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EUROCOPTER INSTRUCTION
TECHNICAL REQUIREMENTS FOR THE QUALIFICATION OF DYNAMIC SYSTEM AND BLADE OVERHAUL / REPAIR CENTERS BY EUROCOPTER Summary This document defines the EUROCOPTER technical standard to be used to determine the repair and overhaul operations to be carried out when this activity is transferred to a delocalized center.
Reference Language: French In case of dispute, the version in the reference language shall prevail.
Date of enforcement: 01/07/2000 Work Group C. Giraud, G. Gaude, S. Bourgoin
Approval Technical Leaders
Executive Committee
SIGNED G. GAUDE
C. GIRAUD
J.P. PERRIN
M. HANCART
P/O G. CURCIO
This document is the property of EUROCOPTER; no part of it shall be reproduced or transmitted to third parties without the express prior written authorization of EUROCOPTER nor shall its contents be disclosed. © EUROCOPTER 06/2000
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RECORD OF MODIFICATIONS
Issue
Date
Pages Modified
Subject of the Modification
A
06/200
All
Technical requirements of the document FSNP-01-02 repeated. This document replaces FSNP-01-02 in part.
APPLICABLE DOCUMENTS
EP-19-30:
Qualification of Overhaul / Repair Centers by EUROCOPTER
EI-050-19-032:
Pre-Assessment File for the Qualification of 3rd -Level Maintenance Overhaul / Repair Centers
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CONTENTS 1. PURPOSE / SCOPE / OVERVIEW ............................................................................ 5 2. PREREQUISITES, REQUIREMENTS, QUALIFICATIONS, ORGANIZATION........... 7 2.1 PREREQUISITES .............................................................................................. 7 2.2 REQUIREMENTS .............................................................................................. 8 2.3 QUALIFICATIONS ............................................................................................. 9 2.4 ORGANIZATION................................................................................................ 10 3. INFRASTRUCTURE (LAYOUT OF WORKSHOPS AND FACILITIES)...................... 12 4. GENERAL RESOURCES FOR ROUTINE OVERHAUL OPERATIONS .................... 13 4-1. GENERAL: DEFINITION OF ROUTINE OPERATIONS IN THE OVERHAUL PROCESS.......................................................................................................... 13 4-2. GENERAL EQUIPMENT REQUIREMENTS ...................................................... 14 5. SPECIFIC EQUIPMENT AND MATERIAL REQUIRED ............................................. 37 6. PUBLICATIONS FOR THE OVERHAUL PROCESS ................................................. 38 6.1 EUROCOPTER PUBLICATIONS....................................................................... 38 6.2 OVERHAUL / REPAIR CENTER PUBLICATIONS ............................................ 39 7. TRAINING AND ADAPTATION TO THE EUROCOPTER OVERHAUL PROCEDURES .......................................................................................................... 40 8. TECHNICAL ASSISTANCE........................................................................................ 41 9. PROVISIONS FOR SPARES ..................................................................................... 42 10. REPAIR OF COMPLEX MACHINED PARTS............................................................. 43 11. RECORDING - TRACEABILITY ................................................................................. 45 12. ACTIVITY REPORT.................................................................................................... 47 12.1 DEFINITION....................................................................................................... 47 12.2 SCOPE............................................................................................................... 47 12.3 PURPOSE.......................................................................................................... 47 12.4 ACTIVITY REPORT FOR POWER TRANSMISSION SYSTEMS ..................... 47 12.5 ACTIVITY REPORT FOR BLADES ................................................................... 50
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TERMINOLOGY 1. Maintenance Levels The manufacturer has classified the different maintenance tasks according to three levels, according to their complexity, the place where they must be performed and the equipment and personnel required. Depot or 3rd -level maintenance is the highest level. It includes the overhaul and repair of the dynamic systems and the blades. The requirements concerning this activity are listed in the document EP-19-30.
2. Reconditioning Reconditioning involves a local operation on the materiel, which is not functioning correctly, irrespective of whether or not it has a specified time between overhauls. On completion of this operation, the materiel is put back into service and its TBO remains the same as it was when it was removed for reconditioning.
3. Overhaul of Dynamic Systems By overhaul, we mean the complete disassembly of the system, dimensional checks and crack detection inspections on the components, reassembly and testing according to the same procedures as for new components. All equipment must be overhauled when it reaches the end of the stipulated time between overhauls (TBO). During overhaul, all worn and damaged parts and components with a service life limit that expires before completion of the next TBO are replaced. 4. Repair Repair is making an assembly or components serviceable, in accordance with the EUROCOPTER design standard and specifications and applies to parts, tooling and test equipment provided or approved by EUROCOPTER.
5. Overhaul Center This term designates an organization authorized by EUROCOPTER to carry out overhaul, reconditioning and repair operations according to the level of approval. Within the scope of its activities, the overhaul center can embody modifications and amendments that correspond to its level of approval, including all the operations from inspection detail parts to the final inspection of the assembly or sub-assembly.
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1.
PURPOSE / SCOPE / OVERVIEW This document defines the requirements to be met by all the maintenance centers that perform overhaul and repair operations on blades, airframes and dynamic systems for which EUROCOPTER is the prime contractor and which require an exacting standard of selection and work in order to guarantee that: − The operations are performed in compliance with the technical specifications. − The quality standard required by the aircraft manufacturer is met. − The quality of the work performed is constant. NOTE: Equivalent operations performed on other equipment items form the subject of specific agreements between the repairer and the manufacturer of the equipment in question, who holds the industrial property rights. This document does not apply to the maintenance centers tasked only with the routine maintenance operations described in the Maintenance Manual (MET, MDE or MMA) or in the Repair Manual (MRR or MRM), which are limited to 2nd -level maintenance. IMPORTANT POINTS Third-level maintenance on a helicopter is one of the major activities of the aeronautical industry with very exacting implementation requirements. The dynamic systems of a helicopter are subject to fatigue stress (i.e. high alternating stress). However, since redundancy is impossible, the failure of a component can lead to a serious accident. For all these reasons, the overhaul or reconditioning of each component must be performed in accordance with the EUROCOPTER methods and procedures, including the "Frozen Operations" on vital parts, and in full compliance with the standard. All Overhaul Centers carrying out major vital operations are requested to adhere to and comply with the Eurocopter publications in force as regards: − the methods and procedures − the use of the appropriate tools − the use of parts covered by a EUROCOPTER certificate of conformity (for new and repaired parts) and distributed by the EUROCOPTER-approved network − the re-use of parts with correct identification of the aircraft type, version, the number of hours logged in service or the number of cycles in accordance with the PRE and the MRV. NOTE: The Overhaul Center undertakes to inform EUROCOPTER in writing of any difficulty or any incident likely to endanger and/or interrupt flight safety and/or the operation of the helicopters. This notification must be confirmed by registered mail with recorded delivery. This document is the property of EUROCOPTER; no part of it shall be reproduced or transmitted to third parties without the express prior written authorization of EUROCOPTER nor shall its contents be disclosed. © EUROCOPTER 06/2000
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If the materiel has been involved in an incident or an accident, a detailed report of the circumstances of the incident/accident and the damage incurred, including that to other parts or components of the helicopter in question, must also be sent. When insurance companies or brokers sell parts and sub-assemblies whose origin and traceability are not clearly established, these parts can only be considered to be airworthy once EUROCOPTER has given written approval for them to be used. The Overhaul Center undertakes not to use any materiel on which difficulties or incidents have occurred until they have received the authorization to do so from EUROCOPTER in writing. Non compliance with the above requirements will result in the cancellation of the EUROCOPTER approval and the discontinuance of the distribution of spares and the appropriate publications for the overhaul of dynamic components.
This document is the property of EUROCOPTER; no part of it shall be reproduced or transmitted to third parties without the express prior written authorization of EUROCOPTER nor shall its contents be disclosed. © EUROCOPTER 06/2000
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2.
PREREQUISITES, REQUIREMENTS, QUALIFICATIONS, ORGANIZATION 2.1
PREREQUISITES Each overhaul center must be certified and approved by its local Official Certification Agency (DGAC/GSAC, FAA, CAA, MOT/DOT, JCAB, etc.) before applying for EUROCOPTER approval. The qualification by the relevant agencies must be documented for the level and type of work performed: Overhaul or reconditioning of dynamic components: Type of helicopter and type of components listed. Non-destructive inspection (crack detection) by magnetic and fluorescent methods. The certificate must indicate the repair station number and the expiry date. For civil aircraft registered in JAA countries, regulation JAR 145 requires that: - it be established that the aircraft are used for commercial passenger or freight transport - a Maintenance Organisation Exposure (MOE) be drawn up. If there are other indications, refer to the table below: Each overhaul center must have its own Quality Manual or MOE which must comply with the rules and regulations of the local certification agency (JAA, DGAC, FAA, CAA, DOT, JCAB, etc.). A copy of this Quality Manual or MOE shall be handed over to EUROCOPTER. The overhaul center organization chart with the names of those is charge shall be supplied to EUROCOPTER. REMARK: - Military Workshops Although military customers (operator-repairer) are not interested in the manufacturer's approval (quality assurance), it is advisable that the workshops carrying out this activity meet the manufacturer's requirements, which were drawn up for both military and civil helicopters.
