120-106-01 - Onboard Systems International
Contents
1. Eurocopter 1461152 mm 55M Connector VIEW A A Connector Bracket 16 19 mm g Y 0 VIEW LOOKING FORWARD 2 8 Installation Instructions 2 2 Cargo Hook Installation The cargo hook assembly includes an electrical pigtail which must be spliced into the Airbus Helicopters Y harness Splice per the following instructions o Cut the leg of Y harness that goes to the cargo hook off within 1 50 2 00 from the Y junction o Cut the electrical pigtail from the cargo hook to a length which provides for optimal routing when spliced with the Y harness o Strip the outer heat shrink wire jacket and shield back 1 Prep the individual wires o Slide the 3 long piece of V2 dia heat shrink P N 450 113 00 and 4 long piece of Va dia heat shrink P N 450 120 00 over the cargo hook pigtail and a 4 long piece of heat shrink tubing P N 450 001 00 over the two individual wires o Prep the wires on the Airbus Helicopters harness and solder the wires from the cargo hook pigtail to them referring to the wiring diagram see Figure 2 2 3 Figure 2 2 1 Wiring Harness Modification Heat Shrink P N 450 113 00 Heat Shrink ju 450 120 00 7 4 50 2 00 a vi Th SH k a tty Ps P N 450 001 00 meee Load Cell sre S o Slide the heat shrink tubing over the individual solder joints and shrink in place using heat gun Cap and stow the remaining three wires o Slide the 4 long pie2. AA A A View Looking Aft Installation Instructions 2 5 2 1 Hydraulic Release System Installation continued Q Aft of the frame route the hose along the top of the structural member shown below and secure with adel clamp P N 512 005 00 at location shown Figure 2 1 7 Adel Clamp Installation A Adel clamp from Figure 2 1 6 is behind this Route the hose to this beam and secure with Adel clamp Enlarge hole to 196 dia if necessary to fit Adel clamp screw Q Aft of the adel clamp installed above route the hose inboard and aft across the airframe centerline to the identical structural member on the left side of the airframe Secure hose to fitting on top of structural member with ty wrap as shown below Ensure the hose is secured so that it does not interfere with the control rods Figure 2 1 7 Hydraulic Hose Routing 2 6 Installation Instructions 2 1 Hydraulic Release System Installation continued Q Route the hose under the airframe support as shown below and secure the hose to the fitting on top of the structural member aft of the airframe support Install grommet edging P N 500 065 00 as necessary to protect hydraulic hose from chafing Figure 2 1 8 Routing under Airframe Cut and install grommet edging in this area to prevent chafing of hydraulic hose Q Route the hose up through the rear cabin bulkhead as shown in Figure 2 1 9
3. NS COM FOR pOARDSYSTEMS COM or THIS MANUAL ab Li 1 4 TW ww W 7p SITE A pa ATE ST RE VISION PL JASE Owner s Manual Talon LC Hydraulic Cargo Hook Kit on the Airbus Helicopters AS350 Part Number 200 281 01 200 281 02 Owner s Manual Number 120 106 01 Revision 7 05 14 14 Z CONBOARD SYSTEMS 1391 5 NW 3rd Court Vancouver WA 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 Page s Reason for Revision 06 16 06 All Original issue 01 14 08 2 10 2 11 Added Remove rubber bumpers from swing assembly instruction and updated Figure 2 2 4 Removed color labels from wiring diagram Figure 2 2 3 02110109 Corrected PIN 232 240 00 to 232 241 00 on 232 222 00 illustrated parts list Updated illustrated parts list to show P N 232 240 01 used on P N 232 241 00 09 29 09 2 3 2 7 3 1 Updated Figure 2 1 3 to show complete collective added note on page 2 7 to allow alternative routing clarified Figure 3 1 08 03 10 Replaced P N 212 014 00 with 212 014 01 and updated hydraulic fluid filling instructions to use new kit Updated warnings cautions and notes section to safety label section Updated safety label format throughout document 12 19 11 5 7 Replaced Cup Seal P N 556 038 00 with Quad Ring P N 556 097 00 inside Slave Cylinder Assembly
