ICA500-1 B
Contents
1. Inflate in 0 5 psig increments Measure pressure in each compartment with mercury manometer or pressure gauge calibrated in increments not greater than 0 1 psi connected to topping valve 2 Allow the inflated float to stand for one hour after initial inflation Then check and readjust pressure in each compartment if necessary to 2 0 psi Record temperature and barometric pressure SEE NON DISCLOSURE NOTICE ON THE COVER PAGE Copyright 2001 2009 Apical Industries Inc Page 20 of 38 All Rights Reserved SN A C N L SUBJECT REF DWG NO REPORT NO INSTRUCTIONS FOR CONTINUED AIRWORTHINESS 20408 ICA500 1 Rev B Copyright 2001 2009 Apical Industries Inc All Rights Reserved 3 Allow the float to remain undisturbed for 24 hours The maximum allowable pressure drop is 0 50 psig after correction for temperature and barometric variations Record the compartment pressures the temperature and barometric reading at the end of the pressure test Correct for temperature variations by subtracting 0 1 psig for every 3 F rise in temperature or adding 0 1 psig for every 3 F drop Correct for barometric conditions by adding 0 1 psig to the final gauge reading for every 0 2 inches of mercury that the barometric pressure had increased or subtract 0 1 psig from final reading for every 0 2 inches of mercury that the barometer has fallen If the corrected pressure falls below specified limits inflate the float to 2 02. 90K MIN DO NOT EXCEED CHART VNE Placard 3 A for 369E Placard 3 B for 369E Figure A 6 Figure A 7 UTILITY FLOATS VNE IAS KNOTS OAT PRESS ALT x 1000 GROSS WT 2501 TO 3000 L3S idee Clo 121 4 6 s 10 12 14 16 tg 30 127 122 107 93 79 20 116 100 36 40 125 107 93 79 v 130 116 i00 87 I 10 126 108 94 30 u7 101 87 128 109 96 32 NO FLIGHT 118 102 39 76 us 99 37 FOR AUTOROTATION VNE REDUCE SPEED BY 2K 85K MINY DO NOT EXCEED CHART VNE Placard 3 C for 369E Figure A 8 SEE NON DISCLOSURE NOTICE ON THE COVER PAGE Page 17 of 38 Copyright 2001 2009 Apical Industries Inc All Rights Reserved SUBJECT REF DWG NO REPORT NO INSTRUCTIONS FOR CONTINUED AIRWORTHINESS 20408 ICA500 1 Rev B SECTION 25 0 FLOAT REMOVAL CLEANING TESTING FIELD REPAIRS AND REINSTALLING 25 1 Floats Annual leak test may be accomplished with floats mounted on skid tube 25 1 1 Float Removal from Aircraft Deflation of float for removal from aircraft shall be accomplished prior to attempting the removal of the float from aircraft struts Test adapter P N A 51219N may be inserted into the topping valve to deflate or valve poppet may be depressed manually to allow air to escape After floats are deflated the floats may be removed from the aircraft by removing bolts washers and gravel guards as listed in Figure C 25 1 2 T
3. This equipment has been constructed to incorporate an aerodynamic design shape for installation on MDHS 369HS 369HM 369HE 369D and 369E helicopters by means of a reinforced fabric attachment girt making the aircraft completely amphibious and increasing its operational capabilities The utility flotation assembly includes the following e Two uninterchangeable floats Each float consists of six separate air holding chambers The chambers are separated by bulkheads made of the same urethane coated nylon as the tube to minimize the loss of buoyancy in the event of puncture or tear Each chamber contains a topping valve for manual inflation and a pressure relief valve PRV to prevent over pressurization The material color is white which provides radiant heat reflection or an optional fabric color is black The float design provides for permanent inflation and full time buoyancy for helicopters assigned to off shore or other over water activities Abrasion resistant chafing material located on the underside of each float and the reinforcement of the personnel walkways are incorporated to provide additional abrasion protection TABLE I FLOAT CHARACTERISTICS Urethane coated nylon Ship set inflated volume 87 4 cubic feet Ship set inflated buoyancy 5452 pounds Operating pressure 2 00 psi Type of inflation Total ship set weight 40 0 pounds approximately SEE NON DISCLOSURE NOTICE ON THE COVER PAGE Copyright 2001 2009 Apical Indus
