120-120-00 - Onboard Systems International
Contents
1. General Information Used to address practices not related to personal injury 1 1 Bill of Materials The following items are included with the Cargo Hook Kits if shortages are found contact the company from whom the system was purchased 200 302 00 200 387 00 T Specifications ion py an mjntals nlt m qajajq nlpjnlnljAlm ud Table 1 1 System Specifications Table 1 2 P N 528 028 00 Cargo Hook Specifications Load capacities given are for the equipment described only Loading limits for your particular helicopter model still apply Consult your flight manual 1 2 Installation Instructions Section 2 Installation Instructions 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 General preparation Remove lower belly panels as necessary to access the areas in which the hose is to be routed If the helicopter currently has the OEM cargo hook kit installed remove the following Q Cargo hook and its associated mounting brackets from the suspension Q External wire harness Q The entire mechanical release cable from the cargo hook up to and including the T handle in the cockpit The 200 302 00 and 200 387 00 cargo hook kits use the helicopter s existing internal wiring and cable suspension Re2. Installation Instructions 2 3 2 1 Master Cylinder Assembly Installation continued Underneath the cabin floor the hose is routed aft and outboard to the right forward suspension cable attach point Figure 2 1 4 is an overview of the routing Figure 2 1 4 Fixed Hydraulic Release System Installation Overview Master Cylinder a oe a See Figure 2 1 5 Quick Disconnect Coupling vi va ii O Aft of the hole in the cabin floor route the hose through existing holes in the airframe as shown below and then secure per Figure 2 1 6 Figure 2 1 5 Hose Routing Under Cabin Floor View Looking Up underneath cabin floor 2 4 Installation Instructions 2 1 Master Cylinder Assembly Installation continued Aft of the 2 frame the hose is routed over the skid gear tube Before Installation Instructions securing the hose with the adel clamps as shown below layout the section of hose that will be above the skid gear tube and install approximately 3 feet 1 meter of the supplied spiral wrap P N 590 013 00 over this section This will protect against rubbing chafing in this area At the two frames through which the hose passes through secure the hose using an Adel Clamp P N 512 010 00 and Bracket P N 512 028 00 as described below O Drill a 196 diameter hole in the frames maintain 2D edge distances to locate the brackets as shown below and s
3. pLEASE CHECK WEB us com FOR TE ATW 7 E www ON BOARD psYS TE VISION 0 y THIS MANUAL pTEST RE THE L Owner s Manual for the 3 5KK Talon LC Hydraulic Cargo Hook Kits on the BO 105S and BO 105LS A 3 Helicopter System Part Numbers 200 302 00 200 387 00 Owner s Manual Number 120 120 00 Revision 5 August 17 2012 Z CONBDARD SYSTEMS I N TERNATIONAL 13915 NW 3 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 Date RECORD OF REVISIONS Page s Reason for Revision 02 20 06 All First Issue 04 04 07 Section 1 2 amp 3 and TOC Updated instructions to reflect hydraulic system being shipped dry Updated warnings cautions and notes to current format Updated part numbers and figures to new master cylinder design 06 26 07 1 2 2 5 2 8 2 9 Added spiral wrap P N 590 013 00 to BOM Added instructions to page 2 5 to install spiral wrap over hydraulic hose Clarified installation instructions and corrected part number for spiral wrap page 2 8 and 2 9 06 30 11 Added kit P N 200 387 00 and BO 105LS A 3 model 01 25 12 Updated design load for kit P N 200 387 00 to 3000 Ibs 08 17 12 Adjusted quantities of Adel Clamps to reflect new slave cylinder hose updated Figure 2 2 2 to reflect
4. Ty wrap hose and harness together here Detail B Installation Instructions 2 9 2 2 Cargo Hook Installation continued Q Connect the electrical connector to the helicopter s existing electrical release connector in the external skin forward of the left front cable suspension attach point Secure the harness to the skid gear tube inboard of the suspension attach clamp with ty wrap P N 512 029 00 as shown below Figure 2 2 3 Release Harness Tie Off Ty wrap Electrical Release Harness Q Connect the disconnect fitting at the end of the hydraulic hose to the master cylinder hose fitting at the disconnect bracket installed previously Q Trim as required to fit and install the INOP placard P N 215 169 00 over the hook advisory light in the cockpit the 528 028 00 cargo hook does not have a hook lock indicator switch For stowage when not in use the 528 028 00 cargo hook requires that a longer cable sling be installed on the helicopter s existing cargo hook retainer bracket Q Remove the existing cable sling and replace with the longer hook retainer sling P N 232 218 00 provided re using the hardware Figure 2 2 4 Hook Retainer Sling Existing Bracket Hook Retainer Sling P N 232 218 00 VIEW LOOKING AFT 2 10 Installation Instructions 2 3 Installation Check out After installation of the Cargo Hook kit and before re installing belly panels perform the following
