instructions for continued airworthiness for …the tank wiring harness contains a single point...

HF-S76-ICA-2800-0004, Rev A of 43

12/30/2014

INSTRUCTIONS FOR CONTINUED AIRWORTHINESS

FOR

AUXILIARY FUEL TANK INSTALLATION

STC No. SR00763DE

REPORT NUMBER

HF-S76-ICA-2800-0004, Rev A

Helifab, Inc.

1318 Smede Highway

Broussard, LA 70518

Telephone: (337) 364-4357

THIS MANUAL IS PREPARED TO PROVIDE INFORMATION, INSTRUCTIONS FOR CONTINUED

AIRWORTHINESS, MAINTENANCE INSTRUCTIONS AND REPAIR PROCEDURES FOR

EQUIPMENT MANUFACTURED BY HELIFAB, INC. THAT MAY BE INSTALLED. ENSURE THAT

THIS MANUAL IS USED FOR ONLY HELIFAB EQUIPMENT.


AND EQUIPMENT MAINTENANCE MANUAL

FOR AUXILIARY FUEL TANK INSTALLATION

HF-S76-ICA-2800-0004, Rev A of 43

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Table of Contents

Section Page No.

Table of Contents ............................................................................................................................................................... 2 Table of Figures .................................................................................................................................................................. 3 Log of Revisions ................................................................................................................................................................ 4 List of Effective Pages ........................................................................................................................................................ 4 1. INTRODUCTION ..................................................................................................................................................... 5

1.1. Revisions and Distribution ................................................................................................................................ 5 1.2. Scope of ICA..................................................................................................................................................... 5 1.3. Precautions ........................................................................................................................................................ 5 1.4. Abbreviations .................................................................................................................................................... 6 2. General Product Information and Description ....................................................................................................... 6

3. AIRWORTHINESS LIMITATIONS ........................................................................................................................ 7 4. INSPECTIONS / MAINTENANCE.......................................................................................................................... 7

4.1. Special Tool Required ....................................................................................................................................... 7 4.2. Special Materials Required ............................................................................................................................... 7 4.3. Torque Values ................................................................................................................................................... 8 4.4. Conditional Inspections after Operational Incidents ......................................................................................... 8 4.5. Overhaul Periods ............................................................................................................................................... 8 4.6. Preflight Checks ................................................................................................................................................ 8 4.7. 100 Hour Inspection .......................................................................................................................................... 9 4.8. 12 Month / Annual Inspection .........................................................................................................................10 4.9. Repairs .............................................................................................................................................................12 4.10. Troubleshooting ...............................................................................................................................................12 4.11. Cleaning ...........................................................................................................................................................15

5. REMOVAL AND INSTALLATION INSTRUCTIONS .........................................................................................16 5.1. Removal of Auxiliary Fuel Tank Assembly (Item 7, in Table 2)....................................................................16 5.2. Installation of Auxiliary Fuel Tank Assembly (Item 7, in Table 2) ................................................................17

6. REQUIRED PLACARDS AND DECALS ..............................................................................................................34 7. WEIGHT AND BALANCE .....................................................................................................................................35 Appendix A: Insert Installation Procedures ......................................................................................................................37 Appendix B: Wiring Diagram ..........................................................................................................................................38




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Table of Figures

Figure Number Page No.

Figure 1 ............................................................................................................................................................ 14 Top of Probe Markings Figure 2 ............................................................................................................................................................ 21 Auxiliary Fuel Tank Assembly Removal / Installation Figure 3 ............................................................................................................................................................ 22 Auxiliary Fuel Tank Assembly Removal / Installation Figure 4 ............................................................................................................................................................ 23 View B (See Figure 3) Figure 5 ............................................................................................................................................................ 23 View A and C (See figure 3) Figure 6 ............................................................................................................................................................ 25 View D (See figure 3) Figure 7 ............................................................................................................................................................ 26 Sump Valve Figure 8 ............................................................................................................................................................ 27 Auxiliary Fuel Tank Assembly Figure 9 ............................................................................................................................................................ 28 Detail F (See figure 8) Figure 10 .......................................................................................................................................................... 29 Detail G, Item 69 Assembly (See figure 8) Figure 11 .......................................................................................................................................................... 30 Detail H, Item 22 Assembly (See figure 2) Figure 12 .......................................................................................................................................................... 31 Detail J, Item 73 Assembly (See figure 8) Figure 13 .......................................................................................................................................................... 32 Auxiliary Fuel Tank Assembly Figure 14 .......................................................................................................................................................... 33 Detail K Figure 15 .......................................................................................................................................................... 34 Decal PN HF-S76-D-5-1 Figure 16 .......................................................................................................................................................... 34 Decal PN HF-S76-D-5-2 Figure 17 .......................................................................................................................................................... 35 Decal PN HF-S76-D-5-3 Figure 18 .......................................................................................................................................................... 35 Decal PN HF-S76-D-5-4




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Log of Revisions

REV # DESCRIPTION OF CHANGE DATE

ISSUED

BY

IR Initial Release 09/17/2013 KDS

A Add HF-S76-I-9-2 installation 12/30/2014 KDS

List of Effective Pages

PAGE REVISION # DATE

1 thru 41 IR 09/17/2013

1 thru 43 A 12/30/2013




HF-S76-ICA-2800-0004, Rev A of 43

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1. INTRODUCTION

These instructions contain the information necessary to inspect and maintain Helifab’s S76 auxiliary

fuel tank installation.

1.1. Revisions and Distribution

These instructions are provided with each S76 auxiliary fuel tank installation kit. Any airworthiness

or flight safety revisions will be sent to all who purchased the affected S76 auxiliary fuel tank kits.

A log of revisions is included in these instructions. Changes to the equipment maintenance manuals

are to be incorporated and are identified as follows:

Revised or extended text and inserted pages with new text contents or new figures are

identified with black marginal bars or referenced symbols. When text is relocated resulting

in a renumbering of pages or task, or in case of printing error corrections, no markings are

provided.