4. This manual provides description operation disassembly assembly repair and testing instructions and an Illustrated Parts List for the 20408 Series Utility Helicopter Floats The equipment is manufactured by Apical Industries Incorporated Oceanside California 1 2 Purpose The purpose of this manual is to maintain the MDHS 369HS 369HM 369HE 369D and 369E Utility Helicopter Float System in peak operating efficiency with the greatest service life 1 3 Revision Control Procedure All revisions to this document shall be controlled by the Apical Engineering Change Notice procedure Each revision will be indicated with a vertical change bar Each revised page shall display the next revision letter and all pages will be summarized on page 6 List of Effective Pages The final sign off shall be by the Fort Worth AEG Office on page 2 Log of Accepted Revisions 14 Service Difficulty Reporting Service Difficulty Reporting shall utilize the form included as Attachment 1 15 Applicability This manual shall be used to maintain the utility floats for the MDHS 369HS 369HM 369HE 369D and 369E SEE NON DISCLOSURE NOTICE ON THE COVER PAGE Copyright 2001 2009 Apical Industries Inc Page 8 of 38 All Rights Reserved SUBJECT REF DWG NO REPORT NO INSTRUCTIONS FOR CONTINUED AIRWORTHINESS 20408 ICA500 1 Rev B 1 6 Abbreviations psi psig F C Hg PRV P N F N LH RH pounds per square inch pounds per square
5. psig and check for leaks by swabbing the tubes with leak solution using a soft brush Table II b Topping Valve Leakage Test This valve may be checked as part of the float pressure test while it is inflated to 2 0 psig 1 Apply leak solution Table IV with brush at mounting patch to float attachment location If bubbles indicate a leak the float assembly must be returned to the factory for replacement of the valve flange base If leakage is due to valve not seating properly check threads in base on float valve If damaged base return to factory If damaged valve threads remove and replace See Figure B Valve Removal and Replacement c Pressure Relief Valve Test This valve may be checked following conclusion of the Float Pressure Test l Apply leak solution Table IV with brush at mounting patch to float attachment location If bubbles indicate a leak the float assembly must be returned to the factory for replacement of the valve flange base SEE NON DISCLOSURE NOTICE ON THE COVER PAGE Page 21 of38 SUBJECT REF DWG NO REPORT NO INSTRUCTIONS FOR CONTINUED AIRWORTHINESS 20408 ICA500 1 Rev B 2 Fill the relief valve aperture with clean water Slowly raise the compartment pressure and watch for bubbles indicating that the valve opens Then reduce pressure watching for a cessation of bubbles 3 The valve should open at 4 0 psig 0 25 psig and should close by 3 0 psig 4 If valve operates improp
6. N 369D292032 is installed Placard 2 Minimum float pressure is 2 0 psig Figure A 2 Placard 2 Placard 3 SEE NON DISCLOSURE NOTICE ON THE COVER PAGE Copyright 2001 2009 Apical Industries Inc All Rights Reserved Page 15 of 38 9D TN Lts wt SUBJECT REF DWG NO REPORT NO INSTRUCTIONS FOR CONTINUED AIRWORTHINESS 20408 ICAS500 1 Rev B UTILITY FLOATS VNE IAS KNOTS PRESS ALT x 1000 GROSS WT 2000 OR LESS LES OAT a2 2 4lsist mimi owl uj 132 125 129 115 110 100 zzz v s FOR AUTOROTATION V REDUCE SPEED BY 2K ED BY 2K FOR AUTOROTATION Vy REDUCE SPE 90K MIN DO ROT CHART V we 85K MIN DO NOT EXCEED CHART V yg Placard 3 A for 369D Placard 3 B for 369D Figure A 3 Figure A 4 UTILITY FLOATS Vue IAS KNOTS OAT PRESS ALT x 1000 GROSS WT 2501 TO 3000 LBS a 2 4 8 FOR AUTOROTATION Vus REDUCE SPEED BY 2K 95K MIN DO NOT EXCEED CHART Va Placard 3 C for 369D Figure A 5 SEE NON DISCLOSURE NOTICE ON THE COVER PAGE Copyright 2001 2009 Apical Industries Inc Page 16 of 38 All Rights Reserved lt ____ gt IV DUSTRAICTS tC SUBJECT REF DWG NO REPORT NO INSTRUCTIONS FOR CONTINUED AIRWORTHINESS 20408 ICA500 1 Rev B UTILITY FLOATS VNE IAS KNOTS PRESS ALT x 1000 GROSS WT 2001 TO 2500 LBS UTILITY FLOATS VNE IAS KNOTS 122 109 100 109 o 4s juo 93 Q 85K MIN DO NOT EXCEED CHART VNE
7. NO REPORT NO INSTRUCTIONS FOR CONTINUED AIRWORTHINESS 20408 ICA500 1 Rev B DETAILS OF REVISIONS REV DATE PAGE DESCRIPTION APPROVED N C 98Janl2 All Initial Release Committee A 98Mar02 1 Deleted Model 500N 2 Page Intentionally Left Blank 8 Deleted Model 500N from Figures A 6 A 7 A 8 9 Deleted Model 500N from 1 2 Purpose and 1 5 Applicability 10 Deleted Model 500N from 1 9 Distribution 11 Deleted Model 500N from 1 10 Description of the System and Installation 16 Deleted Model 500N from Figures A 6 and A 7 17 Deleted Model 500N from Figure A 8 32 Deleted Model 500N from Illustrated Parts Lists for P N 20408 103 and 20408 104 B 03 05 09 5 Revised List of Effective Pages P Bravo 7 Revised List of Figures and List of Tables 12 Added note Section 5 1 1 Added Section 5 1 2 13 Revised Section 5 1 4 Copyright 2001 2009 Apical Industries Inc All Rights Reserved SEE NON DISCLOSURE NOTICE ON THE COVER PAGE Page 3 of 38 SUBJECT REF DWG NO REPORT NO INSTRUCTIONS FOR CONTINUED AIRWORTHINESS 20408 ICA500 1 Rev B RECORD OF SERVICE BULLETINS S B S S B NO DATE DESCRIPTION SEE NON DISCLOSURE NOTICE ON THE COVER PAGE Copyright 2001 2009 Apical Industries Inc Page 4 of 38 All Rights Reserved SN A C N L SUBJECT REF DWG NO REPORT NO INSTRUCTIONS FOR CONTINUED AIRWORTHINESS 20408 ICA500 1 Rev B LIST OF EFFECTIVE PAGES Title Page _Revision No Cover 1 B Page Intentionally Left Blank 2 B Details of
