Onboard Systems TALON MC Keeperless Hook Cargo Hook Suspension System Owner's Manual

CARGO HOOK

SUSPENSION SYSTEM

With

TALON MC Keeperless Hook

For the Bell 204, 205, 210, 212, and 412 series,

Agusta AB412 series,

Rotorcraft Dev. Corp. UH-1H, Northwest Rotorcraft UH-1H, and OAS Parts LLC UH-1H

STC SR00713SE

Part Numbers

200-088-10 w/o Load Weigh

200-088-50 w/o Load Weigh

200-089-10 w/ Load Cell Only (No Indicator)

200-089-11 w/ Load Cell Only (No Indicator)

200-089-20 w/ Load Weigh, C-39 Indicator 28V Lights

200-089-21 w/ Load Weigh, C-39 Indicator 5V Lights

200-089-22 w/ Load Weigh, C-39 Indicator 28V Lights

200-089-23 w/ Load Weigh, C-39 Indicator 5V Lights

Owner's Manual

Owner's Manual Number 120-084-00

Revision 28

February 24, 2016

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

Rev. Date Page(s) Reason for Revision

20 11/02/10 1-2, 2-1, 2-6,

Section 3, 5-3, 5-4,

5-5, 6-8, 6-9, 6-12,

7-8, 7-16 & 7-20

Updated Overhaul Kit BOM to show four instances of screw P/N 510-131-00 replaced by superseding screw,

P/N 510-317-00. Updated return information to include

RMA procedures. Replaced warnings, cautions and notes section with safety labels sections. Updated safety label format to current format throughout document.

21 03/25/11 1-3, 2-8, 7-15 Added -02 C-39 indicator as an optional indicator under

200-089-22, added note to BOM describing difference between 200-089-22 and 200-089-23.

22 05/21/12 1-3, 1-4, Section 3,

5-3, 7-15

Added Bracket P/N 235-035-00 for mounting of load cell connector. Added cargo hook P/N 528-020-10. Updated format of Section 3.

23 08/16/12 3-2, 7-1, 7-2 Added examples of lubrication that can be used on bumper (page 3-2). Clarified inspection requirements for

Bell Helicopter Load Bolt, added paragraph to refer to applicable Bell Service Instructions for fixed provisions.

24 11/02/12 1-3 & 7-15

25 01/14/13 1-3, 2-2, 2-8, 7-2,

7-5, 7-13 thru 7-17

Replaced S/N Tag P/N 215-048-00 with 215-290-00

(these are the same except 215-290-00 does not list a calibration code for the load cell).

Added suspension system P/N 200-088-50.

26

27

03/18/13

09/22/15

1-3, Section 7 Removed suspension system maintenance information and replaced with reference to CMM 122-028-00.

1-3, 5-5 Added upgrade kit P/N 200-151-01 and associated installation instructions.

28 02/24/16 1-3, 1-4, Sections

3, 4, 6

Listed C-39 indicator P/N 210-095-04 and -05 as options.

Removed C-39 operation instructions and replaced with reference to 120-039-00. Updated cargo hook load rigging figure (Figure 3-3).

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.

