Onboard Systems Bell 206L & 407 200-258-00, 200-259-00, 200-259-01 Cargo Hook Suspension System Owner's Manual
The Bell 206L & 407 200-258-00, 200-259-00 and 200-259-01 Cargo Hook Suspension Systems replaces the Bell kit part numbers 206-706-341-101, -105, and 109 Auxiliary Equipment Kit - Cargo Hook. It must be installed with the Bell part number 206-706-341-7, -9, -103, -111, -113, -117, -123, or -125 Auxiliary Equipment Kit- Cargo Hook Provisions or Onboard Systems P/N 200-328-00 Fixed Provisions Kit. The 200-328-00 fixed provisions kit is approved for the 407 model under Onboard Systems STC SR01943SE.
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Cargo Hook
Suspension System
For the
Bell 206L & 407 Series
With
Talon LC Keeperless
Cargo Hook
System Part Numbers
200-258-00, W/O Load Weigh
200-259-00, W/ Load Weigh
200-259-01, W/Load Weigh and 5V Lighting
Owner's Manual Number 120-092-00
Revision 12
03/12/15
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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Record of Revisions
Revision
4
5
Date
04/28/06
Page(s)
2-7
Reason for Revision
Added electrical connection caution statement.
09/07/06 1-2, 2-11, 2-12, Updated manual to allow the installation of wire harness 270-048-04.
6
7
8
9
10
11
12
04/16/07 Section 1, 2-2, 2-7,
2-10, 2-12, 3-9 &
3-1
Section 4
Changed P/N 232-030-01 to 232-030-02 (per
Service Bulletin 159-020-00).
Updated warnings, cautions and notes to current format.
07/10/08 1-3, 2-1, 2-6, 2-7 Added kit P/N 200-245-00 to BOM, added note regarding forward pair of pillow block fasteners, updated torque instructions for nut 510-170-00, and clarified release cable rigging dimension.
09/15/08 1-1, 2-1 Added P/Ns 206-706-341-117, –123, and -125 as compatible Bell provisions kits. Clarified Figure 2-1 and corresponding instructions.
08/11/09
12/18/09
12/22/09
1-3, 2-7
2-11 to 2-14
1-1
03/12/15 Section 1, 2-1, 2-2,
2-7, 2-8, 2-10, 2-
11, 2-13, 2-14, 3-
8, 3-9, 3-12, 4-1,
4-3, 5-1
Added caution note and revised figure 2-7. Changed
P/N 268-004-00 to 268-004-01 for improved service life.
Updated manual to reflect new load weigh harness configuration. Updated EMI note in installation check-out section.
Added P/N 200-328-00 as an eligible fixed provisions kit for the 407 model.
Updated safety labels to ANSI format throughout, added load cell P/N 210-179-01, updated cargo hook load rigging section.
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CONTENTS
Section 1 General Information
Introduction, 1-1
Safety Labels, 1-2
Specifications, 1-3
Inspection, 1-3
Bill of Materials, 1-4
Theory of Operation, 1-5
Section 2 Installation Instructions
Cargo Hook Suspension System Removal, 2-1
Cargo Hook Suspension System Installation, 2-1
Load Weigh System Installation, 2-11
Internal Harness Installation,2-11
C-39 Cockpit Indicator Installation, 2-11
Indicator Internal Back Light, 2-11
Indicator Hook-Open Warning, 2-12
Remote Analog Meter, 2-12
Electrical Connections, 2-12
Installation Check-Out, 2-13
Component Weights, 2-13
Suspension System Location, 2-14
Paper Work, 2-14
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, 3-7
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
iii
CONTENTS,
continued
Section 4 Cargo Hook Suspension System Operation Instructions
Operating Procedures, 4-1
Cargo Hook Loading, 4-2
Cargo Hook Rigging, 4-3
Section 5 Maintenance
Instructions for Returning a System to the Factory, 5-1
Section 6 Certification
FAA STC, 6-1
Canadian Approval, 6-2
EASA Approval, 6-3
Brazilian Approvals, 6-5 iv
Section 1
General Information
Introduction
The 200-258-00, 200-259-00 and 200-259-01 Cargo Hook Suspension
Systems are approved for installation on the following Bell helicopters:
Model Serial Numbers
206L
206L-1
206L-3
206L-4
45001-45153
45154 and on
51001 and on
52001 and on
407 All
The system replaces the Bell kit part numbers 206-706-341-101, -105, and -
109 Auxiliary Equipment Kit - Cargo Hook. It must be installed with the
Bell part number 206-706-341-7, -9, -103, -111, -113, -117, -123, or -125
Auxiliary Equipment Kit- Cargo Hook Provisions or Onboard Systems P/N
200-328-00 Fixed Provisions Kit. The 200-328-00 fixed provisions kit is approved for the 407 model under Onboard Systems STC SR01943SE.