5. TYPE CERTIFICATE 10040440 This Supplemental Type Certificate is issued by EASA acting in accordance with Regulation EC No 216 2008 on behalf of the European Community its Member States and of the European third countries that participate in the activities of SASA under Article 65 of that Regulation and in accordance with Commission Regulation EC No 1702 2003 to ONBOARD SYSTEMS INTERNATIONAL 13915 NW 3RD COURT VANCOUVER WA 98685 USA and certifies that the change in the type design for the product listed below with the limitations and conditions specified meets the applicable Type Certification Basis and environmental protection requirements when operated within the conditions and limitations specified below Original Product TC Number EASA R 011 TC Holder EUROCOPTER DEUTSCHLAND GMBH Model BO 105 S BO 105 LS A 3 Original STC Number FAA STC SRO1694SE Description of Design Change Validation of FAA STC SR01694SE Cargo Hook Kits EASA Certification Basis The Certification Basis for the original product and the following additional or alternative airworthiness requirements are applicable to this certificate approval FAR 27 including amendment 37 The requirements for environmental protection and the associated certificated noise and or emissions levels of the original product are unchanged end remain applicable to this certificate approval See Continuation Shest s For the European Aviation Safety Agency a D
6. functional checks l Swing the installed Cargo Hook to ensure that the hydraulic release hose and the electrical release harness have enough slack to allow full swing of the suspension assembly without straining or damaging them The hose and or harness must not be the stops that prevent the Cargo Hook from swinging freely in all directions Verify that the hydraulic hose routing does not have kinks and is clear of chafing points Ensure that the collective has full movement and is not restricted by the hydraulic hose routing Pull the hydraulic release lever on the collective The Cargo Hook load beam should open Close the cargo hook release circuit breaker and position the battery switch to the ON position With no load on the cargo hook depress the cargo hook electrical release button The Cargo Hook load beam should open Pull the cargo hook up to the stowed position and latch it into the retainer sling Ensure hydraulic hose is free from chafing and kinking and that the electrical harness is protected by the spiral wrap from chafing on the retainer cable 2 4 Component Weights The weight of the Cargo Hook Kits are listed below These kits replace the OEM installed cargo hook remember to subtract the weights of the components removed 2 5 Paper Work Installation Instructions Table 2 2 Component Weights P N 200 302 00 6 2 lbs 2 8 kgs P N 200 387 00 5 9 Ibs 2 7 kgs In the US fill in FAA form 337 for the i
7. usage of Adel Clamps 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 Section 2 Section 3 Section 4 Section 5 General Information Introduction 1 1 Explanation of Signal Words and Symbols 1 1 Bill of Materials 1 2 Specifications 1 2 Installation Instructions 2 1 Master Cylinder Assembly Installation 2 2 2 2 Cargo Hook Installation 2 8 2 3 Installation Check out 2 11 2 4 Component Weights 2 11 2 5 Paper Work 2 11 2 6 Filling Hydraulic Release System 2 12 Cargo Hook Operation Instructions Operating Procedures 3 1 Cargo Hook Loading 3 2 Cargo Hook Rigging 3 3 Maintenance Instructions for Returning a System to the Factory 4 1 Certification FAA STC 5 1 Transport Canada Approval 5 3 ANAC Approval 5 4 EASA STC 5 6 This page intentionally left blank Section 1 General Information Introduction The P N 2