ii

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CONTENTS

Section 1 Suspension System General Information

Introduction, 1-1

Safety Labels, 1-2

Bill of Materials, 1-3

Theory of Operation, 1-4

Section 2 Suspension System Installation Instructions

Suspension System Installation, 2-1

Suspension System Detail, 2-2

Suspension System Manual Release Arrangement, 2-3

Suspension System Manual Release Adjustment, 2-4

Suspension System Electrical Release Installation, 2-5

Ground Wire Installation, 2-5

Multi-Channel Slip-Ring Electrical Installation, 2-5

Suspension System Installation Check-Out, 2-7

Component Weights, 2-8

Paper Work, 2-8

Section 3 Suspension System Operation Instructions

Suspension System Operating Procedures, 3-1

Bumper Lubrication, 3-2

Cargo Hook Rigging, 3-3

Cargo Hook Loading, 3-4

Section 4 Load Weigh General Information

Introduction, 4-1

Indicator Features, 4-1

Indicator Specifications, 4-2

Indicator Pin Out, 4-2

Load Cell Specifications, 4-2

iii

iv

Section 5 Load Weigh Installation Instructions

Introduction, 5-1

Indicator Installation Overview, 5-1

Indicator Internal Back Light, 5-2

Indicator Hook-Open Warning, 5-2

Remote Analog Meter, 5-2

Load Weigh Internal Harness Installation, 5-3

Load Weigh Electrical Connections, 5-3

Load Cell Installation (Kit P/N 200-151-01), 5-5

Load Weigh Installation Check-Out, 5-5

Section 6 Suspension System Inspection, Maintenance, Overhaul

& Trouble Shooting

Section 7 Cargo Hook Inspection, Maintenance & Overhaul

Procedures

Section 8 Certification

FAA STC, 8-1

Approved Model List, 8-2

Foreign Approvals, 8-3

Figures

2-1 Suspension System Detail, 2-2

2-2 Suspension System Manual Release Arrangement, 2-3

3-1 Hook Locked Indication, 3-1

3-2 Ground Release Lever, 3-2

3-3 Examples of Correct & Incorrect Cargo Hook Rigging, 3-4

3-4 Cargo Hook Loading, 3-4

5-1 Installation Overview, 5-1

5-2 Wiring Arrangement, 5-4

Tables

1-2 Bill of Materials, 1-3

2-1 Component Weights, 2-8

4-1 Indicator Specifications, 4-2

4-2 Indicator Pin Out, 4-2

4-3 Load Cell Specifications, 4-2

Section 1

Suspension System General Information

Introduction

The Suspension Systems are replacements for the Bell 204-072-915-103

Suspension System. The Suspension System is approved for loads up to

5,000 pounds (2,267 kgs). See the basic rotorcraft flight manual for the capacity of a specific helicopter. The system attaches to the existing Bell hard point and utilizes the Bell provisions kit. Before installation ensure that the appropriate Bell provisions kit is correctly installed and operational. The cargo hook Suspension System hangs at approximately the center of gravity attached to a lateral beam. It extends through an opening in the bottom of the lower fuselage skin. The cargo hook unit is a keeperless type with provisions for both an electrical and a manual controlled release.

The Suspension System is equipped with an innovative Bumper Ring assembly. The bumper ring is molded from two different polymers. A tough polymer core eliminates the fracturing problem common with the original equipment bumper. A soft outer layer provides a cushion effect that protects the airframe.

The Suspension System is also equipped with a Multi-Channel Slip-Ring assembly that can be used to supply electrical power and control signals to accessory equipment suspended from the rotating cargo hook.

UH-1 Suspension System w/ Keeperless Hook Owner's Manual 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

Bill of Materials

The following items are included with each system, if shortages are found contact the distributor from whom the system was purchased.

Table 1-2 Bill of Materials

Part No.

Description

510-028-00

510-029-00

400-048-00

235-035-00

510-098-00

continued

Screw

Nut

Power Switch

QD Bracket

Cotter Pin

Quantity

528-020-02 Cargo Hook, Keeperless

528-020-04 Cargo Hook, Keeperless

528-020-06 Cargo Hook, Keeperless

528-020-10 Cargo Hook, Keeperless

220-040-00 Bumper Ring

290-210-01 Small Spacer

510-104-00 Nut

510-314-00 Bolt, socket head

210-180-24 Analog Meter

232-010-00^ Clevis Assembly

232-011-00^ Load Bolt Assembly

232-009-01^ Load Link Assembly

210-088-01^ Load Cell Assembly

210-088-02^ Load Cell Assembly

510-097-00^ Washer

510-096-00^ Nut

510-098-00^ Cotter Pin

215-290-00 Data Tag

215-010-00 Placard

215-012-00 Placard

270-059-00 Y-Harness

512-001-00 Ty-Wrap

512-002-00 Ty-Wrap

200-

088-10

* 2

* 1

-

-

-

-

-

200-

088-50

***

2

2

-

-

-

1

2

1

-

-

-

-

2

1

-

200-

089-11

-

1

2

2

-

1

2

-

-

-

-

-

2

1

-

200-

089-20

200-

089-21

200-

089-22

**

200-

089-23

**

200-

151-01

^^

1 232-130-00^ UH-1 Suspension Sub-

Assembly

232-130-50 UH-1 Suspension Sub-

Assembly

* -

210-095-00 C-39 Indicator w/ 28V Lights -

210-095-02 C-39 Indicator w/ 5V Lights -

270-044-01 C-39 Internal Harness

528-020-00 Cargo Hook, Keeperless

*

*

*

*

*

*

*

*

1

-

* 1

* 4

* 2

* 2

-

1

2

1

-

-

2

2

-

1

-

-

-

1

4

2

2

1

-

-

-

-

1

4

2

2

1

-

1

-

1

1

4

2

2

1

-

-

1

1

1

4

2

2

1

-

1 opt

1

1

4

2

2

1

-

-

1

1

* opt opt opt opt opt opt opt

* opt opt opt opt opt opt opt

* opt opt opt opt opt opt opt

* opt opt opt opt opt opt opt

* 1 1 1 1 1 1 1

1

4

2

2

- opt opt opt opt

1 1 1 1

2

-

1

-

2

2

2

-

1

-

2

2

2

-

-

1

2

2

2

-

-

1

2

2

2

1

2

2

1

2

2

1

2

2

1

2

1 1 1 1 1 opt opt opt opt opt

10

10

10

10

10

10

10

10

10

-

-

-

-

-

2

-

1

-

-

Opt

1

1

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

4

4

1

-

-

4

4

1

-

-

4

4

1

1

-

4

4

1

1

-

4

4

1

1

2

UH-1 Suspension System w/ Keeperless Hook Owner's Manual 1-3

Bill of Materials

continued

Table 1-2 Bill of Materials continued

Part No.

