Onboard Systems BO-105 3.5KK Cargo Hook Kit Owner's Manual

Owner’s Manual for the

3.5KK Cargo Hook Kit

on the

BO-105 Series Helicopter

System Part Numbers

200-290-00

200-291-00

Owner's Manual Number 120-110-00

Revision 9

February 3, 2012

13915 NW 3 rd

Court Vancouver Washington 98685 USA

Phone: 360-546-3072 Fax: 360-546-3073 Toll Free: 800-275-0883

www.OnboardSystems.com

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Revision

0

1

2

3

4

5

6

7

8

9

Date

04/04/03

RECORD OF REVISIONS

Page(s)

All First Issue

Reason for Revision

10/10/03 1-1, 1-2, 2-1, 2-4, and 5-2

02/17/06 3-2, 3-3 and T of

C

09/05/06 3-1,

Section 5

528-023-01 cargo hook configuration change

Reference Service Bulletin 159-011-00

Added cargo hook loading section

Updated cargo hook suspension system maintenance information.

09/07/06

09/07/07

1-1, 2-5,

2-6, 4-1

TOC, Section 1,

2-3, 2-4,2-6, 2-7,

2-8, 3-1, 3-3, 3-4,

4-8, and 4-9

02/03/12 1-1, 2-3 to 2-5, 2-

7, 3-1, 3-3, 3-4, 4-

8, 4-9, 4-12,

Section 5

Updated manual to add information for installation of wire harness P/N 270-048-04.

Added Warnings, Cautions and Notes explanation to section 1.

Updated warnings, cautions and notes format throughout.

01/12/09 1-2, 2-2, 2-3 Changed load cell part no. from 210-028-00 to 210-

028-01 (load cells are the identical except -01 has longer electrical harness). Updated Figure 2-3 and clarified corresponding rigging instructions.

Added caution note and revised Figure 2-3. 10/28/09 2-3

3/2/10 2-3, 2-5 to 2-8 &

5-1

Updated manual to reflect new load weigh harness configuration. Changed overhaul frequency criteria. Corrected Figure 2-3.

Replaced Warnings, Cautions and Notes section with Safety Labels section. Updated Safety labels throughout document. Updated RMA information.

Replaced Load Cell P/N 210-028-01 with 210-028-

02 in kit P/N 200-291-00 and added P/N 210-028-

02 to the maintenance section (section 5).

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CONTENTS

Section 1 General Information

Introduction, 1-1

Safety Labels, 1-1

Bill of Materials, 1-2

Specifications, 1-2

Section 2 Installation Instructions

Cargo Hook Removal, 2-1

Cargo Hook Kit Installation, 2-1

Load Weigh System Internal Harness Installation, 2-5

C-39 Cockpit Indicator Installation, 2-5

Indicator Internal Back Light, 2-6

Indicator Hook-Open Warning, 2-6

Remote Analog Meter, 2-6

Electrical Connections, 2-7

Installation Check-Out, 2-8

Component Weights, 2-8

Paper Work, 2-8

Section 3 Cargo Hook Suspension System Operation Instructions

Operating Procedures, 3-1

Cargo Hook Loading, 3-2

Cargo Hook Rigging, 3-3

Section 4 Load Weigh Operation Instructions

Indicator Front Panel, 4-1

The Run Mode, 4-2

To Zero or Tare the Display, 4-3

To Un-Zero the Display, 4-3

Error Codes, 4-4

The Setup Mode, 4-5

Indicator Dampening, 4-7

To look at, or change the dampening level, 4-7

Indicator Calibration, 4-8

To look at or change the calibration code, 4-8

Installation Zero, 4-9

To run the installation zero routine, 4-9

Calibration by Lifting a Known Weight, 4-9

To run calibration by known weight routine, 4-10

CONTENTS, continued

Setting the Scale on a Remote Analog Meter, 4-11

To look at or change the scale, 4-11

Select KG or LB Units, 4-12

To look at or change the units, 4-12

Indicator Version, 4-13

Section 5 Maintenance

Inspection, 5-1

Link Assembly Overhaul, 5-3

Trouble Shooting, 5-4

Instructions for Returning a System to the Factory, 5-5

Section 6 Certification

FAA STC, 6-1

Canadian STC, 6-2

Section 1

General Information

Introduction

The P/N 200-290-00 & P/N 200-291-00 Cargo Hook Suspension Systems are approved for installation on the BO-105 series helicopters. These systems replace the cargo hook, an adapter link assembly, the lower manual release cable and an electrical release wire harness on the MBB supplied cable type suspension system and cargo hook kit. The P/N 200-291-00 system is the same as the 200-290-00 except it features a load cell, cockpit indicator, and associated wiring.

Safety Labels

The following definitions apply to safety labels used in this manual.

Indicates a hazardous situation which, if not avoided, will result in death or serious injury.

Indicates a hazardous situation which, if not avoided, could result in death or serious injury.

Indicates a hazardous situation which, if not avoided, could result in minor or moderate injury.

Draws the reader’s attention to important or unusual information not directly related to safety.

Used to address practices not related to personal injury.

Installation 1-1

Bill of Materials

Specifications

The following items are included with the Cargo Hook Kit, if shortages are found contact the company from whom the system was purchased.

Provisions provided by the MBB 105-E0018 kit for the upper manual release cable, the internal helicopter wiring and the cable suspension system are required to complete the installation.

