Instructions for Continued Airworthiness - Cargo Swing Retrofit Kit

25.15.7 Changing Dampening Level, Section 25 Page 13 25.16.1 Suspension Attachment Hardware, Section 25 Page 14 25.16.2 Manual Release Cable Connection, Section 25 Page 15 25.16.3 Manual Release Cover Removal, Section 25 Page 15 25.16.4 Load Weigh Indicator, Section 25 Page 16 25.16.5 Load Cell Hardware, Section 25 Page 16 25.16.6 Fuel Drain Guard Removal, Section 25 Page 17 25.17.1 Cable Attachment, Section 25 Page 18 25.17.2 Cargo Hook Attachment Hardware, Section 25 Page 19 25.17.3 Manual Release Cable Adjustment, Section 25 Page 20 25.17.4 Manual Release Cable Connection, Section 25 Page 21 25.17.5 Manual Release Cable Rigging, Section 25 Page 22 25.17.6 C-40 Model Re-installation, Section 25 Page 22 25.17.7 Sealant Application Location, Section 25 Page 24 25.17.8 Guard/Retainer Assembly, Section 25 Page 24 25.17.9 Lever Installation, Section 25 Page 25 25.17.10 Cable Setting, Section 25 Page 26 Tables 5.2.1 Swing Suspension Parts List, Section 5 Page 11 5.2.2 Swing Suspension Inspection Criteria, Section 5 Page 13 11.1 Cargo Hook Suspension System Placards, Section 11 Page 1 25.1 Cargo Hook Connector, Section 25 Page 1 25.5.1 Component Weights and CGs, Section 25 Page 5 25.15.1 Troubleshooting, Section 25 Page 6 Instructions for Continued Airworthiness 123-014-02 Revision 5 00-00-00 Page 1 05/09/14 Section 0 Introduction 0.4 Scope The following information is necessary to carry out the service, maintenance, and inspection of the Cargo Swing Retrofit Kit P/N 200-286- 02 and P/N 200-286-03. See section 25.2 for a detailed description of the kit. 0.5 Purpose The purpose of this Instructions for Continued Airworthiness (ICA) manual is to provide the information necessary to inspect, service, and maintain in an airworthy condition the P/N 200-286-02 and P/N 200-286- 03 Cargo Swing Retrofit Kits. 0.6 Arrangement This manual contains instructions for the service, maintenance, inspection and operation of the Cargo Swing Retrofit Kit P/N’s 200-286-02 and 200- 286-03 on Airbus Helicopters model AS350 series helicopters. The manual is arranged in the general order that maintenance personnel would use to maintain and operate the Cargo Hook Swing Suspension System in service. The arrangement is: Section 0 Introduction. Section 4 Airworthiness limitations (none apply to this system.) Section 5 Inspection and overhaul schedule Section 11 Placards and Markings Section 12 Servicing Section 25 Equipment and Furnishings 0.7 Applicability These Instructions for Continued Airworthiness are applicable to Cargo Swing Retrofit Kit P/N 200-286-02 and P/N 200-286-03 for the Airbus Helicopters AS350 series helicopters. Maintenance of this kit, which includes a common cargo hook (P/N 528-029-00), also requires cargo hook CMM 122-017-00 in addition to the instructions provided in this manual. Refer to the appropriate Airbus Helicopters maintenance documentation for instructions regarding parts of the aircraft that interface with these kits. 0.9 Abbreviations FAA Federal Aviation Administration ICA Instructions for Continued Airworthiness CFR Code of Federal Regulations CMM Component Maintenance Manual Instructions for Continued Airworthiness 123-014-02 00-00-00 Page 2 Revision 0 05/18/10 0.12 Precautions The following definitions apply to precaution flags used in this manual. Indicates a hazardous situation which, if not avoided, will result in death or serious injury. Indicates a hazardous situation which, if not avoided, could result in death or serious injury. Indicates a hazardous situation which, if not avoided, could result in minor or moderate injury. Draws the reader’s attention to important or unusual information not directly related to safety. Used to address practices not related to personal injury. 0.19 Distribution of Instructions for Continued Airworthiness Before performing maintenance ensure that the Instructions for Continued Airworthiness (ICA) in your possession is the most recent revision. Current revision levels of all manuals are posted on Onboard Systems Int'l web site at www.onboardsystems.com. Also a Documentation Update Service is available on the web site. Registering for this service provides an e-mail or fax notification when a manual has been revised. Hard copies of all manuals are available from the factory, contact the factory at 800- 275-0883 to request a copy. Instructions for Continued Airworthiness 123-014-02 Revision 0 04-00-00 Page 1 05/18/10 Section 4 Airworthiness Limitations This Airworthiness Limitations section is FAA approved and specifies inspections and other maintenance required under 14 CFR §§ 43.16 and 91.403, unless an alternative program has been FAA approved. No airworthiness limitations are associated with this type design change. Instructions for Continued Airworthiness 123-014-02 04-00-00 Page 2 Revision 0 05/18/10 THIS PAGE INTENTIONALLY LEFT BLANK Instructions for Continued Airworthiness 123-014-02 Revision 10 05-00-00 Page 1 06/20/24 Section 5 Inspection and Overhaul Schedule The scheduled inspections (Annual/100 Hour and 5 Year/1000 Hour) are defined herein. If the system is subjected to unusual circumstances, extreme environmental conditions, etc., it is the responsibility of the operator to perform the inspections more frequently to ensure proper operation. Refer to Section 5.1 for the Annual/100 Hour Inspection and Section 5.2 for the 5 Year/1000 Hour Inspection. 