8. 00 302 00 Cargo Hook Kit is approved for installation on the BO 105S model helicopter equipped with a suspension system installed per American Eurocopter STC SH286NE and the P N 200 387 00 cargo hook kit is approved for installation on a BO 105S or BO 105LS model equipped with a suspension P N 117 80127 These kits replace the cargo hook an adapter link assembly the manual release cable and an external electrical release wire harness on the existing cable type suspension system They utilize the existing cable suspension and internal electrical wiring The P N 200 302 00 and P N 200 387 00 kits are identical except for the adapter link assembly The adapter link assembly serves to connect the cargo hook to the cable suspension shackles and is narrower in kit P N 200 387 00 to accommodate the shackles on the Siren suspension Explanation of Signal Words and Symbols The following definitions apply to the symbols used throughout this manual to draw the reader s attention to safety instructions as well as other important messages Indicates a hazardous situation which if not T D AN G E P 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 N O C E unusual information not directly related to safety
9. C Bite States of Ameria Beportment of Transportation Federal Aviation Administration Supplemental Cype Certificate Number SR01694SE This certificate issued to Onboard Systems 13915 NW 3 Court Vancouver WA 98685 certifies that the change in the type design for the following product with the tanitalions and conditions therefore as ecified hereon meets the airworthiness requirements of Fart 21 of the Code of Federal Kegulaltions Original Product Type Certificate Vianber H3EU Make Eurocopter Deutschland Model BO 105S BO 105LS A 3 Description of the Type Design Change Fabrication of Onboard Systems Models 200 302 00 and 200 387 00 Talon LC Hydraulic Cargo Hook Kits without Load Weigh and Models 200 303 00 and 200 388 00 Talon LC Hydraulic Cargo Hook Kits with Load Weigh in accordance with Federal Aviation Administration FAA approved Onboard Systems Master Drawing List No 155 113 00 Revision 10 dated January 27 2012 or later FAA approved revision Installation of these kits in accordance with FAA approved Onboard Systems Owner s Manual listed in the table below or later FAA approved revision This modification must be inspected and maintained in accordance with Section 5 of the FAA approved Onboard Systems Instructions for Continued Airworthiness ICA and Onboard Systems Component Maintenance Manual listed in the table below or later FAA approved revision See Continuation Sheet Page 3 of 3 Pages Limitations an
10. and Nanutscturer Modelo s BO1055 Modelfs DESCRI O DA MODIFICA O AO PROJETO DE TIPO tDescriprien f Type Design Changer Installation of Onboard Systems Model 200 387 00 Talon LC Hydraulic Cargo Hook Kit without Load Weigh or Onboard Systems Model 200 388 00 Talon LC Hydraulic Cargo Hook kit with Load Weigh in accordance with Onboard Systems Master Drawing List document No 155 113 00 Rev 6 dated 09 Apr 2012 or later approved revision This CST validates in Brazil the STC No SRO16945E issued by FAA USA LIMITA ES E CONDI ES t imitations aed Conditions See continuation sheet for applicable data DATAS Dates at Do Requerimento 9 Aug 2010 Da emiss o 16 Mar 2011 Da reemiss o t pelication tasue Retssus f 4 a H LIO TARQUINIG J NIOR DING ISHIKURA Gerente Geral Certifica o de Produto Aeron utico Superintendente de Aeronavegabilidade Gurara Marager Ancrrisutaa Product Cartiftatiza Weranrthiness Soperrtendent E S00 025 03 12 Ri ot Se 02 02 3450 0 5 4 Certification ANAC Approval continued G Folha de Continua o ao Continwstion Sheet te CERTIFICADO SUPLEMENTAR DE TIPO Supplemental Type Certificate NUMERO 2012S03 06 Number LIMITA ES E CONDI ES tLimitestona and Condisions The approval of this type design change should not be extended to other rotorcraft of these modeis on which other previously approv
11. ansport Canada for installation on Canadian registered aeronautical products This letter confirms formal acceptance of the referenced STC by Transport Canada for only those makes and models identified on the subject STC that have been Type Certified or otherwise accepted in Canada Yours truly Paul Arnell A Regional Manager Aircraft Certification c c Mr Jeffrey E Duven Manager Seattle Aircraft Certification Services Canada Certification 5 3 ANAC Approval 6 CERTIFICADO SUPLEMENTAR DE TIPO Supplemental Type Certificate NUMERO 2012503 06 Number Este certificado emitido com base na Lei n 7565 C digo Brasileiro de Aeronautica de 19 de dezembro de 1986 This cersificate issued in the basis of the Law No THES C digo Brasileiro de Aeren utica dated 19 December 1986 conferidoao Onboard System International ia mea 13915 NW 3rd Court Vancouver WA 98685 USA por ter a modifica o ao projeto de tipo do produto abaixo citado observadas as limita es e condi es for having the chasge to the type design cf the product mentioned below with the limitations and conditions theretor as especificadas satisfeito aos requisitos de aeronavegabilidade aplic veis epecified heresm met the apelicable aleworthinass requirementa Produto Original N mero do Certificado de Tipo EASA R 011 EASA fOrigrra l Product Tyee Certificate Ne Fabricante Eurocopter Deutschl
