Instructions for Continued Airworthiness

12.1.3 Master Cylinder Piston Removal, Section 12 Page 3 12.1.4 Master Cylinder Piston Seal Orientation, Section 12 Page 3 12.1.5 Slave Cylinder Piston Removal, Section 12 Page 4 12.2.1 Hose Arrangement, Section 12 Page 5 12.2.2 Reservoir Disassembly, Section 12 Page 6 Instructions for Continued Airworthiness 123-029-00 Page viii Revision 11 09/18/15 Figures continued 12.2.3 Screw and Stat-o-seal Removal, Section 12 Page 6 12.2.4 Injecting Hydraulic Fluid, Section 12 Page 7 12.2.5 Checking System for Air, Section 12 Page 8 12.2.6 Safety Wire Installation, Section 12 Page 8 12.3.1 Shackle Assembly Lubrication, Section 12 Page 9 12.3.2 Lower Cable Gimbal Lubrication, Section 12 Page 10 12.3.3 Upper Gimbal Grease Fitting Lubrication, Section 12 Page 11 25.2.1 System Overview, Section 25 Page 2 25.15.1 Cargo Hook Electrical Connector, Section 25 Page 5 25.15.2 Wire Harness Routing, Section 25 Page 6 25.15.3 Electrical Schematic, Section 25 Page 7 25.15.4 CAL Code, Section 25 Page 8 25.15.5 Changing Dampening Level, Section 25 Page 8 25.16.1 Suspension Attachment Hardware, Section 25 Page 9 25.16.2 Slave Cylinder Assembly Removal, Section 25 Page 10 25.16.3 Fixed Hydraulic Release Hose Routing, Section 25, Page 11 25.16.4 Release Lever Removal, Section 25, Page 12 25.16.5 Load Weigh Indicator Removal, Section 25, Page 13 25.16.6 Load Cell Attachment Hardware, Section 25, Page 14 25.16.7 Fuel Drain Guard Removal, Section 25, Page 15 25.17.1 Suspension Cable Attachment, Section 25, Page 16 25.17.2 Cargo Hook Attachment Hardware, Section 25, Page 17 25.17.3 Slave Cylinder Assembly Installation, Section 25, Page 18 25.17.4 Hydraulic Hose & Electrical Cable Routing, Section 25 Page 19 25.17.5 Release Lever Installation, Section 25 Page 20 25.17.6 Hose Routing – Aft of Collective, Section 25 Page 20 25.17.7 Lever Adjustment, Section 25 Page 21 25.17.8 Sealant Application Location, Section 25 Page 22 25.17.9 Guard/Retainer Assembly, Section 25 Page 22 25.17.10 Lever Installation, Section 25 Page 23 25.17.11 Cable Setting, Section 25 Page 24 Tables 5.1.1 Swing Frame Foot Parts, Section 5 Page 4 5.1.2 Upper Shackle and Cable Parts, Section 5 Page 5 5.1.3 Strut/Frame Joint Parts, Section 5 Page 6 5.1.4 Frame Half Assembly Parts, Section 5 Page 7 5.1.5 Load Cell/Gimbal Assembly Parts, Section 5 Page 8 5.1.6 Suspension System Inspection Criteria, Section 5 Page 9 11.1.1 Cargo Hook Suspension Placards, Section 11 Page 1 25.1.1 Cargo Hook Connector, Section 25 Page 1 25.5.1 Component Weights and CGs, Section 25 Page 3 25.15.1 Troubleshooting, Section 25 Page 4 Instructions for Continued Airworthiness 123-029-00 Revision 10 00-00-00 Page 1 05/27/14 Section 0 Introduction 0.4 Scope The following information is necessary to carry out the service, maintenance, and inspection of the Cargo Hook Swing Suspension System P/N 200-321-00. 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 200-321-00 Cargo Hook Swing Suspension System. 0.6 Arrangement This manual contains instructions for the service, maintenance, inspection and operation of the Cargo Hook Swing Suspension System P/N 200-321- 00 on Airbus Helicopters Model EC130 B4 series helicopters. The manual is arranged in the general order that maintenance personnel would use to install, 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 Hook Swing Suspension System P/N 200-321-00 (with Cargo Hook P/N 528-028-00) for the Airbus Helicopters EC130 B4 Series Helicopters. Refer to the appropriate Airbus Helicopters maintenance documentation for instructions regarding parts of the aircraft that interface with the P/N 200-321-00 system. 0.9 Abbreviations FAA Federal Aviation Administration FAR Federal Aviation Regulation ICA Instructions for Continued Airworthiness Instructions for Continued Airworthiness 123-029-00 00-00-00 Page 2 Revision 6 09/21/10 0.12 Precautions The following definitions apply to safety labels 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. Current revisions of all manuals are available from the factory. Instructions for Continued Airworthiness 123-029-00 Revision 12 04-00-00 Page 1 03/05/18 Section 4 Airworthiness Limitations 4.2 No airworthiness limitations The Airworthiness Limitations section is FAA approved and specifies inspections and other maintenance required under Secs. 43.16 and 91.403 of the Federal Aviation Regulations unless an alternative program has been FAA approved. No airworthiness limitations are associated with this type design change. Instructions for Continued Airworthiness 123-029-00 04-00-00 Page 2 Revision 12 03/05/18 THIS PAGE INTENTIONALLY LEFT BLANK Instructions for Continued Airworthiness 123-029-00 Revision 9 05-00-00 Page 1 05/10/12 Section 5 Inspection and Overhaul Schedule 5.1 Cargo Hook Swing Suspension System Inspection The scheduled inspection intervals noted below are maximums and are not to be exceeded. If the cargo hook 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. Annually or 100 hours of external load operations, whichever comes first, inspect the cargo hook and suspension per the following. 