5.1 Annual/100 Hour Inspection Annually or 100 hours of external load operations, whichever comes first, inspect the cargo hook and other kit components per the following. A grace period of 1 month or 10 hours of external load operations can be applied to this interval for maintenance scheduling convenience only. Refer also to Component Maintenance Manual (CMM) 122-017-00 for additional inspection. Hours of external load operations should be interpreted to be (1) anything is attached to the primary cargo hook (whether or not a useful load is being transported) and (2) the aircraft is flying. If these conditions are NOT met, time does NOT need to be tracked. The optional C-40 Indicator (P/N 210-293-00 or 210-293-01) also records and displays hours of external load operations accumulated. This resettable hour-meter automatically logs time when the external load goes above 50 lbs and stops counting when it goes under 25 lbs. For this method of tracking hours refer to the C-40 Owner’s Manual for setup and additional instructions. Instructions for Continued Airworthiness 123-014-02 05-00-00 Page 2 Revision 10 06/20/24 5.1 Annual/100 Hour Inspection continued 1. Activate the electrical system and press the Cargo Release button to ensure the cargo hook electrical release system is operating correctly. With no load on it, the cargo hook must release. Reset the hook by hand after release. Depressing the button continuously in excess of 20 seconds will cause the cargo hook solenoid to overheat, possibly causing permanent damage. 2. Activate the manual release system by pulling the release lever in the cockpit. With no load on it, the cargo hook must release. Reset the cargo hook by hand after release. Verify that the hook lock indicator on the side of the hook returns to the fully locked position. In the fully locked position the hook lock indicator must align with the lines on the manual release cover (see Figure 5.1.1). Figure 5.1.1 Hook Lock Indicator 3. Visually inspect the external manual release cable for damage and security, with emphasis on the cargo hook end of the release cable (refer to Figure 5.1.2). Figure 5.1.2 Manual Release Cable Inspection Pay close attention to this area of the manual release cable. Instructions for Continued Airworthiness 123-014-02 Revision 10 05-00-00 Page 3 06/20/24 5.1 Annual/100 Hour Inspection continued 4. Remove the manual release cover from the cargo hook and inspect the visible section of the inner cable for kinks or frays. Manual release cables are wearable items and must be replaced as conditions require. Broken or kinked conduit, inner cable kinks (ref Figure 5.1.3), frays, or sticky operation are each cause for immediate replacement. Figure 5.1.3 Manual Release Cable Conditions Kinked inner cable. Broken or kinked conduit. 5. Check the manual release cable rigging. With the cargo hook load beam closed and locked, rotate the manual release lever clockwise to remove the free play (the free play is taken up when the hook lock indicator begins to move, this is also readily felt as the lever rotates relatively easily for several degrees as the free play is taken up) and hold it in this position while checking the gap between the release lever fork and the cable ball end as shown below. A minimum gap of 1/8” (3.2 mm) should be present as shown in Figure 5.1.4. Figure 5.1.4 Manual Release Cable Rigging Load beam must be closed and locked. 18" (3.2 mm) minimum Manual Release Lever Cable Ball End Manual Release Lever fork Instructions for Continued Airworthiness 123-014-02 05-00-00 Page 4 Revision 11 08/11/26 5.1 Annual/100 Hour Inspection continued 6. Visually inspect for presence and security of fasteners and electrical connections. 7. Visually inspect the external electrical wire harnesses for damage, chafing and security. 8. Visually inspect for corrosion on the exterior of cargo hook, load cell and swing suspension components. 9. Swing the cargo hook and the swing suspension and ensure all pivot points rotate freely without binding. 10. Move the cargo hook and the swing suspension throughout their full ranges of motion and observe the manual release cable, electrical harnesses, and ground strap to ensure that they have enough slack. The release cable, harnesses, and ground strap must not be the stops that prevent the cargo hook or suspension from moving freely in all directions. 11. Visually inspect the cargo hook and swing frame assembly bumpers for damage and security. 12. Visually inspect for dents, scratches and gouges in the swing frame assembly tubes. Refer to Table 5.2.2 for limits. 