Description

120-039-00

Owner’s Manual (C-39)

120-084-00

Owner’s Manual

121-021-00 RFM Supplement

122-004-00 CMM, Cargo Hook

122-028-00 CMM, Suspension System

200-

088-10

-

1

1

1

1

200-

088-50

***

-

1

1

1

1

200-

089-11

1

1

1

1

1

Quantity

200-

089-20

1

1

1

1

1

200-

089-21

1

1

1

1

1

200-

089-22

**

1

1

1

1

1

200-

089-23

**

1

1

1

1

1

200-

151-01

^^

1

1

-

-

-

* Items shipped assembled from factory

^These items were previously included in P/N 210-120-00 (w/o load cell) and P/N 210-120-01 (with load cell).

** The 200-089-22 and 200-089-23 kits are identical except for the C-39 indicator P/N.

*** Non-FAA-PMA approved version.

^^ Kit P/N 200-151-01 is an upgrade kit for an operator with P/N 200-088-10 installed. After installation of this kit, the installed configuration reflects a P/N 200-089-22 or P/N 200-089-23 (depending on C-39 indicator P/N).

Note: the P/N 210-095-00 indicator may be replaced by P/N 210-095-04 (28V NVG backlight) and the P/N 210-095-

02 may be replaced by P/N 210-095-05 (w/ 5V NVG backlight). These indicators are identical with the exception of the backlight.

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 and an external manual release cable provide the means for unlatching the load beam.

The load beam is normally held in the open position by a spring-loaded detent. The load is attached to the load beam by passing the load 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 automatically 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 load ring 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 pedal in the cockpit (not provided with these kits). The pedal operates the internal mechanism of the Cargo Hook to unlatch the load beam. The load can also be released by the manual actuation of the cable mechanism located above the cargo hook and for the P/N 528-020-

10 cargo hook a manual release lever located on the cargo hook below the bumper.

1-4

General Information

Section 2

Suspension System Installation Instructions

Suspension System Installation

The Suspension System interfaces with several Bell components on the helicopter. Before installation, have available and be familiar with the Bell

Service Instructions 204-3 or 212-5, or later bulletins.

Orient the Suspension System so that the manual release control cable is on the left and the clevis is aligned in the Bell hard point, 205-030-107 or

204-030-841, at waterline 38.87, see the next section, Suspension System

Detail.

Install the bolt, washer and nut provided with the Bell provisions kit.

These fasteners are not part of the Suspension System supplied items. See the appropriate Bell service instructions for the correct installation, torque values and maintenance.

The attaching bolt supplied by Bell is a high strength bolt. No substitution of this bolt is allowed. Refer to the Bell Service Instructions for the bolt inspection requirements.

Route the free end of the manual release cable, 268-003-00, aft and to the right (looking aft) of the hard point fitting. See the Suspension System

Manual Release Arrangement, Figure 2-2. Engage ball terminal into the cable connector, 204-070-995, and secure with the cotter pin, MS24665-

155. Place outer housing (conduit) of control cable assembly, 268-003-00, into clamp, 204-070-996-1, and secure with screw AN520-1 or 12, and washer, AN960PD10L into nut plate in existing structure. The conduit end should measure approximately 0.42 inch from clamp, 204-070-996-1.

UH-1 Suspension System w/ Keeperless Hook Owner's Manual

2-1

Suspension System Detail

Figure 2-1 Suspension System Detail (200-089-10 shown)

STA

137.55

WL

38.87

To load weigh internal harness connector

Manual release cable

See Detail A

For 200-088-10, replace Load Cell with link

Detail A

Cable clamp

Stray voltage ground wire, install per

Bell Helicopter Technical Bulletin No 205-81-42,

No 205-82-46, No 205-84-62 or other later Bulletins.

It is CRITICAL that this wire be bonded to the airframe and maintained.

To cockpit accessory circuits, note: wire numbers 3 thru 8 are available for use as required.

