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Owners Manual AW109-A119 Hook Kit 120-141-00

1. A Screw P N 510 391 00 BL 150 0 BL 0 0 Fwd Washer P N 510 419 00 1 89 in gt X3 48 mm I eee Yoo e i Electrical Module Assembly a P N 232 466 00 PN 6 38 in N 162 mm 5 N i OEN Bonding Jumper I laj f P N 410 293 00 fi me Se Des z a WL 125 0 a 0 Sas 4 So A STA 1815 0 eae E Looking Aft View Looking Inboard g Ait Installation Instructions 2 1 Fixed Provisions Kit Installation continued 2 1 4 Electrical Release Wiring Installation continued O O Cut to length if necessary and terminate the M364A20 wire from harness P N 270 180 00 from the circuit breaker panel at module 1 pin A Cut M362A16 wire to length if necessary crimp the supplied ring terminal P N 410 296 00 on and terminate it at relay K8501 connection point A1 Working with harness P N 270 179 00 and working below the helicopter feed the two wires M405A16 and M390A16N from the connector connector no J8505 up through the hole in the belly at STA 1555 0 If installing the Load Weigh System feed the LOAD CELL wire through the hole in the belly at STA 1555 0 and terminate the individual wires in connector J8505 per the schematic in Section 2 4 Mount the J8505 connector within
2. 510 672 00 Screw coy N A N 510 737 00 Washer N 510 909 00 Bolt pP 1 4 General Information Bill of Materials continued Table 1 3 Bill of Materials Fixed Provisions Kit P N 200 355 00 200 369 00 continued Part No Description Qty 200 355 00 200 369 00 Qty 510 911 00 Bolt N 2 510 915 00 Nut 510 918 00 Bolt n e 510 946 00 Screw 510 972 00 Rivet 510 986 00 Washer 511 092 00 Bolt AIAINININ A laln 512 003 00 Ty wrap P E 512 005 00 Adel Clamp 512 021 00 Adel Clamp 512 028 00 90 Deg Angle Bracket VO 512 034 00 Adel Clamp 120 141 00 Owner s Manual 121 055 00 RFMS 123 036 00 ICA The following items are included with the 200 356 00 Cargo Hook Suspension Kit Table 1 4 Bill of Materials Cargo Hook Suspension Kit P N 200 356 00 Part No Description Qty 210 244 00 Suspension Frame With Hook 1 215 256 00 External Load Limit 3086 Decal 215 258 00 External Load Limit 2205 Decal 120 141 00 Owner s Manual 122 015 00 Service Manual 123 036 00 ICA 121 055 00 RFMS mete General Information 1 5 Bill of Materials continued The following items
3. 00 supplied with the load weigh kit Re use the existing hardware Q Route the pin load cell harness forward and connect its connector to the mating connector on the aft bracket Installation Instructions 2 25 2 3 Load Weigh Kit Installation Kit P N 200 357 00 continued 2 3 2 C 39 Indicator Installation The C 39 Indicator as part of the load weigh system provides the reading of the load being carried on the cargo hook Brackets are provided with the kit to mount the C 39 Indicator to the right side forward door post using existing holes or it may also be mounted within the instrument panel using a standard 2 4 hole To install the indicator on the right side forward door post perform the following o Remove the existing access panel on the door post by removing six screws Fi ure 2 3 4 Access Panel o Install the provided C 39 Mounting Plate Assembly P N 232 452 00 in place of the removed access panel This Mounting Plate Assembly incorporates nut plates for mounting the C 39 Bracket Assembly P N 232 45 1 00 2 26 Installation Instructions 2 3 Load Weigh Kit Installation Kit P N 200 357 00 continued 2 3 2 C 39 Indicator Installation continued o Attach the C 39 Bracket Assembly to the Mounting Plate Assembly using two screws P N 510 640 00 Adjust the Support Bracket within the range permitted by the slotted hole to the desired angle and secure in this position by tightening the screws Figure 2 3 5 C 3
4. 215 255 00 sheet of placards in the cockpit in a location visible to the pilot Installation Instructions 2 1 Fixed Provisions Kit Installation continued 2 1 7 Landing Gear Lock Installation NOTICE The Landing Gear Lock installation is applicable to kit P N 200 355 00 for the AI0O9E only If installing kit P N 200 369 00 skip this section The Landing Gear Lock P N 235 177 00 prevents the landing gear from being retracted when the cargo hook suspension is installed o Remove the two screws and washers at locations shown below from the access panel to the left of the landing gear lever o Position the Landing Gear Lock over the two holes and to capture the Landing Gear Lever to prevent actuation and secure with hardware as shown in Figure 2 1 18 Figure 2 1 18 Landing Gear Lock Installation Forward Instrument Panel Landing Gear Lever Landing Gear Lock P N 235 177 00 Screw P N 510 946 00 Washer P N 510 657 00 View Looking Inboard from Left Side Installation Instructions 2 21 2 2 Cargo Hook Suspension Kit Installation This section covers the installation of the cargo hook suspension kit P N 200 356 00 which includes the cargo hook suspension assembly P N 210 244 00 Install the cargo hook suspension assembly per the following o If load weigh kit P N 200 357 00 is being installed modify the cargo hook suspension assembly per Section 2 3 o Install the cargo hook suspe
5. 4 3 Figure 2 4 3 Reservoir Disassembl RESERVOIR Ss BAFFLE Installation Instructions 2 4 Hydraulic System Bleed Procedure continued 5 Remove the screw and stat o seal on the slave cylinder see Figure 2 4 4 6 Fill the syringe with approximately 35 cc of MIL PRF 5606 fluid and purge any remaining air in the syringe and tubing Screw the end of the bleed adapter into the screw hole on the slave cylinder to create a tight seal See figure 2 4 5 7 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 Installation Instructions 2 33 2 4 Hydraulic System Bleed Procedure continued Figure 2 4 5 Injecting Hydraulic Fluid Bleed Adapter Female X Barb Fitting PVC Tubing 8 Continue to force fluid into the master cylinder reservoir until the reservoir is approximately half full 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 bleed adapter from the screw hole Re install the Thread Seal P N 510 740 00 washers P N 510 209 0
6. Level Select the desired dampening level by pressing the Left button Calibration Code matches the Indicator to the Display is previously entered CAL Code CODE Load Cell 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 Installation ZERO matches the Indicator to Display is a combination of load on the Oin the installed Load Cell and to the helicopter Load Cell and normal load cell zero After this procedure the display will be zero offset Remove all weight from the hen no load is on the Carco Hook installed Load Cell except the Cargo h 8 Hook and press any button to complete the procedure and return to the Run Mode Load is used to calibrate the system by lifting No previous display is shown Enter the LOAD a known load 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 ie 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 Scale matches the analog output of the Display is previously entered number To Scale Indicator to an optional remote analog meter Change the number use the Right bu
7. are included with the P N 200 357 00 Load Weigh Kit Table 1 5 Bill of Materials Load Weigh Kit P N 200 357 00 Part No Description Qty 210 095 02 C 39 Indicator Assembly 1 210 301 02 Pin Load Cell Assembly 1 232 451 00 Bracket Assembly 1 232 452 00 Mounting Plate Assembly 1 235 198 00 Outer Cover 1 270 177 00 Load Weigh Internal Harness 1 270 182 00 Jumper Assembly 1 410 199 00 Shield Termination 1 410 312 00 Contact 20 ga 3 510 178 00 Cotter Pin 1 510 493 00 Screw 4 510 637 00 Screw 4 510 639 00 Instrument Mounting Nut 4 510 640 00 Screw 5 510 657 00 Washer 4 512 003 00 Ty wrap 10 512 006 000 Adel Clamp 2 Supersedes 210 226 02 these P Ns are interchangeable 1 6 General Information Bill of Materials continued To complete the cargo hook installation the following parts may be necessary to obtain these parts are frequently found to be on the aircraft from the factory or are standard Agusta parts from Agusta or Onboard Systems Refer to Table 1 5 for structural parts that can be obtained from Agusta or Onboard Systems if they are not present These kits do not include a Rearview Mirror Assembly It is recommended to obtain this assembly from Agusta P N 109 0710 91 3 to complete the installation NOTICE These items may or may not be installed with a standard aircraft therefore verification is recommended befor