1. Activate the electrical system and press the Cargo Release button to ensure the cargo hook electrical release system is operating correctly. The cargo hook must release. Reset the hook by hand after release. If the hook does not release or re-latch, do not use the unit until the problem is fixed. Depressing the electrical release button continuously in excess of 20 seconds will cause the cargo hook release solenoid to overheat, possibly causing permanent damage. 2. Activate the hydraulic release system by pulling the release lever on the collective in the cockpit. The mechanism should operate smoothly and the cargo hook must release. Return the load beam to its closed and locked position 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 should align with the lines on the cover (see Figure 5.1.1). If the hook does not release or re-latch, do not use the unit until the problem is resolved. Figure 5.1.1 Hook Lock Indicator Hook Lock Indicator ACCEPTABLE Hook Lock Indicator Instructions for Continued Airworthiness 123-029-00 05-00-00 Page 2 Revision 9 05/10/12 5.1 Cargo Hook Swing Suspension System Inspection continued 3. Swing the cargo hook and the suspension system throughout their full ranges of motion to ensure the hydraulic hose and electrical harnesses have enough slack and are not kinked or pinched in any possible hook and swing frame locations. The hose and harnesses must not be the stops that prevent the cargo hook or suspension from swinging freely in all directions. 4. Inspect all pivoting joints to ensure that they rotate freely. 5. Visually check for presence and security of fasteners and electrical connections and condition of suspension cables. 6. Visually check for fluid leaks in the hydraulic release system. Some seeping or dampness is acceptable, but if drips or areas cleaned by fluid leaking are present the hook must not be used until the condition is repaired. See troubleshooting section to determine the course of action. 7. Check the fluid level in the master cylinder with the collective against the lower stop. The Master Cylinder features a transparent lid through which the fluid level can be checked. Hydraulic fluid must be visible over the baffle surface (reference Figure 12.1.1). 8. Check the hydraulic release system for air by pulling the lever firmly until it bottoms out. Check the push rod position (see Figure 5.1.2). If some of the green ring on the push rod is visible, the system is adequately bled. If some of the green on the push rod is NOT visible with the lever completely pulled, the system has too much air in it and must be bled, see Section 12.2 for bleeding instructions. Figure 5.1.2 Checking System for Excess Air 9. Visually check for cracks in suspension frame. The frame tubes contain a corrosion preventative compound, which may leak out through a crack and also provide an indication. 10. Visually check shock cord assemblies for security of attachment and condition of cords. Lever Verify green ring on push rod is still visible Instructions for Continued Airworthiness 123-029-00 Revision 10 05-00-00 Page 3 05/27/14 5.1 Cargo Hook Swing Suspension System Inspection continued 11. Visually inspect for presence and security of fasteners. 12. Visually inspect the electrical harnesses and connectors for damage and security. 13. Visually inspect the hydraulic hose and its connection to the cargo hook for damage and security. 14. Visually inspect the cargo hook bumper for damage. 15. Visually inspect for cracks in suspension frame halves. 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 also provide an indication. 16. Inspect suspension cables for broken strands. Pass a cloth over the cables. This will clean the cables for a visual inspection and detect broken wires if the cloth snags on the cable. Ten randomly distributed broken strands in one cable lay (one complete rotation around the wire) or five broken strands in one strand in cable lay are considered unacceptable. 17. Visually inspect the suspension cables for crushing, unstranding, kinking, loss of rope diameter in short lengths, unevenness of outer strands or other damage. Visually inspect for corrosion. 18. Visually inspect for security of C-39 indicator mounting. 19. Inspect 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). 20. Inspect fuel drain guard for damage that causes lever to bind or rub. Remove and replace Guard if it is obstructing free operation of lever. 21. Inspect for fuel leakage. If leakage is noted, re-apply sealant to Retainer as described in Owner’s Manual. Refer to Airbus Helicopters maintenance instructions for other possible causes. 