Manual Release Cable

Slip-Ring assembly

Slip-Ring inspection cover

Cargo hook electrical release cable, from slip-ring assembly

Hook Connector

WIRE PIN FUNCTION

3 A Not Used

1 B Hook open power

2 C Common

Customer Optional Harness:

Wire numbers 3 thru 8 available for use as required for customer needs.

To cargo hook electrical release air-frame connector.

Air-frame connector (all systems except 200-088-50)

WIRE PIN FUNCTION

- A Not used

1 B Hook open power

2 C Common

Air-frame connector (200-088-50 ONLY)

WIRE PIN FUNCTION

2 A Common

1 B Hook open power

- C Not used

To user supplied common equipment connector note: each wire is marked with the slip-ring circuit.

Slip-ring circuit

Channel Function

1 Hook open power

2 Hook open common

3 -

4 -

5 -

6 -

7 -

8 -

Stray voltage ground wire

It is CRITICAL that this wire be bonded to the hook and maintained

Bumper Ring

Cargo Hook

Cargo Hook Load Beam

2-2

Suspension System Installation Instructions

Suspension System Manual Release Arrangement

Figure 2-2 Suspension System Manual Release Arrangement

BL

9.80

204-070-996-1 CLAMP

AN520 1 OR 12 SCREW

AN960PD10L WASHER

BL

0.00

LIFT BEAM (REF)

WL

39.87

0.42 INCH

APPROX

.03

.08

204-070-995

CONNECTOR

204-070-998 SPRING

MS24665-155 PIN

BELL HARD POINT

UPPER MANUAL

RELEASE CABLE

COTTER PIN

STOP BOLT

SWING ARM

MANUAL RELEASE CABLE

BELL HELICOPTER

LOAD BOLT

GREASE FITTING

GREASE ON INSTALLATION

WITH MIL-G-25537 AND AT

EACH 100 HOURS OF FLIGHT

LOWER MANUAL

RELEASE CABLE

.18

.12

.10

MANUAL RELEASE LEVER

-00 AND -02 HOOKS ONLY

UH-1 Suspension System w/ Keeperless Hook Owner's Manual

2-3

Suspension System Manual Release Adjustment

Adjust the conduit of the manual release cable assembly, 268-003-00, to obtain 0.03 to 0.08 inch dimension shown in Figure 2-2 and secure clamp shown in detail A of Figure 2-1. Adjust connector, 204-070-995, shown in

Figure 2-2 to obtain 0.10 inch free play in the control cable as shown in

Figure 2-2. Alternatively the 0.10 clearance may be measured at the 204-

070-995 connector with the cable ball terminal pulled against the swing arm.

The stop bolt of the swing arm should be in contact with the top of the cargo hook case and the swing arm should be parallel to the plane of the main hook attachment bolts when the 0.10 inch measurement is taken.

By grasping the top of the lower control cable, apply tension until all the backlash is taken out. Measure the clearance of the lower control cable ball terminal to the swing arm as shown in Figure 2-2. This measurement shall be 0.12 to 0.18 inches when system is rigged and load beam is latched. If adjustment is made to the stop bolt in order to obtain proper clearance, recheck adjustment of control cable and conduit.

With the cargo hook release pedal against the FORWARD stop, check for the following conditions:

 Ensure that the spring assembly 204-070-998, does not bottom. If the spring assembly should bottom, return the cargo hook pedal to the aft stop and check control cable tension. Cable tension should be 20 to 24 pounds.

 Check the operation of the mechanical release.

 Ensure the swing arm is full up. Ensure lever is not stopped by the bottom end of the control cable outer housing.

 Ensure cargo hook load beam unlocks.



Release the cargo hook pedal and ensure that both the upper and lower manual release cables return to the locking position.



See the Bell Helicopter service instructions that cover the original cargo hook suspension system for additional instructions.

2-4

Suspension System Installation Instructions

Suspension System Electrical Release Installation

Refer to Figure 2-1 for suspension system connector pin-out to verify compatibility with the aircraft side wiring. Connect the electrical release cable to the connector located on the right underside of the lift beam and safety-wire it into place. Refer to Figure 2-1 for connector pin-outs.

Check the manual release cable assembly and the electrical release cable to ensure enough slack is present to allow full swing of the suspension assembly without straining or damaging the cables.

Ground Wire Installation

Bell Helicopter troubleshooting information from the field has revealed the possibility of stray voltage from static discharge existing on the contacts of the cargo release relay. To preclude the inadvertent actuation of the cargo hook due to the possible existence of this stray voltage, it is required that a ground path from the airframe to the Suspension System be provided.

The Suspension System ground wire is shown in Figure 2-1. The free end of this wire must be connected to the airframe per Bell Helicopter technical bulletin no. 205-81-42, 205-82-46 and 205-84-62 or other later bulletins. It is essential that the ground path circuit be properly maintained by ensuring tight corrosion free connections, see the section, Suspension

System Parts List.

