120-110-00 - Onboard Systems International
Contents
1. 3 2 Operation Instructions Cargo Hook Rigging Operation Instructions Extreme care must be exercised when rigging a load to the Cargo Hook Steel load rings are recommended to provide consistent release performance and resistance to fouling The following illustration shows the recommended rigging but is not intended to represent all rigging possibilities Some combinations of small primary rings and large secondary rings could cause fouling during release It is the responsibility of the operator to assure the cargo hook will function properly with each rigging 3 3 Cargo Hook Rigging continued Nylon Type Straps and Rope 3 4 Nylon type straps or similar material or rope must not be used directly on the cargo hook load beam If nylon straps or rope must be used they should be first attached to a steel primary ring Verify that the ring will freely slide off the load beam when it is opened Only the primary ring should be in contact with the cargo hook load beam Figure 3 2 Example of Recommended Cargo Hook Rigging SECONDARY RING PRIMARY RING Operation Instructions Section 4 Load Weigh System Operation Instructions Indicator Front Panel The C 39 Indicator front panel includes the following features The four 7 segment LCD digits show the weight on the Cargo Hook and displays various Setup information The Legends clarify the digital display i e when the LB Legend is tur2. xrom FOR TEMS CO TE AT WWW 1 ONBO ee aL ask CHECK W pt a REVISION OF TH 4 THE Le L pLi Owner s Manual for the 3 5KK Cargo Hook Kit on the BO 105 Series Helicopter System Part Numbers 200 290 00 200 291 00 Owner s Manual Number 120 110 00 Revision 9 February 3 2012 a CONBOARD SYSTEMS I N TERNATIONAL 13915 NW 3 Court Vancouver Washington 98685 USA Phone 360 546 3072 Fax 360 546 3073 Toll Free 800 275 0883 www OnboardSystems com This page intentionally left blank Revision Date RECORD OF REVISIONS Page s Reason for Revision 04 04 03 All First Issue 10 10 03 1 1 1 2 2 1 2 4 and 5 2 528 023 01 cargo hook configuration change Reference Service Bulletin 159 011 00 02 17 06 3 2 3 3 and T of C Added cargo hook loading section 09 05 06 3 1 Section 5 Updated cargo hook suspension system maintenance information 09 07 06 l 1 2 5 2 6 4 1 Updated manual to add information for installation of wire harness P N 270 048 04 09 07 07 TOC Section 1 2 3 2 4 2 6 2 7 2 8 3 1 3 3 3 4 4 8 and 4 9 Added Warnings Cautions and Notes explanation to section 1 Updated warnings cautions and notes format throughout 01 12 09 1 2 2 2 2 3 Changed load cell part no from 210 028 00 to 210 028 01 load cells are the identical except 01 has longer electrical harness Updated Figure 2 3 an
3. Supplemental Type Certificate Number SR00808SE This certifecate issued to Onboard Systems 13915 NW 3rd Court Vancouver WA 98685 certifies thal the change in the type design for lhe following product with the limitations and conditions therefor as yrecified hereon meets the airworthiness reguiremerls of Fart 27 ofthe Federal Aviation Type Certificate Number H3EU Make Messerschmitt Bolkow Blohm Model BO 105S Desorption of the Tppe Design Change Fabrication of Onboard Systems Model 200 253 00 without load weigh and Model 200 254 00 with load weigh Big Mouth Hook Kit and Model 200 290 00 without load weigh and Model 200 291 00 with load weigh 3 5KK Cargo Hook Kit in accordance with FAA approved Onboard Systems Master Drawing List No 155 056 00 Revision 4 dated May 14 2003 or later FAA approved revision and installation of these replacement cargo hooks in accordance with FAA approved Onboard Systems Owner s Manuals No 120 088 00 Revision 4 dated January 23 2003 for the Big Mouth Hook Kit and No 120 110 00 Revision 0 dated April 4 2003 for the 3 5KK Cargo Hook Kit or later FAA approved revisions This modification must be inspected in accordance with Section 5 of the Onboard Systems Owner s Manual No 120 088 00 Revision 4 dated January 23 2003 for the Big Mouth Hook Kit and Section 5 of the Onboard Systems Owner s Manual No 120 110 00 Revision 0 dated April 4 2003 and FAA approved Onboard Systems Cargo Hook Servic
4. 3 1 displayed numbers circuit failure Indicator does not change with Defective load cell indicator Check for damaged internal harness changing hook loads failure or damaged internal replace load cell harness 5 4 Maintenance 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 e Generate an RMA number at our website http Awww onboardsystems com rma php e After you have obtained the RMA number please be sure to e 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 Maintenance 5 5 This page intentionally left blank Section 6 STC rrited Sates of America Bepartnent of Transportation Feteral Aviation Administration