Part No. Description

528-023-01 3.5K Keeperless Hook

232-096-00 Load Link Assembly

270-113-00 Electrical Release Cable

268-026-00 Manual Release Cable Assembly

120-110-00 Owners Manual

121-018-00 RFMS

122-005-00 3.5KK Hook Service Manual

270-048-04 Load Weigh Wire Harness

210-095-00 C-39 Indicator

210-028-02 E-73 Load Link Assembly

215-010-00 Placard

215-012-00 Placard

215-169-00 Indicator Light Placard

400-048-00 Power Switch

512-001-00 Ty-wrap

200-290-00

Quantity

1

1

1

1

1

1

1

-

-

-

-

-

1

-

-

200-291-00

Quantity

1

-

1

1

1

1

1

1

1

1

2

1

1

1

10

* 210-028-02 supersedes P/N 210-028-01. It features a stainless steel body for improved corrosion resistance and includes bushings and travel limiters at the cargo hook. These part numbers are interchangeable.

Table 1-1 System Specifications

Design load

Design ultimate strength

2,205 lb. (1000 kg.)

9,922 lb. (4500 kg.)

Unit weight P/N 200-290-00 4.8 lbs (2.2 kg)

Unit weight P/N 200-291-00 6.3 lbs (2.9 kg)

Table 1-2 P/N 528-023-01 Cargo Hook Specifications

Design load

Design ultimate strength

Electrical release capacity

Mechanical release capacity

Force required for mechanical release at 3,500 lb.

Electrical requirements

Minimum release load

Unit weight

Mating electrical connector

3,500 lbs. (1,580 kg.)

15,750 lbs. (7,140 kg.)

8,750 lbs. (3,970 kg.)

8,750 lbs. (3,970 kg.)

8 lb. Max.(.600” travel)

22-32 VDC 6.9 – 10 amps

0 pounds

3.0 pounds (1.35 kg.)

PC06A8-2S SR

1-2

General Information

Section 2

Installation Instructions

These procedures are provided for the benefit of experienced aircraft maintenance facilities capable of carrying out the procedures. They must not be attempted by those lacking the necessary expertise.

Cargo Hook Suspension Components Removal

If the helicopter currently has the MBB kit installed, remove the cargo hook, the external wire harness, and the mechanical release cable at the connection near the landing gear support tube.

Cargo Hook Kit Installation

Attach the 528-023-01 cargo hook and 232-096-00 link assembly to the shackles using the hardware provided in the MBB kit, see figure 2-1 below. Install the cargo hook so the tip of the hook points aft, which is opposite of the MBB kit.

Figure 2-1 Cargo Hook Installation

Installation Instructions

2-1

Cargo Hook Kit Installation

continued

Connect the manual release cable (P/N 268-026-00) to the cargo hook first, per the following instructions:

Remove the manual release cover from the cargo hook. Thread the fitting at the end of the manual release cable into the manual release boss on the hook side plate until the threads protrude approximately .125” inch beyond the boss (as shown in Figure 2-2) and temporarily secure with jam nut

Leave the manual release cover off of the cargo hook until the other end of the release cable is connected, in order to verify proper setting.

Figure 2-2 Manual Release Cable Fitting Adjustment

manual release cable assembly boss jam nut

.125

Route the cable up the right forward suspension cable to the cargo hook.

Connect the 268-026-00 manual release cable to the connection near the landing gear support tube.

Verify proper setting at the hook:

Place the cable ball end fitting into the hook manual release lever fork as illustrated in Figure 2-3. Rotate the manual release lever in the clockwise direction until the boss on its underside contacts the cam stop and hold in this position. Measure the cable ball end free play with the manual release handle in the cockpit in the non-release position. Adjust the manual release cable system for a minimum of .125 inches (3.2 mm) of free play at the fork as shown in Figure 2-3. The maximum amount of free play is limited by the manual release cover, i.e. – the ball end must fit inside the manual release cover when it is installed.

2-2

Installation Instructions

Cargo Hook Kit Installation

continued

Manual release cable rigging must be done with the cargo hook in the closed and locked position.

Figure 2-3 Manual Release Cable Rigging

manual release lever fork

Installation Instructions

release cable

.125" min.

(3.2 mm) cable ball end

Load beam must be closed and locked

when rigging.

If the gap does not measure at least .125”, make adjustments at the hook only. This is done by disconnecting the cable at the interface with the fixed manual release cable, loosening the jam nut at the hook, and rotating the cable in the required direction.

Connect the 270-113-00 Electrical Release Wire Harness to the Cargo Hook connector. Listed below is the pin out for the cargo hook connector.

Table 2-1 Cargo Hook Connector

Pin Function

A

B

Ground

Positive

The cargo hook is equipped with a suppression diode that will be damaged if the cargo hook electrical connection is reversed.

2-3

Cargo Hook Kit Installation

continued

Route the electrical release cable up the left front suspension cable and attach to the side of body electrical connector.

Secure the electrical release wire harness and manual release cable to the suspension cables using existing clamps.

Un-commanded cargo hook release will happen if the manual and electrical release cables are improperly restrained. The cables must not be the stops that prevent the Cargo Hook from swinging freely in all directions. If the Cargo Hook loads cause the hook to strain against the manual release cable the swaged end of the cable may separate allowing the inner cable to activate the cargo hook manual release mechanism. The result is an un-commanded release. Ensure that no combination of cyclic stick or Cargo Hook position is restrained by the manual or electrical release cables.

