Onboard Systems AS350 Series Cargo Hook Swing Suspension System Owner's Manual

Owner's Manual

For the

Cargo Hook Swing

Suspension System

On the

Airbus Helicopters AS350 Series

System Part Number

200-280-04

STC SR01164SE

Owner's Manual Number 120-104-03

Revision 8

05/09/14

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

This page intentionally left blank.

Revision

0

1

2

3

4

5

6

7

8

Date

10/12/09

09/01/10

01/21/11

Record of Revisions

Page(s) Reason for Revision

All Initial Release

All

5-1 & 6-12

03/15/11 1-3 to 1-6 & 2-5

03/21/11

05/02/11

09/09/11 1-5, 2-13, 2-14

02/19/13 1-5, 2-13, 2-14

05/09/14

6-10 & 6-12

1-4

Title, 1-1, 1-4, 1-5,

Section 2, 4-4, 6-12

Replaced warnings, cautions and notes section with safety labels sections. Updated safety label format to current format throughout document. Added fuel drain guard to kit and associated instructions.

Updated weight for fixed provisions to included fuel drain guard kit.

Replaced bolt (P/N 510-505-00) with bolt (P/N 510-

762-00) in swing frame assembly parts list. Updated

RMA instructions.

Updated Bill Of Materials to include corrected quantities of P/N 510-102-00, 510-085-00 & 510-

455-00. Added fuel drain guard items to Bill of

Materials. Updated figure 2.2.6 to show correct P/N

510-454-00 to 510-085-00.

Added Fuel Drain Warning Placard to System Parts

Numbers section under swing hook/frame assembly.

Added Half Clamp Pad (EC P/N 350A-41-1099-20) to the table of Eurocopter required part numbers.

Updated electrical system interface information to include Eurocopter mod. # 073475.

Updated electrical schematic to reflect a/c side wiring interface of post mods 07-4280 and 07-3450. Added note regarding post-mod. 07-4280.

Updated Eurocopter to Airbus Helicopters. Replaced load cell P/N 210-249-00 with P/N 210-249-03.

Replaced fuel drain guard P/N 290-889-00 with 290-

889-01. Updated Figure 4.5. Added note regarding contact P/N 410-194-00 (on page 1-5).

Register Your Products for Automatic Notifications

Onboard Systems offers a free notification service via fax or email for product alerts and documentation updates. By registering your Onboard Systems products at our website, we will be able to contact you if a service bulletin is issued, or if the documentation is updated.

You can choose to receive notices on an immediate, weekly, or monthly schedule via fax, email or both methods.

There is no charge for this service. Please visit our website at www.onboardsystems.com/notify.php

to get started.

This page intentionally left blank.

CONTENTS

Section 1 General Information

Introduction, 1-1

Specifications, 1-2

Inspection, 1-2

Bill of Materials, 1-3

Theory of Operation, 1-6

Section 2 Installation Instructions

Shackle Assembly Installation, 2-1

Fixed Manual Release Cable Assembly Installation, 2-2

Cockpit Indicator Installation, 2-7

Electrical Wiring Installation, 2-9

Fuel Drain Guard Installation, 2-15

Swing Suspension Installation, 2-21

Removable Manual Release Cable Assembly Installation, 2-22

External Electrical Release and Load Cell Cable Installation, 2-25

Placard Installation, 2-27

Installation Check-Out, 2-28

Component Weights, 2-28

Paper Work, 2-28

Section 3 Load Weigh Systems Operation Instructions

Indicator Front Panel, 3-1

The Run Mode, 3-2

To Zero or Tare the Display, 3-3

To Un-Zero the Display, 3-3

Error Codes, 3-4

The Setup Mode, 3-5

Indicator Dampening, 3-7

To look at, or change the dampening level, 3-7

Indicator Calibration, 3-8

To look at or change the calibration code, 3-8

Installation Zero, 3-9

To run the installation zero routine, 3-9

Calibration by Lifting a Known Weight, 3-9

To run calibration by known weight routine, 3-10

Setting the Scale on a Remote Analog Meter, 3-11

To look at or change the scale, 3-11

Select KG or LB Units, 3-12

To look at or change the units, 3-12

Indicator Version, 3-13

CONTENTS,

continued

Section 4 Operation Instructions

Operating Procedures, 4-1

Disconnecting Removable Provisions, 4-2

Optional Link Assembly, 4-3

Cargo Hook Loading, 4-3

Cargo Hook Rigging, 4-3

Section 5 Maintenance

Instructions for Returning a System to the Factory, 5-1

Section 6 System Part Numbers

210-201-03 AS 350 Swing Removable Provisions, 6-1

210-202-01 AS 350 Swing Fixed Provisions, 6-2

232-137-01 Shackle Assembly, 6-3

232-150-00 Release handle assembly, 6-4

232-151-00 Quick Disconnect Support assembly, 6-5

232-140-01 Forward Attach Cable Assembly, 6-6

232-141-01 Aft Attach Cable Assembly, 6-7

232-142-00 Lower Attach Cable Gimbal Assembly, 6-8

232-143-01 Load Cell Gimbal Assembly, 6-9

232-145-03 Swing Hook-Frame Assembly, 6-10

Section 7 Certification

FAA STC, 7-1

Transport Canada Approval, 7-3

EASA STC, 7-5

Section 1

General Information

Introduction

The P/N 200-280-04 Cargo Hook Swing Suspension System kit consists of fixed provisions (P/N 210-202-01) and removable provisions (P/N 210-

201-03). The fixed provisions are permanently installed on the aircraft while the removable provisions are easily removed when not required on the helicopter’s mission.

These kits are approved for installation on Airbus Helicopters AS350B,

AS350BA, AS350D, AS350B1, AS350B2, and AS350B3 helicopters.

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.

General Information 1-1

Specifications

Table 1.1 Suspension System Specifications

Design load 3,086 lbs. (1,400 kg.)

Design ultimate strength

Unit weight - Fixed Provisions

11,574 lbs. (5,250 kg.)

5 lbs. (2.3 kg.)

Unit weight - Removable Provisions 30 lbs. (13.6 kg.)

Table 1.2 P/N 528-029-00 Cargo Hook Specifications

Design load 3,600 lbs. (1,633 kg.)

Design ultimate strength 13,500 lbs. (6,123 kg.)

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

9,000 lbs. (4,082 kg.)

9,000 lbs. (4,082 kg.)

8 lb. Max.(.600” travel)

22-32 VDC 6.9 – 10 amps

0 pounds

3.0 pounds (1.35 kg.)

PC06A8-2S SR

Inspection

Load capacities given are for the equipment described only. Loading limits for your particular helicopter model still apply. Consult your flight manual.

Inspect the kit items for evidence of damage, corrosion and security of lock wire and fasteners. If damage is evident, do not use the items until they are repaired.

1-2 General Information

Bill of Materials

The following items are included with the 200-280-04 Swing Suspension

System, the 210-202-01 fixed provisions kit, and the 210-201-03 removable provisions kit. If shortages are found contact the company from whom the system was purchased.