5. of the Cargo Hook kit perform the following functional checks 1 Swing the installed Cargo Hook to ensure that the manual release cable assembly and the electrical release cable have enough slack to allow full swing of the suspension assembly without straining or damaging the cables The cables must not be the stops that prevent the Cargo Hook from swinging freely in all directions 2 Apply 10 20 pounds to the cargo hook load beam and pull the handle operated cargo hook mechanical release the Cargo Hook should release 3 Close the cargo hook release circuit breaker and position the battery switch to the ON position Apply 10 20 pounds to the cargo hook load beam and depress the cargo hook electrical release button the Cargo Hook should release Component Weights The weight of the Cargo Hook Kit components are listed below Table 2 2 Component Weights Suspension System W hook W O Load Cell 4 8 lbs 2 2 kg Suspension System W hook W Load Cell 6 3 lbs 2 9 kg 7 oz 0 2 kg 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 document no 121 018 00 into the aircraft Flight Manual 2 8 Installation Instructions Section 3 Cargo Hook Operation Instructions Operating Procedures Operation Instructions Prior to a flight involving external load oper
6. 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 when no load is on the Cargo Hook installed Load Cell except the Cargo 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 i e 5000 kilograms is entered as 500 After the known load is entered press both buttons at the same time and lift the known load When the load is stabilized press either button A new Calibration Code will be calculated and the known load will be displayed This completes the procedure 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 button 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 XxX V Version is the revision le
7. the helicopter the more accurate the calculated Calibration Code will be Load Weigh System Operation Instructions 4 9 Calibration by Lifting a Known Weight continued To Run the Calibration by Lifting a Known Weight Routine 4 10 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 4 7 Running CAL Routine Hook Load X 10 CAL COU SETUP UN ZERD ZERO The CAL legend is turned on and the first digit is blinking The previous load is not displayed At this point if you wish to return to the Run Mode without changing the Calibration Code power cycle the Indicator At this point it is not possible to return to the Run Mode without changing the Calibration Code by using the buttons on the Indicator front panel To proceed with the procedure use the Right button to select the digit to be changed then use the Left button to scroll the blinking digit to the desired number Note that the known weight is entered X 10 a 1000 pound load is entered as 100 When the known load has been entered press both the Right and Left button at the same time The display will look like this Figure 4 8 Entering Load in CAL Routine Hook Load x 10 Load Weigh System Operation Instructions Calibration by Lifting a Known Weight continued The CAL l
8. 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 4 7 4 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 the Run Mode press both buttons at the same time to go to Setup Scroll through the menu until the word CODE is displayed then press the Right button The display should look like this Figure 4 6 Changing the CAL Code Hook Load x 10 CAL abs UN The CAL legend is turned on and the previously entered or computed Calibration Co
9. Cargo Hook Suspension Systems are approved for installation on the BO 105 series helicopters These systems replace the cargo hook an adapter link assembly the lower manual release cable and an electrical release wire harness on the MBB supplied cable type suspension system and cargo hook kit The P N 200 291 00 system is the same as the 200 290 00 except it features a load cell cockpit indicator and associated wiring The following definitions apply to safety labels used in this manual Indicates a hazardous situation which if not T D AN G i R avoided will result in death or serious injury Indicates a hazardous situation which if not avoided could result in death or serious injury Indicates a hazardous situation which if not avoided could result in minor or moderate injury Draws the reader s attention to important or N O C E unusual information not directly related to safety Installation Used to address practices not related to personal injury 1 1 Bill of Materials The following items are included with the Cargo Hook Kit if shortages are found contact the company from whom the system was purchased Provisions provided by the MBB 105 E0018 kit for the upper manual release cable the internal helicopter wiring and the cable suspension system are required to complete the installation 200 290 00 200 291 00 Part No Description Quantity Quantity 528 023 01 3 5K Keeperless Hook 1 232 096 00 Loa
10. R SWITCH SUPPLIED g CUT OFF THE BARE WIRE IF PRESENT DO NOT CONNECT IT TO GROUND TO 28 VDC TO 28 VDC lt immi gt TO AIRFRAME GROUND White Blue Black BACK LIGHT POTENTIOMETER OPERATOR SUPPLIED TO AIRFRAME GROUND TO OPTIONAL EQUIPMENT TO LOAD CELL _ m le go E H DATA RECORDER CONNECTOR Ro P N 410 011 00 410 057 00 amp 410 020 00 ANALOG METER CONNECTOR PIN COLOR FUNCTION P N 410 130 00 MFG ANY MFG P N MS3126F10 6P 1 WH BL Black Ground PIN COLOR FUNCTION 3 WH Red Power A WH Red Power 5 Shield Shield B WH GN Green Clock 7 WH GN Green Clock Signal C WH OR White Data 9 WH OR White Data Signal D WH BL Black Ground 4 Red Flight Switch E Shield Shield 2 Purple Cap Switch Optional White Red POWER CABLE INTERNAL HARNESS ASSEMBLY LIGHT CABLE WITH OPTIONAL CABLE INSTALLED White Red White Blue Black DATA RECORDER ANALOG METER CABLE DEPENDING ON MFG DATE OR DASH NUMBER THIS CABLE MAY TERMINATE IN A CONNECTOR OPTIONAL EQUIPMENT CONNECTORS Installation Instructions Installation Check Out After installation