Figure 2-4 Un-commanded Release From Incorrectly Secured Cable

Install the “INOP” placard (P/N 215-169-00) over the hook advisory light in the cockpit (the 528-023-01 cargo hook does not have a hook lock indicator switch).

2-4

Installation Instructions

Load Weigh System Internal Harness Installation

The Internal Harness is made up of four cables terminated to one large connector.

The connector is plugged into the back of the Indicator. One of the cables is marked “LOAD CELL” and is fitted with a bulkhead fitting. Hardware is provided to attach the bulkhead fitting to the Quick Disconnect Bracket, P/N 235-035-00.

Attach the Quick Disconnect Bracket to the bracket that holds the manual and electrical release fittings on the skin of the aircraft at the cargo hook area.

Another cable is marked “POWER” and is connected to the aircraft electrical power. Another cable is marked “LIGHT”, refer to the Indicator Internal Back

Light section for installation instructions. The last cable is marked “DATA” and can be connected to the optional Data Recorder or Analog Slave Meter. These optional items are not included under this STC.

The data cable may or may not be terminated with a connector depending on manufacture date.

Route cables along the existing harnesses while observing the following precautions:

- Pick up existing wire runs by opening existing cable clamps.

Nylon ties alone may not be used for primary support.

- The distance between supports should not exceed 21 inches.

- Bend radius of wire or harness must not be less than 10 times the wire or harness diameter.

- Inspect and verify that the wire harness may not be manually deflected into a structure with a bend radius of less than .13 (i.e – sharp corners which could cause chafing).

Secure the cables clear of flight control rods.

C-39 Cockpit Indicator Installation

The Indicator, P/N 210-095-00, should be mounted in a position that is convenient, accessible and visible to the pilot. It can be mounted in a standard 2¼" instrument hole. Connect the Indicator to its Internal Harness, refer to Internal Harness

Installation.

Installation Instructions 2-5

Indicator Internal Back Light

The Indicator is equipped with an Internal Back Lighting System that can be connected to the aircraft 28 VDC light dimming circuit. Use a 22 gauge, twisted pair, shielded cable to connect the aircraft dimming circuit to the Internal Harness.

Connect the cable shield wire to airframe ground at the light dimmer end of the cable ONLY.

Indicator Hook-Open Warning

The Indicator is equipped with a Hook-Open Warning feature that can be connected to a cargo hook equipped with a hook open switch. Depending on the capabilities of the cargo hook switch, the Indicator will flash "HOOK OPEN" when the cargo hook load beam is open. The cargo hook switch must be normally open when the cargo hook load beam is in the closed position. When the load beam is open, one side of the switch must be grounded and the other side of the switch is to be connected to the Indicator. Use a 22 gauge, shielded wire to connect the cargo hook switch to the Indicator. Disassemble the Indicator mating connector and carefully solder the wire, from the cargo hook switch, to pin H.

Connect the cable shield wire to airframe ground as close to the cargo hook as possible, at the cargo hook end of the cable ONLY.

Remote Analog Meter

The Indicator is equipped with an Analog drive circuit that can be connected to a remote analog meter. Use a 22 gauge, twisted pair, shielded cable to connect the

Remote Analog Meter to the Indicator. Disassemble the Indicator mating connector and carefully solder the positive wire, from the analog meter, to pin G and the common wire to pin F. Connect the cable shield wire to airframe ground as close to the Analog Meter as possible, at the Analog Meter end of the cable

ONLY.

The 210-095-00 Indicator can be connected to Onboard Systems’ Analog Slave

Meter, P/N 210-180-00, through the “DATA” cable. This meter gives solid weight indications without needle bounce. The Analog Slave Meter may be mounted in any convenient location in a standard 3” instrument hole. Attach connector P/N

410-130-00 to data line per pin out in Figure 2-5 to connect the Analog Slave

Meter to the Internal Harness “DATA” cable. If a data connector is present on the data line use cable P/N 270-059-00 to connect to Analog Slave Meter.

2-6

Installation Instructions

Electrical Connections

Connect the Internal Harness to the Indicator and route the other end to a convenient location for the Indicator power switch part number 400-048-00. The cable is supplied extra long, cut off the excess cable and use as needed to connect the switch and circuit breaker. Connect the white (red if wire harness P/N 270-

048-00 is installed) wire in the power cable to one side of the power switch, connect another piece of suitable wire to the other side of the switch and then to an available 1 or 2 amp circuit breaker. Connect the white/blue (black if wire harness P/N 270-048-00 is installed) wire to the ground bus. The bare wire

(present on P/N 270-048-00 only) should be cut off as it is not needed at this end of the cable. Install the placard 215-010-00 “ELECTRONIC WEIGHING

SYSTEM” next to the power switch and circuit breaker. Install the placard 215-

012-00 “TURN THE WEIGHING SYSTEM OFF WHEN NAVIGATION

EQUIPMENT IN USE” “NO AIRCRAFT OPERATION SHOULD BE

PREDICATED ON THE READING OF THE ONBOARD WEIGHING

SYSTEM” next to the Indicator.

If the C-23 Printer is being utilized with the C-30

Data Recorder, a 5 amp circuit breaker should be used.