12. ate of issue 03 07 2012 NLL j nf TC soe Massimo MAZZOLETTI Certification Manager Rotorcraft Balioons Airships Note The folowing numbers are listed on the certificate EASA current Project Number 0010016454091 SUPPLEMENTAL TYPE CERTIFICATE 10040440 ONBOARD SYSTEMS INTERNATIONAL A Form 97 Issue 4 10 w2 56 Certification EASA STC continued a European Aviation Safety Agency fa X Associated Technical Documentation FAA approved Onboard Systems Rotorcraft Flight Manual Supplement RFMS 121 029 00 dated March 1 2012 or later revisions of the above listed documents approved by EASA in accordance with EASA ED Decision 2004 04 CF or subsequent revisions of this decision FAA approved Onboard Systems Master Drawing List No 155 113 0C Revision 10 dated January 10 2012 FAA approved Onboard Systems Owners s Manual as listed in FAA STC SRO1694SE amended March 9 2012 FAA approved Instructions for Continued Airworthiness as listed in FAA STC SRO1694SE amended March 9 2012 Limitations This STC is restricted to installation of cargo hook kits model 200 387 00 and model 200 388 00 Not included are cargo hook kits model 200 302 00 and mode 200 303 00 Conditions Prior to installation of this modification it must be determined that the interreiationship between this modification and any other previously installed modification and or repair will introduce no adverse effe
13. ct upon the airworthiness of the product end Note The following numbers are listed on the certi icate EASA current Project Number 0010016454001 SUPPLEMENTAL TYPE CERTIFICATE 10040440 ONBOARD SYSTEMS INTERNATIONAL EASA Form 91 Issue 4 24 09 2010 2 2 Certification
14. d Conditions Approval of this change in type design applies to only those Eurocopter model rotorcraft listed above which for kits 200 302 00 and 200 303 00 are equipped with a suspension system P N 105 E0018 installed per STC SH286NE or which for kits 200 387 00 and 200 388 00 are equipped with a Eurocopter suspension system P N 117 80127 See Continuation Sheet Page 3 of 3 Pages This cortificate and the supporting data which s Lhe buses for approval hale Germain in ofret until surrendered suspended revoked or a termination date s otherwise etablisfed ty the Aedninistrator of the Federal Aviation Administration Pate of application November 21 2005 Date reissued Fate of issuance August 17 2006 Date amended March 17 201 1 March 9 2012 By direction ae as a LA k Title a Any alteration of this certificate is punishable by a fine of not exceeding 1 000 or imprisonment not ex 3 or both This certificate may be transferred in accordance with FAR 21 47 FAA Foru 8110 2 10 68 PAGE 1 OF 3 PAGES Certification STC continued Vote Sates of Americar Department of Transportation Federal Aviation Administration Supplemental Type Certificate Continuation Sheet Number SRO1694SE Onboard Systems Sisued August 17 2006 Reissued Amnended March 17 2011 March 9 2012 Deseriplion of the Type Design Change continued Owner s Manual No Instructions for Continued Airwo
15. e hose above the landing gear tube at location shown below Q Drill 196 diameter hole in helicopter skin and attach the Bracket P N 512 028 00 with screw P N 510 391 00 washer P N 510 042 00 and nut P N 510 102 00 Q Place an Adel Clamp P N 512 010 00 over the hose and secure the Adel Clamp to the Bracket with screw P N 510 391 00 washer P N 510 042 00 and nut P N 510 102 00 Rotate the adel clamp to provide the hose with a gradual transition as possible from the end fitting to it Figure 2 1 9 Hose Tie Off Point Adel Clamp Q O O Bracket aS P N 512 028 00 Fwd VIEW LOOKING INBOARD Installation Instructions 2 7 2 2 Cargo Hook Installation 2 8 Q Attach the Cargo Hook and Link Assembly P N 232 211 00 is included with Kit P N 200 302 00 P N 232 503 00 is included with kit P N 200 387 00 to the suspension cable shackles using the hardware removed previously Orient the assembly such that the load beam is pointing forward as shown below Figure 2 2 1 Cargo Hook Installation Shackles Link Assembly Re use existing hardware Q Route the hydraulic hose up the right forward suspension cable and secure it in four places uniformly spaced to the suspension cable using the P N 512 024 00 adel clamps attached to the suspension cable adel clamps as shown in the fi
