ICA500-1 B

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
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 AI’s technical data.
SUBJECT
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INSTRUCTIONS FOR CONTINUED AIRWORTHINESS
20408
ICA500-1
Rev. B
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INSTRUCTIONS FOR CONTINUED AIRWORTHINESS
20408
ICA500-1
Rev. B
DETAILS OF REVISIONS
REV. DATE
PAGE DESCRIPTION
APPROVED
N/C
98Jan12
All
Initial Release
A
98Mar02
1
2
8
9
Deleted Model 500N
Page Intentionally Left Blank
Deleted Model 500N from Figures A.6, A.7, A.8
Deleted Model 500N from 1.2 Purpose and 1.5
Applicability
Deleted Model 500N from 1.9 Distribution
Deleted Model 500N from 1.10 Description of
the System and Installation
Deleted Model 500N from Figures A.6 and A.7
Deleted Model 500N from Figure A.8
Deleted Model 500N from Illustrated Parts Lists
for P/N 20408-103 and 20408-104
10
11
16
17
32
B
03/05/09
5
7
12
13
Committee
Revised List of Effective Pages
Revised List of Figures and List of Tables
Added note Section 5.1.1, Added Section 5.1.2
Revised Section 5.1.4
P. Bravo
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INSTRUCTIONS FOR CONTINUED AIRWORTHINESS
20408
ICA500-1
Rev. B
RECORD OF SERVICE BULLETINS (S/B’S)
S/B NO.
DATE
DESCRIPTION
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INSTRUCTIONS FOR CONTINUED AIRWORTHINESS
20408
ICA500-1
Rev. B
LIST OF EFFECTIVE PAGES
Title
Page Revision No.
Cover
Page Intentionally Left Blank
Details of Revisions
Record of Service Bulletins
List of Effective Pages
Table of Contents
List of Tables and Figures
Section 1.0
Introduction
Section 4.0
Airworthiness Limitations
Section 5.0 Inspection Requirements and Overhaul Schedule
Section 9.0 Towing
Section 11.0 Placards
1
2
3
4
5
6
7
8-10
11
12
14
15
16-17
B
B
B
B
B
B
B
B
B
B
B
B
B
18-38
32
33
B
B
B
Section 25.0 Float Removal, Cleaning, Testing, Field Repairs
and Reinstalling
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INSTRUCTIONS FOR CONTINUED AIRWORTHINESS
20408
ICA500-1
Rev. B
TABLE OF CONTENTS
Identification
Title
Section 1.0
Introduction
1.1
Scope
1.2
Purpose
1.3
Revision Control Procedure
1.4
Service Difficulty Reporting
1.5
Applicability
1.6
Abbreviations
1.7
Precautions
1.8
Units of Measurement
1.9
Distribution
1.10 Description of the System and Installation
8
8
8
8
8
8
9
9
9
9
10
Section 4.0
Airworthiness Limitations
11
Section 5.0
Inspection Requirements and Overhaul Schedule
5.1
Inspection Requirements
5.2
Component Overhaul Schedule
12
12
13
Section 9.0
Towing
14
Section 11.0
Placards
11.1
11.2
11.3
Section 25.0
Page
15
15
15
15
Placard Information
Location
Application
Float Removal, Cleaning, Testing, Field Repairs and Reinstalling
25.1 Floats
25.1.1 Float Removal
25.1.2 Table II
25.1.3 Table III
25.1.4 Cleaning
25.1.5 Testing
25.1.6 Field Repairs
25.1.7 Reinstalling Floats
20
20
20
20
21
21
22
25
32
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20408
ICA500-1
Rev. B
TABLE OF CONTENTS, CONTINUED
Identification
Title
25.1.8 Completion of Installation
25.2 Illustrated Parts List
Page
33
34
LIST OF TABLES
Table Number
Description
Page
I
II
III
IV
V
VI
VII
VIII
Float Characteristics
Consumable Cleaning Materials Required
Visual Check of Assemblies and Components
Testing Equipment/Materials Required
Helicopter Float Repair Kit Items
Trouble Shooting-Float Will Not Maintain Operating Pressure
Special Tools
Repair Materials Required
10
18
19
22
23
31
31
31
LIST OF FIGURES
Figure Number
Description
Page
A.1
A.2
A.3
A.4
A.5
A.6
A.7
A.8
B
C
D
Placard #1
Placard #2
Placard #3-A for 369D
Placard #3-B for 369D
Placard #3-C for 369D
Placard #3-A for 369E
Placard #3-B for 369E
Placard #3-C for 369E
Valve Removal and Replacement - PRV and Topping Valve
Float Attaching Hardware
Utility Float
15
15
16
16
16
17
17
17
30
32
36
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INSTRUCTIONS FOR CONTINUED AIRWORTHINESS
20408
ICA500-1
Rev. B
1.0
1.1
INTRODUCTION
Scope
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.”