8. in all directions Cargo Hook Stowage 4 2 The cargo hook suspension frame features a spring loaded stowage bracket which allows the cargo hook to be rotated upwards and stowed at 90 degrees from its operating position when it is not in use The stowed position increases the ground clearance of the cargo hook reducing chances of it being accidentally damaged Figure 4 2 Cargo Hook Stowage Bracket Cargo Hook e N T 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 3 until an internal latch engages the load beam and latches it in the closed position Figure 4 3 Cargo Hook Loading SOS LS eneee en AaS SISE TISO RR ey Operation Instructions s lt is ssSsSSSSSSSSS gg Cargo Hook Rigging 4 4 Extreme care must be exercised when rigging a load to the Cargo Hook Steel load rings are recommended to provide consistent release performance and resistance to fouling The following illustration shows the recommended rigging and rigging to avoid but is not intended to represent all rigging possibilities It is the responsibility of the operator to ensure the cargo hook will function properly with each rigging Nylon Type Straps and Rope Nylon type s
9. 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 amp ero amp Un Zero Legend Dampening Y Hook Logd Unit Legend CAL DAMP Left Button Load Weigh System Operation Instructions 3 1 The Run Mode 3 2 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 lik
10. 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 Chan ing the Scale Hook Load x 10 CAL Load Weigh System Operation Instructions 3 11 The Setup Mode continued 3 12 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 R
11. the connector bracket P N 232 463 00 installed per Section 2 1 2 with four screws P N 510 481 00 washers P N 510 062 00 and nuts P N 510 029 00 Figure 2 1 13 Wire Routing Q O Installation Instructions Route wires existing harnesses Dee hanes ee a r TOEP aana w Route wire M405A16 from the J8505 connector of harness P N 270 179 00 to relay K8503 cut to length if necessary crimp on ring terminal P N 410 296 00 and terminate to connection point A2 of the relay Route wire M390A18N to the grounding module TB8552 of the Electrical Assembly crimp on contact P N 410 312 00 and terminate at pin C 2 15 2 1 Fixed Provisions Kit Installation continued 2 1 4 Electrical Release Wiring Installation continued O 2 16 Route individual wires from the electrical module assembly to the pilot s cyclic disconnect P7940 per the following o Wire M367A20 from module 1 pin B to pin 51 o Wire M366A20 from module 2 pin F to pin 52 o Wire M368A22 from module 2 pin B to pin 46 o Wire M376A22 from module 2 pin G to pin 43 Route individual wires from the electrical module assembly to the co pilot s cyclic if installed disconnect P7934 per the following o Wire M375A22 from module 1 pin C to pin DD o Wire M377A22 from module 2 pin L to pin EE o Wire M374A22 from module 2 pin C to pin Y o Wire M376A22 from module 2 pin K to pin V For the Hook Armed illumination l
12. 0 and screw P N 510 694 00 see Figure 2 4 6 Figure 2 4 6 Screw Re installation a Stat O Seal 10 Allow the system to rest for several minutes This will allow any air to rise through the system 2 34 Installation Instructions 2 4 Hydraulic System Bleed Procedure continued Installation Instructions 11 12 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 Check the system for air by actuating the lever firmly until it bottoms out Check the push rod position see Figure 2 7 7 If some of the green area on the push rod is visible proceed to step 13 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 needs further bleeding To do this repeat steps 5 11 Figure 2 4 7 Checking System for Air 13 14 15 16 Some of the green ring must be 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 baffle and the reservoir lid Check
13. 9 Support Bracket Installation Bracket Assembly P N 232 451 00 Screw P N 510 640 00 o Install the four instrument mounting nuts P N 510 639 00 into the four mounting holes in the C 39 Indicator o Install the C 39 Indicator P N 210 095 02 or P N 210 095 05 onto the bracket with four screws P N 510 637 00 as illustrated below Figure 2 3 6 C 39 Indicator Installation Screw x4 en 510 637 00 Ze C 39 Indicator Installation Instructions 2 27 2 3 Load Weigh Kit Installation Kit P N 200 357 00 continued 2 3 2 C 39 Indicator Installation continued o Install Outer Cover P N 235 198 00 over the bracket with three screws P N 510 640 00 as illustrated below Figure 2 3 7 Outer Cover Installation Screw x3 K P N 510 640 00 Outer Cover P N 235 198 00 2 28 Installation Instructions 2 3 Load Weigh Kit Installation Kit P N 200 357 00 continued 2 3 3 Load Weigh Internal Harness Installation The electrical schematic for the load weigh system is shown in Figure 2 3 7 The primary leg of the load weigh harness labeled LOAD CELL is routed from the C 39 indicator to the bracket at the belly of the helicopter Route with existing harnesses and cut to length if necessary Strip back outer jacket of the four conductor wire and prep the end and install shield termination P N 410 199 00 per Figure 2 3 8 Crimp on supplied pins P N 410 314 00 and insert pins into
14. Kit P N 200 357 00 continued 2 3 1 Pin Load Cell Installation continued Q Install nut P N 510 170 00 washer P N 510 174 00 and washer P N 510 183 00 onto the end of the pin load cell Tighten nut to until fully seated finger tight only Back off to previous castellation if needed to and insert cotter pin P N 510 178 00 Install and secure cotter pin Do not tighten nut on pin load cell more than finger tight Over tightening will damage load cell Figure 2 3 2 Pin Load Cell Tightening 2 24 Installation Instructions 2 3 Load Weigh Kit Installation Kit P N 200 357 00 continued 2 3 1 Pin Load Cell Installation continued Q Route the pin load cell harness from the load cell to the hydraulic hose at the cargo hook as shown below Figure 2 3 3 Pin Load Cell Harness Routing P N 210 226 02 shown Q Remove the spiral wrap over the electrical release harness and the hydraulic hose and remove the cushioned loop clamp at the top of the aft cross tube Q Replace this cushioned loop clamp with the larger cushioned loop clamp P N 512 006 00 and install it over the bundle which now includes the pin load cell harness Before tightening the screw at this cushioned loop clamp rotate the cargo hook throughout its full range of motion and verify there is adequate slack in the hose and harnesses Q At the LH side frame remove the cushioned loop clamp and replace with the larger cushioned clamp P N 512 006
15. O C f unusual information not directly related to safety Used to address practices not related to personal injury 1 2 General Information Specifications General Information Table 1 1 Kit Specifications Suspension design load 3 086 lbs 1 400 kgs Suspension design ultimate 11 574 Ibs 5 250 kgs strength Fixed Provisions Kit weight 8 5 lbs 3 9 kgs P N s 200 355 00 and 200 369 00 Cargo Hook Suspension Kit weight kit P N 200 356 00 Load Weigh Kit weight 2 1 Ibs 95 kgs Table 1 2 Specifications P N 528 028 00 Cargo Hook Design load Design ultimate strength Electrical release capacity 8 750 lbs 3 969 kg Mechanical release capacity 8 750 lbs 3 969 kg Force required for mechanical release at 3 500 lb Electrical requirements Minimum release load Unit weight 3 0 pounds 1 35 kg Mating electrical connector PCOSA8 2S Load capacities given are for the equipment described only Loading limits for your particular helicopter model still apply Consult your flight manual 1 3 Bill of Materials The following items are included with the 200 355 00 and 200 369 00 Fixed Provisions Kits Table 1 3 Bill of Materials Fixed Provisions Kits P N 200 355 00 200 369 00 Part No Description Qty 200 355 00 Qty 200 369 00 215 255 00 A109 A119 Information Decals 1 1 220 043 00 Fwd Connector Bracket Fairing 232 453 00 Fwd Hard Point As
16. Type Cortificate Number H7EU Make Agusta S p A Model A109E A119 AW119 MK II Deseription of the Tyre Design Change Fabrication of Onboard Systems Model 200 355 00 and 200 369 00 Cargo Hook Fixed Provision Kits Model 200 356 00 Cargo Hook Suspension Kit and Model 200 357 00 Load Weigh Kit in accordance with FAA Approved Onboard Systems Master Drawing List No 155 160 00 Revision 1 dated April 26 2011 or later FAA approved revision Installation of the Onboard Systems Model 200 355 00 200 356 00 200 357 00 or 200 369 00 kits in accordance with FAA approved Onboard Systems Owners Manual 120 141 00 Revision 0 dated April 25 2011 or later FAA approved revision This modification must be inspected and maintained in accordance with section ATA 5 of FAA approved Onboard Systems Instructions for Continued Airworthiness Document 123 036 00 Revision 0 dated May 5 2011 or later FAA approved revision and Onboard Systems Cargo Hook Service Manual 122 017 00 Revision 13 dated March 29 2011 or later FAA approved revision Limitations and Conditions Approval of this change in type design applies to only those model rotorcraft listed above 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 d