8. SN A C N L SUBJECT REF DWG NO REPORT NO INSTRUCTIONS FOR CONTINUED AIRWORTHINESS 20408 ICA500 1 Rev B be inflated to a maximum of 1 0 psi After the repair has dried for 24 hours the product may be inflated to working pressure and tested in accordance with testing instructions in this manual n Clean and inspect the bonded area as follows 1 Clean any adhesive drops and excess adhesive outside the required bond area by wiping with a clean cloth dampened with solvent 2 Inspect for location overlap lifts wrinkles and air bubbles Reactivate and join to repair these defects o Allow the bonded components to cure undisturbed 25 1 6 3 Holes Cuts Tears And Punctures Up To 2 x 10 Inches Note These instructions are for repairs to fabric tears that are limited to a 2 x 10 inch maximum tear curved or straight CAUTION Repair tears by patching both the inside and the outside surfaces of the fabric prior to inflating the float a Trim off loose threads using scissors b Sprinkle a handful of powdered soapstone or talc inside the float opposite the tear area to prevent joining the inside surfaces of the fabric together c Using a clean cloth dry all surfaces to which the patches will be applied d Thoroughly clean the inside surface of the fabric around the tear and the underside of one of the patches using a cloth dampened with solvent e Apply adhesive and activate surfaces as instructed in 25 1 6 2 i j
9. 2608 TEMPLE HEIGHTS DRIVE OCEANSIDE CALIFORNIA 92056 3512 PH 760 724 5300 FAX 760 758 9612 Website apicalindustries com ICA500 1 Rev B 03 05 09 INSTRUCTIONS FOR CONTINUED AIRWORTHINESS FOR UTILITY HELICOPTER FLOAT ASSEMBLIES MCDONNELL DOUGLAS HELICOPTER SERVICE MDHS MODELS 369HS 369HM 369HE FLOAT ASSEMBLY LH P N 20408 101 MODELS 369HS 369HM 369HE FLOAT ASSEMBLY RH P N 20408 102 MODELS 369D 369E FLOAT ASSEMBLY LH P N 20408 103 MODELS 369D 369E FLOAT ASSEMBLY RH P N 20408 104 Lee This technical data package being provided to the FEDERAL AVIATION ADMINISTRATION FAA It includes but is not limited to drawings specifications and other technical data attached hereto and are the Property of APICAL INDUSTRIES INC AI and constitute trade secrets for the purpose of the Trade Secrets and Freedom of Information Act Disclosures to any party for any reason without the permission of AI is prohibited except that disclosures may be made within the FAA s organization consistent with the need to evaluate AT s technical data lt ___S gt IR ee St LE Ss NC SUBJECT REF DWG NO REPORT NO INSTRUCTIONS FOR CONTINUED AIRWORTHINESS 20408 ICA500 1 Rev B This page intentionally left blank SEE NON DISCLOSURE NOTICE ON THE COVER PAGE Copyright 2001 2009 Apical Industries Inc Page 2 of 38 All Rights Reserved SN A C N L SUBJECT REF DWG
10. D AREAS DO NOT INHALE FUMES SEE NON DISCLOSURE NOTICE ON THE COVER PAGE Copyright 2001 2009 Apical Industries Inc Page 19 of 38 All Rights Reserved SN A C N L SUBJECT REF DWG NO REPORT NO INSTRUCTIONS FOR CONTINUED AIRWORTHINESS 20408 ICA500 1 Rev B Do not apply cleaning solvent to float decals or stencil markings b Cleaning Float Assembly If Necessary 1 Clean float assembly fabric surfaces using detergent soap and water solution or cleaning solvent Detergent soap and water solution is the preferred method See Table II Cleaning Materials Required 2 Apply cleaning solvent see Table II with a clean soft cloth or a soft bristle brush for areas of oil dust or dirt Immediately remove excess solvent with clean soft cloth and dry using compressed air shop air The compressed air source should be oil and moisture free and should be equipped with a 20 micron filter for best results 25 1 5 Testing Perform a float pressure test annually and also following the overhaul of float assemblies before returning the equipment to service The relief valve and topping valve tests shall be performed in conjunction with trouble shooting information Table VI during the annual inspection and as part of the float pressure test if replacement or repair of those components was accomplished during overhaul a Float Pressure Test See Table IV 1 Inflate all chambers of the assembly using shop air to 2 0 psig