1.4
Service Difficulty Reporting
Service Difficulty Reporting shall utilize the form included as Attachment 1.
1.5
Applicability
This manual shall be used to maintain the utility floats for the MDHS 369HS, 369HM,
369HE, 369D and 369E.
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20408
ICA500-1
Rev. B
1.6
Abbreviations
psi
psig
ºF
ºC
Hg
PRV
P/N
F/N
LH
RH
1.7
=
=
=
=
=
=
=
=
=
=
pounds per square inch
pounds per square inch gauge
degrees Fahrenheit
degrees Celsius
mercury
pressure relief valve
part number
find number
left hand
right hand
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.
1.8
CAUTION:
May be a maintenance procedure, practice, condition, etc., which could
result in damage or destruction of equipment
NOTE:
May be a maintenance procedure, practice, condition, etc., or a statement
which needs to be highlighted.
Units of Measure
psi
psig
ºF
ºC
=
=
=
=
pounds per square inch
pounds per square inch gauge
degrees Fahrenheit
degrees Celsius
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INSTRUCTIONS FOR CONTINUED AIRWORTHINESS
20408
ICA500-1
Rev. B
1.9
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.
1.10
Description of the System and Installation
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:

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
Material
Ship set inflated volume
Ship set inflated buoyancy
Operating pressure
Type of inflation
Total ship set weight
Urethane coated nylon
87.4 cubic feet
5452 pounds
2.00 psi
Compressed air
40.0 pounds (approximately)
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20408
ICA500-1
Rev. B
SECTION 4.0
AIRWORTHINESS LIMITATIONS
No airworthiness limitations are associated with this STC.
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INSTRUCTIONS FOR CONTINUED AIRWORTHINESS
20408
ICA500-1
Rev. B
SECTION 5.0
5.1
INSPECTION REQUIREMENTS AND OVERHAUL SCHEDULE
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 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.
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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 70º F after 10 minutes. Then measure the pressure
in each Liferaft chamber. Pressure shall be a minimum of 1.75 psi at 70º 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 Schedule
Component
P/N
20408-101
20408-102
20408-103
20408-104
Component
Nomenclature
Float LH
Float RH
Float LH
Float RH
Time Between
Overhaul
3 years
3 years
3 years
3 years
Section
25.1
25.1
25.1
25.1
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.
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20408
ICA500-1
Rev. B
SECTION 9.0
TOWING
Ground towing must be accomplished utilizing a dolly.
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20408
ICA500-1
Rev. B
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
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/N 369D292032 is
installed.
Placard #2:
Minimum float pressure is 2.0 psig.
Figure A.2 Placard #2
Placard #3:
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20408
ICA500-1
Rev. B
Placard #3-A for 369D
Figure A.3
Placard #3-B for 369D
Figure A.4
Placard #3-C for 369D
Figure A.5
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20408
ICA500-1
Rev. B
Placard #3-A for 369E
Figure A.6
Placard #3-B for 369E
Figure A.7
Placard #3-C for 369E
Figure A.8
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20408
ICA500-1
Rev. B
SECTION 25.0 FLOAT REMOVAL, CLEANING, TESTING, FIELD REPAIRS
AND REINSTALLING
25.1
Floats
Note
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 A51219N 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 Table II
TABLE II. CONSUMABLE CLEANING MATERIALS REQUIRED
Description
Cleaning Solvent - Methyl Ethyl Ketone (MEK)
Stiff bristle brush
Soft bristle brush
Detergent
Availability
Commercially available
Commercially available
Commercially available
Commercially available
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20408
ICA500-1
Rev. B
25.1.3 Table III
TABLE III. VISUAL CHECK OF ASSEMBLIES AND COMPONENTS
Component
Fabric/Seams
Pressure Relief Valve (PRV)
Topping Valve
Girt Assembly
Check Procedure
Cuts, tears, punctures,
abrasions (mark with chalk if
discrepant).
