Document Number: AFS-BH407-IBF-KIT-ICA

Revision: G
Date: 18 July 2016

INSTRUCTIONS FOR CONTINUED AIRWORTHINESS

INLET BARRIER FILTER SYSTEM

for the
Bell Helicopter Textron Canada Limited
Model 407 Helicopters
FAA STC No. SR09368RC

17891 Chesterfield Airport Rd.

Chesterfield, MO 63005

COPYRIGHT© 2016
Donaldson Company, Inc.
UNPUBLISHED — ALL RIGHTS RESERVED

LIMITED and/or RESTRICTED RIGHTS NOTICE

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

The Government's rights to use, modify, reproduce, release, perform, display, or disclose these
technical data are restricted to the purpose of evaluating AFS’s design for FAA commercial
certification and airworthiness consideration only. Any reproduction of technical data or portions
thereof marked with this legend, or referring to this legend, must also reproduce the markings and
legend. Any person, other than the Government, who has been provided access to such data
must promptly notify: Aerospace Filtration Systems, Inc., Attn: Business Manager, 17891
Chesterfield Airport Rd, Chesterfield, MO 63005
The data subject to this limited/restricted rights notice is contained on all pages.
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SIGNATURES

Revision Name Signature Date

Prepared By: Jay Foster Original Signed By 12-04-03
Initial
Reviewed By: Daniel Flesher Original Signed By 12-04-03
Release
Approved By: Michael Scimone Original Signed By 12-04-03

Prepared By: Mark Johnson Original Signed By 2-14-07

A Reviewed By: Tom Newman Original Signed By 2-14-07

Approved By: Robert Stenberg Original Signed By 2-14-07

Prepared By: Gary Heyne Original Signed By 11-14-11

B Reviewed By: Roger Wallis Original Signed By 11-14-11

Approved By: Mark Johnson Original Signed By 11-14-11

Prepared By: Gary Heyne Original Signed By 8-14-12

C Reviewed By: Roger Wallis Original Signed By 8-14-12

Approved By: Mark Johnson Original Signed By 8-14-12

Prepared By: Gary Heyne Original Signed By 5-8-13

D Reviewed By: Roger Wallis Original Signed By 5-8-13

Approved By: Mark Johnson Original Signed By 5-8-13

Prepared By: Gary Heyne Original Signed By 8 Aug 13

E Reviewed By: Roger Wallis Original Signed By 8 Aug 13

Approved By: Mark Johnson Original Signed By 8 Aug 13

Prepared By: Gary Heyne Original Signed By 16 Jan 14

F Reviewed By: Roger Wallis Original Signed By 16 Jan 14

Approved By: Mark Johnson Original Signed By 16 Jan 14

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LOG OF REVISIONS
Revision No. Revision Description Release Date

IR Initial Release 12-04-03

A Reformatted document, revised sections 8.5.2 and 8.5.3 02-14-07

B Updated electrical 11-14-11

C Updated Appendix A and figure callouts 8-14-11

Updated Appendix A and figure callouts, added Appendix B for

D 5-8-13
new configurations

E Updated Appendix B callouts 8 Aug 13

F Added Appendix C (Inducer Vent Filter) 16 Jan 14

Updated Section 7.3 and Appendices A and B to support the

G 18 Jul 16
addition of Dry Media filter as an alternate to oiled media

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PROPRIETARY DATA STATEMENT

These data, excluding Chapter 4, Airworthiness Limitations, are proprietary

to Aerospace Filtration Systems, Inc. Disclosure, reproduction, or use of
these data for any purpose other than helicopter operation and/or
maintenance is forbidden without prior written authorization from
Aerospace Filtration Systems, Inc.

EFFECTIVITY

Effectivity for this ICA is for all Bell model 407 helicopters with the
Aerospace Filtration Systems, Inc. (AFS) Inlet Barrier Filter (IBF) System
installed and/or the optional (AFS) Inducer Vent Filter (IVF) System
installed.

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INSTRUCTIONS FOR CONTINUED AIRWORTHINESS

For the Aerospace Filtration Systems Engine Inlet Barrier Filter System
Installed on the Bell Helicopter Textron Canada Model 407 Helicopters

TABLE OF CONTENTS

1 INTRODUCTION .......................................................................................................................... 1
1.1 SCOPE OF THIS MANUAL ................................................................................................................ 1
1.2 USE OF THIS MANUAL ...................................................................................................................... 1
1.3 DEFINITIONS / TERMINOLOGY ....................................................................................................... 1
1.4 ACRONYMS.......................................................................................................................................... 3
1.5 WARNINGS, CAUTIONS, AND NOTES........................................................................................... 4
1.6 UNITS OF MEASURE ......................................................................................................................... 4
1.7 REFERENCE PUBLICATIONS .......................................................................................................... 4
1.8 LIST OF APPLICABLE PUBLICATIONS .......................................................................................... 4
1.9 DISTRIBUTION OF CHANGES ......................................................................................................... 4
1.10 INDICATION OF CHANGES .......................................................................................................... 5
1.11 SYSTEM DESCRIPTION AND OVERVIEW ................................................................................ 5
2 AIRWORTHINESS LIMITATIONS ................................................................................................ 8
2.1 GENERAL.............................................................................................................................................. 9
2.2 FILTER RETIREMENT LIFE .............................................................................................................. 9
2.3 LIFE LIMITED COMPONENTS .......................................................................................................... 9
3 INSPECTION REQUIREMENTS AND OVERHAUL .................................................................. 10
3.1 INSPECTION REQUIREMENTS ..................................................................................................... 10
3.1.1 GENERAL REQUIREMENTS .................................................................................................... 10
3.1.2 FILTER ASSEMBLY INSPECTION .......................................................................................... 10
3.1.3 STRUCTURAL COMPONENT INSPECTIONS ........................................................................ 10
3.1.4 SYSTEMS AND ELECTRICAL COMPONENT INSPECTIONS ............................................. 11
3.2 OVERHAUL REQUIREMENTS........................................................................................................ 11
4 ACCESS PANELS ..................................................................................................................... 12
4.1 GENERAL DESCRIPTION ............................................................................................................... 12
4.2 ACCESS FOR FILTER SERVICING ............................................................................................... 12
4.3 ACCESS FOR MAINTENANCE ....................................................................................................... 12
4.3.1 ACCESS ABOVE BYPASS FLOOR ASSEMBLY .................................................................... 12
4.3.2 ACCESS BELOW BYPASS FLOOR ASSEMBLY .................................................................... 12
5 STORAGE .................................................................................................................................. 14
5.1 STORAGE ........................................................................................................................................... 14
6 PLACARDS, DATA PLATES, AND MARKINGS ....................................................................... 15
6.1 MARKING – Part Number / PMA / Serialization ............................................................................ 15
6.2 DATA PLATE – IBF and IVF Filter Assembly ................................................................................ 15
6.3 PLACARDS / MARKINGS - Cockpit ................................................................................................ 15
7 SERVICING (IBF and Optional IVF Filter Assemblies) ........................................................... 16
7.1 AUTHORIZED MATERIALS ............................................................................................................. 16
7.2 FILTER SERVICE INTERVALS (IBF Assembly and Optional IVF Assembly).......................... 16
7.2.1 GENERAL REQUIREMENTS .................................................................................................... 16
7.2.2 PREPARED FIELD OPERATIONS ............................................................................................ 17
7.2.3 SEVERE ENVIRONMENT OPERATIONS ............................................................................... 17
7.3 FILTER ASSEMBLY SERVICING ................................................................................................... 17
7.3.1 OILED MEDIA FILTER ASSEMBLY........................................................................................ 17
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7.3.2 DRY MEDIA FILTER ASSEMBLY ........................................................................................... 21

7.4 STRUCTURAL COMPONENT SERVICING .................................................................................. 22
7.5 SYSTEMS AND ELECTRICAL SERVICING ................................................................................. 22
7.6 ENGINE WATER WASH ................................................................................................................... 23
7.7 AIRCRAFT WASHING....................................................................................................................... 23
8 TROUBLESHOOTING AND MAINTENANCE ........................................................................... 24
8.1 MAINTENANCE GENERAL.............................................................................................................. 24
8.2 COMPONENTS - GENERAL DESCRIPTION ............................................................................... 25
8.2.1 FILTER ASSY / ENGINE WASH TUBE ASSY / FILTER SEAL ............................................. 25
8.2.2 STRUCTURAL COMPONENTS ................................................................................................ 25
8.2.3 SYSTEMS AND ELECTRICAL COMPONENTS ..................................................................... 25
8.2.4 IVF FILTER ASSY ...................................................................................................................... 26
8.3 FILTER ASSY / ENGINE WASH TUBE ASSY / FILTER SEAL .................................................. 26
8.3.1 FILTER ASSY / ENGINE WASH TUBE ASSY ........................................................................ 26
8.3.2 FILTER SEAL .............................................................................................................................. 32
8.4 STRUCTURAL COMPONENTS ...................................................................................................... 33
8.4.1 BELL 407 AIR INLET COWL ASSEMBLY .............................................................................. 33
8.4.2 BYPASS FLOOR ASSEMBLY ................................................................................................... 34
8.4.3 BYPASS DOOR ........................................................................................................................... 36
8.4.4 BYPASS DOOR SEAL ................................................................................................................ 38
8.4.5 FILTER FRAME ADAPTER ....................................................................................................... 39
8.4.6 ACCESS DOOR / SEAL .............................................................................................................. 40
8.5 SYSTEMS AND ELECTRICAL COMPONENTS ........................................................................... 41
8.5.1 COCKPIT SWITCH / INDICATOR ............................................................................................ 41
8.5.2 DIFFERENTIAL PRESSURE SWITCH ..................................................................................... 43
8.5.3 FILTER MAINTENANCE AID................................................................................................... 46
8.5.4 ACTUATOR................................................................................................................................. 49
8.5.5 WIRING, WIRING HARNESS, CONNECTORS, BACKSHELLS, CIRCUIT BREAKER,
RELAY 52
8.6 FILTER ASSY / (IVF) ......................................................................................................................... 53
8.6.1 FILTER ASSY (IVF).................................................................................................................... 53
8.7 FASTENER LISTING ......................................................................................................................... 55
8.8 PROTECTIVE TREATMENT ............................................................................................................ 56
8.9 TROUBLESHOOTING GUIDE ......................................................................................................... 57
8.10 SPECIAL TOOLS / SPECIAL EQUIPMENT .............................................................................. 58
8.11 CONSUMABLE MATERIALS, SUPPLIES, AND PROTECTIVE TREATMENT
SPECIFICATIONS.......................................................................................................................................... 58

ICA APPENDIX A – PARTS FIGURES (METAL COWL) ............................................................ A-1

ICA APPENDIX B – PARTS FIGURES (COMPOSITE COWL) ................................................... B-1

ICA APPENDIX C – PARTS FIGURES (IVF) .............................................................................. C-1

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LIST OF FIGURES

Figure 1: IBF System and Access Door Installation ......................................................................... 7

Figure 2: Equipment Locations ...................................................................................................... 13
Figure 3: Example of Filter Assembly Data Plate .......................................................................... 15
Figure 4: IBF Markings ................................................................................................................... 15
Figure 5: Oiling Filter Media ........................................................................................................... 20
Figure 6: Engine Wash Tube Assembly Orientation to Filter Assembly ........................................ 27
Figure 7: Hand Seamer used to Straighten or Crimp Pleats .......................................................... 29
Figure 8: Test Equipment Setup .................................................................................................... 45
Figure 9: Test Setup with Manometer ............................................................................................ 45
Figure 10: FMA Reset .................................................................................................................... 47
Figure 11: Actuator / Bypass Door Adjustment .............................................................................. 50

LIST OF TABLES

Table 1: Inspection Intervals .......................................................................................................... 11

Table 2: Differential Pressure Switch Elevation Table ................................................................... 44
Table 3: FMA Elevation Table ........................................................................................................ 48
Table 4: Protective Treatment for Components ............................................................................. 56
Table 5: Troubleshooting Guide ..................................................................................................... 57
Table 6: Consumable Materials, Supplies and Protective Treatment Specifications ..................... 58

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1 INTRODUCTION

1.1 SCOPE OF THIS MANUAL

These Instructions for Continued Airworthiness (ICA) provide the information required to do the
maintenance and repair of the AFS Inlet Barrier Filter (IBF) system installation on the Bell
Helicopter Textron Canada Limited (BHTC) Model 407 helicopters. The ICA should be used in
conjunction with all pertinent BHTC Model 407 manuals and all publications listed in the List of
Applicable Publications (LOAP).

NOTE

Thoroughly review and become familiar with the Appendix A,

Appendix B, and Appendix C – Parts Figures section of this ICA
before performing maintenance on the IBF system.

1.2 USE OF THIS MANUAL

The instructions that are given in this manual and those that have been changed by revisions,
bulletins and/or alerts issued by Aerospace Filtration Systems, Inc. (AFS), BHTC or the
Airworthiness Directives issued by the local Aviation Authority, shall be strictly followed.

1.3 DEFINITIONS / TERMINOLOGY

Access door Allows access to the components mounted below the Bypass Floor
Assembly.

Actuator An electromechanical actuator used to open / close the bypass door.

Air induction screen Screen installed in the engine inlet on baseline configuration aircraft in
lieu of the EAPS or the IBF, to prevent engine foreign object damage.

Air induction cowling This cowling houses the major kit components including the IBF filter
assembly, adaptor frame, bypass floor assembly, associated wiring
and, the access door as shown in Figure 1.

Brownout A brownout condition is a zero visibility condition usually caused by

hovering in a dusty environment.

Bypass The bypass is an alternate air inlet used only when the main engine
air inlet through the filter becomes clogged or blocked.

Bypass door Door located in the Bypass Floor Assembly just aft of the filter that
when opened by the actuator allows unfiltered air for the engine to be
drawn from the aircraft transmission bay.

Bypass floor assembly This floor is located just aft of the filter assembly and forward of the
engine inlet/firewall that seals the bottom of the inlet plenum chamber.
Mounted on the floor are the bypass door, actuator, filter maintenance
aid, and differential pressure switch.

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Cockpit switch / indicator Combination switch/indicator that appears as a square black button
located on cockpit instrument panel within easy reach of the pilot and
labeled “IBF”. The switch is used to activate the actuator by
depressing the button once to open the bypass door and depressing it
a second time to close the bypass door. The button also serves as a
dual indicator. Normally black, the top half of the button illuminates an
amber caution “FILTER” light any time the differential pressure
reaches or exceeds a preset limit, and the bottom half displays an
amber caution “BYPASS” light when the bypass door reaches the full
open position.

Differential pressure Drop in pressure across the filter assembly, which is measured by the
differential pressure switch and the filter maintenance aid.

Filter Barrier type filter

Filter assembly Filter media supported by pleated stainless steel screen on both sides
and the filter assembly frame components around the perimeter of the
filter media.

Filter assembly frame Structure that frames, retains, and seals the outside edges of the filter
media.

Filter downstream side Clean side of the filter media (i.e. the side of the filter facing aft)

Filter media Oiled or Dry materials which allow the air to pass through with a very
low drop in pressure but traps a high percentage of the dust/dirt
particles.

Filter pleats Stainless steel screen is used to form the pleats and hold the filter
media in place

Filter upstream side Dirty side of the filter media (i.e. the side facing forward into the air
stream on which the dirt collects).

Inches of water Unit of measure used for the differential pressure measured across
the filter, as measured with a water manometer or similar apparatus.

IML covers Inner mold line covers used to block off the hole left on the inner skin
of the Air Induction Cowling when the EAPS exhaust duct is removed.

Oiling Process used to apply a uniform amount of oil to oiled filter media.

OML covers Outer mold line covers used to block off the hole left on the outer skin
of the Air Induction Cowling when the EAPS exhaust duct is removed.

On-condition Indicates that servicing of the filter is based on a Filter Maintenance

Aid (FMA) indication in the area marked in “RED”, Power Assurance
Check (PAC) results (where a failed PAC is the result of a dirty Filter
Assembly), and / or any “FILTER” light indication on the cockpit switch
/ indicator.

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Plenum chamber Space between the filter assembly and the engine inlet / firewall (fore
and aft, respectively), and between the Air Induction Cowling and
bypass floor assembly (top and bottom, respectively).

Service cycle Period starting when a filter is cleaned, oiled (if necessary) and placed
into service and ending when the filter is removed for its next
cleaning.

1.4 ACRONYMS

AFS = Aerospace Filtration Systems, Inc.

ATA = Air Transport Association of America, Inc.
BHTC = Bell Helicopter Textron Canada Limited
EAPS = Engine Air Particle Separator
FAR = Federal Aviation Regulation
FMA = Filter Maintenance Aid
FMS = Flight Manual Supplement
FOD = Foreign Object Damage
IBF = Inlet Barrier Filter
IVF = Inducer Vent Filter
ICA = Instructions for Continued Airworthiness
IML = Inner Mold Line
IP = Installation Procedures
IPB = Illustrated Parts Breakdown
LOAP = List of Applicable Publications
MGT = Measured Gas Temperature
OAT = Outside Air Temperature
OML = Outer Mold Line
PAC = Power Assurance Check
RFM = Rotorcraft Flight Manual
SAE = Society of Automotive Engineers
TCDS = Type Certificate Data Sheet
TIS = Time In Service

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1.5 WARNINGS, CAUTIONS, AND NOTES

Warning, cautions and notes are used throughout this manual to emphasize important and critical
instructions.

WARNING

IF YOU DO NOT FOLLOW THE INSTRUCTIONS THAT ARE GIVEN IN A

WARNING, PERSONAL INJURY CAN OCCUR.

CAUTION

IF YOU DO NOT FOLLOW THE INSTRUCTIONS THAT ARE GIVEN IN A

CAUTION, YOU CAN CAUSE DAMAGE TO THE HELICOPTER OR TO THE
COMPONENTS.

NOTE

A note includes supplemental data about the procedure, the practice, the
condition, etc. for the maintenance task.

1.6 UNITS OF MEASURE

U.S. Standard units of measure have been used in preparation of this manual. Typical units used
in this manual include: inches of water measuring differential pressure, inch-pounds of torque, etc.

1.7 REFERENCE PUBLICATIONS

Reserved for future use.

1.8 LIST OF APPLICABLE PUBLICATIONS

Bell Helicopter Textron

407 Series Technical Publications

FAA
FAA Advisory Circular, AC 43.13-1B, Acceptable Methods, Techniques, and Practices – Aircraft
Inspection and Repair

1.9 DISTRIBUTION OF CHANGES

Changes shall be distributed by posting them on the Publications Tab of the AFS webpage
www.donaldsonaerospace-defense.com. Each customer must register to receive access to the
webpage via a personalized log-in/password.

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NOTE

This webpage should be checked prior to the performance of any

maintenance actions on the IBF system to confirm possession of the latest
FAA approved revision. If access to the internet is not possible, contact
AFS at (636) 300-5200 for assistance.

1.10 INDICATION OF CHANGES

All changes will be complete revisions with all pages marked with the latest revision letter.

1.11 SYSTEM DESCRIPTION AND OVERVIEW

a. The Bell 407 IBF system is offered to operators in four kits: a Inlet Barrier Filter (IBF) system kit
for the Bell 407GX (AFS Kit No. 106000-101 or 106000-107), and a kit for the standard Bell 407
(AFS Kit No. 106000-103 or 106000-109). Refer to Appendix A for Kits 106000-101 and -103 and
Appendix B for Kits 106000-107 and -109. The Inducer Vent Filter is an option that is available for
all of the previously mentioned kits (106000-101, -103, -107, -109). Refer to Appendix C.

b. The IBF provides a single forward-facing barrier type filter assembly just aft of the aircraft’s
bifurcated engine air inlet system in the same location and in lieu of the Engine Air Particle
Separator (EAPS) or Air Induction Screen. The IBF installation requires no structural modifications
to the existing air inlet cowl assembly except for the installation of the access door. The access
panel is added on the right side of the air inlet cowl assembly to allow the operator quick access
to the filter for servicing during extensive desert type operations. The IBF provides aircraft
owner/operators a high performance engine air filtration option that significantly improves filtration
efficiency over the EAPS. The IBF will increase the life of the engine through a dramatic reduction
in erosion resulting from the substantial increase in filtration efficiency without degrading engine
performance. The AFS IBF system provides dust separation efficiencies exceeding 99% for
Society of Automotive Engineers (SAE) AC Coarse and AC Fine dust as defined in specification
SAE J726, Air Cleaner Test Code.

c. The IBF system does not interfere with any of the commercial items installed in the Bell 407
production aircraft. The IBF is a complete system in which safety, functionality and serviceability
were major considerations in the design process. The major kit components include the filter
assembly, cockpit switch/indicator, engine wash tube assembly, bypass floor assembly (which
includes the bypass door assembly, actuator, differential pressure switch, and filter maintenance
aid), wiring harness, and an access panel. Figure 1, located at the end of this chapter, provides an
exploded view of the major kit components with the exception of the cockpit switch/indicator and
wiring harness. For a detailed illustration of all kit components, see the Appendix A or Appendix B-
Parts Figures.

d. The major components making up the bypass system include the bypass door, actuator, wiring
harness, cockpit switch/indicator, and differential pressure switch. The cockpit switch/indicator
actually serves three functions: (1) a push button switch to energize the actuator to open/close the
bypass door, (2) the top half of the button illuminates the word “FILTER” in amber any time the
preset differential pressure limit is reached or exceeded, and (3) the bottom half illuminates the
word “BYPASS” in amber when the bypass door reaches the full open position. The cockpit switch /
indicator is also wired into the cockpit panel press-to-test system, and the aircraft lighting dimmer
system.

