 2.2.9 of this document)

Figure 10: Differential Press. Switch (Reference) (Extract from CSP-IPC-4, Section 71-10-10, Figure 2)

Picture 13: Differential Pressure Switch Location

Pressure Switch

Differential Pressure Switch



3.2.2 Locate the BP-40SM and 0.27 diameter hole for the existing aircraft static port on aft end of the fairing.

Picture 14: Static Port Location

3.2.3 Per Drawing 102200-101, install the 102330-101 tube assembly to the differential pressure switch.

Picture 15: Static Port Tubing

3.2.4 Per Drawing 102200-101, install 268N Adapter with Nut and 259N Insert onto the aft end of the new nylon tubing and secure to the BP-40SM Static Port. Install a 90º click bond (CB4020G3N8) near the hole for the existing aircraft static tube for additional support then install the existing static tube and secure per CSP-HMI-3, Section 95-10-00. After existing static tube is installed secure to 90º click bond (CB4020G3N8) using MS3367 wire straps.

3.2.5 Per Drawing 102200-101, install two CB4019G3N click bonds and MS3367 wire straps as required to the inside of the fairing.

Picture 16: Click Bond and Wire Strap Locations

3.2.6 Secure the nylon tubing and existing static line to the two click bonds inside the fairing and secure using two wire straps.

NOTE:The position of the RH and LH inlet fairings (clamshells) is critical to the placement of the floor plates and the new fairing. Prior to drilling and installation of the fairing, place the RH and LH inlet fairings in their locations and check alignment.

3.2.7 Locate the 102300-101 fairing assembly (Ref. Page 3 of this document, Figure 2, Item 1 and FAA AC 43.13-1B, section 4-50, paragraph a-c for additional guidance) onto the aircraft structure. Locate and pilot drill the existing airframe holes on the fairing structural assembly. If any existing holes do not line up with the fairing flange, a new hole may be located and drilled between existing rivet holes ensuring that edge distance for the fairing and aircraft structure and new rivet hole are 2D and the edge distance between new and existing holes are 4D. Ensure the same number of rivets are used as were removed. Use good shop practices and methods for the repair and reference FAA AC 43.13-1B for additional guidance.

Existing Static Tube

New Nylon Tubing

Existing Static Port Location (0.27 diameter hole)

BP-40SM Port

CB4020G3N890º click bond



Picture 17: Fairing Location and Positioning

3.2.8 Bolt the 102303-203 L/H floor plate and 102303-201 floor plate (ref. Fig. 2 items 4 & 5) to the aircraft structure.

Picture 18: Floor Plates Location and Installation

3.2.9 Scribe a line from the aft end of the fairing structural assembly front frame onto the L/H floor plate and floor plate.

Picture 19: Scribing Floor Plates

3.2.10 Remove the fairing structural assembly from the aircraft. Remove the L/H floor plate and floor plate from the aircraft.

3.2.11 Locate and match drill (0.128 dia.) the L/H floor plate and floor plate to the front frame of the fairing structural assembly using the scribed line for alignment (reference drawing 102200-101).

3.2.12 Fasten the L/H floor plate and floor plate to the front frame of the fairing structural assembly with 11 MS20470AD4 rivets (ref. dwg 102200-101).

Picture 20: Floor Plates Riveted to Fairing (Viewed from inside Fairing)

3.2.13 Locate and install 12 MS21059-L3 Nut Plates (ref. dwg 102200-101) on the forward top edge of the aft fairing to match with the left and right forward fairings.

Picture 21: Fairing Nut Plate Installation

L/H Floor Plate

Floor Plate

Nut Plates along edge

LH Floor Plate

Floor Plate



3.2.14 Install the 102300-101 fairing structural assembly (ref. Fig. 2, item 1), using next oversized rivets if required. Seal the perimeter of the fairing with polysulfide sealant. Apply RTV sealant to the bottom of the floor plate-L/H and the floor plate (ref. Fig. 2, items 4 & 5) and bolt onto the airframe using existing hardware.

Picture 22: Fairing Installation

CAUTION Ensure that the fairings and floor plates are adequately sealed to prevent air leaks into the engine inlet plenum.

3.2.15 Install the 102319-201 control rod fairing (ref. Fig. 2, item 6) onto the fairing structural assembly by sliding it down the control rod from the mast base. Install the control rod fairing MS21059-L3 nut plate (ref. dwg 102200-101) to the aircraft structure using 2 NAS1097-AD3 rivets (ref. dwg 102200-101). Apply RTV sealant to the bottom of the control rod fairing and attach the control rod fairing to the floor using 2 AN525-10R8 bolts (ref. dwg 102200-101).

Picture 23: Control Rod Fairing Installation

3.2.16 Slide the control rod boot down the control rod and reconnect the control rod to the mast base per section 63-15-10 of CSP HMI-2.