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2.2
REQUIREMENTS For an overhaul center to be approved by EUROCOPTER it must meet the following requirements: The center must be recognized by the Airworthiness Authorities as specified in paragraph 2.1. Meet all the requirements stipulated in the following paragraphs. Keep EUROCOPTER informed of any difficulties encountered during the overhaul and reconditioning operations. Not repair parts or change procedures without the prior written authorization of EUROCOPTER. Comply with the procedures, methods, service life limits, life cycles and operating time limits, parameters, materials, etc. specified in the EUROCOPTER publications used. Keep the EUROCOPTER publications up to date and use them as long as the approval agreement is valid. Maintain sufficient qualified and experienced personnel. Ensure that all the general-purpose and specific facilities and equipment are kept serviceable in order to guarantee the standard of quality required by EUROCOPTER. Use only spare parts distributed by a EUROCOPTER-accredited and approved network and covered by a Certificate of Conformity issued by EUROCOPTER. Accept to submit a quarterly activity report on the form provided by EUROCOPTER so that it can be included in the reliability assessment designed to ensure the improvement of our products. The Overhaul Centers shall: -
undertake to carry out only the repairs that are specified in the EUROCOPTER documents and in accordance with the repair level stipulated in the agreement
-
accept the principle of periodic inspections conducted by a EUROCOPTER representative
-
make provision for and take out a civil liability insurance policy absolving EUROCOPTER from any discrepancy caused by faulty workmanship by the Overhaul Center.
This document is the property of EUROCOPTER; no part of it shall be reproduced or transmitted to third parties without the express prior written authorization of EUROCOPTER nor shall its contents be disclosed. © EUROCOPTER 06/2000
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2.3
QUALIFICATIONS EUROCOPTER requires two qualification levels for the personnel: a) Aeronautical Mechanics or Specialists licensed by DGAC, FAA, CAA, DOT, MOT, JCAB, etc. and an NDI (crack detection) specialist qualified by the National Laboratory or by an organization recognized by the official agencies. b) The qualifications or certificates issued by EUROCOPTER on completion of an in-house training course in its licensed training center, which include: -
the qualifications for carrying out routine overhaul and reconditioning operations certificates issued by EUROCOPTER: NDI (crack detection) procedures and methods Surface protective treatment touch-up using the Dalic electrolytic pads Planning and Quality
The EUROCOPTER training for dynamic component overhaul is reserved for personnel licensed by the DGAC, FAA, CAA, DOT, MOT, etc. who have verifiable aeronautical experience, especially as regards their qualification for non-destructive inspections. IMPORTANT: In all Overhaul Centers, the personnel must include at least one person qualified by EUROCOPTER, and holder of a valid certificate, in each of the following fields -
Technician operations
for
routine
overhaul
and
reconditioning
-
NDI specialist (Level 2)
-
DALIC process surface treatment specialist
-
Quality Inspector or a second technician cross checking the operations performed.
The qualifications and certificates are valid for two years. They can be renewed providing the audits and monitoring of the activity by EUROCOPTER give satisfactory results, and by additional training when necessary. The qualification awarded by EUROCOPTER is effective only for the Centers and the personnel initially qualified and under no circumstances can it be transferred.
This document is the property of EUROCOPTER; no part of it shall be reproduced or transmitted to third parties without the express prior written authorization of EUROCOPTER nor shall its contents be disclosed. © EUROCOPTER 06/2000
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2.4
ORGANIZATION The overhaul and reconditioning of dynamic components requires a specialized organization structure so that: all the overhaul operations at the qualification level can be performed compliance with the manufacturer's instructions can be ensured a high level of quality assurance and quality control can be achieved. These requirements imply highly qualified personnel and an in-house organization* similar to that given below:
PRESIDENT
OVERHAUL CENTER DIRECTOR
QA DIRECTOR
QA MANAGER
INVESTIGATIONS
QUARANTINE STORE
PUBLICATIONS
PLAN/PROD. CONTROL MANAGER
COMMERCIAL RESP. MANAGER COMMERCIAL
LOGISTICS. MANAGER
OVERHAUL PRODUCTION MANAGER
IN-HOUSE DOCUMENTS
CUSTOMER RECORDS
INCOMING/ OUTGOING MATERIEL
AIRCRAFT MECHANICS
WORK ORDER STANDARDS
PROGRAM ANALYSIS
SPARES STORE
INVOICING & CONTROL
MATERIALS STORE
CLEANING (STRIPPING) SPECIALIST
TOOLING AND EQUIPMENT
NDI (CRACKS) SPECIALIST
BLADES SPECIALIST
DISASSEMBLY
ASSEMBLY TESTING
INSPECTORS PLANNING SCHEDULE COORDINATOR
METROLOGY/ BEARINGS
MINOR REWORK SPECIALIST
* EUROCOPTER is prepared to accept deviations, provided that it is clearly established that the authority of the Quality Manager is fully independent of that of the Production Manager.
PAINT AND SURFACE TREATMENT SPECIALIST
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The following chart defines the in-house organization in more detail and specifies the responsibilities of the Quality Control. OVERHAUL ORGANIZATION CHART DELIVERY ENTRY ACCEPTANCE
ADMINISTRATIVE MANAGEMENT COST ESTIMATES, etc
INVOICING
EQUIPMENT LOG CARDS DISASSEMBLY
FOLLOW-UP DOCUMENTS
QUALITY CONTROL
CLEANING STRIPPING
INHIBITING
CRACK DETECTION
FINISH PAINTING
VISUAL AND DIMENSIONAL CHECKS
EXAMINATION BY REVIEW BOARD FOR QUARANTINE OR SHIPPING TO EC FRANCE
SCRAP OR QUARANTINE
TEARDOWN TESTS
FINAL ASSEMBLY
REASSEMBLY ADJUSTMENT
REWORK MINOR REPAIRS
ACCEPTANCE
MAJOR REPAIRS VIA EC FRANCE (1)
SURFACE TREATMENT
RECONSTRUCTION
OF ASSEMBLY TO BE REINSTALLED
SPARES INVENTORY
PAINTING REFUSAL
ACCEPTANCE
(1) EUROCOPTER – at Marignane and La Courneuve (France) is structured to perform all types of repairs on high-technology parts requiring high-precision machining procedures. This document is the property of EUROCOPTER; no part of it shall be reproduced or transmitted to third parties without the express prior written authorization of EUROCOPTER nor shall its contents be disclosed. © EUROCOPTER 06/2000
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3.
INFRASTRUCTURE (LAYOUT OF WORKSHOPS AND FACILITIES) The infrastructure must be such that the job sequencing is rational. The workshops and facilities must be set out so as to guarantee the correct operational sequences and the intervention of specialists in the best possible conditions in order to obtain the required quality level. Description of the Layout of the Necessary Workshops and Facilities 1
Receiving and Shipping Departments
2
Offices: Planning, Inspection, Quality, Production
3
Archives, Technical Publications
4
Disassembly Point
5
Cleaning and Stripping Area
6
Measurement Area
7
Ball Bearing Inspection Area
8
Non-Destructive Inspection Facilities
9
Rework Area
10
Surface Treatment Area (DALIC process)
11
Paint Shop
12
Secure Quarantine Zone
13
Spares Store (parts and materials)
14
Assembly Point
15
Test Bench
16
Balancing Point
17
Assembly / Disassembly Point for Appraisal / Examination
18
Calibration Point (torque wrenches, caliper gauges, etc.
19
Blades shop
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4.
GENERAL RESOURCES FOR ROUTINE OVERHAUL OPERATIONS 4-1.
GENERAL: DEFINITION OF ROUTINE OPERATIONS IN THE OVERHAUL PROCESS -
Inventory and compliance with the order received for overhaul and general condition check.
-
Inventory and conformity of the documents relative to the materiel.
-
Drawing up of the work order and of the type and standard of work required (code number) according to the condition of the materiel.
-
Disassembly.
-
Cleaning and stripping.
-
Dimensional and visual checks (according to the re-use criteria).
-
Minor rework that does not require machining or special treatment.
-
Protective treatment touch-ups (electrolytic buffing, DALIC process and deembrittlement baths, Alodine, chromic anodizing, etc.).
-
Painting and varnishing (protection).
-
Assembly, adjustment and embodiment of modifications.
-
Dynamic testing with and without load (if required and in accordance with the overhaul publications).
-
Disassembly and inspection after testing (if required).
-
Final testing after disassembly and inspection (if required).
-
Finish painting.
-
Inhibiting and final inspection.
-
Updating of the relevant documents (Equipment Log Cards (FME), Sheets relative to parts to be followed up in service (life-limited parts), etc.), filing of the competed and signed work orders and measurement results (mandatory) and drawing up of the release documents.
This document is the property of EUROCOPTER; no part of it shall be reproduced or transmitted to third parties without the express prior written authorization of EUROCOPTER nor shall its contents be disclosed. © EUROCOPTER 06/2000
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4-2.
GENERAL EQUIPMENT REQUIREMENTS The following is a general list of the minimum equipment required. breakdown is different according to the type of overhaul activity. requirements are divided into two categories: -
Equipment and materiel
-
Materials
The The
1
N 1.
2.
Shipping, Receiving and Handling -
Requires an area large enough to store the materiel before it is overhauled and that waiting to be returned to the customer.
R
-
Requires that the lifting and transporting facilities for equipment used on the work site be selected and adapted to the type of product. Specific tools, trolleys with separate compartments or specially designed containers must be used for fragile components.
R
Offices: Planning, Quality, Production R
Should be limited to the essential to ensure a quality presentation in a professional atmosphere and provide sufficient space for an efficient filing system. 3.
Library Facility (Technical Publications) This area must be large enough to house both the EUROCOPTER and in-house documents that are to be filed and recorded. Copying machines and worktables for consulting and updating the publications should be provided together with the conventional archiving equipment.
1 2
R2
N R
N = Necessary R = Recommended (becomes necessary if problems occur) This document is the property of EUROCOPTER; no part of it shall be reproduced or transmitted to third parties without the express prior written authorization of EUROCOPTER nor shall its contents be disclosed. © EUROCOPTER 06/2000
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N1 4.
Disassembly Area Must be a specialized aeronautical workstation, set out for each dynamic system assembly.
N R
This area should be compatible with the assembly procedure. Each work station should be equipped for a specific dynamic system assembly (MRH, Rotor Shaft, MGB, etc.) so as to be self-contained and include the following:
N
Work benches.
-
Lifting devices (up to 1000 kg (2200 lb.) for the MGB + MRH/Shaft).
-
Mechanics standard tool kits for each workstation or group of workstations.