11. Revisions 3 B Record of Service Bulletins 4 B List of Effective Pages 5 B Table of Contents 6 B List of Tables and Figures 7 B Section 1 0 Introduction 8 10 B Section 4 0 Airworthiness Limitations 11 B Section 5 0 Inspection Requirements and Overhaul Schedule 12 B Section 9 0 Towing 14 B Section 11 0 Placards 15 B 16 17 B Section 25 0 Float Removal Cleaning Testing Field Repairs and Reinstalling 18 38 B 32 B 33 B SEE NON DISCLOSURE NOTICE ON THE COVER PAGE Copyright 2001 2009 Apical Industries Inc Page 5 of 38 All Rights Reserved Ff N A C N L N D SUBJECT REF DWG NO REPORT NO INSTRUCTIONS FOR CONTINUED AIRWORTHINESS 20408 ICA500 1 Rev B TABLE OF CONTENTS Identification _ Title Page Section 1 0 Introduction 8 1 1 Scope 8 1 2 Purpose 8 1 3 Revision Control Procedure 8 1 4 Service Difficulty Reporting 8 1 5 Applicability 8 1 6 Abbreviations 9 1 7 Precautions 9 1 8 Units of Measurement 9 1 9 Distribution 9 1 10 Description of the System and Installation 10 Section 4 0 Airworthiness Limitations 11 Section 5 0 Inspection Requirements and Overhaul Schedule 12 5 1 Inspection Requirements 12 5 2 Component Overhaul Schedule 13 Section 9 0 Towing 14 Section 11 0 Placards 15 11 1 Placard Information 15 11 2 Location 15 11 3 Application 15 Section 25 0 Float Removal Cleaning Testing Field Repairs and Reinstalling 20 25 1 Floats 20 25 1 1 Float Removal 20 25 1 2 Table II 20 25 1 3 Table III 21 25 1 4 Clea
12. T REF DWG NO REPORT NO INSTRUCTIONS FOR CONTINUED AIRWORTHINESS 20408 ICA500 1 Rev B 25 1 8 Completion of Installation a Inspect utility float installation to ensure all components are secured b Open fill valves and inflate the six float chambers with compressed air to 2 0 psig Inflate chambers gradually to maintain equal volume in each chamber Close fill valves SEE NON DISCLOSURE NOTICE ON THE COVER PAGE Copyright 2001 2009 Apical Industries Inc Page 33 of 38 All Rights Reserved SUBJECT REF DWG NO REPORT NO INSTRUCTIONS FOR CONTINUED AIRWORTHINESS 20408 ICA500 1 Rev B 25 2 Illustrated Parts List See the following figure Figure D for part locations L Float LH 369HS 369HM 369HE 20408 101 5 6 ToppingValve B 5120 OE 6 6 PRV y j B SI0I94 L Float RH 369HS 369HM 369HE 204083102 5 6 jToppngValve B 5129 6 Je RY CB SOI L Float LH 369D 3698 20408 103 5 6 ToppingValve B 5129 6 6 PRV J B 1094 SEE NON DISCLOSURE NOTICE ON THE COVER PAGE Copyright 2001 2009 Apical Industries Inc Page 34 of 38 All Rights Reserved SUBJECT REF DWG NO REPORT NO INSTRUCTIONS FOR CONTINUED AIRWORTHINESS 20408 ICA500 1 Rev B L Float RH 369D 3698 20408104 5 6 jToppngVave B520 6 6 PRV BSa SEE NON DISCLOSURE NOTICE ON THE CO
13. VER PAGE Copyright 2001 2009 Apical Industries Inc Page 35 of 38 All Rights Reserved lt ___ SS gt 9D TN Lts wt SUBJECT REF DWG NO REPORT NO INSTRUCTIONS FOR CONTINUED AIRWORTHINESS 20408 ICAS500 1 Rev B Figure D Utility Float SEE NON DISCLOSURE NOTICE ON THE COVER PAGE Copyright 2001 2009 Apical Industries Inc Page 36 of 38 All Rights Reserved SUBJECT REF DWG NO REPORT NO INSTRUCTIONS FOR CONTINUED AIRWORTHINESS 20408 ICA500 1 Rev B SEMI ANNUAL INSPECTION WORKSHEET HELICOPTER REGISTRATION NO Signature and Date Remarks Semi Annual Inspection Ist 2nd 3rd Ath 5th 6th l Inspect floats for chafing breaking or holes Page 13 1 SUBJECT REF DWG NO REPORT NO INSTRUCTIONS FOR CONTINUED AIRWORTHINESS 20408 ICA500 1 Rev B ANNUAL INSPECTION WORKSHEET HELICOPTER REGISTRATION NO Signature and Date Remarks Annual Inspection Year 1 Year2 Year3 Year4 Year5 Year 6 I Inspect the girt for condition function and security 2 Conduct annual float leak test Inspect floats for chafing or damaged areas Page 13 2
14. able II TABLE II CONSUMABLE CLEANING MATERIALS REQUIRED Description Availability Cleaning Solvent Methyl Ethyl Ketone MEK Commercially available Stiff bristle brush Commercially available Soft bristle brush Commercially available Detergent Commercially available SEE NON DISCLOSURE NOTICE ON THE COVER PAGE Copyright 2001 2009 Apical Industries Inc Page 18 of 38 All Rights Reserved SUBJECT REF DWG NO REPORT NO INSTRUCTIONS FOR CONTINUED AIRWORTHINESS 20408 ICA500 1 Rev B 25 1 3 Table III TABLE III VISUAL CHECK OF ASSEMBLIES AND COMPONENTS Check Procedure Fabric Seams Cuts tears punctures See Repair Section 25 1 6 abrasions mark with chalk if If beyond limits return to discrepant factory Pressure Relief Valve PRV Leaks opening and closing If valve leaks replace it pressure only see Testing Section 25 1 6 4 Flange Section 25 1 5 leaks return to factory Leaks only see Testing If valve leaks replace it Section 25 1 5 Section 25 1 6 4 Flange leaks return to factory Girt Assembly Condition function and Return to factory for repair CAUTION The working area for inspection should be covered with a clean tarpaulin carpeting or equivalent protection free of hardware tools and other sharp objects 25 1 4 Cleaning a Use good shop safety precautions and practices at all times when using solvents WARNING USE FLAMMABLE SOLVENTS ONLY IN WELL VENTILATE
