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CAMERON BALOONS Shadow Maintenance Manual

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HOT AIR BALLOON

MAINTENANCE MANUAL

Model
Registration
Note: The manual is only required to be constructor number specific where the balloon is
operated with optional systems or equipment which require the insertion of applicable
maintenance manual supplements
Manufacturer:
email:
technical@cameronballoons.co.uk
STATEMENT OF INITIAL CERTIFICATION
This manual provides the maintenance instructions and inspection schedule for all types
and variants detailed in EASA.BA.012 and EASA.BA.013 as required by EASA Certification
Specification CS31HB, Amendment 1, paragraph CS31HB.82. The technical content of this
document is approved under the authority of DOA nr EASA.21J.140.
Signed...........................
For and on behalf of Cameron Balloons Ltd.
21 December 2011
This Manual is specific to the following balloon:
CAMERON BALLOONS LTD
St. Johns Street, Bedminster, Bristol BS3 4NH
UNITED KINGDOM
Tel: +44(0)1179637216 Fax: +44(0)1179661168
21 December 2011
Date........................
Approval
Constructor's Number
Year Of Construction
website:
www.cameronballoons.co.uk
MAINTENANCE
M A N U A L
Amendment 3 Page i‐i

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Summary of Contents for CAMERON BALOONS Shadow

  • Page 1: Maintenance Manual

    MAINTENANCE Approval M A N U A L HOT AIR BALLOON MAINTENANCE MANUAL This Manual is specific to the following balloon: Model Constructor’s Number Registration Year Of Construction Note: The manual is only required to be constructor number specific where the balloon is operated with optional systems or equipment which require the insertion of applicable maintenance manual supplements CAMERON BALLOONS LTD...
  • Page 2 MAINTENANCE Approval M A N U A L Intentionally Blank Page 10 April 2006 Page i‐ii...
  • Page 3 MAINTENANCE Record of Amendments M A N U A L Amendment Pages Description Date Approval Number Affected List of Supplements and List of Effective Pages i‐iii, i‐iv, i‐v, 05/10/07 The technical content of updated. i‐vii to ix this document is Section 2: Completely re‐issued to include 12 2‐1 to 2‐20 approved under the...
  • Page 4 MAINTENANCE Record of Amendments M A N U A L Intentionally Blank Page Amendment 3 21 December 2011 Page i‐iv...
  • Page 5 MAINTENANCE List of Effective Pages M A N U A L Section Page Date of Issue Section Page Date of Issue Section Page Date of Issue i‐i 21 December 2011 4 (cont.) 4‐7 10 April 2006 6 (cont.) 6‐19 21 December 2011 i‐ii 10 April 2006 4‐8...
  • Page 6 MAINTENANCE List of Effective Pages M A N U A L Intentionally Blank Page 10 April 2006 Page i‐vi...
  • Page 7 MAINTENANCE Contents M A N U A L APPROvAL RECORD OF AMENDMENTS LIST OF EFFECTIvE PAGES CONTENTS SECTION 1 : GENERAL 1.1 INTRODUCTION 1.2 REPAIR PARTS AND MATERIALS 1.3 APPLICABILITy 1.4 PROPANE CyLINDERS SECTION 2 : ENvELOPE REPAIRS 2.1 GENERAL 2.1.1 Stitching 2.1.2 Envelope Thread 2.1.3 Balloon Seam...
  • Page 8 MAINTENANCE Contents M A N U A L 2.4 CONTROL LINES 2.4.1 General 2.4.2 Replacement (complete) 2.4.3 Repair 2.4.3.1 Crown Line 2.4.3.2 Parachute Centralising and shroud lines 2.4.3.4 Turning Vent Lines 2.4.3.5 Parachute Operating Lines and RDS / Smart Vent venting lines 2.4.3.6 RDS, Smart Vent Riplines 2.4.4 Control Line Pulleys and Internal Loops 2.4.5 Control Line Specifications and Usage...