Figure 2-5 Wiring Arrangement

POWER SWITCH

(SUPPLIED)

1 AMP CIRCUIT BREAKER

(OPERATOR SUPPLIED)

White (Red)

TO 28 VDC

TO AIRFRAME GROUND

White/Blue (Black)

CUT OFF THE BARE WIRE (IF PRESENT),

DO NOT CONNECT IT TO GROUND.

POWER CABLE

BACK LIGHT POTENTIOMETER

(OPERATOR SUPPLIED)

TO 28 VDC

TO AIRFRAME GROUND

White (Red)

LIGHT CABLE

White/Blue (Black)

INTERNAL HARNESS ASSEMBLY

(WITH OPTIONAL CABLE INSTALLED)

DATA RECORDER/

ANALOG METER CABLE

TO OPTIONAL EQUIPMENT

DEPENDING ON MFG DATE OR DASH

NUMBER THIS CABLE MAY TERMINATE

IN A CONNECTOR

OPTIONAL EQUIPMENT CONNECTORS

TO LOAD CELL

B

C

D

E

ANALOG METER CONNECTOR

P/N 410-130-00

MFG: ANY MFG P/N:MS3126F10-6P

PIN COLOR FUNCTION

A

WH (Red) Power

WH/GN (Green) Clock

WH/OR (White) Data

WH/BL (Black)

Shield

Ground

Shield

DATA RECORDER CONNECTOR

P/N 410-011-00, 410-057-00

& 410-020-00

1

3

5

PIN COLOR FUNCTION

WH/BL (Black) Ground

WH (Red)

Shield

Power

Shield

7

9

WH/GN (Green) Clock Signal

WH/OR (White)

Red*

Data Signal

Flight Switch

4

2 Purple*

*Optional

Cap. Switch

Installation Instructions

2-7

Installation Check-Out

After installation of the Cargo Hook kit, perform the following functional checks.

1. Swing the installed Cargo Hook to ensure that the manual release cable assembly and the electrical release cable have enough slack to allow full swing of the suspension assembly without straining or damaging the cables. The cables must not be the stops that prevent the Cargo

Hook from swinging freely in all directions.

2. Apply 10-20 pounds to the cargo hook load beam and pull the handle operated cargo hook mechanical release, the Cargo Hook should release.

3. Close the cargo hook release circuit breaker and position the battery switch to the ON position. Apply 10-20 pounds to the cargo hook load beam and depress the cargo hook electrical release button, the Cargo

Hook should release.

Component Weights

The weight of the Cargo Hook Kit components are listed below.

Table 2-2 Component Weights

Item Weight

Suspension System W/ hook, W/O Load Cell

Suspension System W/ hook, W/ Load Cell

Indicator

4.8 lbs (2.2 kg)

6.3 lbs (2.9 kg)

7 oz (0.2 kg)

Paper Work

In the US, fill in FAA form 337 for the initial installation. This procedure may vary in different countries. Make the appropriate aircraft log book entry. Insert the

Rotorcraft Flight Manual Supplement (document no. 121-018-00) into the aircraft

Flight Manual.

2-8

Installation Instructions

Section 3

Cargo Hook Operation Instructions

Operating Procedures

Prior to a flight involving external load operations perform the following:

1. Ensure that the Cargo Hook Kit has been properly installed and that the manual and electrical release cables do not limit the movement of the hook.

2. Be completely familiar with this manual, particularly the section covering the Cargo Hook rigging.

3. Be completely familiar with all BO-105 Helicopter Cargo Hook operating instructions.

4. Activate the electrical system and press the Cargo Hook release button to ensure the cargo hook electrical release is operating correctly. The mechanism should operate smoothly and the Cargo Hook should release. Reset the load beam.

The release solenoid is intended to be energized only intermittently. Depressing the electrical release button continuously in excess of 20 sec. will cause the release solenoid to overheat, possibly causing permanent damage.

5. Activate the manual release handle. The mechanism should operate smoothly and the Cargo Hook should release. Reset the load beam.

See the Cargo Hook Service Manual 122-005-00 and the aircraft’s service instructions that cover the original Cargo Hook installation for additional instructions.

Operation Instructions

3-1

Cargo Hook Loading

The cargo hook can easily be loaded with one hand. A load is attached to the hook by pushing the ring upward against the upper portion of the load beam throat, as illustrated in Figure 3-1, until an internal latch engages the load beam and latches it in the closed position.

Figure 3-1 Cargo Hook Loading

3-2

Operation Instructions

Cargo Hook Rigging

Extreme care must be exercised when rigging a load to the Cargo Hook.

Steel load rings are recommended to provide consistent release performance and resistance to fouling. The following illustration shows the recommended rigging, but is not intended to represent all rigging possibilities.

Some combinations of small primary rings and large secondary rings could cause fouling during release.

It is the responsibility of the operator to assure the cargo hook will function properly with each rigging.

Operation Instructions

3-3

Cargo Hook Rigging,

continued

Nylon Type Straps and Rope

Nylon type straps (or similar material) or rope must not be used directly on the cargo hook load beam. If nylon straps or rope must be used they should be first attached to a steel primary ring.

Verify that the ring will freely slide off the load beam when it is opened. Only the primary ring should be in contact with the cargo hook load beam.

Figure 3-2 Example of Recommended Cargo Hook Rigging

3-4

SECONDARY RING

LOAD

PRIMARY RING

Operation Instructions

Section 4

Load Weigh System Operation Instructions

Indicator Front Panel

The C-39 Indicator front panel includes the following features.