1.2. Scope of ICA

The purpose of these Instructions for Continued Airworthiness (ICA) and Equipment Maintenance

Manual (EMM), is to provide necessary information to maintain, inspect, repair, or replace the

equipment. Maintenance personnel should be thoroughly familiar with standard abbreviations

contained herein. Specific abbreviations or acronyms can be found in the document text with the full

meaning. It is the operator’s responsibility to ensure the correct revision of the ICA is used, requests

for replacement ICA should be made to:

Address:

Helifab, Inc.

1318 Smede Hwy.

Broussard, La

70518

Telephone: (337)364-4357

Website: www.arrowaviationco.com

1.3. Precautions

The following precautions are used throughout this manual and are defined as follows:

WARNING IS USED WHEN UNQUALIFIED PERFORMANCE OR NEGLECT OF

INSTRUCTIONS MAY LEAD TO INJURIES OR DEADLY

ACCIDENTS.

CAUTION IS USED WHEN UNQUALIFIED PERFORMANCE OR NEGLECT OF

INSTRUCTIONS MAY LEAD TO EQUIPMENT DAMAGE

NOTE IS USED WHEN A PARTICULAR ITEM NEEDS TO BE EMPHASIZED




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1.4. Abbreviations

EMM Equipment Maintenance Manual

ICA Instructions for Continued Airworthiness

N/C No Change

Mo. Months

Y Years

PN Part Number

IAW In Accordance With

CG Center of Gravity

LH Left Hand

LHS Left Hand Side

RH Right Hand

RHS Right Hand Side

NA Not Applicable

Cont. Continued

FWD Forward

STA Station

2. General Product Information and Description

There are two auxiliary fuel tank installation part numbers as defined below:

PN HF-S76-I-9-1 Auxiliary fuel tank installation: For use in S-76A, S-76B, S-76C, and S-76D up

to and including serial number 761036.

PN HF-S76-I-9-2 Auxiliary fuel tank installation: For use in S-76D serial number 761037 and

subsequent. There are two differences between the HF-S76-I-9-1 and -2 installations. 1) The

auxiliary tank vent line routing to the existing main fuel tank vent line is different and 2) The fuel

tank assembly part numbers are different (see table 2, note 4).

The auxiliary fuel tank is installed in the baggage compartment and secured to the airframe by

attachment brackets installed to the baggage compartment floor and STA 215 bulkhead. A

honeycomb composite panel spacer board is secured to the baggage compartment floor under the

tank assembly to prevent existing fasteners from damaging the lower side of the auxiliary tank.

Two access doors, one on the left and one on the right hand side of the auxiliary fuel tank, provide

access to the auxiliary fuel transfer hose quick disconnect fittings, auxiliary fuel sump and allows

access for inspection.

The auxiliary fuel tank is constructed of 1/2”thick aluminum honeycomb panel and aluminum

attachment angle with a flexible fuel bladder. A capacitance type fuel probe and 2” indicator

provide quantity indication for the 62 gallon max useable fuel capacity. The fuel transfer is

controlled by an electric motor actuated shutoff valve and two float valves installed in the access

covers of the main tanks. The float valves function automatically to prevent main tank overflow

during fuel transfer from the auxiliary tank and the shutoff valve is controlled by an annunciator /

switch located in the cockpit . A cavity vent/drain and valve compartment drain located on the left

hand side of the auxiliary tank are drained to the external side of the fuselage near the lower left

hand corner of the baggage compartment door. The tank can be removed in less than 30 minutes

when not required, while leaving the fixed auxiliary tank provisions installed for future use. The




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wiring harness, fuel transfer hose(s), and vent line hose connections are quick disconnect for ease of

removal and installation.

The vent system of the tank is plumbed into the existing left hand main tank vent line using a

flexible hose and self sealing quick disconnect fitting. When the tank is removed an optional dust

cap and plug may be used to prevent dirt and debris from contaminating the connection.

The auxiliary fuel transfer hoses attach to the two float valves mounted in the main fuel tank access

panels using two self sealing quick disconnect fittings. When the tank is removed an optional dust

cap and plug may be used to prevent dirt and debris from contaminating the quick disconnect

fittings.

The tank wiring harness contains a single point disconnect located on the right hand aft side of STA

215 bulkhead. A grounding strap is attaches the auxiliary tank splash guard to a grounding angle on

STA 215 bulkhead using two MS27039 #10 screws.

The auxiliary tank sump valve is accessed by opening the quick release door on the left hand side of

the auxiliary fuel tank. A 24” length of tubing is attached to the sump valve to allow fuel drainage

outside of the rotorcraft.

3. AIRWORTHINESS LIMITATIONS

There are no overhauls, time limits, or airworthiness limitations associated with this type

design change.

The Airworthiness Limitations section is FAA approved and specifies maintenance required

under Secs. 43.16 and 91.403 of the Federal Aviation Regulations unless an alternative

program has been FAA approved.

4. INSPECTIONS / MAINTENANCE

4.1. Special Tool Required

Any special tools required for maintenance, removal, or installation of the auxiliary fuel tank will be

specified in the text of this document where applicable.

4.2. Special Materials Required

Any consumable materials required for maintenance, removal, or installation of the auxiliary fuel

tank will be specified in the text of this document where applicable.




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4.3. Torque Values

All hardware shall be torque to the following values unless otherwise specified:

Table 1

Hardware Torque Values

Size Type Torque

3/8 – 24 Sump Valve 75-125 in-lb.

1/4 – 28 Bolt/Screw 50-70 in-lb.

#10 – 32 Bolt/Screw 20-25 in-lb.

#8-32 Bolt/Screw 12-15 in-lb.

-10 Size Flare Fitting 200-350 in-lb.

-12 Size Flare Fitting 300-500 in-lb.

-16 Size Flare Fitting 41-58 ft-lb.

Note: Fastener installation shall be in accordance with FAA advisory circular AC43.13-1B,

chapter 7, paragraph 7-1 thru 7-89.