4. 10 11 13 5 6 Replaced Slave Cylinder Plumbing P N 232 240 01 with P N 232 240 02 05 14 14 2 2 3 2 3 3 Updated cargo hook rigging section changed recommended minimum bend radii of hose to 1 5 inches Section 1 through 4 Register Your Products for Automatic Notifications Onboard Systems offers a free notification service via fax or email for product alerts and documentation updates By registering your Onboard Systems products at our website we will be able to contact you if a service bulletin is issued or if the documentation is updated You can choose to receive notices on an immediate weekly or monthly schedule via fax email or both methods There is no charge for this service Please visit our website at www onboardsystems com notify php to get started ii This page intentionally left blank CONTENTS Section 1 Section 2 Section 3 Section 4 Section 5 Section 6 General Information Introduction 1 1 Safety Labels 1 1 Specifications 1 2 Inspection 1 2 Bill of Materials 1 3 Theory of Operation 1 4 Installation Instructions 2 1 Hydraulic Release System Installation 2 1 2 2 Cargo Hook Installation 2 9 2 3 Installation Check Out 2 12 2 4 Component Weights 2 13 2 5 Cargo Hook Location 2 13 2 6 Paper Work 2 13 2 7 Filling Hydraulic Release System 2 14 Operation Instructions Operating Procedures 3 1 Cargo Hook Rigging 3 2 Cargo Hook Loading
5. Split and install grommet P N 505 014 00 in hole after hose is routed through If this hole is not available route the hose outboard to the existing electrical harness and route with electrical harness to the connector bracket Space hydraulic hose off of electrical harness or apply protective wrap over hose to prevent it from rubbing on wires Figure 2 1 9 Hose Routing through Rear Cabin Bulkhead Installation Instructions 2 7 2 1 Hydraulic Release System Installation continued Q Aft of the rear cabin bulkhead pick up existing electrical harness and secure hydraulic hose to it Prevent the hose from rubbing on the wires by spacing it off or applying protective wrap The hose will route outboard of Y400 and follow the electrical release harness to the connector bracket Q Temporarily remove the Airbus Helicopters connector 55M from the existing connector bracket Remove existing connector bracket by drilling out the three rivets Locate the provided connector bracket as shown below and drill out pilot holes in the supplied connector bracket to 0 129 0 132 3 2 3 4 mm diameter and drill fuel tank support to match Q Secure Connector Bracket to fuel tank support with three rivets P N 510 486 00 Q Insert the hydraulic hose end fitting through the hole and slide it aft to the end of the slot and tighten jam nut Figure 2 1 10 Connector Bracket Installation Hydraulic Connector e 5 7516 00 in
6. Your file Votre r f rence 1905 03 169 Our file Notre r f rence March 24 2003 Onboard Systems 13915 NW 3 Court Vancouver WA 98685 USA Attention Mr Ron Pirtle Subject Acceptance of Foreign STCs SRO11GASE SRO1165SE and SRO1166SE Dear Sir This is in response to your letters dated February 25 2003 making application for Canadian approvals of the subject STCs In accordance with our current policy associated with the review of foreign STCs some STCs applicable to certain categories of rotorcraft 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 STCs fall within these criteria These STCs 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 STCs 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 H W Wong Senior Engineer Aircraft Certification for Minister of Transport c c Mr Jeffrey E Duven Acting Manager Seattle ACO i Canada Certification 6 3 EASA STC European Aviation Safety Agency SUPPLEMENTAL TYPE CERTIFICATE EASA IM R S 00623 This certificate established in ac
7. l j 232 165 00 Master Cylinder Assembly elelplelele 232 165 01 Master Cylinder Assembly 235 135 00 Disconnect Bracket eli 291 105 00 Friction Handle 510 453 00 Bolt 510 042 00 Washer 510 102 00 Nut 512 005 00 Adel Clamp 500 065 00 Grommet Edging 505 014 00 Grommet 590 013 00 Spiral Wrap aN gt x 450 001 00 1 8 Heat Shrink Tubing 1 2 Lg 450 120 00 Va dia Heat Shrink Tubing 4 Lg 450 113 00 Va dia Heat Shrink Tubing 3 Lg 510 486 00 CherryMax Rivet w NI o m m m m w NI o m m m m m m 1 3 Theory of Operation 1 4 The primary elements of the Cargo Hook are the load beam the internal mechanism and a DC solenoid The load beam supports the load and is latched through the internal mechanism The DC solenoid and an external manual release cable provide the means for unlatching the load beam A load is attached to the load beam by passing the cargo sling ring into the throat of the load beam and pushing the ring against the upper portion of the load beam throat which will initiate the hook to close In the closed position a latch engages the load beam and latches it in this position To release the load the latch is disengaged from the load beam With the latch disengaged the weight of the load ca