Picture 24: Control Rod Boot Installation

3.2.17 Install AFS bypass door cable, 102325-201 (ref. Fig. 2, item 7), using 2 AN525-10R6 bolts, 2 MS21042-3 Nuts, 4 MS21919-WDG3 clamps, and existing hardware (reference drawing 102200-101). Use spiral wrap at cable clamp points.

Picture 25: Bypass Cable Installation

3.2.18 Connect the AFS bypass door cable, 102325-201 (ref. Fig. 2, item 7), to the bypass door latch located on the inner wall of the fairing structural assembly (ref. Fig. 2, item 1). Rig cable for proper operation. Test the bypass by pulling the “T” handle located in the crew compartment to activate the bypass door, then reset the bypass door (repeat the activation and reset sequence at least ten times). There shall be no evidence of sticking, binding, or other malfunction.

Control Rod Fairing

Bypass Cable



Picture 26: Bypass Cable Installation

3.2.19 Reconnect antenna harness.

3.2.20 Connect the 102330-101 tube assembly and IBF differential pressure static line using the AN816 adapter, the 266N connector with nut/sleeve, and the 259N insert.

Picture 27: Pressure Switch Connection

3.2.21 Install 102450 forward filter assembly (ref. Fig. 2, item 3), using a straight bladed screwdriver.

Picture 28: Forward Filter Installation

CAUTION Use extreme care when installing the Dzus type fasteners not to overtorque the fasteners. The fasteners should only require one quarter of a turn to lock securely in place. Use extreme care when installing the forward filter assembly not to pierce or damage the filter media with a screwdriver or other hand tool.

3.2.22 Reinstall the air inlet cooling fan screen assembly (if applicable) by slotting the screen holes in the aft direction as required (approximately 0.25 inches) and sliding the screen forward to provide for a noninterference fit with the forward filter assembly (item 3). Trim the left hand aft corner as required to clear the 102319-201 control rod fairing.

Picture 29: Inlet Cooling Fan Installation

Bypass Latch

102330-101 Tube AN816 Adapter 266N Connector 261N Nut Pressure

Switch

New IBF Static Line



3.2.23 Reinstall the forward RH and LH inlet fairings (clamshells) fairings per section 53 of CSP HMI-2.

3.2.24 Install the 102400 upper filter assembly to the structural fairing assembly (ref. Fig. 2, items 2 & 1 respectively) using a straight bladed screwdriver.

Picture 30: Upper Filter Installation

CAUTION Use extreme care when installing the Dzus type fasteners not to overtorque the fasteners. The fasteners should only require one quarter of a turn to lock securely in place. Use extreme care when installing the upper filter assembly not to pierce or damage the filter media with a screwdriver or other hand tool.

NOTE:The following instructions are to be followed if the optional Filter Maintenance Aid (FMA) is to be installed

3.2.25 Install the FMA on the existing particle separator scavenge air valve assembly mounting bracket using two (2) AN525 screws (pick up existing nut plates on the bracket).

Picture 31: FMA Installation

3.2.26 Connect the tube end of the FMA assembly to the AN833-6 elbow on the plenum wall.

Picture 32: FMA Tube Connection

AN833-6

Air Valve Mount Bracket



3.3 Oiling Filters

3.3.1 Oil the Filter media as follows:

Picture 33: Upper Filter Assembly (102400)

Picture 34: Forward Filter Assembly (102450)

CAUTION Do not put any IBF Filter Assembly in service without oiling it.

CAUTION Use only designated oil or an AFS approved substitute. The filter will not function properly if other types of oil are used. Red dye has been added to the oil to show areas of application.

CAUTION Do not use automotive transmission fluids, any kind of motor oil, or diesel fuel to oil IBF filters. Do not use WD-40, LPS, or any other type of lightweight spray lubricants to oil IBF filters. Any of these fluids will damage the filter or degrade its filtering capability.

NOTEThe UPPER Inlet Barrier Filter (102400) will require 14 fluid ounces of filter oil for proper oiling.

The Forward Inlet Barrier Filter (102450) will require 7 fluid ounces of filter oil for proper oiling.

3.3.2 To oil the IBF filter, pour the proper amount of filter oil (14 fl oz - Upper IBF Filter and 7 fl oz - Forward IBF filter) into a squeeze bottle.

Picture 35: Oil Bottle

FilterMedia



3.3.3 Lay filter flat on a clean surface.

CAUTION Do not over oil filters.

3.3.4 Gently squeeze a small stream of oil along the entire length of each pleat, turn filter over and repeat on reverse side. Apply approximately ½ of the bottle to each side of the filter. Use sparingly to ensure coverage of entire filter.

Picture 36: Oiling Filter

3.3.5 Repeat for each filter assembly.

3.3.6 Let each filter sit for 20 minutes to allow oil to wick into surrounding filter media. Apply more filter oil (do not exceed quantity above) to any areas that are still white.

