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

Owner's Manual

For the

Cargo Hook Sling

Suspension System

For the

Eurocopter AS350 Series

System Part Number

200-282-00

Owner's Manual Number 120-105-00

Revision 15

August 1, 2013

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

7

8

9

10

11

12

13

14

15

Date

12/30/04

06/21/05

02/06/07

08/27/07

10/29/07

06/20/08

10/28/09

3/10/10

08/01/13

Record of Revisions

Page(s) Reason for Revision

1-2, 2-12, 2-14, 2-

15

Changed manual release cable part number from 268-024-01 to

268-024-02. Updated Figure 2.5.1 and Figure 2.5.3 to reflect new cable. Corrected p/n of electrical release cable from 270-

107-00 to 270-110-01 on page 2-15. page 2-14,

Section 5

2-8

1-1, 2-4, 2-5, 2-9,

2-13, 2-15, 3-8, 3-

9, 3-12, 4-1 & 4-4

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

17

1-3, 2-8 to 2-19 and

6-1

2-11

2-16

Section 2 & 6-1

1-3, 1-4, Section 2,

3-8, 3-9, 3-12, 4-1,

4-4, & 6-2

Deleted maintenance information and replaced with reference to

ICA maintenance manual and cargo hook service manual.

Updated Figure 2.5.3 and related text to set gap as .125 minimum

(was approximately .125”).

Corrected relay bracket P/N from P/N 290-782-00 to P/N 290-

783-00.

Updated warnings, cautions, and notes to new format.

Updated TOC.

Added Table 1-5 and 1-6, updated wiring installation instructions to incorporate Eurocopter modification #07-3274 including addition of Figure 2.3.2 and revision to Figure 2.3.6. Changed washer p/n from 510-476-00 to 510-095-00.

Changed P/N 270-106-00 to 270-106-02. Added paragraph explaining data line on P/N 270-106-02. Updated electrical schematic. Added paragraph explaining electrical schematic.

Updated electrical schematic (Figure 2.3.6) to show correct termination point for wire ME10E.

Added caution note and revised figure 2.5.3

Updated manual to reflect new load weigh harness configuration.

Clarified manual release cable rigging instructions including

Figure 2.5.3. Updated note regarding EMI test at installation check-out.

Replaced 210-203-00 with 210-203-03. Updated warnings, cautions and notes to new format throughout manual. Updated electrical schematic to reflect current aircraft electrical interface, updated instructions related to connecting to aircraft electrical interface.