8. or add anti chafe strip Provide as gradual a transition as possible at end fittings 2 2 Installation Instructions 2 1 Hydraulic Release System Installation continued 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 7 for filling and bleeding instructions Q Mount the Release Lever Assembly P N 232 165 00 to the collective stick with the Clamp Half P N 290 753 00 and two screws P N 510 390 00 provided pre assembled on the assembly as illustrated below Figure 2 1 3 Release Lever Installation Screws P N 510 390 00 Release Lever Assembly If installing kit P N 200 281 02 for the AS350B3 model a shorter friction adjustment knob for the collective is required because of interference with the master cylinder assembly reservoir This item is supplied as P N 291 105 00 See below for installation instructions Figure 2 1 4 B3 Collective Friction Knob Installation Instructions 2 3 2 1 Hydraulic Release System Installation continued Q Remove the collective to the extent necessary to remove the friction knob Refer to Airbus Helicopters maintenance manual for removal and re installation instructions Q Replace the OEM friction knob with the friction knob P N 291 105 00 provided Q Re install collective per Airbus Helicopters maintenance manual instr
9. 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 Extreme care must be exercised when rigging a load to the Cargo Hook Steel load rings are recommended to provide consistent release performance and resistance to fouling Figure 3 3 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 assure the cargo hook will function properly with each rigging Nylon type straps or similar material or rope must not be used directly on the cargo hook load beam If nylon straps or rope must be used they should be first attached to a steel primary ring Verify that the ring will freely slide off the load beam when it is opened Only the primary ring should be in contact with the load beam Operation Instructions Cargo Hook Rigging continued Figure 3 3 Examples of Cargo Hook Rigging Recommended Primary Ring Long Line Operation Instructions 3 3 This page intentionally left blank Section 4 Maintenance Refer to the Instructions for Continued Airvvorthiness ICA manual 123 013 01 for maintenance of the cargo hook kit For maintenance specific to the cargo hook refer to Cargo Hook Servic
10. Attach Bolt 1 9 510 174 00 Washer 1 10 510 183 00 Washer 1 11 232 146 00 Link Assembly 1 12 512 011 00 Ty wrap 2 13 510 178 00 Cotter Pin 1 System Part Numbers 5 3 System Part Numbers continued 232 146 00 Link Assembly 5 4 Item Part Number Description Qty 1 290 771 00 Adapter Link 1 2 517 052 00 Bushing 1 3 290 364 00 Bushing 1 System Part Numbers System Part Numbers continued 232 166 00 232 166 01 Master Cylinder Assembly ITEM DESCRIPTION a 290 753 00 Clamp Halt OJ a osmoosi Ja 4 290 816 00 sha SSS p s Jeso s12 00 an s u Ja e posso Pion TJ 7 290 813 00 Prush rod JI Ps 290921 00 reseno JI o seos O Ring TJ o 510 390 00 sev JI 6 32 x Va Button Head Cap Screw is 5102500 feon OJ s 556 048 00 Teosa Ja a seor O Ring o is 51055 00 Compression sping JI 19 51053200 Washer Piston Sp JI a0 51500800 sarme oo oa 510 248 007 Hion 22 235 118 00 Master Cynder Bale Ja 23 514 060 00 Compression Spring JI 24 510 530 00 8 32 x 316 Nylon Tip Set sere JI 232 166 01 included with kit P N 200 281 02 uses lever P N 290 811 01 Nj e e ejeje j j iv j j lj l l l System Part Numbers System Part Numbers continued 232 241 00 Slave Cylinder Assembly vvith Plumbing Item Part Number Description 1 232 169 00 Slave Cylinder Assembl
11. Route the hydraulic hose to the left outside the swing frame tubes and up as shown below Connect it to the fixed quick disconnect fitting installed previously Install the supplied spiral wrap P N 590 013 00 over the hose and trim excess Figure 2 2 5 Hose Routing at Frame Forward Add Spiral Wrap P N 590 013 00 over hose View Looking Down Installation Instructions 2 11 2 3 2 12 Installation Check Out After installation of the cargo hook perform the following checks l 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 Swing the installed cargo hook to ensure that the hydraulic hose assembly and the electrical release harness have enough slack to allow full swing of the suspension assembly without straining or damaging the hose or harness The hose and harness must not be the stops that prevent the cargo hook from swinging freely in all directions With no load on the cargo hook load beam pull the release lever on the collective and verify the cargo hook releases Reset the cargo hook load beam With no load on the cargo hook load beam depress the cargo hook electrical release button the cargo hook must release Reset the cargo hook load beam Actuate the release lever on the collective and observe its range of motion Ensure that it is acc
