INSTRUCTIONS FOR CONTINUED AIRWORTHINESS

FIGURE 6: G11470 AUXILIARY CONTROL PANEL .............................................................................................................. 13 FIGURE 7: G11480 CONTROL PANEL ............................................................................................................................... 13 FIGURE 8: G11490 CONTROL PANEL ............................................................................................................................... 14 FIGURE 9: G13115 CONTROL PANEL ............................................................................................................................... 14 FIGURE 10: G13116 CONTROL PANEL ............................................................................................................................. 15 FIGURE 11: EC135 FWD BELLY PANEL ROUTER LOCATION ............................................................................................. 19 FIGURE 12: EC135 FWD BELLY PANEL ROUTER INSTALLATION ........................................................................................ 20 FIGURE 13: EC135 AA35-100 MUX INSTALLATION .......................................................................................................... 21 FIGURE 14: EC135 EAGLE G13045 AMA INSTALLATION .................................................................................................. 22 FIGURE 15: EC135 DIGITAL ROUTER AVIONICS SHELF INSTALLATION ............................................................................... 24 FIGURE 16: G13000 DIGITAL ROUTER CONNECTOR LAYOUT ............................................................................................ 28 FIGURE 17: G13160 DIGITAL ROUTER CONNECTOR LAYOUT ............................................................................................ 30 FIGURE 18: G13120 AUDIO MIXER .................................................................................................................................. 32 FIGURE 19: G13120 AUDIO MIXER WIRING ...................................................................................................................... 35 FIGURE 20: G13120 AUDIO MIXER WIRING ...................................................................................................................... 36 FIGURE 21: G13004 SHT 1 NOTES................................................................................................................................ 41 FIGURE 22: G13004 SHT 2 MAP FOR P1, P2................................................................................................................... 42 FIGURE 23: G13004 SHT 3 MAP FOR P3, P4, P5 ............................................................................................................ 43 FIGURE 24: G13004 SHT 4 J1 CONNECTIONS ................................................................................................................. 44 FIGURE 25: G13004 SHT 5 J2 CONNECTIONS ................................................................................................................. 45 FIGURE 26: G13004 SHT 6 J3 CONNECTIONS ................................................................................................................. 46 FIGURE 27: G13004 SHT 7 J4 CONNECTIONS ................................................................................................................. 47 FIGURE 28: G13004 SHT 8 SINGLE BOARD ROUTER P2, P4, P5 ...................................................................................... 48 FIGURE 29: G13004 SHT 9 SINGLE BOARD ROUTER J2 CONNECTIONS ............................................................................ 49 FIGURE 30: G13004 SHT 10 SINGLE BOARD ROUTER J4 CONNECTIONS .......................................................................... 