Bell 206 A & B - Onboard Systems

latch disengaged, the weight of the load causes the load beam to swing to its open position, and the cargo sling slides off the load beam. The load beam then remains in the open position awaiting the next load. A load release can be initiated by three different methods. Normal release is achieved by pilot actuation of the push-button switch in the cockpit. When the push-button switch is pressed, it energizes the DC solenoid in the Cargo Hook, and the solenoid opens the latch in the internal mechanism. In an emergency, release can be achieved by operating a mechanical release cable. The release cable operates the internal mechanism of the Cargo Hook to unlatch the load beam. The load can also be released by the actuation of a lever located on the side of the Cargo Hook. Installation Instructions 2-1 Section 2 Installation Instructions These procedures are provided for the benefit of experienced aircraft maintenance facilities capable of carrying out the procedures. They must not be attempted by those lacking the necessary expertise. 2.1 Cargo Hook Installation Disconnect the manual release cable from the existing cargo hook and at the bracket on the belly of the helicopter and remove. Disconnect the electrical release harness from the cargo hook, this harness will be re-used with the new cargo hook. Remove the cargo hook and the Universal Assembly (Bell P/N 206-072-189-101 or P/N 204-011-128-1) which attaches the cargo hook to the Bell suspension frame. If installing Kit P/N 200-389-00 which is a load cell upgrade kit for use with an existing Onboard Systems keeperless cargo hook, remove the existing link style load cell, the Universal Assembly, and any other link between the cargo hook and the Bell suspension frame. Attach the Cargo Hook to the Link Assembly using the hardware supplied, as illustrated below. The Link Assembly is “keyed” to prevent incorrect orientation with respect to the cargo hook. It is oriented on the cargo hook as shown below. Figure 2.1 Cargo Hook/Link Assembly w/o Load Weigh Nut P/N 510-170-00 Washer P/N 510-174-00 Washer P/N 510-183-00 Cotter Pin P/N 510-178-00 Link Assembly P/N 232-732-00 Washer P/N 510-183-00 Attach Bolt P/N 290-332-00 Tighten nut on attach bolt to finger tight only and then rotate to previous castellation if necessary to insert cotter pin. Install and secure cotter pin. 2-2 Installation Instructions 2.1 Cargo Hook Installation continued If installing kit P/N 200-389-00 or P/N 200-390-00 (includes load weigh system), assemble the cargo hook to the link assembly with the pin load cell assembly (P/N 210-301-01) per Figure 2.2. Figure 2.2 Cargo Hook/Link Assembly with Pin Load Cell Nut P/N 510-170-00 Washer P/N 510-174-00 Washer P/N 510-183-00 Cotter Pin P/N 510-178-00 Link Assembly P/N 232-732-00 Pin Load Cell Assembly P/N 210-301-01 Tighten nut on pin load cell assembly to finger tight only and then rotate to previous castellation if necessary to insert cotter pin. Install and secure cotter pin. Attach the Cargo Hook/Link Assembly to the Bell suspension frame assembly re-using the Bell hardware that was previously used to attach the Bell Universal Assembly to the frame (see Figure 2.3). The cargo hook load beam must point to the right (the cargo hook electrical connector is to the left). See the appropriate Bell service instructions for the correct installation torque values. After tightening, the Link Assembly must pivot on the bolt and the bolt must not rotate within the suspension frame ears. Figure 2.3 Cargo Hook/Link Assembly Installation Re-use Bell hardware Forward Bell suspension frame Installation Instructions 2-3 2.1 Cargo Hook Installation continued Connect the manual release cable (P/N 268-055-00) to the cargo hook per the following instructions. This manual release cable P/N has a lower profile fitting to attach to the cargo hook and is more flexible than the existing installed manual release cable. These features better accommodate the closer proximity of the cargo hook to the frame with the Link Assembly used in these kits. o Remove the manual release cover from the cargo hook by removing the manual release cover screws (see below). Figure 2.4 Manual Release Cover Removal Remove these two screws. o Thread the fitting at the end of the manual release cable into the manual release boss on the cargo hook side plate until the threads protrude approximately .125 inches beyond the boss and secure with jam nut (as shown in Figure 2.5). 