16. ecure the brackets with screws P N 510 391 00 washers P N 510 042 00 and nuts P N 510 102 00 00 and nuts P N 510 102 00 Figure 2 1 6 Hose Attachment Points Install the Adel Clamps over the hose and attach the Adel Clamps to the brackets with screws P N 510 493 00 washers P N 510 042 B A Install Spiral Wrap over the hose where it is routed E E EA above skid gear tube B A a Adel Clamp E P N 512 010 00 Adel Clamp P N 512 010 00 50 1 oot Bracket P N 512 028 00 SECTION B B 2ND FRAME Bracket P N 512 028 00 SECTION A A 1ST FRAME 2 5 2 1 Master Cylinder Assembly Installation continued Q Route the hose outboard to the right forward suspension cable attachment clevis Remove the existing manual release cable support bracket and adel clamp and replace with the supplied Quick Disconnect Bracket P N 235 128 00 Re use the existing hardware Figure 2 1 7 Disconnect Bracket Installation Quick Disconnect Bracket P N 235 128 00 Q Insert quick disconnect fitting through keyhole slot in bracket and slide inboard capturing the bracket flange between the washer and the end of the fitting Tighten nut Figure 2 1 8 Disconnect Installation VIEW A A Washer VIEW LOOKING INBOARD 2 6 Installation Instructions 2 1 Master Cylinder Assembly Installation continued Secure th
17. ed modifications are incorporated unless it is determined by the installer that the relationship between this change and any of those other previously approved modifications including changes in Type Design will introduce no adverse effect upon the airworthiness of that rotorcraft If the holder agrees to permit another person to use this certificate to alter the product the holder shall give the other person written evidence of that permission Operation must be performed in accordance with FAA approved Rotorcraft Flight Manual Supplement RFMS Document No 121 029 00 Rev 3 dated 01 Mar 2012 or later approved revision Iv Instructions for Continued Airworthiness ICA Document 123 022 00 Rev 4 dated 17 Aug 2011 or later FAA approved revision and Onboard Systems Service Manual document No 122 015 00 Rev 13 dated 15 Nov 2011 or later FAA approved revisions are required for this installation V Approval of this change in type design applies to only the rotorcraft which is equipped with a Eurocopter suspension system P N 117 80127 Vi A copy of this Certificate and the Supplement referred on item Ill above shall be maintained as part of the permanent records of the modified rotorcraft A nnn eee a eet ech Me aj F 400 01F 03 11 FL 02 de 02 H 02 3450 0 Greet jet Certification EASA STC Note This approval is for kit P N s 200 387 00 and 200 388 00 only European Aviation Safety Agency SUPPLEMENTAL
18. fle and the reservoir lid Check the system for proper operation Fully actuate the release lever The hook must open and the lever must have a firm feel Disassemble and thoroughly clean the syringe with isopropyl alcohol Allow it to dry Not cleaning the syringe will render it unusable Reassemble and store for next use Installation Instructions Section 3 Cargo Hook Operation Instructions Operating Procedures Prior to each flight involving external load operations perform the following 1 Activate the electrical system and press the Cargo Hook release button to ensure the cargo hook electrical release is operating correctly The Cargo Hook should release Reset the load beam The cargo hook release solenoid is intended to be energized only intermittently Depressing the electrical release button continuously in excess of 20 seconds will cause the release solenoid to overheat possibly causing permanent damage 2 Activate the manual release lever on the collective The mechanism should operate smoothly and the Cargo Hook should release Reset the load beam 3 Check the hydraulic release system for air by actuating the lever firmly until it bottoms out Check the push rod position see Figure 3 1 If some of the green ring on the push rod is visible the system is adequately bled If some of the green on the push rod is NOT visible with the lever completely pulled the system has too much air in it and must be bled Figu