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e. The IBF system provides a means of monitoring the condition of the filter both in-flight and on the
ground, and a bypass capability should flow through the filter become restricted. In-flight, a
differential pressure switch continuously measures the drop in pressure across the filter, and
triggers the cockpit switch/indicator displaying “FILTER” cautioning the pilot any time the differential
pressure across the filter reaches or exceeds a preset limit. At this point, the IBF is operating at
approximately the same inlet differential pressure normally experienced with the EAPS installed.
The electromechanically actuated bypass door permits unfiltered air to enter the engine inlet
plenum chamber should the filter media become obstructed, and can be opened or closed as
required. On the ground, a Filter Maintenance Aid, mounted under the bypass floor assembly,
displays the maximum differential pressure across the filter reached during the last flight. It is
accessible only on the ground, providing the pilot or mechanic the ability to visually gauge the
current condition of the filter. This gives the mechanic the ability to forecast the timing of the next
service cycle. The Filter Maintenance Aid can be reset by depressing the yellow button marked
“PUSH TO RESET” located on the end of the Filter Maintenance Aid.

f. The design of the bypass system allows the ground crew to cycle the bypass door with power on
the aircraft. The switch can be depressed to actuate the bypass door open, and then depressed
again to actuate it closed. Full functional verification of the bypass system including all
electromechanical components and the filter maintenance aid is possible during routine
maintenance (see Chapter 8).

g. Removal of the filter assembly for servicing is easily achieved by removal of seven fasteners,
which are accessible through the engine air inlets, and then removal of the filter assembly through
the access door on the right side of the Air Induction Cowling.

h. The nozzle on the engine water wash tube assembly provides the equivalent engine wash
capability as currently provided by similar nozzles mounted on the EAPS and Air Induction Screen
installations.

i. The optional IVF is a single filter assembly designed to protect the engine inducer bleed air
(inducer vent) compressor. The IVF is located on the top LH side of the engine cowl aft of the
firewall but forward of the engine exhaust. The IVF installation is dependent on the installation of
the AFS Inlet Barrier Filter (IBF) STC installation (STC No. SR09368RC). The IVF will follow the
same maintenance schedule and filter cleaning cycle as the approved IBF maintenance schedule.

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IVF

IBF

IBF

Figure 1: IBF & IVF System and Access Door Installation

ITEM NO. ITEM NAME

1 Assy – Frame, Adapter, Filter
2 Installation – Barrier Filter
3 Bypass Floor Assembly
4 Assy – Floor Closeout Angle L/H
5 Engine Wash Tube Assembly
6 Assy – Floor Closeout Angle R/H
7 Screw
8 Assy – Cover, Exhaust, EAPS Scavenge, L/H IML
9 Cover Exhaust EAPS Scavenge, L/H OML
10 Screw
11 Modification, Cowling, Inlet (Access Door Mod)
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2.1 GENERAL

The Airworthiness Limitations for the AFS Inlet Barrier Filtration system (IBF) and/or Inducer
Vent Filter as installed on Bell Helicopter Textron Canada Limited model 407 helicopters are
FAA approved.

NOTE

The retirement life given or the failure to give a retirement life to a

component does not constitute a warranty of any kind. The only warranty
applicable to any component is the warranty included in the Purchase
Agreement for the helicopter or the component.

2.2 FILTER RETIREMENT LIFE

After fifteen (15) cleaning cycles, the filter must be removed from service at the next
servicing interval. The filter data tag is scribed after each cleaning cycle (see Paragraph
6.2). When all numerals (1-15) on the data tag have been scribed out, the filter shall be
removed from service at the next service interval. No further cleaning cycles are authorized.

2.3 LIFE LIMITED COMPONENTS

The only life limited component features are the number of cleanings of the filter assembly.
See Paragraph 2.2.

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3 INSPECTION REQUIREMENTS AND OVERHAUL

3.1 INSPECTION REQUIREMENTS

3.1.1 GENERAL REQUIREMENTS

a. Inspection of the IBF system (and where applicable, the IVF system) consists of, in general
terms, inspection of the filter assembly, inspection of the structural components, inspection of
electrical and system components, and a special inspection at three specified points based on
hours after initial installation. The components of the system are divided, generally as a scope of
work, into Filter Assembly / Seal, Structural Components, and Systems and Electrical components
as is done throughout the manual.

b. Refer to the Appendix A – For Bell 407 and 407GX with metal inlet cowling parts figures for
component illustrations that provide supplemental information relative to proper assembly
configuration, orientation, and locations for all components to be inspected per Chapter 3 and
Table 1. Refer to Appendix A for Kit No. 106000-101 and Kit No. 106000-103.

c. Refer to the Appendix B – For Bell 407 and 407GX with composite inlet cowling parts figures for
component illustrations that provide supplemental information relative to proper assembly
configuration, orientation, and locations for all components to be inspected per Chapter 3 and
Table 1. Refer to Appendix B for Kit No. 106000-107 and Kit No. 106000-109.

d. Refer to the Appendix C – For the IVF system that is offered as an option for Bell 407 and
407GX with metal or composite cowls with the IBF system installed.

e. Table 1 gives a recommended inspection schedule for the components of the system. The
Trouble-Shooting Guide, Table 5 found near the end of Chapter 8, also gives additional guidance
when performing inspections and encountering trouble with the system. Chapter 8 also provides
specific inspection guidance and removal/installation procedures for each component and is
structured in the same three major groups as discussed above.

3.1.2 FILTER ASSEMBLY INSPECTION

a. The following inspections pertain to the IBF/IVF assembly and associated components, which
include the filter assembly (i.e. filter frame and filter media), engine wash tube assembly, and all
associated seals/fasteners.

b. ON-CONDITION UP TO TIS LIMIT: Any FMA indication in the “RED”, “FILTER” light indication
of the IBF cockpit switch / indicator or failed PAC requires a conditional inspection in accordance
with Table 1.

c. VISUAL: All filter assembly components (including engine wash tube assembly, seals and
fasteners) are to be visually inspected at every annual in accordance with Table 1 checking for
the following: filter media for tears, punctures, uneven or damaged pleats; seals for tears/damage;
frame components for corrosion, cracks, distortions near holes, and check for missing or
damaged fasteners.

3.1.3 STRUCTURAL COMPONENT INSPECTIONS

VISUAL: All structural IBF/IVF components are to be inspected in accordance with Table 1 every
100 hours and annual. These components include the following: Bell 407 Air Induction Cowling
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(OEM Equipment), Access Door, Adapter Frame Assembly, Bypass Floor Assembly, OML / IML
Covers, Close out Angles, IVF doubler, and IVF Plenum.

3.1.4 SYSTEMS AND ELECTRICAL COMPONENT INSPECTIONS

a. VISUAL: The systems and electrical components are to be visually inspected in accordance
with Table 1 every 100 hours and annual. These components include the following: Wiring, Wiring
Harness, Connectors, Backshells, Circuit Breaker, Cockpit Switch / Indicator, Differential Pressure
Switch, Filter Maintenance Aid, and Actuator.

b. FUNCTION CHECK: Certain systems and electrical components are also to be function
checked in accordance with Table 1 every annual. These components include the following:
Circuit Breaker, Cockpit Switch / Indicator, Differential Pressure Switch, Filter Maintenance Aid,
and Actuator.

Table 1: Inspection Intervals

Inspection Intervals
Inspection
Components Inspection Scheduled
Type Time In Service Notes
100 Hrs. Annual
2, 3, 4, 5,
Conditional 1. On-Condition up to TIS Limit 300 hrs / 1 yr
7
Filter Assembly as
1, 2, 4,
defined in para. 3-1.2. Scheduled 2. Visual X
6,7

Structural Scheduled 1. Visual X X 1, 2, 4, 6

Components as
defined in para. 3-1.3.

Systems and Scheduled 1. Visual X X 1, 2, 4, 6

Electrical Scheduled 2. Function Check X 1, 2, 4, 5
Components as
defined in para. 3-1.4.

Notes.
1. Refer to Chapter 8 for specific inspection requirements and functional check procedures.
2. Refer to Chapter 4 (Figure 3) for access information.
3. FILTER light or failed PAC. This inspection is required any time a FILTER light indication or failed PAC is reported
by the pilot.
4. Reference Appendix A or Appendix B - Parts Figures.
5. Reference Trouble-Shooting Guide, Table 5 of this manual.
6. Perform a visual inspection checking for deformation, buckling, corrosion, cracks, dents, tears, or other signs of
damage and repair in accordance with the procedures in Chapter 8.
7. The maximum filter service interval between cleanings under any conditions is 300 flight hours or 1 year TIS,
whichever comes first. Up to the TIS limit, the inspection of the Filter Assembly is “On-Condition” based on an FMA
indication in the “RED”, any “FILTER” light indication on the Cockpit Switch / Indicator, and / or upon a failed PAC
(where the failed PAC is the result of a dirty Filter Assembly).

3.2 OVERHAUL REQUIREMENTS

There are no overhaul intervals or requirements applicable to this product at this time.

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4 ACCESS PANELS

4.1 GENERAL DESCRIPTION

This chapter addresses how to access the IBF and IVF system installations for servicing or
maintenance.

4.2 ACCESS FOR FILTER SERVICING

Access for removal/installation of the IBF filter assembly for filter servicing requires removal of the
access door (Figure 2, Item B) when AFS IBF Kit is installed. See Chapter 8 for filter assembly
removal/installation procedures and Chapter 7 for filter servicing procedures.

There are no access doors for the IVF assembly. The IVF is mounted on the upper forward left
hand side of the engine cowl. Four quarter turn fasteners and four screws secure the IVF
assembly to the engine cowl. Access to the bottom of the plenum that attaches to the inducer
bleed port on the compressor, is through the engine cowl left hand side panel (Figure 2, Item D).

4.3 ACCESS FOR MAINTENANCE

4.3.1 ACCESS ABOVE BYPASS FLOOR ASSEMBLY

Access for maintenance of the system components located above the bypass floor assembly (i.e.
filter assembly, engine water wash tube assembly, filter frame adapter, bypass door, etc.) requires
removal of the access door (Figure 2, Item B). See Chapter 8 for component removal/installation
procedures, inspection, troubleshooting guide, adjustment/calibration/repair procedures.

4.3.2 ACCESS BELOW BYPASS FLOOR ASSEMBLY

Access for maintenance of components located below the bypass floor assembly (i.e. filter
maintenance aid, pressure differential switch, actuator, wiring harness/connectors) requires
opening the RH access door (Figure 2, Item C) and the LH access door (located in the same
location on the opposite side of the aircraft).

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A
B

D
C

Figure 2: Equipment Locations

Locations of (A) Air Induction Cowling, (B) IBF Access Door,
(C) RH Access Door, and (D) RH Side Panel
[Photo (above) & Line drawing (below)]

FORWARD
A
B

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5 STORAGE

5.1 STORAGE

CAUTION

NEVER INSTALL AN OILED FILTER ASSEMBLY AND/OR OPERATE AN

AIRCRAFT WITH AN OILED FILTER INSTALLED WHERE THE OILED
FILTER MEDIA HAS NOT BEEN PROPERLY OILED.

Long-term storage has no effect on filter assembly reliability if stored unoiled (dry) in a cool, dry
location to discourage possible fungus growth. After storage, the only maintenance to be
performed on the filter before installation on the aircraft shall be oiling (if necessary) of the filter
media. Refer to filter servicing Paragraph 7.3.

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6 PLACARDS, DATA PLATES, AND MARKINGS

6.1 MARKING – Part Number / PMA / Serialization

The IBF system is marked on the floor assembly to contain the top level part number, the serial
number of the system, and the FAA PMA markings, if applicable.

6.2 DATA PLATE – IBF and IVF Filter Assembly

After the filter assembly has been serviced an “X” is marked through one of the unmarked boxes
on the serviceability tag. When the last unmarked box is crossed through the filter assembly will
have to be replaced at the next servicing. See Chapter 7 for servicing procedures.

Figure 3: Example of Filter Assembly Data Plate (IBF Data Plate Shown)

6.3 PLACARDS / MARKINGS - Cockpit

a. The area on the instrument panel just above or below the cockpit switch / indicator is marked
“IBF”. The actual cockpit switch / indicator is internally lit to display amber cautions marked
“FILTER” and “BYPASS”. See Figure 4(A) for markings and Figure 26 for location.

(A) (B)

Figure 4: IBF Markings

(A) Cockpit Switch/Indicator & (B) Circuit Breaker

b. The IBF circuit breaker in the overhead console is marked ”IBF”. See Figure 4(B) for markings
and Figure 25 for location.

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7 SERVICING (IBF and Optional IVF Filter Assemblies)

7.1 AUTHORIZED MATERIALS

Service AFS Filter Assembly with only AFS filter oil (For the IBF:14 oz squeeze bottle – AFS P/N
100100-140; for the IVF: 1.2 oz squeeze bottle – AFS P/N 100100-012, and gallon container –
AFS P/N 100101-000), AFS Air Filter Cleaner (1 gallon container – AFS P/N 100201-000, 5 gallon
container – AFS P/N 100205-000), Zok 27, or other AFS authorized substitutes.

NOTE

Refer to Chapter 8 for removal, inspection, repair and installation of filter

assembly. Upon satisfactory inspection and any required maintenance of
the filter assembly proceed with the rest of the servicing instructions for
the filter assembly.

7.2 FILTER SERVICE INTERVALS (IBF Assembly and Optional IVF Assembly)

The filter service interval is based on the specific aircraft operating environment. The filter service
intervals section is broken up in three parts: general requirements pertaining to all operations,
specific recommendations for operations on prepared fields, and for operations in severe
environments.

7.2.1 GENERAL REQUIREMENTS

NOTE

The maximum filter service interval between cleanings (IBF & IVF) under
any conditions is 300 flight hours or 1 year TIS, whichever comes first. Up
to the TIS limit, the filter is considered an “on-condition” item.

NOTE

The FMA is an aid to help maintenance personnel and pilots to ascertain

the condition of the filter at any point in time or to trend the accumulation
of dirt on the Filter Assembly over a period of time.

a. Up to the 300 hour / 1 year TIS limit, the “on condition” requirement for servicing the Filter
Assembly is based on a FMA indication, a “FILTER” light indication on the Cockpit Switch /
Indicator, or upon a failed PAC (where the failed PAC is the result of a dirty Filter Assembly).

b. Any “FILTER” indication, where the pressure sensor and indicating system are working
properly, requires servicing of the filter assembly. See filter servicing Paragraph 7.3.

c. The gradual increase in differential pressure across the IBF filter assembly causes an increase
in the measured gas temperature (MGT) required to produce a specified torque as measured
during the PAC. A failed PAC due to an increase in differential pressure across the filter is cause
for servicing of the filter assembly. See filter servicing Paragraph 7.3.

d. Any FMA indication in the area marked in “RED” requires servicing of the filter assembly. See
filter servicing Paragraph 7.3.
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e. At any time prior to a “FILTER” indication on the cockpit switch / indicator, an FMA indication in
the “RED”, or a failed PAC, when maintenance or flight personnel see a trend on the FMA that
would warrant servicing of the filter due to operational considerations, such as when the aircraft
will be operating in a remote or off-site location without the ability to readily service the filter, the
filter may be serviced, or replaced. See filter servicing Paragraph 7.3.

f. The maximum number of service cycles for the filter assembly (i.e., cleaning) is limited to 15 for
each filter assembly. The filter assembly includes a data plate that must be scribed to track filter
service cycles in accordance with Paragraph 6.2.

7.2.2 PREPARED FIELD OPERATIONS

a. During typical operations in and out of prepared airfields and landing sites, the IBF filter
assembly will not require frequent servicing. AFS recommends that the filter maintenance aid
(FMA) be checked as part of the preflight inspection. This should be done to gauge the rate of
engine performance degradation due to changes in engine inlet differential pressure as the filters
accumulate dirt in operations considered “prepared fields” operations.

b. Ensure all filter servicing requirements defined in Paragraph 7.2.1 are followed. Refer to
Paragraph 7.3 for servicing of the filter assembly.

7.2.3 SEVERE ENVIRONMENT OPERATIONS

a. When operating in an environment of high sand and dust levels, frequent servicing of the filter
assembly may be required based on the time exposure and severity of the environment. Any
operations in an environment that can result in “brownout” conditions should therefore be
minimized or avoided to the maximum extent possible within the constraints of the operation.
AFS recommends that the filter maintenance aid (FMA) be checked as part of the preflight
inspection.

b. Ensure all filter servicing requirements defined in Paragraph 7.2.1 are followed. Refer to
Paragraph 7.3 for servicing of the filter assembly.

c. In severe operating environments, the filters may be soaked in cleaner prior to cleaning.

7.3 FILTER ASSEMBLY SERVICING

The filter assembly servicing section defines the procedures for pre-cleaning, cleaning, drying,
and, where required, oiling the filter media in the filter assembly.

7.3.1 OILED MEDIA FILTER ASSEMBLY

NOTE

Instructions in this section are intended for the oiled filter media, Donaldson
Company, Inc. part number 106201-103.

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7.3.1.1 OILED MEDIA FILTER PRE-CLEANING

a. Servicing of the filter assembly is determined by the inspection requirements found in Chapter
3 of this document.

b. Prior to any cleaning operation gently brush the dirty side of the filter with a soft bristle brush
similar to a soft paintbrush. Remove as much debris as practical from the filter before
proceeding to the cleaning procedure.

7.3.1.2 OILED FILTER CLEANING

CAUTION

DO NOT CLEAN AFS FILTER ASSEMLBIES WITH GASOLINE, SOLVENTS, PARTS

CLEANERS, STRONG DETERGENTS, OR CAUSTIC CLEANING SOLUTIONS.

CAUTION

DO NOT STEAM CLEAN OR USE HIGH-PRESSURE WASHERS TO CLEAN THE AFS

FILTER ASSEMBLY.

CAUTION

ANY OF THESE PROCESSES WILL DAMAGE FILTER MEDIA AND/OR THE FILTER
FRAMES.

CAUTION

USE ONLY AFS CLEANER OR AN AFS APPROVED SUBSTITUTE.

a. Spray Air Filter Cleaner liberally onto the entire filter media (both sides) until the filter media is
thoroughly soaked. If procured in bulk, transfer a smaller quantity to a spray bottle. A spray
bottle provides a more uniform distribution of the cleaning agent.

b. Let the cleaner soak into the contaminants and filter media for 10 minutes. In severe
environmental conditions (high dirt/debris) the filter may be soaked in cleaner.

c. Rinse the filter with low-pressure water. Use water out of a faucet or hose (without nozzle).
Rinse in the opposite the direction of airflow, i.e., from the clean side to the dirty side. Arrange
the filter so the pleats are vertical, and begin to rinse in a gradual side-to-side motion starting at
the top and working downward. Adjust the pace to correspond with the cleanliness of the water
runoff. As long as the runoff is filled with debris and oil, do not proceed downward.

d. Upon completion, adjust the filter to clean from the dirty side to the clean side, pleats still
vertical.

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e. Repeat the rinsing procedure once again, until there is no visible debris on the surface and the
runoff water is relatively clean.

f. When finished, flip the filter once again and repeat the rinse from clean side to dirty side.

g. Finally, rotate the filter from top to bottom, and perform the final rinse until the runoff water is
free of all debris and oil.

7.3.1.3 OILED FILTER ASSEMBLY DRYING

CAUTION

DO NOT USE COMPRESSED AIR TO DRY THE FILTER ASSEMBLY. IT MAY

DAMAGE THE FILTER MEDIA.

CAUTION

DO NOT USE HEAT FROM ANY SOURCE TO DRY THE AFS FILTER ASSEMBLY.
HEAT MAY SHRINK THE FILTER MEDIA AND MAY DAMAGE THE CORING
MATERIAL WITHIN THE FILTER FRAMES.

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

b. Ensure dirt or debris does not enter or contact the Filter Assembly while drying.

c. After the Filter Assembly dries, mark the service cycle on data plate in accordance with the
Paragraph 6.2.

7.3.1.4 OILED FILTER ASSEMBLY OILING

CAUTION

NEVER PUT AN AFS OILED MEDIA FILTER ASSEMBLY IN SERVICE WITHOUT

OILING IT.

CAUTION

USE ONLY AFS FILTER OIL OR AN AFS APPROVED SUBSTITUTE.

NOTE

A squeeze bottle capable of accurately measuring out fourteen (14) fluid ounces
should be used when applying the oil to the filter as directed below.

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a. The filter will not function properly if other types of oil are used. AFS Air Filter Oil is a unique
blend of mineral and organic oil base stocks and special polymers that form a very efficient “tack
barrier.” Red dye is added to show areas of oil application. Do not use transmission fluid, any
kind of motor oil, or diesel fuel to oil the AFS filter. Do not use “WD-40,” “LPS,” or any other type
of lightweight spray lubricants to oil the AFS filter. Any of those products will damage the filter or
degrade its filtering ability. A squeeze bottle allows for the controlled application of a specific
amount of oil to the filter (See Figure 5).

b. Apply approximately ¾ of the oil that is to be applied to the clean, dried Filter Assembly.
Gently squeeze a small stream of oil along the entire length of each pleat peak, then flip the filter
over and repeat this on the backside. Apply sparingly to ensure coverage of the entire filter.

c. Let the Filter Assembly sit for 20 minutes as the oil “wicks” into the surrounding filter media.
Apply the remaining filter oil to any areas that are still white and to complete the application of
the 14 fluid ounces (IBF) or 1.2 fluid ounces (IVF) from the squeeze bottle.

