AERONAUTlCAL ACCESSORIES, INC.

p.o. BOX 3689

BRISTOL, TENNESSEE 37625-3689
TELEPHONE: 423-538-5151 800-251-7094
TELEFAX: 423-538-8469 E-MAIL: aero-access.com

INSTRUCTIONS
for
CONTINUED AIRWORTHINESS
for

FOLDING MAINTENANCE STEP

PIN 407-536-101 (LIH side kit)
PIN 407-536-102 (R/H side kit)

for

Bell 407 Model Helicopters

Report No. AA-00126

No Revision

October 11, 2000

8ell407 INSTRUCTIONS for CONTINUED AIRWORTHINESS Rpt. AA-00126
for FOLDING MAINTENANCE STEP No Revision

LOG OF REVISIONS

REV. DATE DESCRIPTION EFFECTED

PAGES
10/11/00 . Original Release. All

AERONAUTICAL ACCESSORIES, INC.

October 11, 2000 . Page 2 of 12
Bell 407 INSTRUCTIONS for CONTINUED AIRWORTHINESS Rpt. AA-00126
for FOLDING MAINTENANCE STEP No Revision

LIST OF EFFECTIVE PAGES

LIST OF REVISIONS No Revision (NR) October 11, 2000

LIST OF EFFECTIVE PAGES

Title Pages Revision
COVER 1 NR
LOG OF REVISIONS 2 NR
LIST OF EFFECTIVE PAGES 3 NR
TABLE OF CONTENTS 4 NR
1.0 INTRODUCTION 5 NR
1.1 DISTRIBUTION 5 NR
2.0 DESCRIPTION 5 NR
3.0 MAINTENANCE INSTRUCTIONS 5 NR
3.1 PRE-FLIGHT INSPECTION 5-6 NR
3.2 ANNUAL INSPECTION 6 NR
3.3 REPAIR 6 NR
4.0 TROUBLESHOOTING INFORMATION 7 NR
5.0 REMOVAL AND REPLACEMENT INFORMATION 7 NR
5.1 REMOVAL - FOLDING MAINTENANCE STEP 7-8 NR
5.2 INSTALLATION - FOLDING MAINTENANCE STEP 8 NR
6.0 STRUCTURAL FASTENER DATA 8 NR
7.0 SPECIAL TOOLS NEEDED 8 NR
8.0 RECOMMENDED OVERHAUL PERIODS 8 NR
9.0 AIRWORTHINESS LIMITATIONS 8 NR
10.0 WEIGHT AND BALANCE 8 NR
11.0 REVISION 8 NR
12.0 PARTS BREAKDOWN 9 NR
FIGURE 1 10 NR
APPENDIX A 11 NR
INSPECTION RECORD 12 NR

These Instructions for Continued Airworthiness (lCA), except

for the Airworthiness Limitation Section, have been reviewed
and found to comply with the applicable requirements of
Appendix A to the Federal Aviation Regula' os Part n
1-+--Ib"~:..e..-q.--e.~="'7Date ;;J/fJI,IoD
roup

AERONAUTICAL ACCESSORIES, INC.

October 11, 2000 Page 3 of 12
Bell 407 INSTRUCTIONS for CONTINUED AIRWORTHINESS Rpt. AA-00126
for FOLDING MAINTENANCE STEP No Revision

TABLE OF CONTENTS

Identification Title Page

1.0 INTRODUCTION 5
1.1 DISTRIBUTION 5
2.0 DESCRIPTION 5
3.0 MAINTENANCE INSTRUCTIONS 5
3.1 PRE-FLIGHT INSPECTION 5-6
3.2 ANNUAL INSPECTION 6
3.3 REPAIR 6
4.0 TROUBLESHOOTING INFORMATION 7
5.0 REMOVAL AND REPLACEMENT INFORMATION 7
5.1 REMOVAL - FOLDING MAINTENANCE STEP 7-8
5.2 INSTALLATION - FOLDING MAINTENANCE STEP 8
6.0 STRUCTURAL FASTENER DATA 8
7.0 SPECIAL TOOLS NEEDED 8
8.0 RECOMMENDED OVERHAUL PERIODS 8
9.0 AIRWORTHINESS LIMITATIONS 8
10.0 WEIGHT AND BALANCE 8
11.0 REVISION 8
12.0 PARTS BREAKDOWN 9
FIGURE 1 10
APPENDIX A 11
INSPECTION RECORD 12

AERONAUTICAL ACCESSORIES, INC.

October 11, 2000 Page 4 of 12
Bell 407 INSTRUCTIONS for CONTINUED AIRWORTHINESS Rpt. AA-00126
for FOLDING MAINTENANCE STEP No Revision

1.0 INTRODUCTION
These instructions contain the information necessary to inspect and maintain the
AERONAUTICAL ACCESSORIES, INC. FOLDING MAINTENANCE STEP
(407-536-101, LlH side kit) or 407-536-102 (R/H side kit) on Bell 407 Model
Helicopters.