4.4. Conditional Inspections after Operational Incidents

After any operational incident involving hard landings, sudden stoppage of the drive train or

water immersion, the system must not be operated until a thorough inspection of the

installation has been accomplished IAW section 4.8 of this document.

Notification of incident should be made to the STC holder for additional information and

possible further evaluation.

STC Holder:

Helifab, Inc.

1318 Smede Hwy.

Broussard, La

70518

Telephone: (337)364-4357

Website: www.arrowaviationco.com

4.5. Overhaul Periods

No component overhaul is required for this type design change.

4.6. Preflight Checks

The preflight check shall be accomplished by a qualified technician or pilot.

In addition to the normal preflight inspections mandated by the rotorcraft manufacturer

flight manual, the following preflight checks must be made.




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INSPECTION TASK DESCRIPTION

1. Inspect for general security of auxiliary tank, ensuring no loose or missing

hardware.

2. Check fuel level in auxiliary fuel tank

3. Sump the auxiliary fuel tank and check for water and other contaminants.

Continue to sump the auxiliary tank until the fuel shows no sign of water or

contamination. Ensure sump valve is secured in the closed position after

completion. (The auxiliary fuel tank sump valve is accessed by opening the

access door on the left hand side of the auxiliary fuel tank.)

4. Using the shutoff valve control annunciator/switch in the cockpit, operate

the auxiliary fuel tank shutoff valve from CLOSED to OPEN and ensure

annunciator indicates “OPEN”. Operate the valve from OPEN to CLOSED

and ensure annunciator indicates “CLOSED”

5. Ensure auxiliary fuel tank filler cap is secured and locked.

6. Ensure access doors on the right and left hand side of the auxiliary fuel tank

are closed and locked.

4.7. 100 Hour Inspection

This inspection is to be performed by a qualified technician.

All inspections must be recorded in the rotorcraft records IAW 14 CFR Part 43 or other

applicable regulations.


1. Inspect all mounting brackets, hardware, and potted inserts attaching the tank to the

aircraft for cracks, corrosion, or distortion. Replace any components that are

cracked or distorted. Replace hardware that is stripped or does not function

properly (see instruction shown in appendix A for insert installation instructions).

Corrosion may be blended out using 320 grit or finer aluminum oxide abrasive

paper. Maximum depth of corrosion cleanup to be 10% of material thickness

where the corrosion is located. If corrosion exceeds these limits, replace the

corroded component.

For areas of blended out corrosion, clean and prime area after corrosion removal

using primer PER MIL-P-23377 and topcoat to match surrounding area.

2. Inspect tank structure for loose, missing, malfunctioning or stripped hardware.

Replace as required with same type and size as removed.

3. Inspect all hoses and fittings for leakage, condition and security. Replace leaking

or chaffed hoses or fittings.

4. Inspect all hose quick disconnect fittings for leakage and proper operation.

Replace malfunctioning or leaking fittings.

5. Inspect fuel cap for proper operation and sealing. Replace leaking or

malfunctioning cap.

6. Inspect sump valve for leakage and operation. Replace leaking or malfunctioning

sump valve.




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7. Inspect for fuel bladder leakage. Contact the STC holder for bladder replacement

if leakage is found.

8. Inspect cavity and splash guard drain for clogs. Clear any dirt and debris from

drain hoses.

4.8. 12 Month / Annual Inspection

This inspection is to be performed by a qualified technician.

All inspections must be recorded in the rotorcraft records IAW 14 CFR Part 43 or other

applicable regulations.


1. Remove auxiliary fuel tank from aircraft in accordance with instruction s given in

section 5.1

Inspect all mounting brackets, hardware, and potted inserts attaching the tank to the

aircraft for cracks, corrosion, or distortion. Replace any components that are

cracked or distorted. Replace hardware that is stripped or does not function

properly (see instructions shown in appendix A for insert installation instructions).



where the corrosion is located. If corrosion exceeds these limits, replace the

corroded component.

For areas of blended out corrosion, clean and prime area after corrosion removal

using primer PER MIL-P-23377 and topcoat to match surrounding area.

2. Inspect tank structure for loose, missing, malfunctioning or stripped hardware.

Replace as required with same type and size as removed.

3. For delamination around holes and edges of spacer board or aux fuel tank

honeycomb panels, undercut panel core up to 1” from edge and edgefill using one

of the following materials. Follow manufacturer instructions for mixing,

application and curing.

Epocast 1618 D/B, manufactured by Huntsman Materials

Manobond 6398, manufactured by Magnolia Plastics

EC-3505 B/A, manufactured by 3M Corporation

4. Remove front access cover by removing the four MS27039 #10 screws attaching it

to the tank and inspect the two transfer hoses, fittings, and shutoff valve for leaks,

chaffing, corrosion and general condition. Replace any hoses or fittings that show

signs of chaffing, leaking, frayed braiding, or corrosion exceeding 10% of the

material depth. Corrosion is not permitted on flared sealing surfaces.



where the corrosion is located.

After corrosion cleanup, touch up alodine finish using Henkel Alodine 1132




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Touch-N-Prep pen.

Ensure all hose and fitting connections in the fuel transfer system are properly

torqued per the torque table listed in section 4.3.

5. Inspect quick release hose fittings on the fuel transfer lines for proper operation.

Replace fittings that leak or do not function properly.

6. Inspect shutoff valve for security and wiring for condition. Chaffed, broken or

frayed wiring or connectors must be replaced. Loose or missing hardware is to be

replace with same type and size as existing.

7. Inspect tank for signs of bladder leakage. If bladder leakage is detected the bladder

must be replaced. Contact the STC holder for bladder replacement.

8. Inspect the auxiliary tank vent system lines for cracks or corrosion. Replace any

cracked components. Corrosion may be blended out using 320 grit or finer

aluminum oxide abrasive paper. Maximum depth of corrosion cleanup to be 10% of

material thickness where the corrosion is located. If corrosion exceeds these limits,

replace the corroded component.