The four 7 segment LCD digits show the weight on the Cargo Hook and displays various Setup information.



The Legends clarify the digital display. i.e. when the LB Legend is turned on, the display will be pounds, etc.



The Right button is used to Zero the display in the Run Mode and select the digit to be changed in the Setup Mode.



The Left button is used to Un-Zero the display in the Run Mode and scroll the selected digit in the Setup Mode.

Figure 4-1 Front Panel

Calibration &

Dampening

Legend

Zero & Un-Zero Legend

Unit Legend

Digits

Right Button Left Button

Load Weigh System Operation Instructions 4-1

The Run Mode

The C-39 Indicator has two operating modes, Run and Setup. The Run

Mode is used to display the cargo hook weight and the Setup Mode is used to setup or configure the Indicator to the helicopter and to the Load Cell.

When powered up, the Indicator always comes to life in the Run Mode.

After the Indicator has been correctly installed, power it up by activating the Load Weigh Circuit Breaker. The Indicator will go through a self diagnostic routine. During this routine the display will display all of the digits and legends. If a problem is found during the routine an Error Code will be displayed. For an explanation of Error Codes see the section Error

Codes. After the diagnostic routine the display should look like this:

Figure 4-2 After Diagnostic Routine

4-2

The illustration is of the Indicator in the Run Mode with no load on the hook. Note the LB legend displayed.

Figure 4-3 LB Legend Displayed

The illustration is a typical hook load reading. The display is 3,500 pounds, note the last digit is not displayed.

Load Weigh System Operation Instructions

To Zero or Tare the Display

The zero feature is used to zero or tare the weight on the Cargo Hook that is not wanted, such as the weight of a cargo net or long line. The Right button is used to zero the Indicator reading. When the Right button is pressed the display is zeroed. The zero legend is turned on and the zeroed number is stored in memory. If the Right button is pressed again, before the Un-zero button is pressed, the display blinks in response to the button closure. Zero is only available in the Run Mode.

Figure 4-4 Zeroing the Display

Zero Legend

Un-Zero Legend

To Un-Zero the Display

The Left button is used to add the zeroed value back into the current

Indicator reading or Un-zero the display. When the Left button is pressed, the number previously zeroed is added to the current display and the Unzero legend is turned on. If the Left button is again pressed before the zero button is pressed, the display blinks in response to the button closure. Un-

Zero is only available in the Run Mode.

Load Weigh System Operation Instructions 4-3

Error Codes

Error Codes are the result of difficulties discovered during the Indicator diagnostic tests. Diagnostic tests occur at power up and during the execution of certain routines. Listed below is a matrix of the Error Code displays, their meaning and possible corrective action. Pressing either button will usually bypass the error code, however, the displayed information may be suspect.

Table 4-1 Indicator Error Codes

DISPLAY CAUSE

POSSIBLE

CORRECTIVE ACTION

Err 1 A/D or D/A circuit failure

Potential short in the optional analog meter cable. Clear short and power cycle the Indicator by turning the power to the

Indicator off for a few moments. If Error Code continues, return the Indicator to the factory.

Err 2 NV Ram failure

Err 3 NV Ram write failure

Err 4 NV Ram busy failure

Power cycle the Indicator; if

Error Code continues, return the Indicator to the factory.

Re-enter data, if Error Code continues, return the Indicator to the factory.

Power cycle the Indicator, if

Error Code continues return the Indicator to the factory.

4-4

Load Weigh System Operation Instructions

The Setup Mode

The C-39 Indicator can be used with a wide range of helicopters and load cells. The Setup Mode on the Indicator matches the Indicator to the Load

Cell and to the helicopter. This is done by entering data into the Indicator.

Entered data includes the load cell Calibration Code, the units that the

Indicator should read-out (pounds or kilograms), and several other items.

The Indicator has a group of Setup routines, arranged in menu form, that are used to configure the Indicator. Shown on the next page is a matrix of the Setup routines and a brief discussion of their function and how they are programmed. A complete discussion of each setup item is presented later in this section.

To enter the Setup Mode press both the Right and Left buttons at the same time while the Indicator is powered up and in the Run Mode. To exit the

Setup Mode and return to the Run Mode, press both the buttons at the same time. If you are in a Setup routine and have started to change an entry, but you change your mind before completing the procedure, power cycle the Indicator to exit the Setup Mode and then go to the Run Mode without changing the item. The Indicator is power cycled by turning the

Indicator power off for a few moments.

Load Weigh System Operation Instructions 4-5

The Setup Mode, continued

Table 4-2 Indicator Setup Routines

MENU

Press the Left button to scroll through the menu

DAMP

CODE

0 in

LOAD

Scale

LB KG

XX - V

FUNCTION

Press the Right button to view or change the menu item.

Dampening Level, sets the pilots preference for display dampening.

DISPLAY

To return to the Run Mode press both the

Right and Left buttons at the same time.

Calibration Code, matches the Indicator to the

Load Cell.

Installation ZERO, matches the Indicator to the installed Load Cell and to the helicopter.

After this procedure the display will be zero when no load is on the Cargo Hook.

Load, is used to calibrate the system by lifting a known load.

Scale, matches the analog output of the

Indicator to an optional remote analog meter.

Units, selects the Indicator units (pounds or kilograms).