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

Safety Labels, 1-1

Specifications, 1-2

Inspection, 1-2

Bill of Materials, 1-3

Theory of Operation, 1-5

Section 2 Installation Instructions

Installation Instructions, 2-1

Cargo Hook Sling Suspension System Installation, 2-1

Fixed Manual Release Cable Assembly Installation, 2-1

Cockpit Indicator Installation, 2-6

Electrical Wiring Installation, 2-8

Sling Suspension Installation, 2-13

Removable Manual Release Cable Assembly Installation, 2-14

External Electrical Release and Load Cell Cable Installation, 2-16

Placard Installation, 2-17

Installation Check-Out, 2-17

Component Weights, 2-18

Paper Work, 2-18

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

Cargo Hook Loading, 4-3

Cargo Hook Rigging, 4-4

Section 5 Maintenance

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

Section 6 System Part Numbers

210-204-00 AS 350 Sling Fixed Provisions, 6-1

210-206-00 AS 350 Sling Removable Provisions, 6-2

232-150-00 Release Handle Assembly, 6-3

232-151-00 Quick Disconnect Support assembly, 6-4

232-144-00 Sling Gimbal Assembly, 6-5

232-148-00 Sling Gimbal Sub-assembly, 6-6

Section 7 Certification

FAA STC, 7-1

Canadian Approval, 7-2

EASA Approval, 7-3

CONTENTS,

continued

Figures

2.1.1 Fixed Manual Release Cable Installation Overview, 2-1

2.1.2 Manual Release Lever Installation, 2-2

2.1.3 Cabin Floor Hole Detail, 2-2

2.1.4 Cable Routing Through Frame, 2-3

2.1.5 Grommet Installation, 2-3

2.1.6 Cable Support Bracket, 2-4

2.1.7 QD Bracket Installation, 2-4

2.1.8 Cable Support Clamp Installation, 2-5

2.2.1 Indicator Bracket Installation, 2-6

2.2.2 Indicator Bracket Hardware, 2-6

2.2.3 C-39 Indicator Installation, 2-7

2.3.1 Electrical Wiring Routing Overview, 2-8

2.3.2 P/N 270-108-00 Harness Modification, 2-10

2.3.3 Relay Bracket Installation, 2-10

2.3.4 Relay Installation, 2-11

2.3.5 Connector Bracket Installation, 2-11

2.3.6 Wiring Schematic, 2-12

2.4.1 Sling Suspension Installation, 2-13

2.5.1 Manual Release Cable Rig, 2-14

2.5.2 Manual Release Cable Connection, 2-14

2.5.3 Manual Release Cable Rig Check, 2-15

2.6.1 Un-commanded Release From Incorrectly Secured Cable, 2-17

3-1 Front Panel, 3-1

3-2 After Diagnostic Routine, 3-2

3-3 LB Legend Displayed, 3-2

3-4 Zeroing the Display, 3-3

3-5 Changing Dampening Level, 3-7

3-6 Changing the CAL Code, 3-8

3-7 Running CAL Routine, 3-10

3-8 Entering Load in CAL Routine, 3-10

3-9 Changing the Scale, 3-11

3-10 Changing the Units, 3-12

3-11 Looking at Indicator Version, 3-13

4.1 Manual Release Cable Removal, 4-2

4.2 Cargo Hook Loading, 4-3

4.3 Example of Recommended Cargo Hook Rigging, 4-5

CONTENTS,

continued

Tables

1-1 Suspension System Specifications, 1-2

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

1-3 Onboard Bill of Materials, 1-3

1-4 Eurocopter Parts, 1-4

1-5 Eurocopter Electrical Parts – Pre Mod #07-3274, 1-4

1-6 Eurocopter Electrical Parts – with Mod. #07-3274, 1-4

2-1 Optional Equipment Connectors, 2-8

2-2 Cargo Hook Connector, 2-16

2-3 Component Weights, 2-18

3-1 Indicator Error Codes, 3-4

3-2 Indicator Setup Routines, 3-6

Section 1

General Information

Introduction

The 200-282-00 Cargo Hook Sling Suspension System kit consists of fixed provisions (P/N 210-204-00) and removable provisions (P/N 210-206-00).

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 Eurocopter 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

Design ultimate strength

1,660 lb. (750 kg.)

6,225 lb. (2823 kg.)

Unit weight, Fixed Provisions 5 lbs (2.3 kg.)

Unit weight, Removable Provisions 5.5 lbs (2.5 kg.)

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

Design load

Design ultimate strength

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

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

Electrical release capacity 8,750 lb. (3,970 kg.)

Mechanical release capacity 8,750 lb. (3,970 kg.)

Force required for mechanical release at 3,500 lb.

8 lb. Max.(.600” travel)

Electrical requirements

Minimum release load

Unit weight

22-32 VDC 6.9 – 10 amps

0 pounds

3.0 pounds (1.35 kg.)

Mating electrical connector PC06A8-2S SR

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

Inspection

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 200-282-00 Sling Suspension

System, the 210-204-00 fixed provisions, or the 210-206-00 removable provisions. If shortages are found contact the company from whom the system was purchased.