For painted areas where corrosion has been blended out, clean and prime area after

corrosion removal using primer per MIL-P-23377 and topcoat to match

surrounding area.

For anodized areas where corrosion has been blended out, touch up alodine finish

using Henkel Alodine 1132 Touch-N-Prep pen.

Ensure all hose and fitting connections in the vent system are properly torqued per

the torque table listed in section 4.3.

9. Inspect vent flex line, fittings, and quick disconnect hose fitting for chaffing,

corrosion and general condition. Replace any hoses or fittings that show signs of

chaffing, frayed braiding, or corrosion exceeding 10% of the material depth.

Corrosion is not permitted on flared sealing surfaces.


paper. Maximum depth of corrosion cleanup to be 10% of material thickness where

the corrosion is located.

After corrosion cleanup, touch up alodine finish using Henkel Alodine 1132 Touch-

N-Prep pen.

10. Inspect tank for signs of bladder leakage. If bladder leakage is detected the

bladder must be replaced. Contact the STC holder for bladder replacement.

11. Inspect sump valve, and hose for leakage and proper operation. Replace sump

valve hose and/or sump valve if not operating properly or found to be leaking.

12. Inspect fuel cap lanyard for condition and fuel cap for proper operation and sealing.

Replace leaking or malfunctioning cap. Replace broken or missing fuel cap lanyard.

13. Inspect aircraft structure around auxiliary fuel tank installation for damage and

repair per rotorcraft manufacturer’s maintenance manual if required.

14. Re-install the aux fuel tank in accordance with section 5.2.

15. Inspect the cavity and splash guard drain hoses for leakage. Replace or reseal hoses

as required. Reseal using sealant per AMS-S-8802. Follow manufacturer’s

instructions for mixing, application and curing.




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16. Inspect splash guard for leakage. If leakage is found, reseal splashguard as required

using sealant per AMS-S-8802. Follow manufacturer’s instructions for mixing,

application and curing.

17. Inspect cavity and splash guard drain hoses for clogs. Clear any dirt and debris

from drain hoses.

18. Inspect all tank wire and wire connections located inside the baggage compartment

for chafing, cuts or breaks. Repair wiring as required.

4.9. Repairs

No repairs other than those that can be accomplished with accepted methods or that are called out in this

document are allowed. Normal repairs include paint touch up, corrosion clean-up, or replacement of

damaged hardware and components. Replacement of potted inserts must be accomplished in accordance

with instructions shown in appendix A.

4.10. Troubleshooting

References:

Appendix B, Wiring Diagram

Special Tools:

Multimeter capable of indicating DC voltage and resistance.

Symptom: Fuel leak

Possible Fault(s):

1) Leaking seal or O-ring.

1) Leaking Component (Valve, hose, sump valve, fitting, quick release hose fitting, fuel

bladder etc.)

Corrective Action:

1) Leaking seal or O-ring

a) Remove and replace leaking gasket or O-ring.

2) Leaking Component

a) Remove and replace leaking component.

Symptom: No auxiliary fuel flow to one main tank:

Possible Fault:

1) Float valve malfunction.

Corrective Action:

1) Float valve malfunction

a) Remove and replace malfunctioning float valve.




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Symptom: No auxiliary fuel flow to both main tanks:

Possible Fault(s):

1) Malfunction of auxiliary fuel shutoff valve.

2) Malfunction of both float valves.

Corrective Action:

1) Malfunction of auxiliary fuel shutoff valve.

a) Turn on main rotorcraft power.

b) Check circuit breakers for popped breakers and reset as required. Check

auxiliary fuel shutoff valve wiring and connections for loose connections,

chaffing or broken wires.

c) Activate the auxiliary fuel shutoff valve switch and verify “OPEN” indication. If

no open or closed indication is given or “CLOSED” indication remains, verify

switch is functioning properly, 28V DC power is supplied to the shutoff valve,

and shutoff valve has ground to the rotorcraft.

d) Troubleshoot float valves. If float valve tests and test in step 1(c) are acceptable,

remove and replace auxiliary fuel tank shutoff valve.

2) Malfunction of both float valves

a) Remove main fuel tank access covers and ensure float valves operate freely. If float

valves are stuck closed or do not operate freely, replace the malfunctioning float

valve(s).

Symptom: Incorrect or no auxiliary fuel quantity indication.

Possible Fault(s):

1) Malfunction or mis-calibration of quantity indication probe.

2) Malfunction of aux fuel quantity indicator.

Corrective Action:

1) Malfunction or mis-calibration of quantity indication probe.

a) Rotorcraft attitude must be 0°in both pitch and roll.

b) Turn on main rotorcraft power.

c) Check circuit breakers for popped breakers and reset as required. Check

auxiliary fuel probe wiring and connections for loose connections, chaffing or

broken wires.

d) Verify 28V DC power is supplied to the aux fuel quantity probe and that it has

ground to the rotorcraft.

e) Recalibrate auxiliary fuel probe by following the instructions below. (Refer to

figure 1 which depicts the top of the probe and its markings).

i) Turn rotorcraft main electrical power on.

ii) Add 1.08 gallons (1 gallon and 10.3 oz.) to the completely empty auxiliary

fuel tank.




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iii) Push and hold the momentary switch labeled “PUSH TO ADJ”. The LED

labeled “OVER FULL/EMPTY” must be off. If not, turn the potentiometer

labeled “ADJ. EMPTY” counter-clockwise until the LED turns off.

ATTENTION:

If empty adjustment is rotated too far in the counter-clockwise position the

LED will come on. In the case of over-adjusting, rotate pot clockwise until

the LED goes out.

iv) While holding the switch down, adjust the potentiometer labeled “ADJ.