Multi-Channel Slip-Ring Electrical Installation

The Multi-Channel Slip-Ring assembly is a means of supplying electrical power and control signals to the cargo hook and to accessory equipment suspended from the rotating cargo hook suspension system. Two channels of the Slip-Ring assembly are dedicated to the operation of the cargo hook electrical release mechanism. Six other channels are available to operate suspended equipment such as fire-fighting buckets, agricultural and forest application equipment, logging equipment, construction equipment, longline hooks or an optional hook open warning light.

The Slip-Ring could be wired so that each piece of individual equipment could have its own switch in the cockpit, connecting through a separate

Slip-Ring channel to a common accessory connector (designed by the installer to meet his specific needs) at the hook. Once the Slip-Ring and its control wires are installed, an equipment change would involve simply attaching the equipment to the cargo hook and plugging its control wires into the installer's common equipment connector.

UH-1 Suspension System w/ Keeperless Hook Owner's Manual

2-5

Multi-Channel Slip-Ring Electrical Installation,

continued

The Onboard Systems Multi-Channel Slip-Ring is offered as a means of passing electrical current across the rotating junction between the helicopter cargo hook suspension system and the suspended load. This assembly must be considered as an electrical part only, and not as a completed electrical system. Onboard has not evaluated any end-to-end use of this part other than the cargo hook electrical release mechanism defined herein.

Accordingly, it is the responsibility of the installer and their Authorized

Inspector (AI) to verify that each electrical system incorporating this Slip-

Ring kit meets the applicable electrical requirements of the Federal

Aviation Regulations. All electrical considerations such as electrical load determinations, voltage drops, electrical interference, electrical bus and circuit protections etc. are the responsibility of the end user and may require further FAA approval.

Onboard Systems has accomplished satisfactory electrical load testing of the Slip-Ring assembly only, and has demonstrated maximum load ratings of 10 amps (continuous) and 30 amps (intermittent for 30 seconds) in the standard 28VDC electrical system. Electrical loading above these currents or time limits may harm the assembly performance.

2-6

Suspension System Installation Instructions

Suspension System Installation Check-Out

After installation of the Suspension System, perform the following functional checks. Follow the Bell Helicopter instructions for the specific helicopter.

1. 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.

2. Direct an assistant to observe the Cargo Hook and reset the cargo hook load beam to the closed position as required.

3. Close the cargo hook release circuit breaker and position the battery switch to the ON position. Depress the cargo hook switch. The Cargo

Hook should release.

4. Rotate the suspension system 90 degrees, close the cargo hook and repeat step 3. Rotate the suspension system another 90 degrees, close the cargo hook and repeat step 3. Repeat this procedure until the suspension system is back at its original position. To prevent burning out the solenoid do not hold the switch for more than 5 seconds in any

30 second period. At this time also cycle the Slip-Ring accessories several times to ensure proper operation.

5. With the cargo hook closed, depress the foot operated cargo hook mechanical release, the Cargo Hook should release.

6. See the Bell Helicopter service instructions that cover the original cargo hook suspension system for additional instructions.

UH-1 Suspension System w/ Keeperless Hook Owner’s Manual

2-7

Component Weights

Table 2-1 Component Weights

System Part Number and Description

200-088-10 Suspension System without Load Weigh

200-088-50 Suspension System without Load Weigh

200-089-10 Suspension System with Load Cell

200-089-11 Suspension System with Load Cell

200-089-20 Suspension System with Load Weigh,

C-39 Indicator w/ 28V Lights

200-089-21 Suspension System with Load Weigh,

C-39 Indicator w/ 5V Lights

200-089-22 Suspension System with Load Weigh,

C-39 Indicator w/ 28V Lights (or 5V

Lights)

200-089-23 Suspension System with Load Weigh,

C-39 Indicator w/ 5V Lights

Paper Work

Weight

29 lbs (13 kgs)

29 lbs (13 kgs)

29 lbs (13 kgs)

29 lbs (13 kgs)

32 lbs (14.5 kgs)

32 lbs (14.5 kgs)

32 lbs (14.5 kgs)

32 lbs (14.5 kgs)

Place the Rotorcraft Flight Manual Supplement, document no. 121-021-00, into the Rotorcraft Flight Manual. 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.

2-8

Suspension System Installation Instructions

Section 3

Suspension System Operation Instructions

Suspension System Operating Procedures

Refer to Owner’s Manual 120-039-00 for operation instructions for the C-

39 load weigh indicator.