11. al replace parts Remove Overhaul at the same interval corrosion and treat with as the Cargo Hook Refer to zinc chromate primer Service Manual 122 005 00 Inspect all mounting for overhaul instructions for fasteners to ensure that the cargo hook they are tight Visually inspect the electrical cables for damage and security Visually inspect the manual release cable for damage and security Cycle the electrical and manual release mechanisms to ensure proper cargo hook operation NOTICE Hours of external load operations is defined as the time in which a helicopter is engaged in external load operations This includes time between loads on the hook Maintenance 5 1 Inspection continued Table 5 1 Inspection continued Seq Part Daily Check Number 5 2 210 095 00 Load Indicator 270 048 00 270 048 04 Internal Harness Assembly All fasteners Ensure that the Indicator has been correctly calibrated and the correct Calibration Code has been entered into the Indicator Inspect for cracks excessive wear and security or attachment If worn excessively or cracked replace part Inspection Annually or 100 hours of external load operations whichever comes first Inspect the Indicator for damage and security If damage is found return the Indicator to the factory Same as Daily Check At overhaul interval Calibrate the system by lifting a known weight Check for security of a
12. allation Zero is not done the Indicator will show the weight of the Cargo Hook plus the value of the Load Cell zero offset To Run the Installation Zero Routine With the Indicator powered up and in the Run Mode press both buttons at the same time to go to Setup Scroll through the menu until the symbol 0 in is displayed then press the Right button The CAL legend will be turned on and the current weight on the Cargo Hook will be displayed and blinking Remove any weight that is not to be zeroed out and press either button to complete the procedure and return to the Run Mode Calibration by Lifting a Known Weight Calibration by lifting a known weight is a Setup routine that calculates the Calibration Code for the Load Cell attached to the Indicator It is useful if the load cell Calibration Code is not known or as a cross check to the accuracy of a known Calibration Code The procedure is done by entering the known weight into the Indicator and then lifting the weight This procedure can be done in the shop or on the helicopter The accuracy of the procedure is directly related to the weight of the known load If for example the procedure was done with a 1 000 pound load that was assumed to weigh only 900 pounds all subsequent lifts would be displayed 10 light Be sure to include the weight of everything between the Cargo Hook and the load i e the cable net dirt etc The closer the known load approaches the lifting capacity of
13. anded load release 3 The swaged joint fails and allows the inner cable to activate the hooks mechanical release mechanism and the hook opens Install the INOP placard P N 215 169 00 over the hook advisory light in the cockpit the 528 023 01 cargo hook does not have a hook lock indicator switch 2 4 Installation Instructions Load Weigh System Internal Harness Installation The Internal Harness is made up of four cables terminated to one large connector The connector is plugged into the back of the Indicator One of the cables is marked LOAD CELL and is fitted with a bulkhead fitting Hardware is provided to attach the bulkhead fitting to the Quick Disconnect Bracket P N 235 035 00 Attach the Quick Disconnect Bracket to the bracket that holds the manual and electrical release fittings on the skin of the aircraft at the cargo hook area Another cable is marked POWER and is connected to the aircraft electrical power Another cable is marked LIGHT refer to the Indicator Internal Back Light section for installation instructions The last cable is marked DATA and can be connected to the optional Data Recorder or Analog Slave Meter These optional items are not included under this STC The data cable may or may not be terminated with a connector depending on manufacture date Route cables along the existing harnesses while observing the following precautions Pick up existing wire runs by opening e
14. argo hook Connect the 268 026 00 manual release cable to the connection near the landing gear support tube Verify proper setting at the hook Place the cable ball end fitting into the hook manual release lever fork as illustrated in Figure 2 3 Rotate the manual release lever in the clockwise direction until the boss on its underside contacts the cam stop and hold in this position Measure the cable ball end free play with the manual release handle in the cockpit in the non release position Adjust the manual release cable system for a minimum of 125 inches 3 2 mm of free play at the fork as shown in Figure 2 3 The maximum amount of free play is limited by the manual release cover i e the ball end must fit inside the manual release cover when it is installed Installation Instructions Cargo Hook Kit Installation continued Installation Instructions Manual release cable rigging must be done with the cargo hook in the closed and locked position Figure 2 3 Manual Release Cable Rigging manual release lever Or bee VA release cable cable ball end Load beam must be closed and locked when rigging If the gap does not measure at least 125 make adjustments at the hook only This is done by disconnecting the cable at the interface with the fixed manual release cable loosening the jam nut at the hook and rotating the cable in the required direction Connect the 270 113 00 Electrical R