13. Visually inspect for cracks in suspension frame. Pay special attention to the areas around the welds. The frame tubes contain a corrosion preventative compound, which may leak out through a crack and provide an indication. At any sign of cracking, remove and replace discrepant part. 14. Inspect suspension cables for broken strands, paying close attention to the sections around the thimbles at each end. Pass a cloth over the cables. This will clean the load ropes for a visual inspection and detect broken wires if the cloth snags on the rope. Ten randomly distributed broken wires in one rope lay (one complete rotation around the wire) or five broken wires in one strand in one rope lay is considered unacceptable. One rope lay is the length along the rope which a single strand requires to make one complete spiral around the core. 15. Disassemble and inspect the upper joint of the load cell (16) per the following, referring to Figure 5.2.2 for item numbers in parentheses ( ). If Swing Frame Assembly has been subjected to torsional loading, see Special Inspection for Torsion involving further disassembly and inspection instructions in step 16. a. Remove the cotter pin (22), washer (20), retaining washer (18), and nut (21) from the end of the bolt (19). b. While supporting the load cell and cargo hook (28), remove the bolt and the other retaining washer (18) and slide the Gimbal Shaft (17) out of the joint, separating the load cell from the Gimbal (1.1). c. Visually inspect the Gimbal Shaft for signs of wear, such as pitting, galling, or reduction in diameter. If reduction in diameter is observed, refer to the criteria in Table 5.2.2. There should be no visible wear, except for light burnishing of the outside diameter surface. If the burnishing can be removed using Scotch Brite (3M P/N 7447), it is considered light. Instructions for Continued Airworthiness 123-014-02 Revision 11 05-00-00 Page 5 08/11/26 5.1 Annual/100 Hour Inspection continued d. Inspect the inside diameters of the upper lugs of the load cell (refer to Figure 5.1.5) for signs of wear such as pitting, galling, or elongation of the holes. If elongation is observed, refer to the size limits criteria in Table 5.2.2. There should be no visible wear, aside from light burnishing of the inside diameter surfaces. If the burnishing can be removed using Scotch Brite, it is considered light. Visually inspect for cracks around both lugs, including the transitional areas (indicated in Figure 5.1.5) where the lugs transition into the flat portion of the load cell. Inspect these areas on both sides. Figure 5.1.5 Load Cell Inspection e. Inspect the flanged DU bearings (1.2) of the Gimbal (1.1) that interface with the Gimbal Shaft. Any pits or signs of galling on these bearings are cause for replacement. Additionally, as these bearings wear, the low- friction PTFE layer is removed, exposing the copper layer below (ref. Figure 5.1.6). Across the width of the bearing surface, no more than 50% should be the exposed copper layer. Figure 5.1.6 Gimbal DU Bearing Inspection Criteria inside diameters of upper lugs transitional areas exposed copper Exposed copper should be no more than 50% of bearing surface width. Instructions for Continued Airworthiness 123-014-02 05-00-00 Page 6 Revision 11 08/11/26 5.1 Annual/100 Hour Inspection continued f. Replace worn or damaged parts. If DU bearings require replacement (refer to this section for further disassembly instructions), press in with wet zinc chromate primer (TTP-1757 or equivalent) applied to the inside diameter of the mating hole. g. Re-assemble the load cell to the Gimbal per Section 25.17. Special Inspection for Torsional Loads If the swing frame assembly is used with torsional loads (such as a fertilizer slinger bucket) that are attached directly to the cargo hook via a spreader bar (without any additional restraints), perform additional inspections as specified in this below. Loads attached to the cargo hook with a spreader bar (such as a typical fertilizer bucket) cause the swing frame assembly to react high torsional loads. Repetitive high torsional loads are damaging to the swing frame assembly and require an additional inspection as defined in the following step. 16. Disassemble the upper pivoting joint of the swing frame assembly to remove and inspect the Gimbal Assembly per the following. a. Remove the cotter pin (8), nut (9), Shaft Cap (5) and remove the bolt (10) and the other Shaft Cap. b. Remove the Pivot Shaft while supporting each Swing Frame Half. c. Remove the Gimbal Assembly (1) and the Thrust Washers (15). d. Perform a visual inspection for cracks in the Gimbal (1.1), with specific attention on the transitional areas (on both sides) as identified in Figure 5.1.7, including around the base of the arrow shaped feature. Instructions for Continued Airworthiness 123-014-02 Revision 11 05-00-00 Page 7 08/11/26 5.1 Annual/100 Hour Inspection continued Figure 5.1.7 Gimbal Assembly Inspection If the C-40 Indicator (P/N 210-293-00 or 210-293-01) is installed and connected to the VEMD for the function to increase the main rotor RPM perform the following. 