Version, is the revision level of the Indicator hardware and software.

Blinking display is previously entered

Dampening Level. Select the desired dampening level by pressing the Left button.

Display is previously entered CAL Code.

The Code is changed by selecting the digit to be changed with the Right button. The selected digit will blink. Change the blinking digit by pressing the Left button.

Display is a combination of load on the

Load Cell, and normal load cell zero offset. Remove all weight from the installed Load Cell except the Cargo

Hook, and press any button to complete the procedure and return to the Run Mode.

No previous display is shown. Enter the known load using the Right button to select the digit to be changed and Left button to enter the number. Known load is entered "X 10" i.e.; 5000 kilograms is entered as 500. After the known load is entered, press both buttons at the same time and lift the known load. When the load is stabilized press either button. A new Calibration Code will be calculated and the known load will be displayed. This completes the procedure.

Display is previously entered number. To change the number use the Right button to select a digit, use the Left button to scroll the digit to the desired number. Entry is times 10.

Display is previously selected unit. To change the unit, use the Left button.

Version is for information only, it cannot be changed.

4-6

Load Weigh System Operation Instructions

Indicator Dampening

The Damp or dampening routine allows the pilot to adjust the Indicator dampening level to his preference. The dampening routine is a program that stabilizes the Indicator reading. It offers a trade-off between Indicator responsiveness and stability. Ten dampening levels are available, from 0 through 9. At level 0 the display responds to the slightest change in weight. However, if the load bounced even slightly, the display digits would respond instantly, making the display look unstable. With a dampening level of 9, the display would be stable under the most turbulent conditions, however, it would take several seconds for the display to respond to a change in weight. The ideal dampening level will depend on the flying conditions. A mid range setting of 5 or 6 is usually adequate.

To Look at or Change the Dampening Level

With the Indicator powered up and in the Run Mode, press both buttons at the same time to go to Setup. Scroll through the menu, using the Left button, until the word DAMP is displayed. To look at or change the

Dampening Level press the Right button. The display should look like this:

Figure 4-5 Changing Dampening Level

The CAL and the DAMP legend is turned on and the previously set dampening level is displayed. To return to Run without changing the current dampening level press both the Right and Left buttons at the same time. To change the dampening number, use the Left button to scroll the blinking digit to the desired number. After the selection has been made press both the Right and Left buttons at the same time to return to Run.

Load Weigh System Operation Instructions

4-7

Indicator Calibration

The Calibration Code, or CAL code, is a mandatory input. The Indicator will not accurately display the load without the correct Calibration Code.

The Calibration Code scales the signal from the Load Cell.

If the C-39 Indicator was supplied as part of a Load Weigh System, the

Calibration Code will have been entered into the Indicator by the factory, however, it should be confirmed. If the Indicator is to be mated to a different Load Cell, it must be calibrated before use. Calibration can be done by entering a known Calibration Code or by lifting a known load and having the Indicator calibrate itself. Both options are discussed below.

To Look at or Change the Calibration Code

With the Indicator powered up and in the Run Mode, press both buttons at the same time to go to Setup. Scroll through the menu until the word

CODE is displayed, then press the Right button. The display should look like this:

Figure 4-6 Changing the CAL Code

4-8

The CAL legend is turned on and the previously entered or computed

Calibration Code is displayed. To return to Run without changing the

CAL Code, press both the Right and Left buttons at the same time. To change the Calibration Code, use the Right button to select the digit to be changed, then use the Left button to scroll the blinking digit to the desired number. When the Calibration Code has been entered, press both the

Right and Left button at the same time to return to Run.

Depending on the type of Load Cell, the

Calibration code could be a 3 or 4 digit number.

If the Calibration Code is a 3 digit number a leading zero (0) must be used. For example if a

Load Cell had a CAL Code of 395 it would be entered as 0395.

Load Weigh System Operation Instructions

To Look at or Change the Calibration Code, continued

If the load cell Calibration Code is not known or as a cross check, the

Indicator can generate the Calibration Code. This is done by entering the weight of a known load into the Indicator LOAD routine and then lifting the load. See the section Calibration by Lifting a Known Load.

Installation Zero

Installation zero is a routine that matches the Indicator to the

INSTALLED Load Cell. It adjusts the Indicator reading to compensate for the weight of the Cargo Hook on the Load Cell and whatever zero offset is built into the Load Cell. The Installation Zero procedure is not mandatory.

If done the Indicator will read zero when the Un-Zero button is pressed and there is no weight on the Cargo Hook. If the Installation Zero is not done, the Indicator will show the weight of the Cargo Hook plus the value of the Load Cell zero offset.

To Run the Installation Zero Routine

With the Indicator powered up and in the Run Mode, press both buttons at the same time to go to Setup. Scroll through the menu until the symbol "0 in" is displayed, then press the Right button. The CAL legend will be turned on and the current weight on the Cargo Hook will be displayed and blinking. Remove any weight that is not to be zeroed out and press either button to complete the procedure and return to the Run Mode.

Calibration by Lifting a Known Weight

Calibration by lifting a known weight is a Setup routine that calculates the

Calibration Code for the Load Cell attached to the Indicator. It is useful if the load cell Calibration Code is not known or as a cross check to the accuracy of a known Calibration Code. The procedure is done by entering the known weight into the Indicator and then lifting the weight. This procedure can be done in the shop or on the helicopter. The accuracy of the procedure is directly related to the weight of the known load. If for example the procedure was done with a 1,000 pound load that was assumed to weigh only 900 pounds, all subsequent lifts would be displayed 10% light.