50 FIGURE 31: G13004 SHT 11 J5 CONNECTIONS ............................................................................................................... 51 FIGURE 32: G13004 SHT 12 GNET INTERCONNECTS ..................................................................................................... 52 FIGURE 33: G13004 SHT 13 G13115 CONTROL HEAD WIRING ........................................................................................ 53 FIGURE 34: G13162 SHT 1 NOTES................................................................................................................................ 54 FIGURE 35: G13162 SHT 2 MAP FOR P1, P2................................................................................................................... 55 FIGURE 36: G13162 SHT 3 MAP FOR P3, P4................................................................................................................... 56 FIGURE 37: G13162 SHT 4 MAP FOR P5, P6, P7 ............................................................................................................ 57 FIGURE 38: G13162 SHT 5 J1 CONNECTIONS ................................................................................................................. 58 FIGURE 39: G13162 SHT 6 J3 CONNECTIONS ................................................................................................................. 59 FIGURE 40: G13162 SHT 7 J5 CONNECTIONS ................................................................................................................. 60 FIGURE 41: G13162 SHT 8 J2 CONNECTIONS ................................................................................................................. 61 FIGURE 42: G13162 SHT 9 J4 CONNECTIONS ................................................................................................................. 62 FIGURE 43: G13162 SHT 10 J6 CONNECTIONS ............................................................................................................... 63 FIGURE 44: G13162 SHT 11 J7 CONNECTIONS ............................................................................................................... 64 FIGURE 45: G13162 SHT 12 GNET INTERCONNECTS ..................................................................................................... 65 FIGURE 46: G13162 SHT 13 G13115 CONTROL HEAD WIRING ........................................................................................ 66 SUBJECT REF. MDL. REPORT NO. INSTRUCTIONS FOR CONTINUED AIRWORTHINESS GA182 ICA182-5 Rev. C 11/7/17 Copyright © Eagle Copters USA, Inc. SEE NON-DISCLOSURE NOTICE ON THE COVER PAGE 7 of 70 All Rights Reserved LIST OF APPLICABLE DOCUMENTS Document Number Description GA182-12 Rotorcraft Flight Manual Supplement (EC135) SUBJECT REF. MDL. REPORT NO. INSTRUCTIONS FOR CONTINUED AIRWORTHINESS GA182 ICA182-5 Rev. C 11/7/17 Copyright © Eagle Copters USA, Inc. SEE NON-DISCLOSURE NOTICE ON THE COVER PAGE 8 of 70 All Rights Reserved Section 1.0 Introduction 1.1 Scope This manual provides description, operation, disassembly, inspection, repair and testing instructions and an Illustrated Parts List for the P139-HD Digital Audio System. 1.2 Purpose The purpose of this manual is to maintain the P139-HD Digital Audio System in peak operating efficiency with the greatest service life. 1.3 Revision Control Procedure All revisions to this document shall be identified in the Details of Revisions. All pages will be summarized on page 4, “List of Effective Pages.” 1.4 Service Difficulty Reporting A record of sales shall be maintained by Eagle Copters. Any changes to these instructions resulting from service difficulties shall be distributed to all previous recipients. 1.5 Applicability This manual shall be used to maintain the P139-HD Digital Audio System for Eurocopter EC135 Series Helicopters. 