3.3.7 Reinstall Filter Assemblies into IBF Assembly.



4 MASTER TOOL LIST

5 SPECIAL TOOLING, JIGS, AND FIXTURES

None required.

6 WEIGHT AND BALANCE DATA:

The approximate total weight of the IBF system will be 23.5 (± 1) pounds. The IBF system will not exceed the current weight of the IPS by greater than eight (8) pounds.

6.1 Weigh and record the weights of the control rod fiberglass closeout, and all components of the Particle Separator and associated hardware.

6.2 Weigh and record the weights of the removed bypass door cable and aft engine inlet fairing.

6.3 Record the difference between the weight of the removed components (paragraphs 2.1.5 and 2.2.9 above) and the weight of the installed AFS IBF system in the aircraft logbook. Due to the position of the IBF relative to the center of the aircraft no balancing will be required.

7 RESTORATION

Refer to MD Helicopters Inc. Maintenance Manual and/or AFS MD Helicopters Inc. Operation & Maintenance Manual / Illustrated Parts List (OMM / IPL), MD500-IBF-KIT-OMM/IPL, for the following procedures:

7.1 Remove all temporary tags.

7.2 Replace instrument panel (if applicable).

7.3 Install instrument panel shrouds (if applicable).

7.4 Install the left hand passenger compartment quarter panel assy. (if applicable).

7.5 Install and connect battery.

Tool Description Number Required 1 Pneumatic Drill/Driver 1 2 Straight Head Screwdriver 1 3 Rivet Gun 1 4 Socket Wrench Set (English Units) 1 5 Shop Vacuum 1 6 Air Compressor 1 7 Pneumatic Blind Rivet Driver (optional) 1



7.6 Perform Filter Clogged Indicator operational checks, per CSP-HMI-2, Section 71-10-10, Engine Air Particle Separator Inspection/Check, paragraph 5. If the FMA (Filter Maintenance Aid) is installed, it may be checked at this same time. The FMA may be checked for accuracy by applying approximately 10 inches of water (less than ½ psi) to the system. The reading on the FMA should correspond to the manometer fabricated per Figure 11 (below) within +/- 1 inch of water. Do not exceed 15 inches of water suction as this may damage the FMA

7.7 Perform bypass door operational check per Section 3.2.19 of this document.

7.8 Reweigh the aircraft or use the reference data in Section 6.0 to compute the new weight and balance and record into aircraft logbook.

7.9 Return helicopter to service.

8 MAINTENANCE CHECK FLIGHT.

After complete installation of the IBF, and prior to full release of the aircraft, it is recommended that a maintenance check flight shall be performed in accordance with MDHI procedures.



Figure 11: Differential Press. Switch and FMA (if installed) Operational Check (Reference) (Extract from CSP-HMI-2, Section 71-10-10, Figure 601)

Document Number: MD500-IBF-KIT-OMM/IPLRevision: A

Date: June 28, 2002

COPYRIGHT© 2000Westar Corporation


LIMITED and/or RESTRICTED RIGHTS NOTICEThis document, along with its drawings and photographs, contains Trade Secrets and/or Commercial or Financial Information that is proprietary to Westar Corporation under 5 USC 552 as amended, and is Prohibited from Public Disclosure by 18 USC 1905. Do not duplicate or disclose outside the U.S. Government without the express written permission of Westar Corporation.

The Government's rights to use, modify, reproduce, release, perform, display, or disclose these technical data are restricted to the purpose of evaluating Westar's design for FAA commercial certification and airworthiness consideration only. Any reproduction of technical data or portions thereof marked with this legend, or referring to this legend, must also reproduce the markings and legend. Any person, other than the Government, who has been provided access to such data must promptly notify: Westar Corporation, Attn:Contracts Manager, 4 Research Park Drive, St. Charles, MO 63304-5685


Operation & Maintenance Manual/Illustrated Parts List

INLET BARRIER FILTER SYSTEMfor the

MD Helicopters Inc. (MDHI)MD500 Series Helicopter

FAA Project No. ST9389LA-R

Prepared By: Thomas Newman

Reviewed By: Daniel Flesher

Approved By: Michael Scimone

4 Research Park DriveSt. Charles, MO 63304-5685

Westar Corporation MD500-IBF-KIT-OMM/IPL Proprietary Information

Use or disclosure of this material is subject i MD500 IBF Operation & Maintenance Manual/to the restrictions on the title page Illustrated Parts List

Revision No. Revision Description Approved by: Release DateN/C Initial Submittal M. Scimone 02-08-02

A

Corrected all references to “McDonnell Douglas Helicopter Incorporated” to read “MD Helicopters Inc.” and change references to “Westar” to new name “AFS”; Title pg - add new logo & FAA project no.; Pg i - addrevision block page; Para 2.6 – add new paragraph for Optional Ground Support Equipment providing supplierinformation for the procure ment of filter assembly covers;