15. ations perform the following 1 Ensure that the Cargo Hook Kit has been properly installed and that the manual and electrical release cables do not limit the movement of the hook Be completely familiar with this manual particularly the section covering the Cargo Hook rigging Be completely familiar with all BO 105 Helicopter Cargo Hook operating instructions Activate the electrical system and press the Cargo Hook release button to ensure the cargo hook electrical release is operating correctly The mechanism should operate smoothly and the Cargo Hook should release Reset the load beam The release solenoid is intended to be energized only intermittently Depressing the electrical release button continuously in excess of 20 sec will cause the release solenoid to overheat possibly causing permanent damage Activate the manual release handle The mechanism should operate smoothly and the Cargo Hook should release Reset the load beam See the Cargo Hook Service Manual 122 005 00 and the aircraft s service instructions that cover the original Cargo Hook installation for additional instructions 3 1 Cargo Hook Loading The cargo hook can easily be loaded with one hand A load is attached to the hook by pushing the ring upward against the upper portion of the load beam throat as illustrated in Figure 3 1 until an internal latch engages the load beam and latches it in the closed position Figure 3 1 Cargo Hook Loading
16. ator 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 4 5 The Setup Mode continued Table 4 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 ae Dampening Level sets the pilots preference Blinking display is previously entered DAMP for display dampening Dampening 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
17. bject STC will be entered in the national index of STCs that have been familiarized or accepted by TC for installation on Canadian registered aeronautical products This letter confirms formal acceptance of the referenced STCs by Transport Canada Yours truly J H Nehera Regional Manager Aircraft Certification c c Mr Ali Bahrami Manager Seattle ACO 1601 Lind Avenue S W 3960 Paramount Boulevard Renton Washington 98055 4056 Canada n Certification
18. d clarified corresponding rigging instructions 10 28 09 2 3 Added caution note and revised Figure 2 3 3 2 10 2 3 2 5 to 2 8 amp 5 1 Updated manual to reflect new load weigh harness configuration Changed overhaul frequency criteria Corrected Figure 2 3 02 03 12 1 1 2 3 to 2 5 2 7 3 1 3 3 3 4 4 8 4 9 4 12 Section 5 Replaced Warnings Cautions and Notes section with Safety Labels section Updated Safety labels throughout document Updated RMA information Replaced Load Cell P N 210 028 01 with 210 028 02 in kit P N 200 291 00 and added P N 210 028 02 to the maintenance section section 5 Register Your Products for Automatic Notifications Onboard Systems offers a free notification service via fax or email for product alerts and documentation updates By registering your Onboard Systems products at our website we will be able to contact you if a service bulletin is issued or if the documentation is updated You can choose to receive notices on an immediate weekly or monthly schedule via fax email or both methods There is no charge for this service Please visit our website at www onboardsystems com notify php to get started This page intentionally left blank CONTENTS Section 1 Section 2 Section 3 Section 4 General Information Introduction 1 1 Safety Labels 1 1 Bill of Materials 1 2 Specifications 1 2 Installation Instructions Cargo Hoo
19. d Link Assembly 270 113 00 Electrical Release Cable 268 026 00 Manual Release Cable Assembly 120 110 00 Owners Manual 121 018 00 RFMS 122 005 00 3 5KK Hook Service Manual 270 048 04 Load Weigh Wire Harness 210 095 00 C 39 Indicator 210 028 02 E 73 Load Link Assembly 215 010 00 Placard 215 012 00 Placard 215 169 00 Indicator Light Placard 1 400 048 00 Power Switch 512 001 00 Ty wrap 210 028 02 supersedes P N 210 028 01 It features a stainless steel body for improved corrosion resistance and includes bushings and travel limiters at the cargo hook These part numbers are interchangeable pi fja f jai ak ojat N m m m m Specifications Table 1 1 System Specifications Design load 2 205 Ib 1000 kg Design ultimate strength 9 922 Ib 4500 kg Unit weight P N 200 290 00 4 8 lbs 2 2 kg Unit weight P N 200 291 00 6 3 lbs 2 9 kg Table 1 2 P N 528 023 01 Cargo Hook Specifications Force required for mechanical 8 lb Max 600 travel release at 3 500 Ib Electrical requirements 22 32 VDC 6 9 10 amps Minimum release load 3 0 pounds 1 35 kg Mating electrical connector PCO6A8 2S SR 1 2 General Information Section 2 Installation Instructions These procedures are provided for the benefit of experienced aircraft maintenance facilities capable of carrying out th