  • Page 9: Table Of Contents

    4.5.2.5 Liquid Pilot Light Regulator - PTFE Seal (Modification C298) 4.5.3 vapour Pilot Light 4.5.4 Replacement of Piezo Igniter 4.5.5 Shadow Single Burner Manifold valve Block 4.5.6 Stealth Jet Ring 4.5.7 Shadow / Single Shadow Burner Jets 4.5.8 Crossflow valve...
  • Page 10 MAINTENANCE Contents M A N U A L 4.6 SIROCCO BURNER 4.6.1 Regular Maintenance 4.6.1.1 Lubrication of Main Blast Valve 4.6.1.2 Adjustment of Whisper Valve 4.6.1.3 Adjustment of Pilot Light Valve 4.6.2 Liquid Pilot Light 4.6.2.1 Introduction 4.6.2.2 Replacing Pilot Light Inlet Filter 4.6.2.3 Replacing Vaporiser Outlet Filter and Pilot Light Jet 4.6.2.4 Cleaning / Servicing of Regulator 4.6.3 Cleaning / Adjusting Jet Ring...
  • Page 11 MAINTENANCE Contents M A N U A L SECTION 5 : INSTRUMENT REPAIRS 5.1 FLyTEC ENvELOPE TEMPERATURE SENSOR 5.1.1 Installation 5.1.2 Replacement of Batteries SECTION 6 : MAINTENANCE SCHEDULE 6.1 GENERAL 6.2 SCHEDULED INSPECTIONS AND COMPONENT LIFE 6.2.1 Scheduled Inspections 6.2.2 Component Lives 6.3 UNSCHEDULED INSPECTIONS 6.4 DOCUMENTATION...
  • Page 12 8.3.1 General 8.3.2 Basket Materials 8.4 FUEL SySTEM 8.4.1 General 8.4.2 Consumable Items 8.4.3 Fuel Cylinders 8.4.4 Stealth / Shadow Burner 8.4.5 Sirocco Burner 8.4.6 Stratus Burner 8.4.7 Burner Frames 8.4.8 TEMA 3800 Coupling 8.4.9 Hose Assemblies, Liquid 3/8” Bore 8.4.10 Hose Assemblies, Liquid 1/2”...
  • Page 13 This manual contains maintenance and repair instructions for all Cameron and Thunder & Colt envelopes, baskets and fuel cylinders. Also covered are the maintenance and repair of Shadow, Stealth, Sirocco and Stratus burners. For maintenance and repair instructions for all Sky envelopes, baskets and fuel cylinders, reference should be made to Sky Flight &...
  • Page 14 MAINTENANCE Section 1 : General M A N U A L The Maintenance Schedule, Section 6, applies to all parts of all balloons manufactured by Cameron, Thunder & Colt and Sky regardless of their date of manufacture, and supersedes all previous inspection schedules applicable to these balloons. 1.4 PROPANE CYLINDERS Note: The use ‐...
  • Page 15 MAINTENANCE Section 2 : Envelope Repairs M A N U A L 2.1 GENERAL The general arrangement of balloon envelopes and systems are shown in the Cameron Balloons Flight Manual Issue 10, Section 6. For repairs to envelopes fitted with Trivent Deflation Systems, contact Cameron Balloons Ltd.
  • Page 16 MAINTENANCE Section 2 : Envelope Repairs M A N U A L 2.1.4 Fabric Repair Limitations Pre‐cut and pre‐sewn components must be manufactured by Cameron Balloons Ltd., or by any organisation holding a written approval from Cameron Balloons Ltd. for this pur‐ pose.
  • Page 17 MAINTENANCE Section 2 : Envelope Repairs M A N U A L 2.2 FABRIC REPAIRS 2.2.1 Panel Replacement 1. Unpick all the stitching around the damaged panel. If a seam is covered by a horizontal load tape, this should be unpicked to reveal the panel seam. vertical tapes are sewn on at the same time as the vertical seams are made.
  • Page 18 MAINTENANCE Section 2 : Envelope Repairs M A N U A L These seams are not true balloon seams because the outer row of stitches penetrates only three layers of fabric. If the damage extends to within 25 mm of a seam, the seam should be unpicked and the patch continued to the panel edge.