-
Trolleys with separators to prevent damage to the dynamic components when they are moved.
R
-
An automatic degreasing unit at each work station.
R
-
Trolley for special tools with separators to prevent them being damaged by hitting each other.
R
R N
N
-
A part corrosion inhibiting station.
N
-
A hand press.
N
-
A hydraulic press with a capacity of at least 5 tonnes.
N 3
-
An industrial oven (0 to 400 °C) with a capacity of 1 m , internal ventilation and a temperature regulating system that ensures an accuracy of ± 2 °C.
N
-
Work bench in the press area.
N
-
Surface plate (area: 1 square meter) + locating blocks.
N
NOTE:
2
N
-
The assembly/disassembly areas should include a centralized area for the equipment required for both types of operations:
1
R2
Refer to the MRV work card 60.00.12.800 for further details.
N = Necessary R = Recommended (becomes necessary if problems occur) This document is the property of EUROCOPTER; no part of it shall be reproduced or transmitted to third parties without the express prior written authorization of EUROCOPTER nor shall its contents be disclosed. © EUROCOPTER 06/2000
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N1 4.
R2
Disassembly Area (continued) R
-
Cryogenic unit for liquid nitrogen and dry ice.
-
Refrigeration unit (part contraction – 40 °C).
N
-
Compressed air (7 bars / 101 psi).
N
-
Set of standard extractors.
-
Set of torque wrenches:
R
0 to 1 m.daN 0 to 5 m.daN 1 to 10 m.daN
N
10 to 30 m.daN -
"Acratork" torque wrench test kit for routine calibration 0 to 5 m.daN 5 to 10 m.daN
R
> 10 m.daN
NOTE:
1 2
Refer to the MRV work card 60.00.22.800 for further details.
N = Necessary R = Recommended (becomes necessary if problems occur) This document is the property of EUROCOPTER; no part of it shall be reproduced or transmitted to third parties without the express prior written authorization of EUROCOPTER nor shall its contents be disclosed. © EUROCOPTER 06/2000
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N1 5.
R2
Cleaning and Stripping Area Refer to paragraph 7 of this chapter for the cleaning of ball, roller bearings etc. The cleaning and stripping area must be set out in a rational way in order to avoid creating an uncomfortable environment for the operators, which could affect the quality of the work performed.
N
It is of prime importance that compliance be ensured with the procedures, methods and materials given on the work card 6X.XX.XX.805. It should be noted that certain methods and products can affect the operational integrity of the part and modify its characteristics (service life limit, fatigue strength, etc.) if they are not authorized or recommended by EUROCOPTER. Equipment Required: - Vat for cleaning and stripping with temperature and time controls. - Pressurized water for rinsing. - Specific installation for dry stripping. - Air ventilation and protection against contamination of the environment on all the tanks containing toxic products. NOTE: 6.
R N R R
Refer to the MRV work card 60.00.22.800 for further details.
Measuring and Inspection Room The temperature in the room that houses the measuring equipment must be maintained at 20 ± 2 °C with a relative humidity < 40% and it must be set out in a rational way. In a medium sized company, this area may also include the Calibration shop. In the rest of the measuring and inspection area, the temperature should be 22 ± 4 °C. Equipment Required (all values are expressed in metric units (mm)): - Test benches - Storage for measuring equipment - Surface plate (1500 x 1000, 1:1 accuracy) - Set of locating blocks: 50, 100, 200 mm high - Magnetic Vee blocks - Borescope + spot light: Type SA SS/Wolf 10302 - Binocular microscope: Wild M3 or equivalent - Vertical micrometer gauge column with digital display - Electronic precision balance: Type Sauter RC 2022, capacity 2.1 kg, accuracy to within 0.01 gram, or equivalent
N
N N N N N R N N *
1
N = Necessary R = Recommended (becomes necessary if problems occur) * Necessary for shaft balancing operations
2
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N1 6.
R2
Measuring and Inspection Room (continued) Measuring Equipment NOTE:
1 2
ALL THE MEASURING INSTRUMENTS MUST USE THE METRIC SYSTEM AND GIVE A DIRECT READING IN ACCORDANCE WITH THE EUROCOPTER PUBLICATIONS.
-
Outside micrometer with reference blocks from 0 to 25, 25 to 50, 50 to 75, 75 to 100, 100 to 125, 124 to 150, 150 to 175, 175 to 200 and 200 to 250 (accuracy: ± 0.002).
N
-
2 and 3-point inside micrometer with calibration rings. A complete set of reference blocks: 5 to 100 (accuracy: ± 0.002) and 100 to 125; 125 to 150, 175 to 200 and 200 to 225 (accuracy: ± 0.002).
N
-
Set of caliper gauges with digital readout (Accuracy 0.02 mm) 0 to 200, 0 to 400
N
-
Inside caliper gauges with dial, 10 to 150 (Intertest)
N
-
Disk micrometers: 0 to 25, 25 to 50 + 50 to 75 (accuracy: ± 0.001)
-
Ball micrometer, 0 to 25 (accuracy: ± 0.001)
N
-
Outside micrometer (with 2 mm diameter ball), 0 to 25 (Accuracy 0.002)
N
-
Outside micrometer, 0 to 25 (Accuracy 0.002)
R
-
“Borematic” snap-open bore gauge, 10 to 50
R
-
Depth micrometer, 0 to 75 (Reading to within 0.010)
R
-
Depth gauge with dial indicator (Capacity: 10 mm depth)
N
-
Thickness measuring gauge with a dial indicator
N
-
Dial indicator with adjustable feelers for bores and grooves, 10 to 150 mm
-
Extensible micrometer with dial indicator holder
N
-
Dial indicators, horizontal, perpendicular and lateral types with oscillating feelers and totalizer (3 off)
N
-
Accessories for gauge blocks and replacement balls, 1 and 2 diameter
N
-
Accessories for outside micrometer
N
R
R
N = Necessary R = Recommended (becomes necessary if problems occur) This document is the property of EUROCOPTER; no part of it shall be reproduced or transmitted to third parties without the express prior written authorization of EUROCOPTER nor shall its contents be disclosed. © EUROCOPTER 06/2000
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N1 6.
R2
Measuring and Inspection Room (continued) Measuring Equipment (continued) -
Dial indicator accessories:
N
For use on surface plate
N
Magnetic base rigid arm
N
Magnetic base flexible arm
N
Accessories for 90° support (articulated and centering) (3 off)
N
-
Caliper marking gauge width dial indicator adapters
R
-
Borescope with dial indicator, capable of measuring 25 to 50 and 50 to 3000
R
-
Set of gauge blocks (Class 1) Johansson kit - 122 pieces, 0.99 to 100 mm or Mitutoyo kit - 87 pieces or equivalent
N
-
Spline and teeth measuring pins (set of 2) that can be procured from EUROCOPTER for accurate measurement - Diameters in mm: 1 - 2 - 2.360 - 2.650 - 3 - 3.333 - 3.5 - 5 - 5.250 - 5.5 and 6
N
-
Oil jet inspection pins - diameters: 0.7 - 0.8 - 0.9 - 1.2 - 1.6 and 1.7
N
-
Temporary corrosion prevention station, degreasing and petrolatum lubrication
N
NOTE:
1 2
tanks
for
Baltane
Refer to the MRV work cards 60.00.23.800 / 24.800 / 26.800 / 30.800 / 41.800 / 41.801 for further instructions, details and requirements concerning Quality.
N = Necessary R = Recommended (becomes necessary if problems occur) This document is the property of EUROCOPTER; no part of it shall be reproduced or transmitted to third parties without the express prior written authorization of EUROCOPTER nor shall its contents be disclosed. © EUROCOPTER 06/2000
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N1 7.
R2
Bearing Inspection Station Two methods are to be considered, according to the type of bearing: -
separable bearings
-
non-separable bearings
1. Separable Bearings Bearing cleaning station:
N
For large dimension bearings: ultrasonic cleaning tanks with stainless steel baskets and nylon separators
N
For oil-lubricated bearings, a white spirit tank (brush clean)
N
-
Temporary protective treatment station (48 hours maximum)
N
-
Defect visualization and inspection station:
N
Measuring instruments listed in paragraph 6: work bench (laminate top) with high intensity swiveling lamp and a 2.5x magnifier
N
Magnifiers: 3x, 6x and 9 x
N
-
R
Binocular microscope (Wild M3 type, 6.4x, 16x, 40x) -
Lubricating, Inhibiting and Packing Station:
N
Temporary bearing protective treatment bath (70% Lubro + white spirit at ambient temperature
N
Waxed wrapping paper
N
CAUTION: NOTE:
A fan and environment pollution protection must be provided on each tank containing toxic substances.
Refer to the MRV work cards 60.00.30.800 / 60.00.41.800 / 600.00.42.800 for further information.
2. Non-Separable Bearings -
Station equipped with a bearing analyzer + vertical lathe with pneumatic spindle (EUROCOPTER patent) P/N 86.00.03.27201
NOTE:
1 2 3
A3
The EUROCOPTER-approved repair center may subcontract the inspection of non-separable bearings to EUROCOPTER.
N = Necessary R = Recommended (becomes necessary if problems occur) A = EUROCOPTER only This document is the property of EUROCOPTER; no part of it shall be reproduced or transmitted to third parties without the express prior written authorization of EUROCOPTER nor shall its contents be disclosed. © EUROCOPTER 06/2000
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8.
Non-Destructive Inspections (NDI) Crack detection is one of the major activities for the personnel specifically qualified by the local official agencies (DGAC, FAA, CAA, DOT, MOT, etc.) and who have been trained to use the procedures and methods in the technical publications used and confirmed by EUROCOPTER (in particular for crack detection using the magnetic, dye penetrant and Eddy current methods). EUROCOPTER places this activity in the Vital Operations category. Some of these operations are Frozen Operations and no deviations from the method, procedure, sequence, order etc. can be allowed. For these reasons and in order to guarantee the safety of the materiel after inspection, the detection equipment listed below must be used. At the Repair Centers’ request, EUROCOPTER is willing to assist them if they encounter difficulties or have any doubts when examining faulty parts. N1
R2
8.1 Magnetic Crack Detection Inspection Station (Figure 1) Reference Documents: IGC 04.25.105 and QAF 09-11 (at the latest issue) -
Equipment required: All the manufacturer equipment items listed below are given for information only.