17. argo hook suspension frame visible to the ground operator and near the cargo hook 2 3 Load Weigh Kit Installation Kit P N 200 357 00 The load weigh kit P N 200 357 00 is an optional kit that may be installed with the cargo hook suspension kit NOTICE If not installing the load weigh kit skip this section and proceed to Installation Checkout There are three primary components to install the pin load cell the internal electrical harness and the load weigh indicator Refer to the following sections for installation instructions for each 2 3 1 Pin Load Cell Installation The pin load cell replaces the cargo hook attach bolt P N 290 332 00 in the suspension assembly It is installed per the following Q Remove the nut P N 510 170 00 washer P N 510 174 00 and washer P N 510 183 00 from the end of the attach bolt Q Remove the attach bolt P N 290 332 00 and washer P N 510 183 00 from the cargo hook separating the cargo hook from the suspension beam The bolt and washer are not used with the load weigh installation Q Install the pin load cell through the cargo hook and suspension beam Install so that the head harness end of the load cell is to the right Figure 2 3 1 Pin Load Cell Installation Pin Load Cell Assembly P N 210 226 02 shown or P N 210 301 02 Washer P N 510 183 00 Washer P N 510 174 00 Installation Instructions 2 23 2 3 Load Weigh Kit Installation
18. ated hydraulic hose to a junction fitting on the belly of the helicopter and miscellaneous brackets and hardware for supporting these items Kit P N 200 356 00 is a cargo hook suspension kit which includes the cargo hook a suspension frame assembly which supports the cargo hook and spans the hard points on the belly of the helicopter It also includes the hydraulic hose and electrical release harness which connect the cargo hook to the fixed connectors on the belly of the helicopter Kit P N 200 357 00 is a load weigh kit which includes a pin load cell internal electrical harness and cockpit mounted load weigh indicator It requires that the helicopter be equipped with the P N 200 356 00 Cargo Hook Suspension Kit These kits do not include a Rearview Mirror Assembly It is recommended to obtain this assembly from Agusta P N 109 0710 91 3 to complete the installation 1 1 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 F FR 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
19. b site at www onboardsystems com 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 General Information Introduction 1 1 Explanation of Signal Words and Symbols 1 2 Specifications 1 3 Inspection 1 3 Bill of Materials 1 4 Theory of Operation 1 7 Installation Instructions 2 1 Fixed Provisions Kit Installation 2 1 2 2 Cargo Hook Suspension Kit Installation 2 22 2 3 Load Weigh Kit Installation 2 23 2 4 Hydraulic System Bleed Procedure 2 31 2 4 Installation Check Out 2 36 2 5 Component Weights 2 37 2 6 Paper Work 2 37 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 cali
20. bly w Plumbing 1 5 270 181 00 Electrical Release Harness 1 6 290 332 00 Attach Bolt 1 7 291 500 00 Aft Pin 2 8 291 504 00 Center Bar Tube 2 9 291 555 00 Stowage Clip 1 10 291 556 00 Stowage Clip Rod 1 11 291 558 00 Quick Release Pin Modified 2 12 291 612 00 Modified Bushing 2 13 450 001 00 Heat Shrink AR 14 510 095 00 Washer 12 15 510 102 00 Nut 7 16 510 170 00 Nut 1 17 510 174 00 Washer 1 18 510 178 00 Cotter Pin 1 19 510 183 00 Washer 2 20 510 452 00 Bolt 1 21 510 455 00 Bolt 1 22 510 53 1 00 Screw 2 23 510 565 00 Safety Pin 2 24 510 712 00 Bolt 2 25 510 836 00 Bolt 2 26 510 934 00 Bolt 1 27 510 935 00 Eyebolt 1 28 510 949 00 Bolt 4 29 512 011 00 Ty wrap 1 30 512 027 00 Adel Clamp 2 31 512 028 00 Angle Bracket 1 32 528 028 00 Cargo Hook 1 33 531 010 00 Lanyard Cable 2 34 531 016 00 Crimp Sleeve 4 35 590 013 00 Spiral Wrap AR 6 2 System Part Numbers System Part Numbers continued 232 433 00 Trunnion Assembly ITEM P N DESCRIPTION QTY 1 290 364 00 Bushing 1 2 291 501 00 Trunnion 1 3 291 575 00 Trunnion Pin Radius Filler 2 System Part Numbers 6 3 System Part Numbers continued 6 4 232 465 00 Release Lever Assembly w Plumbing ITEM P N DESCRIPTION QTY 1 232 467 00 Master Cylinder Assembly 1 2 232 473 00 Hose Extension Assembly 1 3 558 021 00 Banjo Bolt 1 4 556 040 00 Crush Washer 2 Syst
21. bration 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 CON T EN T S continued Section 4 Section 5 Section 6 Section 7 Operation Instructions Operating Procedures 4 1 Cargo Hook Stowage 4 2 Cargo Hook Loading 4 3 Cargo Hook Rigging 4 4 Accessory Connector Bracket Provisions 4 6 Maintenance Instructions for Returning a System to the Factory 5 1 System Part Numbers 210 244 00 Cargo Hook Frame Assembly 6 1 232 433 00 Trunnion Assembly 6 3 232 465 00 Release Lever Assembly w Plumbing 6 4 232 467 00 Master Cylinder Assembly 6 5 Certification FAA STC 7 1 Transport Canada Approval 7 2 Section 1 General Information Introduction General Information This Owner s Manual contains installation and operation instructions for cargo hook kit P N s 200 355 00 200 356 00 200 357 00 and 200 369 00 on the Agusta A109E A119 and AW119 MKII Kit P N 200 355 00 for the A109E and P N 200 369 00 for the A119 and AW119 MKII are fixed provisions kits which include the hard points to support the cargo hook suspension assembly internal electrical release wire harness manual release lever on the cyclic and associ
22. ctrical Release Wiring Installation continued oO Before installing the Electrical Module Assembly P N 232 466 00 an additional jumper and or diode supplied with the assembly must be added to it for the Hook Armed illumination light depending on the model helicopter into which it is being installed Refer also to electrical schematics Figure 2 1 14 and Figure 2 1 15 o For the A109E model and A119 and AW119 MkII models without IDS Install supplied wire M393A22 into module 2 pin a and connect diode P N 340 037 00 from module 2 pin M to module 2 pin d insulating the leads with the supplied heat shrink P N 450 001 00 or similar Refer to electrical schematic o For the A119 and AW119 MkII models with IDS Install supplied wire M408A22 into module 2 pin M Do not install diode Install the Electrical Module Assembly in the bay underneath the pilot s seat with three screws P N 510 391 00 and washers P N 510 419 00 Attach one end of the bonding jumper P N 410 293 00 at one of the three mounting points depending on availability of a ground point NOTICE If the inserts are not installed within the panel layout and install 3 inserts P N SL10429 3 4S per Agusta standard practices o Ground other end of Bonding Jumper at an existing ground point using existing hardware or pick up another airframe ground point Figure 2 1 12 Electrical Module Assembly Installation
23. d 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 fo
24. d the a c structural beam flange o Apply Hysol EA934NA adhesive to the shims and Doublers align their hole patterns and secure to the aircraft structural beam with rivet P N 510 913 00 at the forward row of four holes and rivet P N 510 912 00 at the aft row of four holes Figure 2 1 2 Aft Hardpoint Doubler Installation STA 4010 0 a c structural beam Peel Shims P N 291 362 00 A A Drill 129 132 i Aft 8 places total mM Aft Hardpoint Doubler P N 235 180 00 Drill 189 191 3 places through a c beam flange 38 mm 1 50 in Row of holes transferred from removed rivet pattern View A A o Attach each Aft Hard Point note orientation in View A A of Figure 2 1 3 with hardware as shown in Figure 2 1 3 Figure 2 1 3 Aft Hard Point Installation STA 4010 0 L A nw Jp D o Oe em Forward BL Ae BL View A A Aft Hard Point P N 291 361 00 505 0 View Looking Forward Bolt P N 510 911 00 Washer P N 510 419 00 Nut P N 510 112 00 Cotter Pin P N 510 1 15 00 Bolt P N 510 909 00 Washer P N 510 042 00 Washer P N 510 986 00 Barrel Nut P N 232 474 00 Installation Instructions 2 3 2 1 Fixed Provisions Kit Installation continued 2 1 1 Hard Point Installation continued The two forward hard points P N 232 453 00 and their Support Brackets P N 291 363 00 are installed at STA 3067 0 and LBL a
25. e 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 Hook Load x 10 CAL al SETUP UN ZERD 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 NOTICE 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 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 Loa