1.6 Abbreviations and Units of Measure in = inches lbs = pounds P/N = part number I/N = item number LH = left hand RH = right hand SUBJECT REF. MDL. REPORT NO. INSTRUCTIONS FOR CONTINUED AIRWORTHINESS GA182 ICA182-5 Rev. C 11/7/17 Copyright © Eagle Copters USA, Inc. SEE NON-DISCLOSURE NOTICE ON THE COVER PAGE 9 of 70 All Rights Reserved 1.7 Precautions The following precaution definitions will be used to indicate the seriousness of the hazard or condition. WARNING: May be a maintenance procedure, practice, condition, etc., which could result in personal injury or loss of life. CAUTION: May be a maintenance procedure, practice, condition, etc., which could result in damage or destruction of equipment. NOTE: May be a maintenance procedure, practice, condition, etc., or a statement that needs to be highlighted 1.8 Distribution This manual will be distributed to end users (or their mechanics or maintenance departments). A copy of this ICA shall be provided by Eagle Copters with each kit sold. 1.9 Description The Eagle Copters P139-HD Digital Audio System provides a communication system for aircraft crew members and passengers. 1.9.1 The P139-HD Digital Audio System Includes the Following: a. There are 3 Digital Router Systems to choose from, the first is P139- HD (D) which uses Router G13000 in a “Dual-board” configuration. The second is P139-HD (S) which uses Router G13000 in a “Single- board” configuration. The third is P139-HD (T) which uses Router G13160 and is a “Three board” router. b. A minimum of 2 Audio Control Panels for the pilot and co-pilot. A typical installation will include 3 or more Audio Control panels for the pilot, co-pilot, crew members, and/or passengers. The Control Panels come in 7 different configurations P/Ns G11460, G11462, G11470, G11480, G11490, G13115, and G13116 as shown in Figure 4 through Figure 10. The Audio Control Panels can be used interchangeably, depending on the control functions desired although G13115NS and G13116NS panels must not be used as primary control panels for Pilot or Copilot. SUBJECT REF. MDL. REPORT NO. INSTRUCTIONS FOR CONTINUED AIRWORTHINESS GA182 ICA182-5 Rev. C 11/7/17 Copyright © Eagle Copters USA, Inc. SEE NON-DISCLOSURE NOTICE ON THE COVER PAGE 10 of 70 All Rights Reserved c. Sheet metal support tray G13009 and required hardware for mounting the G13000 Digital Audio Router; or sheet metal support tray G13161 and required hardware for mounting the G13160 3-Board Router. Figure 1: Digital Audio System Overview SUBJECT REF. MDL. REPORT NO. INSTRUCTIONS FOR CONTINUED AIRWORTHINESS GA182 ICA182-5 Rev. C 11/7/17 Copyright © Eagle Copters USA, Inc. SEE NON-DISCLOSURE NOTICE ON THE COVER PAGE 11 of 70 All Rights Reserved Figure 2: G13000 Digital Router Figure 3: G13160 3-Board Router SUBJECT REF. MDL. REPORT NO. INSTRUCTIONS FOR CONTINUED AIRWORTHINESS GA182 ICA182-5 Rev. C 11/7/17 Copyright © Eagle Copters USA, Inc. SEE NON-DISCLOSURE NOTICE ON THE COVER PAGE 12 of 70 All Rights Reserved Figure 4: G11460 Control Panel Figure 5: G11462 Control Panel SUBJECT REF. MDL. REPORT NO. INSTRUCTIONS FOR CONTINUED AIRWORTHINESS GA182 ICA182-5 Rev. C 11/7/17 Copyright © Eagle Copters USA, Inc. SEE NON-DISCLOSURE NOTICE ON THE COVER PAGE 13 of 70 All Rights Reserved Figure 6: G11470 Auxiliary Control Panel Figure 7: G11480 Control Panel SUBJECT REF. MDL. REPORT NO. INSTRUCTIONS FOR CONTINUED AIRWORTHINESS GA182 ICA182-5 Rev. C 11/7/17 Copyright © Eagle Copters USA, Inc. SEE NON-DISCLOSURE NOTICE ON THE COVER PAGE 14 of 70 All Rights Reserved Figure 8: G11490 Control Panel Figure 9: G13115 Control Panel SUBJECT REF. MDL. REPORT NO. INSTRUCTIONS FOR CONTINUED AIRWORTHINESS GA182 ICA182-5 Rev. C 11/7/17 Copyright © Eagle Copters USA, Inc. SEE NON-DISCLOSURE NOTICE ON THE COVER PAGE 15 of 70 All Rights Reserved Figure 10: G13116 Control Panel SUBJECT REF. MDL. REPORT NO. INSTRUCTIONS FOR CONTINUED AIRWORTHINESS