Table 1.3 Onboard Systems Bill of Materials

Part

Number

Description

120-104-03 Owner's Manual

121-012-03 RFMS

122-017-00 Cargo Hook Service Manual

123-011-03 ICA

210-095-00 C-39 Indicator

210-095-04* C-39 Indicator, NVG Lights

215-165-00 AS 350 Multiple Decal Sheet

215-166-00 Max Hook Load 3086 Decal

215-168-00 Max Hook Load 2557 Decal

232-137-01 Shackle Assembly

232-140-01 Forward Attach Cable Assembly

232-141-01 Aft Attach Cable Assembly

232-145-03 Hook-Frame Assembly

232-150-00 Release Handle Assembly

232-151-00 Fixed Quick Disconnect Assembly

268-024-02 Manual Release Cable Assembly

270-106-02 LW Internal Harness

270-108-00 Release Internal Harness

270-125-00 Ground Strap, Fixed

290-772-00 Indicator Mount bracket

290-780-00 Attachment Bracket

290-782-00 Connector Bracket

290-783-00 Relay Bracket

290-888-00 Retainer

290-889-01 Guard

290-893-00 Bracket

445-005-00 Relay

500-065-00 Grommet Edging

510-029-00 Nut

510-042-00 Washer

510-062-00 Washer

510-085-00 Washer

510-095-00 Washer

510-102-00 Nut

510-277-00 Screw

510-278-00 Washer

510-279-00 Nut

510-453-00 Bolt

510-455-00 Bolt

2

2

2

2

4

8

4

3

6

1

1

8

2

1

1

1

1

Fixed Kit

210-202-01

Qty

1

1

-

1

1

1

1

-

-

1

1

-

-

4

-

-

1

1

1

1

1

1

2

2

2

2

4

8

4

3

6

1

1

8

2

1

1

1

1

Total Kit

200-280-04

Qty

1

1

1

1

1

1

1

1

1

1

1

1

1

4

2

2

1

1

1

1

1

1

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

Removable

Kit 210-

201-03 Qty

1

1

1

1

-

-

-

1

1

-

-

1

1

-

2

2

-

-

-

-

-

General Information 1-3

Bill of Materials

continued

Table 1.3 Onboard Systems Bill of Materials (Continued)

Part

Number

Description Total Kit

200-280-04

Qty

510-457-00 Screw 4

510-475-00 Screw

510-481-00 Screw

3

8

510-526-00 Cotter Pin

512-024-00 Adel Clamp

610-024-00 Fuel Valve Seal

2

2

1

* The 210-095-04 Indicator is equipped with NVG compatible lights. It is an optional indicator that can be ordered in place of the 210-095-00 Indicator.

Fixed Kit

210-202-01

Qty

4

3

8

2

2

1

Removable

Kit 210-

201-03 Qty

-

-

-

-

-

-

The following is needed for installation of the fuel drain guard and is not included with the kit and should be obtained before installation is begun.

Table 1.4 Needed Supplies

Part Number

PR1422-B

Description

Sealant

Quantity

AR

To complete the cargo hook installation the following Airbus Helicopters parts may be necessary to obtain (these parts are frequently found to be on the aircraft from the factory or are standard Airbus Helicopters parts).

1-4

These items may or may not be installed with a standard aircraft, therefore verification is

recommended before purchasing them.

Table 1.5 Airbus Helicopters Part Numbers

Airbus Helicopters P/N Description

22201BE120074L Screw

23111AG120LE

ASN52320BH120N

Washer

Nut

DHS751-160.62

SL211M5-1

A3125-2 H179

350A-41-1097-20

Grommet

Nut

Quick Disconnect Clamp

Half Clamp, Rear

350A-41-1099-20

350A86-0020-33

ASNA0078A403

Half Clamp Pad

Bracket

Rivet

Quantity

4

8

4

1

3

2

2

2

1

3

The cargo hook electrical system interfaces with the aircraft’s electrical panel. Earlier versions (pre-mod. #07-3274) of the AS350 utilize a fuse type switch panel. The following electrical panel components for these versions are typically found to be on the aircraft, but may be necessary to obtain.

General Information

Bill of Materials

continued

Table 1.6 Airbus Helicopters Electrical Parts – Pre-mod. #07-3274

Airbus Helicopters P/N Description Qty

DHS775-160-42

DHS775-240-22

Indicator Light Body

Indicator Light

1

1

EN2240-6839

DI-2-5*

DA8-16A*

Lamp

Fuse 2.5A

Fuse 16A

4

1

1

AS350B2 and B3 aircraft with modification #07-3274 incorporated utilize a circuit breaker type switch panel. The following electrical panel components for these versions are typically found to be on the aircraft, but may be necessary to obtain.

Table 1.7 Airbus Helicopters Electrical Parts – with Mod. #07-3274

Airbus Helicopters P/N Description Qty

045004A127A

ECS0744A02A5

ECS0744B15A0

Cargo Hook Sling Switch

Circuit Breaker 2.5A

Circuit Breaker 15A

1

1

1

AS350B2 and B3 aircraft with modification #07-3475 (introduced by Airbus

Helicopters Service Bulletin No. AS350-25.01.09) incorporated use a 10 amp circuit breaker installed in the 44 ALPHA panel rather than the 15 amp circuit breaker listed in Table 1.7. This 10 amp circuit breaker (P/N

EN2495-10AM) may be necessary to obtain.

For AS350 B2 and B3 aircraft post-mod 07-4280 refer to the Airbus

Helicopters IPC for Sling switch and circuit breaker P/Ns.

For early B2 models with a Honeywell switch panel, to connect the electrical harnesses to the switch panel it will be necessary to obtain two

IDC contacts that are not supplied with the kit (Amp P/N 640632-3,

Onboard Systems P/N 410-194-00).

General Information 1-5

Theory of Operation

The 200-280-04 Cargo Hook Swing Suspension System is composed of:



A suspended pyramid frame that supports the cargo hook.



An electrical release system that provides means for release by pilot actuation of the push-button switch in the cockpit. When the push-button switch is pressed, it energizes the DC solenoid in the cargo hook, and the solenoid opens the latch in the internal mechanism.



A manual release system, which provides a means of releasing a cargo hook load in the event of an electrical release system failure. A lever mounted to the collective stick actuates it.



Ground personnel may also release a load by the actuation of a lever located on the side of the cargo hook.



A load weigh system, which is comprised of an indicator mounted to the

RH door pillar within the cockpit connected to a load cell between the cargo hook and frame.

A load is attached to the cargo hook by passing a cargo sling ring into the throat of the load beam and pushing the ring against the upper portion of the load beam throat, which will initiate the hook to close. In the closed position, a latch engages the load beam and latches it in this position.

To release the load, the latch is disengaged from the load beam. With the latch disengaged, the weight of the load causes the load beam to swing to its open position, and the cargo sling ring slides off the load beam. The load beam then remains in the open position awaiting the next load.