22. Inspect and maintain the fuel valve, lever and control cable per Airbus Helicopters maintenance documentation. Instructions for Continued Airworthiness 123-029-00 05-00-00 Page 4 Revision 10 05/27/14 5.1 Cargo Hook Swing Suspension System Inspection continued Every 5 years or 1000 hours of external load operations, whichever comes first, inspect the cargo hook and suspension per the following. Remove the suspension assembly from the helicopter (see section 25.17), disassemble, and inspect the component parts per the following instructions. Remove the suspension cables from the suspension frame by removing the cotter pin (item 1), nut (item 4), washers (item 3) and bolt (item 5). Disassemble the foot assemblies by removing the screws (item 11) and washers (item 10) that secure the Hat Bushing (item 9), Outer Thrust Washer (item 9), Paddle Assembly (item 7) and Inner Thrust Washer (item 6). Figure 5.1.3 Swing Frame Foot Disassembly Table 5.1.1 Swing Frame Foot Parts ITEM PART NO. DESCRIPTION QTY 1 510-178-00 Cotter Pin 4 2 290-849-00 Fork Fitting 4 3 510-238-00 Washer 8 4 510-718-00 Nut 4 5 510-438-00 Bolt 4 6 235-155-00 Inner Thrust Washer 4 7 232-302-00 Paddle Assembly 4 7A 291-128-00 Paddle 4 7B 291-134-00 Bushing 4 7C 517-016-00 Bushing 4 7D 518-001-00 Grease Fitting 4 7E 291-250-00 Flanged Bushing 4 8 291-130-00 Hat Bushing 4 9 510-239-00 Washer 4 10 510-635-00 Bolt 4 1 3 5 4 2 Detail A See Detail A Instructions for Continued Airworthiness 123-029-00 Revision 9 05-00-00 Page 5 05/10/12 5.1 Cargo Hook Swing Suspension System Inspection continued Separate the suspension cable fork fittings (item 3) from the Shackle Assemblies (item 2) by removing the safety pins (not shown below) and then the quick release pins (item 1). The parts that comprise the Shackle Assembly are shown in Detail A. If bushings need to be replaced, press out with an appropriately sized removal tool and arbor press. Figure 5.1.4 Upper Shackle and Cable Disassembly Table 5.1.2 Upper Shackle and Cable Parts ITEM PART NO. DESCRIPTION QTY 1 290-851-00 Quick Release Pin 4 2 232-293-00 Shackle Assembly 4 2A 291-135-00 Shackle 4 2B 517-016-00 Bushing 4 2C 291-117-00 Bushing 4 3 290-849-00 Fork Fitting 4 2A 2C 2B Detail A1 3 2 See Detail A Safety pin and lanyards not shown Instructions for Continued Airworthiness 123-029-00 05-00-00 Page 6 Revision 9 05/10/12 5.1 Cargo Hook Swing Suspension System Inspection continued At each end of the two longitudinal struts (item 2), remove the nut (item 5), washer (item 6), Clamp Bushing (item 3), and bolt (item 4) as shown below. Figure 5.1.5 Strut/Frame Joint Disassembly Table 5.1.3 Strut/Frame Joint Parts ITEM PART NO. DESCRIPTION QTY 1 517-055-00 Rod End Fitting 4 2 235-148-00 Longitudinal Strut Weldment 4 3 291-131-00 Clamp Bushing 4 4 510-636-00 Bolt 4 5 510-717-00 Nut 4 6 510-239-00 Washer 4 7 510-178-00 Cotter Pin 4 3 4 Instructions for Continued Airworthiness 123-029-00 Revision 9 05-00-00 Page 7 05/10/12 5.1 Cargo Hook Swing Suspension System Inspection continued 1. Remove the cotter pin (item 13), nut (item 12), and washer (item 11) from the center bolt (item 10). 2. Remove the bracket (item 9). 3. Remove the shaft cap (item 3) from the end of the pivot shaft. 4. Slide one of the two frame weldments (items 1 and 2) off of the pivot shaft (item 4). 5. Slide the Gimbal Assembly (item 7) off of the pivot shaft (item 4). Be sure to support the cargo hook and load cell assembly (not shown) during this step. 6. If bushings need to be replaced, press out with an appropriately sized removal tool and arbor press. Figure 5.1.6 Frame Half Disassembly Table 5.1.4 Frame Half Assembly Parts ITEM PART NO. DESCRIPTION QTY 1 235-149-00 Aft Frame Weldment 1 2 235-150-00 Fwd Frame Weldment 1 3 290-843-00 Shaft Cap 2 4 290-842-00 Pivot Shaft 1 5 517-057-00 Flange Bushing 2 6 517-058-00 Thrust Washer 2 7 232-143-01 Gimbal Assembly 1 7A 290-841-00 Gimbal 1 7B 517-046-00 Flange Bushing 2 7C 517-056-00 Bushing 2 7D 518-003-00 Grease Fitting 1 8 290-862-00 Bumper 1 9 235-170-00 Bracket 1 10 510-676-00 Bolt 1 11 510-174-00 Washer 1 12 510-718-00 Nut 1 13 510-178-00 Cotter Pin 1 3 4 5 6 8 7 5 3 9 10 11 12 Detail A 7A 7B 7D See Detail A Instructions for Continued Airworthiness 123-029-00 05-00-00 Page 8 Revision 10 05/27/14 5.1 Cargo Hook Swing Suspension System Inspection continued 1. Remove the cotter pin (item 6), nut (item 5), washer (item 4), thrust washer (item 2) and remove the bolt (item 1) and other thrust washer. 2. Slide the Shaft (item 3) out to separate the Load Cell Assembly (item 9) from the Gimbal. 