Table 1-3 Onboard Systems Bill of Materials

Part

Number

Description

120-105-00 Owner's Manual

121-013-00 RFMS

122-005-00 Cargo Hook Service Manual

123-012-00 ICA Manual for AS 350 Sling Kit

210-095-XX C-39 indicator Assembly

210-203-03 AS 350 Sling Load Cell Assembly

215-165-00 Multiple Decal Sheet

215-167-00 Max Hook Load 1660 Decal

232-148-00 AS 350 Sling Gimbal Assembly

232-150-00 Release Handle Assembly

232-151-00 Quick Disconnect Support Assy

268-024-02 Manual Release Cable Assy

270-106-02 Load Weigh Internal Harness

270-108-00 Electrical Release Internal Harness

270-110-01 Electrical Release Cable Assembly

290-772-00 Indicator Mount Bracket

290-781-00 Cable Support Bracket

290-782-00 Connector Bracket

290-783-00 Relay 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

510-457-00 Screw

510-475-00 Screw

510-481-00 Screw

512-024-00 Adel Clamp

528-023-01 Cargo Hook

1

1

1

1

1

1

1

1

1

1

Total Kit

Number

200-282-00

1

1

1

1

1

1

1

1

3

2

4

3

5

2

2

2

8

2

1

3

8

3

3

1

1

1

8

-

-

1

-

-

-

1

-

-

1

Removable

Kit Number

210-206-00

1

1

1

1

-

1

-

1

-

-

-

-

-

-

-

-

-

-

1

-

-

-

-

-

-

-

-

1

1

-

1

1

1

-

1

1

-

Fixed Kit

Number

210-204-00

1

1

-

1

1

-

1

-

3

2

4

3

5

2

2

2

8

2

-

3

8

3

3

1

1

1

8

General Information 1-3

Bill of Materials

continued

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

These items may or may not be installed with a standard aircraft, therefore verification is recommended before purchasing them.

Table 1-4 Eurocopter Parts

Eurocopter P/N Onboard P/N Description

DHS751-160.62 610-007-00 Grommet

SL211M5-1

A3125-2 H179

610-009-00

610-011-00

Nut

Quick Disconnect Clamp

350A86-0020-33

ASNA0078A403

610-016-00 Bracket

610-019-00 Rivet

Qty

1

3

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.

Table 1.5 Eurocopter Electrical Parts – Pre-mod. #07-3274

Eurocopter P/N Onboard P/N Description

DHS775-160-42 610-012-00 Indicator Light Body

DHS775-240-22

EN2240-6839

610-013-00

610-014-00

Indicator Light

Lamp

DI-2-5*

DA8-16A*

610-017-00 Fuse 2.5A

610-018-00 Fuse 16A

Qty

1

1

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 1.6 Eurocopter Electrical Parts – with Mod. #07-3274

Eurocopter P/N Onboard P/N Description

045004A127A 610-027-00 Cargo Hook Sling Switch

ECS0744A02A5

ECS0744B15A0

610-028-00 Circuit Breaker 2.5A

610-029-00 Circuit Breaker 15A

Qty

1

1

1

1-4 General Information

Theory of Operation

The 200-282-00 Cargo Hook Sling Suspension System is comprised of:

 A gimbaled suspension with load cell 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 pushbutton 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 cause 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.

General Information 1-5

This page intentionally left blank.

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 Sling Suspension System Installation

2.1 Fixed Manual Release Cable Assembly Installation

Remove lower fairings to access areas underneath cabin floor where cable is routed.

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 a bracket at the centerline of the forward fuel tank support (as shown in Figure 2.1.1). Figure 2.1.1 is an overview of the cable routing and the figures and instructions following detail the cable support installations at various points.

Figure 2.1.1 Fixed Manual Release Cable Installation Overview.

X 1790.15

X 2700 Centerline of fwd fuel tank support

FWD

Y 400

Manual Release Cable

A/C Centerline

View Looking Down

See Figure 2.1.2

See Figure 2.1.3

See Figure 2.1.4

Route cable outboard through this hole.