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

1. Cargo is released electrically by use of the cyclic CARGO RELEASE button. Refer to the applicable RFM Supplement for each helicopter for switch settings and sequence. Activate the electrical system and press the release button to ensure the cargo hook electrical release is operating correctly. The cargo hook must release.

The solenoid in the hook is not rated for continuous duty. Continuous power to the solenoid for longer than 20 seconds will damage the solenoid.

2. Depress the manual release foot pedal in the cockpit to test the cargo hook manual release mechanism. Manually close the hook. After each release the cargo hook must be manually closed. When the hook is closed, verify that the hook locked indicators are aligned. Do not use the hook unless the hook lock indicator is aligned with the engraved line on the manual release cover. If marks are not aligned the hook may not be fully locked.

Figure 3-1 Hook Locked Indication

Hook Lock Indicator

Engraved line on manual release cover

Operation Instructions

3-1

Suspension System Operating Procedures

continued

3. Cargo hook P/N 528-020-10 has a lever for opening the cargo hook from the ground. With no load on the hook, rotate the lever counterclockwise (CCW) until the load beam opens. The hook may be flown in the open position to facilitate loading.

Figure 3-2 Ground Release Lever

Rotate lever to open load beam.

Manual Release Lever

Bumper Lubrication

4. Cycle all accessories attached to the cargo hook suspension slip ring to ensure proper operation.

Some combinations of load weight and airspeed may cause the bumper to bind against the inside of the airframe hell-hole and the sling load to rotate independently of the suspension system.

This situation can lead to inadvertent loss of load.

The outside surface of the bumper ring should be lubricated frequently with a grease such as

AeroShell 7 or Mobilgrease 28 to prevent seizure from occurring.

3-2

Operation Instructions

Cargo Hook Rigging

Extreme care must be exercised in rigging a load to the Cargo Hook. Steel load rings are recommended to provide consistent release performance and resistance to fouling. The following illustration shows the recommended rigging and rigging to avoid.

The examples shown (see Figure 3-3) are not intended to represent all rigging possibilities. It is the responsibility of the operator to assure the hook will function properly with the rigging.

Nylon Type Straps or 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 correctly sized primary ring. Only the primary ring should be in contact with the cargo hook load beam. See following illustration.

Figure 3-3 Examples of Cargo Hook Rigging

Recommended Avoid

Primary Ring

Long Line

Operation Instructions 3-3

Cargo Hook Loading

The cargo hook can easily be loaded with one hand. A load is attached to the hook by pushing the ring upward against the upper portion of the load beam throat, as illustrated in Figure 3-4, until an internal latch engages the load beam and latches it in the closed position.

Figure 3-4 Cargo Hook Loading

LOCKED

6,000 LB Rated Capacity

Part #

Date

528-020-

S/N

SEE STC LIST FOR APPROVED AIRCRAFT www.onboardsystems.com

LOCKED

6,000 LB Rated Capacity

Part #

Date

528-020-

S/N

SEE STC LIST FOR APPROVED AIRCRAFT www.onboardsystems.com

LOCKED

6,000 LB Rated Capacity

Part #

Date

528-020-

S/N

SEE STC LIST FOR APPROVED AIRCRAFT www.onboardsystems.com

Form 215-159-00

3-4

Operation Instructions

Section 4

Load Weigh General Information

Introduction

The Load Weigh System is an optional feature to the Suspension System.

The Load Weigh System consists of three components, the cockpit mounted Indicator, the Internal Harness and the Load Cell. When the Load

Weigh option is specified, the Suspension Systems Load Link, P/N 232-

009-01, is replaced by the Load Cell Assembly P/N 210-088-01 or P/N

210-088-02.

Refer to Owner’s Manual 120-039-00 for operation instructions for the indicator.

Indicator Features

The features of the C-39 Indicator include:



Front panel programmable



Data Recorder communications link



Internal back lighting system

- Indicator P/N 210-095-00, 28 Volt lights

- Indicator P/N 210-095-02, 5 Volt lights

- Indicator P/N 210-095-04, 28 Volt NVG lights

- Indicator P/N 210-095-05, 5 Volt NVG lights



Hook-Open Warning Display



Analog Meter Output Signal

Load Weigh General Information

4-1

Indicator Specifications

Table 4-1 Indicator Specifications

SPECIFICATIONS

Size

Weight

Operating Voltage

Current Consumption

Accuracy Over Operating

Temperature Range

Operating Temperature Range

Storage Temperature Range

Scaleable Analog Output

INDICATOR

Fits standard 2¼" clock hole

.47 lbs (.21 kgs)

21 to 31 VDC

< 25 mA

0.1%



1 digit

+70°C to –45°C

+80°C to –50°C

0 to 5VDC

± 0.5%

Indicator Pin Out

The connector located on the back of the Indicator has the following pin out.