Figure 5: Oiling Filter Media

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7.3.2 DRY MEDIA FILTER ASSEMBLY

NOTE

Instructions in this section are intended for the dry filter media, Donaldson
Company, Inc. part number 106205-101.

CAUTION

DO NOT APPLY OIL TO DONALDSON DRY MEDIA FILTER ASSEMBLY

7.3.2.1 FILTER PRE-CLEANING

a. Servicing of the filter assembly is determined by the inspection requirements found in Chapter
3 of this document.

b. Prior to any cleaning operation gently brush the dirty side of the filter with a soft bristle brush
similar to a soft paintbrush. Remove as much debris as practical from the filter before
proceeding to the cleaning procedure.

7.3.2.2 FILTER CLEANING

CAUTION

DO NOT CLEAN THE FILTER ASSEMBLY WITH GASOLINE, SOLVENTS, PARTS

CLEANERS, DETERGENTS, OR CAUSTIC CLEANING SOLUTIONS.

CAUTION

DO NOT STEAM CLEAN OR USE HIGH-PRESSURE WASHERS TO CLEAN THE

FILTER ASSEMBLY.

CAUTION

DO NOT USE COMPRESSED AIR TO CLEAN THIS FILTER ASSEMBLY.

a. Rinse the clean side of the filter with low-pressure water (40 psi MAXIMUM).

i. Position filter so that the clean side (opposite airflow) is facing the faucet or hose
with pleats vertical

ii. With no nozzle or restriction on the faucet or hose, rinse in a gradual side-to-side
motion starting at the top and working downward. Adjusting the pace to
correspond with the cleanliness of the water runoff. Keeping the hose at least 3-6
inches from the filter.

iii. As long as the runoff is filled with debris, do not proceed downward.

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b. Rinse the dirty side of the filter with low-pressure water (40 psi MAXIMUM).

i. Position Filter so that the dirty side (direction or airflow) is facing the faucet or
hose with pleats vertical

ii. With no nozzle or restriction on the faucet or hose, rinse in a gradual side-to-side
motion starting at the top and working downward. Adjusting the pace to
correspond with the cleanliness of the water runoff.

iii. As long as the runoff is filled with debris, do not proceed downward.

c. Repeat steps a and b until runoff water is free or all debris

d. Rotate the filter from top to bottom, and perform a final rinse until the runoff water is free
of all debris.

7.3.2.3 FILTER DRYING

CAUTION

DO NOT USE COMPRESSED AIR TO DRY THE FILTER ASSEMBLY. IT MAY

DAMAGE THE FILTER MEDIA.

CAUTION

DO NOT USE HEAT FROM ANY SOURCE TO DRY THE AFS FILTER ASSEMBLY.
HEAT MAY SHRINK THE FILTER MEDIA AND MAY DAMAGE THE CORING
MATERIAL WITHIN THE FILTER FRAMES.

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

b. Ensure dirt or debris does not enter or contact the Filter Assembly while drying.

c. After the Filter Assembly dries, mark the service cycle on data plate in accordance with
the Paragraph 6.2.

d. Once dry, the filter may be returned to service.

7.4 STRUCTURAL COMPONENT SERVICING

There are no structural components requiring periodic servicing. See Chapter 6 for inspection
requirements and Chapter 8 for maintenance requirements.

7.5 SYSTEMS AND ELECTRICAL SERVICING

There are no system and electrical components requiring periodic servicing. See Chapter 6 for
inspection requirements and Chapter 8 for maintenance requirements.

NOTE

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The Filter Maintenance Aid is designed to hold the highest differential

pressure across the filter assembly reached during the last flight, and
should be reset after servicing of the filter assembly by depressing the
yellow button marked “PUSH TO RESET” located on the end of the filter
maintenance aid (See Figure 10).

7.6 ENGINE WATER WASH

NOTE

It is not necessary to remove the IBF or the optional IVF filter prior to
conducting an engine wash.

It is recommended the engine water wash frequency be in accordance with the current Rolls-
Royce requirements for operation in a standard environment, desert environment or salt-water
environment.

7.7 AIRCRAFT WASHING

During aircraft washing, the IBF and IVF systems, including the filter assembly, should be
protected or removed to avoid damaging the filter media with high pressure spray nozzles or to
prevent solvents rinsing away the oil in the filter media.

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8 TROUBLESHOOTING AND MAINTENANCE

8.1 MAINTENANCE GENERAL

CAUTION

THOROUGHLY REVIEW AND BECOME FAMILIAR WITH THE APPENDIX A,

APPENDIX B, AND APPENDIX C - PARTS FIGURES BEFORE PERFORMING
MAINTENANCE ON THE IBF OR IVF SYSTEM.

NOTE

Except where otherwise indicated, all torque values shall be in accordance

with Chapter 7 of FAA Advisory Circular AC 43.13-1B.

a. The components of the system are divided, generally as a scope of work, into Filter Assembly /
Seal / Engine Wash Tube, Structural Components, and Systems and Electrical components
throughout the manual. Table 1 gives a recommended inspection schedule for the components of
the system. The troubleshooting guide in Table 5 provides additional guidance for performing
inspections when encountering trouble with the system.

b. The maintenance chapter is organized by removal, inspection, troubleshooting, adjustment,

calibration and / or repair, and installation for the major components noted above, as applicable to
the particular component. For some components a functional check is included. Not all
components will require adjustment, or calibration, or have any approved functional check or
repair procedures. Contact AFS for possible repairs when not listed in this manual. In some
cases defective components will require replacement.

c. In general, visually inspect all structural components for oversized or elongated holes,
deformation, cracks, corrosion, missing fasteners or components, fretting, galling, etc. Any
component exhibiting these conditions requires repair or replacement.

d. In general, visually inspect fasteners for damaged or missing threads, in both the bolt or screw
and the nut or nut plate. If a self-locking fastener can be fully threaded by hand, replace the self-
locking fastener.

e. In general, visually inspect all electrical connections for security, corrosion, arcing, breakdown
of insulation, and overheating. Repair or replace components exhibiting defects. Inspect and
repair components per Bell Helicopter technical manuals or AC 43.13-1, Chapter 11.

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8.2 COMPONENTS - GENERAL DESCRIPTION

8.2.1 FILTER ASSY / ENGINE WASH TUBE ASSY / FILTER SEAL

(Refer to Appendix A, Figures 1, 13 or Appendix B, Figures 1, 13)

a. Filter Assembly - The Filter Assembly is composed of the filter media (stainless steel mesh
covering cotton gauze) bonded into the aluminum alloy filter frame assembly.

b. Engine Wash Tube Assembly - The engine wash tube is composed of formed aluminum tube,
aluminum spray nozzle and associated “AN” fittings and attachment hardware.

c. Seal - The Seal is expanded foam.

8.2.2 STRUCTURAL COMPONENTS

(Refer to Appendix A, Figures 1, 2, 4 or Appendix B, Figures 1, 2, 4)

a. Bell 407 Air Inlet Cowl Assembly (OEM Equipment) - The Bell 407 Air Inlet Cowl Assembly is
part of the original equipment manufacturer supplied for the Bell 407 helicopter. For description
see Bell 407 series technical manuals.

b. Cowling Access Door - The cowling access door is formed and heat treated aluminum alloy
with appropriate mounting holes providing access to the filter assembly and additional access
inside the Air Induction Cowling. Chemical conversion coating and epoxy primer provide an
organic protective coating.

c. Filter Frame Adapter - The Filter Frame Adapter is sheet stock aluminum alloy providing
structural support for the mounting of the Filter Assembly and the Bypass Floor Assembly.
Chemical conversion coating and epoxy primer provide an organic protective coating.

d. Bypass Floor Assembly / Bypass Door / Seal - The Bypass Floor Assembly consists of a
machined aluminum alloy floor, a machined aluminum alloy actuator bracket, a military standard
(MS) aluminum alloy hinge and steel pin, machined aluminum alloy bypass door, stainless steel
mesh screen, aluminum sheet metal mounting brackets and provisions for mounting the
Differential Pressure Switch and Filter Maintenance Aid, and associated MS hardware and other
standard aircraft hardware for mounting and installation provisions.

8.2.3 SYSTEMS AND ELECTRICAL COMPONENTS

(Refer to Appendix A, Figures 7, 9, 10, 22, 23, 24 or Appendix B, Figures 7, 9, 10, 22, 23, 24)

a. Cockpit Switch / Indicator - The cockpit switch / indicator provides both a switching function and
indicating information to the pilot. The construction details of the component do not warrant field
maintenance. Repair or servicing of this component requires the component to be sent back to
AFS for disposition.

b. Differential Pressure Switch - The Differential Pressure Switch provides a signal to the Cockpit
Switch / Indicator for annunciation of the “FILTER” light to signal the differential pressure across
the Filter Assembly has reached a preset value. The construction details of the component do not
warrant field maintenance. Repair of this component requires the component to be sent back to
AFS for disposition.

c. Filter Maintenance Aid - The Filter Maintenance Aid provides an indication to maintenance
personnel as to the trend of the differential pressure across the Filter Assembly. The construction
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details of the component do not warrant field maintenance. Repair of this component requires it
to be sent back to AFS for disposition, or replaced. The FMA is an aid to help maintenance
personnel and pilots to ascertain the current condition or trend in accumulation of dirt on the Filter
Assembly.

d. Actuator - The Actuator provides mechanical actuation of the Bypass Door should the pilot
depress the cockpit switch / indicator. The construction details of the component do not warrant
field maintenance. Repair of this component requires the component to be sent back to AFS for
disposition or replaced.

e. Wiring, Wiring Harness, Connectors, Backshells, Circuit Breaker – The wiring and wiring
harness utilizes wire per Military Specification Mil-W-22759/41. The gauge and marking
identification is specified on the wiring diagram. The connectors, backshells, and circuit breaker
are military specification components, or where applicable, vendor designed components. The
construction details of these components (other than wiring) do not warrant field maintenance.

8.2.4 IVF FILTER ASSY

(Refer to Appendix C, Figures 1 and 2)

a. Filter Assembly - The Filter Assembly is composed of the filter media (stainless steel mesh
covering cotton gauze) bonded into the aluminum alloy filter frame assembly.

b. Plenum - The plenum is flexible component that connects to the bleed air inducer port and
allows a filtered air chamber to lead into the port.

8.3 FILTER ASSY / ENGINE WASH TUBE ASSY / FILTER SEAL

(Refer to Figure 6 and Appendix A, Figures 1, 4, 13 or Appendix B, Figures 1, 4, 13)

8.3.1 FILTER ASSY / ENGINE WASH TUBE ASSY

8.3.1.1 REMOVAL – FILTER ASSY / ENGINE WASH TUBE

a. Remove the Access Door by removing the fasteners that retain the Access Door. Remove the
Access Door (See Appendix A, Figure 1, 17 or Appendix B, Figure 1, 17).

b. Loosen the Engine Wash Tube from the fitting on the Bypass Floor Assembly (Figure 6).

c. Remove the hardware attaching the Filter Assembly to the Filter Frame Adapter (See Appendix
A, Figure 1 or Appendix B, Figure 1). Remove the fasteners from the air intake side of the
cowling.

d. Use a plastic scraper to gently break any seal between the Filter Assembly and the Seal itself.
The Filter Assembly must be carefully removed so as not to damage the Filter Seal. Remove the
Filter Assembly through the slot exposed when the Access Door is removed.

e. Remove the hardware attaching the Engine Wash Tube to the Filter Assembly (See Figure 6
and Appendix A, Figure 13 or Appendix A, Figure 13).

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Revision: G Proprietary Information

(1) Filter Assy

(2) Engine Wash Tube

Assy Clamp Locations

(3) Engine Wash

Tube Assy Fitting

(4) Engine Wash Tube Nozzle

Figure 6: Engine Wash Tube Assembly Orientation to Filter Assembly

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8.3.1.2 INSPECTION – FILTER ASSY / ENGINE WASH TUBE

NOTE

After servicing of the Filter Assembly or at any time the Filter Assembly is
inspected, the pleats may require straightening or crimping. If you cannot
see the bottom of the pleat, the airflow will be restricted and/or the pleats
will adhere to one another when dirt loaded. Any restriction to the flow
through the pleats will result in increased differential pressure and
reduction in dirt loading capacity. In order to insure ideal flow
characteristics through the filter media, the pleats must be straightened or
crimped with a hand seamer.

a. Visually inspect the pleats on both sides of the filter. If you cannot see the bottom of the pleat,
when sighting the length, or depth of the pleat, straightening of the pleat is required. Refer to
“Adjustment” for pleat straightening procedures.

b. If this inspection is in response to a FILTER light indication or failed PAC, perform

troubleshooting per Table 5. If troubleshooting indicates a dirty filter, service filter per paragraph
7.3.

c. Inspect the Filter Assembly frame for cracks, gouges, distortion or deformation, corrosion, loose
or missing fasteners, and missing or deteriorated protective coating. Refer to “Repair” for criteria /
disposition.

d. Inspect the Filter Seal. Refer to “Filter Seal” procedures.

e. Inspect the engine wash tube for cracks, kinks, leaks, corrosion, deformation and security.
Refer to “Repair” for criteria / disposition.

8.3.1.3 TROUBLESHOOTING – FILTER ASSY / ENGINE WASH TUBE

See Table 5 for troubleshooting guide.

8.3.1.4 ADJUSTMENT - FILTER

CAUTION

HAND SEAMER MUST BE LIMITED TO A MAXIMUM JAW DEPTH OF 1 1/4

INCH. A DEEPER JAW DEPTH CAN RESULT IN DEFORMATION OR
DAMAGE TO THE ADJOINING PLEATS.

CAUTION

DO NOT OVER CRIMP AND CRUSH PLEAT; CARE MUST BE TAKEN TO

SQUEEZE THE PLEATS WITHOUT DAMAGING THE PLEATED SCREEN.
THE RADIUS AT THE TOP OF THE PLEAT SHOULD REMAIN INTACT, NOT
CREASED.

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a. If you cannot see the bottom of a pleat, use a hand seamer (See Special Tools / Special
Equipment, Paragraph 8.9.a.) to crimp the pleat and to straighten the pleat. Sight down the length
and depth of the pleat to confirm the pleat is straightened (See Figure 7).

b. Once one side is crimped, flip the filter over and crimp the other side as required following the
guidance above. Use caution not to crush the pleats when straightening them. Use care to
maintain the original radius, as much as possible, at the top of the pleat.

Figure 7: Hand Seamer used to Straighten or Crimp Pleats

8.3.1.5 CALIBRATION

Not applicable.

8.3.1.6 REPAIR - FILTER MEDIA, GENERAL

WARNING

ADHESIVE VAPORS (SUCH AS MAY BE CONTAINED IN SEALING

MATERIAL AMS 3276 OR MIL-S- 8802), MAY CAUSE IRRITATION OF EYES,
NOSE, AND RESPIRATORY SYSTEM. EYE AND SKIN CONTACT WITH
MATERIAL MAY CAUSE IRRITATION. IF INGESTED, MAY CAUSE GASTRIC
DISTRESS. FLUSH EYES WITH WATER FOR 15 MINUTES. WASH SKIN
WITH SOAP AND WATER. IF INHALED, MOVE TO FRESH AIR. IN ALL
CASES GET IMMEDIATE MEDICAL ATTENTION. WORK IN A WELL-
VENTILATED AREA. WEAR GLOVES AND SAFETY GLASSES.
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NOTE

Repair filter media damage after cleaning, do not repair a filter the has
already been oiled

8.3.1.7 REPAIR - FILTER MEDIA, SMALL RUPTURES, TEARS, OR HOLES

a. In the event of damage to the filter media, ruptures in the filter media may be repaired. Small
ruptures defined as smaller than .500 inch diameter or length can be sealed shut without
degradation of performance to the Filter Assembly. The up to 8 small ruptures in the filter media
may be repaired on a single filter, but no repair may be within 1” of an adjacent repair.

b. Prior to performing any of these repairs, the filter material must be cleaned of contamination
and oil. Refer to Chapter 7 for cleaning of the Filter Assembly. Perform the repair to a cleaned
and dry Filter Assembly. Each time the entire Filter Assembly is cleaned, repaired, and oiled
(where necessary), a mark shall be scribed on the Filter Assembly data plate in accordance with
Paragraph 6.2 indicating a cleaning cycle was performed.

c. Trim ruptures, tears, or holes in the filter media up to .500 inches in length or diameter to
remove loose material (wire or cotton gauze).

d. Seal the affected area using two-part Sealant, AMS 3276 or MIL-S-8802. Allow the Sealant to
bleed into the filter material and cure. Follow manufacturer’s directions for proper mixing,
application, and curing of the two-part Sealant.

e. Proceed with oiling (if necessary) the filter. Refer to Chapter 7.

8.3.1.8 REPAIR - FILTER MEDIA, LARGE RUPTURES, TEARS, OR HOLES

Larger ruptures exceeding .500 inch in size are not repairable in the field. Contact AFS for
disposition and possible repair procedures, or discard the Filter Assembly.

8.3.1.9 REPAIR – FILTER ASSY/ ENGINE WASH TUBE, OTHER DAMAGE

a. The repair procedures defined above are for damage resulting in ruptures, tears, or holes in the
filter media. The following is for field repairable damage to the Filter Assembly frame. Field
repairable damage to the Filter Assembly frame is limited to blending of scratches and gouges,
and / or the re-application of protective coatings. See Table 4 for application of protective
coatings.

b. Any damage to the filter frames such as cracking requires the Filter Assembly to be returned to
AFS for evaluation and disposition, or replacement. Any damage to the filter frames such as
warping or distortion (to the extent that the Filter Frame, when installed against the Filter Frame
Adapter and torqued, do not permit the Filter Assembly to sit flush against the Adapter Frame)
requires the Filter Assembly be returned to AFS for evaluation and disposition, or be replaced.

c. Any damage to the Engine Wash Tube Assembly that restricts the flow, allows leakage, or
impacts security is cause for replacement.

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8.3.1.10 INSTALLATION – FILTER ASSY/ ENGINE WASH TUBE

(Aircraft NOT MODIFIED with Access Door)

CAUTION

REMOVE COVER FROM THE ENGINE INLET PRIOR TO INSTALLING THE

AIR INLET COWL ASSEMBLY.

CAUTION

OVER TIGHTENING OF THE FASTENERS MAY RESULT IN THE FASTENER

BEING DAMAGED.
.
a. Position the two clamps on the Engine Wash Tube Assembly to the bottom side of each of the
two support brackets located on two of the three combs on the aft side of the Filter Assembly.
(See Figure 6 for orientation).

b. Install clamps using the associated hardware (See Figure 6, and Appendix A, Figure 13 or
Appendix B, Figure 13).

c. Prior to installation of the Filter Assembly (See Figure 6), the Seal on the Filter Frame Adapter
(See Appendix A, Figure 4 or Appendix B, Figure 4) shall be visually inspected for security and
damage. The Filter Assembly must be carefully positioned against the Filter Frame Adapter.
Ensure the Filter Assembly seats properly (not cocked, i.e. fits flush) against the Filter Frame
Adapter.

d. Install fasteners. Tighten all fasteners to 20-25 inch-pounds.

e. Connect Engine Wash Tube Assembly Fitting to Bypass Floor Assembly (See Figure 6).

f. Install Air Inlet Cowl Assembly. (Refer to Chapter 53 of BHT-407-MM-5)

g. Install Bypass Floor Fasteners to Firewall.

h. Connect electrical Bypass System connector at Bypass System Disconnect. (Refer to

Appendix A, Figure 29 or Appendix B, Figure 29)

8.3.1.11 INSTALLATION – FILTER/ ENGINE WASH TUBE

(Aircraft MODIFIED with Access Door)

CAUTION

REMOVE COVER FROM THE ENGINE INLET PRIOR TO INSTALLING THE

ACCESS DOOR.

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CAUTION

OVER TIGHTENING OF THE FASTENERS MAY RESULT IN THE FASTENER

BEING DAMAGED.

a. Position the two clamps on the Engine Wash Tube Assembly to the bottom side of each of the
two support brackets located on two of the three combs on the aft side of the Filter Assembly.
(See Figure 7 for orientation and Appendix A, Figure 1 or Appendix B, Figure 1, for orientation).

b. Install clamps using the associated hardware (See Appendix A, Figure 13 or Appendix B,
Figure 13).

c. Prior to installation of the Filter Assembly, the Seal shall be visually inspected for security and
damage. The Filter Assembly must be carefully inserted through the access door and positioned
against the mounting frame. Ensure the Filter Assembly seats properly (not cocked, i.e. fits flush)
against the Filter Frame Adapter.

d. Install fasteners from the air intake side of the cowling. Tighten all fasteners to 20-25 inch-
pounds.

e. Connect Engine Wash Tube to Bypass Floor Assembly.

f. Install Access Door.

8.3.2 FILTER SEAL

8.3.2.1 REMOVAL

a. Gain access to the Filter Frame Adapter Assembly by removing the Filter Assembly. Refer to
Paragraphs 4.3.1 and 8.3.1.

b. Carefully remove the Seal by peeling it away from the Filter Frame Adapter (See Appendix A,
Figure 1 or Appendix B, Figure 1). Use a plastic scraper or other suitable tool that is softer than
aluminum to peel the Seal from the Filter Frame Adapter. Discard the removed Seal.

8.3.2.2 INSPECTION

Inspect the Filter Seal for any tears, nicks, gouges, missing pieces or a permanent set or
flattening of the Seal. If the Seal exhibits any of these conditions, repair or replace the Seal.