M. Scimone 06-28-02


Use or disclosure of this material is subject ii MD500 IBF Operation & Maintenance Manual/to the restrictions on the title page Illustrated Parts List

TABLE OF CONTENTS

1.0 OPERATIONAL REQUIREMENTS .................................................................................11.1 System Description.................................................................................................................1

1.2 Pre-Flight Inspection...............................................................................................................21.3 CWA/Emergency Procedures .................................................................................................32.0 AIRWORTHINESS LIMITATIONS & MAINTENANCE REQUIREMENTS ...........3

2.1 Normal Service Limits............................................................................................................32.2 Standard Environment Requirements .....................................................................................4

2.3 Desert Environment Requirements .........................................................................................42.4 Engine Water Wash ................................................................................................................42.5 Uncovered Storage ..................................................................................................................4

2.6 Optional Ground Support Equipment .....................................................................................53.0 FILTER ELEMENT SERVICING.....................................................................................5

3.1 Authorized Materials ...............................................................................................................53.2 Tools Required ........................................................................................................................53.3 Filter Removal/Installation .....................................................................................................6

3.4 Inspection and Pre-Cleaning ...................................................................................................73.5 Cleaning Precautions ...............................................................................................................8

3.6 Applying Cleaner ....................................................................................................................83.7 Rinse Procedure ......................................................................................................................83.8 Drying Procedure ....................................................................................................................9

3.9 Marking Procedure..................................................................................................................93.10 Oiling Precautions...................................................................................................................9

3.11 Squeeze Bottle or Tube Oiling .............................................................................................104.0 FILTER ELEMENT REPAIR ..........................................................................................104.1 Pleat Straightening ................................................................................................................10

4.2 Puncture Damage ..................................................................................................................114.2.1 Small Rupture ....................................................................................................................11

4.2.2 Large Rupture ....................................................................................................................114.3 Maintenance Damage ............................................................................................................114.4 Fastener Replacement ...........................................................................................................12

5.0 ILLUSTRATED PARTS LIST..........................................................................................13


Use or disclosure of this material is subject iii MD500 IBF Operation & Maintenance Manual/to the restrictions on the title page Illustrated Parts List

LIST OF FIGURES

Figure 1: AFS MD500 Inlet Barrier Filter System. ...................................................................2

Figure 2: Example of Filter Assembly Data Plate......................................................................9Figure 3: MD500 IBF Illustrated Parts Breakdown................................................................14

LIST OF TABLES

Table 1: AFS MD500 IBF Parts List.........................................................................................13

Instructions for Continued Airworthiness

“This document in conjunction with the Installation Procedures manual, MD500-IBF-IP, serves to meet the intent of the Federal Aviation Requirements (FAR) to provide Instructions for Continued Airworthiness. Modification of an aircraft by this Supplemental Type Certificate (STC) obligates the aircraft operator to include the maintenance information provided by this document in the operator’s Aircraft Maintenance Manual and the operator’s Aircraft Scheduled Maintenance Program. The Airworthiness Limitations & Maintenance Requirements section is FAA approved and specifies inspections and other maintenance required. The STC kit installation information is contained in the Installation Procedures manual, MD500-IBF-IP, and should also be placed into the appropriate operator’s Aircraft Maintenance Manual.”


Use or disclosure of this material is subject MD500 IBF Operation & Maintenance Manual/to the restrictions on the title page Illustrated Parts List

1

AFS MD500 Inlet Barrier Filter (IBF) System

Operation & Maintenance Manual

1.0 OPERATIONAL REQUIREMENTS

1.1 System Description

The Aerospace Filtration Systems (AFS) IBF system design includes an all-new aircraft upper aft engine inlet fairing assembly. For the purpose of this manual, this component will be referred to as the “aft fairing.” The aft fairing conforms to the inlet duct and upper section of the engine inlet plenum chamber. The IBF system (Figure 1) is an integral aircraft component with subsystem components incorporated into the aft fairing. It is comprised of an aerodynamic structural fairing, integral structural frame and deflector, integral bypass system, two barrier filter assemblies (forward and upper), integral seals, plumbing for the existing differential pressure switch, two forward floor plates and a control rod fairing that interfaces with the existing flexible boot and tail rotor control rod to seal the inlet plenum.

The forward and upper barrier filter assemblies are comprised of the filtration media and mounting frames with captive fasteners. The current interface with the MDHI forward split fairings is maintained, and the tail rotor control rod interface is improved over its current configuration.

The IBF fairing employs a mechanically operated inlet bypass system to permit unfiltered air to enter the engine inlet plenum chamber should the IBF filter media become obstructed. Once the bypass system is rigged during the IBF system installation, no recurring maintenance is required.A standard MDHI MD500 aircraft inlet differential pressure sensor is used and for most installations the existing sensor can be reused. The sensor provides an indication to the pilot of debris accumulation on the filter elements, glossing over due to ice or snow, and when to activate the bypass system prior to the pressure drop across the filters exceeding operational limits.



2

Figure 1: AFS MD500 Inlet Barrier Filter System

1.2 Pre-Flight Inspection

Pre-flight inspection shall be made by the pilot to inspect the filters (forward and upper) for damage, excessive accumulation of debris (straw, leaves, insects, etc.) or snow/ice, missing or damaged fasteners, or the need for servicing or repair of the filters. After extended operation in precipitation (i.e., rain, or a combination of rain and sleet/snow), the sand and dust collected on the external side of the filter media (dirty side) may coagulate in the corners of the filter media pleats. If visual inspection indicates existence of any of the above conditions, the decision whether to service the filter assemblies will reside with the flight crew. Damaged or missing fasteners should be replaced to maintain maximum seal integrity. The filter assemblies use captive fasteners and should not need replacement during normal service. If the fastener should become damaged, perform fastener replacement per manufacturer’s recommendations (seeparagraph 4.3). Operation with either missing fasteners and/or filter damage can severely degrade IBF system separation efficiency and result in possible performance loss, wear, and/or damage to the engine. Damaged filter elements should be either repaired as described in paragraph 4.0 below or replaced.



3

1.3 CWA/Emergency Procedures

The “AIR FILTER CLOGGED” advisory light illuminates when the pressure drop across the IBF elements reaches the aircraft inlet differential pressure switch setting. This light serves as a caution to the pilot that the Turbine Outlet Temperature (TOT) has increased compared to a clean filter element, resulting in decreased turbine temperature margin. The pilot must be aware thatunder normal operation, TOT gradually increases as pressure drop increases thereby reducing power available when temperature limited. The pilot must therefore closely monitor TOT; continued operations in an environment causing the pressure drop and TOT to continue to increase will eventually result in a reduction in power available. Therefore, upon illumination of the advisory light, the pilot must evaluate current conditions, closely monitor TOT, and assess mission requirements to determine whether to continue the flight, open the bypass door or return to place of origin or nearest airfield. The bypass door is mechanically opened by the pilot from the cockpit by pulling a lever mounted above and behind the left crew seat. This lever is connected through a control cable to the bypass door located on the right side of the upper aft fairing assembly. Prior to opening the bypass door however, the pilot must to the extent possible take action to avoid operations in any environment that would be harmful to the unprotected engine. Emergency conditions, requiring immediate opening of the bypass door, could result while operating in extended brown out conditions, inadvertent icing conditions, or upon accumulation of foreign object(s) (e.g. shedding a sheet of ice or multiple small objects including bird/insect strikes). Such emergency conditions would be evident to the pilot by the illumination of the “AIR FILTER CLOGGED” advisory light followed by an immediate increase in TOT.

2.0 AIRWORTHINESS LIMITATIONS & MAINTENANCE REQUIREMENTS

2.1 Normal Service Limits

The actual service interval must be based on a combination of tracking engine Power Check data (Refer to Section V of the applicable MD500 Series Rotorcraft Flight Manual), cumulativeoperating hours, “AIR FILTER CLOGGED” indication and visual inspections. Any steady illumination of the “AIR FILTER CLOGGED” light, where the pressure sensor and indicating system are shown to be working properly, requires servicing of the filter elements at the earliest opportunity. The gradual increase in pressure drop across the IBF elements causes a reduction in temperature margin as measured by the Power Check. When possible, in order to minimize unnecessary filter changes, the servicing of the IBF should only be performed after standard troubleshooting methods are exhausted and the only remaining suspect performance driven anomaly is inlet pressure loss. The recommended service interval is 100 hours, which can be coupled with other aircraft/engine inspections. The decision whether to service the filter based on the results of a visual inspection will reside with the pilot. If physical evidence is present that a fungus is growing over a substantial portion of the filter media assembly (30% per assembly),it will require servicing. Maximum number of service cycles (i.e., cleaning/oiling) is limited to 15 for each filter assembly. The forward and upper filter assemblies include a data plate that must be scribed to track filter service cycles (see paragraph 3.9).



4

2.2 Standard Environment Requirements

During normal conditions and typical operations in and out of prepared airfields and landing sites, the IBF filter elements will not require frequent servicing. A Power Check should be performed every 25 aircraft operating hours to gage the rate of engine performance degradation due to changes in engine inlet pressure drop as the filters accumulate dirt. This is recommended after the first installation and operation of an IBF system with an operator with no prior experience or following relocation to an unknown environment. After establishment of a trend and experience with the IBF system, the Power Check interval may be increased as deemed reasonable. It is recommended, however, that a Power Check be performed at a minimum every 100 operating hours coupled with the scheduled 100-hour inspection.

2.3 Desert Environment Requirements

When operating in an environment of high airborne sand and dust levels, frequent servicing of the filter elements may be required based on the time exposure to the environment. Any operations in this type environment that can result in “brown out” (i.e. severe dust) type conditions should therefore be minimized or avoided to the maximum extent possible. If extended time is being accumulated operating in “brown out” conditions, a Power Check could be required at as low as 10-hour intervals. This reduced interval will be based on the judgment of the pilot. It is recommended that for normal operations in a desert environment that Power Checks be conducted every 25 hours. Servicing requirements for engines operating in this type of environment will be primarily based on the indicated degradation of the engine performance as determined by the Power Check results. Regular operation in a fine sand and dust environment can cause oil loss from the element thus reducing the filter’s separation efficiency.Under such circumstances occasional re-oiling of the element's clean side may be necessary based on the coloration of the element.

NOTE:

Visual inspection for loss of oil should be done on the clean side or down stream side of the filter assembly.

2.4 Engine Water Wash/Rinse

Do not deviate from the published OEM (Rolls-Royce) procedures.

2.5 Uncovered Storage

If an IBF equipped aircraft is stored uncovered and exposed to the environment (rain, snow, etc.) or direct sunlight, the upper filter assembly must be protected and the forward filter assembly inlet duct should be protected from snow accumulation (see paragraph 2.6 below). In particular, the cover must be used to protect the upper filter assembly since long-term exposure to sunlight may degrade the filtration characteristics of the media and generate a service cycle.



5

2.6 Optional Ground Support Equipment

The IBF kit does not include an environmental protection cover, as required in paragraph 2.5 above. This cover is required if the aircraft is not kept in covered storage, e.g. a hanger. Thecover must be capable of protecting both the forward and upper filter assemblies and the static ports at the aft end of the fairing. One such cover is available from a company called Bruce’s Custom Covers in Sunnyvale, California. This cover or any equivalent cover must be procured separately. If using the cover manufactured by Bruce’s Custom Covers, aircraft model 369D uses the P/N 500D-100 cover and models 369E, 369F, and 369FF all use the P/N 500E-100 cover,both of which are designated as an “Intake/Doghouse Cover”. The complete supplier information is as follows:

Bruce’s Custom Covers Phone: 408.738.3959989 E. California Ave. Toll Free (U.S.): 800.777.6405Sunnyvale, CA 94085 Fax: 408.738.2729

www.aircraftcovers.com E-mail: [email protected]

3.0 SERVICING INSTRUCTIONS

3.1 Authorized Materials

Service AFS filters elements with only K&N Air Filter Oil, AFS Air Filter Oil, K&N Air Filter Cleaner, AFS Air Filter Cleaner, or a AFS authorized substitute. See paragraph 3.6 for cleaning procedure and paragraph 3.11 for oiling quantities/procedure.

3.2 Tools Required

5/16-inch Slotted Screwdriver

#2 Phillips Screwdriver

Hand Seamer – 1 1/4 inch maximum jaw depth

NOTE:

Hand seamers are available through many commercialaircraft supply stores (local or on-line) and also through commercial heating and air conditioning supply stores.Recommend the following: Malco Tools “Hand Seamer with Forged Steel Jaw”, Catalog # S2, S3 and S6, see www.malcotools.com/products/seamers/s2.htm. The S3 model is also available through Wicks Aircraft Supply, Part Number TP44-0, “Offset Hand Seamer”, see http://wicks.overcoffee.com/gotopage.php?page=38 or www.wicksaircraft.com.



6

3.3 Filter Removal/Installation

The IBF system uses two barrier filter assemblies that can be easily removed for cleaning and/or replacement. The system is designed for easy access and removal of the filter assemblies with the aircraft shutdown on the ground.

Upper Filter Removal

CAUTION

After removal of the filter assemblies, inspect the filter seals on the aircraft for visible damage and security.

CAUTION

After removal of the filter assemblies, cover the engine inlet to ensure it is protected from FOD, if the assemblies are not reinstalled immediately.

Removal of the top filter requires the disengagement of (14) captive Dzus type fasteners.A ¼ turn (counterclockwise) with a slotted screwdriver is all that is required to remove the Dzus stud (screw head) from the receptacle. Once all the fasteners are loose, filter element must be carefully removed so as not to damage the seals. The upper filter has the seal attached to the underside of the filter assembly.

Upper Filter Installation

WARNING

Prior to installation of the filter assemblies, remove any FOD protection from the engine bellmouth.

Prior to installation of serviced filter assembly, the seal shall be visually inspected for security and damage. Insert the upper filter assembly into the upper aft fairing cutout; insure the assembly is seated properly in the upper opening. Engage the (14) captive Dzus type fasteners by rotating ¼ turn clockwise and ensure the seal is uniformly compressed. Do not over rotate the fasteners, over rotation will result in damage to the stud and/or the receptacle.



7

Forward FilterRemoval

CAUTION

After removal of the filter assemblies, inspect the filter seals on the aircraft for visible damage and security.

CAUTION

After removal of the filter assemblies, cover the engine inlet to ensure it is protected from FOD, if the assemblies are not reinstalled immediately.

To remove the forward filter assembly, remove the right detachable forward upper inlet fairing. Remove the (10) Phillips head screws that secure the oil cooler FOD screen, remove the FOD screen. Disengage the (8) captive Dzus type fasteners that fasten the forward filter assembly to the forward frame. A ¼ turn (counterclockwise) with a slotted screwdriver is all that is required to remove the Dzus stud (screw head) from the receptacle. The forward filter assembly seal is attached to the forward frame.

Forward Filter Installation

WARNING

Prior to installation of the filter assemblies, remove any FOD protection from the engine bellmouth.

Prior to installation of serviced filter assembly, the seal shall be visually inspected for security and damage. Insure that the forward filter assembly is seated properly in the forward frame. Engage the (8) captive Dzus type fasteners by rotating ¼ turn clockwise and ensure the seal is uniformly compressed. Do not over rotate the fasteners, over rotation will result in damage to the stud and/or the receptacle. Reinstall the oil cooler FOD screen and secure with (10) Phillips head screws.

3.4 Inspection and Pre-Cleaning

Remove the filter elements and inspect the serviceability tag. If all the blocks have been marked through, the assembly should be discarded and replaced with a new or other serviceable assembly. If there are service cycles left on the assembly, proceed with pre-cleaning. Carefully remove any large debris by hand or with tweezers then gently brush the dirty side of the filter with a soft bristle brush similar to a soft paintbrush to remove any heavy deposits.



8

3.5 Cleaning Precautions

CAUTION

Do not clean AFS elements with gasoline,solvents, parts cleaners, strong detergents, orcaustic cleaning solutions.

CAUTION

Do not steam clean or use high-pressure washersto clean the AFS element.

Use only K&N Filter Cleaner or a AFS approved substitute. The K&N Filter Cleaner is commercially available (see paragraph 3.1). Use of any product other than those approved by AFSwill cause damage the filter media and/or frame assembly. The use of any other cleaning material is strictly prohibited and voids any manufacturer warranty.

3.6 Applying Cleaner

Spray cleaner liberally onto the entire element (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. With the filter element lying flat (dirty sidedown), let the cleaner soak into the filter media for 15 minutes.

3.7 Rinse Procedure

After the cleaner has soaked for 15 minutes, rinse the filter with low-pressure water. Use water out of a standard faucet or hose (without nozzle). Start flushing in the opposite 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. Upon completion, rotate the filter to clean from the dirty side to the clean side, pleats still vertical. Using very low water pressure to avoid driving the debris deeper into the media, repeat the rinsing procedure until there is no visible debris on the surface and the runoff water is clean. When finished, flip the filter once again and repeat the rinse from clean side to dirty side. Finally, rotate the filter from top to bottom, and perform the final rinse until the runoff water is free of all debris and oil. After the final rinse, inspect filter by viewing through the filter to a direct light source. If debris still remains a repeatcleaning may be necessary.



9

3.8 Drying Procedure

CAUTION

Do not use compressed air since it will damage the filter media.

CAUTION

Do not use heat from any source to dry the AFSelement. Heat will shrink the filter media and may damage the coring material within the filter frames.

After rinsing, shake off the excess water and let the element dry at room or outside air temperature (above freezing).

NOTE

After cleaning and before oiling of the dry filter element, the pleats should be inspected and, if required, straightened or crimped per the procedure at paragraph 4.1 below.

3.9 Marking Procedure

After the filter assembly has dried take a sharp instrument (scribe or center punch) or a vibro-peen and scratch an “X” through one of the unmarked boxes on the serviceability tag. Use caution not to slip and injure yourself or damage the filter element. When the last unmarked box is crossed through the filter assembly will have to be replaced when servicing is required again.

Figure 2: Example of Filter Assembly Data Plate

3.10 Oiling Precautions

WARNING

Never put a AFS Filter Assembly in service without oiling it.



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CAUTION

Use only K&N Air Filter Oil or a AFS approved substitute.

The filter will not function properly if other types of oil are used. Both K&N Air Filter Oil and AFS Oil are a unique blend of oil base stocks and special polymers that form a very efficient “tack barrier.” Dye is added to show areas of oil application. Do not use transmission fluid, anykind 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. Use of any product other than those approved by AFS will cause damage the filter media and/or frame assembly. The use of any other oiling material is strictly prohibited and voids any manufacturer warranty.

3.11 Squeeze Bottle

CAUTION

Use caution not to over oil.

A squeeze bottle allows for the controlled application of a specific amount of oil per filter.Seven fluid ounces (7 fl. oz., 102465-101) is the quantity to be applied to the forward filter assembly (P/N 102450-101) and fourteen fluid ounces (14 fl. oz., 102425-101) should be applied to the upper filter assembly (P/N 102400-101). Lay filter flat, 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. Use caution not to over oil.Let the filter sit for 30 minutes as the oil “wicks” into the surrounding filter media. The oil wicks most effectively when the filter is laying flat. Apply remaining filter oil (not to exceed the quantities above) to any areas that are still white or not yet uniform in color. Use caution not to over oil.

4.0 FILTER ELEMENT REPAIR

4.1 Pleat Straightening

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 adjoiningpleats.



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CAUTION

Do not over crimp and crush pleat, care must be taken to squeeze the pleats without deforming or damaging the pleated screen.

After servicing of the filters, the pleats may require straightening or crimping. When looking down on the filter from either side, you must be able to see the bottom of the pleat. If you cannot see the bottom of the pleat, the airflow will be restricted and/or the pleats will stick together when dust loaded. Any restriction to the flow through the pleats will result in increased pressure drop and reduction in sand loading capacity. In order to insure ideal flow characteristics through the filter media, the pleats must be straightened or crimped with a standard sheet metal tool (hand seamer). Once one side is crimped, flip the filter over and crimp the other side as required following the guidance above.

4.2 Puncture Damage

In the event of damage to the filter system, ruptures in the filter can be repaired without risk of structural deformation of the filter element. Small ruptures defined as smaller than a dime can be sealed shut without degradation of performance. Larger ruptures exceeding a dime in size require the assembly to be returned to AFS for evaluation. Details of these repair procedures are defined below. Prior to performing any of these repairs, the filter material must be cleaned and void of contamination and oil.

4.2.1 Small Rupture

Ruptures or voids in the material up to a dime in size can be trimmed clean to remove loose material (wire or cotton gauze) and encased in a sealing material. The sealing material shall be a two-part sealant, such as AMS 3276, for standard use on the aircraft. Allow the sealant to bleed into the filter material and cure before operating to ensure it will not dislodge into the engine inlet plenum.

4.2.2 Large Rupture

Ruptures in the material exceeding a dime in size are not repairable in the field, and the element shall be returned to AFS for evaluation and disposition.

4.3 Maintenance Damage

The repair procedures defined above are valid for handling damage resulting in ruptures as described above. Any unrepairable damage to the filter frames that impair the integrity of the structural security or sealing surfaces shall require the element to be returned to AFS for evaluation and disposition.



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4.4 Fastener Replacement

In the event a fastener becomes damaged and is no longer functional, replacement fasteners are identified in the section 5.0 Illustrated Parts List. Cut the retaining grommet with a pair of diagonal cutters and remove stud from hole. Insert new stud through ejector blade hole and place new grommet over the end of the stud. Flatten grommet with suitable tool to make the stud captive. If the receptacle is damaged, drill out rivets that secure receptacle. The receptacles used on the IBF are floating receptacles, Dzus Type RF35. When replacing a receptacle be sure to install the spacers, Dzus Type RF35-5 in the receptacle holes prior to riveting the receptacle back in place. Ensure receptacle floats after assembly.


Use or disclosure of this material is subject MD500 IBF Operation & Maintenance Manual/ to the restrictions on the title page Illustrated Parts List

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5.0 ILLUSTRATED PARTS LIST

Parts can be ordered by calling Aerospace Filtration Systems (AFS), a division of WestarCorporation, at (636) 498-6016.

Table 1: AFS MD500 Inlet Barrier Filter System Parts List

Wes

tar C

orpo

ratio

n M

D50

0-IB

F-K

IT-O

MM

/IPL

Prop

rieta

ry In

form

atio

n

Use

or d

isclo

sure

of t

his m

ater

ial i

s sub

ject

MD

500

IBF

Ope

ratio

n &

Mai

nten

ance

Man

ual/

to th

e re

stric

tions

on

the

title

pag

eIll

ustra

ted

Parts

List

14

Figu

re 3

: M

D50

0 IB

F Il

lust

rate

d Pa

rts B

reak

dow

n (S

heet

1 o

f 6)

Wes

tar C

orpo

ratio

n M

D50

0-IB

F-K

IT-O

MM

/IPL

Prop

rieta

ry In

form

atio

n

Use

or d

isclo

sure

of t

his m

ater

ial i

s sub

ject

MD

500

IBF

Ope

ratio

n &

Mai

nten

ance

Man

ual/

to th

e re

stric

tions

on

the

title

pag

eIll

ustra

ted

Parts

List

15

Figu

re 3

: M

D50

0 IB

F Il

lust

rate

d Pa

rts B

reak

dow

n (S

heet

2 o

f 6)



16

Figure 3: MD500 IBF Illustrated Parts Breakdown (Sheet 3 of 6)



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Documents

MD500 STC USA - Donaldson Company · MD500-IBF-KIT-MDL, Revision F Proprietary Information ... Thomas Newman Original Signed By 09/30/2004 Prepared By: Roger Wallis Original Signed