EMPTY” clockwise until the LED just lights. Release the switch and the

LED will go off.

v) Ensure the aux fuel quantity indicator reads 0 lb.

vi) Fill the auxiliary fuel tank until fuel just starts to overrun the fuel filler and

install the fuel cap.

vii) Push and hold the momentary switch labeled “PUSH TO ADJ”. The LED

labeled “OVER EMPTY/FULL” may momentarily blink but must remain

off. If not, turn the potentiometer labeled “ADJ. FULL” clockwise until the

LED turns off.

viii) While holding the switch down, adjust the potentiometer labeled

“ADJ. FULL” counter-clockwise until the LED just lights. Release the

switch and the LED will go off.

ix) Weigh one gallon of fuel used to fill the auxiliary tank and multiply the

weight of one gallon of fuel by 62 gallons to determine the weight of fuel in

the auxiliary tank. Ensure quantity indication gauge indicates the weight of

fuel calculated above ± 6% of the total weight.

x) Calibration is complete.

NOTE:

The LED does not light once the switch is released.

Figure 1

Top of Probe Markings




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f) With the auxiliary fuel tank full of fuel, verify a 1volt output from the quantity

indication probe signal output. g) If all auxiliary fuel probe troubleshooting tests were acceptable and auxiliary fuel

quantity indication still does not does not indicate correctly, troubleshoot the aux fuel

quantity indicator. If tests were not acceptable, remove and replace auxiliary fuel

quantity indication probe.

2) Malfunction of aux fuel quantity indicator.

a) Turn on main rotorcraft power.

b) Check circuit breakers for popped breakers and reset as required. Check

auxiliary fuel quantity indicator wiring and connections for loose connections,

chaffing or broken wires.

c) Verify, 28V DC power is supplied to the aux fuel quantity indicator and that it

has ground to the rotorcraft. d) If quantity indication still does not does not indicate correctly and if all auxiliary fuel

probe troubleshooting test results were acceptable, remove and replace the auxiliary fuel

tank quantity indicator.

4.11. Cleaning

References: None

Special Tools: None

Consumable Materials: Mild Detergent

Procedures:

1. Wash auxiliary tank exterior using a mild aircraft grade cleaning detergent.

2. Rinse thoroughly with fresh water

3. Allow to air dry completely.




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5. REMOVAL AND INSTALLATION INSTRUCTIONS

References: Figures 2 thru 6

NOTE

Fastener installation shall be in accordance with FAA advisory circular AC43.13-1B, chapter 7, section

7-1 thru 7-89 Torque all fasteners in accordance with the torques listed in section 4.3 of this Document

5.1. Removal of Auxiliary Fuel Tank Assembly (Item 7, in Table 2)

The auxiliary fuel tank may be removed, while leaving the fixed provisions installed for

later use.

1. For ease of removal, drain the auxiliary tank using the sump valve or open the shutoff valve

and allow the tank to drain into the aircraft main tanks.

2. Disconnect two fuel transfer hose quick disconnects (Item 66) by accessing through the left

hand and right hand access doors on the auxiliary fuel tank.

3. Disconnect the auxiliary fuel tank single point wiring disconnect located on the right hand

aft side of STA 215 bulkhead. Install plastic cap or similar protective cover over wire

connectors to prevent dirt and debris contamination.

4. Disconnect vent flex hose quick disconnect (Item 68) and install plastic cap covers over the

two quick disconnect halves to prevent dirt and debris contamination. Optional dust cap and

plug for the vent flex line quick disconnect may be purchased from the STC holder (PN

378000-10 dust cap assembly, and PN 378200-10 dust plug assembly)

5. Remove QTY 1 MS27039 #10 screw (Item 17) attaching the electrical bonding strap (Item

16) to the grounding angle on STA 215 bulkhead and retain hardware.

6. Disconnect the cavity and splashguard drain tubing (Item 27) at the overboard drain fitting

(Item 20) located near the forward bottom corner of the left hand baggage compartment

door.

7. Remove QTY 24 AN3-3A bolts (Item 9) and QTY 24 washers (Items 6 and 11) securing the

tank mounting brackets (Item 13,14, and 15) to the baggage compartment floor and tank.

Retain all hardware.

8. Remove auxiliary tank from aircraft.

9. Remove spacer board (Item 2) by removing QTY 2 MS24694 screws (item 4) and QTY 2

NAS1169DD10 washers (Item 4) securing the spacer board to the baggage compartment

floor.

10. Install plastic cap covers over fuel transfer hose quick disconnect halves to prevent dirt and

debris contamination. Optional dust cap and plug for the fuel transfer hose quick disconnect

may be purchased from the STC holder (PN 3907-16 dust cap assembly, and PN 3909-16

dust plug assembly)

NOTE

Do not store auxiliary tank empty. If auxiliary fuel tank is to be stored for an extended

period of time, add approximately one gallon of jet fuel to the tank prior to storage.




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NOTE

All other auxiliary fuel tank components may remain installed. The aux fuel transfer hose

and vent flex line quick disconnects are self sealing.

5.2. Installation of Auxiliary Fuel Tank Assembly (Item 7, in Table 2)

1. Completely drain the auxiliary fuel tank prior to installation.

2. Install spacer board (Item 2) to existing inserts in baggage compartment floor using QTY 2

MS24694 screws (Item4) and QTY 2 NAS1169DD10 washers (Item 3).

3. Remove dust covers and caps from all quick disconnect hose and wiring connectors.

4. Place the auxiliary fuel tank assembly on the spacer board installed in step 2 and slide the

tank forward until the mounts on the forward side of the tank are fully engaged into the

forward mount halves (Item 1) installed to the baggage compartment floor and STA 215

bulkhead.

5. Install the four auxiliary fuel tank mount brackets (Items 13, 14, and 15) to inserts in the

auxiliary fuel tank and baggage compartment floor using QTY 24 AN3-3A bolts (Item 9)and

QTY 24washers (Items 6 and 11).

6. Attach the quick disconnect fittings (Item 66) on the fuel transfer hoses to the float valve

assemblies (Item 22) installed in the main fuel tank access panels.