1. Check the function of the C-40 Indicator to signal the VEMD to send N2 datum of 400 rpm to the FADEC when the measured external load is 331 lbs. (150 kg) or more. This function is applicable to AS350B3s with MOD 07- 4716 incorporated. Perform check per the following. o From the Load screen rotate the rotary push button knob to enter the C-40 Settings screen. o Press the knob to enter the Settings menu. o Scroll down the menu to the Analog Test setting by rotating the knob and press the knob again. o A simulated load of 475 lbs. is output for 3 seconds, verify this load is displayed on the VEMD (if the engine is running in FLIGHT mode this also temporarily sends an N2 datum of 400 rpm to the FADEC resulting in a slight acceleration and deceleration of NR). If the fuel drain guard is installed perform the following. 1. Inspect all fuel drain guard parts for corrosion, gouges, nicks, and dents. If depth of corrosion pits, gouges, nicks, or dents exceed .060”, remove and replace damaged part(s). 2. Inspect Guard for damage that causes lever to bind or rub. Remove and replace Guard if it is obstructing free operation of lever. 3. Inspect for fuel leakage. If leakage is noted, re-apply sealant to Retainer as described in Section 25. Refer to Airbus Helicopters maintenance instructions for other possible causes. Transitional area Instructions for Continued Airworthiness 123-014-02 05-00-00 Page 8 Revision 11 08/11/26 5.2 5 Year/1000 Hour Inspection Every 5 years or 1000 hours of external load operations, whichever comes first, remove the external components from the aircraft and disassemble per the following. A six-month or 100-hour grace period can be applied if needed for maintenance scheduling convenience only. No extension to maintenance is allowed beyond this tolerance grace period. *After disassembly return the Load Cell to the factory for inspection and calibration. The factory will inspect the condition of the load cell and perform acceptance test procedures including calibration and zero balance, repairing as necessary. Remove the suspension by removing the quick release pins at the cable attachments to the shackle assemblies at the landing gear cross tubes and disconnecting the electrical harnesses, ground strap and manual release cable connections at the aircraft. Remove the four Shackle Assemblies from the aircraft hardpoints. Disassemble per the following steps. For item numbers in parentheses ( ), refer to Figure 5.2.1 through Figure 5.2.3 for Swing Suspension parts and Figure 5.2.4 for Shackle Assembly parts. Part numbers are listed in Table 5.2.1. 1. Remove the four suspension cable assemblies from the swing frame feet by removing the cotter pin (35), nut (34), two washers (33) and bolt (31). Remove the Standoff Bushings (32). 2. Separate the Load Cell (16) and Cargo Hook (28) from the Swing Frame by removing the cotter pin (22), nut (21), washer (20), and Shaft Retaining Bushing (18) and sliding the Gimbal Shaft (17) and bolt (19) out with the other Shaft Retaining Bushing (18). 3. At each foot of the swing frame remove the nut (7) and bolt (12) that secure the rod end fittings (13) to the swing frame feet. 4. At the upper pivoting joint of the swing frame remove the cotter pin (8) and nut (9) from the end of the bolt (10) and remove the Shaft Cap (5). 5. Slide the Swing Frame Half (3) off of the Pivot Shaft (4) and remove the bumper (6), thrust washers (15), and Gimbal Assembly (1.1, 1.2, 1.3). 6. Slide the Pivot Shaft out of the opposite Swing Frame Half (3) and remove the other Shaft Cap (5) and bolt. 7. Separate the Cargo Hook and Hook Bumper (23) from the Load Cell by removing the cotter pin (8), nut (27), and washers (25, 26) from the end of the Attach Bolt (24) and slide the Attach Bolt out, removing the other washer (25). 8. Separate the Gimbal Assembly (36.1, 36.2, 36.3) from each suspension cable assembly by removing the cotter pin (35), nut (34), washer (33), and bolt (39). 9. Remove spiral wrap from around the frame tubes. 10. Remove bushings if it is necessary that they be replaced. All self-lubricating bushings use an interference fit to hold them in place. Use an arbor press or similar to press the bushings out of the bore they are mounted in. Do NOT use heat. Instructions for Continued Airworthiness 123-014-02 Revision 11 05-00-00 Page 9 08/11/26 5.2 5 Year/1000 Hour Inspection continued Figure 5.2.1 Suspension Cable to Swing Frame Attachment Hardware 31 33 32 33 34 35 Figure 5.2.2 Swing Frame Assembly P/N 232-145-03 Parts 3 3 4 1.1 2 5 5 6 7 12 14 10 1.2 1.3 15 15 16 17 24 23 18 22 25 19 20 21 13 11 28 9 8 14 4X 4X 4X 4X Sub-assembly P/N 232-145-25 parts 26 27 8 Ground Strap Connection 29 30 Instructions for Continued Airworthiness 123-014-02 05-00-00 Page 10 Revision 11 08/11/26 5.2 5 Year/1000 Hour Inspection continued Figure 5.2.3 Suspension Cable Parts Fork End Fittings (part of 37, 38) 33 Lanyard not shown. 