Be sure to include the weight of everything between the Cargo Hook and the load, i.e. the cable, net, dirt, etc.

The closer the known load approaches the lifting capacity of the helicopter, the more accurate the calculated Calibration Code will be.

Load Weigh System Operation Instructions

4-9

Calibration by Lifting a Known Weight, continued

To Run the Calibration by Lifting a Known Weight Routine

With the Indicator powered up and in the Run Mode, press both buttons at the same time to go to Setup. Scroll through the menu until the word

LOAD is displayed, then press the Right button. The display should look like this:

Figure 4-7 Running CAL Routine

4-10

The CAL legend is turned on and the first digit is blinking. The previous load is not displayed. At this point if you wish to return to the Run Mode without changing the Calibration Code, power cycle the Indicator. At this point it is not possible to return to the Run Mode without changing the

Calibration Code by using the buttons on the Indicator front panel.

To proceed with the procedure, use the Right button to select the digit to be changed, then use the Left button to scroll the blinking digit to the desired number. Note that the known weight is entered "X 10"; a 1000 pound load is entered as 100. When the known load has been entered, press both the Right and Left button at the same time. The display will look like this:

Figure 4-8 Entering Load in CAL Routine

Load Weigh System Operation Instructions

Calibration by Lifting a Known Weight, continued

The CAL legend and the digits will be blinking. Again, at this point if you wish to return to the Run Mode without changing the Calibration Code, power cycle the Indicator. It is not possible to return to the Run Mode by using the buttons on the Indicator front panel without changing the

Calibration Code. If you wish to proceed, lift the known load and when it is stabilized, press either button to complete the procedure. The Indicator will display the load. This ends the procedure. The Indicator is now calibrated to the Load Cell. It is a good practice to go to the Code routine and record the new Calibration code for later reference.

Setting the Scale for a remote analog meter

The Scale routine is used when a user supplied analog meter is connected to the Indicator. It is used to match or calibrate the analog meter to the

Indicator. The Indicator outputs a 0 to 5 VDC analog signal which is proportional to the Load Cell load. The Scale number tells the Indicator at what point in pounds or kilograms it should reach the 5 VDC output. If for example a 5 volt analog meter is used and its full scale reading is 10,000 pounds, the number entered into the Indicator Scale routine would be 1000

(the number is entered X 10). This number tells the Indicator that it should output the proportional 0 to 5 VDC signal between zero pounds and

10,000 pounds.

The Scale number does not affect Onboard Slave Meters, P/N 210-106-00 or 210-180-00. This number only affects user supplied instruments connected to the analog out signal.

To Look at or Change the Scale

With the Indicator powered up and in the Run Mode, press both buttons at the same time to go to Setup. Scroll through the menu until the word

SCALE is displayed, then press the Right button. The display should look like this:

Figure 4-9 Changing the Scale

Load Weigh System Operation Instructions

4-11

To Look at or Change the Scale, continued

The CAL legend is turned on and the previously set Scale number is displayed. To return to Run without changing the Scale, press both the

Right and Left button at the same time. To change the Scale number, use the Right button to select a digit to be changed, then use the Left button to scroll the blinking digit to the desired number. When the complete Scale number has been entered, press both the Right and Left button at the same time to return to Run.

Select KG or LB Units

The units routine sets the display to read in pounds (LB) or kilograms

(KG).

To look at or change the Units

With the Indicator powered up and in the Run Mode, press both buttons at the same time to go to Setup. Scroll through the menu until the word LB or KG is displayed, then press the Right button. The display should look like this:

Figure 4-10 Changing the Units

4-12

The CAL legend is turned on and the previously set unit is displayed. To return to Run without changing the units, press both the Right and Left button at the same time. To change the units press the Left button. When the selection has been made, press both the Right and Left button at the same time to return to Run.

The selected units are displayed when in the Run

Mode.

Load Weigh System Operation Instructions

Indicator Version

The Version routine displays the Indicator's hardware and software revision levels. Version is set at the factory and cannot be changed.

Figure 4-11 Looking at Indicator Version

Load Weigh System Operation Instructions

4-13

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Section 5

Maintenance

Refer to Service Manual 122-005-00 for detailed maintenance information for the Cargo Hook.

Inspection

The inspection of the Cargo Hook Kit shall be in accordance with the table below.

The overhaul interval for the kit components (other than the cargo hook) shall be at the same overhaul interval as the cargo hook. See Service

Manual 122-005-00.

Table 5-1 Inspection

Seq. Part

1

Number

Daily Check

200-290-00

200-291-00

System

1. Inspect all items for cracks, wear and corrosion. If worn excessively or cracked, replace parts. Remove corrosion and treat with zinc chromate primer.

2. Inspect all mounting fasteners to ensure that they are tight.

3. Visually inspect the electrical cables for damage and security.

4. Visually inspect the manual release cable for damage and security.

5. Cycle the electrical and manual release mechanisms to ensure proper cargo hook operation.

Inspection – Annually or 100 hours of external load operations*, whichever comes first.

Same as Daily Check

At overhaul interval.

Tear-down and inspect the detail components (see Figure

5-1) to the requirements outlined in this Manual.