General Information
1-1
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.
1-2
General Information
Specifications
Inspection
Table 1-1 Suspension System Specifications
Design load
Design ultimate strength
3,000 lb. (1360 kg.)
13,500 lb. (6120 kg.)
Unit weight P/N 200-258-00 12 pounds (5.44 kg.)
Unit weight P/N 200-259-00 13 pounds (5.90 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 lb. (1,588 kg.)
13,125 lb. (5,953 kg.)
8,750 lb. (3,969 kg.)
8,750 lb. (3,969 kg.)
8 lb. Max.(.600” travel)
22-32 VDC 6.9 – 10 amps
0 pounds
3.0 pounds (1.35 kg.)
PC06A8-2S SR
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.
General Information
1-3
Bill of Materials
The following items are included with the Suspension System, if shortages are found contact the company from whom the system was purchased. The
Bell Helicopter provisions kit is required to complete the installation.
Part No.
210-167-00
Description
Beam Assembly w/o Load Cell
210-178-00 Beam Assembly with Load Cell
210-179-01*** E-85 Load Cell Assembly
268-004-01 Manual Release Cable
270-074-00
528-023-01
290-331-00
510-229-00
510-095-00
510-102-00
290-370-00
Electrical Release Cable
3,500 Lb. Cargo Hook
Release Fitting
Bolt
Washer
Nut
Trunnion Pin
290-374-00
510-234-00
510-235-00
510-114-00
510-100-00
510-230-00
232-030-02
600-006-00
210-095-00
210-177-00
270-048-04
Thrust Spacer
Nut
Bolt
Nut
Washer
Bolt
Pillow Block Assembly
Release Cable Disconnect
C-39 Indicator
C-39 Indicator, 5V Lighting
Harness Assembly
400-048-00
215-010-00
215-012-00
512-001-00
510-028-00
510-029-00
510-062-00
235-035-00
120-092-00
121-003-00
122-005-00
123-007-00
Power Switch
Placard
Placard
Ty-Wrap
Screw
Nut
Washer
QD Bracket
Owner's Manual
RFM Supplement
Cargo Hook Service Manual
ICA Maintenance Manual
2
1
1
-
1
2
2
2
10
4
4
200-259-00
Quantity
-
1
-
1
1
1
1
2
2
2
2
6
8
1
1
1
1
1
1
2
1
10
6
2
1
-
-
-
2
2
2
10
4
4
200-258-00
Quantity
1
-
-
1
1
1
1
2
2
2
2
-
1
1
1
-
-
1
-
-
-
-
-
200-245-00
Quantity**
-
-
1
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
1
-
1
1
1
1
10
6
6
8
1
1
-
-
-
2
1
-
1
1
10
4
4
2
2
2
200-259-01
Quantity
-
1
-
1
1
1
1
2
2
2
2
6
8
1
1
1
1
1
1
2
1
10
6
* The 210-177-00 Indicator is equipped with a 5 Volt back lighting system. It is an optional indicator that can be ordered in place of the 210-095-00 Indicator.
** P/N 200-245-00 is a load weigh kit that can be purchased separately to upgrade the 200-258-00 kit to a 200-259-00 kit.
*** P/N 210-179-01 supersedes P/N 210-179-00. These assemblies are interchangeable.
1-4
General Information
Theory of Operation
The primary elements of the Cargo Hook are the load beam, the internal mechanism, and a DC solenoid. The load beam supports the load and is latched through the internal mechanism. The DC solenoid, an external manual release cable and a manual release lever provide the means for unlatching the load beam.
The load is attached to the load beam by passing the 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 slides off the load beam. The load beam then remains in the open position awaiting the next load.
A load release can be initiated by three different methods. Normal release is achieved 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. In an emergency, release can be achieved by operating a mechanical release cable. The release cable operates the internal mechanism of the Cargo Hook to unlatch the load beam. The load can also be released by the actuation of a lever located on the side of the Cargo Hook
General Information
1-5
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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 System Installation
If installing the cargo hook suspension system on a helicopter that has a Bell
P/N 206-706-341-125 Fixed Provisions Kit installed, the pillow blocks included with this kit must be removed. Retain the forward pairs of screws and nuts for each pillow block (the aft pairs of fasteners will not be re-used).
The cargo hook suspension systems must be installed with the supplied 232-030-02 Pillow
Blocks. These systems are not compatible with
Pillow Blocks supplied by Bell.
Attach the two P/N 232-030-02 Pillow Block Assemblies as illustrated below. Use sealant on the faying surfaces. At the forward pair of holes at each pillow block, re-use the screws and washers provided with the Bell
Helicopter provisions kit. At the aft pairs of fasteners at each pillow block torque the 510-234-00 nuts and 510-235-00 bolts to 100-130 in-lbs.