7. Attach the quick disconnect fitting (Item 68) on the auxiliary fuel tank vent flex line to the

vent manifold assembly (Item 69) installed in the LH main tank vent line.

8. Attach the electrical bonding strap (item 16) to existing attachment location in the grounding

angle on STA 215 bulkhead using hardware specified.

NOTE

Grounding strap installation shall be per AC43.13-1B, Chapter 11, Section 11-189 thru 11-

195. Verify resistance between fuel filler neck and the grounding angle on STA 215

bulkhead is 1 ohm or less.

9. Attach the auxiliary fuel tank single point electrical connector to its mating half located on

the right hand aft side of STA 215 bulkhead.

11. Attach the cavity and splashguard drain tubing (Item 27) to the overboard drain fitting (Item

20) located near the forward bottom corner of the left hand baggage compartment door.

Apply sealant per AMS-S-8802 to the tubing mating surfaces prior to installation.

12. Accomplish the following function tests. Check for leaks from all hoses, fittings, and valves

during the following function tests.

a. Turn rotorcraft main electrical power on and verify that the auxiliary quantity

indicator reads 0 lb. The auxiliary tank should be completely empty of fuel.

b. Ensure the main tanks contain 550 lb. or less of fuel each.

c. Verify the auxiliary fuel shutoff valve annunciator / switch indicates “CLOSED”.

d. : Actuate the auxiliary fuel shutoff valve switch and verify the switch indicates

“OPEN”.

e. Actuate the auxiliary fuel shutoff valve switch and verify the switch indicates

“CLOSED”.




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f. Fill the auxiliary fuel tank until fuel just starts to overrun the fuel filler and install

and lock the fuel cap.

g. Weigh one gallon of fuel used to fill the auxiliary tank and multiply the weight of

one gallon of fuel by 62 gallons to determine the weight of fuel in the auxiliary tank.

Verify that the quantity indication gauge indicates the weight of fuel calculated

above ± 6% of the total weight.

h. Actuate the auxiliary fuel shutoff valve switch and verify the switch indicates

“OPEN”.

i. Verify that fuel is being transferred from the auxiliary fuel tank to both existing main

tanks by observing the main and auxiliary fuel tank quantity indicators. The main

tank quantity indicators should both rise at approximately the same rate. The fuel

quantity indicated in the auxiliary tank should decrease.

j. Actuate the auxiliary fuel shutoff valve switch and verify the switch indicates

“CLOSED”.

k. Check all hoses, fittings, and valves for signs of leaks and verify that no leaks exist.

l. Perform all required preflight checks in accordance with the installation flight

manual supplement.




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Table 2

Parts List

Item

Number

Nomenclature Part Number Vendor /

Manufacturer 1 FWD Mount Half HF-S76-D-6-16 Helifab, Inc

2 Spacer Board HF-S76-D-1-3 Helifab, Inc

3 Dimpled Washer NAS1169DD10

4 #10 Countersunk Screw MS24694-S57

5 Nut MS21042-3

6 Washer AN960PD10L

7 Aux Tank Assembly HF-S76-A-6-1 (SEE NOTE 4) Helifab, Inc

8 Bolt AN3-5A

9 Bolt AN3-3A

10 Floating Insert NAS1835-3

11 Washer AN960PD10

12 Insert NAS1832-3-3

13 Side Mount HF-S76-D-6-11 Helifab, Inc

14 LH Mount Assembly HF-S76-A-6-5 Helifab, Inc

15 RH Mount Assembly HF-S76-A-6-9 Helifab, Inc

16 Electrical Bonding Strap WM1016-E16E Helifab, Inc

17 #10 Pan Head Screw MS27039-1-06

18 Cavity / Splash Guard Drain Tubing, 5/16” ID,

7/16” OD

F-4040-A Tygon

19 #8 Countersunk Screw MS24694-S3

20 Overboard Drain Fitting Assembly HF-S76-A-6-9 Helifab, Inc.

21 Fuel Probe 114-40022 Helifab, Inc.

22 Float Valve Assembly HF-S76-A-3-1 Helifab, Inc.

23 Fitting 921110 Helifab, Inc

24 Gasket HF-S76-D-6-32 Helifab, Inc.

25 Sump Valve 3750H Helifab, Inc.

26 O-Ring MS29513-011

27 Cable Tie MS3367-1-X or MS3367-2-X

28 Sump Drain Tubing, 1/4” ID, 3/8” OD F-4040-A Tygon

29 Corrosion Resistant Steel Safety Wire, ø0.020 thru

ø0.051”

MS20995

30 Union AN5174D1212

31 O-Ring MS29513-116

32 O-Ring MS29513-213

33 Quick Disconnect HF-S76-D-7-1 Helifab

34 Manifold HF-S76-D-7-2 Helifab

35 Float Valve Arm HF-S76-D-3-1 Helifab

36 Float Lower Mount HF-S76-D-3-2 Helifab

37 Float Upper Mount HF-S76-D-3-3 Helifab

38 Valve HF-S76-D-3-4 Helifab

39 Foam Block HF-S76-D-3-5 Helifab

40 Float Valve Housing HF-S76-D-3-6 Helifab

41 Hose Quick Disconnect HF-S76-D-3-7 Helifab

42 Lip Seal 240733 Helifab

43 Bushing NAS76A5-012

44 Screw MS35206-237

45 Nut MS21042-06

46 Washer AN960PD6L

47 Washer AN960C4

48 Cotter Pin MS24665-1010

49 Pin MS20392-1P22

50 Pin MS20392-1P32

51 Bolt MS35266-61

52 Nutplate NAS1474-A3

53 O-Ring MS29513-217

54 Rivet MS20470AD-5-X

55 Vent Line Assembly HF-S76-A-6-7 Helifab, Inc




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Table 2 (cont.)

Parts List

Notes:

(1) Determine length of fastener upon installation unless otherwise specified.

(2) Length of fasteners may be increased if necessary for proper engagement.

(3) Torque all fasteners per torque table in section 4.3 of this document.