  • Page 19: General

    MAINTENANCE Section 2 : Envelope Repairs M A N U A L 2.3 LOAD TAPE REPAIRS 2.3.1 GENERAL Warning: The envelope load tapes are an essential part of the balloon’s structure. Correct specifications for load tapes are given in Appendix 4 and all repairs must be made using tape of the same specification as the original.
  • Page 20 MAINTENANCE Section 2 : Envelope Repairs M A N U A L 2.3.3 Vertical Load Tapes 2.3.3.1 Standard Joint 500 mm Overlap The standard joint is con‐ structed of parallel row(s) of 3‐step zigzag stitching along the length of the joint or turnback.
  • Page 21 MAINTENANCE Section 2 : Envelope Repairs M A N U A L 2.3.3.4 Single and Twin Needle Box Joint Start Where vertical load tapes intersect with the para‐ chute aperture edge tape or spider tapes a single needle (20 to 25 mm wide tape) or twin needle (45 mm wide tape) box joint is used.
  • Page 22 MAINTENANCE Section 2 : Envelope Repairs M A N U A L 3. Cut a length of replacement tape which is 500 mm longer than the measured length of the removed tape. Note: It is good practice to measure an adjacent tape as a control. For the combination rip/parachute valve there are two different lengths of crown tape.
  • Page 23 MAINTENANCE Section 2 : Envelope Repairs M A N U A L Note: The RDS deflation system has stainless steel rings running along some of the mid‐gore tapes. If one of these tapes is being replaced it is important to ensure that the ring is threaded onto the new tape before sewing the turnback.
  • Page 24 MAINTENANCE Section 2 : Envelope Repairs M A N U A L 2.3.9 Vertical Load Tape to Flying Cable Turnback: 20,25 and 45 mm tape 2.3.9.1 Replacing Flying Cables 1. Unpick the protector and any scoop D‐rings. 2. Unpick the base tape from the Nomex for 100 mm either side of the vertical tape. 3.
  • Page 25 MAINTENANCE Section 2 : Envelope Repairs M A N U A L Unpick the 1st horizontal tape at the top of the Nomex from the envelope for 100mm either side of the vertical tape. Unpick the vertical tape from the envelope to a point 600mm into the first nylon envelope panel.
  • Page 26 MAINTENANCE Section 2 : Envelope Repairs M A N U A L 2.4 CONTROL LINES 2.4.1 General All control lines must be replaced with line identical to the original. The overall length of the control lines must not be reduced. In cases of doubt contact Cameron Balloons Limited.
  • Page 27 MAINTENANCE Section 2 : Envelope Repairs M A N U A L 2.4.2 Replacement (complete) Replacement control lines should be installed whilst removing the original line. Tie the replacement line to one end of the original control line. Pull the other end of the origi‐ nal line through the envelope, untying and retying the knot between the replacement and original line at each pulley, allowing the rope ends to pass through.
  • Page 28 MAINTENANCE Section 2 : Envelope Repairs M A N U A L Older envelopes (pre‐Mod C421) are fitted with a continuous line. If this line is damaged near one end a new Section of line may be knotted in, allowing the damaged Section to be removed.
  • Page 29 MAINTENANCE Section 2 : Envelope Repairs M A N U A L 2.5 FLYING CABLES 2.5.1 Stainless Steel Flying Cables Warning: Replacement flying cables may only be supplied by Cameron Balloons Ltd. Damaged flying cables should be replaced by unpicking and re‐sewing the vertical load tape to flying cable turnback as detailed in Section 2.6.5.
  • Page 30 MAINTENANCE Section 2 : Envelope Repairs M A N U A L The envelope should be rinsed with plenty of water after washing. Avoid vigorous rubbing or scrubbing as this may damage the fabric coating. Do not attempt to wash the balloon in any type of washing machine. When cleaning is complete the envelope should be allowed to dry naturally out of direct sunlight, then once the fabric is dry the balloon should be hot inflated to dry out the load tapes.
  • Page 31 MAINTENANCE Section 3 : Basket Repairs M A N U A L 3.1 ROUTINE MAINTENANCE Clean the basket regularly. The basket Basket Stainless Foam Support should be washed with Suspen‐ Steel Padding Rod Lo‐ sion Wires Frame plain water (no cating Stub detergent), and must...
  • Page 32 MAINTENANCE Section 3: Basket Repairs M A N U A L 3.4 RAWHIDE The rawhide must be kept in good condition as it protects bottom of the basket from abrasion during landings, and contributes significantly to basket strength. Damaged Sections should be removed and replaced. The rawhide should be cut to shape and holes drilled or punched in it to accept the lacing cord.
  • Page 33 MAINTENANCE Section 3: Basket Repairs M A N U A L 3.7 BASkET FRAMES Cameron Balloons Ltd. should be contacted for advice if basket frames are cracked or the tubing is distorted. 3.8 SUPPORT RODS Support Rods must be replaced if cracked or broken. 3.9 SWAGING OF WIRE ROPES For the wire rope swaging procedure, see Appendix 2.
  • Page 34 MAINTENANCE Section 3: Basket Repairs M A N U A L Intentionally blank page 10 April 2006 Page 3‐4...

  • Page 35: Spare Parts

    MAINTENANCE Section 4 : Fuel System Repairs M A N U A L 4.1 GENERAL WARNING: It is essential that any fuel system or burner maintenance is carried out in clean conditions as the presence of dirt may impair the function of seals or cause blockage of the jets.

  • Page 36: Ptfe Paste

    Chlorinated solvents e.g., trichloroethane (ICI ‘Triklone’). ii. Hydrocarbon solvents e.g. petroleum fractions, or citrus based oil. iii.Water based detergents. 4.2.6 Burner Hose Replacement Burner hoses with tapered NPT fittings (Shadow, Stealth and Sirocco burners) should be assembled with PTFE tape. Amendment 1 05 October 2007...

  • Page 37: Torque Settings

    Tapered threads (NPT) may be assembled without using a torque wrench using the procedure detailed in 4.2.6.2. BURNER FUEL HOSES Fitting Thread Form Max. Torque (Nm) Shadow/Stealth Burner Liquid Hose 1/4 NPT Shadow/Stealth Burner vapour Hose 1/4 NPT Sirocco Burner Liquid Hose 1/4 NPT...

  • Page 38: Consumable Items

    MAINTENANCE Section 4 - Fuel System Repairs M A N U A L 4.3 CONSUMABLE ITEMS Consumable items required to complete the fuel system maintenance actions described in this manual are listed in Section 8.4.2 Use only the lubricants specified in each operation and referenced above. In general KSP125 (which is a specially formulated PFPE lubricant) is specified for applications where the components are actually immersed in liquid propane, and silicone based lubricants are specified for all other areas.

  • Page 39: Fuel Cylinders

    MAINTENANCE Section 4 : Fuel System Repairs M A N U A L 4.4 FUEL CYLINDERS 4.4.1 Liquid Offtake Valve - Handwheel Type Note: This type of valve is supplied by several different manufacturers and spare parts are not interchangeable between valves from different manufacturers. Handwheel type valves are fitted with a 1¼”...