15. and k above f Fold the patch in half lengthwise and pass the patch through the tear and install it cement side up on the inside surface of the float fabric directly SEE NON DISCLOSURE NOTICE ON THE COVER PAGE Copyright 2001 2009 Apical Industries Inc Page 28 of 38 All Rights Reserved SN A C N L SUBJECT REF DWG NO REPORT NO INSTRUCTIONS FOR CONTINUED AIRWORTHINESS 20408 ICA500 1 Rev B to 25 1 6 4 under the tear Immediately apply pressure with a hand roller to bond the patch to the inside of the fabric Pressure is important for a good bond If surface cannot be cleaned due to build up of chemicals use sandpaper abrade outside surface of area to be bonded until achieving a dull appearance Thoroughly clean the outside surface of the fabric around the tear and the underside of the other patch using a cloth dampened with solvent Apply adhesive and activate surfaces as instructed in 25 1 6 2 i j and k above Apply the patch gradually from the center as instructed in 25 1 6 2 1 m n and o above Valves Repair And Replacement Pressure relief valves PRV and the topping valves used in the float assemblies shall be inspected for leaks cleaned as required and if faulty should be replaced Valves may be removed and reinstalled using a valve wrench B 51025 See Figure B for valve removal and replacement a Copyright 2001 2009 Apical Industries Inc All Rights Reserved Using spec
16. erly apply leak solution Table IV in aperture of valve If bubbles indicate a leak at this location remove valve from base flange and check threads in flange base and on valve If threads in flange are damaged return float to factory for repair replacement If valve threads are damaged replace as specified See Figure B TABLE IV TESTING EQUIPMENT MATERIALS REQUIRED Range 0 120 in Hg Optional Optional Optional Optional Optional Detergent soap and water solution Note Test set up information 1 Testing of components is accomplished on the float assembly with all components assembled as an operational system Special fixtures and test benches are not required 2 Attachment of inflation shop air source or manometer testing equipment to the float assembly is accomplished using the topping valves and adapters SEE NON DISCLOSURE NOTICE ON THE COVER PAGE Copyright 2001 2009 Apical Industries Inc Page 22 of 38 All Rights Reserved SUBJECT REF DWG NO REPORT NO INSTRUCTIONS FOR CONTINUED AIRWORTHINESS 20408 ICA500 1 Rev B 3 Supplier s Optional Equipment required shall be the type of equipment that can be calibrated for assurance of accuracy 25 1 6 Field Repairs Fabric And Seam Repairs The following repairs will be confined to the patching of punctures tears and holes not greater than 3 inches in diameter or 2 inches by 10 inches in length Replacement of complete section or bulkheads shall n
17. exterior surfaces has been exposed to LPS 5 1 2 Semi Annual Inspection a Complete all preflight inspection requirements b Inspect the cylinders and valves for surface damage or corrosion c Inspect all pull cables and external mounting hardware for any excessive corrosion kinking binding or excessive friction SEE NON DISCLOSURE NOTICE ON THE COVER PAGE Copyright 2001 2009 Apical Industries Inc Page 12 of 38 All Rights Reserved SUBJECT REF DWG NO REPORT NO INSTRUCTIONS FOR CONTINUED AIRWORTHINESS 20408 ICA500 1 Rev B 5 1 3 Every 18 Month Inspection a Inspect the girt for condition function and security If the girt is damaged in any way see Table III b Conduct the 18 month float leak test in accordance with Section 25 1 5 and inspect for chafing or damaged areas 5 1 4 3 Years Inspection a Place aircraft on blocks Bottom of skids should be at least 4 inches above the ground Stand clear of all float assemblies Initiate the float inflation b After inflation measure the pressure in each Float chamber Pressure shall be a minimum of 1 75 psi at 70 F after 10 minutes Then measure the pressure in each Liferaft chamber Pressure shall be a minimum of 1 75 psi at 70 F after 10 minutes c Conduct a float leak test in accordance with Section 25 1 5 and inspect for chafing or damaged areas d Inspect covers for any cuts or tears in accordance with Section 25 1 3 5 2 Component Overhaul Schedu
18. f activating To heat activate Direct the flow from a hot air gun over both cemented surfaces Avoid applying too much heat which may melt the coating or component When the adhesive feels tacky immediately proceed to join the components per step 1 Join the components as follows 1 2 3 4 5 6 Once activated immediately align the two mating surfaces and press together in a wallpapering fashion Use a pusher or roller to expel any entrapped air Press with a pusher or roller over the entire activated area to ensure complete contact When a component is bonded over a seam tape or other uneven base press firmly at the edge of the step off first to avoid bridging Then bond the remainder of the component Apply the patch gradually from the center to the edges to minimize the possibility of air bubbles being trapped beneath the patch Using a smooth edge putty knife and starting at the center of the patch apply pressure and move toward the edge of the patch pushing out any air bubbles or wrinkles Take special care when pushing the edge of the patch to prevent the edges from lifting When all wrinkles and air bubbles have been eliminated uniformly roll the joined area using a hand roller m After the patch has dried for approximately 2 hours the repaired area may Copyright 2001 2009 Apical Industries Inc All Rights Reserved SEE NON DISCLOSURE NOTICE ON THE COVER PAGE Page 27 of 38