The Cargo Hook Swing Kit includes a fuel drain guard. The fuel drain guard protects the fuel drain valve on the helicopter from accidentally being opened or damaged by the cargo swing. The fuel drain valve is located on the bottom of the fuel tank and extends below the belly skin of the helicopter. In this position it is vulnerable to damage or uncommanded opening. The most common occurrence of the cargo hook swing suspension striking the fuel drain valve happens when the helicopter lands on snow or on uneven terrain. The swing has limited ground clearance and when the skid gear sinks into the snow, the swing suspension is pushed upward into the fuel drain valve, opening it and causing fuel to drain. The fuel drain valve can also be opened in flight by the swing suspension flying vertically due to aerodynamics when ferrying with no load or from recoil effects from releasing large cargo hook loads.

1-6 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.

2.1 Shackle Assembly Installation

Airbus Helicopters landing gear fittings (P/N 350A41-1097-20) are standard on B3 and optional on earlier models. If not present, install per

Airbus Helicopters modification 07-2772.

Attach the four Shackle Assemblies (P/N 232-137-01) to the helicopter landing gear fittings with hardware as illustrated in Figure 2.1.1 (Airbus

Helicopters part numbers are shown in italics) except at the RH forward hard point install an Attachment Bracket at the inboard side as illustrated in Figure 2.1.2. Note the orientation of the Shackle Assembly. Torque the nuts to 100-130 in-lbs.

At the Attachment Bracket fasten an Adel Clamp (P/N 512-024-00) with hardware as illustrated, do not torque nut down until manual release cable is routed through (see section 2.2).

Figure 2.1.1 Shackle Assembly Installation

Inboard

Bolt

P/N 22201BE120074L

Washer

P/N 23111AG120LE

Nut

P/N ASN5232BH120N

Washer

P/N 23111AG120LE

Shackle Assembly

P/N 232-137-01

Figure 2.1.2 RH Forward Shackle Assembly Installation

Inboard

Attachment Bracket

P/N 290-780-00

Bolt P/N 510-453-00

Washer P/N 510-042-00

Nut P/N 510-102-00

View Looking Fwd

Adel Clamp

P/N 512-024-00

Installation Instructions 2-1

2.2 Fixed Manual Release Cable Assembly Installation

Remove the lower fairings on the helicopter in order to obtain access to cable routing areas.

The manual release cable installation consists of a fixed section (P/N 268-025-00) and a removable section. The fixed section is routed from the release lever at the collective, aft to an external bracket attached to the lower rear fairing, at the centerline of the forward fuel tank support frame (as shown in Figure 2.2.1).

Figure 2.2.1 is an overview of the cable routing and the figures following detail the cable support installations at various points.

Figure 2.2.1 Fixed Manual Release Cable Installation Overview

X 1790.15

X 2700

FWD

Manual Release Cable

A/C Centerline

View Looking Down

See Figure 2.2.2

See Figure 2.2.3

See Figure 2.2.4

Route cable outboard through this hole.

See Figure 2.2.5

View Looking Outboard

From A/C Centerline

Centerline of fwd fuel tank support

See Figure 2.1.2

Y 400

See Figures 2.2.6

and 2.2.7

2-2 Installation Instructions

2.2 Fixed Manual Release Cable Assembly Installation continued

 Mount the manual release lever (assembly P/N 232-138-00) to the collective stick with the Clamp Half (P/N 290-753-00) and two screws (P/N 510-390-00) provided pre-assembled on the release lever assembly, as illustrated below.

Figure 2.2.2 Manual Release Lever Installation

Screws

P/N 510-390-00

Release Lever Assembly

 Route the cable to underneath the cabin floor through the existing slot by removing the grommet to allow the cable end fitting to be fed through. Reinstall the grommet.

If the slot in floor does not exist, create one with dimensions as shown below in the cabin floor 43 mm from the collective pitch lever unit and 150 mm forward of X1790.15 (see below) and install the grommet (Airbus Helicopters

P/N DG-38).

Figure 2.2.3 Cabin Floor Hole Detail

35mm

Ø25mm

Collective Pitch

Lever Unit

43mm

Fwd

Installation Instructions

150mm FROM X 1790.15

VIEW LOOKING DOWN

A/C Centerline

2-3

2.2 Fixed Manual Release Cable Assembly Installation continued

 Underneath the floor, route the manual release cable through an existing hole in the frame immediately aft of the collective. Secure the cable at this point with an adel clamp (P/N 512-024-00). Fasten the adel clamp to the existing bracket (Airbus Helicopters P/N 350A86-1051-00) with hardware as illustrated below.

Figure 2.2.4 Cable Routing Through Frame

Cabin Floor

A

A

View Looking Aft

Bolt P/N 510-453-00

Washer P/N 510-042-00

Nut P/N 510-102-00

A-A

Adel Clamp

P/N 512-024-00

 Aft of the frame, route the cable outboard through the hole in the structural member as shown in Figure 2.2.1 and Figure 2.2.5 and install Plastic Edging

Grommet (P/N 500-065-00).

Figure 2.2.5 Grommet Installation

Plastic Edging Grommet

P/N 500-065-00

2-4 Installation Instructions

2.2 Fixed Manual Release Cable Assembly Installation continued

 At the RH forward hard point (X2700) secure the cable to the Adel Clamp installed per Figure 2.1.2.

 Install Quick Disconnect Bracket Assembly (P/N 232-151-00) on the RH rear lower fairing (with the fairing removed) at a location 400mm (15.7 in.) to the right of the A/C centerline and in line with the fwd fuel tank support (reference

Figure 2.2.1) utilizing the existing insert holes in the honeycomb panel structure. Secure with fasteners (provided pre-assembled on bracket) as illustrated below.

If your helicopter does not have holes in the honeycomb panel, modify panel per Airbus

Helicopters Service Bulletin No. 25.00.62.

Figure 2.2.6 QD Bracket Installation

Y400

Nut (2)

P/N 510-102-00

Washer (2)

P/N 510-085-00

Bolt (2)

P/N 510-455-00

QD Bracket Assembly

P/N 232-151-00

Installation Instructions 2-5

2.2 Fixed Manual Release Cable Assembly Installation continued

 Install the two clamps (Airbus Helicopters P/N A3125-2 H179) in the RH rear lower fairing that will support the removable section of the manual release cable. The clamps are installed at points 1 and 2 (see below) using existing inserts in the belly of the helicopter. Do not install a clamp at the furthest aft insert.

If your helicopter does not have holes in the honeycomb panel, modify it per Airbus

Helicopters Service Bulletin No. 25.00.04.

Figure 2.2.7 Cable Support Clamp Installation

A

Y400

1

A

Nut

P/N 510-102-00

Washer

P/N 510-085-00

2

A/C Centerline

Bolt

P/N 510-455-00

Fwd A-A

Rotated 90°

Clamp

Eurocopter P/N A3125-2 H179

View Looking Up

At Lower Aft Cowling

Fuel Tank Support

Centerline

2-6 Installation Instructions

2.3 Cockpit Indicator Installation

The Indicator is mounted on the RH door pillar. If nut clips are not pre-installed in the door pillar, install them per the following.