  • Page 40: Tema 3800 Outlet

    MAINTENANCE Section 4 - Fuel System Repairs M A N U A L 3. Tighten the nut below the handle fractionally while preventing the valve stem from rotating either with a second spanner or the handle. 4. Slot the handle back onto the stem and check the operation of the valve. When the nut is correctly tightened the handle should rotate easily but with noticeable friction.

  • Page 41: Replacement Of Contents Gauge Dial Indicator

    MAINTENANCE Section 4 : Fuel System Repairs M A N U A L 4.4.3.1 Replacement of Contents Gauge Dial Indicator The dial indicator may be replaced with the cylinder filled or partially filled. 1. Undo the two retaining screws and remove the dial indicator. 2.

  • Page 42: Padded Top Ring

    MAINTENANCE Section 4 - Fuel System Repairs M A N U A L 4.4.6 Padded Top Ring The polyurethane foam top ring cannot be repaired, and if damaged should be replaced. Fitting a new ring is made easier by heating the ring in an oven at its lowest setting (max.

  • Page 43: Stealth / Shadow Burner

    MAINTENANCE Section 4 : Fuel System Repairs M A N U A L 4.5 STEALTH / SHADOW BURNER 4.5.1 Regular Maintenance Regular lubrication of the blast valve and whisper valve with Cameron KSP125 grease will improve the life of the valve seals.

  • Page 44: Adjustment Of Pilot Light Valve

    Pilot Light Filter Housing / vapour Inlet Blast valve Handle Pilot Light valve Stem With Piezo Slotted End Pilot Light Igniter valve Handle Shadow / Stealth Manifold Block 10 April 2006 Page 4‐10...

  • Page 45: Liquid Pilot Light

    Cameron KSP125 grease. 3. Refit the filter housing and tighten using the stealth multi‐tool. Shadow / Stealth Liquid Pilot Light 4.5.2.3 Stripping and Cleaning of Regulator Unit To clean the regulator assembly and jet proceed as follows‐ 1. Loosen the socket set screw (3) in the side of the pilot flame tube (1) and remove the flame tube.

  • Page 46: Stripping And Cleaning Of Pilot Light Jet

    MAINTENANCE Section 4 - Fuel System Repairs M A N U A L 4. Remove the jet (2) using the Stealth multi‐tool. Invert the regulator body and remove the filter (4) and spring (5). 5. Carefully clean the inside of the regulator and the piston assembly using a soft lint free cloth and silicone spray.

  • Page 47: Vapour Pilot Light

    To remove and clean the pilot light jet and outlet filter‐ 1. Loosen the socket set screw in the side of the pilot light body (2) and remove the pilot light body (1). Shadow / Stealth vapour Pilot Light 10 April 2006 Page 4‐13...

  • Page 48: Replacement Of Piezo Igniter

    5. Test the igniter for correct operation. Correct location of the igniter will set the correct spark gap. 4.5.5 Shadow Single Burner Manifold Valve Block Regular maintenance and servicing follow the same procedures as described for the Stealth / Shadow burner.

  • Page 49: Shadow / Single Shadow Burner Jets

    Incorrect placement of the foils or inner ring will result in an erratic flame pattern. 4.5.7 Shadow / Single Shadow Burner Jets Burner jets may be removed for cleaning, inspection or replacement using a socket spanner. The copper washer underneath the jet must be replaced each time the jet is removed.