GA182 ICA182-5 Rev. C 11/7/17 Copyright © Eagle Copters USA, Inc. SEE NON-DISCLOSURE NOTICE ON THE COVER PAGE 16 of 70 All Rights Reserved Section 2.0 Airworthiness Limitations There no airworthiness limitations associated with this STC. The Airworthiness Limitation section is FAA approved and specifies inspections and other maintenance required under Part 43.16 and 91.403 of Federal Regulations unless an alternate program has been FAA approved. . SUBJECT REF. MDL. REPORT NO. INSTRUCTIONS FOR CONTINUED AIRWORTHINESS GA182 ICA182-5 Rev. C 11/7/17 Copyright © Eagle Copters USA, Inc. SEE NON-DISCLOSURE NOTICE ON THE COVER PAGE 17 of 70 All Rights Reserved Section 3.0 Inspection Requirements and Overhaul Schedule 3.1 Inspection Requirements 3.1.1 2 Year/2000 Hour Inspection a. Make sure the individual modules are properly secured and the restraining hardware is not damaged or deformed. b. Remove the Router from the mounting tray. See Section 4.0. c. Inspect all sheet metal components for damage and corrosion. If damage or excessive corrosion is found replace parts per Section 4.0. Corrosion that has penetrated more than .02” is cause for replacement in machined aluminum components. Corrosion that has penetrated more than .02” is cause for replacement on sheet metal components. d. Inspect all wiring for damage and proper security. Any wires that are damaged need to be repaired or completely replaced. e. Reinstall any removed or replaced parts per applicable portions of Section 4.0 and return aircraft to operational condition. 3.1.2 Special Inspections a. In the event that the aircraft experiences a “Hard Landing”, then conduct the inspection requirements called out in Section 3.1.1. b. In the event that the aircraft experiences a “Lightning Strike”, then conduct the inspection requirements called out in Section 3.1.1. 3.2 Overhaul Schedule There is no overhaul schedule for this kit. SUBJECT REF. MDL. REPORT NO. INSTRUCTIONS FOR CONTINUED AIRWORTHINESS GA182 ICA182-5 Rev. C 11/7/17 Copyright © Eagle Copters USA, Inc. SEE NON-DISCLOSURE NOTICE ON THE COVER PAGE 18 of 70 All Rights Reserved Section 4.0 Digital Audio Router Removal, Inspection and Re-Installation Note: The following instructions are applicable to Digital Audio Routers G13000 & G13160 defined in Section 1.9.1. 4.1 Digital Router Removal – FWD Belly Panel Location Installation These instructions are for EC135 aircraft with the router mounted under the cabin floor behind the FWD Belly Panel as shown in Figure 11. a. Disconnect all cables from the Digital Router. b. If installed, disconnect cable from either the AA35-100 Mux Unit or Eagle Copters G13045 Audio Mixing Amp mounted beneath the router. c. Remove (6) 5mm hex bolts securing the support plate to the VRU Frame as shown in Figure 12. d. Remove (4) AN3-3A bolts securing router to the support plate. e. If either the AA35-100 Mux Unit or Eagle Copters G13045 Audio Mixing Amp is installed, remove (4) AN525-832R6 screws securing unit to the support plate as shown in Figure 13 and Figure 14. SUBJECT REF. MDL. REPORT NO. INSTRUCTIONS FOR CONTINUED AIRWORTHINESS GA182 ICA182-5 Rev. C 11/7/17 Copyright © Eagle Copters USA, Inc. SEE NON-DISCLOSURE NOTICE ON THE COVER PAGE 19 of 70 All Rights Reserved Figure 11: EC135 FWD Belly Panel Router Location SUBJECT REF. MDL. REPORT NO. INSTRUCTIONS FOR CONTINUED AIRWORTHINESS GA182 ICA182-5 Rev. C 11/7/17 Copyright © Eagle Copters USA, Inc. SEE NON-DISCLOSURE NOTICE ON THE COVER PAGE 20 of 70 All Rights Reserved Figure 12: EC135 FWD Belly Panel Router Installation SUBJECT REF. MDL. REPORT NO. INSTRUCTIONS FOR CONTINUED AIRWORTHINESS GA182 ICA182-5 Rev. C 11/7/17 Copyright © Eagle Copters USA, Inc. SEE NON-DISCLOSURE NOTICE ON THE COVER PAGE 21 of 70 All Rights Reserved Figure 13: EC135 AA35-100 MUX Installation SUBJECT REF. MDL. REPORT NO. INSTRUCTIONS FOR CONTINUED