 Hold the Indicator Bracket (P/N 290-772-00) at a location as shown below and transfer its hole pattern to the door pillar.

Figure 2.3.1 Indicator Bracket Installation

Fwd

RH Door Pillar

C-39 Indicator Bracket

P/N 290-772-00

View Looking Outbd

 Drill three mounting holes in the RH door pillar to install the nut clips. Reuse the electrical bonding screw at the fourth location (see below).

 After completing electrical bonding, install the three nut clips (Airbus

Helicopters P/N SL211M5-1) and fasten Indicator Bracket with three screws

(P/N 510-475-00) and three washers (P/N 510-095-00).

Figure 2.3.2 Indicator Bracket Hardware

Electrical Bonding Screw

Screw

P/N 510-475-00

Washer

P/N 510-095-00

Installation Instructions 2-7

2.3 Cockpit Indicator Installation

continued

 Install C-39 Indicator (P/N 210-095-00 or P/N 210-095-04) onto bracket with hardware as illustrated below.

Figure 2.3.3 C-39 Indicator Installation

C-39 Indicator

A

A

Screw P/N 510-457-00 (4)

CAL

DAMP

Hook L oad

X 10

0 LB K

G

UN-ZER

O SETU P

ZER O

A-A

2-8 Installation Instructions

2.4 Electrical Wiring Installation

Install electrical harnesses (P/N 270-106-02 and P/N 270-108-00). Route them along the existing harnesses (reference Figure 2.4.1) 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”.

Make the appropriate connections with terminal lugs. Secure the C-39 indicator harness (P/N 270-106-02) along the canopy with clamps and connect to the C-39 indicator. Refer to Figure 2.4.7 for electrical schematic.

The electrical harness includes a line with that can be equipped an accessory connector for use with an Onboard Systems Data Recorder or Analog Meter.

These items are not included under this STC. If the accessory line is not used, stow this line of the harness.

Figure 2.4.1 Electrical Wiring Routing Overview

X2700

Connector Bracket

Install per Figure 2.4.5

C-39 Indicator

3N ground Relay Bracket - 23M

Install per Figure 2.4.3

Y400

Y400

Installation Instructions 2-9

2.4 Electrical Wiring Installation continued

If installing the wire harnesses on a newer AS350B2 or B3 model equipped with a switch panel of circuit breaker design (Airbus Helicopters mod. #07-3274 incorporated) the electrical harness P/N 270-108-00 requires a minor modification.

Cut the ME1E wire off just prior to the butt splice and discard the splice and the 20 ga. wires.

Figure 2.4.2 P/N 270-108-00 Harness Modification

Cut wire here.

ME1E

16 ga.



Splice

20 ga.

20 ga.

In preparation for installing the Relay Bracket (P/N 290-783-00) create two holes in the LH beam at Y400 as illustrated in Figure 2.4.3.

Figure 2.4.3 Relay Bracket Installation

Existing hole

Forward

1.30 in.

(33 mm)

7.1 in.

(180 mm)

LH Beam

Y 400

Z 2450

Ø0.169 in.

(4.3 mm)

2 pl's





Secure Relay Bracket with two screws (P/N 510-277-00), two washers (P/N

510-278-00), and two nuts (P/N 510-279-00).

Place relay socket (part of 270-108-00 electrical harness) into relay bracket mounting holes from below and secure to relay and relay bracket with hardware provided with relay (as illustrated below).

2-10 Installation Instructions

2.4 Electrical Wiring Installation continued

Figure 2.4.4 Relay Installation

Up

Relay

P/N 445-005-00

Fwd

Relay Bracket

P/N 290-783-00





Relay Socket

P/N 445-004-00

(part of 270-108-00 electrical harness)

Install Connector Bracket (P/N 290-782-00) at fuel tank support frame as illustrated below.

Fasten hook release connector (32M) and load cell connector (55M) to the

Connector Bracket with screws (P/N 510-481-00), washers (P/N 510-062-00), and nuts (P/N 510-029-00).

Install screws with their heads on the bottom side of bracket flange (if nuts are installed on bottom side they will interfere with mating connector).

Figure 2.4.5 Connector Bracket Installation

Load Cell Connector

55M

Hook Release Connector

32M

A

A-A

Looking Down

Connector Bracket

P/N 290-782-00

A

7.28 in (185 mm)

1.18 in (30 mm)

Rivets (3)

View Looking Forward

Y=0

 Install electrical markers (P/N 215-165-00).

Installation Instructions 2-11

2.4 Electrical Wiring Installation continued

Install the Ground Strap (P/N 270-125-00) terminal at the 3N ground connector bracket at the LH airframe beam at Y400 per the following:

 Remove upper mounting hardware (see below) for 3N connector bracket and retain.

 Prepare the surface for electrical bonding per Airbus Helicopters electrical bonding procedure. Refer to section 20.02.07 of the Airbus Helicopters

Standard Practices Manual.

 Install ground strap terminal, re-using hardware removed per above step.

Figure 2.4.6 Ground Strap Installation Location

Remove hardware

2-12

 Route the Ground Strap to the load weigh and electrical release harnesses installed previously and route with these harnesses, while securing with tywraps, to their termination points at the Connector Bracket.





Route the Ground Strap around the Connector Bracket and position it such that the disconnect fitting at the end can be routed through the connector access hole and extended below the lower fairing (when installed).

Re-install lower fairings

Installation Instructions

2.4 Electrical Wiring Installation continued

The electrical schematic for the electrical release system and the load weigh system is shown below along with the aircraft’s interface points. Airbus Helicopters modification

#’s 07-4280 and 07-3450 are reflected below. Earlier Airbus Helicopters configurations which affected how and where wire numbers ME1E, ME2E and ME10E of the electrical release harness and load weigh harness interface with the helicopter are shown on the following page. Refer to the applicable Airbus Helicopters Wiring Diagrams Manual for additional information and for other cargo hook aircraft side wiring configurations that may not be shown.

For the C-39 Indicator backlighting, install wire 2LK71E to an available pin in the instrument panel or console lighting circuit (31L for pre-mod 07-4280), at 28 volts the indicator’s internal bulb draws 25 mA.

If existing Airbus Helicopters cargo hook or load weigh wiring is installed and terminated at the locations below, remove the wires completely or remove from connectors and cap and stow them.

Figure 2.4.7 Electrical Schematic

Existing Airbus Helicopters Wiring, post-Mod #07-4280

A1

44ALP BREAKER PANEL

A1

SWING

10A

BUS

OPT1

23M

ME1E

24M

A A

B B

ME5E

32M

A A

B B

C C

ME5E

A1 X2 X1 A2

ME4NE

ME2E

X4

10

31ALP32 BREAKER PANEL

2.5A

ME10E

2

7

13

18

To "CARGO REL" cyclic button.

3N

55M

ME87E

55M

E

F

C

D

A A

B B

E

F

C

D

ME87E

BELLY DISCONNECT 1N

Note: Data line included with

Load Weigh Harness P/N 270-106-02 only.