12. hoses uncoiled straight and running uphill See Figure 2 7 2 Figure 2 7 2 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 7 3 the reservoir seal is supplied for shipping purposes only after removal discard reservoir seal Installation Instructions 2 15 2 7 Filling Hydraulic Release System continued Figure 2 7 3 Reservoir Disassembly NY Reservoir Lid _Reservoir Seal 5 Remove the screw and stat o seal on the slave cylinder see Figure 2 7 4 Figure 2 7 4 Screw and Stat o seal Removal SLAVE CYLINDER 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 7 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 2 16 Installation Instructions 2 7 Filling Hydraulic Release System continued 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 7 5 Injecting Hydra
13. 23 Onboard Systems Certification 6 5
14. 3 4 Maintenance Instructions for Returning a System to the Factory 4 1 System Part Numbers 200 281 01 AS 350 Hook Replacement Kit 5 1 232 222 00 Cargo Hook Link Assembly 5 2 232 146 00 Link Assembly 5 3 232 166 00 Master Cylinder Assembly 5 4 232 241 00 Slave Cylinder Assembly w Plumbing 5 5 232 169 00 Slave Cylinder Assembly 5 6 Certification STC 6 1 Canadian Approval 6 3 iii This page intentionally left blank Section 1 General Information Introduction Safety Labels The 200 281 01 and 200 281 02 Cargo Hook Kits are approved as a replacement for the following cargo hook on Airbus Helicopters AS350 Series equipped with a B3 type swing system The B3 type swing systems are installed on AS350B3 models and can be retrofitted to earlier models via Airbus Helicopters Service Bulletin 2500 62 P N AS 21 5 7 The 200 281 02 Cargo Hook Kit is approved for installation on the AS350B3 model The 200 281 01 is approved for installation on the AS350B2 and earlier models The following definitions apply to Safety Labels used in this manual Indicates a hazardous situation which if not d D ANGI R avoided will result in death or serious injury Indicates a hazardous situation which if not avoided could result in death or serious injury avoided could result in minor or moderate injury A CAUTION Indicates a hazardous situation which if not Draws the reader s attention to important or N
15. Hook Location See the Airbus Helicopters provided Flight Manual Supplement for external load weight and balance data 2 6 Paper Work In the US fill in FAA form 337 for the initial installation This procedure may vary in different countries Make the appropriate aircraft log book entry Insert the Rotorcraft Flight Manual Supplement P N 121 014 01 into the Rotorcraft Flight Manual Installation Instructions 2 13 2 7 2 14 Filling Hydraulic Release System 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 123 013 01 Instruction for Continued Airworthiness Filling and bleeding the hydraulic release system is most easily accomplished on the bench prior to installation on the aircraf
16. Kits in accordance with FAA approved Onboard Systems Master Drawing List No 155 088 00 Revision 8 dated October 26 2007 or later FAA approved revision installation of the 200 281 00 cargo hook kit in accordance with FAA approved Onboard Systems Owner s Manual No 120 106 00 revision 6 dated July 1 2005 or later FAA approved revision This modification must be inspected and maintained in accordance with Section ATA 5 of the FAA approved Onboard Systems Instructions for Continued Airworthiness Document No 123 013 00 revision 3 dated July 1 2005 or later FAA approved revision and Onboard Systems Cargo Hook Service Manual No 122 005 00 revision 9 dated January 3 2006 or later FAA approved revision continued on page 3 Limitations and Conditions Approval of this change in type design applies only to those Eurocopter AS350 model rotorcraft listed above that are equipped with the Eurocopter 1400kg Cargo Swing System as installed per Eurocopter Service Bulletin 25 00 62 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 with a 200 281 00 cargo hook kit must be op