  • Page 50: Crossflow Valve

    M A N U A L 4.5.8 Crossflow Valve A Waverley ball valve is used as a crossflow valve on all Shadow / Stealth combination burners. Minor leaks from the handle of the valve may be cured by tightening the stem‐...
  • Page 51 MAINTENANCE Section 4 : Fuel System Repairs M A N U A L 4.6 SIROCCO BURNER 4.6.1 Regular Maintenance 4.6.1.1 Lubrication of Main Blast Valve Blast valve Lubrication 1. Using a flat blade screwdriver, undo the Screw lubrication port blanking screw and remove.
  • Page 52 MAINTENANCE Section 4 - Fuel System Repairs M A N U A L 4.6.1.3 Adjustment of Pilot Light Valve If the pilot light valve fails Manifold Block to shut off satisfactorily Retaining Screw Pressure then it can be adjusted as Whisper valve Gauge Stem With...
  • Page 53 MAINTENANCE Section 4 : Fuel System Repairs M A N U A L The replacement of liquid pilot light jets and filters is carried out ‘on‐condition’, any contamination of the liquid pilot light system usually manifesting itself as a progressive reduction in pilot flame size.
  • Page 54 MAINTENANCE Section 4 - Fuel System Repairs M A N U A L ‘Dual Action Handle’ ‐ Assemblies CB2694, CB2695. a. Using a large cross‐head screwdriver, remove the two screws retaining the cross bar handle. b. The cross bar handle can now be removed, moving the blast valve handles as necessary.
  • Page 55 MAINTENANCE Section 4 : Fuel System Repairs M A N U A L 3. Replace the pilot light jet and filter a. Using a 3 mm Allen key, loosen the socket set screw (4) and remove pilot light flame tube (2). b.
  • Page 56 MAINTENANCE Section 4 - Fuel System Repairs M A N U A L 4.6.2.4 Cleaning / Servicing of Regulator 1. Disassemble the manifold block from the coil / jet ring assembly a. Disassemble the manifold block from the coil / jet ring assembly as described in Section 4.6.2.3 steps 1 and 2 and remove the flame tube assembly.
  • Page 57 MAINTENANCE Section 4 - Fuel System Repairs M A N U A L 7. Reassemble regulator piston a. Fit a new stem ‘O’‐ring (11). lubricate the ‘O’‐ring lightly with Cameron KSP125 grease prior to assembly. 8. Reassemble the regulator a. Carefully refit the piston (9) to the regulator upper body assembly (6). b.
  • Page 58 MAINTENANCE Section 4 - Fuel System Repairs M A N U A L 4.6.4 Replacement of Piezo Igniter The piezo igniter has no user serviceable parts. If any part is defective it should be replaced. 1. Remove the piezo igniter a.
  • Page 59 MAINTENANCE Section 4 : Fuel System Repairs M A N U A L 4.7 STRATUS BURNER 4.7.1 Regular Maintenance 4.7.1.1 Lubrication of Main Blast, Liquid Fire and Pilot Light Valves If the control valves become Pressure Gauge stiff to operate the valve stems seals may require lubrication.
  • Page 60 MAINTENANCE Section 4 - Fuel System Repairs M A N U A L 4.7.2.2 Stripping and Cleaning of Regulator Unit To clean the regulator assembly and jet proceed as follows‐ 1. Unscrew the hexagon regulator housing (6) together with the pilot light flame tube, using the tube spanner tool supplied with the burner.
  • Page 61 MAINTENANCE Section 4 : Fuel System Repairs M A N U A L 9. Refit the pilot light flame tube onto the regulator ensuring that the parts are tightly screwed together, and that the air regulator (4) is covering only one of the two intake holes.
  • Page 62 MAINTENANCE Section 4 - Fuel System Repairs M A N U A L 5. Refit the pilot light flame tube ensuring that the parts are tightly screwed together and that the air regulator (4) is covering only one of the two intake holes. 6.
  • Page 63 Other failures will require replacement of the valve. 4.8 Mk. 4 MINI BURNER The MK Iv Mini burner uses a single Shadow manifold mated with a mini coil / can assembly. Maintenance is identical to the single Shadow burner with the exception of the burner jets which should be bonded in place with Loctite 572.
  • Page 64 MAINTENANCE Section 4 - Fuel System Repairs M A N U A L 4.9.2 Aluminium Heat Shields Aluminium heatshields are fitted using 4 mm Allen screws and domed nuts, which should be locked using Loctite 270 Studlock. 4.9.3 Gimbal Mounted Burner Removal To remove the burner from the frame, remove the four bolts or aerotight nuts (Mod.
  • Page 65 MAINTENANCE Section 4 : Fuel System Repairs M A N U A L 4.9.4.2 Gimbal Block (CB2950-Mod C512) Assembly of the heavy duty gimbal Minimum of 2 block is similar to the standard gimbal ‘Thin’ threads showing Side with block but the bolts are replaced by after assembly Centre interference studs and Aerotight nuts.
  • Page 66 MAINTENANCE Section 4 - Fuel System Repairs M A N U A L 4.11 HOSE END FITTINGS There are two types of fittings used on the ends of the burner fuel hoses. 4.11.1 Tema 3800 Coupling The ‘O’‐rings may be replaced if defective. Lubricate the new ‘O’‐rings with silicone spray prior to fitting.

  • Page 67: Section 5 : Instrument Repairs

    MAINTENANCE Section 5 : Instrument Repairs M A N U A L 5.1 FLYTEC ENVELOPE TEMPERATURE SENSOR 5.1.1 Installation An attachment point for the Flytec temperature sensor is located on a load tape approximately 2 m below the parachute edge. To fit the temperature sender: 1.
  • Page 68 MAINTENANCE Section 5 : Instrument Repairs M A N U A L Intentionally blank page 10 April 2006 Page 5‐2...

  • Page 69: Section 6 : Maintenance Schedule

    MAINTENANCE Section 6 : Maintenance Schedule M A N U A L 6.1 GENERAL This is the manufacturer’s recommended Maintenance Schedule for all Cameron, Colt, Thunder, Thunder & Colt and Sky hot air balloons. The following pages can be copied and used as a check list/record of inspection for complete balloons or components inserting the details in the boxes provided.

  • Page 70: Component Lives

    MAINTENANCE Section 6 : Maintenance Schedule M A N U A L 6.2.2 Component Lives Life Limit Component Permitted Permitted Calender Hours variation variation Envelope: velcro, Rip Panel edge velcro None None 100 hr None (triangular and rectangular panels) Basket: ‐...

  • Page 71: Envelope

    MAINTENANCE Section 6 : Maintenance Schedule M A N U A L 6.5 ENVELOPE Envelope Hours at inspection date: Envelope hours at end of preceding calender year Applicable AD or SB: Document Check: 6.5.1 Envelope Structure Pass/Fail Component Check / Inspect / Record ( )/(x) Crown Line Inspect condition Crown Ring Inspect for damage and Corrosion...