See Figure 2.1.5

See Figure 2.1.6

See Figures 2.1.7

and 2.1.8

Installation Instructions

View Looking Outboard

From A/C Centerline

2-1

2-2

2.1 Fixed Manual Release Cable Assembly Installation

continued

Mount the manual release lever (assembly P/N 232-138-00) to the collective shaft 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 2.1.2 Manual Release Lever Installation

Clamp Half

P/N 290-753-00

Screws

P/N 510-390-00

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. Re-install grommet.

If the slot in the 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 (Eurocopter P/N DG-38).

Figure 2.1.3 Cabin Floor Hole Detail

35mm

Ø25mm

Collective Pitch

Lever Unit

43mm

Fwd

150mm FROM X 1790.15

VIEW LOOKING DOWN

A/C Centerline

Installation Instructions

2.1 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 by securing an Adel clamp (P/N 512-024-

00) to the existing bracket (Eurocopter P/N 350A86-1051-00) with hardware as illustrated below and routing the cable through it.

Figure 2.1.4 Cable Routing Through Frame

Cabin Floor

A

Bolt P/N 510-453-00

Washer P/N 510-042-00

Nut P/N 510-102-00

Adel Clamp

P/N 512-024-00

A

View Looking Aft

A-A

Aft of the frame, route the cable outboard through the hole in the structural member as shown in Figure 2.1.1 and Figure 2.1.5 and install Plastic Edging

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

Figure 2.1.5 Grommet Installation

Plastic Edging Grommet

P/N 500-065-00

Installation Instructions 2-3

2.1 Fixed Manual Release Cable Assembly Installation

continued

At the inboard side of the RH forward landing gear fitting (X2700) secure Cable

Support Bracket (P/N 290-781-00) with hardware as illustrated below. Route release cable through and secure Adel Clamp (P/N 512-024-00) to Cable Support

Bracket with hardware as illustrated below.

Figure 2.1.6 Cable Support Bracket Installation

Bolt P/N 510-453-00

Washer P/N 510-042-00

X2700

Bolt P/N 510-453-00

Clamp P/N 512-024-00

Inboard

Nut P/N 510-102-00

Washer P/N 510-454-00

Bracket P/N 290-781-00

Landing Gear Fitting

Washer P/N 510-042-00

Nut P/N 510-102-00

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

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

Nut (2)

P/N 510-102-00

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

Service Bulletin No. 25.00.62.

Figure 2.1.7 QD Bracket Installation

Y400

Washer (2)

P/N 510-454-00

Bolt (2)

P/N 510-455-00

QD Bracket Assembly

P/N 232-151-00

2-4 Installation Instructions

2.1 Fixed Manual Release Cable Assembly Installation

continued

Install the 2 clamps (Eurocopter P/N A3125-2 H179) 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.

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

Service Bulletin No. 25.00.62.

Figure 2.1.8 Cable Support Clamp Installation

A

Y400

1

A

2

A/C Centerline

Nut

P/N 510-102-00

Bolt

P/N 510-455-00

Fwd A-A

Rotated 90°

View Looking Up

At Lower Aft Cowling

Fuel Tank Support

Centerline

Washer

P/N 510-454-00

Clamp

Eurocopter P/N A3125-2 H179

Installation Instructions 2-5

2.2 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 location as shown below and transfer its hole pattern to the door pillar.

Figure 2.2.1 Indicator Bracket Installation

Fwd

View Looking Outbd

RH Door Pillar

C-39 Indicator Bracket

P/N 290-772-00

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 (Eurocopter 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 2.2.2 Indicator Bracket Hardware

Electrical Bonding Screw

2-6

Screw

P/N 510-475-00

Washer

P/N 510-095-00

Installation Instructions

2.2 Cockpit Indicator Installation

continued

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

Figure 2.2.3 C-39 Indicator Installation

C-39 Indicator

A

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

A

CAL

DAMP

Hook L oad

X 10

0 LB K

G

UN-ZER

O SETU

P

ZER

O

A-A

Installation Instructions 2-7

2.3 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 2.3.1) 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”.

- 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 electrical contacts supplied with kit.