26. e purchasing them Refer to Section 2 1 for identification of Doublers Table 1 6 Additional Structural Parts Required Agusta P N Equivalent Description Qty Onboard Systems P N 109 0854 51 133 235 174 00 Bulkhead Fitting Doubler 2 109 0882 23 109 235 175 00 Fwd Hard Point Doubler 2 109 0882 23 107 235 176 00 Fwd Hard Point Internal Doubler 2 109 0882 23 115 235 180 00 Aft Hard Point Doubler 2 109 0882 23 113 291 362 00 Aft Hard Point Shim 1 N A 510 912 00 Rivet 8 N A 510 913 00 Rivet 8 Table 1 7 Additional Electrical Parts Required Agusta P N Description Qty 83 453 015 Pushbutton Electrical Switch cyclic 1 999 8001 74 211 Bus Bar 1 General Information 1 7 Theory of Operation 1 8 The cargo hook system is comprised of e The cargo hook and suspension assembly The suspension assembly spans the aircraft hard points and supports the cargo hook e The electrical release system The electrical release system provides means for release by pilot actuation of the push button switch on the cyclic When the push button switch is pressed it energizes the solenoid in the cargo hook and the solenoid opens the latch in the internal mechanism which allows the load to fall free e The manual release system The manual release system provides a means of releasing a cargo hook load in the event of an electrical release system failure The manual release sys
27. e this Fi ure 3 2 After Diag nostic Routine Hook Load xX 10 CAL I SETUP UN ZERO Zi 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 Hook Load x 10 SETUP UN ZERO ZERO 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 Hook Load Zero Legend x 10 Un Zero Legend UN ZEI 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 Un zero legend is turned on If the Left button is again pressed before the zero button is pressed t
28. em Part Numbers System Part Numbers continued 232 467 00 Master Cylinder Assembly ay we S A DWR mc VAN ra z 9 LP 4 a Q System Part Numbers 6 5 System Part Numbers continued 6 6 232 467 00 Master Cylinder Assembly ITEM P N DESCRIPTION QTY 1 235 124 00 Baffle 1 2 290 812 00 Barrel Nut 1 3 290 813 00 Push Rod 1 4 290 814 01 Piston 1 5 290 906 00 Lever 1 6 290 908 00 Shaft 1 7 290 922 00 Reservoir Lid 1 8 291 143 00 Friction Strip 1 9 291 281 00 Master Cylinder 1 10 291 282 00 Clamp Half 1 11 510 082 00 Nut 1 12 510 095 00 Washer 2 13 510 125 00 Cotter Pin 1 14 510 248 00 Helicoil 2 15 510 390 00 Screw 2 16 510 424 00 Screw 2 17 510 450 00 Bolt 1 18 510 530 00 Set Screw 1 19 510 532 00 Washer 1 20 514 055 00 Spring 1 21 514 060 00 Spring 1 22 515 008 00 Snap Ring 1 23 556 044 00 O ring 1 24 556 047 00 O ring 1 25 556 048 00 Cup Seal 1 System Part Numbers Section 7 Certification FAA STC Hnit States of Americi Pepartment of Transportation Federal Aviation Administration Supplemental Type Certificate Number SR02139SE This certificate issued to Onboard Systems 13915 NW 3 Court Vancouver WA 98685 herefor as specified hereon meets the airworthiness reguirements of Part 27 of the Federal Aviation Original Product
29. esign 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 FAA approved Onboard Systems Rotorcraft Flight Manual Supplement RFMS No 121 055 00 Revision 0 dated July 8 2011 or later FAA approved revision A copy of this Certificate the FAA approved RFMS and maintenance manuals must be maintained as a part of the permanent records of the modified rotorcraft surrendered suspended revoked or a termination dale is otherwise established by the Administrator of the Federal Aviation Administration Date of application September 17 2009 Date reissued Date of issuance September 13 2011 Date amended By direction of the Adminis Signature Acting Manager Seattle Aircraft Certification Office Title Any alteration of this certificate is punishable by a fine of not exceeding 1 000 or imprisonment not exceeding 3 years or both This certificate may be transferred in accordance with FAR 21 47 FAA For 8110 2 10 68 Certification 7 1 Transport Canada Approval Transport Transports Bei en Hae Civil Aviation Aviation Civie Suite 620 Your fe Votre nificance 800 Burrard Street Pa Ore Vancouver B C RDMIS 7446360 v1 V6Z 2J8 NAPA P 12 0040 April 3 2012 Onboard Systems 13915 NW 3 Court Vancouver WA 98685 USA Attention Mr Mark Hanson Subject Acceptance of Fore
30. g its four holes with those in the belly panel Figure 2 1 6 Forward Hard Point Installation Overview External Components Bolt P N 510 290 00 Washer P N 510 737 00 Fwd Hardpoint Doubler F N 235 179 00 Radius Filler Peeling Shim P N 291 849 00 P N 291 367 00 To Forward O Fwd Hardpoint P N 232 453 00 Ny Ny Ny L Bolt P N 511 092 00 Washer P N 510 737 00 x2 Nut P N 510 915 00 gt Cotter Pin P N 510 115 00 V v V Peel Shims P N 291 367 00 are provided for the forward hard points To determine the amount of shimming if any perform the following O Temporarily install each Fwd Hard Point Assembly to the aircraft using two bolts P N 511 092 00 four radius fillers P N 291 849 00 four washers P N 510 737 00 and two nuts P N 510 915 00 at the aft pair of holes and two bolts P N 510 290 00 and washers P N 510 737 00 at the forward pair of holes Install the Cargo Hook Frame Assembly by inserting the aft pins through the aft hard points and rotating the front up Check for alignment by attempting to pin the forward attach points through the forward hard points If the pins cannot be inserted shim forward hard points as necessary using the peeling shims Upon completion of shimming if necessary re install the Fwd Hard Point Assembly hardware as needed Depending on amount of shimming additional washers may be necessary under the nuts to al
31. g 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 e Contact Technical Support by phone or e mail Techhelp OnboardSystems com e Generate an RMA number at our website http www onboardsystems com rma php e After you have obtained the RMA number please be sure to e Package the component carefully to ensure safe transit e 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 e 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 210 244 00 Cargo Hook Suspension Assembly System Part Numbers 6 1 System Part Numbers continued 210 244 00 Cargo Hook Suspension Assembly ITEM P N DESCRIPTION QTY 1 215 150 00 Serial Number Decal 1 2 232 433 00 Trunnion Assembly 1 3 232 434 00 A109 A119 Sled Assembly 1 4 232 482 00 Slave Cylinder Assem
32. he 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 3 4 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 POSSIBLE DISPLAY CAUSE CORRECTIVE ACTION A D or D A circuit failure NV Ram failure NV Ram write failure NV Ram busy 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 Power cycle the Indicator if Error Code continues return the Indicator to the factory Re enter data if Error Code continues return the Indicator to the factory Power cycle the Indicator if Error Code continues return the Indicator to the factory 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 T
33. his is done by entering data into the Indicator Entered data includes the load cell Calibration Code the units that the Indicator should read out pounds or kilograms and several other items The Indicator has a group of Setup routines arranged in menu form that are used to configure the Indicator Shown on the next page is a matrix of the Setup routines and a brief discussion of their function and how they are programmed A complete discussion of each setup item is presented later in this section To enter the Setup Mode press both the Right and Left buttons at the same time while the Indicator is powered up and in the Run Mode To exit the Setup Mode and return to the Run Mode press both the buttons at the same time If you are in a Setup routine and have started to change an entry but you change your mind before completing the procedure power cycle the Indicator to exit the Setup Mode and then go to the Run Mode without changing the item The Indicator is power cycled by turning the Indicator power off for a few moments Load Weigh System Operation Instructions 3 5 The Setup Mode continued Table 3 2 Indicator Setup Routines MENU FUNCTION DISPLAY Press the Right button to view or change the To return to the Run Mode press both the scroll through the menu menu item Right and Left buttons at the same time Dampening Level sets the pilots preference Blinking display is previously entered DAMP for display dampening Dampening