  • Page 72: Deflation System

    MAINTENANCE Section 6 : Maintenance Schedule M A N U A L 6.5.2 Deflation System Pass/Fail Component Check / Inspect / Record ( )/(x) Inspect for damage, porosity, overheating or weakness Fabric (especially edges) Panels Inspect joints and stitching Inspect for damage, wear, security (both on the deflation Sewn Loops panel and envelope) Centralising...

  • Page 73: Turning Vents/Side Dump

    MAINTENANCE Section 6 : Maintenance Schedule M A N U A L 6.5.3 Turning Vents/Side Dump Pass/Fail Component Check / Inspect / Record ( )/(x) Inspect for damage, porosity, overheating or weakness (especially inside the envelope) Fabric Panels Inspect joints and stitching Free Tapes Inspect condition of stitching at ends of tapes Pulling...

  • Page 74: Grab Test Results

    MAINTENANCE Section 6 : Maintenance Schedule M A N U A L 6.5.6 Grab Test Results 6.5.6.1 Grab Test Results-Envelope Colour Result Colour Result 6.5.6.2 Grab Test Results-Deflation System Colour Result (panel/edge) Colour Result (panel/edge) Notes: Workpack No. Inspection Date Inspectors Signature/No.

  • Page 75: Burner System

    MAINTENANCE Section 6 : Maintenance Schedule M A N U A L 6.5.7 Burner System Burner Type: Part No.: Burner Serial No.: Frame Part No: Serialised Parts Coil Block Pass/Fail Component Check / Inspect / Record ( )/(x) Inspect welds for cracking Inspect tubes for distortion/deformation/cuts/gouges Burner Frame Inspect frame for security of fasteners (heat shields,flexi corners)

  • Page 76: Basket

    MAINTENANCE Section 6 : Maintenance Schedule M A N U A L 6.5.8 Basket Basket Type: Part No.: Serial No.: Pass/Fail Component Check / Inspect / Record ( )/(x) Basket wires Inspect for damage Inspect welds for cracking Basket Frames Inspect tubes for distortion/deformation Weave Inspect for damage, deterioration, completeness...

  • Page 77: Fuel Cylinders

    MAINTENANCE Section 6 : Maintenance Schedule M A N U A L 6.5.9 Fuel Cylinders Initial Test date Current Man./Part no. Serial No. PRV Date ( Manufacture Date) Test Date Pass/Fail ( )/(x) Component Check / Inspect / Record Check, Periodic inspection for each cylinder is valid (date) Cylinder Inspect for damage, corrosion Inspect for damage, corrosion, correct operation...

  • Page 78: Inspection Criteria/ Techniques

    MAINTENANCE Section 6 : Maintenance Schedule M A N U A L 6.6 INSPECTION CRITERIA/ TECHNIQUES 6.6.1 Envelope Structure Crown ring: Light surface corrosion or minor surface damage that could abrade the load tapes may be removed or smoothed over with a Scotchbrite pad. Note the size of damage/corrosion and the face of the ring on which it occurs in the log book.

  • Page 79: Turning Vents/Side Dump

    MAINTENANCE Section 6 : Maintenance Schedule M A N U A L Control line pulleys: Pulleys should be in good condition, free to rotate and be securely attached to the envelope. Check the pulley for axle wear by attempting to move the pul‐ ley sheave within the body of the pulley.
  • Page 80 MAINTENANCE Section 6 : Maintenance Schedule M A N U A L Corner buffers: (flexible corner frames) Check for wear or damage. Note: Damaged worn or missing corner buffers are not an inspection failure, but replacement is recommended as missing buffers will increase wear and the risk of damage to other parts of the flexible corner system.

  • Page 81: Basket

    3‐5 mm (measured in the vertical plane at the end of the blast valve handle) minimum. Operate the whisper (liquid fire) valve. Check for leaks around the valve stem. The whis‐ per valve on Shadow, Stealth and Sirocco burners should have between 15 and 20 move‐...

  • Page 82: Ancillary Equipment (If Fitted)

    MAINTENANCE Section 6 : Maintenance Schedule M A N U A L Check that the basket runners are secure, tighten and trim the runner bolts if necessary (refer to Section 3.4)Trapped mud and debris should be removed from underneath the skids and hidden areas as this will cause the basket to rot.

  • Page 83: Fuel Cylinders

    MAINTENANCE Section 6 : Maintenance Schedule M A N U A L 6.6.7 Fuel Cylinders If there is any doubt over the nature of any defects found during the inspection of fuel cylinders, the cylinders must be referred to Cameron Balloons for further inspection. If a cylinder has been deemed unsuitable for further service, it is deemed unsuitable for use in balloons AND unsuitable for the safe storage of liquefied gases.

  • Page 84: Periodic Inspection

    MAINTENANCE Section 6 : Maintenance Schedule M A N U A L Connect a vapour hose and ignite the pilot light. Check the joint at the quick connect coupling for leaks. If the regulator is of the adjustable type, check the regulator adjustment over a range of pressures.