Data line may or may not be terminated with a connector, depending on manufacture date.

2LK72NE

ME6NE

2LK71E

INSTRUMENT

LIGHTING

30M

L

M

N

P

G

H

J

K

A

B

C

D

E

F

R

L

M

N

P

G

H

J

K

A

B

C

D

E

F

R

16

11

20ALP-J1A P1A

U/CA FLOOR U/CA FLOOR

Existing Airbus Helicopters Wiring, post-Mod #07-3450 shown.

Installation Instructions 2-13

2.4 Electrical Wiring Installation continued

Figure 2.4.7 Electrical Schematic, continued

ME1E

27 

2

1

27 

16A

ME1E

X3

31 32

9

15A

ME2E

ME10E

4 21 

2.5A

12

17

ME3E

25 

6

7

9

25 

P.C.B

15

14

13

5

11

21 

19

2.5A

CONTROL

PANEL

10

8

11

10

12

8

9

4

Existing Airbus Helicopters Wiring, pre-mod #07-3475

E

3

4

32 

16A

ME1E

A

3

31 

2.5A

ME2E

Existing Airbus Helicopters Wiring, post-mod #07-1737

Existing Airbus Helicopters Wiring, pre-mod #07-1737

SLING

ME10E

22 10 9

A

24

C

1

2

3

21

20

9

8

20 Cyclic Lever PCB

Existing Airbus Helicopters Wiring, Post-Mod #07-3273

2-14 Installation Instructions

2.5 Fuel Drain Guard Installation

If installing the kit on a helicopter that has NOT been retrofitted with the B-2 style dual fuel pump type tank (Airbus Helicopters P/N 350A55-1015-

0251), the fuel drain guard installation is omitted. Skip to section 2.6.

In preparation for installing the fuel drain guard:

 Obtain ProSeal sealant (P/N PR1422-B).

 Verify that the fuel drain lever has been modified per AD 2005-03-08 requirements.

 Completely drain the fuel from the fuel tank.

 Begin disassembly of the fuel drain assembly by disconnecting the fuel drain control cable from the Lever (Airbus Helicopters P/N 350A55-1043-21). To free the control cable, remove the Sleeve (Airbus Helicopters P/N N1-5ALU) and Cable Grip (Airbus Helicopters P/N 58-2-009). See Figure 2.5.1.

Figure 2.5.1 Removing Control Cable

Installation Instructions 2-15

2.5 Fuel Drain Guard Installation continued

 Remove and retain spring (Airbus Helicopters P/N 350A55-1044-21) and

Lever.

 Remove the cable support bracket. Retain the two attachment screws.

 Remove the connections from the common ground point on the lever retainer.

 Remove the safety wire securing the Fuel Drain Valve (Airbus Helicopters P/N

350A52-1008-01). Remove the Fuel Drain Valve and the Retainer from the tank. Discard used Fuel Valve Seal (Airbus Helicopters P/N SD16X-21P).

 Remove the residual sealant from the tank, taking care to not mar the sealing surface. Prepare the area for sealing per Airbus Helicopters Standard Practices

Manual.



Figure 2.5.2 Fuel Drain Disassembly Complete

270-19

Prepare the Retainer (P/N 290-888-00) for electrical bonding by removing the anodize from the area shown in Figure 2.5.3.

Figure 2.5.3 Prepare Retainer

2-16

Remove anodize this area

Installation Instructions

2.5 Fuel Drain Guard Installation continued

 Prepare PR1422-B or equivalent fuel tank sealant per Airbus Helicopters

Standard Practices Manual. Apply sealant to Retainer as shown in Figure 2.5.4.

Retain unused sealant to ensure proper cure.

Figure 2.5.4 Apply Sealant

Apply sealant to this surface

Figure 2.5.5 Position Guard

On some aircraft, the guard may have to be modified to fit the key on the fuel tank. In these cases, the sides of the clearance slot on the guard should be widened the minimum amount necessary in order to fit over the key. See figures 2.5.6 and

2.5.7.

Installation Instructions 2-17

2.5 Fuel Drain Guard Installation continued

Figure 2.5.6 Fuel Tank Key

Key

Figure 2.5.7 Modification of Guard Slot

 Carefully place the Retainer inside the Guard by inserting the tab through the slot in the Guard. Press the retainer to the tank firmly and center it about the drain hole. See Figure 2.5.8.

Figure 2.5.8 Retainer/Guard Assembly

 Secure the Guard and Retainer by re-installing the Fuel Drain Valve with Fuel

Valve Seal, P/N 610-024-00 (Airbus Helicopters P/N SD16X-21P). Use a flatblade screwdriver to prevent the Retainer from twisting when tightening the

Fuel Drain Valve. Torque per Airbus Helicopters specifications.

The guard is not intended to fit tightly with the fuel tank. When properly installed, the guard should have freedom to move slightly.

2-18 Installation Instructions

2.5 Fuel Drain Guard Installation continued

 Secure the Fuel Drain Valve with safety wire using the small hole in the retainer tab.

 Re-install the electrical connections to the new Retainer tab per Airbus

Helicopters Electrical Bonding Procedure. Refer to Airbus Helicopters

Standard Practices Manual, 20.02.07.

 Install the Lever by placing it in Retainer slot and rotating upwards. Secure with cotter pin (P/N 510-526-00). See Figure 2.5.9.

Figure 2.5.9 Install Lever

COTTER PIN

LEVER

 Install a second cotter pin through the other holes in the Guard (this cotter pin is for valve protection only and is not used for rigging purposes).

 Prepare to install Bracket (P/N 290-893-00) by threading the control cable through the Bracket hole. Install Bracket using the two screws removed previously.

 Pass the cable through the spring and then the Lever. Install the Sleeve and

Cable Grip.

To avoid inadvertent fuel loss, Airbus Helicopters

P/N 58-2-009 Cable Grip must be used with this installation.

 Adjust the cable travel by doing the following: allow the lever to rest against the cotter pin stop. Slide the Cable Grip up to the bottom of the lever and secure. See Figure 2.5.10.

Installation Instructions 2-19

2.5 Fuel Drain Guard Installation

continued

Figure 2.5.10 Adjust Cable Travel

Cable Grip

Cable





Check the cable adjustment with the release handle on the side of the aircraft.

There should be a minimum of .25 inch (6mm) cable travel before valve opens.

Adjust the Cable Grip as required.

Trim excess cable to within .25” of cable grip.

 Allow the sealant to cure per Airbus Helicopters Standard Practices Manual before adding fuel. Verify proper cure of unused sealant.

 Add fuel to the tank and check for leakage.

 Re-install aft lower cowling. Check for clearance between Guard and cowling.

If required trim cowling cutout to provide a min of .125 inch (3.5mm) clearance between the cowling and guard. See Figure 2.5.11 for completed installation.

Figure 2.5.11 Installation Complete

2-20 Installation Instructions

2.6 Swing Suspension Installation

 Install the cable assemblies onto the swing suspension frame with hardware

 provided pre-assembled onto the cable clevis end. Fasten the two shorter cable assemblies (P/N 232-140-01) onto the forward pivot points of the suspension frame and the two longer cable assemblies (P/N 232-141-01) to the aft pivot points.