(4) Aux tank assembly part number HF-S76-A-6-12 superceeds part number HF-S76-A-6-1. Assembly part

number HF-S76-A-6-1 can only be used with installation PN HF-S76-I-9-1. Assembly part number

HF-S76-A-6-12 can be used with installation part number HF-S76-I-9-1 or -2

Item

Number

Nomenclature Part Number Vendor /

Manufacturer 56 Clamp MS21919WH10


58 O-Ring MS29513-123

59 Shutoff Valve HF-S76-A-6-11 Helifab, Inc

60 Fitting AN20760D16


62 Washer AN960PD10L

63 Nut MS21042-3

64 Tee Fitting FBM2286 Helifab, Inc

65 Flex Hose 156005-16D-0154 Helifab, Inc

66 Coupling Half 390509-16 Helifab, Inc

67 Flex Hose 156005-10D0104 Helifab, Inc

68 Quick Disconnect Half 3755-10 Helifab, Inc

69 Vent Manifold Assembly HF-S76-A-7-1 Helifab, Inc

70 Union ANS5174D1010

71 Valve Adapter HF-S76-D-6-5 Helifab, Inc

72 Splash Guard Assembly HF-S76-A-6-2 Helifab, Inc

73 Filler Neck Assembly HF-S76-A-6-3 Helifab, Inc

74 Fuel Cap 457-370 Helifab, Inc

75 Lanyard MS27380-3

76 Cotter Pin MS24665-298

77 Washer Head Screw AN525-416R7

78 Washer AN960PD416L

79 Nut MS21042-4

80 Cap Adapter 457-3 Helifab, Inc

81 Gasket HF-S76-D-6-34 Helifab, Inc

82 Filler Neck HF-S76-D-6-7 Helifab, Inc

83 Drain Tee Assembly HF-S76-A-6-8 Helifab, Inc

84 Latch H-5000-2-040-081 Helifab, Inc

85 Nut MS35691-45

86 Straight Hose Barb Fitting AN841-6D

87 Gasket HF-S76-D-6-33 Helifab, Inc

88 Fitting AN20760D10

89 Fitting 921110 Helifab, Inc

90 Hose Tee HF-S76-D-6-15

91 Flex Hose 156005-10D0110 Helifab, Inc

92 Vent Manifold Assembly HF-S76-A-7-2

93 Vent Tubing, 3/4” ID,

1” OD

F-4040-A Tygon

94 ADEL CLAMP MS21919WDG28

95 Screw MS27039-1

96 Rivnut NAS1329A3K130

97 Hose Barb Fitting AN841-12D

98 Manifold HF-S76-D-7-4 Helifab, Inc

99 Aux Tank Assembly HF-S76-A-6-12 (SEE NOTE 4) Helifab, Inc




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Figure 2

Auxiliary Fuel Tank Assembly Removal / Installation (Applicable to -1 and -2 installations)




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Figure 3

Auxiliary Fuel Tank Assembly Removal / Installation (Applicable to -1 and -2 installations except as noted in table 2, note 4)




HF-S76-ICA-2800-0004, Rev A of 43

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Figure 4

View B (See Figure 3) (Applicable to -1 and -2 installations except as noted in table 2, note 4)

Figure 5




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View A and C (See figure 3) (Applicable to -1 and -2 installations except as noted in table 2, note 4)




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Figure 6

View D (See figure 3) (Applicable to -1 and -2 installations)




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Figure 7

Sump Valve (Applicable to -1 and -2 installations)




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Figure 8

Auxiliary Fuel Tank Assembly (Applicable to -1 installation only)




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Figure 9

Detail F (See figure 8) (Applicable to -1 and -2 installations except as noted in table 2, note 4)




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Figure 10

Detail G, Item 69 Assembly (See figure 8) (Applicable to -1 installation only)




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Figure 11

Detail H, Item 22 Assembly (See figure 2) (Applicable to -1 and -2 installations)




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Figure 12

Detail J, Item 73 Assembly (See figure 8) (Applicable to -1 and -2 installations)




HF-S76-ICA-2800-0004, Rev A of 43

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Figure 13

Auxiliary Fuel Tank Assembly (Applicable to -2 installation only)




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Figure 14

Detail K (Applicable to -2 installation only)




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6. REQUIRED PLACARDS AND DECALS

A. References: Figure 15 thru 18

Required decals

Decal part number HF-S76-D-5-1 (Reference figure 15)

Located in visible location, as close as possible to auxiliary fuel tank shutoff valve

switch.


Located on interior side of left and right hand baggage compartment doors in visible

location.


Located in visible location on left hand side of auxiliary fuel tank under fuel filler


Located in visible location on aft side of auxiliary fuel tank directly above items 14

and 15.

Figure 15

Decal PN HF-S76-D-5-1

Figure 16





HF-S76-ICA-2800-0004, Rev A of 43

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Figure 17


Figure 18


7. WEIGHT AND BALANCE

Aircraft CG must be determined using the auxiliary fuel tank and fuel weights and must be

within rotorcraft limits. When the auxiliary fuel tank is installed, a maximum of 70Lb of

baggage may be carried in the baggage compartment. Baggage tiedown locations are provided

on the aft side of the auxiliary fuel tank and all baggage must be secured in accordance with

rotorcraft flight manual.

Installation of the auxiliary fuel tank installation has the following effect on weight and balance:




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Table 3

Auxiliary Fuel Tank Installation Weights

Item Weight (lb.) ARM (in.) Moment/100 Note

Auxiliary Fuel Tank

Assembly

104.5 229 23930.5 (1)

Auxiliary Fuel Tank Provisions

(-1 Installation Only)

5.5 189 1039.5 (2)

Auxiliary Fuel Tank Provisions

(-2 Installation Only)

6.1 196 1195.6 (2)

Notes:

(1) Auxiliary fuel tank assembly includes all components mechanically secured to the tank

up to and including the hose quick release fittings. Also included is the weight of the

honeycomb spacer board installed under the auxiliary tank assembly and unusable fuel.