Secure the C-39 indicator harness (P/N 270-106-02) along the canopy with clamps and connect the C-39 indicator connector. Refer to Figure 2.3.6 for electrical schematic.

The P/N 270-106-02 electrical harness includes a data line for use with an Onboard

Systems Data Recorder or Analog Meter. These items are not included under this

STC. Attach connectors to data line per pin out in Table 2.3.1 to connect the

Analog Slave Meter or Data Recorder to the electrical harness “DATA” line. If a data connector is present on the data line use harness P/N 270-059-00 to connect to

Analog Slave Meter. If the accessory connector is not used, stow this line of the harness.

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

Table 2.3.1 Optional Equipment Connectors

Analog Meter Connector

P/N 410-130-00

Mfg P/N: MS3126F10-6P

Pin Color

A WH

Function

Power

Data Recorder Connector

P/N 410-011-00, 410-057-00 & 410-020-00

Pin Color

1 WH/BL

Function

Ground

E

B

C

WH/GN

WH/OR

D WH/BL

Shield

Clock

Data

Ground

Shield

3

5

7

9

4

2

WH

Shield

WH/GN

WH/OR

Red*

Purple*

*Optional

Power

Shield

Clock Signal

Data Signal

Flight Switch

Cap. Switch

2-8 Installation Instructions

2.3 Electrical Wiring Installation

continued

Figure 2.3.1 Electrical Wiring Routing Overview

X2700

Connector Bracket

Install per Figure 2.3.5

C-39 Indicator

Y400

Y400

Relay Bracket - 23M

Install per Figure 2.3.3

If installing the wire harnesses on a newer AS350B2 or B3 model equipped with a switch panel of circuit breaker design (Eurocopter mod. #07-3274 incorporated) the electrical harness P/N 270-108-00 requires minor modification as follows. Cut the ME1E wire off just prior to the butt splice and discard the splice and the 20 ga. wires.

Figure 2.3.2 P/N 270-108-00 Harness Modification

Cut wire here.

Splice

20 ga.

16 ga.

ME1E

20 ga.

Install Relay Bracket (P/N 290-783-00) by creating two holes in the LH beam at

Y400 as illustrated in Figure 2.3.3.

Figure 2.3.3 Relay Bracket Installation

Existing hole

1.30 in.

(33 mm)

7.1 in.

(180 mm)

LH Beam

Y 400

Z 2450

Ø0.169 in (2)

Installation Instructions 2-9

2.3 Electrical Wiring Installation

continued

Secure Relay Bracket with two screws (P/N 510-277-00), washers (P/N 510-278-

00), and 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).

Figure 2.3.4 Relay Installation

Relay

P/N 445-005-00

Up

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. Locate

Connector Bracket as shown below and drill support frame for rivets (Eurocopter

P/N ASNA0078A403) to match its hole pattern. Drill out pilot holes in Connector

Bracket for rivets.

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).

Installation Instructions

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 2.3.5 Connector Bracket Installation

Hook Release Connector

32M

Load Cell Connector

55M

A

A-A

Looking Down

Connector Bracket

P/N 290-782-00

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

A

7.28 in (185 mm)

1.18 in (30 mm)

Rivets (3)

View Looking Forward

Y=0

2-11

2.3 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. Eurocopter modification #’s 07-4280 and 07-3450 are reflected below. Earlier Eurocopter 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 Eurocopter

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 Eurocopter 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 2.3.6 Electrical Schematic

Existing Eurocopter 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

A A

B B

C

D

E E

F F

C

D

BELLY DISCONNECT 1N

ME87E

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

F

G

H

J

K

L

M

N

P

R

D

E

A

B

C

F

G

H

J

K

L

M

N

P

R

A

B

C

D

E

16

11

20ALP-J1A P1A

U/CA FLOOR U/CA FLOOR

Existing Eurocopter Wiring, post-Mod #07-3450 shown.