35 39 34 37 40 38 41 36.2 36.1 36.3 Figure 5.2.4 Shackle Assembly Parts 42.1 42.5 42.3 42.2 42.4 Instructions for Continued Airworthiness 123-014-02 Revision 11 05-00-00 Page 11 08/15/26 5.2 5 Year/1000 Hour Inspection continued Table 5.2.1 Swing Suspension Parts List Item Part No. Description Qty 11 232-143-01 Load Cell Gimbal Assembly 1 1.1 290-841-00 Gimbal 1 1.2 517-046-00 Flanged DU Bearing 2 1.3 517-056-00 DU Bearing 2 1.43 518-003-00 Grease Fitting 1 2 235-116-00 Frame Strut Weldment 2 3 235-117-00 Swing Frame Half 2 4 290-842-00 Pivot Shaft 1 5 290-843-00 Cap-Shaft 2 6 290-862-00 Bumper 1 7 510-104-00 Nut 4 8 510-178-00 Cotter Pin 2 9 510-440-006 Nut 1 10 510-506-00 Bolt 1 11 510-510-00 Jam Nut 4 12 510-762-00 Bolt 4 13 517-055-00 Spherical Rod End 4 14 517-057-00 Flanged DU Bearing 2 15 517-058-00 Thrust Bearing 2 16 210-249-035 Load Cell 1 17 290-739-00 Shaft - Gimbal 1 18 290-740-00 Retaining Bushing - Shaft 2 19 510-443-00 Bolt 1 20 510-220-00 Washer 1 21 510-320-00 Nut 1 22 510-115-00 Cotter Pin 1 23 290-774-00 Hook Bumper 1 24 290-775-00 Long Attach Bolt 1 25 510-183-00 Washer 2 26 510-174-00 Washer 1 27 510-170-00 Nut 1 28 528-029-00 Cargo Hook 1 29 270-126-00 Ground Strap 1 30 510-391-00 Screw 1 31 510-439-00 Bolt 4 32 290-749-00 Standoff Bushing 8 33 510-221-00 Washer 12 34 510-718-004 Nut 8 35 510-178-00 Cotter Pin 8 Instructions for Continued Airworthiness 123-014-02 05-00-00 Page 12 Revision 11 08/11/26 5.2 5 Year/1000 Hour Inspection continued Table 5.2.1 Swing Suspension Parts List continued Item Part No. Description Qty 361 232-142-00 Lower Attach Gimbal Assembly 4 36.1 290-746-00 Gimbal 12 36.2 517-048-00 DU Bearing 22 36.3 517-016-00 DU Bearing 12 37 232-177-00 Forward Suspension Cable 2 38 232-178-00 Aft Suspension Cable 2 39 510-438-00 Bolt 4 40 290-851-00 Quick Release Pin 4 41 514-048-00 Safety Pin 4 411 232-137-01 Shackle Assembly 4 42.1 215-396-00 Shackle Assembly Placard 12 42.2 290-750-00 Attach Fitting Bushing 12 42.3 290-850-00 Shackle 12 42.4 517-016-00 DU Bearing 12 42.5 517-047-00 Flanged DU Bearing 22 Item(s) not shown in figures - 268-024-00 Manual Release Cable 1 1 Item not shown assembled. 2 Quantity is per assembly. 3 Not shown. 4 Alternate nut P/N is 510-440-00 5 Load Cell P/N 210-249-03 supersedes P/Ns 210-249-00, 210-199-01, and 210-199-00. 6 Optionally use nut P/N 510-718-00 in place of nut P/N 510-440-00. General Notes: 1) Swing Frame Assembly P/N 232-145-25 is comprised of items 1 through 15. 2) Spiral Wrap P/N 590-013-00 is wrapped around the horizontal swing frame tubes. Instructions for Continued Airworthiness 123-014-02 Revision 11 05-00-00 Page 13 08/11/26 5.2 5 Year/1000 Hour Inspection continued Return the Load Cell Assembly (P/N 210-249-03) to the factory for inspection and calibration. The factory will inspect the condition of the load cell and perform acceptance test procedures including calibration and zero balance, repairing as necessary. In addition, carefully inspect, and if necessary, repair or replace the detail parts in accordance with the instructions in Table 5.2.2. Inspect the parts in a clean, well-lit room. Overhaul Kit P/N 212-040-00 is recommended to use for re-assembly of the swing suspension. The overhaul kit contains fasteners, bushings and other recommended items to be replaced. The cargo hook has its own Overhaul Kit, refer to its CMM. Table 5.2.2 Swing Suspension Inspection Criteria Seq Component Inspection Criteria & Limit Repair Action Finish Recommended replacement at overhaul 1. Gimbal (1.1), Gimbal (36.1) Surface cracks – inspect under illuminated magnification (minimum 2X / 4 diopter). None. Cracks of any size are cause for part replacement. N/A No 2. Frame Strut Weldment (2) Dents, gouges, and scratches – 0.020 in. (0.51 mm) deep. Blend at 10:1 ratio as required to provide smooth transitions. Protect affected surfaces with MIL- PRF-23377 Type 1 primer or equivalent and MIL-PRF-85285 Type 1 coating or equivalent. No Surface cracks – inspect under illuminated magnification (minimum 2X / 4 diopter). None. Cracks of any size are cause for part replacement. N/A 3. Swing Frame Weldment (3) Dents, gouges, and scratches – 0.020 in. (0.51 mm) deep. Blend at 10:1 ratio as required to provide smooth transitions. Protect affected surfaces with MIL- PRF-23377 Type 1 primer or equivalent and MIL-PRF-85285 Type 1 coating or equivalent. No Surface cracks – inspect under illuminated magnification (minimum 2X / 4 diopter). None. Cracks of any size are cause for part replacement. N/A Bent lateral tube, gap measured along a straight edge is greater than .35” (see figure below). None. N/A .35 in (9 mm) max. Instructions for Continued Airworthiness 123-014-02 05-00-00 Page 14 Revision 11 08/11/26 5.2 5 Year/1000 Hour Inspection continued Table 5.2.2 Swing Suspension Inspection Criteria continued Seq Component Inspection Criteria & Limit Repair Action Finish Recommended replacement at overhaul 4. Pivot Shaft (4) Wear on outside diameter, diameter less than 0.990” (25.1 mm). None N/A No 5. Shaft Cap (5) Dents, nicks, cracks, gouges, scratches and