See section 5.1 and 5.2 for removal and reinstallation of auxiliary fuel tank assembly.

(2) The auxiliary fuel tank provisions include all other components of the installation that

are not included in the auxiliary fuel tank assembly weight. Auxiliary tank provisions

may remain installed when the auxiliary fuel tank assembly is removed.

The new empty weight and corresponding CG location must be determined and entered in

the aircraft permanent records.

Table 4

Auxiliary Fuel Tank, Useable Fuel Weights

Weight (Lb) ARM (in) Moment /100 Note

50 232.8 116

100 232.4 232

150 231.7 348

200 231.3 463

250 231.0 578

300 230.7 693

350 230.5 807

400 230.4 922

403 (JP-4) 230.3 929 (3)

415.4 (JP-8) 230.3 957 (4)

421.6 (JP-5) 230.3 971 (5)

Notes:

(1) The auxiliary fuel quantity indicator is calibrated for JP-5 (Jet-A) fuel at 6.8 pounds per

gallon under standard conditions (60°F).

(2) The useable fuel capacity of the auxiliary fuel tank is 62 gallons.

(3) Weight and moment of fuel for full auxiliary fuel tank using JP-4 (Jet B) fuel at 6.5 pounds

per gallon under standard conditions (60°F)

(4) Weight and moment of fuel for full auxiliary fuel tank using JP-8 (Jet A1) fuel at 6.7 pounds


(5) Weight and moment of fuel for full auxiliary fuel tank using JP-5 (Jet A) fuel at 6.8 pounds





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Appendix A Insert Installation Procedures

HF-S76-ICA-2800-0004, Rev A of 43

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Appendix B Wiring Diagram

ITEM QTY REQ'D PER DASH NUM. PART NUMBER NOMENCLATURE MATERIAL SPECIFICATIONSNO 01 02 03 04 05 06

1 1 HF-S76-A-6-11 SHUTOFF VALVE HELIFAB, INC.2 DELETED3 A/R M39029/5-115 SOCKET4 1 MS3416-12N BACKSHELL5 A/R M39029/4-110 PIN6 1 MS3418-12N 90 DEG BACKSHELL7 1 MS3416-14N BACKSHELL8 1 MS3417-14N BACKSHELL WITH STRAIN RELIEF9 1 LED-52-14-KB-E17H5 ANNUN SWITCH (2J1 OPEN, 3E1 CLOSED) AEROSPACE OPTICS

10 1 18-200 PLUG AEROSPACE OPTICS11 1 M39029/63-368 SOCKET 12 A/R HIX-1/8 HEAT SHRINK EDMO13 A/R 36152 RED #6 TERMINAL EDMO14 1 MS3320-5 5 AMP CIRCUIT BREAKER15 A/R 36154 RED #10 TERMINAL EDMO16 1 114-40022 FUEL TRANSMITTER AHLERS AEROSPACE, INC17 A/R M39029/32-259 SOCKET18 1 263-30008 AUX FUEL INDICATOR AHLERS AEROSPACE, INC19 2 MS3320-1 1 AMP CIRCUIT BREAKER20 1 M39029/5-115 SOCKET21 4 HML-3 SOLDER SLEEVE

AFQP1 1 D38999/26FC8SN CONNECTOR PLUGAFQJ2 1 MS3472L12-08S BULKHEAD CONNECTORAFQP2 1 MS3476L12-08P CONNECTOR PLUGAFQJ3 1 MS3472L14-18S BULKHEAD CONNECTORAFQP3 1 MS3476L14-18P CONNECTOR PLUGAFQP4 1 MS3126F10-6S CONNECTOR PLUGAFQP5 1 MS3126F10-6S CONNECTOR PLUG

22 1 MS85049/39-13N 90 DEG STRAIN RELIEF

DRAWN:ENGINEERING:CHECKED:INITIAL RELEASE DATE:STC NO:NHA:DRAWING SIZE: BSCALE: NTS1318 SMEDE HWY DRAWING NO: HF-S76-ICA-2800-0004BROUSSARD, LA 70518 FILE NO:PH(337)364-4357 FAX(337)364-4186 LATEST REV./DATE: REV A 12/30/14WWW.ARROWAVIATIONCO.COM SHEET: 41

S76 AUX FUEL TANK WIRING DIAGRAM

VENDOR/ MANUFACTURER

- PROPRIETARY NOTICE -THIS DOCUMENT AND THE INFORMATION HEREIN ARE PROPRIETARY DATA TO ARROW AVIATION AND ALL DESIGN MANUFACTURING,

REPRODUCTION, USE, PATENT RIGHTS, AND SALES RIGHTS REGARDING THE SAME ARE EXPRESSLY RESERVED. THIS DATA IS SUBMITTED UNDER A CONFIDENTIAL RELATIONSHIP FOR A SPECIFIC PURPOSE AND NEITHER THIS DOCUMENT NOR THE INFORMATION CONTAINED

HEREIN SHALL BE REPRODUCED, USED, OR DISCLOSED TO OTHERS.

INSTALLATION INSTRUCTIONS: 1. WIRE TYPE: M22759/41-XX-9, M27500/XXSDXT23 (WHERE XX DENOTES WIRE SIZE, X DENOTES # OF CONDUCTORS)2. ELECTRICAL WIRING HARNESS CLAMPING AS PER AC 43.13-1B CH 11 SEC 11.3. ELECTRICAL BONDING AND GROUNDING AS PER AC 43.13-1B CH 11 SEC 15.4. WIRE SPLICING PRACTICES AS PER AC 43.13-1B CH 11 SEC 13.5. WIRE INSULATION STRIPPING AND LACING AS PER AC 43.13-1B CH 11 SEC 12.6. WIRE INSTALLATION AND ROUTING OF WIRING HARNESSES AS PER AC 43.13-1B CH 11 SEC 8.

instructions for continued airworthiness for …the tank wiring harness contains a single point...

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