Installation Instructions 2-11

2.3 Electrical Wiring Installation

continued

Figure 2.3.6 Electrical Schematic

ME1E

27 

2

1

27 

16A

ME2E

ME10E

4

2.5A

ME3E

25 

6

7

9

25 

P.C.B

21 

15

14

13

5

11

21 

19

2.5A

CONTROL

PANEL

12

17

8

11

10

10

12

8

9

4

ME1E

ME1E

ME2E

X3

31 32

9

15A

Existing Eurocopter Wiring, pre-mod #07-3475

E

3

4

32 

16A

A

3

31 

2.5A

Existing Eurocopter Wiring, pre-mod #07-1737

SLING

Existing Eurocopter Wiring, post-mod #07-1737

ME10E

22 10 9

2

3

A

24

C

1

21

20

9

8

20 Cyclic Lever PCB

Existing Eurocopter Wiring, Post-Mod #07-3273

2-12 Installation Instructions

2.4 Sling Suspension Installation

Attach the Sling Suspension with Cargo Hook onto the hard point at the helicopter centerline using the hardware supplied, as illustrated below. Orient the cargo hook such that its load beam points forward (as shown below).

Figure 2.4.1 Sling Suspension Installation

Helicopter hard point

Centerline of fuel tank support

Gimbal Pin

P/N 290-766-00 Cotter Pin

P/N 510-081-00

Bolt

P/N 510-451-00

Washer

P/N 510-336-00

Nut

P/N 510-259-00

Washer

P/N 510-336-00

Fwd

2.5 Removable Manual Release Cable Assembly Installation

Connect the removable manual release cable (P/N 268-024-02) to the cargo hook first, per the following instructions:

Remove the manual release cover from the cargo hook. Thread the fitting at the end of the manual release cable into the manual release boss on the hook side plate until the threads protrude approximately .125” inch beyond the boss and secure with jam nut (as shown in Figure 2.5.1).

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

Installation Instructions 2-13

2.5 Removable Manual Release Cable Assembly Installation

continued

Figure 2.5.1 Manual Release Cable Rigging

2-14

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 below). If necessary, minor adjustments may be made at the release handle assembly on the collective.

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).

Snap the removable cable Adapter Fitting into the inboard spring clip on the Quick

Disconnect Support Assembly.

Figure 2.5.2 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

Installation Instructions

2.5 Removable Manual Release Cable Assembly Installation

continued

Verify proper setting at the hook:

Place the cable ball end fitting into the hook manual release fork fitting as illustrated in Figure 2.5.3. Move the manual release lever in the clockwise direction until it is against the cam stop. Measure the cable ball end free play with the manual release handle in the cockpit in the non-release position. The gap must be a minimum of .125” (3.2 mm) (see below).

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

Figure 2.5.3 Manual Release Cable Rigging Check manual release lever fork

release cable

.125" min.

(3.2 mm) cable ball end

Load beam must be closed

and locked when rigging.

If the gap is less than .125”, make adjustments at the hook only. This is done by disconnecting the cable at the interface with the fixed manual release cable (Figure

2.5.2), loosening the jam nut, and rotating the cable in the required direction.

Installation Instructions 2-15

2.6 External Electrical Release and Load Cell Cable Installation

Connect the appropriate end of the cargo hook electrical release cable (P/N 270-

110-01) to the Cargo Hook (24M, ref. Figure 2.3.4) and secure with safety wire.

Connect the other end of the cable to the appropriate connector (32M) mounted per section 2.3.

See table 2-5 for connector pin out information.

Table 2-2 Cargo Hook Connector

Pin Function

A Ground

B Power

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

Connect the electrical cable from the load cell (55M) cable to the appropriate connector (55M) mounted per section 2.3.