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 2.5 Initial Release Cable Adjustment boss jam nut Approx. .125 in. (3.2mm) Manual Release Cable 2-4 Installation Instructions 2.1 Cargo Hook Installation continued o Route the manual release cable as shown to the bracket on the left side of the frame weldment and connect it by removing the pre-installed nut and washer and re-installing them over the manual release cable’s end fitting after inserting through the hole in the bracket. Figure 2.6 Manual Release Cable Routing Manual Release Cable (P/N 268-055-00) View Looking Down Forward o Connect the cable ball end to the fixed manual release cable’s coupler by compressing its spring and inserting the ball. Figure 2.7 Manual Release Cable Connection 2. Insert Cable Ball End 1. Compress spring. Existing Fixed Manual Release Cable Coupler Forward Installation Instructions 2-5 2.1 Cargo Hook Installation continued o At the cargo hook, ensure the manual release cable is between the two prongs of the release lever fork as illustrated in Figure 2.8. Manual release cable rigging must be done with the cargo hook in the closed and locked position. o With the cargo hook closed and locked, rotate the release lever in the clockwise direction to remove free play (the free play is taken up when the hook lock indicator begins to move, this is also felt as the lever rotates relatively easily for several degrees as the free play is taken up) and measure the gap between the cable ball end and the release lever fork with the manual release lever in the cockpit in the non-release position. This gap should be a minimum of .125 inches (3.2 mm) as shown in Figure 2.8. Figure 2.8 Manual Release Cable Rigging Hook Lock Indicator Release Lever Manual Release Cable Release Lever Fork Cable Ball End .125 in. min. (3.2 mm) Load beam must be closed and locked for rigging. o If necessary adjust the manual release cable system to obtain the minimum gap of .125 inches at the release lever fork (the maximum gap is limited by the manual release cover, i.e.- the release cable must fit within the cover when it is installed). The system can be adjusted some at the cargo hook by loosening the jam nut and disconnecting it at the bracket on the frame and rotating the manual release cable in the required direction. Be sure to maintain full thread engagement between the manual release cable end fitting and cargo hook. o Re-install the manual release cover with the two screws and ensure the manual release cable jam nut is tightened securely against the cargo hook. 2-6 Installation Instructions 2.1 Cargo Hook Installation continued o Attach the supplied loop clamps, P/N 512-010-00, through the end loops of the existing cargo hook restraining shock cord. Route the shock cord through the eyelet and over the existing threaded rod as illustrated in Figure 2.9. o Secure the loop clamps to the cargo hook manual release side as illustrated in Figure 2.10 using the bolts (P/N 510-257-00) and washers (P/N 510-042-00) provided. Torque bolts to 20-25 in-lbs. Figure 2.9 Cargo Hook Retraction Overview threaded rod shock cord (not supplied) cushioned loop clamps Figure 2.10 Loop Clamp Installation cushioned loop clamps (P/N 512-010-00) Installation Instructions 2-7 2.1 Cargo Hook Installation continued The cargo hook kits use the existing Bell electrical release harness. Connect the electrical release harness connector to the Cargo Hook and route it and the pin load cell harness (if load weigh system is installed) with the manual release cable. Secure it to the manual release cable in several locations along its length with ty-raps or nylon ties. Listed below is the pin out for the cargo hook connector. Table 2.1 Cargo Hook Connector Pin Function A Ground B Positive Early versions of the Cargo Hook were equipped with a suppression diode that will be damaged if the Cargo Hook electrical connections are reversed. Do not attach the electrical connector until the polarity of the aircraft connector is determined to be compatible with the Cargo Hook connector listed in Table 2.1. 2-8 Installation Instructions 2.2 Load Weigh System Installation 2.2.1 Internal Harness Installation The Internal Harness is made up of four cables terminated to one connector (see Figure 2.2.1 for overview). 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. This cable is connected to the load cell. 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 the LOAD CELL cable with the hook manual release cable and electrical release cable to the cargo hook area. The LOAD CELL cable connector can be attached to the existing cargo hook manual and electrical disconnect bracket on the belly of the helicopter using the furnished Bracket P/N 235-035-00 and hardware. Route the POWER cable to the location for the Power switch (see section 2.2.5). Route the LIGHT cable to the aircraft’s instrument panel lighting circuit (see Section 2.2.3). Secure the cables to existing wiring bundles with the Ty-wraps. Secure the cables clear of flight control rods. Installation Instructions 2-9 2.2 Load Weigh System Installation continued Figure 2.2.1 Wiring Arrangement Overview Ground 1 WH/BL (Black) Power Shield 5 3 Shield WH (Red) Data Signal Clock Signal Flight Switch Cap. Switch 7 9 4 2 Purple* WH/OR (White) WH/GN (Green) Red* Shield Shield E Ground Data Clock Power WH/BL (Black) WH/OR (White) WH/GN (Green) D C B P/N 410-130-00 WH (Red) A PIN COLOR FUNCTION PIN COLOR FUNCTION Optional equipment connectors *Optional ANALOG METER CONNECTOR P/N 410-011-00, 410-057-00 DATA RECORDER CONNECTOR & 410-020-00 MFG: ANY, MFG P/N:MS3126F10-6P To optional equipment Data Recorder/Analog Meter cable Depending on manufacture date, this leg of the harness may or may not be terminated with a connector. 