8.3.2.3 REPAIR
WARNING

ADHESIVE VAPORS (IN SEALANT SUCH AS RTV 736) MAY CAUSE

IRRITATION OF EYES, NOSE, AND RESPIRATORY SYSTEM. EYE AND
SKIN CONTACT WITH MATERIAL MAY CAUSE IRRITATION. IF INGESTED,
MAY CAUSE GASTRIC DISTRESS. FLUSH EYES WITH WATER FOR 15
MINUTES. WASH SKIN WITH SOAP AND WATER. IF INHALED, MOVE TO
FRESH AIR. IN ALL CASES GET IMMEDIATE MEDICAL ATTENTION. WORK
IN A WELL-VENTILATED AREA. WEAR GLOVES AND SAFETY GLASSES.
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a. Small tears, nicks, or gouges in the Seal may be repaired using RTV 736 Sealant. Use a
wooden tongue depressor, cotton swab, or similar tool to dab a small amount of Sealant on the
damage to repair tears, nicks, or gouges in the Seal. Smooth over Sealant to create a smooth
flush repair similar to the original Seal cross section. Allow to dry before re-installing filter. If the
repair does not allow the Filter Assembly from sealing to the Adapter replace the Seal.

b. If the Seal exhibits extensive tears, deep nicks or gouges, or missing pieces that would prevent
the filter from properly sealing, replace the Seal.

8.3.2.4 INSTALLATION

a. Gain access to the Filter Seal. Refer to Filter Assembly removal and Filter Seal removal.

b. To install the Seal, apply RTV 736 adhesive to the Filter Frame Adapter. Locate and apply the
Seal on Filter Frame Adapter and press in place.

8.4 STRUCTURAL COMPONENTS

8.4.1 BELL 407 AIR INLET COWL ASSEMBLY

(Refer to Figure 2, Appendix A, Figures 1, 2, 29 or Appendix B, Figures 1, 2, 29)

8.4.1.1 REMOVAL

a. Disconnect electrical Bypass System Connector (Refer to Appendix A, Figure 29 or Appendix

B, Figure 29)

b. Remove fasteners from Bypass Floor Assembly attaching to engine firewall.

c. Remove Air Induction Cowling (See Figure 2, Item A and refer to Bell Helicopter Maintenance
Manuals).

8.4.1.2 INSPECTION

a. The AFS IBF interfaces the Air Induction Cowling at the Filter Assembly Adapter Frame,
Bypass Floor Assembly, Access Door, and if applicable IML / OML covers. See Appendix A,
Figures 1, 2 or Appendix B, Figures 1, 2. At these locations inspect for chafing or fretting,
elongation of fastener holes, damage to nut plates and fasteners, corrosion, cracking, and
deformation.

b. Inspection for the above conditions and any other conditions that may be applicable are defined
in the Bell Helicopter 407 technical manuals.

8.4.1.3 TROUBLESHOOTING

Not applicable.

8.4.1.4 ADJUSTMENT

Not applicable.

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8.4.1.5 CALIBRATION

Not applicable

8.4.1.6 REPAIR

For repairs see Bell Helicopter 407 technical manuals.

8.4.1.7 INSTALLATION

a. Install Bell 407 Air Induction Cowling (See Figure 2, Item A and refer to Maintenance Manuals
as applicable).

b. Install hardware in the Bypass Floor Assembly to the Firewall.

c. Connect Bypass System electrical disconnect.

8.4.2 BYPASS FLOOR ASSEMBLY

(Refer to Appendix A, Figure 1, 2, 8, 13, 29 or Appendix B, Figure 1, 2, 8, 13, 29)

8.4.2.1 REMOVAL

a. Disconnect the wiring harness from the Bypass System Disconnect (Refer to Appendix
A, Figure 29 or Appendix B, Figure 29)

b. Remove the hardware attaching the Bypass Floor Assembly to the Firewall from the Engine
side of the Firewall.

c. Gain access to the Bypass Floor by removing the Bell 407 Air Induction Cowling (See Figure 2,
Item A and refer to Maintenance Manual as applicable).

d. Disconnect the Engine Wash Tube (Appendix A, Figure 13 or Appendix B, Figure 13) from the
adapter on the Bypass Floor Assembly (Appendix A, Figure 8 or Appendix B, Figure 8).

e. Remove the Filter Assembly (Appendix A, Figure 1 or Appendix B, Figure 1) with the Engine
Wash Tube attached.

f. Remove the hardware attaching the Bypass Floor Assembly to the Filter Frame Adapter
(Appendix A, Figure 2 or Appendix B, Figure 2).

g. Remove the hardware attaching the Floor Closeout Angles to the Bell 407 Air Induction
Cowling (Appendix A, Figure 2 or Appendix B, Figure 2).

h. Remove the Bypass Floor Assembly (Appendix A, Figure 1 or Appendix B, Figure 1).

8.4.2.2 INSPECTION

a. Cracking. Visually inspect the Bypass Floor Assembly and related parts for cracking using 10x
magnification at the corners, radiuses, and transitions in part thickness. Any fretting of faying
surfaces, such as those at a crack may emit a black or grey dust or soot like material indicative of
a crack. Inspect suspect areas carefully using the 10x magnification. Refer to adjustment /
calibration / repair for disposition of cracks in the Bypass Floor Assembly or parts.
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b. Reserved.

c. Protective Coatings. Visually inspect the Bypass Floor Assembly and related parts for missing,
damaged, or “scratched through” protective coatings. Re-apply protective coatings per Table 4 of
this chapter.

d. Corrosion. Visually inspect the Bypass Floor Assembly and related parts for corrosion in
accordance with AC 43.13-1, Chapter 6 and Table 4.

e. Missing, damaged or loose associated components. Visually inspect the Bypass Floor
Assembly for missing damaged or loose components.

8.4.2.3 TROUBLESHOOTING

Not applicable.

8.4.2.4 CALIBRATION / ADJUSTMENT

Not applicable.

8.4.2.5 REPAIR

a. Cracks. No un-repaired cracks are allowed in the Bypass Floor Assembly. Contact AFS for
disposition and possible repairs.

b. Warping or distortion. Contact AFS for disposition and possible repairs.

c. Protective Coatings. Re-apply protective coatings per Table 4 of this chapter.

d. Corrosion. Treat corrosion in accordance with AC 43.13-1, Chapter 6 and Table 4.

e. Missing, damaged or loose associated components. Replace missing or damaged

components.
Secure loose components.

8.4.2.6 INSTALLATION

a. Position the Bypass Floor Assembly (See Appendix A, Figure 1 or Appendix B, Figure 1) to the
Bell 407 Air Induction Cowling (See Figure 2, Item A).

b. Install the hardware attaching the Bypass Floor Assembly to the Filter Frame Adapter (See
Appendix A, Figure 2 or Appendix B, Figure 2).

c. Install the hardware attaching the Floor Closeout Angles to the Bell 407Air Induction Cowling
(See Appendix A, Figure 2 or Appendix B, Figure 2).

d. Install the Filter Assembly (See Appendix A, Figure 1 or Appendix B, Figure 1) with the Engine
Wash Tube attached.

e. Connect the Engine Wash Tube (See Appendix A, Figure 13 or Appendix B, Figure 13) to the
adapter on the Bypass Floor Assembly (See Appendix A, Figure 8 or Appendix B, Figure 8).
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f. Install the Bell 407 Air Induction Cowling (See Figure 2, Item A and refer to Maintenance
Manual as applicable).

g. Install the hardware attaching the Bypass Floor Assembly to the Firewall from the Engine side
of the Firewall.

h. Connect the wiring harness to the Bypass System Disconnect (Refer to Appendix A, Figure 29)

8.4.3 BYPASS DOOR

(Ref. Appendix A, Figures 1, 6, 8, 9, 10, 14 or Appendix B, Figures 1, 6, 8, 9, 10, 14)

8.4.3.1 REMOVAL

a. Gain access to the Bypass Floor Assembly (See Paragraph 4.3).

b. Remove the Bypass Floor Assembly from the Bell 407 Air Induction Cowling (Refer to
Paragraph 8.4.2.1).

c. Remove the bolt attaching the Actuator to the Bypass Door Clevis Plate (See Figure 11 and
Appendix A, Figure 10 or Appendix B, Figure 10).

d. Carefully open the flattened end of one end of the hinge (See Appendix A, Figure 14).

e. Remove the hinge pin (See Appendix A, Figure 10 or Appendix B, Figure 10).

f. Remove the Bypass Door (See Appendix A, Figure 10 or Appendix B, Figure 10).

8.4.3.2 INSPECTION

a. Cracking. Visually inspect the Bypass Door and related parts for cracking using 10x
magnification at the corners, radiuses, and transitions in part thickness. Any fretting of faying
surfaces, such as those at a crack may emit a black or grey dust or soot like material indicative of
a crack. Inspect suspect areas carefully using the 10x magnification. No cracks are allowed in
the Bypass Door. If cracks are found, Bypass Door must be replaced.

b. Warping or distortion. Visually inspect the Bypass Door and related parts for warping or
distortion. Any warping or distortion that keeps the Bypass Door from creating a seal to the
Bypass Floor requires disposition instructions from AFS or replacement of the door.

c. Protective Coatings. Visually inspect the Bypass Door and related parts for missing, damaged,
or “scratched through” protective coatings. Re-apply protective coatings per Table 4 of this
chapter.

d. Corrosion. Visually inspect the Bypass Door and related parts for corrosion in accordance with
AC 43.13-1, Chapter 6, and Table 4.

e. Missing, damaged or loose associated components. Visually inspect for missing, damaged, or
loose components.

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8.4.3.3 TROUBLESHOOTING

See Table 5.

8.4.3.4 ADJUSTMENT

Refer to Actuator / Bypass Door Adjustment (See paragraph 8.5.4.7).

8.4.3.5 CALIBRATION

Not applicable.

8.4.3.6 REPAIR

a. Cracks. No cracks are allowed in the Bypass Door. Cracks are not repairable. If cracks exist,
Bypass Door must be replaced.

b. Warping or distortion. Visually inspect the Bypass Door for warping or distortion. With the
Bypass Door in the closed position the Bypass Door Seal should be uniformly compressed. If
there are gaps refer to Bypass Door Adjustment. After adjustments are performed if the gaps still
exist, the door is warped or distorted beyond limit. Replace Bypass Door.

c. Protective Coatings. Visually inspect the Bypass Door for missing, damaged, or “scratched
through” protective coatings. Re-apply protective coatings per Table 4 of this chapter.

d. Corrosion. Treat corrosion in accordance with AC 43.13-1B, Chapter 6 and Table 4.

e. Missing, damaged or loose associated components. Replace missing or damaged

components.
Secure loose components.

8.4.3.7 INSTALLATION

a. Locate the Bypass Door to the Bypass Floor Assembly (See Appendix A, Figure 10 or
Appendix B, Figure 10).

b. Install the Bypass Door to the Bypass Floor Assembly by installing the hinge pin (See Appendix
A, Figure 10 or Appendix B, Figure 10). Crimp both ends of hinge to prevent pin from backing out
(See Appendix A, Figure 14 or Appendix B, Figure 14).

c. Temporarily install the Bolt attaching the Actuator to the Bypass Door Clevis Plate (See Figure
11, and Appendix A, Figure 10 or Appendix B, Figure 10).

d. Perform functional check per Actuator / Bypass Door Adjustment procedures (Refer to
Paragraph 8.5.4.4).

CAUTION

TO PREVENT INTERNAL DAMAGE TO THE ACTUATOR, HOLD THE ROD

END WHILE LOOSENING, TIGHTENING, OR APPLYING TORQUE TO THE
JAMB NUT.
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CAUTION

INSTALL THE ACTUATOR BOLT TO THE BYPASS DOOR CLEVIS PLATE IN

THE CORRECT ORIENTATION. FAILURE TO CORRECTLY INSTALL THE
BOLT WILL RESULT IN DAMAGE TO THE BYPASS FLOOR AND
ACTUATOR.

e. Upon completion of Actuator / Bypass Door Adjustment procedures confirm the permanent
installation of hardware securing the Actuator rod end to the Bypass Door Clevis Plate (See
Figure 11).

8.4.4 BYPASS DOOR SEAL

(Ref. Appendix A, Figures 10, 12 or Appendix B, Figures 10, 12)

8.4.4.1 REMOVAL

a. Remove Bypass Floor Assembly from the Air Induction Cowling (Refer to Paragraph 8.4.2.1).

b. Remove Bypass Door (Refer to Paragraph 8.4.3.1).

c. Remove the Bypass Door Seal retainer (See Appendix A, Figure 12 or Appendix B, Figure 12)
by carefully drilling out the MS20470AD4 rivets. Carefully peel away Seal retainer. The retainer
is to be reused, do not discard.

d. Remove the damaged Seal (See Appendix A, Figure 12 or Appendix B, Figure 12) by peeling it
away from the door. Scrape all sealant and Seal pieces from Bypass Door.

8.4.4.2 INSPECTION

a. Inspect the Bypass Door Seal for proper compression upon closing of the Bypass Door. The
Seal should be compressed approximately 50% from its non-compressed cross section. Adjust
Bypass Door to attain correct seal compression.

b. Inspect the Bypass Door Seal for any nicks, gouges, missing pieces or a permanent set or
flattening of the Seal. If the Seal exhibits any of these conditions that would prevent the door from
properly sealing, replace the Seal.

8.4.4.3 TROUBLESHOOTING

See Table 5 for trouble shooting guidance.

8.4.4.4 ADJUSTMENT / CALIBRATION / REPAIR

Perform adjustment to attain proper seal compression per instructions for Actuator / Bypass Door
Adjustment.

8.4.4.5 INSTALLATION

a. Gain access to the Bypass Door with old Bypass Door Seal removed (Refer to Paragraph
8.4.3.1).
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b. Prior to installing Seal Retainer, bond Bypass Door Seal in place on the Bypass Door using
RTV-736 (See Appendix A, Figure 12 or Appendix B, Figure 12).

c. Install Seal Retainer and install rivets.

d. Install Bypass Door.

8.4.5 FILTER FRAME ADAPTER

(Refer to Appendix A, Figures 1, 4 or Appendix B, Figures 1, 4)

8.4.5.1 REMOVAL

a. Break the sealant (AMS-3276) from the Filter Frame Adapter to the air inlet cowl stiffener
(Refer to Appendix A, Figures 1, 4 or Appendix B, Figures 1, 4).

b. Remove the hardware attaching the Filter Frame Adapter to the Bypass Floor Assembly.

c. Drill out rivets used to secure the Filter Frame Adapter to the Air Induction Cowling stiffener.

d. Remove the Filter Frame Adapter from the Air Induction Cowling.

8.4.5.2 INSPECTION

a. Cracking. Visually inspect the Filter Frame Adapter for cracking using 10x magnification at the
corners, radiuses, and transitions in part thickness. Any fretting of faying surfaces, such as those
at a crack may emit a black or grey dust or soot like material indicative of a crack. Inspect
suspect areas carefully using the 10x magnification. Refer to adjustment / calibration / repair for
disposition of cracks in the Filter Frame Adapter assembly.

b. Warping or distortion. Visually inspect the Filter Frame Adapter for distortion. Any warping or
distortion causing the Filter Assembly not to seal requires disposition instructions from AFS, or
replacement of the component.

c. Protective Coatings. Visually inspect the Filter Frame Adapter for missing, damaged, or
“scratched through” protective coatings. Re-apply protective coatings per Table 4.

d. Corrosion. Visually inspect the Filter Frame Adapter and related parts for corrosion in
accordance with AC 43.13-1, Chapter 6, and Table 4.

e. Missing, damaged or loose associated components. Visually inspect for missing, damaged, or
loose components.

8.4.5.3 TROUBLESHOOTING

Not applicable.

8.4.5.4 ADJUSTMENT / CALIBRATION / REPAIR

a. Cracks. No crack repair is allowed in the Filter Frame Adapter without disposition from AFS.

b. Warping or distortion. Contact AFS for disposition and possible repair, or replace component.
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c. Protective Coatings. Visually inspect the Filter Frame Adapter for missing, damaged, or
“scratched through” protective coatings. Re-apply protective coatings Table 4 of this chapter.

d. Corrosion. Treat corrosion in accordance with AC 43.13-1, Chapter 6, and Table 4.

e. Missing, damaged or loose associated components. Replace missing, or damaged

components. Secure loose components.

8.4.5.5 INSTALLATION

a. Locate the Filter Frame Adapter to the Air Induction Cowling stiffener and to the Bypass Floor
Assembly. Secure the Filter Frame Adapter to the Bypass Floor Assembly with the nine (9) AN3
bolts and washers. Seal the Filter Frame Adapter to the Bell 407 Air Induction Cowling stiffener
with AMS-3276 sealant Table 6 (Refer to Appendix A, Figures 1, 4 or Appendix B, Figures 1, 4).

b. Secure the Filter Frame Adapter to the Bell 407 Air Induction Cowling stiffener using twenty
(20) NAS1097AD4-5 rivets.

8.4.6 ACCESS DOOR / SEAL

(Refer to Appendix A, Figures 17, 21 or Appendix B, Figures 17, 21)

8.4.6.1 REMOVAL

a. Remove the fasteners that attach the Access Door to the Air Induction Cowling (Refer to
Appendix A, Figures 17, 21 or Appendix B, Figures 17, 21).

b. Remove the Access Door.

c. To remove the seal, peel away from the Air Induction Cowling. Use care not to scratch the Air
Induction Cowling.

8.4.6.2 INSPECTION

a. Cracking. Visually inspect the Access Door for cracking. Any fretting of faying surfaces, such
as those at a crack may emit a black or grey dust or soot like material indicative of a crack.
Inspect suspect areas carefully using the 10x magnification. Inspect areas around fasteners
carefully. No cracking is allowed.

b. Warping or distortion. Visually inspect the Access Door for distortion. Warping or distortion will
be evident by bowing or springing of components when removed from their installed position.
The Access Door should fit the engine inlet door flush with no gaps. Refer to adjustment /
calibration / repair for adjustment and repair of the Access Door.

c. Protective Coatings. Visually inspect the Access Door for missing, damaged, or “scratched
through” protective coatings.

d. Corrosion. Visually inspect the Access Door for corrosion in accordance with AC 43.13-1,
Chapter 6, and Table 4.

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e. Inspect the Seal for adhesion to the Air Induction Cowling and tears. No more than .400 inch
long tears can be repaired. Tears greater than .400 inch require replacement of the seal.

8.4.6.3 TROUBLESHOOTING / ADJUSTMENT / CALIBRATION

Not applicable.

8.4.6.4 REPAIR

a. Cracks. No cracks are allowed in the Access Door.

b. Warping or distortion. Carefully attempt to straighten or re-align distorted or warped Access

Doors to fit the contour of the Air Induction Cowling. If the Access Door will not lay flush with the
Air Induction Cowling after attempting to straighten, replace the Access Door.

c. Protective Coatings. Visually inspect the Access Door for missing, damaged, or “scratched
through” protective coatings. Re-apply protective coatings per Table 4 of this chapter.

d. Corrosion. Treat corrosion in accordance with AC 43.13-1, Chapter 6, and Table 4.

e. Repair torn seal using RTV 736, Table 6. Apply a thin layer between the seal and the Air
Induction Cowling.

8.4.6.5 INSTALLATION

a. Clean the Air Induction Cowling where the Seal will be installed. Peel the backing away from
the Access Door Seal. Install the Seal to the Air Induction Cowling centering the Seal over the
opening in the Fairing (Refer to Appendix A, Figures 17, 21 or Appendix B, Figures 17, 21).

b. Locate the Access Door to the Air Induction Cowling.

c. Install the fasteners that attach the Access Door to the Air Induction Cowling.

8.5 SYSTEMS AND ELECTRICAL COMPONENTS

8.5.1 COCKPIT SWITCH / INDICATOR

(Refer to Appendix A, Figures 22, 23, 26 or Appendix B, Figures 22, 23, 26)

8.5.1.1 REMOVAL

a. Gain access to the back of the instrument panel (Refer to Appendix A, Figures 22, 23, 26 or
Appendix B, Figures 22, 23, 26).

b. Remove connector at back of Cockpit Switch / Indicator.

c. Remove Cockpit Switch / Indicator cover.

d. Turn lug ¼ turn counter clockwise to unlock Cockpit Switch / Indicator from panel.

e. Slide Cockpit Switch / Indicator out of panel.

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f. Tag and secure wiring.

8.5.1.2 INSPECTION

a. Inspect Cockpit Switch / Indicator for proper functioning. Refer to Paragraphs 8.5.1.5 and
8.5.1.6, and to Table 5 for troubleshooting.

b. Inspect Cockpit Switch / Indicator for security, damage, overheating, corrosion, or distortion.
Replace defective component or contact AFS for disposition.

8.5.1.3 TROUBLESHOOTING

See Table 5 for troubleshooting guide.

8.5.1.4 ADJUSTMENT / CALIBRATION / REPAIR

Not applicable. Contact AFS for disposition of defective component or replace.

8.5.1.5 FUNCTION CHECK – “BYPASS” INDICATION

CAUTION

THIS PROCEDURE INTRODUCES THE POSSIBILITY OF ENGINE FOD.

a. Verify the Bypass Door is closed and aircraft electric power is ON.

b. Depress Cockpit Switch / Indicator to open the Bypass Door.

c. The word “BYPASS” should illuminate on the lower part of the Cockpit Switch / Indicator
segment when the door reaches the full open position.

d. Verify the Bypass Door is open.

e. Depress the Cockpit Switch / Indicator again to close the Bypass Door.

f. The word “BYPASS” should extinguish on the lower part of the Cockpit Switch / Indicator
segment.

g. Verify the Bypass Door is closed and if no longer needed, that aircraft electric power is OFF.