AIRWORTHINESS GA182 ICA182-5 Rev. C 11/7/17 Copyright © Eagle Copters USA, Inc. SEE NON-DISCLOSURE NOTICE ON THE COVER PAGE 22 of 70 All Rights Reserved Figure 14: EC135 Eagle G13045 AMA Installation SUBJECT REF. MDL. REPORT NO. INSTRUCTIONS FOR CONTINUED AIRWORTHINESS GA182 ICA182-5 Rev. C 11/7/17 Copyright © Eagle Copters USA, Inc. SEE NON-DISCLOSURE NOTICE ON THE COVER PAGE 23 of 70 All Rights Reserved 4.2 Digital Router Removal – Avionics Shelf Installation These instructions are for EC135 aircraft with the router mounted in the Aft Avionics Bay Shelf. a. Disconnect all cables from the Digital Router. b. Loosen the thumb screw securing the router into the tray and slide the router out of the tray shown in Figure 15. NOTE The Tray does not need to be removed on a regular basis for inspection or overhaul. The Tray should only be removed if cracked or excessively corroded and needs to be replaced. c. Remove the (4) MS24693S276 Screws and (2) Shims connecting the Tray to the avionics bay shelf as shown in Figure 15. d. The #10 inserts in avionics bay shelf (I/N 4) are replaced only if damaged. This is done in accordance with the Eurocopter Maintenance Manual. SUBJECT REF. MDL. REPORT NO. INSTRUCTIONS FOR CONTINUED AIRWORTHINESS GA182 ICA182-5 Rev. C 11/7/17 Copyright © Eagle Copters USA, Inc. SEE NON-DISCLOSURE NOTICE ON THE COVER PAGE 24 of 70 All Rights Reserved Figure 15: EC135 Digital Router Avionics Shelf Installation SUBJECT REF. MDL. REPORT NO. INSTRUCTIONS FOR CONTINUED AIRWORTHINESS GA182 ICA182-5 Rev. C 11/7/17 Copyright © Eagle Copters USA, Inc. SEE NON-DISCLOSURE NOTICE ON THE COVER PAGE 25 of 70 All Rights Reserved Parts List for Figure 15: For Router G13000 Installation I/N QTY PART NUMBER DESCRIPTION 1 1 G13000 P139-HD Router 2 1 G13009 Tray 3 2 G13009-3 Shim 4 4 80-004-2-12 or 80-005-2-12 Insert, #10-32 5 4 MS24693S276 Screw, #10-32 x 1.0 Flat Head Parts List for Figure 15: For Router G13160 Installation I/N QTY PART NUMBER DESCRIPTION 1 1 G13160 P139-HD Router 2 1 G13161 Tray 3 2 G13161-3 Shim 4 4 80-004-2-12 or 80-005-2-12 Insert, #10-32 5 4 MS24693S276 Screw, #10-32 x 1.0 Flat Head SUBJECT REF. MDL. REPORT NO. INSTRUCTIONS FOR CONTINUED AIRWORTHINESS GA182 ICA182-5 Rev. C 11/7/17 Copyright © Eagle Copters USA, Inc. SEE NON-DISCLOSURE NOTICE ON THE COVER PAGE 26 of 70 All Rights Reserved 4.3 Digital Router and hardware Inspection a. The Digital Router contains no user serviceable internal components. Do not disassemble router or the factory warranty will be voided. Return the unit to Eagle Copters for service. b. Inspect all sheet metal for cracks or excessive corrosion. If any of the parts are cracked or excessively corroded (refer to Section 3.1.1 for corrosion limits) they must be removed from the aircraft and replaced. 4.4 Digital Router Re-Installation FWD Belly Panel Location These instructions are for EC135 aircraft with the Router mounted under the cabin floor behind the FWD Belly Panel as shown in Figure 11. This installation also provides an option (at the installer’s discretion) for mounting an AA35-100 Audio Mixer (MUX) or the Eagle Copters G13045 Audio Mixing Amp (AMA). a. This installation makes use of the mounting frame for the Eurocopter Video Radar Unit (VRU) installation L316M1807101. If the VRU is installed into the aircraft, then the Router cannot be installed into the frame and must be installed in the Aft Avionics Shelf. b. Mount Router onto Support Plate G13130-1 using (4) AN3-3A bolts as shown in Figure 12. c. Install (6) 5mm x 14mm hex bolts securing the support plate to the VRU Frame. d. If either the Optional AA35-100 Mux Unit or Eagle Copters G13045 Audio Mixing Amp is to be installed, mount units to support plate using (4) AN525-832R6 screws as shown in Figure 13 and Figure 14 . e. Reconnect all applicable cables to the Digital Router. Reference Figure 16 for all Digital