17. O C E unusual information not directly related to safety CAUTION a General Information Used to address practices not related to personal 1 1 Specifications Table 1 1 P N 528 028 00 Cargo Hook Specifications Design load 3 500 Ibs 1 580 kg Design ultimate strength 13 125 lbs 5 952 kg Mechanical release capacity 8 750 lbs 3 970 kg Force required for mechanical 12 lbs max Master Cylinde release at 3 500 Ib Mating electrical connector Electrical release capacity 8 750 lbs 3 970 kg Load capacities given are for the equipment described only Loading limits for your particular helicopter model still apply Consult your flight manual Inspection Inspect the cargo hook for evidence of damage corrosion and security of lock wire and fasteners If damage is evident do not use the unit until it has been repaired 1 2 General Information Bill of Materials General Information The following items are included with the Cargo Hook Kit if shortages are found contact the company from whom the system was purchased Table 1 2 Bill of Materials Part Quantity Quantity Number Description 200 Er 01 200 Er 02 120 106 01 Cargo Hook Kit Owner s Manual 121 014 01 Flight Manual Supplement 122 015 00 Cargo Hook Service Manual 123 013 01 ICA Maintenance Manual 215 169 00 AS350 Light Indicator Placard 232 222 00 Cargo Hook Link Assembly jvj
18. ce of 4 dia heat shrink over the solder joints and shrink in place o Slide the 3 long piece of 2 dia heat shrink over the convoluted tubing so that it overlaps it by approximately 1 and shrink in place Figure 2 2 2 Wiring Harness Modification completed Installation Instructions 2 9 2 2 Cargo Hook Installation Figure 2 2 3 Wiring Diagram Existing Eurocopter Harness MESE ME93NF oa Cap and stow gt ME88G these wires ME89G OT The cargo hook is equipped with a suppression diode that will be damaged if the cargo hook electrical connections are reversed See table 2 1 for cargo hook connector pin function Table 2 1 Cargo Hook Connector Function Pin Fincion A Gren a Power 2 10 Installation Instructions 2 2 Cargo Hook Installation continued Attach the Cargo Hook and Bumper Assembly P N 232 222 00 to the existing load cell re using the Airbus Helicopters hardware see below The cargo hook load beam should point to the left side of the aircraft Remove rubber bumpers from swing assembly Figure 2 2 4 Swing Mount Cargo Hook Installation Assembl J AS350B3 SWING ASSEMBLY RUBBER BUMPER REMOVE AS350B3 LOAD CELL Forward Or N RE USE HARDWARE CARGO HOOK
19. cordance with Regulations EC No 1592 2002 and EC No 1702 2003 and issued to Onboard Systems 13915 NW 3rd Court Vancouver WA 98685 USA 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 Type Certificate number DGAC TC No 84 Manufacturer Eurocopter France Model Eurocopter AS 350 B3 Helicopter Description of Design Change Cargo Hook Kit installation in accordance with FAA STC No SR1166SE issued January 22 2003 6 4 Certification EASA STC continued European Aviation Safety Agency Associated Technical Documentation AS 350 B3 Flight Manual and RFM Supplement Onboard No 121 014 00 dated January 15 2003 and revised on July 23 2004 or later approved revisions Limitations and Conditions 1 This STC is approved only for the product configuration as defined in the approved design data referred to in the paragraph Description Compatibility with other aircraft engine configurations shall be determined by the installer This certificate shall remain valid unless otherwise surrendered or revoked For the European Aviation Safety Agency Date of Issue 15 March 2005 N H M Mazzoletti Certification Manager Rotorcraft Ballons and Airships STC EASA IM R S 006
20. e 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 www 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 Include the RMA number and reason for the return on your purchase or work order Include your name address phone and fax number and email as applicable Return the components freight cartage insurance and customs prepaid to Onboard Systems 13915 NW 3rd Court Vancouver Washington 98685 USA Phone 360 546 3072 This page intentionally left blank Section 5 System Part Numbers 200 281 01 Cargo Hook Replacement Kit Item Part No Description Qty 1 232 222 00 Cargo Hook Link Assembly 1 2 232 165 00 Master Cylinder Assembly 1 3 235 135 00 Disconnect Bracket 1 4 215 169 00 AS350 Light Indicator Placard 2 57 510 453 00 Bo