1.1 DISTRIBUTION

These instructions are provided with each FOLDING MAINTENANCE STEP.

Any airworthiness or flight safety revisions will be immediately sent to all affected
FOLDING MAINTENANCE STEP owners.

2.0 DESCRIPTION

The AERONAUTICAL ACCESSORIES, INC. FOLDING MAINTENANCE STEP

provides an extra measure of safety during pre-flight and maintenance
operations. The FOLDING MAINTENANCE STEP provides a sturdy step and
allows the pilot or mechanic to more safely stand/climb on the aircraft during
inspection.

3.0 MAINTENANCE INSTRUCTIONS

3.1 PRE-FLIGHT INSPECTION

The FOLDING MAINTENANCE STEP shall receive a Pre-flight visual inspection.

Inspect for proper installation of hardware, any unusual wear patterns, corrosion
and/or damage (scratches, nicks, dents, cracks). Ensure the damage limits
presented in Table 1 are not exceeded for the FOLDING MAINTENANCE STEP.
Replace parts as required.

NOTE
Removal of FOLDING MAINTENANCE STEP from helicopter
is not required for inspection. If any damage is noted during
the Pre-flight Inspection, refer to Section 3.3 Repair or Section
4.0 Troubleshooting Information.

The Pre-flight inspection consists of the following items:

1. Inspect the Folding Maintenance Step for nicks, scratches, dents, corrosion
or cracks.

NOTE
The indications of corrosion are 1) corrosion deposits (a white
or gray powder on aluminum or rust colored deposits on steel),
2) pits in the aluminum or steel surface, 3) blisters, bulging or
flaking of protective coatings.

AERONAUTICAL ACCESSORIES, INC.

October 11, 2000 Page 5 of 12
Bell 407 INSTRUCTIONS for CONTINUED AIRWORTHINESS Rpt. AA-00126
for FOLDING MAINTENANCE STEP No Revision

2. Check the folding function of the step.

3. Inspect the attaching fasteners for security

TABLE 1: DAMAGE AND REPAIR LIMITS

COMPONENT MAXIMUM ALLOWABLE DAMAGE AND REPAIR LIMITS

SCRATCHES/NICKS/DENTS CRACKS

Folding Maintenance To a depth of .025" None

Step - Base
Folding Maintenance To a depth of .025" None
Step - Step

3.2 ANNUAL INSPECTION

The FOLDING MAINTENANCE STEP shall receive an Annual Inspection consisting of

the following items:

1. Complete the Pre-flight inspection listed above.

2. Check the torque value on the Folding Maintenance Step attaching

hardware and adjust as required to 50-70 in/lbs.

3. Inspect Baggage Door Retention Strap for tears or frays and check
attaching fasteners for security, replace if necessary.

4. Utilize the Inspection Record provided in Appendix A to document

Inspection completion.

3.3 REPAIR

Repair scratches, nicks, dents and corrosion as follows:

1. Lightly polish the affected area using Scotch-Brite pads. Ensure the limi~s
presented in Table 1 are not exceeded. Take care to remove as little of
the component protective coatings as possible.

2. For the aluminum components, after corrosion or damage repair: Clean

repaired area with isopropyl alcohol', brush Alodine bare aluminum areas
per MIL-C-5541 or equivalent, and paint area to match existing finish.

3. For the Steel components, after corrosion or damage repair: Prime with a
rust prohibitive primer and paint area to match existing finish.

AERONAUTICAL ACCESSORIES, INC.

October '11, 2000 Page 6 of 12
Bell 407 INSTRUCTIONS for CONTINUED AIRWORTHINESS Rpt. AA-00126
for FOLDING MAINTENANCE STEP No Revision

4.0 TROUBLESHOOTING INFORMATION

TABLE 2: TROUBLESHOOTING GUIDE (See Figure 1)

PROBLEM PROBABLE CAUSE REMEDY

Folding Fasteners loose or Check Folding Maintenance Step

Maintenance missing. fastening hardware for security,
Step is loose or replace as necessary.
vibrates.

Screw Bottomed out in Check torque on fasteners, if loose

insert. may require additional washers.

Sealant is deteriorated. Remove Folding Maintenance Step

and replace sealant (MIL-S-8802 or
equivalent) and reinstall Folding
Maintenance Step.

Pin is Loose. Contact Aeronautical Accessories,

Inc. for replacement.

Spring is bent out of Inspect spring, if bent contact

shape. Aeronautical Accessories, Inc. for
replacement.

Cracks or other damage Check Folding Maintenance Step

in Folding Maintenance condition with damage and repair
Step around fasteners. limits. Repair or replace if necessary.