1 amp circuit breaker (not supplied) power switch (supplied) Connector to C-39 indicator To load cell To airframe ground TO 28 VDC To 28 VDC to airframe ground White/Blue (Black) White (Red) power cable light cable White/Blue (Black) White (Red) Cut off bare wire (if present, do not connect it to ground. Back light potentiometer (not supplied) 2.2.2 Indicator Installation The Indicator should be mounted in a position that is convenient, accessible and visible to the pilot. It can be mounted in a standard 2¼" instrument hole. Connect the Indicator to its Internal Harness, refer to Internal Harness Installation. 2-10 Installation Instructions 2.2 Load Weigh System Installation continued 2.2.3 Indicator Internal Back Light The 210-095-00 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. The 210-095-02 Indicator is equipped with an Internal Back Lighting System that can be connected to the aircraft 5 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. 2.2.4 Remote Analog Meter The 210-095-00 and 210-095-02 Indicator are equipped with an Analog drive circuit that can be connected to a user supplied 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 and 210-095-02 Indicator can be connected to Onboard Systems’ Analog Slave Meter, P/N 210-180-00, through the “DATA” cable. 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 2-3 to connect the Analog Slave Meter to the Internal Harness “DATA” cable. If a data connector is present on the data line use cable P/N 270-059-00 to connect to Analog Slave Meter. Installation Instructions 2-11 2.2 Load Weigh System Installation continued 2.2.5 Electrical Connections Install the supplied power switch, P/N 400-048-00. The “POWER” cable on the Internal Harness is supplied extra long, cut off the excess cable and use as needed to connect the switch and circuit breaker. Connect the “POWER” white (red if wire harness P/N 270-048-00 is installed) wire 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 as illustrated in Figure 2.2.1. Connect the circuit breaker to the 28VDC bus. Connect the white/blue (black if wire harness P/N 270-048-00 is installed) wire to the ground bus. The bare wire (with P/N 270-048-00 harness only) should be cut off as it is not needed at this end of the cable. Use a minimum of 22 gauge wire to make all connections. Secure the connections and protect from corrosion. Connect the Internal Harness to the Indicator connector. 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. If the C-23 Printer is being utilized with the C-20 or C-30 Data Recorder, a 5 amp circuit breaker should be used. 2-12 Installation Instructions 2.3 Installation Check-Out After installation of the Cargo Hook Kit, perform the following functional checks. 1. With no load on the cargo hook load beam, pull the handle operated cargo hook mechanical release, the Cargo Hook should release. Reset the cargo hook load beam. 2. Close the cargo hook release circuit breaker and position the battery switch to the ON position. With no load on the cargo hook load beam, depress the cargo hook electrical release button, the Cargo Hook should release. Reset the cargo hook load beam 3. Swing the Cargo Hook to ensure that the manual release cable and the electrical harnesses have enough slack to allow full swing of the Cargo Hook without straining or damaging the cable or harnesses. The cable or harnesses must not be the stops that prevent the Cargo Hook from swinging freely in all directions. 4. Swing the Cargo Hook fore and aft and ensure the Link Assembly rotates on the bolt at the Bell frame and that the bolt does not rotate. Un-commanded cargo hook release will happen if the manual release cable is improperly restrained. The cable 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 release cable. Figure 2.3.1 Un-commanded Release From Incorrectly Secured Cable Installation Instructions 2-13 2.4 Component Weights The weights of the Cargo Hook Kits are listed in Table 2.4.1 below. Select kit component weights are listed in Table 2.4.2. Table 2.4.1 Kit Weights Item Weight Kit P/N 200-267-02 4.1 lbs (1.86 kgs) Kit P/N 200-389-00 2.4 lbs (1.1 kgs) Kit P/N 200-390-00 5.4 lbs (2.45 kgs) Table 2.4.2 Component Weights Item Weight Cargo Hook 3.1 lbs (1.4 kgs) Link Assembly 0.63 lbs (.29 kgs) Manual Release Cable 0.27 lbs (.12 kgs) Pin Load Cell Assembly 0.30 lbs (.13 kgs) C-39 Indicator 0.47 lbs (.21 kgs) Load Weigh Internal Harness 0.64 lbs (.29 kgs) 2.5 Cargo Hook Location Table 2.5.1 Cargo Hook Location Fuselage Station 108.5 2.6 Paper Work In the US, fill in FAA form 337 for the initial installation. This procedure may vary in different countries. Make the appropriate aircraft log book entry. Insert the Rotorcraft Flight Manual Supplement P/N 121-059-00 into the Rotorcraft Flight Manual. 