34. ight On the A109E model route wire M393A22 to the helicopter s J8615 connector On the A119 and AW 9 MkII models without an integrated display system IDS route wire M393A22 to the helicopter s P7605J1 connector On the A119 and AW 19 MkII models with an integrated display system IDS route wire M408A22 to the helicopter s TB7603 1 connector NOTICE Refer also to the Agusta cargo hook wiring diagrams for additional details on the shipside wiring Install the J8502 J8501 J8505 and J8506 decals from the P N 215 255 00 decal sheet near the respective connections see wiring schematic Installation Instructions 2 1 Fixed Provisions Kit Installation continued 2 1 4 Electrical Release Wiring Installation continued Figure 2 1 14 Internal Electrical Release Schematic A109E and A119 AW119 MKII without IDS Primary Cargo Hook CB8505 Pilot s Cyclic Disc Co pilot s Cyclic Disc cCDDEE ZAABB YX WY M375A22 M406A22 M365A22N M390A18N M393A22 or M406A22 M365A22N M390A16N TB8552 P7605J1 k CAWS y H 1 HOOK ARMED J gt M393A22 x d 1 CAUTION PANEL Installation Instructions 2 17 2 1 Fixed Provisions Kit Installation continued 2 1 4 Electrical Release Wiring Installation continued Figure 2 1 15 Internal Electrical Release Schematic A119 AW119 MKII with IDS Primary Cargo Hook F M362A16 bus bar Co pilot s Pilot s Cyclic D
35. ign STC SR02139SE Dear Sir This is in response to FAA letter dated November 1 2011 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 Transport Canada for installation on Canadian registered aeronautical products This letter confirms formal acceptance of the referenced STC by Transport Canada Should you require additional information with regards to this matter or clarification please do not hesitate to contact the undersigned at 604 666 5597 Yours truly VA Henry W Wong Senior Engineer Aircraft Certification for Minister of Transport c c Mr Ross Landes Acting Manager FAA Seattle ACO Canada i 7 2 Certification
36. ign cotter pin holes Tighten aft pair of bolts at each hard point to 50 70 in lbs 5 6 7 9 Nm and secure the nuts with cotter pins P N 510 115 00 Tighten forward pair of bolts to 25 35 in lbs 2 8 3 9 Nm Installation Instructions 2 1 Fixed Provisions Kit Installation continued 2 1 2 Support Brackets Installation Installation Instructions The support brackets installation includes the installation of an aft connector bracket near the forward hard point location and a forward connector bracket and fairing underneath the center console The aft connector bracket P N 232 475 00 is installed to the left and just aft of the left forward hard point at STA 3140 using existing inserts in the lower belly panel Figure 2 1 7 Aft Connector Bracket Installation STA 3140 0 A BL 205 0 Tir an Bolt P N 510 918 00 Washer P N 510 419 00 Aft Connector Bracket Assembly P N 232 475 00 View A A Looking Aft 2 7 2 1 Fixed Provisions Kit Installation continued 2 1 2 Support Brackets Installation continued The forward connector bracket P N 232 463 00 is installed on the belly of the helicopter below the center console between the pilot and co pilot seats Position the bracket as shown and secure with three screws and washers as shown NOTICE Inserts in the belly are normally installed at this loca
37. ims P N 291 362 00 from Onboard Systems and install them per the following instructions 2 1 2 1 Fixed Provisions Kit Installation continued 2 1 1 Hard Point Installation continued o Layout the Doubler P N 235 180 00 locations and remove the four 4 rivets from the row of existing rivets in the lower panel that interfere with these locations Figure 2 1 1 Aft Hardpoint Doubler Location BL 205 0 Doubler STA4010 0 ere Pee ree View Looking Up from underneath helicopter o Transfer the hole pattern of the four 4 removed rivets to the Doubler and drill four holes 129 132 in 3 28 3 35mm in diameter at these locations o Drill a row of four holes 129 132 in 3 28 3 35mm in diameter 1 50 in 38 mm forward of the row drilled in the previous step refer to Figure 2 1 2 maintaining proper spacing minimum of 4D between rivets and 2D edge margin o Drill 189 191 4 80 4 85 mm through the aft flange of the aircraft structural beam to match the aft three holes in the Doubler and four 129 132 in 3 25 3 35 mm holes in the belly panel to match the forward four holes in the Doubler o Clean the areas of the lower panel which will mate with the doublers 2 2 Installation Instructions Fixed Provisions Kit Installation continued 2 1 1 Hard Point Installation continued o Install peel shims P N 291 362 00 as necessary to fill the gap between the Doublers an
38. inkage Ensure hose is clear of any potential chafing points Wrap hose with spiral wrap to protect from rubbing on wiring Figure 2 1 10 Securing Hydraulic Hose Remove screw and install L Bracket P N 512 028 00 gt anise o Route the hose towards the center of the aircraft and into the bay underneath the center console 2 10 Installation Instructions 2 1 Fixed Provisions Kit Installation continued 2 1 3 Fixed Hydraulic Release System Installation continued o Temporarily install the adel clamp P N 512 005 00 over the hose and loosely secure to the Angle Bracket P N 291 617 00 with bolt P N 510 453 00 washer P N 510 419 00 and nut P N P N 510 102 00 Position the Angle Bracket in a best fit location on the aircraft structure between the two bays see Figure 2 1 9 such that the hose will route through the hose in the belly and clear at least 1 25 mm around the foot pedal control tube when moved throughout its range of motion o Before installing the Angle Bracket route the hose to the hole in the belly to mate up with the forward connector bracket P N 232 463 00 installed previously and ensure it reaches the designated mounting hole Ensure that the hose is secured clear of flight control linkage and any potential chafing points and is wrapped to protect from chafing o After verifying satisfactory routing per the previous two steps drill two 098 in 2 50 mm holes to match the hole pattern in A
39. isc Cyclic Disc nN N q G rc y q x RK S J8605 Hook Disc M390A18N eo l PRIMARY HOOK ARMED i i i fs e M408A22 1 3 l B _ M406A22 ae ee M365A22N M390A16N TB8552 2 18 Installation Instructions 2 1 Fixed Provisions Kit Installation continued 2 1 4 Electrical Release Wiring Installation continued The Intermediate Electrical Harness P N 270 178 00 is installed external to the aircraft and is routed from the forward connector bracket back to the aft connector bracket and is secured along the hydraulic hose It serves as an intermediate harness between the internal cargo hook electrical wiring including load weigh system wiring if installed and the harnesses on the cargo hook suspension assembly see Figure 2 1 16 NOTICE On the A119 models the forward skid gear tube will need to be lowered from the belly in order for the electrical harness connector s to be routed through Connect the single connector end P8505 to the mating connector mounted within the forward connector bracket and route it along the hydraulic hose securing it to the hydraulic hose at locations 2 0 4 0 inches from and on both sides of each adel clamp with ty wraps P N 512 003 00 Mount the cargo hook electrical release J8501 and the load cell J8506 connectors to the aft connector bracket with screws P N 510 672 00 washers P N 510 062 00 and nuts P N 510 029 00 Figu
40. nd RBL 205 0 NOTICE The Doublers Onboard Systems P Ns 235 174 00 235 175 00 and 235 176 00 for the forward hard points are typically installed at the factory by the OEM If they are not installed obtain and install them per the following instructions also refer to Agusta Service Instruction A119 SI 002 o If Doublers on the forward panel of the fuel tank frame are not already installed clean and prep the mating surfaces as necessary and bond the Doublers P N 235 174 00 in position using EA934NA adhesive aligning the holes with the inserts in the panel o Position the Support Brackets over the Doublers and temporarily secure with enough of the screws P N 510 644 00 and washers P N 510 419 00 provided to hold them securely in position for marking the bottom flanges for drilling Figure 2 1 4 Support Bracket and Doubler Overview Fwd panel of fuel tank frame Washer X8 P N 510 419 00 ScreewX8 NL u P N 510 644 00 po Pe ee lt Support Bracket P N 291 363 00 Doubler P N 235 174 00 cabin floor Installation Instructions 2 1 Fixed Provisions Kit Installation continued 2 1 1 Hard Point Installation continued Installation Instructions o Transfer the location of the aft pair holes at each forward hard point position to the lower flange of the Support Brackets and match drill 257 290 6 5 7 4 mm holes in position or remove the Support Brackets and use a d