-
Magnetic crack detection equipment that can be used with both methods (electric and magnetic). Equipment combining the two methods is not accepted by EUROCOPTER in view of its borderline performance. Direct reading of the current peak values (1) on the indicator is indispensable. NOTE:
-
1 2
At the present time, the machine to be used must have a capacity of 6500 amperes. Overhead ultra-violet light and/or portable ultra-violet light High-intensity UV lighting source Magnetic field meter (tangential field strength) Demagnetizer Magnetic field meter (demagnetization check) Portable crane (200 kg (440 lb.) capacity Tanks for Baltane degreasing and petrolatum lubrication
N
N R N N N R R
Standard utilities: Electricity (including 24V) Compressed air ≈ 7 bars (101 psi) Water
N = Necessary R = Recommended (becomes necessary if problems occur) This document is the property of EUROCOPTER; no part of it shall be reproduced or transmitted to third parties without the express prior written authorization of EUROCOPTER nor shall its contents be disclosed. © EUROCOPTER 06/2000
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N1
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8.1 Magnetic Crack Detection Inspection Station (continued) -
-
-
Control and Calibration Equipment: Sample for product validity check
For periodic
N
“Berthold” cross
performance checks
N
Microcrack specimens
of material and
N
Crack sample parts
personnel
N
Equipment inspection schedule (daily, weekly, monthly)
N
Names and photos of the NDI specialists with their License number, vision test, etc.
N
Miscellaneous Equipment: Copper braids (to prevent electrical arc on parts)
N
PTFE-coated bars (of various diameters in accordance with MRV), diameter in mm: 6, 8, 10, 12, 14, 15, 25, 35, 40, 45, 65, 70, 80, 110 and 160
N
Special jaws (rollers, vee-blocks, rotating disks)
R
Parts trolley with separation to prevent damage to the parts during transportation
R
Materials Required: Fluorescent penetrant in accordance with the EUROCOPTER technical publications CAUTION:
1 2
N
The NDI area must be equipped with an exhaust fan system over the crack detection equipment and electrical insulation on the floor to protect the operator.
N = Necessary R = Recommended (becomes necessary if problems occur) This document is the property of EUROCOPTER; no part of it shall be reproduced or transmitted to third parties without the express prior written authorization of EUROCOPTER nor shall its contents be disclosed. © EUROCOPTER 06/2000
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8.1 Magnetic Crack Detection Inspection Station (continued) The magnetic crack detection equipment must be protected with blue (or black) curtains from floor to ceiling on all sides and on the ceiling, unless the room is totally blacked out or the windows are tinted blue. EXTRACTOR FAN 300 kg (660 lbs) PIVOTING LIFTING EQUIPMENT
EAST
ELN 5120 OVERHEAD LIGHT
DEMAGNETIZER
ELN 25A UV INSPECTION LIGHT
C30 MAGNETIC CRACK DETECTOR
WEST BALTANE DEGREASING (brush or rag) PETROLATUM LUBRICATION
PARTS FOR TREATMENT TROLLEY STORAGE CONTAINERS FOR: - TEST SPECIMENS TREATED PARTS TROLLEY
BALTANE DEGREASING
- MASTERS - MEASURING ELEMENTS - COPPER BARS ETC...
Figure 1
This document is the property of EUROCOPTER; no part of it shall be reproduced or transmitted to third parties without the express prior written authorization of EUROCOPTER nor shall its contents be disclosed. © EUROCOPTER 06/2000
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8.2 Dye Penetrant Crack Detection Inspection Station (Figure 2) Reference Documents: IGC 04.25.100, IGC 04.25.101; QAF 05-09; MP 62.11.04, MP 62.11.05, MP 62.11.82, MP 62.11.41.83 -
-
-
-
-
Equipment Required: The examination booth, isolated by blue (or black) curtains, with the same characteristics as those for the magnetic station. A series of stainless steel tanks with temperature indicator and timer as shown in Figure 2 Examination booth with overhead ultra-violet light Already Portable ultra-violet light specified High-intensity UV lighting source in § 8.1 Control and Calibration Equipment: Sample for product validity check For periodic Microcrack specimens performance (IGC 04.25.100) checks of material Crack sample parts and personnel Equipment inspection schedule (daily, weekly, monthly) Names and photos of the NDI specialists with their License number, vision test, etc. Miscellaneous Equipment: Lifting system with rails Parts trolley with separations to prevent impact damage Spray gun for developer fluid (1.2 to 1.5 bar, reservoir with agitator) Spray for rinsing with soft water (2 to 3 bars) Dry compressed air spray gun Drying cabinet (like an oven) 90 °C Standard Utilities: Electricity (including 24V) Compressed air (7 bars (101 psi)) Water
2
N N R
N N N N N
R R N N R N N N N
Materials Required: All the materials used must be in accordance with the EUROCOPTER document IGC 04.25.101 and Figure 2. CAUTION:
1
N
All the tanks containing toxic substances must have an extractor fan system, a water recycling system and an environment protection system.
N = Necessary R = Recommended (becomes necessary if problems occur) This document is the property of EUROCOPTER; no part of it shall be reproduced or transmitted to third parties without the express prior written authorization of EUROCOPTER nor shall its contents be disclosed. © EUROCOPTER 06/2000
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8.2 Dye Penetrant Crack Detection Inspection Station (continued)
RINSING IN RUNNING WATER
DAMP APPLICATION WITH SPRAY GUN AT 1.2 to 1.5 BARS PRESSURE (STIRRER IN SPRAY GUN TANK)
NEUTRAL OIL (VASELINE) LUBRICATION
1
TREATED PARTS TROLLEY
1 TRICHL0ROETHYLENE VAPOR DEGREASING AT 87 °C FOR 2 TO 3 MINUTES
1
1
1
ALKALINE DEGREASING AT 60 °C + 5 °C FOR 4 MINUTES MP 62.11.05
2
RINSING WITH WATER FROM SPRAY GUN UNDER 2 - 3 BARS PRESSURE FOR 3 MIN. MAX.
8
1
SOAKING FOR 10 MINUTES
1
APPLICATION OF DYE PENETRANT FOR 10 MIN. AT AMBIENT TEMPERATURE
7
SULFO-CHROMIC RINSING IN RECYCLED WATER
6
1
PARTS FOR TREATMENT TROLLEY
MP 62.11.04
DRYING WITH 90°C AIR FOR APPROX. 3 MIN. (to be defined according to dimensions of part)
ELN 25A UV INSPECTION LAMP
996 R9D1 VISUALIZATION BOOTH WITH BLUE CURTAINS
SULFO-CHROMIC ETCHING AT AMBIENT TEMPERATURE FOR 20 MINUTES
5
MP 62.41.83 RECIPIENT SALTANE POUR ALKALINE PIECES EN TITANE RINSING IN SANS RECYCLED DEGRAISSAGE WATER TRICHLO EN PHASE VAPEUR 3
SALTANE VAT FOR TITANIUM PARTS WITHOUT TRICHLOROETHYLENE DEGREASING MP 62.51.00
4
WATER RECYCLING SYSTEM
ALARM, TIMER AND TEMPERATURE INDICATOR
Figure 2 - Typical Installation This document is the property of EUROCOPTER; no part of it shall be reproduced or transmitted to third parties without the express prior written authorization of EUROCOPTER nor shall its contents be disclosed. © EUROCOPTER 06/2000
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N1 9.
R2
Rework Area Arranged in specific work areas for detail parts and sub-assemblies to perform minor rework operations (no machining), stud replacement, adjustment of setting shims, corrosion removal and identification marking (vibro-etching).
- Equipment Required
1 2
Work benches with vices
N
White spirit cleaning station (or equivalent products)
N
Portable pneumatic (or electric) drill
N
Pneumatic vibro-etcher
N
Compressed air (7 bars (101 psi))
R
Drill press
R
Horizontal surface grinder with magnetic table and automatic micrometer feed (type Muller MP 52 or equivalent)
R
NOTE:
At the repairer's request, EUROCOPTER will provide a set of pre-ground shims. The repairer will not then need to invest in a horizontal surface grinder.
NOTE:
Refer to the MRV work card 60.00.30.800 for further details concerning the additional small general-purpose equipment required.