Overhaul at the same interval as the Cargo Hook. Refer to

Service Manual 122-005-00 for overhaul instructions for the cargo hook.

(*) Hours of external load operations is defined as the time in which a helicopter is engaged in external load operations. This includes time

between loads on the hook.

Maintenance

5-1

Inspection

continued

Table 5-1 Inspection continued

Seq. Part

Number

Daily Check

3

4

210-095-00

Load

Indicator

Ensure that the Indicator has been correctly calibrated and the correct Calibration Code has been entered into the

Indicator.

None

Inspection – Annually or 100 hours of external load operations, whichever comes first.

Inspect the Indicator for damage and security. If damage is found return the

Indicator to the factory.

None 270-048-00

270-048-04

Internal

Harness

Assembly

5 All fasteners Inspect for cracks, excessive wear and security or attachment. If worn excessively or cracked, replace part.

Same as Daily Check

At overhaul interval.

Calibrate the system by lifting a known weight.

Check for security of attachment, damaged wires and connectors. Replace if damaged.

Most system problems will be the result of damaged wires.

Keep the cables clean and ensure that they are not chafing.

Recommended to replace at overhaul.

5-2

Maintenance

Link Assembly Overhaul

Figure 5-1 Link Assembly Parts

1

2

QTY 3

Table 5-2 Link Assembly Parts

ITEM PART NO. DESCRIPTION QTY

1

2

290-607-00*

290-364-00

Load Link

Bushing

1

3

* With a 200-291-00 kit (with Load Weigh), 290-031-00 or 291-550-00

(part of load cell assembly 210-028-01 and 210-028-02 respectively)

Load Cell Link is installed rather than 290-607-00. Load Cell P/N

210-028-01 does not include bushings.

Carefully inspect and if necessary repair the detail parts in accordance with the instructions in Table 5-3. Inspect the parts in a clean, well-lit room.

Perform magnetic particle inspection in accordance with ASTM-E1444 and MIL-STD-1907, Grade A on the parts listed below. No cracks are permitted in any of these parts.

1. Load Link or Load Cell Link (item 1) depending on kit installed.

Since it is necessary to remove the covers it is recommended that the

Load Cell Assembly be returned to the factory for magnetic particle inspection of the Load Cell Link. If the inspection is to be performed by the customer, contact the factory for additional guidance.

Maintenance 5-3

Link Assembly Overhaul

Table 5-3 Inspection

Component Damage Remedy Finish

Load Link

P/N 290-607-00

Load Cell Link

P/N 291-550-00

Load Cell

P/N 290-031-00

Dents, nicks, cracks, gouges, corrosion or scratches.

Repair dents, gouges, nicks, scratches and corrosion if less than .030” deep, blend out at a ratio of 20:1, length to depth, replace if otherwise damaged.

Dents, nicks, cracks, gouges, corrosion or scratches.

Repair dents, gouges, nicks, scratches and corrosion if less than .030” deep, blend out at a ratio of 20:1, length to depth, replace if otherwise damaged.

Wear on inside diameter. Maximum permissible bushing ID is .520 inches. Remove and replace if it exceeds .520.

Bushing

P/N 290-364-00

(also included with Load Cell

Assembly P/N

210-028-02).

Trouble Shooting

Table 5-4 Trouble Shooting

DIFFICULTY

Load Weigh Indicator does not light up.

PROBABLE CAUSE

Faulty wiring, circuit breaker or switch.

Where Am I? (Lost when programming the Indicator)

Indicator displayed load is incorrect.

Indicator displayed load is not stable.

Indicator displayed load takes too long to change the reading when the load is changed.

Do not recognize the Indicator displayed numbers.

Indicator does not change with changing hook loads.

Incorrect Calibration Code.

Dampening level is too small.

Dampening level is too large.

NV Ram failure, A/D or D/A circuit failure.

Defective load cell, indicator failure or damaged internal harness.

This part is 15-5PH, passivated. No touch up finish required.

Touch up with zinc chromate primer.

CORRECTIVE ACTION

Check the power switch, circuit breaker and wiring. If this doesn’t help, return the unit to the factory.

Turn the Indicator power off for a few moments. When it comes to life it will be in the Run mode.

Insure the correct Calibration Code has been entered.

Adjust the dampening level to a larger number.

Adjust the dampening level to a smaller number.

Refer to Error Codes in Table 3-1.

Check for damaged internal harness, replace load cell.

5-4

Maintenance

Instructions for Returning Equipment to the Factory

If an Onboard Systems product must be returned to the factory for any reason (including returns, service, repairs, overhaul, etc) obtain an RMA number before shipping your return.

An RMA number is required for all equipment returns.



To obtain an RMA, please use one of the listed methods.



Contact Technical Support by phone or e-mail

([email protected]).



Generate an RMA number at our website: http://www.onboardsystems.com/rma.php



After you have obtained the RMA number, please be sure to:



Package the component carefully to ensure safe transit.





Write the RMA number on the outside of the box or on the mailing label.

Include the RMA number and reason for the return on your purchase or work order.



Include your name, address, phone and fax number and email (as applicable).



Return the components freight, cartage, insurance and customs prepaid to:

Onboard Systems

13915 NW 3rd Court

Vancouver, Washington 98685

USA

Phone: 360-546-3072

Maintenance 5-5

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Section 6

STC

Certification 6-1

Canadian Approval

6-2

Certification