19. ial tool valve wrench B 51025 remove valve by inserting wrench into molded flange and turn counter clockwise to remove valves Insert wrench slot over molded tab of topping valve and turn counter clockwise Check threads in recessed molded fitting bonded in the float and if necessary clean using a dry cloth or soft bristle brush If discrepant replace at factory Insert valve into threads of recessed molded fitting and turn clockwise by hand to ensure that threads are not crossed Continue to turn by hand until valve is seated Attach wrench turn clockwise and torque to 30 40 inch pounds SEE NON DISCLOSURE NOTICE ON THE COVER PAGE Page 29 of 38 SUBJECT REF DWG NO REPORT NO INSTRUCTIONS FOR CONTINUED AIRWORTHINESS 20408 ICA500 1 Rev B REP TOPPING VALVE Of PLUG TAI PI A E LI 1 Y ia 4 amp N WRENCH B Z MOLDED PL ALVE i RET LC 7 i J SEAL PARTS OF VALVE MOLDED FLANGE eu ALVE BASE BONDEI TO INFLATION TUBE Figure B Valve Removal and Replacement PRV and Topping Valve SEE NON DISCLOSURE NOTICE ON THE COVER PAGE Copyright 2001 2009 Apical Industries Inc Page 30 of 38 All Rights Reserved SUBJECT REF DWG NO REPORT NO INSTRUCTIONS FOR CONTINUED AIRWORTHINESS 20408 ICA500 1 Rev B 25 1 6 5 Table VI TABLE VI TROUBLE SHOOTING FLOAT WILL NOT MAINTAIN OPERATING PRESSURE Probable Cause Hole in fabric Tear i
20. inch gauge degrees Fahrenheit degrees Celsius mercury pressure relief valve part number find number left hand right hand 1 7 Precautions The following precaution definitions will be used to indicate the seriousness of the hazard or condition WARNING May be a maintenance procedure practice condition etc which could result in personal injury or loss of life CAUTION May be a maintenance procedure practice condition etc which could NOTE result in damage or destruction of equipment May be a maintenance procedure practice condition etc or a statement which needs to be highlighted 1 8 Units of Measure psi psig F C pounds per square inch pounds per square inch gauge degrees Fahrenheit degrees Celsius SEE NON DISCLOSURE NOTICE ON THE COVER PAGE Copyright 2001 2009 Apical Industries Inc Page 9 of 38 All Rights Reserved SUBJECT REF DWG NO REPORT NO INSTRUCTIONS FOR CONTINUED AIRWORTHINESS 20408 ICA500 1 Rev B 1 9 1 10 Distribution This manual will be distributed with each MDHS 369HS 369HM 369HE 369D and 369E Utility Float System purchased It will also be available to float end users or their mechanics or maintenance departments Repair Stations and other companies by request only A log of all recipients of this manual shall be maintained by Apical Any changes to this manual shall be distributed to all recipients Description of the System and Installation
21. le Nec c Component Time Between Section Nomenclature Eu med 101 Float LH 3 years sd years 25 1 1 20408 102 _ Float RH 20408 103 Float LH 20408 104 Float RH Note 1 The TBO of 3 years is from the date of installation or 5 years from the last hydrostatic test The DOT Cylinder Hydrotest requirement is 5 years from the date of manufacture or the last test SEE NON DISCLOSURE NOTICE ON THE COVER PAGE Copyright 2001 2009 Apical Industries Inc Page 13 of 38 All Rights Reserved A D A INDUSTR ES NC SUBJECT REF DWG NO REPORT NO INSTRUCTIONS FOR CONTINUED AIRWORTHINESS 20408 ICA500 1 Rev B SECTION 9 0 TOWING Ground towing must be accomplished utilizing a dolly SEE NON DISCLOSURE NOTICE ON THE COVER PAGE Copyright 2001 2009 Apical Industries Inc Page 14 of 38 All Rights Reserved SUBJECT REF DWG NO INSTRUCTIONS FOR CONTINUED AIRWORTHINESS 20408 SECTION 11 0 PLACARDS 11 1 Placard Information Placards 1 2 and 3 see below 11 2 Location Mount Placard on instrument panel in plain view of pilot 11 3 Application REPORT NO ICA500 1 Rev B Placards contain an air curing pressure sensitive adhesive Pry off to remove To install remove paper backing and apply pressure Allow to remain undisturbed for 24 hours Placard 1 Night flight over water beyond autorotation capability to ground prohibited Figure A 1 Placard 1 Note Placard 1 is not required if night landing lighting kit P