N = Necessary R = Recommended (becomes necessary if problems occur) This document is the property of EUROCOPTER; no part of it shall be reproduced or transmitted to third parties without the express prior written authorization of EUROCOPTER nor shall its contents be disclosed. © EUROCOPTER 06/2000
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10. Surface Treatment Station Reference Document; IFMA 276 Certain surface treatments cause embrittlement and this can have an adverse effect on the operational integrity and the properties of the parts treated (e.g. shorter service life, reduced fatigue strength, lower corrosion resistance) if they are not carried out in accordance with the methods and procedures stipulated in the EUROCOPTER overhaul publications. Consequently, in order to prevent the fatigue strength of any parts being affected, EUROCOPTER has decided to authorize accredited Repair Centers to perform only the treatments that do not cause embrittlement. The following list of equipment and materials has been drawn up so as to ensure a minimum investment on the part of the Repair Center. MINIMUM EQUIPMENT: to treat a surface of 15 cm² maximum (for all EUROCOPTER-approved Repair Centers) - "DALIC" electrolytic buffing unit (pad plating – See Figure 3, page 29) Direct current generator – Output current: 30 Amp., 30 to 50 Volts a) For pad cadmium plating (steel parts) Anode X13 (10 each) – code 0105 Anode cover No. 13 (bag of 50) – code 0205 Pad holder AX (box of 4) – code 0302 Approved Dalic products, made in France Cadmium N (1 liter) – code 11003A Stripping agent (1 liter) – surface preparation – code 10006A Passivation solution No. 2 (1 liter) – code 10033A For cadmium plating touch-ups on blades: Cadmium bath No. 13 per IFCN 08 Chromic finish bath No. 8 per IFCN 08 b) For pad chromic anodizing (OAC) (alloy parts) Same anode, anode cover and pad holder as for pad cadmium plating + cover Box No. 14 (bag of 10) – code 0214 French-made Dalic products only are authorized Chromic anodizing product Y1 (1 liter) – code 10025A Stripping product Z (1 liter) – code 10007A *
1 2
N
N N N N N N N
N
N N
All Dalic France identification numbers are subject to change without notice
N = Necessary R = Recommended (becomes necessary if problems occur) This document is the property of EUROCOPTER; no part of it shall be reproduced or transmitted to third parties without the express prior written authorization of EUROCOPTER nor shall its contents be disclosed. © EUROCOPTER 06/2000
EI 050-19-031-A Page 28/55
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10. Surface Treatment Station (continued) - Minimum Equipment Required (continued) - Work table assembly TT5 – code E15003 - Chromic finish bath for cadmium plating per MTV MP 62.11.50 (Steel parts at ambient temperature) with solution (with stirrer) - Chromic anodizing finish bath per MTV MP 62.41.30 (aluminium alloy parts). If the aluminium part has steel bushes, studs etc. do not use the chromic anodizing finish bath. - Common Equipment - Trichloroethylene or equivalent degreasing vat - Class B water for rinsing and neutralizing - Alodine 1200 S bath with agitator (with temperature controller and timer) (MTV MP 62.41.20) - Acid product for local touch-ups on magnesium casings +parts - Permascope or Deltascope or Mikrotest to check the cadmium plating thickness - Testascope to check the chromic anodizing thickness - Optional Equipment (EUROCOPTER subsidiary) for brush plating parts larger than 15 cm and for re-coating - Generator, model Dalic NOVA 60A 50V – code E0560.0A Output current: 60 Amps at 50 V. NOTE: This generator replaces the Dalic machine, model NV30A - Turning gear/positioner assembly (Horizontal/Vertical) – code E07001 - Centering lens support (long parts) – code 07003 - Work table assembly TT5 (code 15003) with air/pollution extractor or equivalent - Mobile Hydroton station, version B (PMHB) – code 09001, for the preparation of surfaces to be re-coated NOTE:
1 2
N N
N N N N N N
N
N N N N
This PMHB requires a supply of dry, de-oiled compressed air (pressure: 4.5 bars (65 psi), flow rate 75 cubic meters of negative pressure air per hour)
N = Necessary R = Recommended (becomes necessary if problems occur) This document is the property of EUROCOPTER; no part of it shall be reproduced or transmitted to third parties without the express prior written authorization of EUROCOPTER nor shall its contents be disclosed. © EUROCOPTER 06/2000
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10. Surface Treatment Station (continued) - Maximum Equipment Required (Eurocopter Subsidiary) (contd.) - Rack 2297 assembly – code 15011 to hold the electrolyte pads during the treatment - Hydroton booth, type H5B, to house the PMHB – code 09002 - DALIPOMPE pump assembly, 2 heads – code 09002 - Pad support racks, Types: RE 25 code 0303, RE 40 code 0304, RE 50/75/100 code 0305, RSE 100/6 CODE 0306 - Anodes, Types: T6 code 0102, X10 code 0104, X13 code 0105, RE25P code 0106, RE50 code 0108, RE1009 code 0112, RE75P code 0110, A1501 code 0117 - Covers: No. 1 code 0201, 2 code 0202, 13 code 0205, F13 code 0211, Box No. 14 code 0214, 25 code 0206, 40 code 0207, No.1_F100 code 0210 - Dalic France electrolytic solutions for: cadmium plating code 11003A and chromic anodizing code 10025A (brush plating), nickel plating code 11020A, 11019A and 11023A, silver plating code S13009A, chromium plating code EP11005A and copper plating code S11010A (for re-coating and inside diameters) and miscellaneous products, inhibitor No. 10 code 10021A - Abrasive CC 115 code 0811 and CC35 code 0813 (25 kg) - Other Surface Treatments with Non-Embrittlement Baths - Matt chrome pickling for magnesium parts MP 62.41.30 and 31 - Phosphatation (Bonderite treatment) MP 62.31.30 (Parcolubrite) - Chromic anodizing MP 62.41.30 and 31
N R N N N
N
N
R R R R
EUROCOPTER offers all its approved Repair Centers the possibility to perform the surface treatments in the EUROCOPTER workshops using the equipment and non-embrittlement baths listed above. (The complete surface treatment can only be carried out at EUROCOPTER) NOTE:
1 2
Refer to the MRV work card 60.00.24.800 for further information.
N = Necessary R = Recommended (becomes necessary if problems occur) This document is the property of EUROCOPTER; no part of it shall be reproduced or transmitted to third parties without the express prior written authorization of EUROCOPTER nor shall its contents be disclosed. © EUROCOPTER 06/2000
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Dalic Process Treatment Station (Brush Plating) (Figure 3)
BALTANE DEGREASING BATH
DALIC PROCESS TYPE H5B HYDROTON BOOTH
EXTRACTOR
1/2 m3 ~
DALIC NVOA 60.50 GENERATOR WITH VARIABLE-SPEED DRIVE
ANODE AND DALIC PRODUCTS STORAGE CABINET
1/2 m3 ~
1/2 m3 ~
CADMIUM PLATING CHROMIC FINISH BATH PER MP 62.11.50
CHROMIC ANODIZING CHROMIC FINISH SEALING BATH PER MP 62.11.50
SOFTENED WATER RINSING BATH
EXTRACTORS
Figure 3
This document is the property of EUROCOPTER; no part of it shall be reproduced or transmitted to third parties without the express prior written authorization of EUROCOPTER nor shall its contents be disclosed. © EUROCOPTER 06/2000
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11. Paint Shop The paint shop must be completely separate from the other overhaul facilities. Moreover it must be fully equipped to meet all the requirements specified in the overhaul publications (MRV and MTV). It shall also comply with the safety standards in force in the country. The relative humidity must be maintained between 40% and 70%. Painting is a vital activity ensuring additional protection against corrosion. Parts and components must be painted in accordance with the requirements for the areas to be painted and those not to be painted. Before being painted, the part surfaces must be clean (no corrosion, no traces of oil, etc.) and thoroughly degreased. The products (paint, varnish, "Proseal" sealing product, etc.) to be used must be left in their original containers for at least 8 hours in the paint shop until they reach the ambient temperature. The expiry date for the products shall not be exceeded. - Major products used in the overhaul process: -
Paint: Strontium epoxy primer P5/P20 (application per IFM 195) nitrovinyl or nitroacrylic primer P80 with polyurethane top coat P81
N
-
Varnish: Graphoil D148,Dow-corning 3400, Dow-corning 3402 (anti-fretting products to be used per IFM 391 and 322), PTFE – used for protection.
N
-
Paint Varnish (baked): Pyrolac 610 – 611 bis P10 (used per MP 64.41.20) Pyrolac 611.P11 (used per MP 68.45.10)
-
Miscellaneous Products: Molykote X106
NOTE:
1 2
Proseal P1221 – PR1221B etc.,
R N N
Refer to the MRV work card 60.00.24.800 for further information.
N = Necessary R = Recommended (becomes necessary if problems occur) This document is the property of EUROCOPTER; no part of it shall be reproduced or transmitted to third parties without the express prior written authorization of EUROCOPTER nor shall its contents be disclosed. © EUROCOPTER 06/2000
EI 050-19-031-A Page 32/55
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12. Quarantine Area The quarantine area forms part of the Quality Assurance Department. It is used to store all damaged or out-of-tolerance parts well away from all other parts in good condition and thus prevent damaged or out-oftolerance parts being used again during overhaul or repair. The quarantine area must contain the parts that have been declared unworthy for flight, such as:
1 2
-
Parts beyond the repair possibility of the Overhaul Manual awaiting examination or the decision of a EUROCOPTER specialist.
N
-
Parts that have reached their operating or cycle limit (to be destroyed during disassembly) and held for 60 days maximum to be returned to the customer, if requested.
N
-
Parts that have been involved in an accident or an incident (to be presented to the Airworthiness Authorities or the insurance company).
N
All parts in this category must be labeled or destroyed to ensure that they cannot be used again.
N
In all cases, the label affixed to the components and assemblies shall contain all the information on their history.
N
The quarantine area must be a secure area, and accessible only by the Quality Control Department managers.
N
N = Necessary R = Recommended (becomes necessary if problems occur) This document is the property of EUROCOPTER; no part of it shall be reproduced or transmitted to third parties without the express prior written authorization of EUROCOPTER nor shall its contents be disclosed. © EUROCOPTER 06/2000
EI 050-19-031-A Page 33/55
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13. Spares and Materials Storage Area The spares store must be designed in such a way that all new and repaired parts from a EUROCOPTER-approved network can be stored, fully protected against deterioration.
N
Elastomers and other life-limited products must be stored in a ventilated area, where the temperature and relative humidity can be controlled and where they can be protected from harsh lighting.
N
Materials with a cure date shall be stored according to their shelf life (first in – first out).
N
Toxic, flammable and explosive materials shall be stored in a special area with fireproof partitions. When necessary, a refrigerator or a freezer shall be available to store certain products.
R
14. Assembly Area (May be the disassembly area) NOTE:
Refer to the MRV work cards 60.00.24.800 / 60.00.26.800 / 60.00.51.800 for further information and requirements.
15. Test Bench Facility The current test bench requirements are specified by EUROCOPTER. The part numbers and details concerning the test benches required are given in the specific tooling lists. As a general rule, all test benches conveying power should be installed in test cells with the required facilities (electricity, water, compressed air, etc.) and a ventilation system (forced air fan and extractor).