Router Connection Ports. SUBJECT REF. MDL. REPORT NO. INSTRUCTIONS FOR CONTINUED AIRWORTHINESS GA182 ICA182-5 Rev. C 11/7/17 Copyright © Eagle Copters USA, Inc. SEE NON-DISCLOSURE NOTICE ON THE COVER PAGE 27 of 70 All Rights Reserved 4.5 Digital Router Re-Installation Avionics Shelf Installation This installation provides mounting provisions for the Digital Audio Router in the Aft avionics bay shelf area for the EC135 as shown in Figure 15. The location is shown for reference only. The exact placement of the Router is dependent on the other pre- existing installed equipment. Orientation of the tray is at the installer’s discretion. Maintain 2 e/d edge margin for all mounting holes. NOTE If the Tray has not been removed skip to step (d) and connect the Router to the existing Tray. If Tray has been replaced continue to step (a). a. Locate Tray to avoid existing structures and devices installed. Orientation of the tray is at the installer’s discretion. b. Locate and install (4) #10-32 inserts (I/N 4) in accordance with Eurocopter Repair Manual. c. Mount Tray to shelf using (2) Shims and (4) MS24693S276 Screws. d. Slide router into tray so that clip on base of router engages slot on rear of tray. Be sure router is seated fully down. Secure router to tray using attached thumb screw. e. Reconnect all applicable cables to the Digital Router. Reference Figure 16 and Figure 17 for all Digital Router Connection Ports. SUBJECT REF. MDL. REPORT NO. INSTRUCTIONS FOR CONTINUED AIRWORTHINESS GA182 ICA182-5 Rev. C 11/7/17 Copyright © Eagle Copters USA, Inc. SEE NON-DISCLOSURE NOTICE ON THE COVER PAGE 28 of 70 All Rights Reserved Figure 16: G13000 Digital Router Connector Layout J6 NETWORK PORT J7 MEMORY PORT J3 J1 J4 J2 J5 SUBJECT REF. MDL. REPORT NO. INSTRUCTIONS FOR CONTINUED AIRWORTHINESS GA182 ICA182-5 Rev. C 11/7/17 Copyright © Eagle Copters USA, Inc. SEE NON-DISCLOSURE NOTICE ON THE COVER PAGE 29 of 70 All Rights Reserved f. G13000 Digital Router Connections 1. J1 is used to connect COM1 and radios XCVR3 – XCVR11. 2. J2 is used to connect COM2 and radios XCVR12 – XCVR20. 3. J3 is used to connect the Pilot’s control panel, Pilot’s headset group, headset groups 3 – 7 and passenger control panels. 4. J4 is used to connect the Copilot’s control panel, Copilot’s headset group, headset groups 8 – 12 and additional passenger control panels. 5. J5 is used to connect power, ground, Pilot’s COM1 Isolate, and Copilot’s COM2 Isolate. 6. J6 is a network port used for system configuration adjustment. 7. J7 is a memory card slot used for storing system configuration data onto removable media. SUBJECT REF. MDL. REPORT NO. INSTRUCTIONS FOR CONTINUED AIRWORTHINESS GA182 ICA182-5 Rev. C 11/7/17 Copyright © Eagle Copters USA, Inc. SEE NON-DISCLOSURE NOTICE ON THE COVER PAGE 30 of 70 All Rights Reserved Figure 17: G13160 Digital Router Connector Layout J8 NETWORK PORT J9 MEMORY PORT J6 J5 J2 J1 J7 J3 J4 SUBJECT REF. MDL. REPORT NO. INSTRUCTIONS FOR CONTINUED AIRWORTHINESS GA182 ICA182-5 Rev. C 11/7/17 Copyright © Eagle Copters USA, Inc. SEE NON-DISCLOSURE NOTICE ON THE COVER PAGE 31 of 70 All Rights Reserved g. G13160 Digital Router Connections 1. J1 is used to connect COM1 and radios XCVR3 – XCVR11. 2. J2 is used to connect the Pilot’s control panel, Pilot’s headset group, headset groups 3 – 7 and passenger control panels. 3. J3 is used to connect COM2 and radios XCVR12 – XCVR20. 4. J4 is used to connect the Copilot’s control panel, Copilot’s headset group, headset groups 8 – 12 and additional passenger control panels. 5. J5 is used to connect radios XCVR21 – XCVR30. 6. J6 is used to connect headset groups 13 – 18 and additional passenger control panels. 7. J7 is used to connect power, ground, Pilot’s COM1 Isolate, and Copilot’s COM2 Isolate. 8. J8 is a network port used for system configuration adjustment. 