20. de 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 To Look at or Change the Calibration Code continued If the load cell Calibration Code is not known or as a cross check the Indicator can generate the Calibration Code This is done by entering the weight of a known load into the Indicator LOAD routine and then lifting the load See the section Calibration by Lifting a Known Load Installation Zero Installation zero is a routine that matches the Indicator to the INSTALLED Load Cell It adjusts the Indicator reading to compensate for the weight of the Cargo Hook on the Load Cell and whatever zero offset is built into the Load Cell The Installation Zero procedure is not mandatory If done the Indicator will read zero when the Un Zero button is pressed and there is no weight on the Cargo Hook If the Inst
21. displayed Figure 4 3 LB Legend Displayed Hook Load x 10 LB Jal 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 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 4 4 Zeroing the Displa Hook Load Zero Legend x 10 j Un Zero Legend To Un Zero the Display The Left button is used to add the zeroed value back into the current Indicator reading or Un zero the display When the Left button is pressed the number previously zeroed is added to the current display and the Un zero legend is turned on If the Left button is again pressed before the zero button is pressed the display blinks in response to the button closure Un Zero is only available in the Run Mode Load Weigh System Operation Instructions 4 3 4 4 Error Codes Error Codes are the result of difficulties discovered during the Indicator diagnostic tests Diag
22. e Manual No 122 005 00 dated October 10 2002 for the 3 5KK Cargo Hook Kit or later FAA approved revisions Gnitations and Conditions Approval of this change in type design applies to only Messerchmitt Bolkow Blohm model rotorcraft listed above which are modified with a FAA approved installation of a Breeze Eastern P N 14027 6 hook per STC SH286NE This approval should not be extended to 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 Modified rotorcraft must be operated in accordance with an FAA approved copy of Onboard Systems Rotorcraft Flight Manual Supplement RFMS No 120 088 00 dated June 5 2000 for the Big Mouth Kit and Onboard Systems Rotorcraft Flight Manual Supplement RFMS No 121 018 00 Revision 0 dated September 11 2003 for the 3 5KK Cargo Hook Kit or later FAA approved revisions A copy of this Certificate Owner s Manual Service Manual and the FAA approved RFMS must be maintained as a 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 This certificate and the s
23. e procedures They must not be attempted by those lacking the necessary expertise Cargo Hook Suspension Components Removal If the helicopter currently has the MBB kit installed remove the cargo hook the external wire harness and the mechanical release cable at the connection near the landing gear support tube Cargo Hook Kit Installation Attach the 528 023 01 cargo hook and 232 096 00 link assembly to the shackles using the hardware provided in the MBB kit see figure 2 1 below Install the cargo hook so the tip of the hook points aft which is opposite of the MBB kit Figure 2 1 Cargo Hook Installation Installation Instructions 2 1 Cargo Hook Kit Installation continued 2 2 Connect the manual release cable P N 268 026 00 to the cargo hook first per the following instructions Remove the manual release cover from the cargo hook Thread the fitting at the end of the manual release cable into the manual release boss on the hook side plate until the threads protrude approximately 125 inch beyond the boss as shown in Figure 2 2 and temporarily secure with jam nut Leave the manual release cover off of the cargo hook until the other end of the release cable is connected in order to verify proper setting Figure 2 2 Manual Release Cable Fitting Adjustment manual release cable assembly Route the cable up the right forward suspension cable to the c
24. ed 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 4 9 Changing the Scale Hook Load x 10 CAL Co Load Weigh System Operation Instructions 4 11 To Look at or Change the Scale continued Select KG or LB Units 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 The units routine sets the display to read in pounds LB or kilograms KG To look at or change the Units 4 12 With the Indicator powered up and in the Run Mode press both buttons at the same time to go to Setup Scroll through the menu until the word LB or KG is displayed then press the Right button The display should look like this Figure 4 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 Ru