Table 4-2 Indicator Pin Out

K

L

M

N

F

G

H

J

P

R

Pin

A

B

C

D

E

Function

+ 28 VDC In

- Load Cell Signal

+ Load Cell Signal

+ Load Cell Excitation

Load Cell Common

Analog Out Common

+ Analog Out

Hook Open

Data Recorder Clock

Data Recorder Data

Shield

Back Light Common

Back Light Source

Aircraft Ground

Not Used

Load Cell Specifications

Table 4-3 Load Cell Specifications

SPECIFICATIONS

Weight

Accuracy Over Operating

Temperature Range

Operating Temperature Range

Storage Temperature Range

LOAD CELL

2.0 lbs (.91 kgs)

0.5%



1 digit

+70°C to –45°C

+80°C to –50°C

4-2

Load Weigh General Information

Section 5

Load Weigh Installation Instructions

Introduction

The Indicator 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

Load Weigh Internal Harness Installation. See the section below for an overview of the installation.

Indicator Installation Overview

Figure 5-1 Installation Overview

Load Weigh Installation Instructions

5-1

Indicator Internal Back Light

The 210-095-00 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 Indicator. Disassemble the Indicator mating connector and carefully solder the positive wire, from the aircraft light dimming circuit, to pin M and the common wire to pin N. Connect the cable shield wire to airframe ground at the light dimmer end of the cable

ONLY.

The 210-095-02 Indicator is equipped with an Internal Back Lighting

System that can be connected to the aircraft 5 VDC light dimming circuit.

Use a 22 gauge, twisted pair, shielded cable to connect the aircraft dimming circuit to the Internal Harness. Connect the cable shield wire to airframe ground at the light dimmer end of the cable ONLY.

Indicator Hook-Open Warning

The 210-095-00 and 210-095-02 Indicators are 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 210-095-00 and 210-095-02 Indicators are 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 and 210-095-02 Indicator can be connected to Onboard

Systems’ Analog Slave Meter, P/N 210-180-00, through the “DATA” cable. This meter gives solid weight indications without needle bounce.

The Analog Slave Meter may be mounted in any convenient location in a standard 3” instrument hole. Attach connector, P/N 410-130-00, to data line per pin out in Figure 5-2 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.

5-2

Load Weigh Installation Instructions

Load Weigh Internal Harness Installation

The Internal Harness is made up of four cables terminated to one connector. The connector is plugged into the back of the Indicator. One of the cables is marked “LOAD CELL” and is fitted with a bulkhead fitting.

A connector bracket (P/N 235-035-00) is provided which can be used to mount the bulkhead fitting. This cable is connected to the load cell.

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

Internal Back Light section for installation instructions. The last cable is marked “DATA” and can be connected to the optional Data Recorder or

Analog Slave Meter. These optional items are not included under this

STC.

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

Load Weigh Electrical Connections

Connect the power cable to the Indicator and route the other end to a convenient location for the indicator power switch part number 400-007-

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 wire

(or red wire if earlier harness configuration P/N 270-044-00 is installed) 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 wire (or black wire if 270-

044-00 is installed) to the ground bus. The bare wire should be cut off as it is not needed at this end of the cable. Install the placard 215-010-00

“ELECTRONIC WEIGHING SYSTEM” next to the power switch and circuit breaker. Install the placard 215-012-00 “TURN THE WEIGHING

SYSTEM OFF WHEN NAVIGATION EQUIPMENT IN USE” “NO

AIRCRAFT OPERATION SHOULD BE PREDICATED ON THE

READING OF THE ONBOARD WEIGHING SYSTEM” next to the

Indicator.

Load Weigh Installation Instructions 5-3

Load Weigh Electrical Connections,

continued

Figure 5-2 Wiring Arrangement

POWER SWITCH

(SUPPLIED)

1 AMP CIRCUIT BREAKER

(OPERATOR SUPPLIED)

White (Red)

TO 28 VDC

TO AIRFRAME GROUND

White/Blue (Black)

CUT OFF THE BARE WIRE (IF PRESENT),

DO NOT CONNECT IT TO GROUND.