21. erated in accordance with an FAA approved copy of Onboard Rotorcraft Flight Manual Supplement RFMS No 121 014 00 revision 0 dated January 15 2003 or later FAA approved revision A copy of this Certificate FAA approved RFMS and Maintenance Manual must be maintained as part of the permanent records of the modified rotorcraft continued on page 3 rendered suspended revoked or a termination date is otherwise established by the Administrator of the Sederal Aviation Administration Date of annkioation August 15 2002 Date reissued Date of issuance January 22 2003 Date amended December 21 2007 Any alteration of this certificate is punishable by a fine of not exceeding 1 000 or imprisonment not exceeding 3 or both This certificate may be transferred in accordance with FAR 21 47 FAA FORM 8110 2 10 68 Certification 6 1 FAA STC continued Bote States of America Bepartiment of Transportution Feteral Aviation Administration Supplemental Type Certificate Continuation Sheet Murder SRO1166SE Onboard Systems International Reissued Amended December 21 2007 Deserjntion of the Type Design Change Installation of the 200 281 01 and 200 281 02 cargo hook kits in accordance with FAA approved Onboard Systems Owner s Manual No 120 106 01 revision 0 dated June 16 2006 or later FAA approved revision This modification must be inspected and maintained in accordance with Section ATA 5 of the FAA approved Onboard Sy
22. essible and that there is no interference throughout its range of motion refer to Figure 2 3 1 If necessary adjust the lever position by loosening the set screw and turning the lever adjustment screw ref Figure 2 3 2 in the required direction Re tighten set screw Figure 2 3 1 Lever Position Adjust lever position to approximately center its range of motion within this area Ensure access and clearance is present at its starting and ending positions Lever Adjustment Screw Installation Instructions 2 4 Component Weights The weights and cgs of the Cargo Hook kit components are listed below When performing weight and balance calculations remember to deduct equipment removed such as manual release cable etc Table 2 2 Weights and CGs 200 281 01 Removable Provisions 5 1 lbs 2 3 kgs 133 in 3375 mm 1 0 Ib 45 kgs 110in 2794 mm 6 1 Ibs 2 8 kgs 129 2 in 3282 mm Table 2 3 Weights and CGs 200 281 02 Removable Provisions 5 1 lbs 2 3 kgs 133 in 3375 mm 1 2 Ib 54 kgs 110 in 2794 mm 6 3 lbs 2 9 kgs 128 6 in 3266 mm The removable provisions include the hook external hydraulic release hose bumper and electrical release harness These items are easily removed if they are not needed on the helicopter s mission The fixed provisions are those items of the kit that remain on the aircraft The only fixed item in this kit is the Master Cylinder with hydraulic hose 2 5 Cargo
23. is routed from the release lever at the collective underneath the cabin floor and aft to meet up with the existing cargo hook electrical release harness as shown in Figure 2 1 1 Figure 2 1 1 is an overview of the hose routing and the figures following detail the support installations at various points Figure 2 1 1 Fixed Hydraulic Release System Installation Overview ee Centerline of fwd fuel tank support 4 Y 400 Connector Bracket Y 400 ii View Looking Down See Figure 2 1 3 va See Figures 2 1 6 amp 2 1 7 See Figure 2 1 4 a See Figure 2 1 5 ei Support F ae Pe IN 2 Installation Instructions 2 1 2 1 Hydraulic Release System Installation continued Observe the following precautions ref Figure 2 1 2 when routing the hydraulic hose e Use care to avoid kinking the hose e Recommended minimum hose bend radii is 1 5 inches Avoid abrupt change in direction of the hose just outside the end fittings Provide gradual transitions where possible e Verify that the hose routing is clear of and cannot be deflected into chafe points Figure 2 1 2 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
24. lt 1 6 510 042 00 J Washer 1 T 510 102 00 Nut 1 8 512 005 00 Adel Clamp 1 97 500 065 00 Grommet Edging 1 104 505 014 00 Grommet 1 11 450 001 00 1 8 Heat Shrink Tubing 1 Lg 2 12 510 486 00 CherryMax Rivet 3 Item not shown in Figure System Part Numbers 5 1 System Part Numbers continued 200 281 02 Carg 5 2 o Hook Replacement Kit Item Part No Description Qty 1 232 222 00 Cargo Hook Link Assembly 1 2 232 165 01 Master Cylinder Assembly 1 3 235 135 00 Disconnect Bracket 1 4 215 169 00 AS350 Light Indicator Placard 2 5 291 105 00 Friction Knob 1 6 510 453 00 Bolt 1 7 510 042 00 Washer l 8 510 102 00 Nut 1 QE 512 005 00 Adel Clamp 1 108 500 065 00 Grommet Edging 1 11 505 014 00 Grommet 1 125 450 001 00 1 8 Heat Shrink Tubing 1 Lg 2 13 510 486 00 CherryMax Rivet 2 Item not shown in Figure System Part Numbers System Part Numbers continued 232 222 00 Cargo Hook Link Assembly SLAVE CYLINDER ASSEMBLY INSTALLATION BUMPER NOT SHOWN FOR CLARITY Item Part Number Description Qty 1 528 028 00 Cargo Hook 1 2 232 241 00 Slave Cylinder Assembly w Plumbing 1 3 510 531 00 Screw 2 4 512 003 00 Ty wrap 1 5 290 940 00 Bumper 1 6 270 138 00 Electrical Release Harness 1 ti 510 170 00 Nut 1 8 290 775 00