19. gure 2 2 2 Route the electrical release harness up the left forward suspension cable and secure it in four places uniformly spaced to the suspension cable using the P N 512 024 00 adel clamps attached to the suspension cable adel clamps as shown in the figure 2 2 2 To protect the electrical harness when the cargo hook is in the stowed position cut and install a 2 to 3 foot length of the supplied Spiral Wrap P N 590 013 00 over it at location shown in Figure 2 2 2 Position of the wrap is to be checked at installation check out as described in section 2 3 NOTICE Allow sufficient slack in the hose and electrical release harness between the last tie off point at the cargo hook bumper and the lowest adel clamp to account for pivoting and movement of the cargo hook Installation Instructions 2 2 Cargo Hook Installation continued Figure 2 2 2 Hose and Harness Routing at Suspension Cables Suspension Cable iG J e TS el Clamp Sea ne P N 512 010 00 Inboard ENE or P N 512 024 00 Hydraulic Hose depending on hose size Electrical Release Harness Inboard Adel Clamp Section A A P N 512 024 00 At left forward suspension cable Suspension Cable Section A A At right forward suspension cable Add spiral wrap over electrical harness at this location Leave sufficent slack between cargo hook and lowest adel clamp to allow cargo hook to pivot in all directions without straining harness or hose
20. gure 3 3 Example of Recommended Cargo Hook Rigging SECONDARY RING 3 4 Operation Instructions Section 4 Maintenance Refer to the Instructions for Continued Airworthiness ICA manual 123 022 00 for maintenance of the cargo hook kit For detailed maintenance of the cargo hook refer to Cargo Hook Service Manual 122 015 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 NOTICE An RMA number is required for all equipment returns e To obtain an RMA please use one of the listed methods Contact Technical Support by phone or e mail Techhelp OnboardSystems com Generate an RMA number at our website http Awww onboardsystems com rma php e 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 e Include the RMA number and reason for the return on your purchase or work order e 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 4 1 This page intentionally left blank Section 5 ST
21. ied for shipping purposes only after removal discard reservoir seal Figure 2 6 2 Reservoir Disassembly Screw 2 Reservoir Lid Reservoir Seal Installation Instructions 2 13 2 6 Filling Hydraulic Release System continued 2 14 5 Remove the screw and stat o seal on the slave cylinder see Figure 2 6 3 Figure 2 6 3 Screw and Stat o seal Removal SLAVE CYLINDER Fill a syringe with approximately 35 cc of MIL H 5606 fluid Screw the end of the syringe into the screw hole on the slave cylinder to create a tight seal See Figure 2 6 4 While observing the reservoir slowly push on the syringe plunger to force fluid through the slave cylinder hydraulic hose and up to the master cylinder reservoir There will be some resistance during filling this is normal Injecting the fluid into the system too rapidly may cause the fluid to spray up and out of the master cylinder reservoir Wear safety glasses when observing fluid reservoir while filling Figure 2 6 4 Injecting Hydraulic Fluid Bleed Adapter Female X Barb Fitting PVC Tubing Installation Instructions 2 6 Filling Hydraulic Release System continued 8 Continue to force fluid into the master cylinder reservoir until the reservoir is approximately half full NOTICE If bleeding an already filled system you may need to draw fluid from the master cylinder reservoir during this step to prevent overflow 9 Remove the
22. ings Installation Instructions 2 1 Master Cylinder Assembly Installation continued Install the Master Cylinder w Fixed Plumbing P N 232 208 01 per the following Q Mount the Master Cylinder Assembly to the collective stick with the Clamp Half P N 290 912 00 and two screws P N 510 390 00 provided pre assembled on the assembly in the location illustrated below Figure 2 1 2 Release Lever Installation Master Cylinder Assembly Bracket Collective FERN RV i N I des epp D View Looking Down Between Forward Seats Remove the bellows at the base of the collective and route the hose down through the hole in the cabin floor through which the collective electrical wire harness is routed Take care during installation to avoid kinking the hose Q Secure hose with adel clamps P N s 512 010 00 and 512 021 00 as shown below using hardware provided Add sufficient loop as shown below between the adel clamps to account for full movement of collective Figure 2 1 3 Hydraulic Hose Routing Leave sufficient loop here to account for full movement of collective Adel Clamp P N 512 010 00 Exis ing collective wire harness led Adel Clamp P N 512 010 00 Adel Clamp P N 512 021 00 A x O conne Hydraulic Hose Section A A