3. Separate the Cargo Hook (item 14) and Bumper (item 13) from the Load Cell Assembly by removing the Cotter Pin (item 13), nut (item 12), washers (item 8) and Attach Bolt (item 7). Figure 5.1.7 Load Cell/Gimbal Disassembly Instructions Table 5.1.5 Load Cell/Gimbal Assembly Parts ITEM PART NO. DESCRIPTION QTY 1 510-443-00 Bolt 1 2 290-740-00 Thrust Washer 2 3 290-739-00 Shaft 1 4 510-220-00 Washer 1 5 510-719-00 Nut 1 6 510-115-00 Cotter Pin 1 7 290-775-00 Attach Bolt 1 8 510-183-00 Washer 2 9* 210-249-04 Load Cell Assembly 1 10 510-174-00 Washer 1 11 510-170-00 Nut 1 12 510-178-00 Cotter Pin 1 13 290-839-01 Bumper 1 14 528-028-00 Cargo Hook 1 * P/N 210-249-04 supersedes P/N 210-249-01 & 210-199-02. These parts are interchangeable. SEE FIGURE 5.2.4 9 13 6 7 4 8 Instructions for Continued Airworthiness 123-029-00 Revision 12 05-00-00 Page 9 03/05/18 5.1 Cargo Hook Swing Suspension System Inspection continued Return the Load Cell Assembly (P/N 210-199-02, 210-249-01 or 210-249-04) 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 5.1.6. Inspect the parts in a clean, well-lit room. Table 5.1.6 Suspension System Inspection Criteria Component Damage Permitted without Repair Repair Maximum Damage which Causes Replacement Fork End Fitting P/N 290-849-00 (item 2, Figure 5.1.3) Wear on inside diameter of lug holes, diameter less than .392”. Dents, gouges, and scratches less than .020” deep outside lug areas. Dents, gouges, and scratches less than .010” deep around lugs. None. Blend at 20:1 ratio, length to depth, to provide smooth transitions. Wear on inside diameter of clevis holes, diameter greater than .392”. Dents, gouges, and scratches greater than .060” deep outside lug areas. Dents, gouges, and scratches greater than .030” deep around lugs. Cracks. Hat Bushing P/N 291-130-00 (item 8, Figure 5.1.3) Wear on shoulder diameter, diameter greater than .867”. None. Wear on shoulder diameter, diameter less than .867”. Instructions for Continued Airworthiness 123-029-00 05-00-00 Page 10 Revision 9 05/10/12 Table 5.1.6 Suspension System Inspection Criteria continued Component Damage Permitted without Repair Repair Maximum Damage which Causes Replacement Inner Thrust Washer P/N 232-155-00 (item 6, Figure 5.1.3) These bushings have a Teflon type film overlaid on a layer of sintered copper on one side. Teflon film still covers more than 50% of the bushing wear area. Note: The bushing wear area is the side that faces the Paddle fitting (reference Figure 5.2.1). None. If copper is visible over more than 50% of the bushing wear area, remove and replace the bushing. Paddle P/N 291-128-00 (item 7A, Figure 5.1.3) Dents, gouges, corrosion and scratches less than .010” deep. Blend at 20:1 ratio, length to depth, to provide smooth transitions. Dents, gouges, corrosion and scratches greater than .030” deep. Cracks. Bushing P/N 291-134-00 (item 7B, Figure 5.1.3) Wear on inside diameter, diameter less than .892”. None. Wear on inside diameter, diameter greater than .892”. Bushing P/N 517-016-00 (Item 7C, Figure 5.1.3) These bushings have a Teflon type film overlaid on a layer of sintered copper. Teflon film still covers more than 50% of the bushing wear area. None If copper is visible over more than 50% of the bushing wear area, remove and replace the bushing. Bushing P/N 291-250-00 (item 7E, Figure 5.1.3) Wear on inside diameter, diameter less than .892”. None. Wear on inside diameter, diameter greater than .892”. Quick Release Pin P/N 290-851-00 (item 1, Figure 5.1.4). Wear on outside diameter, diameter greater than .362”. None. Wear on outside diameter, diameter less than .362”. Cracks. Instructions for Continued Airworthiness 123-029-00 Revision 9 05-00-00 Page 11 05/10/12 Table 5.1.6 Suspension System Inspection Criteria continued Component Damage Permitted without Repair Repair Maximum Damage which Causes Replacement Shackle P/N 291-135-00 (item 2A, Figure 5.1.4). Dents, gouges, corrosion and scratches less than .010” deep. Blend at 20:1 ratio, length to depth, to provide smooth transitions. Dents, gouges, corrosion and scratches greater than .030” deep. Cracks. Bushing P/N 517-016-00 (item 2B, Figure 5.1.4). These bushings have a Teflon type film overlaid on a layer of sintered copper. Teflon film still covers more than 50% of the bushing wear area. None. If copper is visible over more than 50% of the bushing wear area, remove and replace the bushing. Bushing P/N 291-117-00 (item 2C, Figure 5.1.4). These bushings have a Teflon type film overlaid on a layer of sintered copper. Teflon film still covers more than 50% of the bushing wear area. None. If copper is visible over more than 50% of the bushing wear area, remove and replace the bushing. Rod End Fitting P/N 517-055-00 (item 1, Figure 5.1.5) Wear on or elongation of inside diameter of spherical bearing, diameter less than .330”. None. Wear on or elongation of inside diameter of spherical bearing, diameter greater than .330”. Dents, gouges, corrosion and scratches less than .020” deep. None. Dents, gouges, corrosion and scratches greater than .020” deep. Binding of spherical bearing in its housing. Longitudinal Strut Weldment P/N 235-148-00 (item 2, Figure 5.1.5). Dents, gouges, and scratches less than .030” deep. Blend at 20:1 ratio, length to depth, to provide smooth transitions. Protect affected surfaces with MIL-PRF- 23377 Type 1 epoxy primer or equivalent and MIL-PRF-85285 Type 1 polyurethane coating or equivalent. Dents, gouges and scratches greater than .060” deep. Cracks. Clamp Bushing P/N 291-131-00 (item 3, Figure 5.1.5). Wear on inside diameter, diameter less than .324”. None. Wear on inside diameter, diameter greater