8.5.1.6 FUNCTION CHECK – “FILTER” INDICATION

a. Perform Differential Pressure Switch function check.. Refer to Paragraphs 8.5.2.5

b. Verify Cockpit Switch / Indicator “FILTER” amber light illuminates.

8.5.1.7 INSTALLATION

a. Slide Cockpit Switch / Indicator into panel opening in correct orientation (Refer to Appendix A,
Figures 22, 23 and 26).
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b. Open switch cover. Turn lug ¼ turn clockwise to lock Cockpit Switch / Indicator into panel.

c. Attach connector at rear of Cockpit Switch / Indicator.

d. Perform Cockpit Switch / Indicator Function Check.

8.5.2 DIFFERENTIAL PRESSURE SWITCH

(Refer to Figures 8 and 9, Appendix A, Figures 9, 22, 23, 29 or Appendix B, Figures 9, 22,
23, 29)

8.5.2.1 REMOVAL

a. Gain access to the area below the Bypass Floor Assembly (Refer to paragraph 4.3.2).

b. Remove hoses, fittings, and attaching hardware from the Differential Pressure Switch (See
Appendix A, Figure 9 or Appendix B, Figure 9).

c. Disconnect and secure connector (See Appendix A, Figure 6 or Appendix B, Figure 6).

e. Remove Differential Pressure Switch.

8.5.2.2 INSPECTION

Inspect for general serviceability, damage, corrosion, and missing components. Inspect the
attaching hardware for security.

8.5.2.3 TROUBLESHOOTING

See Table 5 for troubleshooting guidance.

8.5.2.4 ADJUSTMENT / CALIBRATION / REPAIR

The construction details of the component do not warrant field maintenance. Repair of this
component requires the component to be sent back to AFS for disposition.

8.5.2.5 FUNCTION CHECK

CAUTION

THIS PROCEDURE INTRODUCES THE POSSIBILITY OF ENGINE FOD.

CAUTION

IMPROPER USE OF THE TEST EQUIPMENT COULD RESULT IN DAMAGE

TO THE SWITCH CALIBRATION.

CAUTION

IMPROPER USE OF THE TEST EQUIPMENT COULD RESULT IN DAMAGE

TO THE SWITCH.
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CAUTION

PULLING AN ALTITUDE OF GREATER THAN 1880 FEET ABOVE FIELD

ELEVATION WILL DAMAGE THE DIFFERENTIAL PRESSURE SWITCH.

a. Gain access to the top side of the Bypass Floor Assembly (Refer to paragraph 4.3.1).

b. Connect the low pressure calibrator or altimeter test set to the plenum side of the DP switch by
slipping a piece of 3/16 inch ID vinyl tubing over the end of the differential pressure switch static
port. Ensure that the fit between the tube and the static port is tight, i.e. no leakage. (Ref. Figure 8
and 9)

c. Ensuring that aircraft electrical power is ON, operate the test set to an indicated altitude above
the field elevation and gradually increase altitude or if using a low pressure calibrator gradually
increase the differential pressure. The differential pressure switch should actuate and send a
signal to the Cockpit Indicator illuminating the IBF “FILTER” light within the following range:

Test Station Elevation (ft)

Test Method 0 2000 4000 6000 8000 10000
Low Pressure Calibrator
9.0 ± 0.9
(inches of H2O)
Altimeter Test Set
(ft above test station 620 ±60 ft 660 ±60 ft 700 ±70 ft 740 ±70 ft 790 ±80 ft 840 ±80 ft
elevation)

Table 2: Differential Pressure Switch Elevation Table

d. If the Cockpit Switch / Indicator does not illuminate, pull IBF circuit breaker. Run the altimeter
test set up to top of the range, check for continuity across the terminals of the Differential
Pressure Switch. If continuity is present, the Differential Pressure Switch function is acceptable
and the rest of the circuit is suspect. Upon completion of testing, ensure that aircraft electrical
power is OFF. Refer to Table 5.

WARNING

Applying a vacuum greater than 221 in-H2O (8 psi) may result in damaging
the DP switch.

e. This will functionally check both the differential pressure switch and the “FILTER” portion of the
Cockpit Switch / Indicator.

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DP Switch
or FMA

Altimeter or
Manometer

Handheld
Reservoir Vacuum
Pump

Figure 8: Test Equipment Setup

Figure 9: Test Setup with Manometer

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8.5.2.6 INSTALLATION

a. Gain access to the area below the Bypass Floor Assembly (Refer to paragraph 4.3.2)

b. Place Differential Pressure Switch in position (Refer to Appendix A, Figure 9 or Appendix B,

Figure 9).

c. Attach hoses, fittings, and attaching hardware.

d. Connect and secure connector (See Appendix A, Figures 6, 29 or Appendix B, Figures 6, 29).

e. Perform Function Check of Differential Pressure Switch (Refer to paragraph 8.5.2.5).

8.5.3 FILTER MAINTENANCE AID

(Refer to Figure 10 and Appendix A, Figures 8, 15 or Appendix B, Figures 8, 15)

8.5.3.1 REMOVAL

a. Gain access to the area below the Bypass Floor Assembly (Refer to paragraph 4.3.2)

b. Disconnect Tube Assembly from Filter Maintenance Aid (Appendix A, Figures 8, 15 or

Appendix B, Figures 8, 15).

c. Remove hardware and Mount Frame from Filter Maintenance Aid.

d. Remove Filter Maintenance Aid.

8.5.3.2 INSPECTION

a. Inspect the Filter Maintenance Aid and associated mounting for discoloration affecting
readability, cracks, deformation, missing or damaged components, and serviceability.

b. Inspect the Filter Maintenance Aid Plenum Tube Assembly for debris and insure that the tube is
clear and unobstructed.

c. Inspect the associated components, such as the Mount Assembly and hardware for missing
components, cracks, distortion or deformation, scratches or gouges, or missing protective
coatings.

8.5.3.3 TROUBLESHOOTING

See Troubleshooting Guide, Table 5.

8.5.3.4 ADJUSTMENT / CALIBRATION / REPAIR

The construction details of the component do not warrant field maintenance. Repair of this
component requires the component to be sent back to AFS for disposition, or replaced.

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8.5.3.5 Adjustment

The Filter Maintenance Aid is designed to hold the highest differential pressure across the filter
assembly reached during the last flight, and can be reset by depressing the yellow button marked
“PUSH TO RESET” located on the end of the filter maintenance aid (See Figure 10).

PRESS YELLOW
Button to RESET

Figure 10: FMA Reset

8.5.3.6 Repair

a. The construction details of the component do not warrant field maintenance. Repair of this
component requires the component to be sent back to AFS for disposition, or replaced.

b. If the Filter Maintenance Aid fails the function check, disconnect the plenum tube assembly
(Appendix A, Figure 8 or Appendix B, Figure 8) from the Filter Maintenance Aid (Appendix A,
Figure 8 or Appendix B, Figure 8), and inspect for damage or blockage of the tube assembly.
Inspect the opening on the Filter Maintenance Aid for obstructions. Remove obstructions as
required. Reattach tube assembly and perform function check (Refer to paragraph 8.5.3.7). If it
fails function check, replace FMA.

c. Replace damaged sheet metal components of the Mount Assembly and missing or damaged
hardware.

d. Re-apply corrosion protection to Mount Hardware per Table 6.

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8.5.3.7 FUNCTION CHECK

CAUTION

THIS PROCEDURE INTRODUCES THE POSSIBILITY OF ENGINE FOD.

CAUTION

IMPROPER USE OF THE ALTIMETER TEST SET COULD RESULT IN

DAMAGE TO THE FILTER MAINTENANCE AID.

CAUTION

IMPROPER USE OF THE ALTIMETER TEST SET SUCH AS PULLING AN

ALTITUDE OF GREATER THAN 1880 FEET ABOVE FIELD ELEVATION WILL
DAMAGE THE FILTER MAINTENANCE AID.

a. Gain access to the area above the Bypass Floor Assembly (Refer to paragraph 4.3.1)

b. Connect the Barfield (or equivalent) altimeter test set vacuum system to the plenum tube
assembly (Appendix A, Figure 8 or Appendix B, Figure 8), by slipping a piece of 3/16 inch ID vinyl
tubing over the end of the tube assembly. Ensure that the fit between the tubing and tube
assembly is tight, i.e., no leakage.

c. Reset the Filter Maintenance Aid by depressing the yellow button marked “PUSH TO RESET”
located on the end of the filter maintenance aid (See Figure 10).

d. The maintenance aid should indicate in the red zone within the following range:

Test Station Elevation (ft)

Test Method 0 2000 4000 6000 8000 10000
Low Pressure Calibrator
12.0 ± 1.2
(inches of H2O)
Altimeter Test Set
830 880 930 990 1060 1130
(ft above test station
±80 ft ±90 ft ±90 ft ±100 ft ±110 ft ±110 ft
elevation)

Table 3: FMA Elevation Table

8.5.3.8 INSTALLATION

a. Gain access to the area below the Bypass Floor Assembly (Refer to paragraph 4.3.2)

b. Position the Filter Maintenance Aid into the Mount Assembly (Appendix A, Figures 8,15 or
Appendix B, Figures 8,15).

c. Install hardware and connect Tube Assembly.

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8.5.4 ACTUATOR
(Refer to Figure 11, and Appendix A, Figures 6, 10, 14, 22, 23, 29 or Appendix B, Figures 6, 10, 14,
22, 23, 29)

8.5.4.1 REMOVAL

a. Gain access to the area below the Bypass Floor Assembly (Refer to paragraph 4.3.2)

b. Disconnect and secure circular connector at Actuator (Appendix A, Figure 6 or Appendix B,

Figure 6).

c. Remove hardware (Figure 11, Detail A) attaching the Actuator (Figure 11, Detail A) to the
Bypass Door Clevis Plate (Figure 11, Detail A).

d. Remove hardware (Appendix A, Figure 10 or Appendix B, Figure 10) attaching the Actuator
(Appendix A, Figure 10 or Appendix B, Figure 10) to the Actuator Support (Appendix A, Figure 14
or Appendix B, Figure 14).

e. Remove Actuator (Appendix A, Figure 10 or Appendix B, Figure 10).

8.5.4.2 INSPECTION

a. Inspect Actuator for cracks, damage, security of installation, corrosion, and serviceability.

b. Inspect the Circular Connector for damage, security, corrosion and serviceability.

c. Inspect the Bypass Floor contact to the Bypass Door Seal. The Seal should be compressed
approximately 50% with no visible gaps. Use care not to damage the seal when checking for
gaps / compression of the Seal. Refer to Adjustments if Seal compression is discrepant.

8.5.4.3 TROUBLESHOOTING

a. Refer to Table 5 for troubleshooting guidance.

b. Perform Function Check. If Function Check indicates a discrepancy with the Actuator replace
the actuator.

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8.5.4.4 ADJUSTMENT

Detail A

Figure 11: Actuator / Bypass Door Adjustment

a. Clear the area of the Bypass Door of any tools, hardware, or other obstructions.

b. After ensuring that aircraft power is ON, depress Cockpit Switch / Indicator (Appendix A, Figure
26 or Appendix B, Figure 26) to actuate the Actuator to open the bypass door (this fully extends
the actuator rod). Verify the Bypass Door is open approximately 45 degrees. If Bypass Door
opening is not approximately 45 degrees, measure Actuator rod extension from centerline of one
ball end to the other ball end. Measurement should be between 7.37 and 7.43 inches. If not,
contact AFS for disposition or replace actuator.

c. Remove hardware from Actuator rod end at Bypass Door. Refer to Figure 11, Detail A.

CAUTION

TO PREVENT INTERNAL DAMAGE TO THE ACTUATOR, HOLD THE ROD

END WHILE LOOSENING, TIGHTENING, OR APPLYING TORQUE TO THE
JAMB NUT.

CAUTION

INSTALL THE ACTUATOR BOLT TO THE BYPASS DOOR CLEVIS PLATE IN

THE CORRECT ORIENTATION. FAILURE TO CORRECTLY INSTALL THE
BOLT WILL RESULT IN DAMAGE TO THE BYPASS FLOOR AND
ACTUATOR.

d. Loosen jamb nut (6) and adjust rod end (5) in or out, as required, one-half turn to attain greater
or less Seal compression to the Bypass Door.
e. Temporarily re-install rod end bolt through the Bypass Door Clevis Plate. Actuate Cockpit
Switch / Indicator to retract the Bypass Door. The Seal should be compressed approximately

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50% with no visible gaps. Use care not to damage the seal when checking for gaps /
compression of the Seal. Refer to Adjustments if Seal compression is discrepant.

f. Repeat steps b through e until the Seal is compressed correctly.

g. Permanently install hardware to attach the Actuator rod end to the Bypass Door Clevis Plate.
Torque jamb nut (6) 25 TO 30 INCH-POUNDS. Torque nut (7) 30 TO 40 INCH-POUNDS.

h. Perform function check per paragraph 8.5.4.7.

i. Depress Cockpit Switch / Indicator to actuate the Actuator to close the bypass door and then
ensure that aircraft power is OFF.

8.5.4.5 CALIBRATION

Not applicable.

8.5.4.6 REPAIR

a. Repair of the actuator is limited to removal of minor surface corrosion from the actuator shaft
using fine sandpaper or crocus cloth (Table 6).

b. Damage to the actuator, such as cracking of the attachment lug, distortion, warping, or failure
to actuate requires disposition by AFS or replacement.

c. The Actuator rod end and attachment hardware can also be replaced if they are damaged,
corroded, or unserviceable. Referring to Figure 11, Detail A, replace the Actuator rod end (5) by
loosening the jamb nut and removing / replacing the rod end. Perform the Actuator / Bypass
Door Adjustment procedure per paragraph 8.5.4.4.

8.5.4.7 FUNCTION CHECK

a. Clear the area of the Bypass Door of any tools, hardware, or other obstructions.

b. Ensure that aircraft power is ON, and then depress Cockpit Switch / Indicator (Appendix A,
Figure 26 or Appendix B, Figure 26) to actuate the Actuator to close the bypass door.

c. Perform Seal compression inspection per the Actuator / Bypass Door Adjustment procedures,
paragraph 8.5.4.4.

d. Depress Cockpit Switch / Indicator to actuate the Actuator to open the bypass door (this fully
extends the actuator rod). Verify the Bypass Door is open approximately 45 degrees. If Bypass
Door opening is not approximately 45 degrees, measure Actuator rod extension from centerline of
one ball end to the other ball end. Measurement should be between 7.37 and 7.43 inches. If not,
contact AFS for disposition or replace actuator.
e. Verify the word “BYPASS” illuminates on the Cockpit Switch / Indicator, and ensure aircraft
power is OFF.

f. If conditions are not met refer to Troubleshooting guide, Table 5, and Adjustment procedures,
paragraph 8.5.4.4.

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8.5.4.8 INSTALLATION

CAUTION

THIS PROCEDURE INTRODUCES THE POSSIBILITY OF ENGINE FOD.

CAUTION

TO PREVENT INTERNAL DAMAGE TO THE ACTUATOR, HOLD THE ROD

END WHILE LOOSENING, TIGHTENING, OR APPLYING TORQUE TO THE
JAMB NUT.

CAUTION

INSTALL THE ACTUATOR BOLT TO THE BYPASS DOOR CLEVIS PLATE IN

THE CORRECT ORIENTATION. FAILURE TO CORRECTLY INSTALL THE
BOLT WILL RESULT IN DAMAGE TO THE BYPASS FLOOR AND
ACTUATOR.

a. Gain access to the area below the Bypass Floor Assembly (Refer to paragraph 4.3.2)

b. Clear the area of the Bypass Door of any tools, hardware, or other obstructions.

c. Install the Circular Connector to the Actuator (Appendix A, Figure 7 or Appendix B, Figure 7).
Ensure aircraft power is ON. Depress Cockpit Switch / Indicator (Appendix A, Figure 26 or
Appendix B, Figure 26) to actuate the Actuator to open the bypass door (this fully extends the
actuator rod).

d. Orient actuator to the Bypass Door and Actuator Support (As shown in Appendix A, Figure 6 or
Appendix B, Figure 6).

e. Install hardware (Appendix A, Figure 10 or Appendix B, Figure 10) attaching the Actuator
(Appendix A, Figure 10 or Appendix B, Figure 10) to the Actuator Support (Appendix A, Figure 14
or Appendix B, Figure 14).

f. Temporarily install the Bolt (Figure 11, Detail A) attaching the Actuator (Figure 11, Detail A) to
the Bypass Door Clevis Plate (Figure 11, Detail A).

g. Perform functional check per Actuator / Bypass Door Adjustment procedures (See paragraph
8.5.4.7).

h. Upon completion of Bypass Door Adjustment procedures confirm the permanent installation of
hardware (Figure 11, Detail A) securing the Actuator rod end (Figure 11, Detail A) to the Bypass
Door Clevis Plate (Figure 11, Detail A), and that aircraft power is OFF.

8.5.5 WIRING, WIRING HARNESS, CONNECTORS, BACKSHELLS, CIRCUIT BREAKER,

RELAY
(Refer to Appendix A, Figures 6, 7, 22, 23, 29 or Appendix B, Figures 6, 7, 22, 23, 29)

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8.5.5.1 REMOVAL

a. Prepare aircraft for work performed on the electrical system by disconnecting the battery.

b. Remove hardware, clamps, spiral wrap from component, as applicable. Tag interfacing
components for later installation. Remove affected components.

8.5.5.2 INSPECTION

The IBF wiring, wiring harness, and associated components is constructed of standard aircraft
wire and connectors. Standard aircraft maintenance procedures should be used for inspections
and repair of the harness and connectors. Routine aircraft maintenance should include visual
inspection for evidence of chafing, damage, corrosion and insuring the circuit breaker and all pins,
connectors, and backshells are secure. Inspect wiring, wiring harness and associated
components per AC 43.13-1, Chapter 11.

8.5.5.3 TROUBLESHOOTING

a. See Table 5 for troubleshooting guidance.

b. See Appendix A, Figures 22, 23 or Appendix B, Figures 22, 23 for wiring diagram, wire marking
and identification, routing, and installation information.

8.5.5.4 ADJUSTMENT / CALIBRATION

Not applicable.

8.5.5.5 REPAIR

Standard aircraft maintenance procedures should be used for repair of the wiring, wire harness
and associated components. See Appendix A, Figures 22, 23 or Appendix B, Figures 22, 23 for
wiring diagram, wire marking and identification, routing, and installation information. Perform
repairs to affected components per AC 43.13-1, Chapter 11.

8.5.5.6 INSTALLATION

a. Prepare aircraft for work performed on the electrical system by disconnecting the battery.

b. Install affected component using appropriate hardware. Connect wiring per wiring diagram.
Install clamps, spiral wrap and heat shrink as applicable to affected components per AC 43.13-1,
Chapter 11.

8.6 FILTER ASSY / (IVF)

(Refer to Appendix C)

8.6.1 FILTER ASSY (IVF)

8.6.1.1 REMOVAL – FILTER ASSY / PLENUM

a. Loosen the four quarter turn fasteners and remove the four screws. Filter may now be
removed. (See Appendix C, Figure C-6).

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b. Cover the plenum opening to prevent the introduction of FOD. (Appendix C, Figure C-1 or C-2).

c. To remove plenum, open the LH side (engine access) panel. (See Figure 2). Remove the
clamp from the bottom of the plenum attaching the plenum to the inducer bleed port.

d. Use a plastic scraper to gently break any seal between the plenum and the inducer bleed port
itself. Remove plenum through the top of the engine cowl and cover the inducer bleed port.

8.6.1.2 INSPECTION – FILTER ASSY / PLENUM

NOTE

After servicing of the Filter Assembly or at any time the Filter Assembly is
inspected, the pleats may require straightening or crimping. If you cannot
see the bottom of the pleat from both sides of the filter, the airflow will be
restricted and/or the pleats will adhere to one another when dirt loaded.
Any restriction to the flow through the pleats will result in increased
differential pressure and reduction in dirt loading capacity. In order to
insure ideal flow characteristics through the filter media, the pleats must be
straightened or crimped with a hand seamer.

a. Visually inspect the pleats on both sides of the filter. If you cannot see the bottom of the pleat,
when sighting the length, or depth of the pleat, straightening of the pleat is required. Refer to
Section 8.3.1.4 “Adjustment” for pleat straightening procedures.

b. If this inspection is in response to a FILTER light indication or failed PAC, perform

troubleshooting per Table 5. If troubleshooting indicates a dirty filter, service filter (IBF and IVF, if
installed) per paragraph 7.3.

c. Inspect the Filter Assembly frame for cracks, gouges, distortion or deformation, corrosion, loose
or missing fasteners, and missing or deteriorated protective coating. Refer to “Repair” for criteria /
disposition.

d. Inspect the Plenum for nicks, tears, or gouges.

8.6.1.3 TROUBLESHOOTING – FILTER ASSY / ENGINE WASH TUBE

See Table 5 for troubleshooting guide.