POWER CABLE

BACK LIGHT POTENTIOMETER

(OPERATOR SUPPLIED)

TO 28 VDC

TO AIRFRAME GROUND

White (Red)

LIGHT CABLE

White/Blue (Black)

INTERNAL HARNESS ASSEMBLY

(WITH OPTIONAL CABLE INSTALLED)

DATA RECORDER/

ANALOG METER CABLE

TO OPTIONAL EQUIPMENT

DEPENDING ON MFG DATE OR DASH

NUMBER THIS CABLE MAY TERMINATE

IN A CONNECTOR

OPTIONAL EQUIPMENT CONNECTORS

TO LOAD CELL

B

C

D

E

ANALOG METER CONNECTOR

P/N 410-130-00

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

PIN COLOR FUNCTION

A

WH (Red) Power

WH/GN (Green)

WH/OR (White)

WH/BL (Black)

Shield

Clock

Data

Ground

Shield

DATA RECORDER CONNECTOR

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

& 410-020-00

7

9

3

5

PIN COLOR FUNCTION

1

WH/BL (Black) Ground

WH (Red)

Shield

Power

Shield

WH/GN (Green) Clock Signal

4

WH/OR (White)

Red*

Data Signal

Flight Switch

2 Purple*

*Optional

Cap. Switch

Connect the Internal Harness to the Indicator connector. Install the placard

215-010-00 “ELECTRONIC WEIGHING SYSTEM” next to the power switch and circuit breaker. Install the placard 215-012-00 “TURN THE

WEIGHING SYSTEM OFF WHEN NAVIGATION EQUIPMENT IN

USE” “NO AIRCRAFT OPERATION SHOULD BE PREDICATED ON

THE READING OF THE ONBOARD WEIGHING SYSTEM” next to the

Indicator.

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

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

5-4

Load Weigh Installation Instructions

Load Cell Installation (Kit P/N 200-151-01)

Load Weigh Kit P/N 200-151-01 is an upgrade kit for an operator with kit

P/N 200-088-10 installed. Upon installation the kit reflects a P/N 200-

089-22 or P/N 200-089-23 (depending on C-39 indicator installed).

To install the load cell, remove the suspension system from the helicopter and remove the load link assembly near the top of the suspension system.

Place the Load Cell Assembly (P/N 210-088-02) within the clevis of the bell housing, and re-install bolt, washer and nut. Tighten nut to finger tight and rotate to next castellation to insert cotter pin (P/N 510-098-00).

Ensure the load cell assembly pivots freely within the clevis.

Re-install the clevis assembly onto the top pivot point of the load cell assembly with the bolt, washer and nut remove previously. Tighten nut to finger tight and rotate to next castellation to insert cotter pin (P/N 510-

098-00). Ensure the clevis assembly pivots freely on the load cell assembly.

Re-install the suspension onto the helicopter per Section 2. Install the remaining components of the load weigh kit per this section.

Load Weigh Installation Check-Out

After the system has been properly installed, activate the circuit breaker to turn the system on. Refer to Owner’s Manual 120-039-00 for operation instructions.

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 load cell 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.

Swing the hook assembly to the full extremes to verify that it does not self trip.

Ensure that all electrical cables are secured clear of flight control rods and hydraulic lines.

Load Weigh Installation Instructions

5-5

This page intentionally left blank.

Section 6

Suspension System Inspection, Maintenance,

Overhaul & Trouble Shooting

For inspection, maintenance, overhaul procedures, and trouble shooting for the cargo hook suspension system refer to Component Maintenance

Manual 122-028-00.

Current revision levels of all manuals are posted on Onboard Systems Int'l web site at www.onboardsystems.com. Hard copies of current revision levels of all manuals are also available from the factory.

Suspension System Inspection, Maintenance, Overhaul & Trouble Shooting

6-1

This page intentionally left blank.

Section 7

Cargo Hook Inspection, Maintenance &

Overhaul Procedures

For inspection, maintenance, and overhaul procedures for the cargo hook refer to Cargo Hook Component Maintenance Manual 122-004-00.

Current revision levels of all manuals are posted on Onboard Systems Int'l web site at www.onboardsystems.com. Hard copies of current revision levels of all manuals are also available from the factory.

Instructions for Returning Equipment to the Factory

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

An RMA number is required for all equipment returns.



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



Contact Technical Support by phone or e-mail

([email protected]).



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



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



Package the component carefully to ensure safe transit.



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



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



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



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

Onboard Systems

13915 NW 3rd Court

Vancouver, Washington 98685

USA

Phone: 360-546-3072

UH-1 Suspension System w/ Keeperless Hook Owner's Manual

7-1

This page intentionally left blank.

Section 8

Certification

FAA STC

Certification

8-1

Approved Model List

8-2

UH-1 Suspension System w/ Keeperless Hook Owner's Manual

Foreign Approvals

Certification 8-3

Foreign Approvals

continued

8-4

UH-1 Suspension System w/ Keeperless Hook Owner's Manual

Foreign Approvals

continued

Certification 8-5

Foreign Approvals

continued

8-6

Certification

Foreign Approvals

continued

Certification 8-7

Foreign Approvals

continued

8-8

Certification