The forward end of the suspension is determined by the orientation of the cargo hook. When the suspension is installed the cargo hook load beam

must point to the left side of the helicopter (the manual release cable is routed to the right side of the helicopter).

Install the Swing Suspension onto the aircraft by attaching the four clevises at the end of the cables to the INBOARD holes on the Shackle Assemblies with the Quick Release Pins (P/N 290-851-00) as shown in Figure 2.6.1. Install the attached safety pins at each Quick Release Pin.

Figure 2.6.1 Cargo Hook Swing Suspension Assembly Installation

Shackle Assembly

Safety Pin

Quick Release Pin

Installation Instructions 2-21

2.7 Removable Manual Release Cable Assembly Installation

Connect the manual release cable (P/N 268-024-02) to the cargo hook per the following instructions: o Remove the manual release cover from the cargo hook by removing two screws (see below).

Figure 2.7.1 Manual Release Cover Removal

Remove these two screws.

o Thread the fitting at the end of the manual release cable into the manual release boss on the cargo hook side plate until the threads protrude approximately .125 inches beyond the boss and secure with jam nut (as shown in Figure 2.7.2). 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 2.7.2 Initial Release Cable Adjustment boss

Manual Release Cable jam nut

Approx. .125 in. (3.2mm)

2-22 Installation Instructions

2.7 Removable Manual Release Cable Assembly Installation continued

 Route the cable from the hook through the aft end of the suspension frame as illustrated below. Clip the cable into the clamps at points 1 and 2 (installed per section 2.2).

Figure 2.7.3 Release Cable Routing

Forward

Do not route through clamp at this location

2

1

Route cable outside of frame

Manual Release Cable

View Looking Down

o Connect the other end of the removable cable assembly to the end of the fixed cable by sliding the Adapter Fitting back to expose the swaged cable end fitting and connecting this fitting to the swaged cable end fitting on the fixed cable as shown below.

The pre-set compressed spring length is set at the factory to be 1.94/2.00 inches (see figure 2.7.4). If necessary, minor adjustments can be made at the release handle assembly on the collective. o Thread the Adapter Fitting on the removable cable onto the fixed cable adapter fitting and lock in position by engaging a castellation with the Locking Pin

(P/N 514-052-00). o Snap the removable cable Adapter Fitting into the inboard spring clip on the

Quick Disconnect Support Assembly.

Installation Instructions 2-23

2.7 Removable Manual Release Cable Assembly Installation continued

Figure 2.7.4 Manual Release Cable Connection

Removable Manual Release Cable

Adapter Fitting

Fixed Manual Release Cable

Adapter Fitting

1.94/2.00

Locking Pin

P/N 514-052-00 o At the cargo hook, ensure the manual release cable is between the two prongs of the release lever fork as illustrated in Figure 2.7.5.

2-24

Manual release cable rigging must be done with the cargo hook in the closed and locked position. o With the cargo hook closed and locked, rotate the release lever in the clockwise direction to remove free play (the free play is taken up when the hook lock indicator begins to move, this is also felt as the lever rotates relatively easily for several degrees as the free play is taken up) and measure the gap between the cable ball end and the release lever fork with the manual release lever in the cockpit in the non-release position. This gap should be a minimum of .125 inches (3.2 mm) as shown in Figure 2.7.5.

Figure 2.7.5 Manual Release Cable Rigging

Release Lever o o o o

Cable Ball End

Manual Release Cable

.125 in. min.

(3.2 mm)

Release Lever Fork

Load beam must be closed and locked for rigging.

Installation Instructions

2.7 Removable Manual Release Cable Assembly Installation continued o If necessary adjust the system to obtain the minimum gap of .125 inches at the release lever fork as shown in Figure 2.7.5 (the maximum gap is limited by the manual release cover, i.e.- the release cable must fit within the cover when it is installed). The system can be adjusted at the manual release lever on the collective or minor adjustments can be made at the cargo hook by loosening the jam nut and turning the manual release cable in the required direction (this requires that the manual release cable be disconnected from the fixed release cable and the quick release clamps on the belly). Be sure to maintain full thread engagement between the manual release cable fitting and cargo hook. o Move hook and swing frame throughout its range of motion while observing free play. At no point should the free play be less than .030”. o Check that the cable housing is not kinked or pulled tight in any hook and swing frame position. o Re-install the manual release cover with the two screws and ensure the manual release cable jam nut is tightened securely against the cargo hook.

2.8 External Electrical Release and Load Cell Cable Installation

 Connect the end of the cargo hook electrical release cable to the fixed electrical release connector (32M) installed per Section 2.4.

 Connect the ground strap from the hook to the fixed ground strap installed per section 2.4.

 Connect the end of the load cell cable to the fixed load weigh harness connector (55M) installed per Section 2.4.

See table 2-1 for connector pin out information

Table 2.1 Cargo Hook Connector

Pin Function

A Ground

B Power

Installation Instructions 2-25

2.8 External Electrical Release and Load Cell Cable Installation continued

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

Un-commanded cargo hook release will happen if the manual release cable is improperly restrained.

The cable 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 release cables.

Figure 2.8.1 Un-commanded Release From Incorrectly Secured Cable

2-26 Installation Instructions

2.9 Placard Installation

 Install appropriate load limitation placard, P/N 215-166-00 (3086 lb max. hook load) or P/N 215-168-00 (2557 lb max. hook load), dependent on the model of

AS350 on which the system is being installed. Consult the Airbus Helicopters

Flight Manual Supplement applicable to your particular helicopter for the external load limitation. Locate the placard on the belly of the helicopter, visible to the ground operator and near the hook.

The provided load limitation placards P/N 215-

166-00 and P/N 215-168-00 feature black letters on a transparent background. If being installed on a dark-colored helicopter the lettering may not be readily visible. In this instance new placards of the same size and with the same text may be fabricated with a different background to provide visibility.

The lettering must contrast with the background.

If installation is being done under a Brazilian

CHST, bilingual placards are required. The required placards are illustrated in Section 7, fabricate as shown or contact Onboard Systems for price and availability. Install appropriate load limitation placard, P/N 215-200-00 (1400 kg max. hook load) or P/N 215-201-00 (1160 kg max. hook load), dependent on the model of AS350 on which the system is being installed. Install “SOLTA-

CARGA” placard (P/N 215-202-00) on the manual release lever in the cockpit over, or next to, the

“CARGO RELEASE” engraving.

Installation Instructions 2-27

Installation Check-Out

After installation of the Cargo Hook Swing Suspension System, perform the following functional checks.

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

Hook or suspension from swinging freely in all directions.

2. With no load on the cargo hook load beam, pull the handle operated cargo hook mechanical release, the Cargo Hook should release. Reset the load beam.

3. With no load on the cargo hook load beam, depress the cargo hook electrical release button, the Cargo Hook should release. Reset the load beam.