2-14 Installation Instructions This page intentionally left blank. Operation Instructions 3-1 Section 3 Operation Instructions Operating Procedures If the load weigh system is installed, refer to Owner’s Manual 120-039-00 for operation instructions for the C-39 load weigh indicator. Prior to a flight involving external load operations, perform the following. 1. Ensure that the manual release cable and electrical release harnesses do not limit the movement of the cargo hook. 2. 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 must release. Reset the hook by hand after the release. If the hook does not release or re-latch, do not use the unit until the difficulty is resolved. The cargo hook release solenoid is intended to be energized only intermittently. Depressing the electrical release button continuously in excess of 20 seconds will cause the release solenoid to overheat, possibly causing permanent damage. 3. Activate the manual release lever to test the cargo hook manual release mechanism. The mechanism should operate smoothly and the Cargo Hook must release. Reset the load beam by hand after release. Verify that the hook lock indicator on the side of the hook returns to the fully locked position. If the hook does not release or re-latch, do not use the unit until the problem is resolved. In the fully locked position the hook lock indicator must align with the lines on the manual release cover (see Figure 3.1). Figure 3.1 Hook Lock Indicator 3-2 Operation Instructions Operating Procedures continued 4. Visually check the manual release cable for damage, paying close attention to the flexible conduit at the area of transition to the cargo hook end fitting (refer to Figure 3.2). Check for splitting of the outer black conduit in this area and separation of the conduit from the steel end fitting. Figure 3.2 Manual Release Cable Check Pay close attention to this area of the manual release cable. Manual release cables are wearable items and must be replaced as condition requires. Broken or kinked conduit, inner cable kinks (ref Figure 3.3), frays, or sticky operation are each cause for immediate replacement. Figure 3.3 Manual Release Cable Conditions Kinked inner cable. Broken or kinked conduit. Operation Instructions 3-3 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 3.4, until an internal latch engages the load beam and latches it in the closed position. Figure 3.4 Cargo Hook Loading 3-4 Operation Instructions Cargo Hook Rigging Extreme care must be exercised when rigging a load to the Cargo Hook. Steel load rings are recommended to provide consistent release performance and resistance to fouling. The following illustration shows the recommended rigging and rigging to avoid, but is not intended to represent all rigging possibilities. It is the responsibility of the operator to ensure the cargo hook will function properly with each rigging. Nylon Type Straps and Rope Nylon type 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. Operation Instructions 3-5 Cargo Hook Rigging, continued Figure 3.5 Cargo Hook Rigging Primary Ring Long Line Recommended Avoid This page intentionally left blank. Maintenance 5-1 Section 4 Maintenance Refer to ICA 123-042-00 for maintenance information for the cargo hook kits and Component Maintenance Manual (CMM) 122-017-00 for detailed maintenance information including overhaul for the Cargo Hook. 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. An RMA number is required for all equipment returns. • To obtain an RMA, please use one of the listed methods. • Contact Technical Support by phone or e-mail (Techhelp@OnboardSystems.com). • Generate an RMA number at our website: http://www.onboardsystems.com/rma.php • After you have obtained the RMA number, please be sure to: • Package the component carefully to ensure safe transit. • Write the RMA number on the outside of the box or on the mailing label. • Include the RMA number and reason for the return on your purchase or work order. • Include your name, address, phone and fax number and email (as applicable). • Return the components freight, cartage, insurance and customs prepaid to: Onboard Systems 13915 NW 3rd Court Vancouver, Washington 98685 USA Phone: 360-546-3072 This page intentionally left blank. Certification 5-1 Section 5 Certification FAA STC 5-2 Certification Transport Canada STC Certification 5-3 EASA STC 5-4 Certification EASA STC continued Certification 5-5 ANAC STC 5-6 Certification ANAC STC continued Certification 5-7 ANAC STC Placards Placards in this section are for installation with the ANAC STC. Install the following per Section 2.2.5 if the optional load weigh system is installed. Install the following per Section 2.2.5 if the optional load weigh system is installed. 5-8 Certification Install the following on the underside of the cargo hook: Install the following over the manual release cable conduit: