AFS MD500 Series, Operation & Maintenance Manual

Page 1: ...om 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 A...

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Page 3: ...nell 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 add revision block page Para 2 6 add new paragraph for Optional Ground Support Equipment providing supplier information for the procurement of filter assembly covers M Scimone 06 28 02 B Added Filter Maintenance Aid FMA information to include Sec...

Page 4: ...ATER WASH RINSE 4 2 5 UNCOVERED STORAGE 4 2 6 OPTIONAL GROUND SUPPORT EQUIPMENT 5 3 0 SERVICING INSTRUCTIONS 5 3 1 AUTHORIZED MATERIALS 5 3 2 TOOLS REQUIRED 5 3 3 FILTER REMOVAL INSTALLATION 6 3 4 INSPECTION AND PRE CLEANING 7 3 5 CLEANING PRECAUTIONS 8 3 6 APPLYING CLEANER 8 3 7 RINSE PROCEDURE 8 3 8 DRYING PROCEDURE 9 3 9 MARKING PROCEDURE 9 3 10 OILING PRECAUTIONS 9 3 11 SQUEEZE BOTTLE 10 4 0 F...

Page 5: ... Parts List 22 LIST OF PICTURES Picture 1 FILTER MAINTENANCE AID 13 Picture 2 FILTER MAINTENANCE AID RESET 13 Instructions for Continued Airworthiness This document 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...

Page 6: ...rings 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 ...

Page 7: ...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 f...

Page 8: ...reign 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 ...

Page 9: ...ns 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 ...

Page 10: ...oghouse Cover The complete supplier information is as follows Bruce s Custom Covers Phone 408 738 3959 989 E California Ave Toll Free U S 800 777 6405 Sunnyvale CA 94085 Fax 408 738 2729 www aircraftcovers com E mail bruce aircraftcovers com 3 0 SERVICING INSTRUCTIONS 3 1 AUTHORIZED MATERIALS Service AFS filters elements with only K N Air Filter Oil P N 99 0551 or 99 0555 AFS Air Filter Oil P N 10...

Page 11: ...ely Removal of the top filter requires the disengagement of 14 captive Dzus type fasteners A 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 assem...

Page 12: ...orward 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 ...

Page 13: ...er element lying flat dirty side down 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 a...

Page 14: ...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 th...

Page 15: ...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 La...

Page 16: ...ilter 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...

Page 17: ...nent requires it to be sent back to AFS for disposition or replacement The FMA is an aid to help maintenance personnel to ascertain the current condition or trend in accumulation of dirt on the Filter Assembly 4 5 1 Removal Access the aft compartment behind the left hand passenger seat Disconnect the hose from the AN842 4D nipple Then remove the hardware and FMA Retaining Ring from Filter Maintena...

Page 18: ...NANCE AID ABOVE 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 BELOW FMA unit is mounted to the scavenge valve bracket assembly behind the left hand passenger compartment quarter panel assy Picture 2 FILTER MAINTENANCE AID RESET RED Zone RED Zone GREEN Zone YE...

Page 19: ...ON IMPROPER USE OF THE ALTIMETER TEST SET COULD RESULT IN DAMAGE TO THE FILTER MAINTENANCE AID CAUTION IMPROPER USE OF THE ALTIMETER TEST SET SUCH AS PULLING AN ALTITUDE OF GREATER THAN 1880 FEET ABOVE FIELD ELEVATION WILL DAMAGE THE FILTER MAINTENANCE AID Connect the Barfield or equivalent altimeter test set vacuum system to the end of the fitting inside the plenum area Ensure that the fit betwee...

Page 20: ... Control Rod 1 Sheet 2 16 102303 201 Floor Plate 1 Sheet 2 17 102303 203 Floor Plate L H 1 Sheet 2 18 102305 201 Attach Plate Sides 2 Sheet 2 19 102306 201 Attach Plate Aft 1 Sheet 2 20 102370 101 Latch Assembly 1 Sheet 3 21 MS24665 132 Cotter Pin 1 Sheet 3 22 102375 201 Plunger Latch 1 Sheet 3 23 C0360 035 0560 M Spring 1 Sheet 3 24 102371 201 Body Latch 1 Sheet 3 25 102373 201 Lever Latch 1 Shee...

Page 21: ...MM IPL Proprietary Information Use or disclosure of this material is subject MD500 IBF Operation Maintenance Manual to the restrictions on the title page Illustrated Parts List Revision B 16 Figure 3 MD500 IBF Illustrated Parts Breakdown Sheet 1 of 6 ...

Page 22: ...MM IPL Proprietary Information Use or disclosure of this material is subject MD500 IBF Operation Maintenance Manual to the restrictions on the title page Illustrated Parts List Revision B 17 Figure 3 MD500 IBF Illustrated Parts Breakdown Sheet 2 of 6 ...

Page 23: ...MM IPL Proprietary Information Use or disclosure of this material is subject MD500 IBF Operation Maintenance Manual to the restrictions on the title page Illustrated Parts List Revision B 18 Figure 3 MD500 IBF Illustrated Parts Breakdown Sheet 3 of 6 ...

Page 24: ...MM IPL Proprietary Information Use or disclosure of this material is subject MD500 IBF Operation Maintenance Manual to the restrictions on the title page Illustrated Parts List Revision B 19 Figure 3 MD500 IBF Illustrated Parts Breakdown Sheet 4 of 6 ...

Page 25: ...MM IPL Proprietary Information Use or disclosure of this material is subject MD500 IBF Operation Maintenance Manual to the restrictions on the title page Illustrated Parts List Revision B 20 Figure 3 MD500 IBF Illustrated Parts Breakdown Sheet 5 of 6 ...

Page 26: ...MM IPL Proprietary Information Use or disclosure of this material is subject MD500 IBF Operation Maintenance Manual to the restrictions on the title page Illustrated Parts List Revision B 21 Figure 3 MD500 IBF Illustrated Parts Breakdown Sheet 6 of 6 ...

Page 27: ...these parts can also be ordered by calling Aerospace Filtration Systems AFS at 636 300 5200 Item No Part No Description Qty Ref Fig 4 45 102380 103 Indicator Assembly 1 Sheet 1 46 102381 101 Tube Assembly 1 Sheet 1 47 102383 201 Hose 1 Sheet 1 48 102384 101 Mount Kit Assembly 1 Sheet 1 49 102390 201 Maintenance Indicator 1 Sheet 1 50 3604 Clamp 2 Sheet 1 51 AN842 4D Nipple 1 Sheet 1 52 AN894D6 4 A...

Page 28: ...prietary Information Use or disclosure of this material is subject MD500 IBF Operation Maintenance Manual to the restrictions on the title page Illustrated Parts List Revision B 23 Figure 4 MD500 IBF Optional Equipment Illustrated Parts Breakdown Sheet 1 of 1 ...

Page 29: ...this material is subject MD500 IBF Operation Maintenance Manual to the restrictions on the title page Illustrated Parts List Revision B 24 Figure 5 MD500 IBF Alternative Function Check Method Extract from CSP HMI 2 Section 71 10 10 Figure 601 The FMA replaces the Air Sensing switch AIR SENSING SWITCH ...