corrosion – 0.060 in. (1.52 mm) deep Blend at 10:1 ratio as required to provide smooth transitions. Passivate per AMS-QQ- P-35 or ASTM A967. No 6. Bumper (6) Gouges and scratches greater than .060” deep. Splitting. None. N/A No 7. DU Bearing (1.2, 1.3, 15, 36.2, 36.3, 42.4, 42.5) Wear – more than 50% copper showing. None N/A Yes 8. Rod End (13) Wear on or elongation of inside diameter of spherical bearing, diameter greater than .330 in. (8.4 mm). Binding of spherical bearing in its housing. None N/A No 9. DU Thrust Washer (15) Wear on side facing Gimbal – more than 50% copper showing. None. N/A Yes 10. Load Cell Assembly (16) Dents, gouges, and scratches greater than .020 in. deep in the load link. Blend at 10:1 ratio as required to provide smooth transitions. Passivate per AMS-QQ- P-35 or ASTM A967. No Elongation of or wear on inside diameter of upper lugs, diameter greater than .759 in. (19.3 mm). Galling, pitting on inside diameter. None. N/A Dents, gouges, and scratches greater than .060 in. (1.5 mm) deep in the Covers. Blend at 10:1 ratio as required to provide smooth transitions. Apply conversion coating (MIL-DTL- 5541) to affected Cover surfaces. Wear on ID of bushing - 0.520 in. (13.2 mm) None. N/A 11. Gimbal Shaft (17) Wear on OD - .732 in. (18.6 mm) Galling, pitting. None N/A No 12. Retaining Bushing (18) Wear on shoulder OD - .420 in. (10.7 mm) None N/A No 13. Hook Bumper (23) Gouges and scratches greater than .060 in (1.5 mm) deep. None N/A No Instructions for Continued Airworthiness 123-014-02 Revision 11 05-00-00 Page 15 08/11/26 5.2 5 Year/1000 Hour Inspection continued Table 5.2.2 Swing Suspension Inspection Criteria continued Seq Component Inspection Criteria & Limit Repair Action Finish Recommended replacement at overhaul 14. Attach Bolt (24) Wear on OD - .495 in. (12.6 mm) None N/A No 15. Suspension Cable (37, 38) Fork End Fittings Wear on ID of clevis holes - 0.397 in. (10.1 mm) None N/A No Dents, gouges and scratches – 0.020 in. (0.51 mm) deep Blend at 10:1 ratio to provide smooth transitions. Parts are 303 stainless steel, no touch up finish required. No Surface cracks – inspect under illuminated magnification (minimum 2X / 4 diopter). None N/A No 16. Suspension Cable (37, 38) Wire Rope Inspect for damage as detailed in 100 Hour/Annual Inspection None N/A No 17. Quick Release Pin (40) Wear on OD - 0.362 in. (9.2 mm) None N/A No 18. Shackle (42.3) Dents, gouges and scratches – 0.020 in. (0.51 mm) deep Blend at 10:1 ratio to provide smooth transitions. Protect affected surfaces with MIL-PRF-23377 Type 1 epoxy primer or equivalent and MIL-PRF- 85285 Type 1 coating or equivalent. No 19. All remaining nuts, bolts, cotter pins, washers Wear, corrosion or deterioration. None N/A Yes 20. S/N Plate Damaged or illegible None N/A No Instructions for Continued Airworthiness 123-014-02 05-00-00 Page 16 Revision 11 08/11/26 5.2 5 Year/1000 Hour Inspection continued Swing Frame Re-assembly Re-assemble the suspension frame per the following. 1. Install replacement self-lubricating bushings with wet zinc chromate primer (TTP-1757 or equivalent) applied to the inside diameter of the mating bore. 2. Apply a light film of grease (Mobilgrease 28 is recommended) to the outside diameter of the Pivot Shaft (4) and insert it through one frame half, thrust washer* (15), Gimbal Assembly (1), thrust washer* (15) and through second frame half. Do not fully seat frame halves yet. *Ensure Teflon impregnated wear surfaces (darker sides) of thrust washers are facing gimbal. 3. Rotate the Pivot Shaft so that the raised “keys” at each end are horizontal. 4. Align the rod ends (13) to seat in the pockets of the swing frame feet. 5. Before fully seating and securing the frame halves together position the bumper (6) in between them. 6. Capture each end of the Pivot Shaft with Shaft Caps (5) and insert bolt (10) through, and thread the nut (9) on. Ensure that the rod ends are aligned with the holes in both feet. 7. Torque the nut (9) to 20 ft-lbs. Rotate the nut to the next castellation, not to exceed 30 ft-lbs. 8. Install and secure cotter pin (8). 9. Secure rod ends to frame feet with bolt (12) and nut (7). Torque to 8 – 12 ft-lbs. 10. Ensure the rod ends at each end of the frame struts are parallel, i.e.- the rod ends should be able to be rotated within the limits of the pockets in the frame feet. If necessary, loosen a jam nut (11), rotate the strut so the tightened rod end is against the pocket, rotate other rod end in the same direction (to be parallel), and tighten its jam nut. 11. Attach the Load Cell (16) to the Gimbal Assembly (1) per section 25.17. 12. Attach the Cargo Hook (28) and Hook Bumper (23) to the Load Cell per section 25.17. 13. Apply grease (Mobilgrease 28 is recommended) to the holes of the Fork End Fittings of the Forward and Aft Suspension Cable Assemblies (37, 38). Instructions for Continued Airworthiness 123-014-02 Revision 11 05-00-00 Page 17 08/11/26 5.2 5 Year/1000 Hour Inspection continued 14. Assemble the Gimbal Assemblies (36) onto the Fork End Fittings of the suspension cable assemblies with bolt (39), washer (33), and nut (34). 