  • Page 85: Annual Inspection Of Fuel Cylinders- Definition Of Cylinder Damage And Guidance On Rejection Limits

    MAINTENANCE Section 6 : Maintenance Schedule M A N U A L 6.6.7.5 Annual Inspection of Fuel Cylinders- Definition of Cylinder Damage and Guidance on Rejection Limits Note: 1. Consideration of appearance, location and number of defects also play a part in the evaluation of damage.

  • Page 86: Grab Test

    MAINTENANCE Section 6 : Maintenance Schedule M A N U A L 6.7 GRAB TEST The grab test should be performed on each colour of fabric in the envelope. For each colour the fabric should be tested in the highest panel in which it occurs in the envelope.

  • Page 87: Flight Test

    MAINTENANCE Section 6 : Maintenance Schedule M A N U A L 6.8 FLIGHT TEST Flight tests must be conducted only with careful measurement. Fuel consumption varies widely with temperature, loading and altitude, so a subjective impression of the balloon’s performance is of little use. A flight test must be made in stable air conditions at a precisely known weight near the maximum take off mass (MTOM).
  • Page 88 MAINTENANCE Section 6 : Maintenance Schedule M A N U A L The warning streamer is attached to the link with a bent wire hook. To attach, open up the hook using a pair of pliers, attach the streamer and bend the hook firmly closed again.
  • Page 89 MAINTENANCE Section 7 : Supplements M A N U A L 7.1 INTRODUCTION This Section contains the appropriate supplements and additional approved data neces‐ sary to maintain continued airworthiness of the balloon the balloon when equipped with various optional systems and equipment not included in the main manual. The balloon shall be operated in accordance with the applicable supplement and/or ad‐...
  • Page 90 MAINTENANCE Section 7 : Supplements M A N U A L 7.3 ADDITIONAL DATA When the envelope detailed in the approval section is being used in conjuction with ......................(insert details of basket/burner) the following approved data must be used......................
  • Page 91 MAINTENANCE Section 8 : Repair Parts and Materials M A N U A L 8.1 GENERAL This Section provides a list of design definitions of the replacement parts and materials used in the maintenance of the balloon and its ancillary equipment. All parts and materials are available from Cameron Balloons Ltd.
  • Page 92 MAINTENANCE Section 8 : Repair Parts and Materials M A N U A L 8.2.4 Envelope Load Tape Part Number Description CE‐2013‐1000 12mm polyester, minimum strength 300kg (661lbs), white CE‐2013‐1001 12mm polyester, minimum strength 300kg (661lbs), black CE‐2020‐2101 20mm polyester, minimum strength 1021kg (2250 lbs), black CE‐2020‐1101 20mm polyester, minimum strength 1021kg (2250 lbs), white CE‐2020‐5001...
  • Page 93 MAINTENANCE Section 8 : Repair Parts and Materials M A N U A L 8.2.6 Envelope Control and Rigging Lines Part Number Description CB‐1474‐0001 3.5 mm Line, Kevlar Cored, Polyester overbraid, white CB‐1504‐0003 3 mm Line, Polyester, Parachute Line (white) CE‐4103‐0001 3 mm Line, Kevlar, Parachute Line(yellow) CE‐4106‐0001...
  • Page 94 MAINTENANCE Section 8 : Repair Parts and Materials M A N U A L Note: * Designed for use with 5mm Maillon Rapide Quick Link, CE‐1403‐0005 For details of available combinations and options, please contact Cameron Balloons Ltd. 8.3 BASkET 8.3.1 General When ordering replacement basket parts and materials it is essential to state the Brand (e.g.
  • Page 95 MAINTENANCE Section 8 : Repair Parts and Materials M A N U A L 8.4 FUEL SYSTEM 8.4.1 General When ordering replacement Burner or other fuel system parts, it is essential to state the Brand (e.g. Cameron or Thunder & Colt), the part number / serial no. and the type of burner or cylinder.
  • Page 96 MAINTENANCE Section 8 : Repair Parts and Materials M A N U A L 8.4.4 Stealth / Shadow Burner Part Number Description CB‐2609‐0000 ‘O’‐Ring Seals, Lubrication Port blanking Screw CB‐2603‐0000 Liquid Pilot Light Jet Service Kit CB‐2604‐0000 Liquid Pilot Light Regulator Service Kit CB‐2606‐0000...
  • Page 97 M A N U A L 8.4.9 Hose Assemblies, Liquid 3/8” Bore OLD PART NUM- PART NUMBER DESCRIPTION USAGE Hose Assembly 3/8"NB, 2.6 m, MKIv, MKIv Super, Shadow, Sirocco, CB‐7626‐1100 CB‐0379‐1008 1/4NPTM to 1/4NPTM REGO fitting Hose Assembly 3/8"NB, 2.6 m, T&C Burners, REGO Fitting, CB‐0379‐2008/CB‐...