8.6.1.4 ADJUSTMENT - FILTER

Refer to Section 8.3.1.4

8.6.1.5 CALIBRATION
Not applicable.

8.6.1.6 REPAIR - FILTER MEDIA, GENERAL

Refer to Section 8.3.1.6

8.6.1.7 REPAIR - FILTER MEDIA, SMALL RUPTURES, TEARS, OR HOLES

Refer to Section 8.3.1.7

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8.6.1.8 REPAIR - FILTER MEDIA, LARGE RUPTURES, TEARS, OR HOLES

Refer to Section 8.3.1.8

8.6.1.9 REPAIR – FILTER ASSY/ FRAME, OTHER DAMAGE

a. The repair procedures defined above and in Sections 8.3.1.6, 8.3.1.7, and 8.3.1.8, are for
damage resulting in ruptures, tears, or holes in the filter media. The following is for field repairable
damage to the Filter Assembly frame. Field repairable damage to the Filter Assembly frame is
limited to blending of scratches and gouges, and / or the re-application of protective coatings.
See Table 4 for application of protective coatings.

b. Any damage to the filter frames such as cracking requires the Filter Assembly to be returned to
AFS for evaluation and disposition, or replacement. Any damage to the filter frames such as
warping or distortion (to the extent that the Filter Frame, when installed against the doubler and
torqued, does not permit the Filter Assembly to sit flush against the doubler) requires the Filter
Assembly be returned to AFS for evaluation and disposition, or be replaced.

c. Any damage to the Plenum that restricts the flow, allows leakage, or an improper sealing of the
filter is cause for replacement.

8.6.1.10 INSTALLATION – FILTER ASSY/ PLENUM

CAUTION

REMOVE COVER FROM THE INDUCER BLEED PORT PRIOR TO

INSTALLING THE PLENUM ASSEMBLY.

CAUTION

OVER TIGHTENING OF THE FASTENERS MAY RESULT IN THE FASTENER

BEING DAMAGED.

a. Insert the plenum through the top of the engine cowl.

b. Uncover the inducer bleed port and slip the end of the plenum over the bleed port.

c. Secure plenum to the inducer bleed port using the original clamp (replace clamp if
unserviceable).

d. Install IVF filter assembly.

e. Secure the four quarter turn fasteners and four screws (tighten screws to 20-25 inch-pounds).

f. Ensure the filter has a good seal on the plenum. (See Appendix C, Figure C-1 or C-2).

8.7 FASTENER LISTING

Refer to the Appendix A, Appendix B, or Appendix C – Parts Figures for a listing of fasteners and
their location.

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8.8 PROTECTIVE TREATMENT

a. The fairing assembly and structural components of the IBF system is composed primarily of
aluminum alloy materials, except for standard hardware components and fasteners, and vendor
components. Aluminum components are coated with an epoxy primer. Scratched or damaged
aluminum components should be touched up with a small paint brush dipped in epoxy primer.
Prepare epoxy primer per manufacturer’s instructions.

b. Aircraft finishes scratched or damaged should be recoated with the finish specified in the
aircraft maintenance records and maintenance manual.

c. For the systems and electrical components, there are no protective treatments specified.
Contact AFS for disposition of damaged components, or replace the damaged component.

Table 4: Protective Treatment for Components

Component Material Limits of Damage Protective Treatment

Filter Assembly Alum. Alloy Sheet Stk. Scratches, pitting, Re-apply Epoxy Primer
gouges must be less Ref Table 6
than 20% of part
thickness. See note 1.

Engine Wash Tube Alum. Alloy Tubing Scratches, pitting, Chemical conversion
gouges must be less coating. Ref Table 6
than 20% of part
thickness. See note 1.

Bypass Floor Assembly

Bypass Floor Machined Alum Alloy Scratches, pitting, Re-apply Epoxy Primer
gouges must be less Ref Table 6
than 10% of part
thickness. See note 1.
Bypass Door Machined Alum Alloy Scratches, pitting, Re-apply Epoxy Primer
gouges must be less Ref Table 6
than 10% of part
thickness. See note 1.
Actuator Bracket Machined Alum Alloy Scratches, pitting, Re-apply Epoxy Primer
gouges must be less Ref Table 6
than 10% of part
thickness. See note 1.
Filter Maint Aid Bracket Alum. Alloy Sheet Stk. Inspect for Serviceability Re-apply Epoxy Primer
Ref Table 6

Filter Frame Adapter Alum. Alloy Sheet Stk. Scratches, pitting, Re-apply Epoxy Primer
gouges must be less Ref Table 6
than 20% of part
thickness. See note 1.

Access Door Alum. Alloy Sheet Stk. Inspect for proper sealing Chemical conversion
/ serviceability. coating. Ref Table 6
Then re-apply aircraft
finish per aircraft records.

Notes:

1. Contact AFS for disposition instructions for components with more severe discrepancies or replace.

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8.9 TROUBLESHOOTING GUIDE

The following table defines the probable cause, remedy, and ICA reference to the applicable procedure for correcting the trouble listed in
the table. Multiple failures are not addressed in this table such as a failed actuator and failed wiring existing at the same time.

Table 5: Troubleshooting Guide

ITEM TROUBLE PROBABLE CAUSE REMEDY ICA REF
1 FILTER light fails to illuminate Faulty connector Check connectors to aircraft power, cockpit switch/indicator, and actuator. Para. 8.5.5.
Faulty circuit Check circuit continuity and repair circuit. Para. 8.5.5.
Faulty cockpit indicator Verify using caution light press-to-test; replace cockpit switch/indicator. Para. 8.5.1.
Faulty delta P switch Replace differential pressure switch. Para. 8.5.2.
Faulty Relay Check aircraft dimmer circuit; replace relay. Para. 8.5.5.
2 FILTER light is dim Failed LED(s) in indicator Verify using caution light press-to-test; replace cockpit switch/indicator. Para. 8.5.1.
3 FILTER light stays illuminated Bypass obstructed Clear bypass path.
Faulty delta P switch Replace differential pressure switch. Para. 8.5.2.
4 BYPASS light fails to illuminate Actuator misrigged Check actuator rigging. Para. 8.5.4.
Faulty connector Check connectors to aircraft power, cockpit switch/indicator, and actuator. Para. 8.5.5.
Faulty circuit Check circuit continuity and repair circuit. Para. 8.5.5.
Faulty cockpit indicator Verify using caution light press-to-test; replace cockpit switch/indicator. Para. 8.5.1
Faulty actuator limit switch Replace actuator. Para. 8.5.4.
Faulty Relay Check aircraft dimmer circuit; replace relay. Para. 8.5.5.
5 BYPASS light is dim Failed LED(s) in indicator Verify using caution light press-to-test; replace cockpit switch/indicator. Para. 8.5.1.
6 BYPASS light stays illuminated Faulty actuator limit switch Replace actuator. Para. 8.5.4.
7 Bypass door fails to close Actuator misrigged Check actuator rigging. Para. 8.5.4.
Faulty connector Check connectors to aircraft power, cockpit switch/indicator, and actuator. Para. 8.5.5.
Faulty circuit Check circuit continuity and repair circuit. Para. 8.5.5.
Faulty cockpit switch Check switch continuity in CLOSE position; replace cockpit switch/indicator. Para. 8.5.1.
Faulty actuator Replace actuator. Para. 8.5.4.
8 Bypass door fails to open Actuator misrigged Check actuator rigging. Para. 8.5.4.
Faulty connector Check connectors to aircraft power, cockpit switch/indicator, and actuator. Para. 8.5.5.
Faulty circuit Check circuit continuity and repair circuit. Para. 8.5.5.
Faulty cockpit switch Check switch continuity in BYPASS position; replace cockpit switch/indicator. Para. 8.5.1
Faulty actuator Replace actuator. Para. 8.5.4.
9 FILTER light illuminates Obstructed inlet Clear engine inlet.
Dirty filter Verify by checking FMA & inspect filter; service filter. Para. 7.3.
10 Engine fails PAC Obstructed inlet Clear engine inlet.
Dirty filter Verify PAC results, check FMA, & inspect filter; service filter. Para. 7.3.
NOTE: If engine still fails PAC - check engine.
11 Engine wash spray pattern not uniform Spray nozzle clogged Inspect & clear tube/nozzle to remove dirt / debris. Para. 8.3.1.
12 FILTER/BYPASS fails to dim Faulty Relay Check aircraft dimmer circuit; replace relay. Para. 8.5.5.
13 FILTER/BYPASS fails to brighten Faulty Relay Check aircraft dimmer circuit; replace relay. Para. 8.5.5.

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8.10 SPECIAL TOOLS / SPECIAL EQUIPMENT

NOTE

Standard Aircraft Mechanic Tools are not listed.

a. Hand Seamer – 1 1/4 inch maximum jaw depth. Hand seamers are available through many
commercial aircraft supply stores and also through commercial heating and air conditioning
supply stores. Recommend the following: Malco Tools “Hand Seamer with Forged Steel Jaw”,
Catalog # S2, S3 and S6. The S3 model is also available through Wicks Aircraft Supply, Part
Number TP44-0, “Offset Hand Seamer”.

b. Barfield or Equivalent Manufacturer Altimeter Test Set

8.11 CONSUMABLE MATERIALS, SUPPLIES, AND PROTECTIVE TREATMENT

SPECIFICATIONS

Table 6: Consumable Materials, Supplies and Protective Treatment Specifications

Item Description Spec / Part No.

Consumables

1 Sealant AMS 3276

2 Sealant MIL-S-8802
3 Sealant RTV 736
4 Sand paper 400-600 grit Commercial avail.
5 Crocus Cloth Commercial avail.

Supplies

6 Air Filter Oil Squeeze bottle – AFS P/N 100100-140

6.1 Air Filter Oil Gallon container – AFS P/N 100101-000
6.2 Air Filter Oil 5 Gallon Container -AFS P/N 100105-000
7 Air Filter Cleaner 12oz squirt bottle – AFS P/N 100200-120
7.1 Air Filter Cleaner Gallon container – AFS P/N 100201-000
7.2 Air Filter Cleaner 5 Gallon container – AFS P/N 100205-000
7.3 Air Filter Cleaner Zok 27

Protective Treatment Specs

8 Epoxy Primer. MIL-PRF-23337

MIL-C-5541 (One commercial trade name,
9 Chemical Conversion Coating
“Alodine”)
See Aircraft Records for appropriate Finish /
10 Aircraft Finish
Top Coat.

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ICA APPENDIX A – PARTS FIGURES

FOR BELL 407/407GX WITH METAL COWL

TABLE OF FIGURES

Figure A-1: 106000-101/-103 IBF System Kit – Major Components ............................................ 2

Figure A-2: Adapter Frame, Floor & Closeout Angle Installation ................................................. 4
Figure A-3: IPS Scavenge Air Exhaust Cover Assembly - IML .................................................... 6
Figure A-4: Filter Adapter Frame Assembly .................................................................................. 7
Figure A-5: Floor Closeout Angle Assembly ................................................................................. 8
Figure A-6: Wire Harness Assembly Installation ........................................................................... 9
Figure A-7: Wire Harness Assembly ............................................................................................ 10
Figure A-8: Firewall Seal and Maintenance Indicator Installation ............................................... 11
Figure A-9: Differential Pressure Switch Installation................................................................... 13
Figure A-10: Bypass Door Assembly and Actuator Installation................................................... 15
Figure A-11: Ambient Tube Assembly ......................................................................................... 17
Figure A-12: Bypass Door Assembly ........................................................................................... 18
Figure A-13: Filter Hardware Kit.................................................................................................. 20
Figure A-14: Floor Assembly ....................................................................................................... 22
Figure A-15: Maintenance Indicator Mount Assembly ................................................................ 24
Figure A-16: Actuator Mount Assembly ...................................................................................... 25
Figure A-17: Access Door Kit Installation ................................................................................... 26
Figure A-18: Angle Assembly, Sill, Door, Access – AFT, LWR................................................. 28
Figure A-19: Angle Assembly, Sill, Door, Access – FWD, LWR ............................................... 29
Figure A-20: Angle Assembly, Sill, Door, Access – FWD, UPR ................................................ 30
Figure A-21: Access Door Assembly............................................................................................ 31
Figure A-22: 106400-101 Electrical System Installation Schematic (Bell 407)........................... 32
Figure A-23: 106400-105 Electrical System Installation Schematic (Bell 407GX) ............... 33
Figure A-24: 106400-101/-105 Electrical System Installation ..................................................... 34
Figure A-25: Overhead Console ................................................................................................... 35
Figure A-26: Cockpit Switch/Indicator Installation (Bell 407) .................................................... 36
Figure A-27: Main Instrument Panel - Cockpit Switch/Indicator Installation (407GX) .............. 37
Figure A-28: Wire Routing – Forward Relay Panel, Looking Inboard, LH Side ......................... 38
Figure A-29: Wire Routing – Airframe......................................................................................... 39
Figure A-30: Wire Routing - IBF Disconnect, Transmission Bay................................................ 40

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Figure A-1: 106000-101/-103 IBF System Kit – Major Components

(Bell 407GX/407 respectively)

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UNIT
INDEX
NUMBER
PART NUMBER ITEM NAME PER
ASSY

FIGURE A-1: IBF System Kit & Access Door

Installation
Adapter Frame Assembly
1 106102-101 1
(See Figure 4 for breakdown)

2 106219-205 Filter Seal 1

Filter Hardware Kit

3 106200-101 1
(See Figure 13 for breakdown)
Filter Hardware Kit (Dry Alternate)
3* 106200-103 1
(See Figure 13 for breakdown)
Engine Wash Tube Assembly
4 106202-101 1
(See Figure 13 for breakdown)
Bypass Floor Assembly
5 106110-101 1
(See Figure 6, 8, 9 & 10 for breakdown)
Angle Assembly
6 106103-101 1
(See Figure 5 for breakdown)
Angle Assembly
7 106103-102 1
(See Figure 5 for breakdown)
Access Door Kit
8 106301-101 1
(See Figure 17 for breakdown)

9 106104-201 OML Exhaust Cover 1

IML Exhaust Cover Assembly

10 106105-101 1
(See Figure 3 for breakdown)

11 AN525-10R8 Screw 2

12 AN525-10R7 Screw 1

* Filter Hardware Kit (Dry 106200-103) may be used in lieu of Filter Hardware
Kit (Oiled 106200-101)

** AN929-8J Cap used on initial installation to cap bleed airline.

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Figure A-2: Adapter Frame, Floor & Closeout Angle Installation

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UNIT
INDEX
NUMBER PART NUMBER ITEM NAME PER
ASSY

FIGURE A-2: Adapter Frame, Floor & Closeout

Angle Installation
Adapter Frame Assembly
1 106102-101 1
(See Figure 4 for breakdown)
Bypass Floor Assembly
2 106110-101 1
(See Figure 6, 8, 9 & 10 for breakdown)
Closeout Angle Assembly
3 106103-101 1
(See Figure 5 for breakdown)
Closeout Angle Assembly
4 106103-102 1
(See Figure 5 for breakdown)
106119-201 Data Plate (used on -103) 1
5
106119-205 Data Plate (used on -101) 1

6 MS20470AD4-4 Rivet 2

7 MS20470AD4-5 Rivet 13

8 MS20470AD5-9 Rivet 4

9 NAS1097AD4-7-5 Rivet 2

10 NAS1097AD3-8 Rivet 16

11 NAS6203-3 Bolt 12

12 NAS1149D0332J Washer 23

13 NAS6203-4 Bolt 11

14 MS21919WDG2 Clamp 3

15 AN3C4A Bolt 6

16 NAS1149C0332R Washer 6

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Figure A-3: IPS Scavenge Air Exhaust Cover Assembly - IML

UNIT
INDEX
NUMBER PART NUMBER ITEM NAME PER
ASSY

FIGURE A-3: IPS Scavenge Air Exhaust

Cover Assembly - IML
106155-201 Cover, Scavenge, IPS – IML (current)
1 1
106105-203 Cover, Scavenge, IPS – IML (superseded)

2 MS21061L3 Platenut 1

2 NAS1097AD3-4 Rivet 2

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Figure A-4: Filter Adapter Frame Assembly

UNIT
INDEX
NUMBER PART NUMBER ITEM NAME PER
ASSY

FIGURE A-4: Adapter Frame Assembly

1 106219-205 Seal, Filter 1

106152-201 Frame, Adapter, Filter (current)

2 1
106102-201 Frame, Adapter, Filter (superseded)

3 106107-201 Spacer, Adapter – Thin 4

4 106106-201 Spacer, Adapter – Thick 3

5 NAS1097AD3-6 Rivet (Not Shown) 14

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Figure A-5: Floor Closeout Angle Assembly

UNIT
INDEX
NUMBER PART NUMBER ITEM NAME PER
ASSY

FIGURE A-5: Floor Closeout Angle Assembly

106153-201 Angle, Closeout, Floor (LH) (current)

1 1
106103-203 Angle, Closeout, Floor (LH) (superseded)
106108-203 Seal, Angle (LH) (current)
2 1
106108-201 Seal, Angle (LH) (superseded)

3 MS21059L3 Platenut 8

4 NAS1097AD3-3 Rivet 16

106153-202 Angle, Closeout, Floor (RH) (current)

5 1
106103-204 Angle, Closeout, floor (RH) (superseded)
106108-204 Seal, Angle (RH) (current)
6 1
106108-202 Seal, Angle (RH) (superseded)

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Figure A-6: Wire Harness Assembly Installation

UNIT
INDEX
NUMBER PART NUMBER ITEM NAME PER
ASSY

FIGURE A-6: Wire Harness Assembly

Installation
106401-105 Wire Harness Assembly (Current)
1 1
106401-103 Wire Harness Assembly (Superseded)

2 NAS1149DN416J Washer 16

3 MS21042L04 Nut 8

4 MS35206-215 Screw 4

5 MS35206-216 Screw 4

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Figure A-7: Wire Harness Assembly

UNIT
INDEX
NUMBER PART NUMBER ITEM NAME PER
ASSY

FIGURE A-7: Wire Harness Assembly

1 D38999/20MA35SN Receptacle 1

2 M85049/38S9W Backshell 1

3 M85049/38S11W Backshell 1

4 D38999/20WB5PN Receptacle 1

5 M85049/39S9W Backshell 1

6 D38999/26WA98SA Plug 1

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Figure A-8: Firewall Seal and Maintenance Indicator Installation

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UNIT
INDEX
NUMBER PART NUMBER ITEM NAME PER
ASSY

FIGURE A-8: Firewall Seal and Maintenance

Indicator Installation

1 106125-207 Seal, Firewall 1

2 NAS6203-2 Bolt 2

3 NAS1149D0332J Washer 2

4 100442-201 Retainer, Indicator, Maintenance 1

5 100444-201 Cushion, Indicator, Maintenance 2

6 104441-205 Indicator, Maintenance 1

7 A-400-1-2 Adapter 1

8 106167-201 Tube, Plenum 1

9 MS35489-65 Grommet 1

10 AN832-4D Union 1

11 NAS1149D0716J Washer 1

12 AN924-4D Nut, Jam 1

13 AN929-4 Cap 1

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Figure A-9: Differential Pressure Switch Installation

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UNIT
INDEX
NUMBER PART NUMBER ITEM NAME PER
ASSY

FIGURE A-9: Differential Pressure Switch

Installation
Tube Assembly, Ambient
1 106115-101 1
(See Figure 11 for breakdown)

2 AN924-4D Nut, Jam 1

3 NAS1149D0716J Washer 1

4 106167-201 Tube, Plenum 1

5 MS35489-65 Grommet 1

6 A-402-1 Nut 1

7 A-404-1 Back Ferrule 1

8 A-403-1 Front Ferrule 1

9 100409-101 Delta-P Switch 1

10 AN525-10R8 Bolt 1

11 MS21919WDG28 Clamp 1

12 3604 Clamp, Hose 2

13 106116-201 Hose, Ambient 1

14 AN838-4D Elbow 1

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Figure A-10: Bypass Door Assembly and Actuator Installation

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UNIT
INDEX
NUMBER PART NUMBER ITEM NAME PER
ASSY

FIGURE A-10: Bypass Door Assembly and

Actuator Installation

1 106111-101 Floor Assembly 1

2 106120-101 Door Assembly, Bypass 1

3 MS20253-2-1825 Pin 1

4 NAS6204-10D Bolt 1

5 NAS1149D0416J Washer 1

6 MS24665-132 Pin, Cotter 1

7 MS14144L4 Nut 1

8 NAS1149D0463J Washer 2

9 MS246945117 Screw 1

10 MS21045L4 Nut 1

11 106113-203 Actuator 1

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Figure A-11: Ambient Tube Assembly

UNIT
INDEX
NUMBER PART NUMBER ITEM NAME PER
ASSY

FIGURE A-11: Ambient Tube Assembly

1 106165-201 Tube, Ambient 1

2 MS20819-4D Sleeve 1

3 AN818-4D Nut 1

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Figure A-12: Bypass Door Assembly

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UNIT
INDEX
NUMBER PART NUMBER ITEM NAME PER
ASSY

FIGURE A-12: Bypass Door Assembly

1 106124-203 Hinge Half, Door, Bypass 1

2 106121-203 Door, Bypass 1

3 106122-201 Seal, Door, Bypass 1

4 106123-201 Retainer, Seal, Door, Bypass 1

5 106127-201 Plate, Clevis 2

6 NAS1149D0332J Washer 2

7 NAS6203-10 Bolt 2

8 NAS1149D0363J Washer 2

9 MS21042L3 Nut 2

10 NAS1097AD4-4 Rivet 4

11 MS20470AD4-6 Rivet 10

12 MS20470AD4-5 Rivet 14

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Figure A-13: Filter Hardware Kit

(Cowl not shown for clarity)

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UNIT
INDEX
NUMBER PART NUMBER ITEM NAME PER
ASSY

FIGURE A-13: Filter Hardware Kit

1 106201-103 Filter Assembly 1

1* 106205-101 Dry Media Filter Assembly (Alternate) 1

2 106202-101 Tube Assembly, Engine Wash 1

3 NAS6203-7 Bolt 7

4 NAS1149D0332J Washer 11

5 NAS6203-3D Bolt 2

6 MS21919WDG4 Clamp 2

7 MS14144L3 Nut,Castle 2

8 MS24665-86 Pin, Cotter 2

*Dry Media Filter Assembly (106205-101) may be used in lieu of Filter
Assembly (106201-103)