Un-commanded cargo hook release will happen if the manual and electrical release cables are improperly restrained. The cables must not be the stops that prevent the Cargo Hook from swinging freely in all directions. If the Cargo

Hook loads cause the hook to strain against the manual release cable the swaged end of the cable may separate allowing the inner cable to activate the cargo hook manual release mechanism. The result is an un-commanded release. Ensure that no combination of cyclic stick or Cargo Hook position is restrained by the manual or electrical release cables

2-16 Installation Instructions

2.6 External Electrical Release and Load Cell Cable Installation

continued

Figure 2.6.1 Un-commanded Release From Incorrectly Secured Cable

2.7 Placard Installation

Install appropriate load limitation placard, P/N 215-167-00 (1660 lb max. hook load). Locate the placard on the belly of the helicopter, visible to the ground operator and near the hook.

2.8 Installation Check-Out

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

1. Swing the installed Cargo Hook Sling Suspension 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 cargo hook 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. 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.

Installation Instructions 2-17

2.8 Installation Check-Out

continued

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-2001-01.

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.

Component Weights

The weights of the Cargo Hook Sling Suspension System components are listed below.

Table 2-3 Component Weights and Cgs

Item Weight Station

Fixed Provisions 5 lbs (2.3 kg.) 92 in. (2337 mm)

Removable Provisions 5.5 lbs (2.5 kg.) 134.4 in. (3415 mm)

Complete Install 10.5 lbs (4.8 kg.) 114.2 in. (2901 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. Place the

Rotorcraft Flight Manual Supplement P/N 121-013-00 in the Rotorcraft Flight

Manual.

2-18 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

Right Button Left 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

The Run Mode continued

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

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.

Err 4 NV Ram busy failure 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 accomplished 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.

Load Weigh System Operation Instructions 3-7

The Setup Mode,

continued

Indicator Calibration

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

The Calibration Code scales the signal from the Load Cell.

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

Calibration Code will have been entered into the Indicator by the factory, however, it should be confirmed. If the Indicator is to be mated to a different

Load Cell, it must be calibrated before use. Calibration can be done by entering a known Calibration Code or by lifting a known load and having the Indicator calibrate itself. Both options are discussed below.

To Look at or Change the Calibration Code

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

Figure 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.

Load Weigh System Operation Instructions

The Setup Mode,

continued

To Look at or Change the Calibration Code, continued

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

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

Installation Zero

Installation zero is a routine that matches the Indicator to the INSTALLED

Load Cell. It adjusts the Indicator reading to compensate for the weight of the Cargo Hook on the Load Cell and whatever zero offset is built into the

Load Cell. The Installation Zero procedure is not mandatory. If done the

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

To Run the Installation Zero Routine

With the Indicator powered up and in the Run Mode, press both buttons at the same time to go to Setup. Scroll through the menu until the symbol "0 in" is displayed, then press the Right button. The CAL legend will be turned on and the current weight on the Cargo Hook will be displayed and blinking.

Remove any weight that is not to be zeroed out and press either button to complete the procedure and return to the Run Mode.

Calibration by Lifting a Known Weight

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

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

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

cable, net, dirt, etc.

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

Load Weigh System Operation Instructions 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

3-12

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

The selected units are displayed when in the Run

Mode.

Load Weigh System Operation Instructions

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

Daily prior to each cargo hook use perform the following:

1. Ensure that the Cargo Hook Sling Suspension 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 Service

Manual 122-005-00 and the ICA Maintenance Manual 123-012-00.

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

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.

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

Cargo Hook or the suspension from swinging freely in all directions.

6. Visually check for presence and security of fasteners, and condition of cables. Swing the Cargo Hook and the suspension in fore and aft and side to side directions to check for freedom of rotation at all joints.

See the troubleshooting table in the ICA for additional instructions.

Operation Instructions 4-1

Disconnecting Removable Provisions

For helicopter missions in which the cargo hook sling 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 (see Figure 2.5.2) 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 4-1 Manual Release Cable Disconnect

Release Cable Cap

Fwd

Inbd

2. Remove the electrical release cable and the load cell cable at the bulkhead connectors at the fuel tank support frame.

3. Remove the Sling Suspension at the helicopter hard point (reference

Figure 2.4.1).