23. llowing is the procedure 1 Obtain the hydraulic hook bleed kit 212 014 01 This kit consists of 2 ounces of MIL PRF 5606 fluid a syringe a female barb fitting a length of PVC tubing and a bleed adapter fitting The bleed kit is included in new Hydraulic Hook kits Assemble the bleed kit by press fitting each component together 2 If the system is already installed on the aircraft place an absorbent towel under the master cylinder If the master cylinder is not installed on the aircraft lightly clamp the master cylinder in a vise to hold it in a vertical position and position the slave cylinder so that its level is below the level of the master cylinder NOTICE Use best shop practices to keep foreign material out of the hydraulic system FOD will plug orifices damage seals and or scratch sealing surfaces necessitating system rebuild Use only clean hydraulic fluid from sealed containers Installation Instructions 2 6 Filling Hydraulic Release System continued 3 Connect the master cylinder assembly to the slave cylinder assembly if not already done If filling or bleeding on the bench as much as possible arrange the hoses uncoiled straight and running uphill See Figure 2 6 1 Figure 2 6 1 Hose Arrangements GOOD HOSE ARRANGEMENT POOR HOSE ARRANGEMENT 4 Remove screws reservoir lid reservoir seal and baffle from the master cylinder reservoir as shown in Figure 2 6 2 The reservoir seal is suppl
24. nitial installation This procedure may vary in different countries Make the appropriate aircraft log book entry Insert the Rotorcraft Flight Manual Supplement P N 121 029 00 into the Rotorcraft Flight Manual 2 11 2 6 Filling Hydraulic Release System 2 12 Each hydraulic system is typically shipped dry A label affixed to the Master Cylinder and Slave Cylinder assemblies will state if each hydraulic assembly has been filled and bled Proper bleeding is critical to the operation of the hydraulic release system An improperly bled system will not release the cargo hook mechanism A reservoir seal is installed beneath the reservoir lid This seal serves to prevent hydraulic fluid left over from the testing process from leaking during shipping The reservoir seal is for shipping purposes only and must be removed and discarded before bleeding or installation of the hydraulic release system If there is a need to fill and or bleed the system follow the procedures listed below If you need to remove and repair any items in the hydraulic system refer to 123 022 00 Instruction for Continued Airworthiness Filling and bleeding the hydraulic release system is most easily accomplished on the bench prior to installation on the aircraft This process may also be accomplished after the system is installed Filling and bleeding requires two persons one to inject hydraulic fluid through the system and the other to observe the reservoir Fo
25. re 3 1 Checking System for Air Verify green ring on push rod is still visible Operation Instructions 3 1 Cargo Hook Loading The cargo hook can easily be loaded with one hand A load is attached to the hook by pushing the ring upward against the upper portion of the load beam throat as illustrated in Figure 3 2 until an internal latch engages the load beam and latches it in the closed position Figure 3 2 Cargo Hook Loading 3 2 Operation Instructions Cargo Hook Rigging Extreme care must be exercised when rigging a load to the Cargo Hook Steel load rings are recommended to provide consistent release performance and resistance to fouling The following illustration shows the recommended rigging but is not intended to represent all rigging possibilities Some combinations of small primary rings and large secondary rings could cause fouling during release It is the responsibility of the operator to assure the cargo hook will function properly with each rigging 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 Operation Instructions 3 3 Cargo Hook Rigging continued Fi
26. rthiness and Cargo Zz Hook Component Maintenance Manual 120 120 00 Revision 4 dated 123 022 00 Revision 4 dated August 17 2011 January 25 2012 122 015 00 Revision 13 dated November 15 2011 120 122 00 Revision 6 dated 123 022 00 Revision 4 dated August 17 2011 January 25 2012 122 015 00 Revision 13 dated November 15 2011 120 120 00 Revision 4 dated 123 022 00 Revision 4 dated August 17 2011 January 25 2012 ___ 122 015 00 Revision 13 dated November 15 2011 120 122 00 Revision 6 dated 123 022 00 Revision 4 dated August 17 2011 January 25 2012 ___ 122 015 00 Revision 13 dated November 15 2011 Kit Part No 200 302 00 200 303 00 200 387 00 Limitations and Conditions continued This approval should not be extended to other rotorcraft of these models on which other previously approved modifications are incorporated unless it is determined by the installer that the relationship between this change and any of those other previously approved modifications including changes in type design will introduce no adverse effect upon the airworthiness of that rotorcraft Rotorcraft modified in accordance with this STC must be operated in accordance with a copy of an FAA approved Onboard Systems RFMS 121 029 00 Revision 3 dated March 1 2012 or later FAA approved revision A copy of this certificate FAA approved RFMS Owner s Manual ICA and component maintenance manuals m