  • Page 98 8.4.11 Hose Assemblies, Vapour 1/4” Bore PART NUMBER DESCRIPTION Usage OLD PART NUMBER Hose Assembly, 1/4"NB, 1.8m 1/4 CB‐7418‐1800 Shadow, MKIv, MKIv Super CB‐0379‐3006 NPT to Dynaquip Male Hose Assembly, 1/4"NB, 2.4m 1/4 CB‐7424‐1800 Shadow, MKIv, MKIv Super CB‐0379‐3008 NPT to Dynaquip Male Hose Assembly, 1/4"NB, 3.1m 1/4...
  • Page 99 MAINTENANCE Appendix I : Reserved M A N U A L Intentionally blank page 21 December 2011 Amendment 3 Page A1‐1...
  • Page 100 MAINTENANCE Appendix I : Reserved M A N U A L Intentionally Blank Page Amendment 3 21 December 2011 Page A1‐2...
  • Page 101 MAINTENANCE Appendix 2 : Swaging Procedure M A N U A L A2.1 GENERAL Swage bores should be lubricated periodically with soft mineral grease prior to pressing. Use only Intal copper ferrules. Upon completion of the swage, the joint must be proof loaded to 50% of the minimum breaking strain of the wire given in Table A2‐2, unless agreed otherwise with the local competent authority.
  • Page 102 MAINTENANCE Appendix 2 : Swaging Procedure M A N U A L ‘Dead End’ of rope 0.5 D MINIMUM should be flush or slightly protruding Fig. A2‐2 Joint After Swaging Table A2-1 Wire Rope Diameter (mm) Swage Identification Intal Ferrule Fibre Core Solid Core Intal Swage...
  • Page 103 MAINTENANCE Appendix 2 : Swaging Procedure M A N U A L 0.5‐1 D 0.5‐1 D Fig. A2‐3 Limiter Before Swaging Min. 0.25 D Min.0.25 D Fig. A2‐4 Limiter After Swaging A2.4 PROCEDURE - BASkET WIRE REPAIRS This procedure is only to be used for repairing damage to wires between the basket top frame and the loop end.
  • Page 104 MAINTENANCE Appendix 2 : Swaging Procedure M A N U A L Secure appropriate swage in press as detailed in CCL Systems Operating and Maintenance Instructions issue A dated March 1995. Thread ferrule 2 onto the new Section of rope. Position and lightly hold ferrule 1 in swage bore.
  • Page 105 MAINTENANCE Appendix 3 : Pressure Relief Valve Date Marking M A N U A L A3.1 Inspection A graphical representation of the types of PRv used is given in Fig. A3‐1 to aid identifica‐ tion A3.2 Date Marking of Pressure Relief Valves A3.2.1 CB-8412-0000 Calor 250210 or 25/2 The date is shown as month and year Example: 03/01 would be March 2001...
  • Page 106 MAINTENANCE Appendix 3 : Pressure Relief Valve Date Marking M A N U A L A3.2.5 CB-8412-4000 Sherwood PV435A Month (numeric or alphabetic) and year (double digit numeric) of production Example: 03/99 or C/99 both mean March 1999 A3.2.6 CA-0001-0171 Sherwood PV435L (Thunder & Colt V-Series Cylinders only) Month and year of production‐...
  • Page 107 MAINTENANCE Appendix 4 : Envelope Load Tape Specification M A N U A L A4.1 All Cameron Envelopes and Thunder & Colt Envelopes, CN3001 and Subsequent The base tape is either 25 mm polyester (Min. strength 1814 kg) or 45mm polyester (Min.
  • Page 108 MAINTENANCE Appendix 4 : Envelope Load Tape Specification M A N U A L Table : A4.1 Vertical Load Tape Specifications-Current Envelope Type Envelope Volume Vertical Load Tape Specification A‐Type 105 to 160 20 mm polyester of minimum strength 1020kg (2250 lbs) 180 to 340 25 mm polyester of minimum strength 1815 kg (4000 lbs) 340 HO to 375...
  • Page 109 MAINTENANCE Appendix 4 : Envelope Load Tape Specification M A N U A L Table A4.2 : Vertical Load Tape Specifications: T & C Envelopes CN0001 to CN3000 Envelope Type Envelope Size Range Vertical Load Tape Specification Colt A 25A to 56A 20 mm polyester of minimum strength 680 kg (1500 lbs) 69A to 210A 20 mm polyester of minimum strength 1020kg (2250 lbs)
  • Page 110 MAINTENANCE Appendix 4 : Envelope Load Tape Specification M A N U A L Intentionally blank page 10 April 2006 Page A4‐4...
  • Page 111 MAINTENANCE Appendix 5 : Control Line Specification and Usage M A N U A L A5.1 GENERAL This Section gives the specification of control lines used on Cameron and Thunder & Colt Balloons. A5.2 SPECIFICATIONS Minimum Designation Description Tensile Colours Strength Aramid core with poly‐...
  • Page 112 MAINTENANCE Appendix 5 : Control Line Specification and Usage M A N U A L A5.3 Usage (continued) Cameron / T&C T&C Control Line CN3001-4999, CN10000- CN 0-3000 Parachute Shroud Line Ø3mm Kevlar Ø3mm Polyester Centralising Line Ø3mm Kevlar Ø3mm Kevlar Ø8mm Kevlar Red/White Operating Line Ø8mm Red*...

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