25. egend and the digits will be blinking Again at this point if you wish to return to the Run Mode without changing the Calibration Code power cycle the Indicator It is not possible to return to the Run Mode by using the buttons on the Indicator front panel without changing the Calibration Code If you wish to proceed lift the known load and when it is stabilized press either button to complete the procedure The Indicator will display the load This ends the procedure The Indicator is now calibrated to the Load Cell It is a good practice to go to the Code routine and record the new Calibration code for later reference Setting the Scale for a remote analog meter The Scale routine is used when a user supplied analog meter is connected to the Indicator It is used to match or calibrate the analog meter to the Indicator The Indicator outputs a 0 to 5 VDC analog signal which is proportional to the Load Cell load The Scale number tells the Indicator at what point in pounds or kilograms it should reach the 5 VDC output If for example a 5 volt analog meter is used and its full scale reading is 10 000 pounds the number entered into the Indicator Scale routine would be 1000 the number is entered X 10 This number tells the Indicator that it should output the proportional 0 to 5 VDC signal between zero pounds and 10 000 pounds The Scale number does not affect Onboard Slave Meters P N 210 106 00 or 210 180 00 This number only affects user suppli
26. elease Wire Harness to the Cargo Hook connector Listed below is the pin out for the cargo hook connector Table 2 1 Carg Pin Function Pe o Hook Connector Positive The cargo hook is equipped with a suppression diode that will be damaged if the cargo hook electrical connection is reversed 2 3 Cargo Hook Kit Installation continued Route the electrical release cable up the left front suspension cable and attach to the side of body electrical connector Secure the electrical release wire harness and manual release cable to the suspension cables using existing clamps Un commanded cargo hook release will happen if the manual and electrical release cables are improperly restrained The cables must not be the stops that prevent the Cargo Hook from swinging freely in all directions If the Cargo Hook loads cause the hook to strain against the manual release cable the swaged end of the cable may separate allowing the inner cable to activate the cargo hook manual release mechanism The result is an un commanded release Ensure that no combination of cyclic stick or Cargo Hook position is restrained by the manual or electrical release cables Figure 2 4 Un commanded Release From Incorrectly Secured Cable 1 Hook rotates and strains against the manual release cable conduit 2 The strain on the conduit exceeds the pull off force between the swaged fitting and the conduit we 4 The load ring falls free in an un comm
27. is part is 15 5PH P N 290 607 00 gouges corrosion or corrosion if less than 030 deep blend out ata passivated No Load Cell Link scratches ratio of 20 1 length to depth replace if touch up finish P N 291 550 00 otherwise damaged required Load Cell Dents nicks cracks Repair dents gouges nicks scratches and Touch up with zinc P N 290 031 00 gouges corrosion or corrosion if less than 030 deep blend out ata chromate primer scratches ratio of 20 1 length to depth replace if otherwise damaged Bushing Wear on inside diameter Maximum permissible bushing ID is 520 P N 290 364 00 inches Remove and replace if it exceeds 520 also included with Load Cell Assembly P N 210 028 02 Trouble Shooting Table 5 4 Trouble Shooting DIFFICULTY PROBABLE CAUSE CORRECTIVE ACTION Load Weigh Indicator does not Faulty wiring circuit breaker or Check the power switch circuit breaker light up switch and wiring If this doesn t help return the unit to the factory Where Am I Lost when Turn the Indicator power off for a few programming the Indicator moments When it comes to life it will be in the Run mode incorrect been entered stable number Indicator displayed load takes too Dampening level is too large Adjust the dampening level to a smaller long to change the reading when number the load is changed Do not recognize the Indicator NV Ram failure A D or D A Refer to Error Codes in Table
28. k Removal 2 1 Cargo Hook Kit Installation 2 1 Load Weigh System Internal Harness Installation 2 5 C 39 Cockpit Indicator Installation 2 5 Indicator Internal Back Light 2 6 Indicator Hook Open Warning 2 6 Remote Analog Meter 2 6 Electrical Connections 2 7 Installation Check Out 2 8 Component Weights 2 8 Paper Work 2 8 Cargo Hook Suspension System Operation Instructions Operating Procedures 3 1 Cargo Hook Loading 3 2 Cargo Hook Rigging 3 3 Load Weigh Operation Instructions Indicator Front Panel 4 1 The Run Mode 4 2 To Zero or Tare the Display 4 3 To Un Zero the Display 4 3 Error Codes 4 4 The Setup Mode 4 5 Indicator Dampening 4 7 To look at or change the dampening level 4 7 Indicator Calibration 4 8 To look at or change the calibration code 4 8 Installation Zero 4 9 To run the installation zero routine 4 9 Calibration by Lifting a Known Weight 4 9 To run calibration by known weight routine 4 10 CONTENTS continued Setting the Scale on a Remote Analog Meter 4 11 To look at or change the scale 4 11 Select KG or LB Units 4 12 To look at or change the units 4 12 Indicator Version 4 13 Section 5 Maintenance Inspection 5 1 Link Assembly Overhaul 5 3 Trouble Shooting 5 4 Instructions for Returning a System to the Factory 5 5 Section 6 Certification FAA STC 6 1 Canadian STC 6 2 Section 1 General Information Introduction Safety Labels The P N 200 290 00 amp P N 200 291 00