than .324”. Instructions for Continued Airworthiness 123-029-00 05-00-00 Page 12 Revision 9 05/10/12 Table 5.1.6 Suspension System Inspection Criteria continued Component Damage Permitted without Repair Repair Maximum Damage which Causes Replacement Aft Weldment P/N 235-149-00 (item 1, Figure 5.1.6) Fwd Weldment P/N 235-150-00 (item 2, Figure 5.1.6) Dents, gouges, scratches, nicks, and corrosion less than .010” deep in frame tubes or at welds. Dents, gouges, scratches, nicks, and corrosion less than .020” deep in machined junction fittings. Blend at 20:1 ratio, length to depth, to provide smooth transitions. Protect affected surfaces with MIL-PRF- 23377 Type 1 epoxy primer or equivalent and MIL-PRF-85285 Type 1 polyurethane coating or equivalent. Dents, gouges, scratches, nicks and corrosion greater than .020” in frame tubes or at welds. Dents, gouges, nicks, scratches and corrosion greater than .030” in machined junction fittings. Visible cracks. Shaft Cap P/N 290-843-00 (item 3, Figure 5.1.6) Dents, gouges, and scratches less than .030” deep. Blend at 20:1 ratio, length to depth, to provide smooth transitions. Part is 15-5 stainless steel, no touch up paint required. Dents, gouges, and scratches greater than .060” deep. Cracks Pivot Shaft P/N 290-842-00 (item 4, Figure 5.1.6). Wear on outside diameter, diameter greater than .993”. None. Wear on outside diameter, diameter less than .993”. Cracks. Flange Bushing P/N 517-057-00 (item 5, Figure 5.1.6). These bushings have a Teflon type film overlaid on a layer of sintered copper. Teflon film still covers more than 50% of the bushing wear area. None. If copper is visible over more than 50% of the bushing wear area, remove and replace the bushing. Thrust Washer P/N 517-058-00 (item 6, Figure 5.1.6). These bushings have a Teflon type film overlaid on a layer of sintered copper. Teflon film still covers more than 50% of the bushing wear area. None If copper is visible over more than 50% of the bushing wear area, remove and replace the bushing. Instructions for Continued Airworthiness 123-029-00 Revision 9 05-00-00 Page 13 05/10/12 Table 5.1.6 Suspension System Inspection Criteria continued Component Damage Permitted without Repair Repair Maximum Damage which Causes Replacement Bumper P/N 290-862-00 (item 8, Figure 5.1.6). Dents, gouges, and scratches less than .060” deep. None. Dents, gouges, and scratches greater than .060”. Splitting. Bracket P/N 235-170-00 (item 9, Figure 5.1.6). Dents, gouges, and scratches less than .030” deep. Blend at 20:1 ratio, length to depth, to provide smooth transitions. Part is stainless steel, no touch up paint required. Dents, gouges, and scratches greater than .060” deep. Cracks Gimbal, P/N 290-841-00 (item 7A, Figure 5.1.6). Dents, gouges, and scratches less than .010” deep. Blend at 20:1 ratio, length to depth, to provide smooth transitions. Dents, gouges, and scratches greater than .030” deep. Cracks. Bushing P/N 517-046-00 (item 7B, Figure 5.1.6) These bushings have a Teflon type film overlaid on a layer of sintered copper. Teflon film still covers more than 50% of the bushing wear area. None. If copper is visible over more than 50% of the bushing wear area, remove and replace the bushing. Bushing P/N 517-056-00 (item 7C, Figure 5.1.6) These bushings have a Teflon type film overlaid on a layer of sintered copper. Teflon film still covers more than 50% of the bushing wear area. None. If copper is visible over more than 50% of the bushing wear area, remove and replace the bushing. Instructions for Continued Airworthiness 123-029-00 05-00-00 Page 14 Revision 12 03/05/18 Table 5.1.6 Suspension System Inspection Criteria continued Component Damage Permitted without Repair Repair Maximum Damage which Causes Replacement Load Cell Assembly P/N 210-199-02 P/N 210-249-01 P/N 210-249-04 (item 9, Figure 5.1.7) Dents, gouges, and scratches less than .020” deep outside lug areas. Dents, gouges, and scratches less than .010” deep around lugs. Blend at 20:1 ratio, length to depth, to provide smooth transitions. Dents, gouges and scratches greater than .060” deep outside lug areas. Dents, gouges, and scratches greater than .030” deep in lug areas. Cracks. Wear on inside diameter of upper lugs, diameter less than .759”. None Wear on inside diameter of upper lugs, diameter greater than .759”. Gimbal Shaft, P/N 290-739-00 Item 3 (Figure 5.1.7). Wear on outside diameter, diameter greater than .737”. None. Wear on outside diameter, diameter less than .737”. Cracks. Attach Bolt, P/N 290-775-00 (Item 7, Figure 5.1.7). Wear on outside diameter, diameter greater than .495”. None. Wear on outside diameter, diameter less than .495”. Bumper, P/N 290-839-01 (item 13, Figure 5.1.7). Dents, gouges, and scratches less than .060” deep. None Dents, gouges, and scratches greater than .060”. Bushing P/N 517-046-00 (item 15, Figure 5.1.7) These bushings have a Teflon type film overlaid on a layer of sintered copper. Teflon film still covers more than 50% of the bushing wear area. None. If copper is visible over more than 50% of the bushing wear area, remove and replace the bushing. Instructions for Continued Airworthiness 123-029-00 Revision 11 05-00-00 Page 15 09/18/15 5.1 Cargo Hook Swing Suspension System Inspection continued Suspension Frame Re-assembly after Inspection Re-assemble the suspension frame per the following (refer to Figures 5.1.6 and 5.1.7). 