Leaks, opening and closing
pressure only - see Testing
(Section 25.1.5).
Leaks only - see Testing
(Section 25.1.5).
Condition, function and
security
Disposition
See Repair (Section 25.1.6).
If beyond limits, return to
factory.
If valve leaks, replace it
(Section 25.1.6.4). Flange
leaks, return to factory.
If valve leaks, replace it
(Section 25.1.6.4). Flange
leaks, return to factory.
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
VENTILATED AREAS. DO NOT INHALE FUMES.
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20408
ICA500-1
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Note
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. (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.
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ICA500-1
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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.
4. 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.
5. 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.
6. If the corrected pressure falls below specified limits, inflate the float to 2.0
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.
2. 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.
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.
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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 improperly, 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
Equipment
Manometer
Pressure Gauge
Description/Function
Scale increments not more than 0.10 psi.
Range: 0 - 120 in. Hg.
Increments not greater than 0.1 psi
Barometer
Scale increments not more than 0.10 in. Hg.
Stopwatch
Plain timer, 0.10 second graduations
Thermometer
Scale increments not more than 1° F
Leak Test Solution
Leak test
Detergent soap and water solution
Supplier
Note 3
Optional
Note 3
Optional
Note 3
Optional
Note 3
Optional
Note 3
Optional
Optional
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.
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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 not 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
25.1.6.1
4
2
2
1
1
1
1
1
1
1
Cement Bonding
PROJECT
Urethane Coated
Fabric
WASHING
MEK 100%
ACTIVATING
MEK 100%
ADHESIVE
LA 4123 or
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.
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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
Roller
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
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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 until the final cure
period as specified below.
Adhesive Pot Life and Cure Times
Supplier
Apical Industries
Grade
LA 4123
Pot Life
6 hours
Initial Cure
12 hours
Final Cure
48 hours
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
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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 cleaning solvent to evaporate completely before applying
adhesive.
Note
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.
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INSTRUCTIONS FOR CONTINUED AIRWORTHINESS
20408
ICA500-1
Rev. B
3) Close the adhesive container when not in active use.
k. Activate the adhesive by one of the following methods:
1) To solvent activate: Wipe both cemented surfaces lightly but
thoroughly with a clean cloth dampened with solvent. Join the
components per step (l) within 15 seconds of activating.
2) 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 (l).
l. Join the components as follows:
1) 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.
2) Press with a pusher or roller over the entire activated area to ensure
complete contact.
3) 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.
4) Apply the patch gradually from the center to the edges to minimize the
possibility of air bubbles being trapped beneath the patch.
5) 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.
6) 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
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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. 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
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INSTRUCTIONS FOR CONTINUED AIRWORTHINESS
20408
ICA500-1
Rev. B
under the tear.
g. Immediately apply pressure with a hand roller to bond the patch to the
inside of the fabric. Pressure is important for a good bond.
h. If surface cannot be cleaned due to build up of chemicals, use sandpaper
to
abrade outside surface of area to be bonded until achieving a dull
appearance.
i. Thoroughly clean the outside surface of the fabric around the tear and the
underside of the other patch using a cloth dampened with solvent.
j. Apply adhesive and activate surfaces as instructed in 25.1.6.2 i., j. and k.
above.
k. Apply the patch gradually from the center as instructed in 25.1.6.2 l., m.,
n. and o. above.
25.1.6.4
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. Using special 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 counterclockwise.
b. 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.
c. 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.
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INSTRUCTIONS FOR CONTINUED AIRWORTHINESS
20408
ICA500-1
Rev. B
Figure B.