41. ngle Bracket P N 291 617 00 and attach Angle Bracket using two rivets P N 510 972 00 o Fully tighten the adel clamp onto the Angle Bracket Figure 2 1 9 Securing Hydraulic Hose A119 shown gt o Remove the nut from the end of the hose fitting and insert the fitting through the 5 16 hole in the bracket and re install the nut over it to secure it to the bracket Installation Instructions 2 11 2 1 2 12 Fixed Provisions Kit Installation continued 2 1 3 Fixed Hydraulic Release System Installation continued The Intermediate Plumbing Assembly is routed between the forward connector bracket and the aft connector bracket and supported along the belly using existing inserts o Connect the appropriate end of the plumbing assembly to the fitting at the forward connector bracket installed previously o At existing belly panel inserts at STA 1832 0 2019 0 2207 0 2394 0 2582 0 2769 0 and 2956 0 refer to Figure 2 1 10 secure the hydraulic hose with spacer P N 510 647 00 adel clamp P N 512 005 00 screw P N 510 645 00 and washer P N 510 419 00 For kit P N 200 369 00 for the A119 and AW119 MKII NOTICE On the A119 models the forward skid gear tube will need to be lowered from the belly in order for the electrical harness P N 270 178 00 connector s to be routed through See section 2 1 4 o Place adel clamp P N 512 034 00 over the forward cross tube and attach adel clamp P N 512 005 00 with hydraulic h
42. nsion assembly P N 210 244 00 onto the hard points as shown in Figure 2 2 1 Figure 2 2 1 Suspension Frame Assembly Installation STA 4010 0 3067 0 gt AFA T FAN cet ISL 1 Angle frame assembly upward as shown and move aft to engage aft hard points 2 Rotate forward end of Quick Release Pin X2 frame assembly upward to align with holes in forward hard points and insert pins o Secure the quick release pins with the attached safety pins o Connect the hydraulic hose connector the electrical release harness connector and load weigh harness connector if load weigh kit is being installed to their respective mating connectors on the Aft Connector Bracket installed earlier Table 2 1 Cargo Hook Connector Function a foom EE Power Earlier versions of the cargo hook were equipped with a suppression diode that will be damaged if the electrical connection is reversed 2 22 Installation Instructions 2 2 Cargo Hook Suspension Kit Installation continued o Install appropriate load limitation placard P N 215 256 00 3086 lb external load limit for the A119 and AW119Mk II model or P N 215 258 00 2205 Ib external load limit for the A109E model Consult the Agusta Flight Manual Supplement applicable to your particular helicopter to verify the external load limitation Locate the placard on the belly of the helicopter or on the c
43. om For D Seni E MS CO BOAR mg s W vW W oN weg SITE AT THIS pLEASE CMEC AEST REVISION OF 1 aBa TE D uk Owner s Manual Cargo Hook Suspension System Kits Agusta A109E A119 AW119 MKII Kit Part Numbers 200 355 00 200 356 00 200 357 00 200 369 00 Owner s Manual Number 120 141 00 Revision 4 August 24 2015 Zo CONBOARD SYSTEMS IN 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 Record of Revisions Revision Date Reason for Revision 02 03 11 Initial Release Revised washers for aft hard point installation to accommodate bolt grip length clarified routing instructions for release lever 04 25 11 hose and deleted one of the two attach points to cyclic shaft changed screws for fwd connector bracket attachment and fairing attachment to a shorter screw P N 510 580 00 11 18 13 2 23 thru 2 25 Updated pin load cell installation instructions Revised instructions for installation of Support Brackets 12 16 13 2 4 thru 2 6 P N 291 363 00 added radius fillers P N 291 849 00 and changed bolt P N 510 914 00 to 511 092 00 1 6 2 23 2 Added pin load cell P N 210 301 02 Updated load 08 24 15 25 4 4 4 5 rigging section Current revision levels of all manuals are posted on Onboard Systems Int l we
44. on 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 Chan ing Dampening Level Hook Load x 10 CAL DAMP 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 3 8 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 th
45. ose routed through it with screw P N 510 453 00 washer P N 510 419 00 and nut P N 510 102 00 Figure 2 1 10 Intermediate Hydraulic Hose Routing installation applicable to A119 AW119 only kit P N 200 369 00 BL 100 0 BL 65 0 Forward Connector Bracket ve Dn Landing gear tube support point Ae BLO O0 BL0 0 Aft Connector Bracket 1832 0 l Insert at this location is i i pera BL 334 5 applicable to A109E only 2582 0 pas kit P N 200 355 00 l STA i 2956 0 STA View Looking Down 3140 0 Landing gear tube support point installation applicable to A119 AW119 only kit P N 200 369 00 o At the aft connector bracket installed previously insert the hose assembly s quick release fitting through the keyhole and slide it to the end of the slot and tighten the nut to secure it into place Installation Instructions 2 1 Fixed Provisions Kit Installation continued 2 1 4 Electrical Release Wiring Installation Remove circuit breaker panel and other panels as necessary to route wires from the circuit breakers to underneath the pilot and co pilot seats Remove pilot and co pilot seats and the access panels below and in between the seats NOTICE If the optional load weigh kit Kit P N 200 357 00 is being installed route its wiring harness through the structure as the relea
46. own 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 Hook Load x 10 3 10 Load Weigh System Operation Instructions The Setup Mode continued Calibration by Lifting a Known Weight continued The CAL legend and the digits will be blinking Again at this point if you wish to return to the Run Mode without changing the Calibration Code power cycle the Indicator It is not possible to return to the Run Mode by using the buttons on the Indicator front panel without changing the Calibration Code If you wish to proceed lift the known load and when it is stabilized press either button to complete the procedure The Indicator will display the load This ends the procedure The Indicator is now calibrated to the Load Cell It is a good practice to go to the Code routine and record the new Calibration code for later reference Setting the Scale for a remote analog meter The Scale routine is used when a user supplied analog meter is connected to the Indicator It is used to match or calibrate the analog meter to the Indicator The Indicator outputs a 0 to 5 VDC analog signal which is proportional to the Load Cell load The Scale number tells the Indicator at what point in pounds or kilograms it should reach the 5 VDC output If for example a 5 volt analog meter is used and its full scale reading is 10 000 pounds the number entered into
47. r 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 Hook Load x 10 CAL OUT UN ZEI RO 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 kn
48. re 2 1 16 Electrical Schematic External Wiring Intermediate Electrical Harness P N 270 178 00 Load Cell P8505 J8506 A A See Internal Load Weigh Schematic T oN See Internal Release Schematic rx nmogo w gt a ee TN ON TON ON TN amog o o gt cw EN Cargo Hook 13 A o ID J8501 IAS Z r q nee oN oN CN w gt q oN oN gt Installation Instructions 2 19 2 1 2 20 Fixed Provisions Kit Installation continued 2 1 5 Connector Bracket Fairing Installation When the electrical wiring and hydraulic hose installation is completed the Fairing P N 220 043 00 can be installed over the forward connector bracket Position the Fairing over the forward connector bracket and align the holes and secure it to the bracket in two places and to the inserts in the belly of the helicopter in five places with the fasteners as shown in the figure below Figure 2 1 17 Fairing Installation STA 1639 0 BLO Q Fairing P N 220 043 00 BL 100 0 Screw P N 510 391 00 Washer P N 510 419 00 Screw P N 510 580 00 Washer P N 510 419 00 5 PLCS View A A Looking Up 2 1 6 Placard Installation Install the Carrying of External Loads placard part of the P N