29. n 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 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 4 11 Looking at Indicator Version Hook Load x 10 CAL LB KG UN ZERD Load Weigh System Operation Instructions 4 13 This page intentionally left blank Section 5 Maintenance Refer to Service Manual 122 005 00 for detailed maintenance information for the Cargo Hook Inspection The inspection of the Cargo Hook Kit shall be in accordance with the table below The overhaul interval for the kit components other than the cargo hook shall be at the same overhaul interval as the cargo hook See Service Manual 122 005 00 Table 5 1 Inspection Seq Part Daily Check Inspection Annually or 100 At overhaul interval Number hours of external load operations whichever comes first 200 290 00 1 Inspect all items for Same as Daily Check Tear down and inspect the 200 29 1 00 cracks wear and detail components see Figure System corrosion If worn 5 1 to the requirements excessively or cracked outlined in this Manu
30. ned 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 4 1 Front Panel Calibration amp Zero amp Un Zero Legend 7 Hook Logd Dampening Unit Legend Left Button Load Weigh System Operation Instructions 4 1 The Run Mode 4 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 to life in the Run Mode After the Indicator has been correctly installed power it up by activating the Load Weigh Circuit Breaker The Indicator will go through a self diagnostic routine During this routine the display will display all of the digits and legends If a problem is found during the routine an Error Code will be displayed For an explanation of Error Codes see the section Error Codes After the diagnostic routine the display should look like this Figure 4 2 After Diagnostic Routine Hook Load X 10 CAL SETUP UN ZERO ZERO 4j The illustration is of the Indicator in the Run Mode with no load on the hook Note the LB legend
31. ness DATA cable Ifa data connector is present on the data line use cable P N 270 059 00 to connect to Analog Slave Meter Installation Instructions Electrical Connections Connect the Internal Harness to the Indicator and route the other end to a convenient location for the Indicator power switch part number 400 048 00 The cable is supplied extra long cut off the excess cable and use as needed to connect the switch and circuit breaker Connect the white red if wire harness P N 270 048 00 is installed wire in the power cable to one side of the power switch connect another piece of suitable wire to the other side of the switch and then to an available 1 or 2 amp circuit breaker Connect the white blue black if wire harness P N 270 048 00 is installed wire to the ground bus The bare wire present on P N 270 048 00 only should be cut off as it is not needed at this end of the cable Install the placard 215 010 00 ELECTRONIC WEIGHING SYSTEM next to the power switch and circuit breaker Install the placard 215 012 00 TURN THE WEIGHING SYSTEM OFF WHEN NAVIGATION EQUIPMENT IN USE NO AIRCRAFT OPERATION SHOULD BE PREDICATED ON THE READING OF THE ONBOARD WEIGHING SYSTEM next to the Indicator NOTICE If the C 23 Printer is being utilized with the C 30 Data Recorder a 5 amp circuit breaker should be used Figure 2 5 Wiring Arrangement 1 AMP CIRCUIT BREAKER amp OPERATOR SUPPLIED POWE
32. nostic 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 4 1 Indicator Error Codes POSSIBLE DISPLAY CAUSE CORRECTIVE ACTION A D or D A circuit Potential short in the optional failure 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 NV Ram failure Power cycle the Indicator if Error Code continues return the Indicator to the factory NV Ram write failure Re enter data if Error Code continues return the Indicator to the factory NV Ram busy failure 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 This 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 Indic
33. ttachment damaged wires and connectors Replace if damaged Most system problems will be the result of damaged wires Keep the cables clean and ensure that they are not chafing Recommended to replace at overhaul Maintenance Link Assembly Overhaul Maintenance Figure 5 1 Link Assembly Parts Table 5 2 Link Assembly Parts ITEM PART NO DESCRIPTION With a 200 291 00 kit with Load Weigh 290 031 00 or 291 550 00 part of load cell assembly 210 028 01 and 210 028 02 respectively Load Cell Link is installed rather than 290 607 00 Load Cell P N 210 028 01 does not include bushings Carefully inspect and if necessary repair the detail parts in accordance with the instructions in Table 5 3 Inspect the parts in a clean well lit room Perform magnetic particle inspection in accordance with ASTM E1444 and MIL STD 1907 Grade A on the parts listed below No cracks are permitted in any of these parts 1 Load Link or Load Cell Link item 1 depending on kit installed Since it is necessary to remove the covers it is recommended that the Load Cell Assembly be returned to the factory for magnetic particle inspection of the Load Cell Link If the inspection is to be performed by the customer contact the factory for additional guidance 5 3 Link Assembly Overhaul Table 5 3 Inspection Component Damage Remedy Finish Load Link Dents nicks cracks Repair dents gouges nicks scratches and Th