The 232-030-02 Pillow Blocks install exactly as the Bell pillow blocks with the exception of the
P/N 510-235-00 bolts. These bolts are a shorter grip length than those used with the Bell pillow blocks and they are installed with the heads down to give clearance for the beam when it rotates.
Figure 2-1 Pillow Block Installation
FWD
BELL FITTINGS
206-072-927-3
206-072-943-1
206-072-943-101
NUT P/N 510-234-00
MS21084L04
Re-use Bell fasteners at fwd pairs of holes.
Installation Instructions
SIDE VIEW
BOLT P/N 510-235-00
MS21250-18
PILLOW BLOCK ASSEMBLY
232-030-02
2-1
Cargo Hook Suspension System Installation,
continued
Attach the Beam Assembly, P/N 210-167-00 or 210-178-00, to the Pillow
Blocks as illustrated.
The long end of the Carriage must point to the left side of the aircraft as illustrated below.
Position the Thrust Spacers, P/N 290-374-00, on both sides of the Pillow
Blocks to center the Beam Assembly between the Pillow Blocks and allow
.000/.060 lateral movement of the beam assembly. The thrust spacers must be positioned on both sides of the pillow block so that when a lateral load is applied, the beam will not rub directly (metal to metal) against the pillow block. In addition to the above, the thrust spacers must be positioned so that when a lateral load is applied it will be distributed to both pillow blocks. To check this, apply approximately 10 pounds to the beam in the lateral direction. There should be a maximum of .060 gap when measured as shown in the Figures 2-3 and 2-4.
Figure 2-2 Cargo Hook Suspension Assembly Installation
2-2
Installation Instructions
Cargo Hook Suspension System Installation,
continued
Figure 2-3 Beam Assembly, Left End Play Adjustment
Installation Instructions 2-3
Cargo Hook Suspension System Installation,
continued
Figure 2-4 Beam Assembly, Right End Play Adjustment
2-4
Installation Instruction
Cargo Hook Suspension System Installation,
continued
Secure the two Trunnion Pins, P/N 290-370-00, with fasteners as illustrated.
Torque the 510-230-00 bolts and 510-114-00 nuts to 56-79 in-lbs. Torque the 510-229-00 bolts and 510-102-00 nuts to 20-25 in-lbs.
Figure 2-5 Trunnion Pin Fasteners
510-230-00 Bolt, 510-100-00 Washer & 510-114-00 Nut, 2 each
Installation Instructions
2-5
Cargo Hook Suspension System Installation,
continued
Attach the Cargo Hook, P/N 528-023-01 to the Suspension Assembly as illustrated. The Cargo Hook load beam must point to the right.
Figure 2-6 Cargo Hook to Carriage Installation
2-6
Tighten nut 510-170-00 on bolt 290-332-00 to finger tight, then rotate to next castellation to install and secure cotter pin 510-178-00.
Installation Instructions
Cargo Hook Suspension System Installation,
continued
Remove the manual release cover from the new cargo hook. Thread the manual release adapter, P/N 290-331-00 into the new cargo hook manual release boss on the hook sideplate. Connect the manual release cable to the adapter. Place the cable ball end fitting into the hook manual release fork fitting as illustrated in Figure 2-7. Move the manual release lever in the clockwise direction until it is against the cam stop (this is felt as the lever moves relatively easily for several degrees before hitting the cam stop).
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 to allow a minimum of .125” of free play at the fork fitting as shown in
Figure 2-7.
Manual release cable rigging must be done with
the cargo hook in the closed and locked position.
Figure 2-7 Manual Release Cable Rigging
Manual Release Adapter manual release lever fork cable ball end
Installation Instructions
release cable
.125" min.
(3.2 mm)
Load beam must be closed
and locked when rigging.
Route the Manual and the Electrical Release cables as illustrated in Figures
2-8 and 2-9.
Connect the cargo hook electrical release cable connector to the Cargo
Hook. Listed below is the pin out for the cargo hook connector.
Table 2-1 Cargo Hook Connector
Pin Function
A Ground
B Positive
2-7
.
Cargo Hook Suspension System Installation,
continued
Earlier versions of the cargo hook were equipped with a suppression diode that will be damaged if the cargo hook electrical connection is reversed.
Do not attach the electrical connector until polarity of the aircraft connector is determined to be compatible with the Cargo Hook connector listed in Table 2-1.
Figure 2-8 Manual and Electrical Release Cable Routing, without Load Weigh
View looking from the bottom
2-8
Installation Instructions
Cargo Hook Suspension System Installation,
continued
Figure 2-9 Manual and Electrical Release Cable Routing, with Load Weigh
Installation Instructions
2-9
Cargo Hook Suspension System Installation,
continued
Un-commanded cargo hook release will happen if the manual release cable is 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 release cable.