49. rill press o Center a Radius Filler about each hole in the lower flange of the Support Bracket reference Figure 2 1 6 and transfer each hole location in the Support Brackets to a Radius Filler P N 291 849 00 and drill 257 290 6 5 7 4 mm through o Re install if removed and complete the installation of the two Support Brackets per Figure 2 1 4 o As necessary fill the gap between the bottom of the Support Brackets and the adjacent structure with Peel Shims P N 291 365 00 The forward pair of fasteners for the forward hard points are attached to inserts in the bottom panel which are reinforced at each location with an internal Doubler see below o If the inserts and doubler are not installed at each location install inserts Agusta P N K100H4A95 17 not supplied and Doubler not supplied per Agusta instructions A119 SI 002 NOTICE Doubler P N 235 176 00 is interchangeable with Agusta Doubler P N 109 0882 23 107 Figure 2 1 5 Internal Doubler internal doubler Onboard Systems P N 235 176 00 Agusta P N 109 0882 23 107 00 2 5 2 1 2 6 Fixed Provisions Kit Installation continued 2 1 1 Hard Point Installation continued Working external to the aircraft s lower belly panel prep the mating surfaces and bond the P N 235 175 00 Doublers if Doublers Agusta P N 109 0882 23 109 are not already installed to the external surface of the lower panel alignin
50. rom the C 39 indicator connector to terminal block TB8552 where it is terminated at pin G o For the C 39 indicator 5VDC back lighting route wire M396A22 from the C 39 indicator connector to TB7301 where it is terminated at module 1 pin A on the A119 or module 6 pin c on the A109E or other available pin to accommodate the 5VDC lights o Wire OB M02A2 is routed from the C 39 indicator to TB8551 where it is terminated at module 1 pin S o Install Jumper P N 270 182 00 wire no M410A20 between TB8551 module 1 pin T and relay K8501 point A1 of the electrical module assembly Installation Instructions 2 4 Hydraulic System Bleed Procedure If there is a need to fill and or bleed the system follow the procedures listed below Proper bleeding is critical to the operation of the hydraulic release system An improperly bled system will not release the cargo hook mechanism If you need to remove and repair any items in the hydraulic system refer to 123 036 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 Bleeding procedure 1 Obtain the hydraulic hook bleed kit 212 014 01 This kit consists of 2 ounce
51. rovides the means of system calibration General Information Section 2 Installation Instructions These procedures are provided for the benefit of experienced aircraft maintenance facilities capable of carrying out the procedures Those lacking the necessary expertise should not attempt them This Owner s Manual provides instructions for the installation of the four kits outlined in Section 1 The installation instructions for each kit are provided in the following sections 2 1 Fixed Provisions Kit P N 200 355 00 200 369 00 2 2 Cargo Hook Suspension Kit P N 200 356 00 2 3 Load Weigh Kit P N 200 357 00 2 1 Fixed Provisions Kit Installation Kit P Ns 200 355 00 200 369 00 2 1 1 Hard Installation Instructions This part of the installation consists of installing the hard points and their supporting brackets and doublers internal cargo hook electrical release wiring fixed hydraulic release system and electrical support brackets Point Installation The hard points are fastened to the belly of the helicopter and provide the attachment points for the cargo hook suspension frame The two aft hard points P N 291 361 00 are installed at STA 4010 0 and LBL and RBL 205 0 Each aft hard point requires that a Doubler P N 235 180 00 be installed between it and the lower belly panel of the helicopter NOTICE These doublers are normally found to be installed by the OEM at the factory If they are not obtain them and Peel Sh
52. s of MIL PRF 5606 fluid MIL PRF 87257 fluid may also be used 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 as shown Figure 2 4 1 Hydraulic Hook Bleed Kit Bleed Adapter PVC Tubing sy Female X Barb Fitting Syringe 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 that 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 31 2 32 2 4 Hydraulic System Bleed Procedure 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 4 2 Figure 2 4 2 Hose Arrangement GOOD HOSE ARRANGEMENT POOR HOSE ARRANGEMENT 4 Remove screws reservoir lid and baffle from the master cylinder reservoir as shown in Figure 2
53. se wiring harness is installed Refer to section 2 3 3 for load weigh harness installation instructions o Install the circuit breaker P N 440 010 00 in the overhead console reference Figure 2 1 11 Figure 2 1 11 Circuit Breaker Location 115 VAC 1 26 VAC SAS VG GYRO ADI SAS ADF GYRO SAS PO QOQQ00 9900 COMP CONV COMP DC BUS ADI HOIST ELT EMER FIRE SUN CHIP PD DIDIS DIe CARGO AFETY STBY PWR CABLE CABLE FLOATS EXTING LT BURNER HOOK WOOK CUTI CUT2 Circuit Breaker P N 440 010 00 Circuit Breaker Panel Overhead Console o Connect the ring terminals on the M364A20 and M362A16 wires of harness P N 270 180 00 to the circuit breaker with hardware provided with the circuit breaker o Route the M364A20 and M362A16 wires with existing harnesses from the circuit breaker down to the bay underneath the pilot s seat o Observe the following precautions while routing all wires e Pick up existing wire runs by opening existing cable clamps Nylon ties alone may not be used for primary support e The distance between supports should not exceed 21 inches e Bend radius of wire or harness must not be less than 10 times the wire or harness diameter e Inspect and verify that the wire harness may not be manually deflected into a structure with a bend radius of less than 13 Installation Instructions 2 13 2 1 2 14 Fixed Provisions Kit Installation continued 2 1 4 Ele
54. sembly 232 463 00 Fwd Connector Bracket Assembly 232 464 00 Intermediate Hose Assembly 232 465 00 Release Lever Assembly w Plumbing 232 466 00 Electrical Module Assembly 232 474 00 Barrel Nut Assembly 232 475 00 Aft Connector Bracket Assembly me A Rel m m ple 235 177 00 Landing Gear Lock 270 178 00 Intermediate Electrical Harness 270 179 00 Internal Electrical Harness 270 180 00 Electrical Harness 291 361 00 Aft Hard Point 291 363 00 Support Bracket 291 365 00 Peel Shim 291 367 00 Peel Shim 291 617 00 Angle Bracket 291 849 00 Radius Filler 410 293 00 Bonding Jumper 410 296 00 Ring Terminal 410 312 00 Contact Size 20 440 010 00 Circuit Breaker RIND BIR RR NIN e m A Rl m m m DR I NINI Aje NIN m 510 029 00 Nut N N 510 042 00 Washer P pP 510 062 00 Washer N N 510 102 00 Nut 510 112 00 Nut 510 115 00 Cotter Pin 510 290 00 Bolt 510 391 00 Screw MW BY AIM U A BIAIN 510 419 00 Washer P N pP Ko 510 453 00 Bolt 510 481 00 Screw 510 580 00 Screw o AJU oo BY AR 510 644 00 Screw nN nN 510 645 00 Screw 510 647 00 Spacer NIN 510 657 00 Washer
55. tem included with this kit utilizes hydraulics A lever master cylinder assembly mounted to the cyclic when actuated moves a piston through the master cylinder which transmits this motion via the hydraulic line to a slave cylinder piston on the cargo hook The slave cylinder piston extends and actuates the internal mechanism of the cargo hook and allows the load to fall free e Ground personnel may also release a load by the actuation of a lever located on the side of the cargo hook 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 sling to its open position and the cargo sling ring slides off the load beam The load beam then remains in the open position awaiting the next load The 200 357 00 kit is a load weigh system which includes an indicator mounted within the instrument panel a pin load cell at the cargo hook and the interconnecting wire harness The indicator displays the weight of the load carried on the cargo hook It supplies the precision excitation voltage to the pin load cell conditions the return signal outputs a proportional analog signal and p
56. the P8505 connector per the schematic shown in Figure 2 3 9 Figure 2 3 8 Load Weigh Schematic cargo hook electrical release wire K8501 from CB8505 shown for reference rocco M362A16 l I M410A20 i l E I s T uy l bat C 39 Indicator Connector CN is PIB oe Gn 4 29907 TB8551 P8505 A A Ja D WH OR cle c WH GN cdle Load Cell B WH p E WH BL e R 2 G M H J K A109E A119 M M395A22 5 7 M3422 1 o or RI TB7301 G H J wey All TB8552 Installation Instructions 2 29 2 3 Load Weigh Kit Installation Kit P N 200 357 00 continued 2 30 2 3 3 Load Weigh Internal Harness Installation continued Figure 2 3 9 Shield Terminations 1 50 13 in 38 3 3mm 38 13 in 9 7 3 3 mm a CONDUCTORS SHIELD MATERIAL a INSTALL SHIELD TERMINATIONS PER THE FOLLOWING 1 PREPARE CONDUCTOR AS SHOWN ABOVE 2 INSTALL SHIELD TERMINATION OVER CENTER OF EXPOSED SHIELD MATERIAL 3 APPLY HEAT FROM HEAT GUN TO TERMINATION UNTIL SOLDER RING MELTS AND THE TERMINATION HAS SEALED THE CABLE VERIFY THAT CONTINUITY EXISTS FROM THE DRAIN TO THE SHIELD o Route wire M395A22N from the C 39 indicator connector to the grounding terminal block TB8552 pin H of the electrical module assembly supplied with the fixed provisions kit P N 200 355 00 and 200 369 00 o Route wire OB MO01A22N f