22. leaning solvent to evaporate completely before applying adhesive When washing coated fabric do not allow excess solvent to collect at the edges of seams Do not apply solvent to decals or stencil markings whenever possible since they can be removed by the solvent i Apply the first coat of adhesive to the bond area as follows 1 Brush a uniform coat of adhesive onto the bond area rubbing the adhesive firmly into the fabric or component 2 Allow the first coat to air dry completely before proceeding Check dryness with the back of your knuckle 3 Close the adhesive container when not in active use j Apply the second coat of adhesive to the bond area as follows 1 Brush a second uniform coat of adhesive onto the bond area painting the adhesive lightly over the first coat 2 Allow the second coat to air dry completely before proceeding Check dryness with the back of your knuckle SEE NON DISCLOSURE NOTICE ON THE COVER PAGE Copyright 2001 2009 Apical Industries Inc Page 26 of 38 All Rights Reserved SN A C N L SUBJECT REF DWG NO REPORT NO INSTRUCTIONS FOR CONTINUED AIRWORTHINESS 20408 ICA500 1 Rev B l 3 Close the adhesive container when not in active use Activate the adhesive by one of the following methods 1 2 To solvent activate Wipe both cemented surfaces lightly but thoroughly with a clean cloth dampened with solvent Join the components per step 1 within 15 seconds o
23. n fabric Leaking PRV Check threads See 25 1 3 Check threads See 25 1 3 TA Denotes the following if valve leaks at the mounting base return float assembly to factory for repair replacement valve 25 1 6 6 Table VII TABLE VII SPECIAL TOOLS Apical Part Number Application B 51025 Valve Wrench Removal and installation of all float valves A 51219N Test Adapter Accepts gauge to test float psi 25 1 6 7 Table VIII TABLE VIII REPAIR MATERIALS REQUIRED Material Equipment Specification and or Vendor Designation Identification L2030UPW Apical Industries Inc LA 4123 Apical Industries Inc 2 1 4 x 4 Apical Industries Inc SEE NON DISCLOSURE NOTICE ON THE COVER PAGE Copyright 2001 2009 Apical Industries Inc Page 31 of 38 All Rights Reserved _ INDUSTRIES INC SUBJECT REF DWG NO REPORT NO INSTRUCTIONS FOR CONTINUED AIRWORTHINESS 20408 ICAS500 1 Rev B 25 1 7 Reinstalling Floats a Reinstall float and install bolts F N 30 washers F N 31 and gravel guards F N 32 33 34 See Figure C b Torque bolts F N 30 from the forward end of the float to the aft using the specified torque value of 15 20 inch pounds 5 230 GRAVEL GUARD f GRAVEL GUARD 32 Figure C Float Attaching Hardware SEE NON DISCLOSURE NOTICE ON THE COVER PAGE Copyright 2001 2009 Apical Industries Inc Page 32 of 38 All Rights Reserved SUBJEC
24. ning 2 25 1 5 Testing 22 25 1 6 Field Repairs 25 25 1 7 Reinstalling Floats 32 SEE NON DISCLOSURE NOTICE ON THE COVER PAGE Copyright 2001 2009 Apical Industries Inc Page 6 of 38 All Rights Reserved SUBJECT REF DWG NO REPORT NO INSTRUCTIONS FOR CONTINUED AIRWORTHINESS 20408 ICA500 1 Rev B TABLE OF CONTENTS CONTINUED Identification _ Title Page 25 1 8 Completion of Installation 33 25 2 Illustrated Parts List 34 LIST OF TABLES Table Number Description Page I Float Characteristics 10 II Consumable Cleaning Materials Required 18 III Visual Check of Assemblies and Components 19 IV Testing Equipment Materials Required 22 V Helicopter Float Repair Kit Items 23 VI Trouble Shooting Float Will Not Maintain Operating Pressure 31 VII Special Tools 31 VIII Repair Materials Required 31 LIST OF FIGURES Figure Number Description Page A l Placard 1 15 A 2 Placard 2 15 A 3 Placard 3 A for 369D 16 AA4 Placard 3 B for 369D 16 A 5 Placard 3 C for 369D 16 A 6 Placard 3 A for 369E 17 A 7 Placard 3 B for 369E 17 A 8 Placard 3 C for 369E 17 B Valve Removal and Replacement PRV and Topping Valve 30 C Float Attaching Hardware 32 D Utility Float 36 SEE NON DISCLOSURE NOTICE ON THE COVER PAGE Copyright 2001 2009 Apical Industries Inc Page 7 of 38 All Rights Reserved SN A C N L SUBJECT REF DWG NO REPORT NO INSTRUCTIONS FOR CONTINUED AIRWORTHINESS 20408 ICA500 1 Rev B 1 0 INTRODUCTION 1 1 Scope
25. oller To ensure a proper bond use the chart below to determine the minimum size patch to be used if applicable Size of tear Minimum overlap on all sides of damaged area up to 1 8 inch 1 inch 1 8 inch to 2 inches 2 inches 2 inches to 10 inches inside patch 1 inch outside patch 2 inches 25 1 6 2 Holes Cuts Tears And Punctures Up To 3 Inches a Using a clean cloth dry the surface to which the patch is to be applied b If surface cannot be cleaned due to build up of chemicals use sandpaper to abrade area to be bonded until achieving a dull appearance CAUTION SEE NON DISCLOSURE NOTICE ON THE COVER PAGE Copyright 2001 2009 Apical Industries Inc Page 24 of 38 All Rights Reserved SUBJECT REF DWG NO REPORT NO INSTRUCTIONS FOR CONTINUED AIRWORTHINESS 20408 ICA500 1 Rev B c Do not touch or handle the cemented areas because oils in the fingers can contaminate the adhesive Check for dryness by touching with the back of the hand or knuckles only d Adhesives have a limited pot life which means that the adhesive will go bad after a specified length of time Adhesives may not be used after their pot life has expired as indicated on the container label Dispose of expired cement appropriately e The adhesive bond develops increasing strength over a period of days CAUTION Cemented components should not be tested or inflated until the initial cure period specified below Product should not be packed un