9. J9 is a memory card slot used for storing system configuration data onto removable media. SUBJECT REF. MDL. REPORT NO. INSTRUCTIONS FOR CONTINUED AIRWORTHINESS GA182 ICA182-5 Rev. C 11/7/17 Copyright © Eagle Copters USA, Inc. SEE NON-DISCLOSURE NOTICE ON THE COVER PAGE 32 of 70 All Rights Reserved Section 5.0 G13120 Audio Mixer Removal, Inspection and Re-Installation Figure 18: G13120 Audio Mixer SUBJECT REF. MDL. REPORT NO. INSTRUCTIONS FOR CONTINUED AIRWORTHINESS GA182 ICA182-5 Rev. C 11/7/17 Copyright © Eagle Copters USA, Inc. SEE NON-DISCLOSURE NOTICE ON THE COVER PAGE 33 of 70 All Rights Reserved 5.1 G13120 Audio Mixer Removal a. Disconnect cable connector from the Audio Mixer. b. Disconnect (4) #8-32 screws securing the Audio Mixer to the mounting structure. 5.2 G13120 Audio Mixer Inspection a. The Audio Mixer contains no user serviceable internal components. Do not disassemble router or the factory warranty will be voided. Return the unit to Eagle Copters for service. b. Inspect all sheet metal for cracks or excessive corrosion. If any of the parts are cracked or excessively corroded (refer to Section 3.1.1 for corrosion limits) they must be removed from the aircraft and replaced. 5.3 G13120 Audio Mixer Installation a. The Audio Mixer is designed to be mounted in a variety of locations within the airframe, provided it is protected from the environment. It may be mounted to a deck, bulkhead, tray, avionics shelf or other structure rated to carry a 8 oz. load. b. The exact mounting location is left to the installer’s discretion provided that the installation of the Audio Mixer does not interfere with other equipment installed. Refer to Figure 18 for laying out mounting holes. c. Mount the Audio Mixer using (4) #8-32 screws, washers and locknuts or nutplates. When mounting into composite structure, #8-32 potted inserts should be used. d. Unless otherwise specified, follow aircraft manufacturer’s standard practices and maintenance manuals for installation of all hardware. e. Maintain a minimum 2 e/d edge margin for all installed fasteners. SUBJECT REF. MDL. REPORT NO. INSTRUCTIONS FOR CONTINUED AIRWORTHINESS GA182 ICA182-5 Rev. C 11/7/17 Copyright © Eagle Copters USA, Inc. SEE NON-DISCLOSURE NOTICE ON THE COVER PAGE 34 of 70 All Rights Reserved 5.4 G13120 Audio Mixer Cable Maintenance a. Refer to Figure 19 and Figure 20 for cable harness fabrication instructions. b. Unless otherwise specified, follow the aircraft manufacturer’s electrical wiring practices and maintenance manuals for installation of all system wiring. c. Unless otherwise noted, all shielded wire is M27500-(ga)TG(n)T14 and all unshielded wire is M22759/16-(ga)-9, where (ga) is the wire gauge and (n) is the number of wires inside the shield. d. Unless otherwise noted, all wire is 22 GA. e. All Bonding and Grounding will be In Accordance With AC 43.13-1B, Chapter 11, Section 15. f. Route all system cabling through existing cable runs. g. Secure all cabling using nylon cable ties and/or cable clamps using standard practices. 5.5 G13120 Audio Mixer Operation a. The G13120 Audio Mixer is designed to mix audio from up to 8 sources into 3 outputs. b. The first two inputs and outputs (1D and 2D) are considered Essential, and will remain functional even when the mixer is not powered or detects an internal fault due to the failsafe relays and detection internal to the mixer. c. If the mixer is not powered or is in fault mode (Essential), Input 1 will be connected directly via relay closure to Output 1D, and Input 2 will be connected directly to Output 2D. d. The direct inputs in essential mode are non-adjustable. e. The level that is present at Inputs 1 and 2 will be present at 1D and 2D respectively. f. Output 3 is not relay direct protected and will therefore drop off line in unpowered or fail mode. This output is designed to be a monitor port to a non-critical device. g. It is