Folding Pin is bent. Inspect pin, if bent contact

Maintenance Aeronautical Accessories, Inc. for
Step does not replacement.
fold properly.

Spring is bent out of Inspect spring, if bent contact

shape. Aeronautical Accessories, Inc. for
. - replacement.

5.0 REMOVAL AND REPLACEMENT INFORMATION

(Refer to Table 3 and Figure 1 for part identification.)

5.1 REMOVAL - FOLDING MAINTENANCE STEP

1. Remove the six screws (5), and the six washers (6). Retain hardware for
reinstallation.

AERONAUTICAL ACCESSORIES, INC.

October 11, 2000 Page 7 of 12
8ell407 INSTRUCTIONS for CONTINUED AIRWORTHINESS Rpt. AA-00126
for FOLDING MAINTENANCE STEP No Revision

2. Remove the Folding Maintenance Step (1 or 2).

NOTE
Use of a heatgun to soften sealant may facilitate removal.

5.2 INSTALLATION - FOLDING MAINTENANCE STEP

1. Coat under side of Folding Maintenance Step (1 or 2) with sealant (MIL-S-

8802 or equivalent).

2. Install the Folding Maintenance Step (1 or 2) with the six screws (5) and
six washers (6). Torque screws to 50-70 inllbs.

6.0 STRUCTURAL FASTENER DATA

For hardware identification see Table 3 and Figure 1.

7.0 SPECIAL TOOLS NEEDED

Torque wrench

8.0 RECOMMENDED OVERHAUL PERIODS

No component overhaul required for this type design change.

9.0 AIRWORTHINESS LIMITATIONS

No airworthiness limitations associated with this type design change.

10.0 WEIGHT AND BALANCE

Weight Change: 2.0 Ibs. (each)

Station: 145.18

Lateral Arm: ±28.00 (one side only)

0.0 (both sides)

11.0 REVISION

A Log Of Revision section is incluged in these instruction$ and will be utilized to

document all changes. Change recommendations should be submitted to:

AERONAUTICAL ACCESSORIES INC.

P.O. Box 3689
Bristol, TN 37625-3689

AERONAUTICAL ACCESSORIES, INC.

October 11, 2000 Page 8 of 12
Bell 407 INSTRUCTIONS for CONTINUED AIRWORTHINESS Rpt. AA-00126
for FOLDING MAINTENANCE STEP No Revision

12.0 PARTS BREAKDOWN

Table 3 contains Parts Breakdown data for the FOLDING MAINTENANCE STEP
as illustrated in Figure 1.

TABLE 3: FOLDING MAINTENANCE STEP (407-536-101/-102)

PARTS BREAKDOWN

INDEX PART NUMBER ITEM NAME QTY QTY

NUMBER -101 -102

1 407-535-101 Folding Maintenance Step 1

Assy. LlH

2 407-535-102 Folding Maintenance Step 1

Assy. R/H

3 206-468-108 Baggage Door Retention 1

Strap Kit
206-468-001 (1) Retention Strap
206-468-002 (1) Doubler Assembly
099-009-004 (1) Footmans Loop

4 495SF428-16-6 Insert 6 6
aiL 495SF-428-16-4

5 MS27039-4-11 Screw 6 6

6 NAS 1149D0416J Washer 6 6

aiL AN960JD416L

AERONAUTICAL ACCESSORIES, INC.

October 11, 2000 Page 9 of 12
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8ell407 INSTRUCTIONS for CONTINUED AIRWORTHINESS Rpt. AA-00126
for FOLDING MAINTENANCE STEP No Revision

APPENDIX - A

AERONAUTICAL ACCESSORIES, INC.

October 11, 2000 Page 11 of 12 .
Bell 407 INSTRUCTIONS for CONTINUED AIRWORTHINESS Rpt. AA-00126
for FOLDING MAINTENANCE STEP No Revision

Annual Inspection Record

Work Order Number:
Registration Number: _
Serial Number:
Total Time:
Date:

Inspect the FOLDING MAINTENANCE STEP for the following in accordance with
Section 3.2 ANNUAL INSPECTION.

_ _ 1. Inspect the Folding Maintenance Step for nicks, scratches, dents,

corrosion or cracks.

NOTE
The indications of corrosion are 1) corrosion deposits (a
white or gray powder on aluminum or rust colored
deposits on steel), 2) pits in the aluminum or steel
surface, 3) blisters, bulging or flaking of protective
coatings.

_ _2. Check the folding function of the step.

_ _3. Inspect the attaching fasteners for security.

_ _4. Check the torque value on the attaching hardware and adjust as required
to 50-70 in/lbs.

_ _5. Inspect Baggage Door Retention Strap for tears or frays and check
attaching fasteners for security.

Signature A & P No. _

Signature Inspector

AERONAUTICAL ACCESSORIES, INC.

October 11, 2000 Page 12 of 12