26. ot be attempted in the field since operating integrity and or air retaining capabilities of the float shall be affected All major repairs shall be accomplished at a certified repair depot or factory facilities Repair kit items are as follows TABLE V HELICOPTER FLOAT REPAIR KIT ITEMS Item Quantity 5 inch diameter repair patches 4 x 12 inch rectangular patches 6 x 14 inch rectangular patches 8 ounce tube of adhesive with brush Adhesive information sheet Wrench B 51025 Topping up valve B 51209 PRV valve B 51019 4 Instruction sheet Test adapter A 51219N eee tl oe oe ee NO NO SS 25 1 6 1 Cement Bonding PROJECT WASHING ACTIVATING ADHESIVE Urethane Coated MEK 100 MEK 100 LA 4123 or Fabric equivalent a All mixing containers cans stirrers and mixing equipment shall be clean and free of any dirt contamination and dried adhesive b Supplies 1 Cloth lint free undyed or white cotton cut to about 8 square SEE NON DISCLOSURE NOTICE ON THE COVER PAGE Copyright 2001 2009 Apical Industries Inc Page 23 of 38 All Rights Reserved SN A C N L SUBJECT REF DWG NO REPORT NO INSTRUCTIONS FOR CONTINUED AIRWORTHINESS 20408 ICA500 1 Rev B 2 Brush utility size suited to the bond area 3 Solvent containers Safety storage can for solvent Pump plunger can Brush container with cover Rag can with cover Solvent waste can Spent rag can 4 Hand tools Pusher plastic or metal R
27. til the final cure period as specified below Adhesive Pot Life and Cure Times Supplier Pot Life Initial Cure Apical Industries LA 4123 f The adhesive bonding process is effected by environmental conditions of temperature and humidity Low temperatures will slow drying and cure times Adhesive bonding cannot be performed at temperatures lower than 55 F High humidity may cause moisture to condense on the bond area as indicated by a foggy white appearance on the cement or component Before applying additional cement or before activation flash evaporate the moisture by wiping lightly with additional solvent g Clean the bond area as follows 1 Fold a clean cloth in half then in half again to form a square Dampen SEE NON DISCLOSURE NOTICE ON THE COVER PAGE Copyright 2001 2009 Apical Industries Inc Page 25 of 38 All Rights Reserved SN A C N L SUBJECT REF DWG NO REPORT NO INSTRUCTIONS FOR CONTINUED AIRWORTHINESS 20408 ICA500 1 Rev B the cloth with solvent Squeeze the excess solvent from the cloth back into the pump can screen 2 Wash the bond area by wiping in one direction only to remove all visible contamination and release agents Do not wipe back and forth as this only smears contaminants 3 Refold the cloth as necessary to keep a clean wiping surface Each cloth should give eight wiping surfaces When the cloth is soiled dispose of it and all chemicals properly h Allow the c
28. tries Inc Page 10 of 38 All Rights Reserved SUBJECT REF DWG NO REPORT NO INSTRUCTIONS FOR CONTINUED AIRWORTHINESS 20408 ICA500 1 Rev B SECTION 4 0 AIRWORTHINESS LIMITATIONS No airworthiness limitations are associated with this STC SEE NON DISCLOSURE NOTICE ON THE COVER PAGE Copyright 2001 2009 Apical Industries Inc Page 11 of 38 All Rights Reserved Ff N A C N L N D SUBJECT REF DWG NO REPORT NO INSTRUCTIONS FOR CONTINUED AIRWORTHINESS 20408 ICA500 1 Rev B SECTION 5 0 INSPECTION REQUIREMENTS AND OVERHAUL SCHEDULE 5 1 Inspection Requirements WARNING Prior to working on or around the helicopter Safety Pins must be installed in both of the Valve Assemblies 5 1 1 Preflight Inspection NOTE The calendar inspection and overhaul intervals such as the 18 month and 3 year inspections are from the date of installation Conduct a walk around the LH and RH float assemblies and inspect for damaged areas Any chafing break or hole in the coated fabric is suspect and should be investigated If damaged refer to float field repairs in Section 25 1 CAUTION For the utility float exterior surface care must be taken when using the degreaser from LPS Laboratories LPS Instant Super Cleaner Degreaser or any similar solvent to clean the helicopter rotors or airframe exterior The float exterior surface should be covered with a tarpaulin prior to LPS exposure or flushed off with water if the float
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