57. the Release Lever Assembly P N 232 465 00 to the cyclic as shown below with the two screws provided pre assembled onto the assembly Adjust the location if necessary so that the lever is accessible and comfortably reached by hand from the cyclic grip but not be able to contact or interfere with operation of any cyclic grip control when it is actuated Operation will be verified at installation check out when the release system is operational o Route the hydraulic hose along the cyclic and secure it using the adel clamps and hardware as shown in Figure 2 1 9 Figure 2 1 9 Release Lever Assembly Installation 1 9 2 5 in Release Lever Assembly 48 63 5 mm w Plumbing P N 232 465 00 Adel Clamp P N 512 005 00 Bolt P N 510 453 00 gt Nut P N 510 102 00 Na Adel Clamp P N 512 021 00 eS 2 9 2 1 Fixed Provisions Kit Installation continued 2 1 3 Fixed Hydraulic Release System Installation continued o At the base of the cyclic route the quick disconnect end through the lower right corner of the boot and into the bay underneath the seat o Remove the inboard screw at the cyclic connector bracket and install an L Bracket P N 512 028 00 Secure the hose to this L bracket with an adel clamp P N 512 005 00 using the supplied screw P N 510 453 00 washer P N 510 419 00 and nut P N 510 102 00 Move cyclic throughout its range of motion to ensure that the hose is secured clear of flight control l
58. 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 bleed kit with isopropyl alcohol Allow it to dry Not cleaning the syringe will render it unusable Re assemble and store for next use 2 35 2 5 2 36 Installation Check Out After installation of the system perform the following functional checks Q Swing the installed cargo hook to its full extremes to ensure that the hydraulic hose and electrical harnesses have enough slack to allow full range of motion without straining or damaging the hose or harnesses The hose or harnesses must not be the stops that prevent the cargo hook from pivoting freely in all directions With no load on the cargo hook load beam pull lever on the cyclic the cargo hook must release Reset the cargo hook load beam With no load on the cargo hook load beam depress the cargo hook electrical release button on the pilot s cyclic the Cargo Hook should release Reset the cargo hook load beam 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 NOTICE The cargo hook and load cell are of a class of equipment not known to have a high potential for interference This class of equipment does not require special EMI installation testing i e FADEC as required in paragraphs 7 and 8 of FAA policy memorand
59. tion for the Agusta connector bracket which has the same hole pattern as bracket P N 232 463 00 If these inserts and the through hole are not present install them and create the through hole in the belly per Agusta cargo hook installation drawing 109 0854 51 or Service Instruction A119 SI 002 as applicable Figure 2 1 8 Fwd Connector Bracket Installation Forward Connector Bracket P N 232 463 00 Screw P N 510 580 00 Washer P N 510 419 00 Right 3 PLCS M Fwd BL 100 0 BL 65 0 BL 0 0 BL 0 0 ANJ Hole in belly for hose and harnesses View Looking Down Fwd landing gear tube A119 AW119 2 1 Fixed Provisions Kit Installation continued 2 1 3 Fixed Installation Instructions Hydraulic Release System Installation The hydraulic release system is supplied dry It is recommended that the system be filled and bled on the bench before installing it on the helicopter Refer to section 2 4 for filling and bleeding instructions The fixed hydraulic release system consists of the release lever master cylinder assembly which is mounted on the cyclic and hose which is routed from the master cylinder to underneath the pilot seat and then towards the center of the aircraft where it is routed through the hole in the belly to the forward connector bracket installed previously o Remove seats and center console cover to access areas of routing o Mount
60. traps 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 Cargo Hook Rigging continued Figure 4 4 Example of Recommended Cargo Hook Rigging Recommended Avoid Primary Ring Long Line ff Operation Instructions ise Accessory Connector Bracket Provisions Each longitudinal beam of the cargo hook suspension frame includes two threaded 10 32 holes that can be used for mounting a bracket not supplied for supporting electrical connectors for accessories such as a long line cargo hook Figure 4 5 Accessory Connector Bracket Provisions Example of accessory bracket not supplied with kit Tapped holes 10 32 for mounting an accessory bracket 4 6 Operation Instructions Section 5 Maintenance Refer to the Instructions for Continued Airworthiness ICA manual 123 036 00 for maintenance of the fixed provisions kit load weigh kit and cargo hook suspension kits For maintenance specific to 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 includin
61. tton to select a digit use the Left button to scroll the digit to the desired number Entry is times 10 LB KG Units selects the Indicator units pounds or Display is previously selected unit To kilograms change the unit use the Left button XX V Version is the revision level of the Indicator Version is for information only it cannot hardware and software 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 butt
62. ty is resolved The cargo hook release solenoid is intended to be energized only intermittently Depressing the electrical release button continuously in excess of 20 seconds will cause the release solenoid to overheat possibly causing permanent damage 2 Pull the lever on the cyclic to test the cargo hook manual release system The system should operate smoothly and the Cargo Hook must release Reset the cargo hook by hand after release Verify that the hook lock indicator on the side of the hook returns to the fully locked position If the hook does not release or re latch do not use the unit until the problem is resolved In the fully locked position the hook lock indicator must align with the lines on the manual release cover see Figure 4 1 Figure 4 1 Hook Lock Indicator Hook Lock Indicator Hook Lock Indicator ACCEPTABLE NOT ACCEPTABLE LOCK INDICATOR DIAMOND LOCK INDICATOR DIAMOND IS NOT VISIBLE OR IS IS ALIGNED WITH ENGRAVED VISIBLE BUT IS NOT ALIGNED WITH ENGRAVED LINES ON THE COVER LINES ON THE COVER AS SHOWN ABOVE Operation Instructions A Operating Procedures continued 3 Swing the installed Cargo Hook to ensure that the hydraulic hose and electrical harnesses have enough slack to allow full swing of the cargo hook without straining or damaging the harnesses and or hydraulic hose The hydraulic hose and harnesses must not be the stops that prevent the Cargo Hook or the suspension from moving freely
63. um ASW 2001 01 If Load Weigh Kit P N 200 357 00 is installed perform the following Q 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 Installation Instructions 2 6 Component Weights The weights and cgs of the Cargo Hook Kits are listed below Table 2 6 1 Weight amp CGs Cargo Hook Kits ME E Fixed Provisions Kit A109 8 5 Ibs 3 9 kgs 125 9 in 3200 mm P N 200 355 00 BN 200 3570 P N 200 357 00 Fixed Provisions Kit A119 8 5 lbs 3 9 kgs P N 200 369 00 The load weigh kit replaces the attach bolt and washer in kit P N 200 356 00 The attach bolt and washer weigh 0 12 Ibs Cargo Hook Suspension Kit 20 5 Ibs 9 3 kg 129 9 in 3300 mm P N 200 356 00 2 7 Paper Work Installation Instructions 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 in the aircraft Flight Manual 2 37 This page intentionally left blank 2 38 Installation Instructions Section 3 Load Weigh System Operation Instructions Indicator Front Panel The C 39 Indicator front
64. un 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 Hook Load x 10 CAL LB KG 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 NOTICE 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 Hook Load x 10 LB KG Load Weigh System Operation Instructions 3 13 This page intentionally left blank Section 4 Operation Instructions Operating Procedures Prior to a flight involving external load operations perform the following 1 Activate the electrical system and press the Cargo Hook release button to ensure the cargo hook electrical release is operating correctly The Cargo Hook must release Reset the hook by hand after the release If the hook does not release or re latch do not use the unit until the difficul

Owners Manual AW109-A119 Hook Kit 120-141-00

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