4-2 Operation Instructions

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

Figure 4.2 Cargo Hook Loading

Operation Instructions 4-3

Cargo Hook Rigging

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

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

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

release.

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

Nylon Type Straps and Rope

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

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

beam.

4-4 Operation Instructions

Cargo Hook Rigging,

continued

Figure 4.3 Example of Recommended Cargo Hook Rigging

SECONDARY RING

LOAD

PRIMARY RING

Operation Instructions 4-5

This page intentionally left blank.

Section 5

Maintenance

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

012-00 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

( [email protected]

).





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



Package the component carefully to ensure safe transit.





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

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

210-204-00 AS 350 Sling Fixed Provisions

5

6

7

8

Item Part Number Description

1

2

4

232-151-00

232-150-00

210-095-00

Quick Disconnect Support Assembly

Release Handle Assembly

C-39 Indicator

Qty

1

1

1

290-772-00 Indicator Mount Bracket

290-781-00 Cable Support Bracket

290-783-00 Relay Bracket

445-005-00 Relay

1

1

1

1

9 290-782-00 Connector Bracket

10 500-065-00 Grommet Edging

11 270-106-02 Load Weigh Internal Harness

12 270-108-00 Release Internal Harness

13 215-165-00 Multiple Sticker Sheet

1

1

1

1

1

System Part Numbers 6-1

System Part Numbers

continued

210-206-00 AS 350 Sling Removable Provisions

Item Part Number Description

1 232-148-00 AS 350 Sling Gimbal Assembly

2

3

210-203-03*

528-023-01

AS 350 Sling Load Cell Assembly

3,500 lb. Keeperless Cargo Hook

4

5

270-110-01 Electrical Release Cable Assembly

268-024-02 Manual Release Cable Assembly

6 215-167-00 Max Hook Load 1660 Decal

*Supersedes 210-203-00, these P/N’s are interchangeable.

1

1

1

Qty

1

1

1

6-2 System Part Numbers

System Part Numbers

continued

232-150-00 Release Handle Assembly

11

12

13

14

15

16

17

Item Part Number Description

1 268-025-00 Fixed Manual Release Cable

2

3

4

510-317-00

290-757-00

510-210-00

Screw

Cover

8-32 Locking Heli-Coil

5

6

7

8

9

10

290-754-00

517-049-00

290-759-00

510-450-00

510-449-00

290-755-00

Lever Body

Pulley

Shaft

Bolt, handle pivot

Bolt, pulley pivot

Handle

510-042-00

510-082-00

510-125-00

510-248-00

290-753-00

510-390-00

510-095-00

Washer

Nut

Cotter Pin

10-32 Heli-Coil

Clamp Half

Screw, Mounting Clamp

Washer

1

2

3

1

2

2

2

1

1

1

1

1

1

Qty

1

2

1

2

System Part Numbers 6-3

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

6-4 System Part Numbers

System Part Numbers

continued

232-144-00 Sling Gimbal Sub-Assembly

1

3

Item Part Number Description

1 517-051-00 Bushing

2 290-294-00 Attach Bushing

3 290-767-00 Gimbal

2

Qty

1

2

1

System Part Numbers 6-5

System Part Numbers

continued

232-148-00 AS 350 Sling gimbal assembly

Item Part Number Description

1

2

3

510-081-00

510-259-00

510-336-00

Cotter pin

Nut castellated thin

Washer

4

5

6

7

290-766-00 Gimbal Pin

510-183-00 Washer

1

2

290-332-00 Attach Bolt 1

232-144-00 Swing Gimbal Sub Assembly 1

8

9

510-451-00 Bolt

510-174-00 Washer

10 510-170-00 Nut

11 510-178-00 Cotter pin

1

1

1

1

Qty

1

1

2

6-6 System Part Numbers

Section 7 Certification

FAA STC

Certification 7-1

Canadian Approval

7-2 Certification

EASA Approval

Certification 7-3

EASA Approval

continued

7-4 Certification