4. Perform an EMI ground test per AC 43.13-1b section 11-107. For equipment that can only be checked in flight an EMI flight test may be required.

The cargo hook is of a class of equipment not known to have a high potential for interference.

This class of equipment does not require special

EMI installation testing (i.e. FADEC) as required in paragraphs 7 and 8 of FAA policy memorandum

ASW-2001-02.

5. Power on the Indicator and allow it to warm up for 5 minutes (with no load on the hook). Press both Indicator buttons at the same time to go to the Setup

Mode. Scroll through the menu until the symbol “0 in” is displayed, then press the right button. Remove any weight that is not to be zeroed out and press either button to complete the procedure.

6. If fuel drain guard was installed, pull the handle on the side of the helicopter and verify that fuel is dispensed from the valve.

Component Weights

The weights and cgs of the Cargo Hook Swing Suspension System components are listed below.

Table 2.2 Component Weights

Item Weight

Removable Provisions 30.0 lbs (13.6 kg)

Fixed Provisions 5.5 lbs (2.5 kg)

Fuel Drain Guard

Total

0.40 lbs (.18 kg)

35.9 lbs (16.3 kg)

Station

133 in (3375 mm)

110 in (2794 mm)

135 in. (3430 mm)

129.4 in (3288 mm)

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 P/N 121-012-03 in the Rotorcraft Flight

Manual

.

2-28 Installation Instructions

Section 3

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 display 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 3.1 Front Panel

Calibration &

Dampening

Legend

Zero & Un-Zero Legend

Unit Legend

Digits

Left Button Right Button

Load Weigh System Operation Instructions 3-1

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 on in the Run Mode.

After the Indicator has been correctly installed, power it up by activating the aircraft electrical system. 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 3.2 After Diagnostic Routine

3-2

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

Figure 3.3 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 3.4 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 3-3

The Run Mode continued

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 3.1 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.

3-4 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 3-5

The Setup Mode,

continued

Table 3.2 Indicator Setup Routines

MENU

Press the Left button to scroll through the menu

DAMP

FUNCTION

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

Dampening Level, sets the pilots preference for display dampening.

CODE

0 in

LOAD

Scale

LB KG

XX - V

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.

3-6 Load Weigh System Operation Instructions

The Setup Mode,

continued

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 3.5 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.

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.

Load Weigh System Operation Instructions 3-7

The Setup Mode,

continued

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 3.6 Changing the CAL Code

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.

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.

3-8 Load Weigh System Operation Instructions

The Setup Mode,

continued

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 3-9

The Setup Mode,

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 3.7 Running CAL Routine

3-10

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 3.8 Entering Load in CAL Routine

Load Weigh System Operation Instructions

The Setup Mode,

continued

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 3.9 Changing the Scale

Load Weigh System Operation Instructions 3-11

The Setup Mode,

continued

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 3.10 Changing the Units

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.

3-12 Load Weigh System Operation Instructions

The Setup Mode,

continued

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 3.11 Looking at Indicator Version

3-12 Load Weigh System Operation Instructions

This page intentionally left blank.

Section 4

Operation Instructions

Operating Procedures

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

1. Activate the electrical system and press the Cargo Hook release button to ensure the cargo hook electrical release is operating correctly. The Cargo Hook must release. Reset the hook by hand after the release. If the hook does not release or relatch, do not use the unit until the difficulty is resolved.

The cargo hook release solenoid is intended to be energized only intermittently. Depressing the electrical release button continuously in excess of

20 seconds will cause the release solenoid to overheat, possibly causing permanent damage.

2. Activate the manual release lever to test the cargo hook manual release mechanism. The mechanism should operate smoothly and the Cargo Hook must release. Reset the load beam by hand after release. Verify that the hook lock indicator on the side of the hook returns to the fully locked position. If the hook does not release or re-latch, do not use the unit until the problem is resolved.

In the fully locked position the hook lock indicator must align with the lines on the manual release cover (see Figure 4.1).

Figure 4.1 Hook Lock Indicator

Operation Instructions 4-1

Disconnecting Removable Provisions

For helicopter missions in which the cargo hook swing suspension system is not needed, its removable provisions may be removed per the following instructions.

1. Remove the removable section of the manual release cable by unclipping it from the bracket on the belly of the helicopter, disengaging the locking pin and unthreading the Adapter Fitting. Unclip the Release

Cable Cap (see below) from the bracket and thread it over the open end of the fixed manual release cable assembly and clip it into the inboard spring clip on the bracket.

Figure 4.2 Manual Release Cable Removal

Release Cable Cap

Fwd

Inbd

2. Disconnect the electrical cables and the ground strap at the belly of the helicopter.

3. Remove the Swing Suspension by removing the safety pins and then the quick release pins that secure the cables to each of Shackle Assemblies at the aircraft hard points.

Figure 4.3 Suspension Removal

Shackle Assembly

Safety Pin

Quick Release Pin

4-2 Operation Instructions

Optional Link Assembly

An optional Link Assembly (P/N 232-436-00) may be used in place of the

Load Cell Assembly. This link assembly does not provide for load weighing. It is directly interchangeable with the Load Cell Assembly, including using the same hardware. Refer to ICA manual for instructions for removal and re-installation.

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 4.4, until an internal latch engages the load beam and latches it in the closed position.

Figure 4.4 Cargo Hook Loading

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 and rigging to avoid, but is not intended to represent all rigging possibilities.

Operation Instructions 4-3

Cargo Hook Rigging

continued

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.

Multiple load rings, 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 4.5 Cargo Hook Rigging Examples

Recommended Avoid

Primary Ring

Long Line

4-4 Operation Instructions

Section 5

Maintenance

Refer to the Instructions for Continued Airworthiness (ICA) manual 123-

011-03 for maintenance of the cargo hook suspension system. For maintenance of the cargo hook refer to Cargo Hook Service Manual 122-

017-00.

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 5-1

This page intentionally left blank.