R
This does not apply to the test facilities that operate either at the nominal speed or the nominal torque. The control panels should be installed outside the test area so as to prevent all risks of an incident likely to cause the rupture of a part at high speed. NOTE:
1 2
N
Refer to the MRV work cards 60.00.60.801 / 60.00.65.800 0 for further information.
N = Necessary R = Recommended (becomes necessary if problems occur) This document is the property of EUROCOPTER; no part of it shall be reproduced or transmitted to third parties without the express prior written authorization of EUROCOPTER nor shall its contents be disclosed. © EUROCOPTER 06/2000
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16. Balancing Shop This shop should be located in restricted atmosphere (no airflow) in order to ensure adequate balance correction. For all helicopters, this shop should be equipped with: -
Dynamic balancing machine with associated equipment to meet the requirements for the balancing schedule (MRV work card 6X.XX.XX.850).
N
-
Precision balance (0.01 gram accuracy) with 0.05 gram graduations refer to § 6, page 17.
N
NOTE:
The dynamic balancing of an assembly can be performed by EUROCOPTER. In this case, the Repairer does not need to lay out capital to purchase a dynamic balancing machine.
17. Assembly / Disassembly Area A clean work space should be reserved, large enough to carry out disassembly/assembly and the examination of parts involved in an incident or an accident (blade strike – overtorque – overheating, etc.)
N
18. Calibration Shop Temperature and humidity control is mandatory in this shop. The shop must be equipped for the calibration of all the equipment requiring periodic calibration. Repair Centers may subcontract the calibration of equipment to a laboratory with government agency approval.
1 2
N
R
N = Necessary R = Recommended (becomes necessary if problems occur) This document is the property of EUROCOPTER; no part of it shall be reproduced or transmitted to third parties without the express prior written authorization of EUROCOPTER nor shall its contents be disclosed. © EUROCOPTER 06/2000
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19. Blades Shop In addition to the areas described above and according to the level of operations performed on blades specified in the EUROCOPTER agreement, one or two specific rooms shall be provided: -
Level C-Cov operations: a repair room
-
Level B – Bov operations: a repair room and a balancing room
N
1. Repair Room This room must be large enough for the blades and the equipment to be handled easily and for work to be carried out on several blades at the same time. Temperature and humidity control (temperature between 20 and 26 °C and relative humidity between 40 and 60%) and permanent recording of these parameters must be provided in this room.
N
An air lock must be provided on all access points between the airconditioned room and the outside.
N
This room must be dust-free which means that certain operations such as the sanding of large areas, must be carried out elsewhere.
N
This room shall also include: - a water supply - a compressed air supply (7 bars) - at least three 220 V/50 Hz - 16 A electrical sockets - a blade handling trolley - wall racks for blade storage (stabilized temperature and relative humidity) - a glass cloth dispenser, also used for storage, out of the light - a 150 kg-capacity hoist - a tool storage area - a work bench with a vice - a mechanic's standard tool kit - all the specific equipment and tooling (see file No. 2) required by the technical publications
N N N R N N R N N N N
Moreover, the room shall meet the safety requirements in force in the country (fire protection, electrical safety standards, etc.)
1 2
N = Necessary R = Recommended (becomes necessary if problems occur) This document is the property of EUROCOPTER; no part of it shall be reproduced or transmitted to third parties without the express prior written authorization of EUROCOPTER nor shall its contents be disclosed. © EUROCOPTER 06/2000
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19. Blades Shop (continued) 2. Balancing Room
1 2
This room must be large enough for the blades and the equipment to be handled easily.
N
This room shall be at least as long as the largest type of blade overhauled, plus four meters.
N
The other characteristics of the balancing room shall be the same as those for the main room, however, the air conditioning system must not cause any air disturbance so as not to affect the values.
N
All the specific balancing equipment and tooling (see file No. 2) required by the technical publications must be provided in this room.
N
N = Necessary R = Recommended (becomes necessary if problems occur) This document is the property of EUROCOPTER; no part of it shall be reproduced or transmitted to third parties without the express prior written authorization of EUROCOPTER nor shall its contents be disclosed. © EUROCOPTER 06/2000
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5.
SPECIFIC EQUIPMENT AND MATERIAL REQUIRED The EUROCOPTER Overhaul Manuals (MRV) that cover the routine operations for each dynamic system are divided into Volumes and Chapters. The information required to identify the tooling, test benches, equipment, etc. used to perform the overhaul operations correctly in accordance with the EUROCOPTER technical standard are given in the following documents: 6X.XX.XX.8026X.XX.XX.8086X.XX.XX.8516X.XX.XX.8526X.XX.XX.8536X.XX.XX.85462.10.XX.XXX64.10.XX.XXX-
Special Tools and Other Specific Equipment Acceptance Tests on Test Benches and Test Facilities Opening After Workshop Tests Acceptance Tests on Aircraft Opening After Tests on Aircraft MGB Depressurization Test Main Rotor Blades Tail Rotor Blades
The above work cards list all the equipment required to perform the routine overhaul operations (See § 4.1, page 13). These work cards are mandatory and form part of the EUROCOPTER Quality Standard. All Overhaul Centers are required to use the appropriate equipment, especially the tooling, test benches, etc. in accordance with the general Quality Assurance practices. All the equipment must be identified with the part numbers given in the Overhaul Manual and must comply with the EUROCOPTER Tooling Specification. The use of tooling or equipment not identified or approved by EUROCOPTER may result in damage to an assembly or a part (incorrect setting, incorrect adjustment, etc.). All test equipment, especially the test benches and test facilities must be approved and certified by a EUROCOPTER specialist when they are installed on the site. NOTE: All approval actions carried out by EUROCOPTER for tooling, equipment and material that was not purchased from or specified by EUROCOPTER shall be charged to the Repair Center.
This document is the property of EUROCOPTER; no part of it shall be reproduced or transmitted to third parties without the express prior written authorization of EUROCOPTER nor shall its contents be disclosed. © EUROCOPTER 06/2000
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6.
PUBLICATIONS FOR THE OVERHAUL PROCESS Publications required for overhaul: -
EUROCOPTER publications
-
Overhaul/Repair Center publications
6.1
EUROCOPTER PUBLICATIONS -
Overhaul Manuals (MRV or FREM for former aircraft range)
-
Overhaul Practices Manual (MTV)
-
Other publications described below:
The MRV or FREM cover all the routine operations specified in § 4.1, page 13. The MRV supplements these manuals and gives details of the practices used in the procedures and methods specific to EUROCOPTER: Crack detection Surface treatment Paint treatments Bearing Inspection Varnish application, etc. The 3rd level ("D" level) publications, MRV and MTV shall be purchased from EUROCOPTER and the Overhaul Center undertakes to place an order including a subscription for a period of two (2) years. Remarks: -
These publications are covered by a copyright. They cannot be reproduced or disclosed without the consent of the aircraft manufacturer. Only the translations provided by the aircraft manufacturer are considered to be valid.
In addition to the MRV (or FREM) and MTV, the following documents must be available at the Overhaul Centers in the EUROCOPTER network: Master Servicing Recommendations (PRE) Repair Manual (MRR or MMA) Maintenance manual (MET or MDE, for reference only) Illustrated Parts Catalog (IPC, for reference only) Standard Practices Manual (MTC, for reference only) Service Telex and Service Bulletins (SBT) Service Letters (LS) Letters to Repair Stations (LR) This document is the property of EUROCOPTER; no part of it shall be reproduced or transmitted to third parties without the express prior written authorization of EUROCOPTER nor shall its contents be disclosed. © EUROCOPTER 06/2000
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6.1
EUROCOPTER PUBLICATIONS (continued) IMPORTANT The Master Servicing recommendations (PRE) is the document that takes precedence for reference to all TBO (service life and cycle limits, overtorque, overspeed, blade strike, hard landing, etc.).
6.2
OVERHAUL / REPAIR CENTER PUBLICATIONS In-house Quality Assurance procedures in accordance with the Quality Manual approved by the local airworthiness authorities (FAA, CAA, MOT, etc.). IMPORTANT Any process or procedure different from that recommended in the aircraft manufacturer's publications, must be assessed and approved by the aircraft manufacturer.
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7.
TRAINING AND ADAPTATION TO THE EUROCOPTER OVERHAUL PROCEDURES The training provided by EUROCOPTER is intended for experienced aeronautical personnel qualified by the airworthiness authorities (DGAC, FAA, CAA, etc.) or by organizations approved by them, especially for the non-destructive inspections. Under no circumstances can this training be proposed to inexperienced personnel. The customer must arrange this training at least 6 months in advance. The training program is divided into five (5) main sections: 1. Quality Control and Quality Assurance Organization and Procedures to guarantee the chronological order and the sequence of the overhaul process, the embodiment of mandatory modifications and Service Bulletins / Service Telex etc. This training also covers the traceability of the materiel in accordance with the EUROCOPTER Master Servicing Recommendations and the calibration of equipment etc. 2. Instructions contained in the publications, the procedures and the methods relative to the Overhaul and Reconditioning specific to Eurocopter. 3. All the overhaul activities, disassembly, cleaning, paint stripping, dimensional and visual inspections, failure analysis, minor rework, assembly, adjustment, testing, etc. in accordance with the overhaul publications. 4. Non-destructive inspection (crack detection) in accordance with the general standard applied locally (minimum) and the procedures specific to Eurocopter explained in the Overhaul Practices Manual (MTV). The personnel are recommended to obtain the COFREND level 2 qualification or an equivalent qualification beforehand (Document QAF 18.003 refers). 5. Surface treatments authorized by EUROCOPTER which embrittlement of the parts treated (usage and procedures).
do
not
cause
Each training program covers all the dynamic systems of the helicopter. This training is carried out on parts that have completed their TBO, using the EUROCOPTER equipment, procedures and methods. Training specific to a given assembly can be considered on request. The transfer of technology by a EUROCOPTER instructor is proposed in the Overhaul Center, in order to use the equipment and facilities available on the site. On completion of the training, the Overhaul Center personnel can begin work immediately. All training given in the customer's Overhaul Center implies a technical assessment of the customer's facilities beforehand. All the equipment must be available for this assessment (publications, special tools, test benches, spares and parts). This document is the property of EUROCOPTER; no part of it shall be reproduced or transmitted to third parties without the express prior written authorization of EUROCOPTER nor shall its contents be disclosed. © EUROCOPTER 06/2000
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It is possible for the training to be given on the Repair Center materiel, in order to reduce the cost of the training by performing part of certain overhaul operations. On completion of the training course given by the instructor, providing their assessment is satisfactory, the trainees will receive a diploma or a certificate for: - Overhaul and Reconditioning Procedures (Diploma) - Non-Destructive Inspections (Certificate) - DALIC Process (Certificate). They are valid for 2 years form the date of issue. At the end of this time, renewal by the EUROCOPTER representative is possible after each audit scheduled every two (2) years. After a cycle of four years, a refresher course will systematically be proposed. NOTE: Blade training courses will be given in the La Courneuve plant. Training will be invoiced at the EUROCOPTER economic rates for the current year and on the basis of each week for two (2) specialists only. However, a third "instructor" trainee may be accepted.