27. syringe from the screw hole Re install the Stat O Seal P N 510 496 00 and screw P N 510 493 00 see Figure 2 6 5 Figure 2 6 5 Screw Re installation E Stat O Seal 10 Allow the system to rest for several minutes This will allow any air to rise through the system 11 Very slowly pull the release lever on the master cylinder and watch for bubbles If bubbles are observed rising within the reservoir continue to slowly cycle the lever until there are no more Actuating the lever releases air trapped within the master cylinder Pull the lever very slowly When the reservoir is not baffled and capped a hard pull will cause fluid to erupt over the edge of the reservoir Installation Instructions 2 15 2 6 Filling Hydraulic Release System continued 2 16 12 Check the system for air by actuating the lever firmly until it bottoms out Check the push rod position see Figure 2 6 6 If the green area on the push rod is visible proceed to step 13 If the green on the push rod is not visible with the lever completely pulled the system has too much air in it and needs further bleeding To do this repeat steps 5 11 Figure 2 6 6 Checking System for Air 13 14 15 16 Verify green ring on push rod is still visible After the system is properly bled verify that the reservoir is approximately half full of hydraulic fluid Fluid should be visible above the baffle Re install the baf
28. tain the hardware used to fasten the cargo hook mounting brackets to the suspension shackles and the hardware to fasten the adel clamps to the suspension cables Plug the hole in the floor through which the T handle was installed This hole will not be used 2 1 2 1 2 2 Master Cylinder Assembly Installation The hydraulic release system is supplied dry It is recommended that the system be filled and bled on the bench before installing on the helicopter Refer to section 2 6 for filling and bleeding instructions The Master Cylinder Assembly P N 232 208 01 installation consists of installing the master cylinder on the collective in the cockpit and routing the attached hose to a bracket to be installed near the right forward suspension cable Observe the following precautions ref Figure 2 1 1 when routing the hydraulic hose e Use care to avoid kinking the hose e Recommended minimum hose bend radii is 1 inch Avoid abrupt change in direction of the hose just outside the end fittings Provide smooth transitions where possible e Verify that the hose routing is clear of and cannot be deflected into chafe points Figure 2 1 1 General Hose Routing Practices Maximize bend radii Use adel clamp and bracket shown ty wraps or other suitable means to secure hose at various points Suspend clear of if possible or add anti chafe strip Provide as smooth a transition as possible at end fitt
29. ust be maintained as part of the permanent records of the modified rotorcraft If the holder agrees to permit another person to use this certificate to alter the product the holder shall give the other person written evidence of that permission END a Any alteration of this certificate is punishable by a fine of not exceeding 1 009 or imprisonment not exceeding 3 years or both This certificate may be transferred in accordance with FAR 21 47 FAA Fonu 8110 2 10 68 PAGE 3 OF 3 PAGES 5 2 Certification Transport Canada Approval Transport Transports Cana Cana Aviation Aviation Suite 620 Yowr file Votre r f rence 800 Burrard Street 100S GA 06 99 Vancouver B C P 06 0386 V6Z 238 RDIMS 2017614 September 14 2006 Mr Mark Hansen Onboard Systems 1315 NW 3 Court Vancouver WA 98685 U S A Dear Mr Hanson Subject Canadian Acceptance of FAA STC SR01694SE This is in response to the FAA SeattleACO letter dated August 24 2006 requesting Transport Canada approval of the subject STC In accordance with our current policy associated with the review of foreign STCs some STCs applicable to certain categories of aircraft may be accepted solely on the basis of their foreign certification and do not require the issue of a corresponding certificate by Transport Canada The subject STC falls within these criteria This STC will be entered in the national index of STCs that have been reviewed and accepted by Tr
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