Section 6

System Part Numbers

210-201-03 AS 350 Swing Removable Provisions

4

5

6

Item Part Number Description

1 232-145-03 Hook Frame Assembly

2

3

232-140-01

232-141-01

Forward Attach Cable Assembly

Aft Attach Cable Assembly

268-024-02

215-166-00

215-168-00

Manual Release Cable Assembly

Max Hook Load 3086 Decal

Max Hook Load 2557 Decal

1

1

1

Qty

1

2

2

System Part Numbers 6-1

System Part Numbers

continued

210-202-01 AS 350 Swing Fixed Provisions

3

4

5

Item Part Number Description

1

2

232-151-00

232-150-00

Fixed Quick Disconnect Assembly

Release Handle Assembly

232-137-01 Shackle Assembly

210-095-00 C-39 Indicator Assembly

290-772-00 Indicator Mount Bracket

6

7

8

9

290-780-00 Cable Attach Bracket

290-783-00 Relay Bracket

445-005-00 Relay

290-782-00 Connector Bracket

10 500-065-00 Grommet Edging

11 270-106-02 Load Weigh Internal Harness

12 270-108-00 Electrical Release Internal Harness

13 215-165-00 Multiple Sticker Sheet

14 270-125-00 Ground Strap

15 290-888-00 Retainer

16 290-889-01 Guard

17 290-893-00 Bracket

6-2

1

1

1

1

1

1

1

1

1

1

1

1

4

1

1

Qty

1

1

System Part Numbers

System Part Numbers

continued

232-137-01 Shackle Assembly

1

3

Item Part Number Description

1 517-047-00 Bushing

2

3

290-850-00

517-016-00

Airframe Attach Fitting

Bushing

2

1

Qty

2

1

1

System Part Numbers 6-3

System Part Numbers

continued

232-150-00 Release Handle Assembly

Item Part Number Description Qty

1 268-025-00 Fixed Manual Release Cable 1

2 510-215-00 Cover Screws 2

3 290-757-00 Cover

4 510-210-00 8-32 Locking Heli-Coil

5 290-754-00 Lever Body

6 517-049-00 Pulley

7 290-759-00 Shaft

8 510-450-00 Bolt, Handle pivot

9 510-449-00 Bolt, Pulley Pivot

10 290-755-00 Handle

11 510-042-00 Washer

12 510-082-00 Nut

13 510-125-00 Cotter Pin

14 510-248-00 10-32 Heli-Coil

15 290-753-00 Clamp Half

16 510-390-00 Screw, Mounting Clamp

17 510-095-00 Washer

1

1

2

2

2

1

2

2

1

1

1

1

1

2

1

6-4 System Part Numbers

System Part Numbers

continued

232-151-00 Quick Disconnect Support Assembly

Item Part Number Description

1

2

3

4

290-797-00 Attach Bracket

290-791-00 Release Cable Cap

514-053-00 Spring Clip

510-102-00 Nut

5

6

7

510-085-00 AN 970-3

510-455-00 NAS 6603-13

514-050-00 Spring Clip

8

9

510-211-00

531-016-00

Button Head Screw

Crimp Sleeve

10 531-015-00 Lanyard

3

2

6”

2

2

1

Qty

1

1

1

2

System Part Numbers 6-5

System Part Numbers

continued

232-140-01 Forward Attach Cable

3

4

4

2

3

5

1

7

8

9

10

6

Item Part Number Description

1 232-177-00 Forward Attach Cable

2 290-851-00 Quick Release Pin

3 531-015-00 Lanyard Cable

4 531-016-00 Crimp Sleeve

5 510-464-00 Hitch Pin

6 510-438-00 Bolt

7 510-221-00 Washer

8 510-440-00 3/8" Castellated Nut

9 510-178-00 Cotter Pin

10 510-439-00 Bolt

11 232-142-00 Lower Attach Gimbal Assembly

12 290-749-00 Standoff Bushing

2

1

1

3

Qty

1

1

2

2

2

1

1

2

11

9

8

7

12

6-6 System Part Numbers

System Part Numbers

continued

232-141-01 Aft Attach Cable Assembly

3

4

4

2

3

5

1

7

8

9

10

6

Item Part Number Description

1 232-178-00 Aft Attach Cable

2 290-851-00 Quick Release Pin

3 531-015-00 Lanyard Cable

4 531-016-00 Crimp Sleeve

5 510-464-00 Hitch Pin

6 510-438-00 Bolt

7 510-221-00 Washer

8 510-440-00 3/8" Castellated Nut

9 510-178-00 Cotter Pin

10 510-439-00 Bolt

11 232-142-00 Lower Attach Gimbal Assembly

12 290-749-00 Standoff Bushing

Qty

1

1

2

2

1

1

3

2

2

1

1

2

11

9

8

7

12

System Part Numbers 6-7

System Part Numbers

continued

232-142-00 Lower Attach Cable Gimbal Assembly

3

2

1

Item Part Number Description

1 517-048-00 Bushing

2 290-746-00 Lower Cable Gimbal

3 517-016-00 Bushing

Qty

2

1

1

6-8 System Part Numbers

System Part Numbers

continued

232-143-01 Loadcell Gimbal Assembly

2

3

4

Item Part Number Description

1 517-056-00 Bushing Upper Hook Gimbal

2 290-841-00 Gimbal Link

3 517-046-00 Bushing Lower Hook Gimbal

4 518-003-00 Grease Fitting

Qty

2

1

2

1

1

System Part Numbers 6-9

System Part Numbers

continued

232-145-03 Swing Hook-Frame Assembly

6-10 System Part Numbers

System Part Numbers

continued

232-145-03 Swing Hook-Frame Assembly

,

continued

17

18

19

18

20

21

28

25

29

30

27

26

25

24

23

SEE GROUND STRAP

CONNECTION DETAIL

21

22

GROUND STRAP CONNECTION

AND ROUTING DETAIL VIEW

34

35

36

System Part Numbers 6-11

System Part Numbers

continued

232-145-03 Swing Hook-Frame Assembly

3

4

5

6

Item Part Number Description

1 235-117-00 Swing Frame Half

2 290-845-00 Foot – Right

510-762-00

510-104-00

517-055-00

510-510-00

Bolt

Nut

Spherical Bearing

Jam Nut

7

8

235-116-00

510-440-00

9 290-843-00

10 290-842-00

11 517-057-00

Frame Strut

Nut, Castellated

Shaft Cap

Shaft – Pivot

Bearing

12 517-058-00

13 232-143-01

14 290-862-00

15 510-506-00

16 290-846-00

17 510-443-00

18 290-740-00

19 290-739-00

20 510-220-00

21 510-178-00

22 270-107-00

23 510-170-00

24 510-174-00

25 510-183-00

26 510-320-00

Bearing

Loadcell/Gimbal Assembly

Bumper

Bolt

Foot – Left

Bolt

Shaft Retaining Bushing

Shaft – Gimbal

Washer

Cotter Pin

Electrical Release Cable

Nut

Washer

Washer

Nut, Castellated

Qty

2

2

4

4

4

4

2

1

2

1

2

2

1

1

1

2

1

2

1

1

3

1

1

1

1

1

27

28

31

528-029-00

290-775-00

29 290-774-00

30 210-249-03*

590-008-00

32 215-183-00

33 510-429-00

34 270-126-00

35 510-391-00

3600 lb. Keeperless Cargo Hook

Long Hook Attach Bolt

Hook Bumper

AS350 Swing Load Cell Assembly

Plastic Tubing Wrap

Serial Number Plate

Drive Screw

Ground Strap

Screw

1

1

1

1

80”

1

4

1

1

36 512-011-00

37 215-271-00

Ty-Wrap

Fuel Drain Warning Placard

2

1

* Supersedes 210-249-00, 210-199-01 and 210-199-00. These part numbers are interchangeable.

6-12 System Part Numbers

Section 7

Certification

FAA STC

Certification 7-1

FAA STC continued

7-2 Certification

Transport Canada Approval

Certification 7-3

This page intentionally left blank.

7-4 Certification

EASA STC

Certification 7-5

EASA STC

continued

7-6 Certification

EASA STC

continued

Certification 7-7