8.
TECHNICAL ASSISTANCE This assistance is defined by contract: -
Continuous EUROCOPTER logistic and technical assistance
-
Regular visits on the basis of one visit per year (minimum 1 visit every 2 years)
-
Technical assistance at the customer's facilities as necessary
EUROCOPTER may require that one of their dynamic system specialists be present in the Overhaul / Repair Center to assist the customer during the first overhaul of a dynamic system. This may be a condition in the contract and a requirement for the final certification by EUROCOPTER.
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9.
PROVISIONS FOR SPARES -
The manufacturing process for parts to be overhauled is a long process that can take up to 24 months. In view of the time it takes to procure the materials and manufacture these parts, it is imperative that requirements be anticipated well in advance of the actual need. By projecting requirements, the Procurement department can ensure a sufficient number of parts to meet customers' orders. In this way, overhauls will be carried out on time, the customers' downtime will be kept as low as possible, as will his direct operating costs.
-
The hard times for dynamic system components are recorded and these components must be overhauled when they reach their TBO or calendar time limit. The overhaul period of an assembly allows the center to estimate the volume of work to be completed in its workshops.
-
Parts to be overhauled often present wear beyond the acceptable design wear limits. EUROCOPTER ahs therefore developed repair and reconditioning processes so that this type of part can be recovered and thus help to reduce direct operating costs. It is therefore up to the Overhaul Center to build up a sufficient stock of these parts (rotable pool) to ensure that repaired parts are always available to meet the customers' needs.
This explains why EUROCOPTER is able to meet requirements express according to the required time limits (delivery to the manufacturing cycle) but cannot meet urgent orders from their stock. However, when urgent orders are received in exceptional circumstances, each one will be considered and dealt with in the best possible way. EUROCOPTER requires its Overhaul Centers to keep a minimum permanent stock of all the components they have been approved to overhaul. By minimum stock, we understand: The actual quantity adjusted according to the workload of the Overhaul Center calculated on a yearly basis. When the activity is started, the recommended stock should include: -
5 sets of spares that are replaced in all cases
-
2 sets of parts (other than those replaced in all cases)
-
For bearings, gears, oil jets, etc. the quantity is specified in the Overhaul Manual.
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10.
REPAIR OF COMPLEX MACHINED PARTS In collaboration with the Scientific Department, the EUROCOPTER Planning Department has drawn up repair processes for parts affected by wear, fretting corrosion, corrosion etc. to be applied by the Overhaul/Repair Centers, in order to bring down overhaul costs for their customers. All the repairs developed are submitted to the Scientific Department and to the French Airworthiness Authority (DGAC) for approval. These repairs are classified in 3 categories (repair level A, B or C)) and entered on the work card No. 6X.XX.XX.820 (Re-Use Criteria) to inform the Overhaul Centers of the repairs that can be carried out. Definition of the Repair Levels for EUROCOPTER Helicopter Parts We have established the repair levels A, B and C so that the EUROCOPTER-approved Overhaul/Repair Centers can avoid large investments in the publications, facilities and equipment required to carry out the frozen operation procedures on which there are no concessions. Such investments may well be out of proportion with respect to the savings generated by carrying out the overhaul. Category A Repairs Repairs that require extensive facilities and a top-level aeronautical industrial organization. For this type of repair on vital parts, additional substantiation fatigue tests must be performed on several parts in order to guarantee the same operational integrity and the same service life as the original parts. In view of the redhibitory costs incurred for the tests and analyses and the small number of parts concerned, these repairs are carried out only by EUROCOPTER. Category B-Bov Repairs Repairs on conventional, non-vital (category B) or vital (category Bov) parts that require the same industrial organization as the category A repairs but do not necessitate substantiation by means of counter fatigue tests in that the procedures and methods have been designated "Frozen Operations" and must be strictly adhered to. EUROCOPTER Marignane or La Courneuve may authorize certain level B repairs after assessing the technical capabilities of a level-C approved Overhaul Center. EUROCOPTER may authorize repairs on vital parts involving an embrittlement process, such as surface treatment with immersion in baths for: - cadmium plating, nickel plating, copper plating, chromium plating - hard anodizing (OAD) - chromic anodizing (OAC) - sulfuric anodizing (OAS) providing that the facilities (surface treatment installation, de-embrittlement oven, inspection equipment), the process sheets, the types of baths used, probative test pieces if necessary are assessed and the organization is appropriate.
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The process will than be approved for application on all non-vital parts and only on the vital parts for which the approval was requested. A new approval process will be required for it to be applied to a different vital part. EUROCOPTER will not authorize any repairs on special processes such as: Shot peening Work hardening Flame plating, etc. Category C-Cov Repairs Category C is also used to classify the EUROCOPTER-approved Overhaul Centers who perform routine overhaul operations. Category C repairs on vital parts (Cov) require particular card for the "Frozen Operations" and the vital procedures during the machining phases. EUROCOPTER authorizes approved overhaul centers in its network to carry out category C-Cov repairs after assessing their facilities. Technical Publications Our specific overhaul publications are broken down into repair categories and they are supplied individually according to the repairs the center has been approved to perform. General Requirement EUROCOPTER-approved overhaul centers must demonstrate their capability to perform the repairs. They must be equipped with precision machinery (lathes, grinders, precision boring machine, etc.) and accurate dimensional inspection tooling guaranteeing compliance with the required repair process. Qualification of the Machinists It is of prime importance that all the repairs carried out using a machining process be performed by a quality industrial center and by professional machinists. EUROCOPTER does not offer specific training for this activity.
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11.
RECORDING - TRACEABILITY 1. Incorporation of the Complete Overhaul Procedure 1.1 Drawing up a file for each component 1.2 Acceptance Check a) Inventory or parts b) Follow-up sheet c) Record of faults found 1.3 Equipment and tooling required 1.4 Disassembly (Note all faults) 1.5 Cleaning 1.6 Inspection a) Life-limited parts – discarding – quarantine area b) Marking of the model designation c) Bearings (as necessary) d) Visual and dimensional checks - Discarded parts – quarantine area - Repair or reconditioning e) Magnetic crack detection 1.7 Protective Treatment a) Dalic process b) Painting c) Marking 1.8 Modifications embodied 1.9 Assembly a) Directives b) Quality controls c) Recording of measurements taken during assembly d) Follow-up sheets for parts with limited service life 1.10 Testing 1.11 Final Rework 1.12 Accompanying parts 1.13 Storage and preservation 1.14 Equipment log card and release documents
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2. Quality Control Facilities 2.1 On-site work a) Disassembly b) Repairs and reconditioning c) Dimensional checks d) Surface treatment e) Crack detection - Magnetic particle inspection - Dye penetrant inspection f) Calibrated tools g) Test bench certification 2.2 External vendors a) Non-destructive inspections b) Repair c) Reconditioning 2.3 General a) Airworthiness file b) Eye test for the personnel carrying out non-destructive inspections c) Limited-access area for discarded parts d) Inventory of tools and list of requirements e) Manufacturer's repair schemes (vital parts – frozen operations) f) Procurement of parts from authorized sources
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12.
ACTIVITY REPORT 12.1
DEFINITION The Activity Report is a summary report for which EUROCOPTER has drawn up a model applicable to the entire helicopter range.
12.2
SCOPE In accordance with the contractual commitments the Overhaul / Repair Center must regularly (quarterly) provide the manufacturer with the reports on the activities in which the operations on the dynamic components (including blades) are recorded. The activity reports must also include any new irregularities found, that are not listed and covered in the technical publications. If the irregularity noted could affect safety, the Overhaul Center is requested to inform EUROCOPTER as rapidly as possible, and not to wait until the date the next activity report is due. If the materiel has been involved in an incident or an accident, the manufacturer's requirements must be met (see details in Important Points §, pages 5 and 6).
12.3
PURPOSE The activity reports enable EUROCOPTER to:
12.4
-
produce statistics on the non-systematic removal and replacement of parts during reconditioning and overhaul, and thus modify the MTBF and MTBR
-
follow up the overhaul, repair and operation activities of the center
-
check the efficiency of the control system in use in the center.
ACTIVITY REPORT FOR POWER TRANSMISSION SYSTEMS Refer to the following pages.
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EI 050-19-031-A Page 48/55
OVERHAUL / REPAIR REPORT SERVICE FACILITY NAME : ______________________________________________________________________ ADDRESS : ____________________________________________________________________________________ WORK ORDER N° : ________________________ Materiel Induction Date :____________________
DATE OPENED :___________________________________ Materiel Release Date : _____________________________
CUSTOMER, OWNER of MATERIEL : ______________________________________________________________ ______________________________________________________________________________________________ Intermediate Facility : ___________________________________________________________________________ Customer Location : (City, State, Country)__________________________________________________________ ______________________________________________________________________________________________ A.