1. Insert Pivot Shaft (P/N 290-842-00) through one bushing, thrust washer* (P/N 517-058-00), Gimbal Assembly, thrust washer* (P/N 517-058-00) and through second frame half bushing. * Ensure Teflon impregnated wear surfaces (darker sides) of thrust washers are facing gimbal. 2. Rotate the pivot shaft so that the raised “keys” at each end are horizontal. 3. Before fully seating and securing the frame halves together, install the bumper (P/N 290-862-00). 4. Capture each end of pivot shaft with Shaft Caps (P/N 290-843-00) and install bolt (P/N 510-506-00), washer (P/N 510-174-00) and nut (P/N 510-718-00). Ensure that the rod ends are aligned with the holes in both feet. 5. Torque the nut to 20 ft-lbs. Rotate the nut to the next castellation, not to exceed 30 ft-lbs. 6. Install and secure cotter pin (P/N 510-178-00). 7. Secure rod ends to frame feet with bolt (P/N 510-505-00) and washer (P/N 510-173-00), nut (P/N 510-717-00) and cotter pin (P/N 510-178-00). Install nut and tighten to 50 in-lbs, then rotate to next castellation, not to exceed 85 in- lbs, and install cotter pin. 8. Slide Load Cell Assembly over Gimbal Assembly, align holes, and then insert Gimbal Shaft (P/N 290-739-00) through. Place Shaft Retaining Bushings (P/N 290-740-00) over each end of Gimbal Shaft, insert bolt (P/N 510-443-00) through, and secure with washer (P/N 510-220-00) and nut (510-320-00). Tighten nut to 60-70 in-lbs and rotate to next castellation if necessary to insert cotter pin. The Load Cell Assembly must pivot freely about its upper attach point independently of the bolt (P/N 510-443-00) and nut, back the nut off to previous castellation if necessary to achieve this. 9. Install the Inner Thrust Washer* (P/N 235-155-00), Paddle Assembly** (232-302-00) and Hat Bushing (P/N 291-130-00) over each swing frame foot and secure with washer (P/N 510-239-00) and bolt (510-639-00). Reference Figure 5.1.3. Torque bolt to 8 – 12 ft-lbs and secure with safety wire. * Ensure the Teflon impregnated wear surface (darker side) of the thrust washer is facing the Paddle Assembly. ** Ensure proper orientation of Paddle Assembly with Flanged Bushing towards Hat Bushing as per Figure 5.1.3. 10. Install the suspension cables onto the swing frame assembly. The pair of shorter cables must be installed onto the forward end of the swing frame. Install with bolt, washer, nut and cotter pin. Install nut and tighten to 20 in- lbs, then rotate to next castellation, not to exceed 30 in-lbs, and install cotter pin. Instructions for Continued Airworthiness 123-029-00 05-00-00 Page 16 Revision 9 05/10/12 5.2 Cargo Hook Overhaul Schedule Overhaul the cargo hook in accordance with the guidelines below. Contact Onboard Systems for the latest revision of overhaul instructions for the cargo hook and guidance to locate authorized overhaul facilities. Time Between Overhaul (TBO): 1000 hours of external load operations or 5 years, 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. Instructions for Continued Airworthiness 123-029-00 Revision 0 11-00-00 Page 1 09/12/07 Section 11 Placards and Markings 11.1 Placards The 200-321-00 Cargo Hook Swing Suspension System Kit includes the following placards shown in Table 11.1.1. Table 11.1.1 Cargo Hook Suspension System Placards Placard part number and appearance Location P/N 215-168-00 Located on the belly of the aircraft near the cargo hook suspension in clear view of the ground support personnel. (text is engraved on manual release lever shown) Located on the release lever of the hydraulic release master cylinder assembly. Master cylinder assembly is located on the collective. P/N 215-271-00 Located on the swing suspension frame near the serial number plate. Instructions for Continued Airworthiness 123-029-00 11-00-00 Page 2 Revision 0 09/12/07 THIS PAGE INTENTIONALLY LEFT BLANK. Instructions for Continued Airworthiness 123-029-00 Revision 12 12-00-00 Page 1 03/05/18 Section 12 Servicing 12.1 Maintenance of the Hydraulic Release System The system is filled with fluid at installation and does not consume fluid unless it leaks out. If any leakage is detected, the fluid level should be immediately checked. To check the fluid level: 1. Position the collective against the lower stop. 2. The Master Cylinder features a transparent lid through which the fluid level can be checked. Hydraulic fluid must be visible over the baffle surface (see Figure 12.1.1). 