25. orrectly The Cargo Hook must release Reset the load beam by hand If the hook does not release or re latch do not use the unit until the problem is resolved The release solenoid is intended to be energized only intermittently Depressing the electrical release button continuously in excess of 20 seconds will cause the release solenoid to overheat possibly causing permanent damage 5 Activate the manual release lever in the cockpit to test the cargo hook manual release mechanism The mechanism should operate smoothly and the Cargo Hook must release Reset the load beam by hand Verify that the hook lock indicator on the side of the hook returns to the fully locked position In the fully locked position the hook lock indicator must align with the lines on the manual release cover see Figure 3 1 If the hook does not release or re latch do not use the unit until the problem is resolved Figure 3 1 Hook Lock Indicator Hook Lock Indicator Hook Lock Indicator N Ex Q V VA 0 p LOCKED K 4 LOCKED K KR LSI KR AA KS EPI KS LLI SOR K T ORR RRO NIS U GJ 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 Cargo Hook Loading Cargo Hook Rigging 3 2 The cargo hook can easily be loaded with one hand A load is attached to
26. sible 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 7 7 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 baffle 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 bleed kit with isopropyl alcohol Allow it to dry Not cleaning the kit will render it unusable Reassemble and store for next use 2 19 This page intentionally left blank Section 3 Operation Instructions Operating Procedures Prior to a flight involving external load operations perform the follovving 1 Ensure that the hydraulic hose and electrical release harnesses do not limit the movement of the cargo hook 2 Be completely familiar with this manual particularly the Cargo Hook rigging section 3 Be completely familiar with all Airbus Helicopters Cargo Hook operating instructions and the ICA 123 013 01 4 Activate the electrical system and press the cargo hook release button to ensure the cargo hook electrical release is operating c
27. stems Instructions for Continued Airworthiness Document No 123 013 01 revision 1 dated October 25 2007 or later FAA approved revision and Onboard Systems Cargo Hook Service Manual No 122 015 00 revision 4 dated July 6 2006 or later FAA approved revision Rotorcraft modified in accordance with this STC with a 200 281 01 or 200 281 02 cargo hook kit must be operated in accordance with an FAA approved copy of Onboard Systems Rotorcraft Flight Manual Supplement RFMS No 121 014 01 revision 0 dated December 13 2007 or later FAA approved revision A copy of this certificate FAA approved RFMS Ovyner s Manual and Service Manual must be maintained as part of the permanent records of the modified rotorcraft A copy of this Certificate FAA approved RFMS and Maintenance Manual must 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 Any alteration of this certificate is punishable by a fine of not exceeding 1 000 or imprisonment not exceeding 3 years or both FAA FORM 8110 2 1 10 69 This certificate may be transferred in accordance with FAR 21 47 PAGE 3 OF 3 PAGES 6 2 Certification Canadian Approval Transport Transports iv Canada Canada Aviation Aviation Aircraft Certification Branch 620 800 Burrard Street Vancouver BC V6Z 2J8
28. t 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 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 as shown Figure 2 7 1 Hydraulic Hook Bleed Kit Bleed Adapter PVC Tubing Female X Barb Fitting Syringe 2 Ifthe 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 Installation Instructions 2 7 Filling Hydraulic Release System continued 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 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
29. uctions Q Mount the Release Lever Assembly P N 232 165 01 to the collective stick with the Clamp Half P N 290 753 00 and two screws P N 510 390 00 provided pre assembled on the assembly as illustrated below NOTICE Locate the Release Lever Assembly on the collective shaft as close as possible to the throttle twist grip as shown in Figure 2 1 5 Q Adjust the Friction Knob to its outermost position and verify that there is clearance with the reservoir on the release lever assembly Figure 2 1 5 AS350B3 Release Lever Installation Release Lever Assembly NOTICE The lever position is to be adjusted if necessary at installation check out after the system is filled and bled 2 4 Installation Instructions 2 1 Hydraulic Release System Installation continued Q Route the hose to underneath the cabin floor through the existing slot through which the manual release cable was routed through to the right of the base of the collective Q Underneath the floor route the hydraulic hose through an existing hole in the frame immediately aft of the collective Secure the hose at this point with an adel clamp P N 512 005 00 Fasten the adel clamp to the existing bracket Airbus Helicopters P N 350A86 0020 33 with hardware as illustrated below Figure 2 1 6 Hose Routing Through Frame Cabin Floor __ Bolt P N 510 453 00 Washer P N 510 042 00 Nut P N 510 102 00 uru D V Adel Clamp P N 512 005 00 J
30. ulic Fluid Bleed Adapter Female X Barb Fitting PVC Tubing Syringe 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 drav fluid from the master cylinder reservoir during this step to prevent overflow 9 Remove the bleed adapter 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 7 6 Installation Instructions 2 17 2 7 Filling Hydraulic Release System continued Figure 2 7 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 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 2 18 Installation Instructions 2 7 Filling Hydraulic Release System continued Installation Instructions 12 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 the green area on the push rod is vi
31. uses the load beam to swing to its open position and the cargo sling slides off the load beam The load beam then remains in the open position awaiting the next load A load release can be initiated by three different methods Normal release is achieved by pilot actuation of the push button switch in the cockpit When the push button switch is pressed it energizes the DC solenoid in the Cargo Hook and the solenoid opens the latch in the internal mechanism In an emergency release can be achieved by operating the hydraulic release system The hydraulic release system is operated via a lever in the cockpit and actuates the internal mechanism of the Cargo Hook to unlatch the load beam The load can also be released by the actuation of a lever located on the side of the Cargo Hook General Information Section 2 Installation Instructions These procedures are provided for the benefit of experienced aircraft maintenance facilities capable of carrying out the procedures They must not be attempted by those lacking the necessary expertise 2 1 Hydraulic Release System Installation Remove the swing suspension external electrical release harness and the external section of the manual release cable from the helicopter Remove the lower cowlings as necessary to access and remove the internal section of the manual release cable system The hydraulic release system installation consists of a fixed section and a removable section The fixed section
32. y 2 232 240 02 Slave Cylinder Plumbing Assembly 3 560 006 00 Quick Disconnect 4 556 041 00 O Ring 5 558 031 00 Banjo Bolt E S rei This item supersedes P N 232 240 00 amp 232 240 01 These assemblies are interchangeable 5 6 System Part Numbers System Part Numbers continued 232 169 00 Slave Cylinder Assembly Item Part Number Description 1 290 803 00 Slave Cylinder 2 290 802 00 Cylinder Cap 3 290 805 00 Piston 4 517 040 00 Bushing 5 6 7 510 496 00 Stat O Seal 510 493 00 Screw 556 097 00 Quad Ring Saee iE S lt lt System Part Numbers 5 7 This page intentionally left blank Section 6 Certification FAA STC Fated Gites of Ameria Fepartwent of Grumspurtution Federal Aviation Adeninbstestion Supplemental Type Certificate Number SRO1166SE This certificate issued to Onboard Systems international 13915 NW 3rd Court Vancouver WA 98685 certifies that the change in the type design for the following product with the limitations and conditions therefor as specified harson meets the airworthiness reguirements of Part 27 of the Federal Aviation Kegulations Original Produot Tyne Gertificate Numbar HSEU Make Eurocopter France Modol AS350B AS350B1 AS350B2 AS350B3 AS350BA amp AS350D of the Iye Design Changs Fabrication of Onboard Systems Model 200 281 00 200 281 01 and 200 281 02 Cargo Hook
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