15. Tighten nut (34) to finger tighten then rotate to next castellation if necessary to insert cotter pin. Ensure the Gimbal Assembly pivots freely on the bolt (back off to previous castellation if it does not). Install cotter pin (35). 16. Apply grease (Mobilgrease 28 is recommended) to the shank of the bolts (31). 17. Fasten the Gimbal Assemblies of the two longer Aft Suspension Cable Assemblies onto the aft feet of the Swing Frame Assembly and the two shorter Aft Suspension Cable Assemblies onto the forward feet of the Swing Frame Assembly (reference Figure 5.2.5 for orientation). At each joint, assemble with bolt (31), washers (33), Standoff Bushings (32), and nut (34). Tighten nut to 95-110 in-lb and rotate to next castellation to insert cotter pin (35). Ensure each Gimbal rotates freely on the frame foot. Figure 5.2.5 Swing Frame Orientation Cargo hook load beam must point left (as shown) when system is installed on aircraft. Aft cable assembly attach points 18. Re-install the suspension system on the aircraft per Section 25.17. Instructions for Continued Airworthiness 123-014-02 05-00-00 Page 18 Revision 11 08/11/26 5.3 Cargo Hook Overhaul Schedule Time Between Overhaul (TBO) for the cargo hook: 5 years or 1000 hours of external load operations, whichever comes first. Hours of external load operations should be interpreted to be (1) anything is attached to the primary cargo hook (whether or not a useful load is being transported) and (2) the aircraft is flying. If these conditions are NOT met, time does NOT need to be tracked. Overhaul instructions for the cargo hook are contained in Component Maintenance Manual 122-017-00. Contact Onboard Systems for guidance to locate authorized overhaul facilities. Instructions for Continued Airworthiness 123-014-02 Revision 4 11-00-00 Page 1 05/04/12 Section 11 Placards and Markings 11.1 Placards The Cargo Swing Retrofit Kits include the following placards shown in Table 11.1. Table 11.1 Cargo Hook Suspension System Placards Placard part number and appearance Location P/N 215-166-00 or P/N 215-168-00 dependent on the model of AS350 on which the system is installed. Located on the belly of the aircraft near the cargo hook suspension in clear view of the ground support personnel. P/N 215-271-00 Located on the swing suspension frame near the serial number plate. P/N 215-272-00 One Side Opposite Side Located on the manual release cable, near the cargo hook. Instructions for Continued Airworthiness 123-014-02 11-00-00 Page 2 Revision 4 05/04/12 THIS PAGE INTENTIONALLY LEFT BLANK Instructions for Continued Airworthiness 123-014-02 Revision 4 12-00-00 Page 1 05/04/12 Section 12 Servicing 12.2 Lubrication Information Lubrication of the Cargo Swing Suspension system is required every 500 hours of external load operations. To obtain maximum life under severe duty conditions such as logging or seismic work, it is recommended to lubricate the Swing Suspension every 250 hours. Recommended types of lubricant are AeroShell 17 (MIL-G-21164) or Mobilgrease 28 (MIL-G- 81322). Lubricate the Cargo Swing Suspension at points noted in Figure 12.1 and 12.2. Instructions for Continued Airworthiness 123-014-02 12-00-00 Page 2 Revision 4 05/04/12 12.2 Lubrication Information, continued Shackle Assembly Lubrication Remove the Shackle Assemblies from the aircraft hard points and lubricate them and the mating fittings on the suspension cables as shown in Figure 12.1. This applies to all four Shackle Assemblies on the helicopter. Figure 12.1 Shackle Assembly Lubrication Lubricate Inside Of Bushings On Both Ends Of Shackle Lubricate Inside of Bushing Lubricate Inside of Cable End Fitting Instructions for Continued Airworthiness 123-014-02 Revision 4 12-00-00 Page 3 05/04/12 12.2 Lubrication Information, continued Upper Gimbal Grease Fitting Lubricate Upper Gimbal Assembly at the grease fitting located as shown in Figure 12.2. You may have to rotate the hook slightly to access the grease fitting. Figure 12.2 Upper Gimbal Grease Fitting Lubrication Upper Gimbal Grease Fitting Instructions for Continued Airworthiness 123-014-02 12-00-00 Page 4 Revision 4 05/04/12 THIS PAGE INTENTIONALLY LEFT BLANK Instructions for Continued Airworthiness 123-014-02 Revision 0 25-00-00 Page 1 05/18/10 Section 25 Equipment and Furnishings Un-commanded cargo hook release will happen if the manual release cable is improperly restrained. The cable must not be the stop that prevents 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 Swing Frame or Cargo Hook position is restrained by the manual release cable. Figure 25.1 Un-commanded Cargo Hook Release 25.1 Cargo Hook Connector Listed below is the pin out for the cargo hook connector. Table 25.1 Cargo Hook Connector Pin Function A Ground B Positive Instructions for Continued Airworthiness 123-014-02 25-00-00 Page 2 Revision 9 08/16/22 25.2 DescriptionThe Cargo Swing Retrofit Kit is a conversion kit for AS350 operators with an