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Figure A-14: Floor Assembly

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UNIT
INDEX
NUMBER PART NUMBER ITEM NAME PER
ASSY

FIGURE A-14: Floor Assembly

106161-201 Floor (Current)

1 1
106111-201 Floor (Superseded)
Mount Assy, Indicator, Maint. (Current)
106130-101
2 (See Figure 15 for breakdown) 1
104442-103
Mount Assy, Indicator, Maint. (Superseded)

3 106112-101 Mount Assy, Actuator 1

4 106133-201 Bracket, Electrical 1

5 106142-201 Screen, Bypass - Large 1

6 106141-201 Screen, Bypass - Small 1

7 106118-201 Hinge, Piano - Floor 1

8 MS21061L3 Platenut 2

9 MS21059L3 Platenut 5

10 MS21075L3N Platenut 7

11 106126-201 Spacer, Indicator, Maintenance 1

12 MS20470AD4-5 Rivet 3

13 NAS1097A3-3-5 Rivet 30

14 NAS1097AD4-4 Rivet 14

15 MS20470AD5-6 Rivet 1

16 NAS1097AD4-8-5 Rivet 2

17 NAS1097AD4-7 Rivet 10

18 NAS1097AD4-5 Rivet 7

19 A3236-6 Washer 14

Use or disclosure of this material is subject A-23 AFS Bell 407 IBF
to restrictions on the title page Instructions for Continued Airworthiness
AFS-BH407-IBF-KIT-ICA Aerospace Filtration Systems, Inc.
Revision: G Proprietary Information

Figure A-15: Maintenance Indicator Mount Assembly

UNIT
INDEX
NUMBER PART NUMBER ITEM NAME PER
ASSY

FIGURE A-15: Maintenance Indicator Mount

Assembly
106131-201 Mount, Indicator, Maintenance (Current)
1 1
104442-205 Mount, Indicator, Maintenance (Superseded)

2 MS21061L3 Platenut 2

3 NAS1097AD3-3 Rivet 4

Use or disclosure of this material is subject A-24 AFS Bell 407 IBF
to restrictions on the title page Instructions for Continued Airworthiness
AFS-BH407-IBF-KIT-ICA Aerospace Filtration Systems, Inc.
Revision: G Proprietary Information

Figure A-16: Actuator Mount Assembly

UNIT
INDEX
NUMBER PART NUMBER ITEM NAME PER
ASSY

FIGURE 16: Actuator Mount Assembly

106162-201 Mount, Actuator (Current)

1 1
106112-203 Mount, Actuator (Superseded)

2 MS21075L3N Platenut 2

3 NAS1097AD3-4 Rivet 4

Use or disclosure of this material is subject A-25 AFS Bell 407 IBF
to restrictions on the title page Instructions for Continued Airworthiness
AFS-BH407-IBF-KIT-ICA Aerospace Filtration Systems, Inc.
Revision: G Proprietary Information

Figure A-17: Access Door Kit Installation

(Cowl not shown for clarity)

Use or disclosure of this material is subject A-26 AFS Bell 407 IBF
to restrictions on the title page Instructions for Continued Airworthiness
AFS-BH407-IBF-KIT-ICA Aerospace Filtration Systems, Inc.
Revision: G Proprietary Information

UNIT
INDEX
NUMBER PART NUMBER ITEM NAME PER
ASSY

FIGURE A-17: Cowl Modification/Access Door

Installation
1 106302-201 Plate, Sill, Door, Access - FWD 1
Angle Assy, Sill, Door, Access – FWD, UPR
2 106304-101 1
(See Figure 20 for breakdown)
Angle Assy, Sill, Door, Access – FWD, LWR
3 106305-101 3
(See Figure 19 for breakdown)
4 MS20470AD4-4 Rivet 8

5 CR3214-4-2 Rivet, Blind 8

6 106303-203 Plate, Sill, Door, Access – AFT 1

7 106306-203 Angle, Sill, Door, Access – AFT, UPR 1

8 106307-205 Angle, Sill, Door, Access – AFT, MID 1

Angle Assy, Sill, Door, Access – AFT, LWR
9 106308-101 1
(See Figure 18 for breakdown)
10 MS20470AD4-5 Rivet 20

11 NAS1097AD4-5 Rivet 5

12 MS21061L3 Platenut 2

13 NAS463YDD10M Shim 1

14 NAS463YDD10H Shim 1

15 MS20605R3W7 Rivet 2

16 MS21075L3N Platenut 6

17 NAS1195D3XM Shim 5

18 NAS1195D3XH Shim 2

19 NAS1097AD3-7 Rivet 4

20 NAS1097AD3-6 Rivet 16

21 MS21075L08N Platenut 3

22 AN525-832R9 Screw 3
Access Door Assembly
23 106310-101 1
(See Figure 21 for breakdown)
24 AN525-10R10 Screw 16

Use or disclosure of this material is subject A-27 AFS Bell 407 IBF
to restrictions on the title page Instructions for Continued Airworthiness
AFS-BH407-IBF-KIT-ICA Aerospace Filtration Systems, Inc.
Revision: G Proprietary Information

Figure A-18: Angle Assembly, Sill, Door, Access – AFT, LWR

UNIT
INDEX
NUMBER PART NUMBER ITEM NAME PER
ASSY

FIGURE A-18: Angle Assembly, Sill, Door –

Aft,Lower
106309-201 Angle, Sill, Door – AFT, LWR (current)
1 1
106308-201 Angle, Sill, Door – AFT, LWR (superseded)

2 MS21075L3N Platenut 1

3 NAS1195D3XM Shim 1

4 NAS1097AD3-4 Rivet 2

Use or disclosure of this material is subject A-28 AFS Bell 407 IBF
to restrictions on the title page Instructions for Continued Airworthiness
AFS-BH407-IBF-KIT-ICA Aerospace Filtration Systems, Inc.
Revision: G Proprietary Information

Figure A-19: Angle Assembly, Sill, Door, Access – FWD, LWR

UNIT
INDEX
NUMBER PART NUMBER ITEM NAME PER
ASSY

FIGURE A-19: Angle Assembly, Sill, Door –

Forward, Lower
106316-201 Angle, Sill, Door - Fwd, Upr (Current)
1 1
106305-201 Angle, Sill, Door - Fwd, Upr (Superseded)

2 MS21075L3N Platenut 1

3 NAS1195D3XH Shim 1

4 NAS1097AD3-4-5 Rivet 2

Use or disclosure of this material is subject A-29 AFS Bell 407 IBF
to restrictions on the title page Instructions for Continued Airworthiness
AFS-BH407-IBF-KIT-ICA Aerospace Filtration Systems, Inc.
Revision: G Proprietary Information

Figure A-20: Angle Assembly, Sill, Door, Access – FWD, UPR

UNIT
INDEX
NUMBER PART NUMBER ITEM NAME PER
ASSY

FIGURE A-20: Angle Assembly, Sill, Door –

Forward, Upper
106314-201 Angle, Sill – Forward, Upper (current)
1 1
106304-203 Angle, Sill – Forward, Upper (superseded)

2 MS21075L3N Platenut 1

3 NAS1195D3XH Shim 1

4 NAS1097AD3-4-5 Rivet 2

Use or disclosure of this material is subject A-30 AFS Bell 407 IBF
to restrictions on the title page Instructions for Continued Airworthiness
AFS-BH407-IBF-KIT-ICA Aerospace Filtration Systems, Inc.
Revision: G Proprietary Information

Figure A-21: Access Door Assembly

UNIT
INDEX
NUMBER PART NUMBER ITEM NAME PER
ASSY

FIGURE 21: Access Door Assembly

106311-201 Door, Access (current)

1 1
106310-201 Door, Access (superseded)
2 106312-205 Seal, Door, Access 1

Use or disclosure of this material is subject A-31 AFS Bell 407 IBF
to restrictions on the title page Instructions for Continued Airworthiness
AFS-BH407-IBF-KIT-ICA Aerospace Filtration Systems, Inc.
Revision: E Proprietary Information

Figure A-22: 106400-101 Electrical System Installation Schematic (Bell 407)

Use or disclosure of this material is subject A-32 AFS Bell 407 IBF
to restrictions on the title page Instructions for Continued Airworthiness
AFS-BH407-IBF-KIT-ICA Aerospace Filtration Systems, Inc.
Revision: E Proprietary Information

Figure A-23: 106400-105 Electrical System Installation Schematic (Bell 407GX)

Use or disclosure of this material is subject A-33 AFS Bell 407 IBF
to restrictions on the title page Instructions for Continued Airworthiness
AFS-BH407-IBF-KIT-ICA Aerospace Filtration Systems, Inc.
Revision: E Proprietary Information

WIRE RO UTING – AIRFRAME

SEE FIGURE 24

O VERHEAD CONSOLE
SEE FIGURE 25

MAIN INSTRUMENT PANEL

SEE FIGURE 26 (Bell 407)
SEE FIGURE 27 (Bell 407GX)

FWD RELAY PANEL

LEFT -HAND SIDE
SEE FIGURE 28 (Bell 407/407GX)
WIRE RO UTING – TRANSMISSION BAY/IBF DISCONNECT
SEE FIGURE 25

Figure A-24: 106400-101/-105 Electrical System Installation

(Bell 407/407GX Respectively)
Use or disclosure of this material is subject A-34 AFS Bell 407 IBF
to restrictions on the title page Instructions for Continued Airworthiness
AFS-BH407-IBF-KIT-ICA Aerospace Filtration Systems, Inc.
Revision: E Proprietary Information

Figure A-25: Overhead Console

106400-101/-105 (Bell 407/407GX respectively)

UNIT
INDEX
NUMBER PART NUMBER ITEM NAME PER
ASSY

FIGURE A-25: Overhead Console

1 MS26574-3 Circuit Breaker 1

2 100375-233 Placard “IBF” 1

3 100375-237 Placard (blank) 1

4 100-050B-500 Plug 1

Use or disclosure of this material is subject A-35 AFS Bell 407 IBF
to restrictions on the title page Instructions for Continued Airworthiness
AFS-BH407-IBF-KIT-ICA Aerospace Filtration Systems, Inc.
Revision: E Proprietary Information

Figure A-26: Cockpit Switch/Indicator Installation (Bell 407)

UNIT
INDEX
NUMBER PART NUMBER ITEM NAME PER
ASSY

FIGURE A-26: Cockpit Switch/Indicator

Installation

1 LED-42-15-KB-36066 Cockpit Switch/Indicator (used on 407) 1

2 18-200 Connector 1

3 100375-233 Placard “IBF” 1

4 M85049/22-192 Socket (Not Shown) 10

Use or disclosure of this material is subject A-36 AFS Bell 407 IBF
to restrictions on the title page Instructions for Continued Airworthiness
AFS-BH407-IBF-KIT-ICA Aerospace Filtration Systems, Inc.
Revision: E Proprietary Information

Figure A-27: Main Instrument Panel - Cockpit Switch/Indicator Installation (407GX)

UNIT
INDEX
NUMBER PART NUMBER ITEM NAME PER
ASSY

FIGURE A-26: Cockpit Switch/Indicator

Installation

1 LED-42-14-KB-SBASV Cockpit Switch/Indicator (used on 407GX) 1

2 18-200 Connector 1

3 100375-233 Placard “IBF” 1

4 M85049/22-192 Socket (Not Shown) 10

Use or disclosure of this material is subject A-37 AFS Bell 407 IBF
to restrictions on the title page Instructions for Continued Airworthiness
AFS-BH407-IBF-KIT-ICA Aerospace Filtration Systems, Inc.
Revision: E Proprietary Information

Figure A-28: Wire Routing – Forward Relay Panel, Looking Inboard, LH Side
106400-101/-105 (Bell 407/407GX respectively)

Use or disclosure of this material is subject A-38 AFS Bell 407 IBF
to restrictions on the title page Instructions for Continued Airworthiness
AFS-BH407-IBF-KIT-ICA Aerospace Filtration Systems, Inc.
Revision: E Proprietary Information

Figure A-29: Wire Routing – Airframe

106400-101/-105 (Bell 407/407GX respectively)

Use or disclosure of this material is subject A-39 AFS Bell 407 IBF
to restrictions on the title page Instructions for Continued Airworthiness
AFS-BH407-IBF-KIT-ICA Aerospace Filtration Systems, Inc.
Revision: E Proprietary Information

Figure A-30: Wire Routing - IBF Disconnect, Transmission Bay

106400-101/105 (Bell 407/407GX respectively)

Use or disclosure of this material is subject A-40 AFS Bell 407 IBF
to restrictions on the title page Instructions for Continued Airworthiness
AFS-BH407-IBF-KIT-ICA Aerospace Filtration Systems, Inc.
Revision: G Proprietary Information

ICA APPENDIX B – PARTS FIGURES

FOR BELL 407/407GX WITH COMPOSITE COWL

TABLE OF FIGURES

Figure B-1:106000-107/-109 IBF System Kit – Major Components ............................................. 2

Figure B-2: Adapter Frame, Floor & Closeout Angle Installation ................................................. 4
Figure B-3: Cowl Forward Lip Modification.................................................................................. 6
Figure B-4: Filter Adapter Frame Assembly................................................................................... 7
Figure B-5: Floor Closeout Angle Assembly.................................................................................. 8
Figure B-6: Wire Harness Assembly Installation ........................................................................... 9
Figure B-7: Wire Harness Assembly ............................................................................................ 10
Figure B-8: Firewall Seal and Maintenance Indicator Installation ............................................... 11
Figure B-9: Differential Pressure Switch Installation ................................................................... 13
Figure B-10: Bypass Door Assembly and Actuator Installation................................................... 15
Figure B-11: Ambient Tube Assembly ......................................................................................... 17
Figure B-12: Bypass Door Assembly............................................................................................ 18
Figure B-13: Filter Hardware Kit.................................................................................................. 20
Figure B-14: Floor Assembly........................................................................................................ 22
Figure B-15: Maintenance Indicator Mount Assembly................................................................. 24
Figure B-16: Actuator Mount Assembly....................................................................................... 25
Figure B-17: Access Door Kit Installation.................................................................................... 26
Figure B-18: Angle Assembly, Sill, Door, Access – AFT, LWR ................................................. 28
Figure B-19: Angle Assembly, Sill, Door, Access – FWD, LWR................................................ 29
Figure B-20: Angle Assembly, Sill, Door, Access – FWD, UPR................................................. 30
Figure B-21: Access Door Assembly............................................................................................ 31
Figure B-22: 106400-101 Electrical System Installation Schematic (Bell 407) ........................... 32
Figure B-23: 106400-105 Electrical System Installation Schematic (Bell 407GX) ..................... 33
Figure B-24: 106400-101/-105 Electrical System Installation ..................................................... 34
Figure B-25: Overhead Console.................................................................................................... 35
Figure B-26: Cockpit Switch/Indicator Installation (Bell 407)..................................................... 36
Figure B-27: Main Instrument Panel - Cockpit Switch/Indicator Installation (407GX) .............. 37
Figure B-28: Wire Routing – Forward Relay Panel, Looking Inboard, LH Side ......................... 38
Figure B-29: Wire Routing – Airframe......................................................................................... 39
Figure B-30: Wire Routing - IBF Disconnect, Transmission Bay ................................................ 40

Use or disclosure of this material is subject B-1 AFS Bell 407 IBF
to restrictions on the title page Instructions for Continued Airworthiness
AFS-BH407-IBF-KIT-ICA Aerospace Filtration Systems, Inc.
Revision: G Proprietary Information

Figure B-1:106000-107/-109 IBF System Kit – Major Components

(Bell 407GX/407 respectively)

Use or disclosure of this material is subject B-2 AFS Bell 407 IBF
to restrictions on the title page Instructions for Continued Airworthiness
AFS-BH407-IBF-KIT-ICA Aerospace Filtration Systems, Inc.
Revision: G Proprietary Information

UNIT
INDEX
NUMBER
PART NUMBER ITEM NAME PER
ASSY

FIGURE B-1: IBF System & Access Door

Installation
Frame Assembly, Adapter, Filter
1 106102-103 1
(See Figure 4 for breakdown)

2 106219-205 Seal, Filter 1

Filter Hardware Kit

3 106200-101 1
(See Figure 13 for breakdown)
Filter Hardware Kit (Dry Alternate) 1
3* 106200-103
(See Figure 13 for breakdown)
Engine Wash Tube Assembly
4 106202-101 1
(See Figure 13 for breakdown)
Bypass Floor Assembly
5 106110-101 1
(See Figure 6,8,9,10 for breakdown)
Angle Assembly - LH
6 106103-103 1
(See Figure 5 for breakdown)
Angle Assembly – RH
7 106103-104 1
(See Figure 5 for breakdown)
Access Door Installation
8 106301-101 1
(See Figure 17 for breakdown)

* Filter Hardware Kit (Dry 106200-103) may be used in lieu of Filter Hardware
Kit (Oiled 106200-101)

** AN929-8J Cap used on initial installation to cap bleed airline.

Use or disclosure of this material is subject B-3 AFS Bell 407 IBF
to restrictions on the title page Instructions for Continued Airworthiness
AFS-BH407-IBF-KIT-ICA Aerospace Filtration Systems, Inc.
Revision: G Proprietary Information

Figure B-2: Adapter Frame, Floor & Closeout Angle Installation

Use or disclosure of this material is subject B-4 AFS Bell 407 IBF
to restrictions on the title page Instructions for Continued Airworthiness
AFS-BH407-IBF-KIT-ICA Aerospace Filtration Systems, Inc.
Revision: G Proprietary Information

UNIT
INDEX
NUMBER PART NUMBER ITEM NAME PER
ASSY

FIGURE B-2: Adapter Frame, Floor & Closeout

Angle Installation
Adapter Frame Assembly
1 106102-103 1
(See Figure 4 for breakdown)
Bypass Floor Assembly
2 106110-101 1
(See Figure 6, 8, 9 & 10 for breakdown)
Closeout Angle Assembly
3 106103-103 1
(See Figure 5 for breakdown)
Closeout Angle Assembly
4 106103-104 1
(See Figure 5 for breakdown)
106119-207 Data Plate (used on -107) 1
5
106119-209 Data Plate (used on -109) 1

6 MS20470AD4-4 Rivet 2

7 MS20470AD4-5 Rivet 13

8 MS20426AD4-5 Rivet 2

9 MS21140S04-06 Rivet 12

10 MS21140S04-07 Rivet 4

11 MS21140S04-08 Rivet 1

12 AN620-5 Washer 18

13 NAS6203-3 Bolt 7

14 NAS6203-4 Bolt 2

15 NAS1149D0316J Washer 9

16 AN3C3A Bolt 5

17 AN3C4A Bolt 14

18 NAS1149C0332R Washer 19

19 MS21919WDG2 Clamp 3

Use or disclosure of this material is subject B-5 AFS Bell 407 IBF
to restrictions on the title page Instructions for Continued Airworthiness
AFS-BH407-IBF-KIT-ICA Aerospace Filtration Systems, Inc.
Revision: G Proprietary Information

Figure B-3: Cowl Forward Lip Modification

UNIT
INDEX
NUMBER PART NUMBER ITEM NAME PER
ASSY

FIGURE 3: Cowl Forward Lip Modification

1 MS21060L3 Platenut 6

2 MS21062L3 Platenut 2

3 NAS1399CFA3-2 Rivet, Blind 16

Use or disclosure of this material is subject B-6 AFS Bell 407 IBF
to restrictions on the title page Instructions for Continued Airworthiness
AFS-BH407-IBF-KIT-ICA Aerospace Filtration Systems, Inc.
Revision: G Proprietary Information

Figure B-4: Filter Adapter Frame Assembly

UNIT
INDEX
NUMBER PART NUMBER ITEM NAME PER
ASSY

FIGURE 4: Filter Adapter Frame Assembly

1 106102-203 Frame, Adapter, Filter 1

2 106106-201 Spacer, Adapter – Thick 3

3 106107-201 Spacer, Adapter – Thin 4

4 NAS1097AD3-6 Rivet 14

Use or disclosure of this material is subject B-7 AFS Bell 407 IBF
to restrictions on the title page Instructions for Continued Airworthiness
AFS-BH407-IBF-KIT-ICA Aerospace Filtration Systems, Inc.
Revision: G Proprietary Information

Figure B-5: Floor Closeout Angle Assembly

UNIT
INDEX
NUMBER PART NUMBER ITEM NAME PER
ASSY

FIGURE B-5: Angle Assembly, Closeout, Floor

1 106153-203 Angle, Closeout, Floor (LH) 1

2 106108-203 Seal, Angle (LH) 1

3 MS21060L3 Platenut 8

4 NAS1097AD3-3 Rivet 16

5 106153-204 Angle, Closeout, Floor (RH) 1

6 106108-204 Seal, Angle, Side (RH) 1

Use or disclosure of this material is subject B-8 AFS Bell 407 IBF
to restrictions on the title page Instructions for Continued Airworthiness
AFS-BH407-IBF-KIT-ICA Aerospace Filtration Systems, Inc.
Revision: G Proprietary Information

Figure B-6: Wire Harness Assembly Installation

UNIT
INDEX
NUMBER PART NUMBER ITEM NAME PER
ASSY

FIGURE B-6: Floor and Wire Harness Assembly

1 106401-105 Wire Harness Assembly 1

2 NAS1149DN416J Washer 16

3 MS21042L04 Nut 8

4 MS35206-215 Screw 4

5 MS35206-216 Screw 4

Use or disclosure of this material is subject B-9 AFS Bell 407 IBF
to restrictions on the title page Instructions for Continued Airworthiness
AFS-BH407-IBF-KIT-ICA Aerospace Filtration Systems, Inc.
Revision: G Proprietary Information