3. Remove lid and add MIL-PRF-87257 (optional: MIL-PRF-5606) hydraulic fluid as required until the baffle surface is partially or fully submerged. Figure 12.1.1 Checking Hydraulic Fluid Level Baffle surface Master Cylinder Reservoir If leakage is noted around any plumbing fittings, the fittings may be tightened until the leakage quits. If leakage is noted around the pistons in either the master or slave cylinders the leaking cylinder must be repaired. See the instructions for repair in this section. Instructions for Continued Airworthiness 123-029-00 12-00-00 Page 2 Revision 12 03/05/18 12.1 Maintenance of the Hydraulic Release System continued Master Cylinder Repair If fluid is leaking around the piston, the only repair is to remove and replace the cup seal and O-ring. The master cylinder must be disassembled, inspected and then re- assembled with new seals. Disassembly: 1. Remove snap ring. Use caution when removing snap ring since the piston is spring loaded against the washer and snap ring. The piston will pop out of the housing when the snap ring is removed. Use the lever to put pressure on the piston while removing snap ring. 2. Loosen the set screw and disconnect barrel nut on lever from the push rod. See Figure 12.1.2. 3. Remove the piston and spring. See Figure 12.1.3 for parts breakdown. 4. Inspect the master cylinder bore for scratches. If any scratches or gouges are visible in the bore, the master cylinder must be replaced. Re-assembly 1. If the bore condition is acceptable, replace the lip seal and O-ring on the piston assembly. Maintain orientation as shown in Figure 12.1.4. Stretch seals over piston into grooves. 2. To assemble the master cylinder, lubricate the piston seals and cylinder bore generously with hydraulic fluid. 3. Place the spring in the cylinder bore. 4. Pass the push rod through the washer. 5. Thread the push rod into the barrel nut until approximately 1/16” of thread is visible through the opposite side of the barrel nut. 6. Insert the small spring into the piston assembly and insert the piston assembly into the master cylinder bore using a firm rocking motion. 7. Use the lever to compress the spring and hold the piston in place. 8. Use snap ring pliers to install the snap ring. 9. Secure push rod threads by tightening set screw. Figure 12.1.2 Master Cylinder Lever Disconnect A DETAIL A Washer Barrel Nut Set Screw Turn until Barrel Nut is disconnected from push rod. Snap Ring Push Rod Instructions for Continued Airworthiness 123-029-00 Revision 8 12-00-00 Page 3 12/16/11 12.1 Maintenance of the Hydraulic Release System continued Master Cylinder Repair continued Figure 12.1.3 Master Cylinder Piston Removal Spring Piston Assembly Spring Push Rod Washer Snap Ring Figure 12.1.4 Master Cylinder Piston Seal Orientation Cup Seal (P/N 556-048-00) Note seal orientation. O-ring (P/N 556-047-00) Piston (P/N 290-814-01) Slave Cylinder Repair If the slave cylinder is leaking fluid around the piston rod, the only repair possible is to remove and replace the quad ring or cup seal (earlier production units of the slave cylinder assembly used a cup seal instead of the quad ring). Disassembly: 1. Remove cap, piston, and seal (see Figure 12.1.5). 2. Inspect bore of slave cylinder for scratches or gouges. If any are present the assembly must be replaced. 3. Remove bushing in cap by pressing it out. 4. Remove quad ring (or cup seal) by stretching it over the piston. Re-assembly: 1. Press new bushing into cap. 2. Stretch new quad ring over piston into groove. 3. Clean and lubricate cylinder bore and piston seal with hydraulic fluid. 4. Insert piston into cylinder taking care not to damage edges of quad ring. 5. Screw on cap and torque to 50-60 inch pounds. Instructions for Continued Airworthiness 123-029-00 12-00-00 Page 4 Revision 8 12/16/11 12.1 Maintenance of the Hydraulic Release System continued Slave Cylinder Repair continued Figure 12.1.5 Slave Cylinder Piston Removal Piston (P/N 290-805-00) Quad Ring (P/N 556-097-00) Cylinder Cap (P/N 290-802-00) Bushing (P/N 517-040-00) Instructions for Continued Airworthiness 123-029-00 Revision 12 12-00-00 Page 5 03/05/18 12.2 Bleeding Hydraulic System Filling and bleeding the hydraulic release system is most easily accomplished on the bench, prior to installation on the aircraft. This process may also be accomplished after the system is installed. Filling and bleeding requires two persons, one to inject hydraulic fluid through the system and the other to observe the reservoir. Following is the procedure: 1. Obtain the hydraulic hook bleed kit, 212-014-02. This kit consists of 2 ounces of MIL-PRF-87257 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. MIL-PRF-5606 fluid is also compatible with the hydraulic system and was formerly included with new cargo hook kits. It is interchangeable and miscible with MIL-PRF-87257 fluid. 2. If the system is already installed on the aircraft, place an absorbent towel under the master cylinder. If the master cylinder is not installed on the aircraft, lightly clamp the master cylinder in a vise to hold it in a vertical position and position the slave cylinder so that its level is below the level of the master cylinder. 