important to follow the setup instructions exactly in order for the mixer to work properly in the Essential Mode. SUBJECT REF. MDL. REPORT NO. INSTRUCTIONS FOR CONTINUED AIRWORTHINESS GA182 ICA182-5 Rev. C 11/7/17 Copyright © Eagle Copters USA, Inc. SEE NON-DISCLOSURE NOTICE ON THE COVER PAGE 35 of 70 All Rights Reserved Figure 19: G13120 Audio Mixer Wiring SUBJECT REF. MDL. REPORT NO. INSTRUCTIONS FOR CONTINUED AIRWORTHINESS GA182 ICA182-5 Rev. C 11/7/17 Copyright © Eagle Copters USA, Inc. SEE NON-DISCLOSURE NOTICE ON THE COVER PAGE 36 of 70 All Rights Reserved Figure 20: G13120 Audio Mixer Wiring SUBJECT REF. MDL. REPORT NO. INSTRUCTIONS FOR CONTINUED AIRWORTHINESS GA182 ICA182-5 Rev. C 11/7/17 Copyright © Eagle Copters USA, Inc. SEE NON-DISCLOSURE NOTICE ON THE COVER PAGE 37 of 70 All Rights Reserved 5.6 G13120 Audio Mixer Setup and Adjustment a. Notes listed below apply to Figure 19 and Figure 20. SUBJECT REF. MDL. REPORT NO. INSTRUCTIONS FOR CONTINUED AIRWORTHINESS GA182 ICA182-5 Rev. C 11/7/17 Copyright © Eagle Copters USA, Inc. SEE NON-DISCLOSURE NOTICE ON THE COVER PAGE 38 of 70 All Rights Reserved a. Setup Notes: Failure to follow these instructions will result in improper operation of the Audio Mixer. SUBJECT REF. MDL. REPORT NO. INSTRUCTIONS FOR CONTINUED AIRWORTHINESS GA182 ICA182-5 Rev. C 11/7/17 Copyright © Eagle Copters USA, Inc. SEE NON-DISCLOSURE NOTICE ON THE COVER PAGE 39 of 70 All Rights Reserved Section 6.0 Cable Maintenance 6.1 General Notes a. The installation of the Eagle Copters P139-HD Digital Audio System requires the application of accepted aircraft equipment practices, according to FAA publication, AC43.13-1B, ACCEPTABLE METHODS, TECHNIQUES AND PRACTICES, AIRCRAFT INSPECTION AND REPAIR, and the installer shall strictly comply with paragraph 428.a of that Advisory Circular. b. The requirement regarding the securing of wire bundles using nonmetallic clamps is addressed by the use of nylon cable ties. The part numbers and description of these ties is as follows: Cable Tie Selection Chart Thomas & Betts Brand Cat. No. UPC Bod Width in. Length in. Max. Wire Bundle Dia. in. Military Standard Part No. Tensile Strength lbs. TY23M 82436 .091 3.62 .625 MS3367-4 18 TY24M 82447 .140 5.50 1.125 MS3367-5 40 TY25M 82457 .184 7.31 1.750 MS3367-1 50 c. Following the guidelines in AC43.13-1B, cable ties are attached at a maximum of 4” spacing and ties are attached to nylon cable tie anchors, as necessary. d. The configuration of the wiring and cabling will vary from aircraft to aircraft. The installation of the Eagle Copters P139-HD Digital Audio System will not change the existing wiring or cabling, but rather will utilize existing wire and cable runs and will not interfere with the existing aircraft equipment installations. SUBJECT REF. MDL. REPORT NO. INSTRUCTIONS FOR CONTINUED AIRWORTHINESS GA182 ICA182-5 Rev. C 11/7/17 Copyright © Eagle Copters USA, Inc. SEE NON-DISCLOSURE NOTICE ON THE COVER PAGE 40 of 70 All Rights Reserved 6.2 Cable Maintenance a. For the installation of a Digital Audio System using a G13000 Digital Router, refer to Figure 21 thru Figure 33 for detailed wiring schematic drawings G13004 (Sheets 1 -13). b. For the installation of a Digital Audio System using a G13160 3-board Router, refer to Figure 34 thru Figure 46 for detailed wiring schematic drawings G13162 (Sheets 1-13). c. Each cable configuration and location will vary from installation to installation. Refer to notes made during installation to determine exactly where each cable is installed. Be sure to carefully document the Radios and Control panels installed and their related connections for future maintenance and troubleshooting purposes. d. If a cable needs to be repaired or replaced due to damage, refer to the appropriate cable drawing in Section 6.3. All cables should be built utilizing proper aviation practices.