Figure B-7: Wire Harness Assembly

UNIT
INDEX
NUMBER PART NUMBER ITEM NAME PER
ASSY

FIGURE B-7: Wire Harness Assembly

1 D38999/20MA35SN Receptacle 1

2 M85049/38S9W Backshell 1

3 M85049/38S11W Backshell 1

4 D38999/20WB5PN Receptacle 1

5 M85049/39S9W Backshell 1

6 D38999/26WA98SA Plug 1

Use or disclosure of this material is subject B-10 AFS Bell 407 IBF
to restrictions on the title page Instructions for Continued Airworthiness
AFS-BH407-IBF-KIT-ICA Aerospace Filtration Systems, Inc.
Revision: G Proprietary Information

Figure B-8: Firewall Seal and Maintenance Indicator Installation

Use or disclosure of this material is subject B-11 AFS Bell 407 IBF
to restrictions on the title page Instructions for Continued Airworthiness
AFS-BH407-IBF-KIT-ICA Aerospace Filtration Systems, Inc.
Revision: G Proprietary Information

UNIT
INDEX
NUMBER PART NUMBER ITEM NAME PER
ASSY

FIGURE B-8: Firewall Seal and Maintenance

Indicator Installation

1 106125-207 Seal, Firewall 1

2 NAS6203-2 Bolt 2

3 NAS1149D0332J Washer 2

4 100442-201 Retainer, Indicator, Maintenance 1

5 100444-201 Cushion, Indicator, Maintenance 2

6 104441-205 Indicator, Maintenance 1

7 A-400-1-2 Adapter 1

8 106167-201 Tube, Plenum 1

9 MS35489-65 Grommet 1

10 AN832-4D Union 1

11 NAS1149D0716J Washer 1

12 AN924-4D Nut, Jam 1

13 AN929-4 Cap 1

Use or disclosure of this material is subject B-12 AFS Bell 407 IBF
to restrictions on the title page Instructions for Continued Airworthiness
AFS-BH407-IBF-KIT-ICA Aerospace Filtration Systems, Inc.
Revision: G Proprietary Information

Figure B-9: Differential Pressure Switch Installation

Use or disclosure of this material is subject B-13 AFS Bell 407 IBF
to restrictions on the title page Instructions for Continued Airworthiness
AFS-BH407-IBF-KIT-ICA Aerospace Filtration Systems, Inc.
Revision: G Proprietary Information

UNIT
INDEX
NUMBER PART NUMBER ITEM NAME PER
ASSY

FIGURE B-9: Differential Pressure Switch

Assembly Installation
Tube Assembly, Ambient
1 106115-101 1
(See Figure 11 for breakdown)
2 AN924-4D Nut, Jam 1

3 NAS1149D0716J Washer 1

4 106167-201 Tube, Plenum 1

5 MS35489-65 Grommet 1

6 A-402-1 Nut 1

7 A-404-1 Back Ferrule 1

8 A-403-1 Front Ferrule 1

9 100409-101 Delta-P Switch 1

10 AN525-10R8 Bolt 1

11 MS21919WDG28 Clamp 1

12 3604 Clamp, Hose 2

13 106116-201 Hose, Ambient 1

14 AN838-4D Elbow 1

Use or disclosure of this material is subject B-14 AFS Bell 407 IBF
to restrictions on the title page Instructions for Continued Airworthiness
AFS-BH407-IBF-KIT-ICA Aerospace Filtration Systems, Inc.
Revision: G Proprietary Information

Figure B-10: Bypass Door Assembly and Actuator Installation

Use or disclosure of this material is subject B-15 AFS Bell 407 IBF
to restrictions on the title page Instructions for Continued Airworthiness
AFS-BH407-IBF-KIT-ICA Aerospace Filtration Systems, Inc.
Revision: G Proprietary Information

UNIT
INDEX
NUMBER PART NUMBER ITEM NAME PER
ASSY

FIGURE B-10: Bypass Door and Actuator

Installation
Floor Assembly
1 106111-101 1
(See Figure 14 for breakdown)
Door Assembly, Bypass
2 106120-101 1
(See Figure 12 for breakdown)

3 MS20253-2-1825 Pin 1

4 NAS6204-10D Bolt 1

5 NAS1149D0416J Washer 1

6 MS24665-132 Pin, Cotter 1

7 MS14144L4 Nut 1

8 NAS1149D0463J Washer 2

9 MS246945117 Screw 1

10 MS21045L4 Nut 1

11 106113-203 Actuator 1

Use or disclosure of this material is subject B-16 AFS Bell 407 IBF
to restrictions on the title page Instructions for Continued Airworthiness
AFS-BH407-IBF-KIT-ICA Aerospace Filtration Systems, Inc.
Revision: G Proprietary Information

Figure B-11: Ambient Tube Assembly

UNIT
INDEX
NUMBER PART NUMBER ITEM NAME PER
ASSY

FIGURE B-11: Ambient Tube Assembly

1 106165-201 Tube, Ambient 1

2 MS20819-4D Sleeve 1

3 AN818-4D Nut 1

Use or disclosure of this material is subject B-17 AFS Bell 407 IBF
to restrictions on the title page Instructions for Continued Airworthiness
AFS-BH407-IBF-KIT-ICA Aerospace Filtration Systems, Inc.
Revision: G Proprietary Information

Figure B-12: Bypass Door Assembly

Use or disclosure of this material is subject B-18 AFS Bell 407 IBF
to restrictions on the title page Instructions for Continued Airworthiness
AFS-BH407-IBF-KIT-ICA Aerospace Filtration Systems, Inc.
Revision: G Proprietary Information

UNIT
INDEX
NUMBER PART NUMBER ITEM NAME PER
ASSY

FIGURE B-12: Bypass Door Assembly

1 106124-203 Hinge Half, Door 1

2 106121-203 Door, Bypass 1

3 106122-201 Seal, Bypass Door 1

4 106123-201 Retainer, Seal, Bypass 1

5 106127-201 Plate, Clevis 2

6 NAS1149D0332J Washer 2

7 NAS6203-10 Bolt 2

8 NAS1149D0363J Washer 2

9 MS21042L3 Nut 2

10 NAS1097AD4-4 Rivet 4

11 MS20470AD4-6 Rivet 10

12 MS20470AD4-5 Rivet 14

Use or disclosure of this material is subject B-19 AFS Bell 407 IBF
to restrictions on the title page Instructions for Continued Airworthiness
AFS-BH407-IBF-KIT-ICA Aerospace Filtration Systems, Inc.
Revision: G Proprietary Information

Figure B-13: Filter Hardware Kit

Use or disclosure of this material is subject B-20 AFS Bell 407 IBF
to restrictions on the title page Instructions for Continued Airworthiness
AFS-BH407-IBF-KIT-ICA Aerospace Filtration Systems, Inc.
Revision: G Proprietary Information

UNIT
INDEX
NUMBER PART NUMBER ITEM NAME PER
ASSY

FIGURE B-13: Filter Hardware Kit

1 106201-103 Filter Assembly 1

1* 106205-101 Dry Media Filter Assembly (Alternate) 1

2 106202-101 Tube Assembly, Engine Wash 1

3 NAS6203-7 Bolt 7

4 NAS1149D0332J Washer 11

5 NAS6203-3D Bolt 2

6 MS21919WDG4 Clamp 2

7 MS14144L3 Nut,Castle 2

8 MS24665-86 Pin, Cotter 2

*Dry Media Filter Assembly (106205-101) may be used in lieu of Filter
Assembly (106201-103)

Use or disclosure of this material is subject B-21 AFS Bell 407 IBF
to restrictions on the title page Instructions for Continued Airworthiness
AFS-BH407-IBF-KIT-ICA Aerospace Filtration Systems, Inc.
Revision: G Proprietary Information

Figure B-14: Floor Assembly

Use or disclosure of this material is subject B-22 AFS Bell 407 IBF
to restrictions on the title page Instructions for Continued Airworthiness
AFS-BH407-IBF-KIT-ICA Aerospace Filtration Systems, Inc.
Revision: G Proprietary Information

UNIT
INDEX
NUMBER PART NUMBER ITEM NAME PER
ASSY

FIGURE B-14: Floor Assembly

1 106161-201 Floor 1

Mount Assembly, Indicator, Maintenance

2 106130-101 1
(See Figure 15 for breakdown)
Mount Assembly, Actuator
3 106112-101 1
(See Figure 16 for breakdown)

4 106133-201 Bracket, Electrical 1

5 106142-201 Screen, Bypass - Large 1

6 106141-201 Screen, Bypass - Small 1

7 106118-201 Hinge, Floor 1

8 MS21061L3 Platenut 2

9 MS21059L3 Platenut 5

10 MS21075L3N Platenut 7

11 106126-201 Spacer, Indicator, Maintenance 1

12 MS20470AD4-5 Rivet 3

13 NAS1097A3-3-5 Rivet 30

14 NAS1097AD4-4 Rivet 14

15 MS20470AD5-6 Rivet 1

16 NAS1097AD4-8-5 Rivet 2

17 NAS1097AD4-7 Rivet 10

18 NAS1097AD4-5 Rivet 7

19 A3236-6 Washer 14

Use or disclosure of this material is subject B-23 AFS Bell 407 IBF
to restrictions on the title page Instructions for Continued Airworthiness
AFS-BH407-IBF-KIT-ICA Aerospace Filtration Systems, Inc.
Revision: G Proprietary Information

Figure B-15: Maintenance Indicator Mount Assembly

UNIT
INDEX
NUMBER PART NUMBER ITEM NAME PER
ASSY

FIGURE 15: Maintenance Indicator Mount

Assembly

1 106131-201 Mount, Indicator, Maintenance 1

2 MS21061L3 Platenut 2

3 NAS1097AD3-3 Rivet 4

Use or disclosure of this material is subject B-24 AFS Bell 407 IBF
to restrictions on the title page Instructions for Continued Airworthiness
AFS-BH407-IBF-KIT-ICA Aerospace Filtration Systems, Inc.
Revision: G Proprietary Information

Figure B-16: Actuator Mount Assembly

UNIT
INDEX
NUMBER PART NUMBER ITEM NAME PER
ASSY

FIGURE 16: Actuator Mount Assembly

1 106162-201 Mount, Actuator 1

2 MS21075L3N Platenut 2

3 NAS1097AD3-4 Rivet 4

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to restrictions on the title page Instructions for Continued Airworthiness
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Revision: G Proprietary Information

Figure B-17: Access Door Kit Installation

(Cowl not shown for clarity)

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to restrictions on the title page Instructions for Continued Airworthiness
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Revision: G Proprietary Information

UNIT
INDEX
NUMBER PART NUMBER ITEM NAME PER
ASSY

FIGURE B-17: Cowl Modification/Access Door

Installation

1 106302-203 Plate, Sill, Door, Access - FWD 1

2 106303-203 Plate, Sill, Door, Access – AFT 1

Angle Assy, Sill, Door, Access – FWD, UPR

3 106304-103 1
(See Figure 20 for breakdown)
Angle Assy, Sill, Door, Access – FWD, LWR
4 106305-103 3
(See Figure 19 for breakdown)

5 106306-205 Angle, Sill, Door, Access – AFT, UPR 1

6 106307-207 Angle, Sill, Door, Access – AFT, MID 1

Angle Assy, Sill, Door, Access – AFT, LWR

7 106308-103 1
(See Figure 18 for breakdown)
Access Door Assembly
8 106310-101 1
(See Figure 21 for breakdown)

9 MS20470AD4-4 Rivet 8

10 MS20470AD4-5 Rivet 19

11 MS21140S04-02 Rivet, Blind 18

12 MS21140S04-03 Rivet, Blind 4

13 MS21060L3 Platenut 3

14 MS21062L3 Platenut 4

15 NAS463YC10H Shim 2

16 NAS1399CFA3-3 Rivet, Blind 8

17 NAS1097AD3-3-5 Rivet 6

18 NAS1149C0332R Washer 16

19 MS27039C1-10 Screw 16

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to restrictions on the title page Instructions for Continued Airworthiness
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Revision: G Proprietary Information

Figure B-18: Angle Assembly, Sill, Door, Access – AFT, LWR

UNIT
INDEX
NUMBER PART NUMBER ITEM NAME PER
ASSY

FIGURE 18: Angle Assembly, Sill, Door,

Access – AFT, LWR

1 106309-203 Angle, Sill, Door, Access – AFT, LWR 1

2 MS21076L3N Platenut 1

3 NAS1097AD3-3-5 Rivet 2

Use or disclosure of this material is subject B-28 AFS Bell 407 IBF
to restrictions on the title page Instructions for Continued Airworthiness
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Figure B-19: Angle Assembly, Sill, Door, Access – FWD, LWR

UNIT
INDEX
NUMBER PART NUMBER ITEM NAME PER
ASSY

FIGURE B-19: Angle Assembly, Sill, Door,

Access – FWD, LWR

1 106316-203 Angle, Sill, Door, Access – FWD, LWR 1

2 NAS1870C3-2 Platenut 1

3 NAS1097AD3-3-5 Rivet 2

Use or disclosure of this material is subject B-29 AFS Bell 407 IBF
to restrictions on the title page Instructions for Continued Airworthiness
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Revision: G Proprietary Information

Figure B-20: Angle Assembly, Sill, Door, Access – FWD, UPR

UNIT
INDEX
NUMBER PART NUMBER ITEM NAME PER
ASSY

FIGURE B-20: Angle Assembly, Sill, Door,

Access – FWD, UPR

1 106314-203 Angle, Sill, Door – FWD, UPR 1

2 NAS1870C3-2 Platenut 1

3 NAS1097AD3-3-5 Rivet 2

Use or disclosure of this material is subject B-30 AFS Bell 407 IBF
to restrictions on the title page Instructions for Continued Airworthiness
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Revision: G Proprietary Information

Figure B-21: Access Door Assembly

UNIT
INDEX
NUMBER PART NUMBER ITEM NAME PER
ASSY

FIGURE 21: Access Door Assembly

1 106311-201 Door, Access 1

2 106312-205 Seal, Door, Access 1

Use or disclosure of this material is subject B-31 AFS Bell 407 IBF
to restrictions on the title page Instructions for Continued Airworthiness
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Figure B-22: 106400-101 Electrical System Installation Schematic (Bell 407)

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Figure B-23: 106400-105 Electrical System Installation Schematic (Bell 407GX)

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WIRE RO UTING - AIRFRAME

SEE FIGURE 29

O VERHEAD CONSOLE
SEE FIGURE 25

MAIN INSTRUMENT PANEL

SEE FIGURE 26 (Bell 407)
SEE FIGURE 27 (Bell 407 GX)

IBF DISCONNECT / TRANSMISSION BAY WIRING

SEE FIGURE 29 & 30

FWD RELAY PANEL

LEFT HAND SIDE
SEE FIGURE 28

Figure B-24: 106400-101/-105 Electrical System Installation

(Bell 407/407GX Respectively)

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to restrictions on the title page Instructions for Continued Airworthiness
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Figure B-25: Overhead Console

106400-101/-105 (Bell 407/407GX respectively)

UNIT
INDEX
NUMBER PART NUMBER ITEM NAME PER
ASSY

FIGURE B-25: Overhead Console

1 MS26574-3 Circuit Breaker 1

2 100375-233 Placard “IBF” 1

3 100375-237 Placard (blank) 1

4 100-050B-500 Plug 1

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Figure B-26: Cockpit Switch/Indicator Installation (Bell 407)

UNIT
INDEX
NUMBER PART NUMBER ITEM NAME PER
ASSY

FIGURE B-26: Cockpit Switch/Indicator

Installation

1 LED-42-15-KB-36066 Cockpit Switch/Indicator (used on 407) 1

2 18-200 Connector 1

3 100375-233 Placard “IBF” 1

4 M85049/22-192 Socket (Not Shown) 10

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to restrictions on the title page
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Figure B-27: Main Instrument Panel - Cockpit Switch/Indicator Installation (407GX)

UNIT
INDEX
NUMBER PART NUMBER ITEM NAME PER
ASSY

FIGURE 27: Cockpit Switch/Indicator

Installation

1 LED-42-14-KB-SBASV Cockpit Switch/Indicator (used on 407GX) 1

2 18-200 Connector 1

3 100375-233 Placard “IBF” 1

4 M85049/22-192 Socket (Not Shown) 10

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to restrictions on the title page
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Revision: E Proprietary Information

Figure B-28: Wire Routing – Forward Relay Panel, Looking Inboard, LH Side
106400-101/-105 (Bell 407/407GX respectively)

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to restrictions on the title page
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Revision: E Proprietary Information

Figure B-29: Wire Routing – Airframe

106400-101/-105 (Bell 407/407GX respectively)

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to restrictions on the title page
AFS-BH407-IBF-KIT-ICA Aerospace Filtration Systems, Inc.
Revision: E Proprietary Information

Figure B-30: Wire Routing - IBF Disconnect, Transmission Bay

106400-101/105 (Bell 407/407GX respectively)

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to restrictions on the title page
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Revision: F Proprietary Information

ICA APPENDIX C – PARTS FIGURES

FOR BELL 407/407GX INDUCER VENT FILTER

TABLE OF FIGURES

Figure C-1:106250-101 IVF System Kit – Major Components..........................................C-2

Figure C-2:106250-101 IVF System Kit – Major Components…..………………………C-3
Figure C-3: Doubler Installation (Aluminum Cowl) ..............................................................C-5
Figure C-4: Doubler Installation (Composite Cowl).............................................................C-7
Figure C-5: Firewall Assembly Modification .........................................................................C-9
Figure C-6: Inducer Vent Filter Assembly………….…………………………………….C-10

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(ALUMINUM COWL INSTALLATION)

Figure C-1:106250-101 IVF System Kit – Major Components

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to restrictions on the title page Instructions for Continued Airworthiness
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Revision: F Proprietary Information

(COMPOSITE COWL INSTALLATION)

Figure C-2:106250-101 IVF System Kit – Major Components

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to restrictions on the title page Instructions for Continued Airworthiness
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Revision: F Proprietary Information

UNIT
INDEX
NUMBER PART NUMBER ITEM NAME PER
ASSY

FIGURE C-1 & C-2: IVF System Major Components

1 106251-101 IVF Filter Assembly 1

2 106261-201 Plenum 1

3 106262-201 Doubler 1

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Figure C-3: Doubler Installation (Aluminum Cowl)

Use or disclosure of this material is subject C-5 AFS Bell 407 IBF
to restrictions on the title page Instructions for Continued Airworthiness
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Revision: F Proprietary Information

UNIT
INDEX
NUMBER PART NUMBER ITEM NAME PER
ASSY

FIGURE C-3: Doubler Installation (Aluminum Cowl)

1 106262-201 Doubler 1

2 MS20426AD3-3 Rivet 6

3 MS21061L3 Platenut 3

4 NAS1097AD3-3-5 Rivet 2

5 NAS1097AD3-4-5 Rivet 6

6 NAS1097AD4-5 Rivet 24

7 NAS1097AD4-5-5 Rivet 2

8 NAS1097AD4-6 Rivet 3

9 NAS1097AD4-7 Rivet 7

10 NAS1870-3-2 Platenut 1

11 NAS463YDD10 Shim 3

12 NAS1097AD3-4 Rivet 2

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to restrictions on the title page Instructions for Continued Airworthiness
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Revision: F Proprietary Information

Figure C-4: Doubler Installation (Composite Cowl)

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to restrictions on the title page Instructions for Continued Airworthiness
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Revision: F Proprietary Information

UNIT
INDEX
NUMBER PART NUMBER ITEM NAME PER
ASSY

FIGURE C-4: Doubler Installation (Composite Cowl)

1 106262-201 Doubler 1

2 CB9061AA3-500 Bushing 6

3 NAS1200M4-4 Rivet 14

4 NAS1200M4-6 Rivet 2

5 NAS1200M4-7 Rivet 3

6 NAS1200M3-4-5 Rivet 4

7 NAS1200M3-3 Rivet 2

8 NAS1203-4 Bolt 2

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Figure C-5: Firewall Assembly Modification

UNIT
INDEX
NUMBER PART NUMBER ITEM NAME PER
ASSY

FIGURE C-5: Firewall Assembly Modification

1 RF35 Receptacle 1

2 RF35-5L Spacer 2

3 NAS1200M3-3 Rivet 2

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to restrictions on the title page Instructions for Continued Airworthiness
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Figure C-6: Inducer Vent Filter Assembly

Use or disclosure of this material is subject C-10 AFS IBF 407

to restrictions on the title page Instructions for Continued Airworthiness
AFS-BH407-IBF-KIT-ICA Aerospace Filtration Systems, Inc.
Revision: F Proprietary Information

UNIT
INDEX
NUMBER PART NUMBER ITEM NAME PER
ASSY

FIGURE C-6: Inducer Vent Filter Assembly

1 106258-201 Data Plate 1

2 100601-201 Ejecting Blade 4

3 100601-203 Ejecting Blade 4

4 A35T57* Stud 4

5 GH35 Grommet 4

6 NAS1097AD3-3 Rivet 16

7 NAS1097AD4-3-5 Rivet 2

8 WES7900-10-A-13 Captive Bolt 4

* - A35T54 or A35T60 Studs may be required for proper fit and security of the filter during installation

Use or disclosure of this material is subject C-11 AFS IBF 407

to restrictions on the title page Instructions for Continued Airworthiness