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 hoses uncoiled, straight and running uphill. See Figure 12.2.1. Figure 12.2.1 Hose Arrangement Poor Hose Arrangement Good Hose Arrangement Instructions for Continued Airworthiness 123-029-00 12-00-00 Page 6 Revision 12 03/05/18 12.2 Bleeding Hydraulic System continued 4. Remove screws, reservoir lid, and baffle from the master cylinder reservoir as shown in Figure 12.2.2. Figure 12.2.2 Reservoir Disassembly Screw (2) Reservoir Lid Baffle 5. Remove the safety wire, screw, washers and thread-seal on the slave cylinder, see Figure 12.2.3. Figure 12.2.3 Screw and Stat-o-seal Removal 6. Fill a syringe with approximately 35 cc of hydraulic fluid. Screw the end of the syringe into the screw hole on the slave cylinder to create a tight seal. See Figure 12.2.4. 7. While observing the reservoir, slowly push on the syringe plunger to force fluid through the slave cylinder, hydraulic hose, and up to the master cylinder reservoir. There will be some resistance during filling—this is normal. Injecting the fluid into the system too rapidly may cause the fluid to spray up and out of the master cylinder reservoir. Wear safety glasses when observing fluid reservoir while filling. Instructions for Continued Airworthiness 123-029-00 Revision 12 12-00-00 Page 7 03/05/18 12.2 Bleeding Hydraulic System continued Figure 12.2.4 Injecting Hydraulic Fluid Bleed Adapter PVC tubing Female X Barb Fitting Syringe 8. Continue to force fluid into the master cylinder reservoir until the reservoir is approximately half full. If bleeding an already filled system, you may need to draw fluid from the master cylinder reservoir during this step to prevent overflow. 9. Remove the syringe from the screw hole. Re-install the Thread-Seal (P/N 510- 740-00), washers (P/N 510-209-00) and screw (P/N 510-694-00), see Figure 12.2.3. 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 cycle the lever until there are no more. Actuating the lever releases trapped air in the system. 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. 12. Check the system for air by actuating the lever firmly until it bottoms out. Check the push rod position (see Figure 12.2.5). If the green area on the push rod is visible, proceed to step 13. If the green on the push rod is not visible with the lever completely pulled, the system has too much air in it and needs further bleeding. To do this, repeat steps 5 – 11. Instructions for Continued Airworthiness 123-029-00 12-00-00 Page 8 Revision 4 02/09/09 12.2 Bleeding Hydraulic System continued Figure 12.2.5 Checking System for Air 13. After the system is properly bled, verify that the reservoir is approximately half full of hydraulic fluid. Fluid should be visible above the baffle. 14. Re-install the baffle and the reservoir lid. 15. Check the system for proper operation. Fully actuate the release lever. The hook must open and the lever must have a firm feel. 16. At the slave cylinder, safety wire the three drilled head screws together using .025 safety wire per MS20995C, see Figure 12.2.6. Figure 12.2.6 Safety Wire Installation 17. Disassemble and thoroughly clean the syringe with isopropyl alcohol. Allow it to dry. Not cleaning the syringe will render it unusable. Reassemble and store for next use. Lever Verify green ring on push rod is still visible Safety wire between these screws. Instructions for Continued Airworthiness 123-029-00 12-00-00 Page 10 Revision 0 09/12/07 12.3 Lubrication Information Lubrication of Cargo Hook Swing Suspension system is required every 500 hours of hook operation. To obtain maximum life under severe duty conditions such as logging or seismic work, it is recommended to lubricate the Swing Suspension system approximately every 250 hours. Lubricate the Cargo Hook Swing Suspension at points noted in Figures 12.3.1 through 12.3.3. Recommended lubricants are AeroShell 17, MIL-G-21164 or Mobilgrease 28, MIL-G-81322. 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 12.3.1. This applies to all four Shackle Assemblies on the helicopter. Figure 12.3.1 Shackle Assembly Lubrication Lubricate pin O.D. Lubricate bushing I.D. Refer to Eurocopter maintenance documentation for attach hardware. Instructions for Continued Airworthiness 123-029-00 12-00-00 Page 10 Revision 9 05/10/12 12.3 Lubrication Information continued Lower Cable Gimbal Lubrication Lubricate the four lower cable and swing frame joints as shown in Figure 12.3.2. The swing frame joint has an NAS516-1A grease fitting for lubrication. For re-assembly after lubrication, tighten castellated self-locking nut on suspension cable pivot bolt and tighten to 20 in-lbs, then rotate to next castellation, not to exceed 30 in-lbs, and install cotter pin. Do not over-tighten these bolts, as this may cause undue stress in the cable clevis fittings. Ensure cable clevis fittings rotate freely after tightening. Figure 12.3.2 Lower Cable and Swing Frame Joint Lubrication Apply grease at fitting. Lubricate bolt O.D.