34. upporiing data which is the basis for approval shall remain in efect until sur rendered sugpended revoked or a termination date i otherwise established ly the Mdininistrator of the Date of application March 31 2000 Date reissued January 13 2003 June 5 2000 a 2001 September 11 2003 Signature Acting Manager Seattle Aircraft Certification Office Title Any alteration of this certificate is punishable by a fine of nat exceeding 1 000 or imprisonment not exceeding 3 years or both FAA FORM 8110 2 10 68 This certificate may be transferred in accordance with FAR 21 47 Canadian Approval i Transport Transports Canada Canada Aviation Aviation Aircraft Certification Branch 620 800 Burrard Street Vancouver BC V6Z 2J8 Your file Voire r f rence Our fia Notre r f rence 5009 02 August 4 2000 Onboard Systems 11212 NW St Helens Road Portland OR 97231 Attention Mr Donn Snyder Subject Type Design Examination of FAA STC SR 00808SE Dear Sir Madam This is in response to your letters dated June 12 2000 requesting Transport Canada TC approval of subject STC In accordance with our revised policy associated with the familiarization of FAA STCs some STCs applicable to certain categories of aircraft may be accepted solely on the basis of their FAA certification and do not require the issuance of a corresponding certificate by TC The referenced STC falls within that criteria Notwithstanding the su
35. vel of the Indicator Version is for information only it cannot hardware and software be changed 4 6 Load Weigh System Operation Instructions 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 O the display responds to the slightest change in weight However if the load bounced even slightly the display digits would respond instantly making the display look unstable With a dampening level of 9 the display would be stable under the most turbulent conditions however it would take several seconds for the display to respond to a change in weight The ideal dampening level will depend on the flying conditions A mid range setting of 5 or 6 is usually adequate To Look at or Change the Dampening Level With the Indicator powered up and in the Run Mode press both buttons at the same time to go to Setup Scroll through the menu using the Left button until the word DAMP is displayed To look at or change the Dampening Level press the Right button The display should look like this Figure 4 5 Changing 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
36. witch must be normally open when the cargo hook load beam is in the closed position When the load beam is open one side of the switch must be grounded and the other side of the switch is to be connected to the Indicator Use a 22 gauge shielded wire to connect the cargo hook switch to the Indicator Disassemble the Indicator mating connector and carefully solder the wire from the cargo hook switch to pin H Connect the cable shield wire to airframe ground as close to the cargo hook as possible at the cargo hook end of the cable ONLY Remote Analog Meter 2 6 The Indicator is equipped with an Analog drive circuit that can be connected to a remote analog meter Use a 22 gauge twisted pair shielded cable to connect the Remote Analog Meter to the Indicator Disassemble the Indicator mating connector and carefully solder the positive wire from the analog meter to pin G and the common wire to pin F Connect the cable shield wire to airframe ground as close to the Analog Meter as possible at the Analog Meter end of the cable ONLY The 210 095 00 Indicator can be connected to Onboard Systems Analog Slave Meter P N 210 180 00 through the DATA cable This meter gives solid weight indications without needle bounce The Analog Slave Meter may be mounted in any convenient location in a standard 3 instrument hole Attach connector P N 410 130 00 to data line per pin out in Figure 2 5 to connect the Analog Slave Meter to the Internal Har
37. xisting cable clamps Nylon ties alone may not be used for primary support The distance between supports should not exceed 21 inches Bend radius of wire or harness must not be less than 10 times the wire or harness diameter Inspect and verify that the wire harness may not be manually deflected into a structure with a bend radius of less than 13 i e sharp corners which could cause chafing Secure the cables clear of flight control rods C 39 Cockpit Indicator Installation Installation Instructions The Indicator P N 210 095 00 should be mounted in a position that is convenient accessible and visible to the pilot It can be mounted in a standard 214 instrument hole Connect the Indicator to its Internal Harness refer to Internal Harness Installation 2 5 Indicator Internal Back Light The Indicator is equipped with an Internal Back Lighting System that can be connected to the aircraft 28 VDC light dimming circuit Use a 22 gauge twisted pair shielded cable to connect the aircraft dimming circuit to the Internal Harness Connect the cable shield wire to airframe ground at the light dimmer end of the cable ONLY Indicator Hook Open Warning The Indicator is equipped with a Hook Open Warning feature that can be connected to a cargo hook equipped with a hook open switch Depending on the capabilities of the cargo hook switch the Indicator will flash HOOK OPEN when the cargo hook load beam is open The cargo hook s
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