existing Airbus Helicopters cargo hook swing system. This kit utilizes some of the existing Airbus Helicopters system’s fixed components, i.e. – those which are compatible. These components include the fixed manual release cable, miscellaneous supporting brackets and miscellaneous hardware. The Cargo Swing Retrofit Kit consists of five primary components/sub-system; these are the Swing Suspension Assembly, Electrical Release System, Manual Release Cable System, Load Weigh System and the Cargo Hook. The Swing Suspension Assembly (see Figure 25.2.1) consists of a welded frame assembly which is attached to hard points and suspended below the belly of the helicopter by four cable assemblies. The frame assembly supports the cargo hook and a load cell through a gimbal. The Electrical Release System provides a means to release a cargo hook load through the use of an existing switch in the cockpit. The kit includes the external electrical release harness and the internal electrical harness which interfaces with the existing electrical release switch and circuit breaker interface points on the aircraft. The Manual Release Cable System consists of an external removable adapter cable that connects the cargo hook to the existing Airbus Helicopters fixed manual release cable. This system provides an additional means to release a cargo hook load. The Load Weigh System consists of an indicator mounted within the cockpit, the load cell on the swing suspension assembly, and associated wiring. Figure 25.2.1 Swing Suspension Assembly Overview Aft Cable Assemblies Electrical Release and Load Cell Harnesses, Ground Strap Forward Cable Assemblies Load Cell Cargo Hook Manual Release Cable Welded Frame Assembly Instructions for Continued Airworthiness 123-014-02 Revision 9 25-00-00 Page 3 08/16/22 25.2 Description continued The Load Weigh System provides the pilot with an indication of the weight of the external load on the cargo hook. There are two eligible indicator models, the C-39 Indicator (P/N 210-095-00) or the next generation C-40 Indicator (P/N 210-293-00 or 210-293-01) which is included with kit P/N 200-286-03. The C-40 Indicator’s Analog Out signal can be connected to the VEMD (with the applicable Airbus mod) to serve as part of the system to increase the main rotor RPM when an external load of 150 kg or greater is measured by the load cell. The cargo hook is the means used to attach an external load to the aircraft. A load is attached to the cargo hook by passing a load ring into the throat of the load beam and pushing the ring against the upper portion of the load beam throat (see Figure 25.2.2), which will initiate the hook to close. In the closed position, a latch engages the load beam and latches it in this position. A load release can be initiated by three different methods. Normal release is achieved by pilot actuation of a push-button switch in the cockpit. When the push-button switch is pressed, it energizes the solenoid in the cargo hook, and the solenoid opens the latch in the internal mechanism. In the event of an electrical failure, load release can be achieved by operating the manual release cable. The release cable actuates the internal mechanism of the cargo hook to unlatch the load beam. A rigging window provides a means to verify the manual release cable setting with respect to the internal mechanism. Ground personnel can also release the load by actuating a manual release lever located on the side of the cargo hook (see Figure 25.2.2). Figure 25.2.2 Cargo Hook Overview Manual Release Lever Load Beam Manual Release Cable Load Ring Rigging window Instructions for Continued Airworthiness 123-014-02 25-00-00 Page 4 Revision 9 08/16/22 25.2 Description continued The Fuel Drain Guard protects the fuel drain valve on AS350 helicopters from accidentally being opened. The fuel drain valve is located on the bottom of the fuel tank and extends below the belly of the helicopter. This location makes it vulnerable to damage or un-commanded fuel drainage on helicopters equipped with a cargo hook swing suspension. The most common occurrence of the cargo hook swing suspension striking the fuel drain valve happens when the helicopter lands on snow or on uneven terrain. The swing suspension has limited ground clearance and when the skid gear sinks into the snow, the swing suspension is pushed upward into the fuel drain valve, opening it and causing fuel to drain. The fuel drain valve can also be opened in flight by the swing suspension flying vertically due to aerodynamics when ferrying with no load or from recoil effects from releasing large cargo hook loads. The Fuel Drain Guard provides mechanical protection for the fuel drain valve to prevent accidental contact while interfacing with Airbus Helicopters’ existing valve, lever and control cable. The kit includes a Bracket, which replaces Airbus Helicopters’ bracket and provides an optimized mounting point for the control cable. Figure 25.2.3 Fuel Drain Guard Overview Bottom of fuel tank Bracket Lever Guard Fuel drain valve