AIRCRAFT DESCRIPTION : A/C MODEL : ________________ SERIAL N° : _______________ MFG. DATE :_________________________________ TIME SINCE NEW : _______________________ VERSION : (Note 1) _________________________________________________________________________
B.
COMPONENT DESCRIPTION : PART NUMBER : ___________________________________________ SERIAL N° ____________________________________ VERSION : (Note 1) ______________________ MFG. DATE :_______________________________ TSN : _______________ TSR : ______________ TSO : _____________________________________ NUMBER OF CYCLES_________________________
C.
REMOVAL INFORMATION :
(TIME EXPIRED : (Note 2)
SLL
TBO
REPAIR )
INCIDENT ACCIDENT APPLICATION of : SB AD LS LR REASON for REMOVAL______________________________________________________________________ __________________________________________________________________________________________ __________________________________________________________________________________________ D.
PARTS REPLACEMENT : 1. During the Overhaul Process (service facility) ___________________________________________________ certifies that all systematic parts called out in the Overhaul Manual have been replaced with new parts QUALITY MANAGERS NAME : (please print) _____________________________________________________ SIGNATURE : _____________________________________ DATE : ________ STAMP : __________ 2. During the Overhaul Process (service facility) ___________________________________________________ certifies that all Over and Above part, (other than systematic) listed on page 2 have been replaced with new or overhauled parts procured from an approved EUROCOPTER LOGISTIC CENTER. QUALITY MANAGERS NAME : (please print) _____________________________________________________ SIGNATURE : _____________________________________ DATE : ________ STAMP : __________ 3. During the Overhaul Process (service facility) ___________________________________________________ certifies that, (First Return Modifications), Life Limited Parts, Service Bulletins, AD's have been applied and complies with the Overhauled Manual, PRE and other Eurocopter publications. QUALITY MANAGERS NAME : (please print) _____________________________________________________ SIGNATURE : _____________________________________ DATE : ________ STAMP : __________
E.
TECHNICAL STANDARD QUALITY : During the Overhaul Process (service facility)______________________________________________________ certifies that all of the overhaul and repair process to include testing have been applied in accordance with the latest revision of the EUROCOPTER Publications QUALITY MANAGERS NAME : (please print) _____________________________________________________ SIGNATURE : _____________________________________ DATE : ________ STAMP : __________ NOTE 1 : Detail the history of each version the aircraft or component has flown under. NOTE 2 : The component has reached the end of its service period.
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EI 050-19-031-A Page 49/55
OVERHAUL / REPAIR REPORT REPLACEMENT LIST for OVER AND ABOVE PARTS (other than systematic) Item Nomenclature 1 Reason for Replacement
Part Number
Serial N°
Version (Note 1)
Item Nomenclature 2 Reason for Replacement
Part Number
Serial N°
Version (Note 1)
Item Nomenclature 3 Reason for Replacement
Part Number
Serial N°
Version (Note 1)
Item Nomenclature 4 Reason for Replacement
Part Number
Serial N°
Version (Note 1)
Item Nomenclature 5 Reason for Replacement
Part Number
Serial N°
Version (Note 1)
Item Nomenclature 6 Reason for Replacement
Part Number
Serial N°
Version (Note 1)
Item Nomenclature 7 Reason for Replacement
Part Number
Serial N°
Version (Note 1)
Item Nomenclature 8 Reason for Replacement
Part Number
Serial N°
Version (Note 1)
USE AS MANY PAGES AS NEEDED Note 1 :Detail the history of each version the aircraft or component has flown under.
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12.5 ACTIVITY REPORT FOR BLADES The overhaul Center must send a quarterly activity report, copies of all the reports written by the center for all the blades inspected and/or repaired during the previous three months, using the following models for the Ecureuil helicopter range, to the EUROCOPTER plant at La Courneuve. Report sheets covering other helicopter types are available from EUROCOPTER, La Courneuve, on request. The Overhaul/Repair Center will also enclose a blades activity report in accordance with the following model.
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EI 050-19-031-A Page 51/55 SUMMARY OF BLADES REPAIRED BY REPORT No.
BLADE TYPE
BLADE No.
END OF WORK DATE
CUSTOMER
COST OF REPAIR
COMMENTS
NOTE : EUROCOPTER requests you to send this information on 3.5" diskettes using EXCEL (MICROSOFT INC.), DBASE III or IV (ASHTON-TATE CORP.) or LOTUS software or by e-mail to the following address:
[email protected] This document is the property of EUROCOPTER; no part of it shall be reproduced or transmitted to third parties without the express prior written authorization of EUROCOPTER nor shall its contents be disclosed. © EUROCOPTER 06/2000
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For customer use only. Customer’s logo or identification
EUROCOPTER - Etablissement de La Courneuve
Inspection report No:................... Manufacturer’s part number
Serial number
350A.12.0030 ._ _ Operating time
Previously repaired date ......................... at ................. Hrs Customer
Reason for return :... .................... ......
No
Yes
Accident:
Concession
No
Yes
N° ........................
No
Probably
Spar number
Pitch horns N° before repair
Pitch horns N° after repair
............................
..........................
..........................
.......................... .......................... M E T AL L I C L / E P R O T E C T I O N D I S B O N D E D Upper mm2
Lower mm2
Total mm2
Blade with part number Blade without part number
MOD Application
BOTTOM SIDE
Yes
Original
Blade 1 (Serial number side)
Log card
Manufacturer’s part number after repair
35_A.12.00 _._ _ CONCLUSION :.. ......
Inspection date
Made by *
Final check date
Certified by
Returned to customer on :
Name of customer on delivery
A35030A
Blade 2
......
TOP SIDE
......
Edition 08/1998 * Please write in block capitals
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IR NR : ________________ _______________________ Location PAINT Polyurethane strip Area 1 Skin All areas Outside area A Metallic parts
Defect
SERIAL WT OT
Repair
Replace
NR :
Certificate for work performed
Lacking
64.10.00.764 64.10.00.769 64.10.00.764
POLYURETHANE PROTECTIONS Blister / Lower surface Bond separation Ripping Perforation Reversion Blister Anti-sand tape Ripping (Optional) Notch Blister Root poly Wear protection Ripping Post MOD 07.5587 Notch LEADING EDGE METALLIC PROTECTIONS Score with sharp All SST strips edges Dent with sharp edges Bond separation see WC 64.10.00.605 Erosion Perforation Crack Dent without Bonding strap perforation pre MOD 07.5587 Perforation
Blade
20 60 00 404 20 60 00 420 20 60 00 420
1 2 64 10 00 715 64 10 00 715 64 10 00 715 64 10 00 715 64 10 00 713 64 10 00 713 64 10 00 713
20.60.00.404 64.10.00.716 64.10.00.716 64 10 00 716 Blade
1
2
20.60.00.422 20.60.00.422
Bond separation see WC 64.10.00.605
SKIN Root fabric over bonding strap Post MOD 07.5587 Area B
Blade
Bond separation Blister Bond separation
Area E
Bond separation Edge bond separation Internal bond separation Bond separation
Areas B and D simultaneously
Score Perforation
Area C Area D
Perforation Score Dent
Area C Area D
Area D Tip end trailing edge side
Area E Tip weight block Pre MOD 07.5549
1 2 64 10 00 774 64 10 00 774
64 10 00 763
64.10.00.777
64.10.00.763 20.60.00.429 64.10.00.765 64.10.00.776
64.10.00763
Dent or perforation
Corrosion
WT / OT : Within /Out of Tolerance Limits
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EI 050-19-031-A Page 54/55
IR NR : ________________ _______________________ Location
METALLIC PARTS Chinese weights
Pitch horns Pitch horn bushings Bonding strap Post MOD 07.5587 Tracking lobes Tip weights Lock plate Balance mounting plate Screws, washers, spacers, nuts, cotter pins Laminated bearings
Laminated bearings Metallic area
Cap
Defect
SERIAL
WT OT
Repair
Replace
Blade
Dent Corrosion Pitch horn area Corrosion outside pitch horn Dent Corrosion Elongation
1
NR :
Certificate for work performed
2
64 10 00 762 64 10 00 762 64 10 00 762 64.10.00.762 64.10.00.762
64 10 00 707 64 10 00 707 64.10.00.707
Dent Bond separation Distortion Crack Noise Damage Dent Distortion Corrosion Damage
64.10.00.762 64.10.00.762 64.10.00.762 64.10.00.775
64.10.00.708 64 10 00 708 64.10.00.711 64.10.00.704 64.10.00.703 64.10.00.703 64.10.00.703 64.10.00.703
Corrosion Bond separation
64 10 00 770
64.10.00.704 64.10.00.704
Cracks Runs Dent
Centering pin deterioration Dent
64 10 00 770 64 10 00 762 64.10.00.770
64 10 00 770 64 10 00 764 64.10.00.770
64.10.00.704
64.10.00.703
Bore elongation Bellcrank and cap Pre MOD 07.552 Pre-load shims Bellcrank
Centering pin depression Bond separation Dent
64.10.00.775 64.10.00.762 64.10.00.775 64.10.00.775 64.10.00.764 64.10.00.770 64.10.00.775
Bore elongation 64.10.00.775 Elongation of transverse bore
64.10.00.775
WT / OT : Within /Out of Tolerance Limits
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IR NR : ________________ _______________________ Location
SPAR Spar
Spar edges Reinforcement pad
Spar - to - seal junction
Defect
SERIAL
WT OT
Repair
Replace
NR :
Certificate for work performed
Crack Splinters See WC 64.10.00.602 Crack Irregular aspect Crack Elongation Dent Cohesive failure See WC 64.10.00.602 Transverse cracks across slopes See WC 64.10.00.602 Bond separation
Ambient conditions :
Temperature Humidity
WT / OT : Within /Out of Tolerance Limits
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