Figure 2-10 Un-commanded Release From Incorrectly Secured Cable
2-10
Installation Instructions
Load Weigh System Installation Instructions
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 connector. Hardware is provided to attach the bulkhead connector 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 part number and manufacture date.
Route the cables in the most convenient manner. Secure the cables to the existing wiring bundles with the Ty-wraps. Secure the cables clear of flight control rods.
C-39 Cockpit Indicator Installation
The Indicator, P/N 210-095-00 or P/N 210-177-00, 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.
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.
Installation Instructions
2-11
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 (Figure 2-11) 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.
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 wire 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 harness only) should be cut off as it is not needed at this end of the cable.
2-12
Installation Instructions
Figure 2-11 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,
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)
DATA RECORDER/
ANALOG METER CABLE
TO OPTIONAL EQUIPMENT
DEPENDING ON MFG DATE OR DASH
NUMBER THIS CABLE MAY TERMINATE
IN A CONNECTOR
INTERNAL HARNESS ASSEMBLY
(WITH OPTIONAL CABLE INSTALLED)
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 410-130-00, 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)
WH/OR (White)
4
Red*
2
Purple*
*Optional
Clock Signal
Data Signal
Flight Switch
Cap. Switch
If the C-23 Printer is being utilized with the C-20 or C-30 Data Recorder, a 5 amp circuit breaker should be used.
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.
Installation Instructions
2-13
Installation Check-Out
After installation of the Cargo Hook Suspension System, perform the following functional checks.
1. Swing the installed Cargo Hook on the beam to its full extremes 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. With no load on the cargo hook load beam, pull the handle operated cargo hook mechanical release, the Cargo Hook should release. Reset the cargo hook load beam.
3. Close the cargo hook release circuit breaker and position the battery switch to the ON position. With no load on the cargo hook load beam, depress the cargo hook electrical release button, the Cargo Hook should release. Reset the cargo hook load beam
4. See the Bell Helicopter service instructions for your specific helicopter model for additional installation instructions.
5. Perform an EMI ground test per AC 43.13-lb section 11-107. For equipment that can only be checked in flight an EMI flight test may be required.
The cargo hook and load cell are 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-2001-01.
6. Power on the Indicator and allow 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.
2-14
Installation Instructions
Component Weights
The weight of the Cargo Hook Suspension System components are listed below.
Table 2-2 Component Weights
Item
Suspension System W/ hook, W/O Load Cell
Suspension System W/ hook, W/ Load Cell
Indicator and Wire Harness
Weight
12.0 lbs (5.5 kgs)
12.5 lbs (5.7 kgs)
0.5 lbs (.23 kgs)
Suspension System Location
Table 2-3 Suspension System Location
Fuselage Station
Paper Work
121.0
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-
003-00) into the Rotorcraft Flight Manual.
Installation Instructions
2-15
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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 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 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 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 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
3-8
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.
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.
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
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
3-10
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
3-12
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.
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
Load Weigh System Operation Instructions
3-13
This page intentionally left blank.
Section 4
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 Owner’s Manual, Cargo Hook
Component Maintenance Manual 122-005-00 and the ICA Maintenance
Manual 123-007-00.
3. 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 release. If the hook does not release or re-latch, do not use the unit until the difficulty is resolved.
The 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.
4. 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 hook by hand after release. If the hook does not release or re-latch, do not use the unit until the difficulty is resolved.
Operation Instructions
4-1
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 4-1, until an internal latch engages the load beam and latches it in the closed position.
Figure 4-1 Cargo Hook Loading
4-2
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. Figure 4-2 shows the recommended rigging and rigging to avoid, but is not intended to represent all rigging possibilities.
It is the responsibility of the operator to ensure the cargo hook will function properly with each rigging.
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 4-2 Examples of Cargo Hook Rigging
Recommended Avoid
Operation Instructions
4-3
This page intentionally left blank.
Section 5
Maintenance
Refer to the Instructions for Continued Airworthiness (ICA) manual 123-
007-00 for maintenance of the cargo hook suspension system. For maintenance of the cargo hook refer to Cargo Hook Service Manual 122-
005-00.
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
).
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 Certification
FAA STC
Certification
6-1
Canadian Approval
6-2
Certification
EASA Approval
Certification
6-3
EASA Approval
continued
6-4
Certification
Brazilian Approvals
Certification
6-5
Brazilian Approvals
continued
6-6
Certification
Brazilian Approvals
continued
Certification
6-7
Brazilian Approvals
continued
6-8
Certification

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Key features
- 3,000 lb. (1360 kg.) load capacity
- 13,500 lb. (6120 kg.) ultimate strength
- Load Weigh system
- 5V lighting
- Mechanical release cable
- Electrical release system
- Cockpit display
- Optional remote analog meter
- Installation zero routine
- Calibration routine