Valve Removal and Replacement - PRV and Topping Valve
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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
Remedy
Hole in fabric
Patch hole. See 25.1.6.2.
Tear in fabric
Patch tear. See 25.1.6.3.
Leaking PRV **
Check threads. See 25.1.3.
Leaking topping valve **
Check threads. See 25.1.3.
**
Denotes the following: if valve leaks at the mounting base, return float assembly to
factory for repair/replacement.
25.1.6.6
Table VII.
TABLE VII. SPECIAL TOOLS
Apical Part Number
Nomenclature
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
Float material
Adhesive
Activating agent
Brush, 1” wide
Spatula (pusher) or dull putty knife
Cotton cloths
Specification and/or Vendor Designation
Identification: L2030UPW; Apical Industries, Inc.
LA 4123; Apical Industries, Inc.
Methyl Ethyl Ketone (MEK)
Commercial - solvent resistant
2 1/4” x 4”; Apical Industries, Inc.
Commercial waste - clean and soft
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20408
ICA500-1
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.
Figure C. Float Attaching Hardware
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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.
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INSTRUCTIONS FOR CONTINUED AIRWORTHINESS
20408
ICA500-1
Rev. B
25.2
Illustrated Parts List
See the following figure (Figure D) for part locations.
F/N
Qty
5
6
30
31
32
33
34
6
6
56
56
2
1
1
F/N
Qty
5
6
30
31
32
33
34
6
6
56
56
2
1
1
F/N
Qty
5
6
30
31
32
33
34
6
6
56
56
2
1
1
Description
Float, LH - 369HS, 369HM, 369HE
Topping Valve
PRV
Bolt
Washer
Gravel Guard
Gravel Guard
Gravel Guard
Part No.
20408-101
B-51209
B-51019-4
NAS1223C4
HS306-222
369H92043-3
369H92043-1
369H92043-2
Description
Float, RH - 369HS, 369HM, 369HE
Topping Valve
PRV
Bolt
Washer
Gravel Guard
Gravel Guard
Gravel Guard
Part No.
20408-102
B-51209
B-51019-4
NAS1223C4
HS306-222
369H92043-3
369H92043-1
369H92043-2
Description
Float, LH - 369D, 369E
Topping Valve
PRV
Bolt
Washer
Gravel Guard
Gravel Guard
Gravel Guard
Part No.
20408-103
B-51209
B-51019-4
NAS1223C4
HS306-222
369H92043-3
369H92043-1
369H92043-2
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20408
ICA500-1
Rev. B
F/N
Qty
5
6
30
31
32
33
34
6
6
56
56
2
1
1
Description
Float, RH - 369D, 369E
Topping Valve
PRV
Bolt
Washer
Gravel Guard
Gravel Guard
Gravel Guard
Part No.
20408-104
B-51209
B-51019-4
NAS1223C4
HS306-222
369H92043-3
369H92043-1
369H92043-2
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20408
ICA500-1
Rev. B
Figure D. Utility Float
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INSTRUCTIONS FOR CONTINUED AIRWORTHINESS
20408
ICA500-1
Rev. B
SEMI-ANNUAL INSPECTION WORKSHEET
HELICOPTER REGISTRATION NO.
Signature and Date
1.
2.
3.
4.
5.
6.
Remarks
Semi-Annual Inspection #:
1.
1st
2nd
Inspect floats for chafing, breaking
or holes.
Page 13.1
3rd
4th
5th
6th
SUBJECT
REF. DWG. NO.
REPORT NO.
INSTRUCTIONS FOR CONTINUED AIRWORTHINESS
20408
ICA500-1
Rev. B
ANNUAL INSPECTION WORKSHEET
HELICOPTER REGISTRATION NO.
Signature and Date
1.
2.
3.
4.
5.
6.
Remarks
Annual Inspection:
1.
Inspect the girt for condition, function
and security.
2.
Conduct annual float leak test.
Inspect floats for chafing or damaged
areas.
Year 1
Year 2
Page 13.2
Year 3
Year 4
Year 5
Year 6