CSP-HMI-2 MAINTENANCE MANUAL

~ '-- - ----..-1 CARGO HOOK 3690 OPTIONAL CYCLIC STICK GRIP RIGHT OF LEFT HAND COMMAND P605J TB3-4 TB3-1 I I M531A16--jo"}- M520B20 SP92 I I r-'-+----t--+--. ~M520AA16 ::J ::CB603 I I 1~ II HOOK RELEA SE 0 15Ao-- I I SWITC H (S4) I I -'- P1 30 J I I r--A ..._- 10-20-rn-- M520C20-_j 1 1... - - - s- 2oiJj- M522A2o- _ _j M522D16- -Q-- M522C16 .., M523A20 _____JffiTB 1 ~ 19 At~~ 1 A - · , I TB3-1 I I NOTES: '- j L M523B16N-@ ~ L _ _ M523BB20 • ..1 CARGO HOOK 369D RIGHT HAND COMMAND CYCLIC STICK GRIP 3-1149, 1151-1184 1. 3690294402 CENTER ELECTRICAL CONSOLE: -703 WITH ARMAMENT PANEL -701 WITHOUT ARMAMENT PANEL 2. 369D294500 CENTER ELECTRICAL CONSOLE WITH VHF-FM RADIO SET AND ASW EQUIPPED HELI COP TERS. F-+----+---t----,M531A16-f0l- M520B20 J616P ~ : 13-M520AA16:::J I I I I CB603 I I HOOK RELEASE 1{"'o2- M520A 16 I I SWITCH 15 A I I __._ WHTNIO P109J I I .... - ORBLUEID M521F20--f-1 1... - WHT/GRAY E M520F20 - _j OR GRAY P109J TB1-19 lsT1- M521F20 ----Gl---- NOTE 2 LLJ-M520F20 - - - ~ G25-5005-1 Figure 101. Cargo Hook - Wiring Diagrams (Sheet 1 of 4) Page 104 Revision23 25-50-00 MD Helicopters, Inc. CSP-HMI-2 MAINTENANCE MANUAL CARGO HOOK RE- J130P LEASE SWITCH ill i .__ -1QORBLU --- - S4 B .__ - 9 OR GAY- - - - M521E2tr M532A2 K104 J109-A (REF) J 109-B (REF) M5 0820 IT~1 J9P __][-- M520AA1·--rn~ M531A16 I I CB603 ~ 1~ 2 0 o=-- - - M520A16- - _j 15A '--- --+-- M523A20N1 1~G: ::~ELEASE ._____ M52 2 C16 ----T~>- 4 -----M522D16------1 I I I 1 I 369D CYCLIC STICK GRIP LEFT OR RIGHT HAND COMMAND 1150, 1185-1204 - ~523BB20N ~-- - - M523816r-r- - I L _____ _, CR3 M531B1=:J J605P -- M522D1B- -- I - - - - - - I TB3-4 I I I L ___ \J M523C2011 CARGO HOOK ASSEMBLY 369E/FF CYCLIC STICK GRIP LEFT OR RIGHT HAND COMMAND ~- .---- ---M523A2o------l I I I I I I -- M520B2 - --~ - - - M520AA16--- rn .- 1 ~~~ TB3 -1 ~ C~3 I I v '\2 I M531A16 - +------l 0 15A I I : HOOK RELEASE I I I SWITCH (PILOT'S} '--- M520A 16- - ___j I 9 j1 o.-- - - - _ffi - -- - - - M522A20- -- - : : HOO~~~;--- - -w-------- M521E2Q----_J : SWITCH (CO- PILOT'S} I 9-¥ o-- - - -_iii_ - ----- M522C2o------' : L ----- ---w------- M521G2o------_j G25-5005-2 Figure 101. Cargo Hook - Wiring Diagrams (Sheet 2 of 4) 25 - 50 - 00 Page 105 Revision 23 CSP-HMI-2 MD Helicopters, Inc. N.UUNTENANCEMANUAL CB118 P616J REF}.- - - 1 ~ M520A16~ M52 0M16 15A CB603 1 ,.---.... 2 0 0 1 5A Page 106 R evis ion 23 M53 1A16--r."'' M520820 r ----- ...... 1 I M532A20 I CR3 1 I M523A20N --;l._ ~ E24 369E/FF RI GHT H AND COM - MAND CONF I GURAT I ON Figure 101. Cargo Hook - Wiring Diagrams (Sheet 3 of 4) P/J120 2 M1015A16 ----- ill -- - -- --- - M1015816 -:::::: : :: ::-;• ILJj r·--- M1105A2 2 -· · I r · ---- -- M1107A22 ---- {!ill -- : i K201 X1 'I I H OOK RELAY , I ~ M1179A22N x2 I I E37 <D TB200-4 EFFECTIVE 369E 384 & SUBS AND 369FF 076 & SUBS Figure 101. Cargo Hook - Wiring Diagrams (Sheet 4 of 4) 25-50-00 G 25-50 05-3 H OOKASSY G25-5005-4 MD Helicopters, In c. CSP-HMI-2 N.UUNTENANCEMANUAL CARGO HOOK REMOVAL/INSTALLATION 1. Cargo Hook Replacement A. Cargo Hook Removal Remove the cargo hook a sse mbly including the cargo hook manual rel ease cable and el ect ri- cal harn ess as follows: (1). Remove cotter pin (Ref. Figur e 405), washer, a nd sl otte d bushing from manua l release lever on pilot's cyclic stick. (2). Loosen locking nu t secu rin g adjustment nut sha ft to rele ase lever br acket. (3). Remove screws (Ref. Figure 401 ), nuts, was h ers, and clamp s sec urin g manualrelease cable to cyclic s ti ck (4). Remove adjustment nut sha ft (Re f. Figure 405) from rele ase lever br acket. (5). Loo sen dust cover from pilot's cyclic stick contr ol t rim cover (Ref. Section 25-3 0- 00 ). (6). Remove passenger/cargo compartment left foot fai rin g trim (Ref. Section 25-3 0-00 ). (7). Carefully pu sh manu al r el ease cable (Re f. Figure 401) down through gr om- me ts in pilot's floor and fu se lage skin. Do not pull on cable housing. (8). Remove cargo hook electrical harne ss plu g from rece pt acle in fuselage; in sta ll pr ot ective ca ps on r ecepta cl e and plug. (9). Remove clamps (Ref. Figure 402) sec urin g cable a nd harness to clips on fuselage underside. (10 ). Remove four bol ts (Ref. Figur e 404) securing cargo ho ok ba se to attachholes in fu sel age k ee l. B. Cargo Hook Installation In sta ll at ion of the cargo hook k it consis ts of attachin g the hook, an d electrical/manual release cables on the under s ide of t he helicop- ter, routing an d se curin g the manua l re lease cable, install ation and adjustment of the manual r el ease lever as follows: (1 ). Secure base of cargo hook assem bly (Ref. Fi g ur e 404) to fuselage undersidewi th bol ts and washers. (2). Remove protective cap from car go hook electrical receptacle ( J605); check t ha t BATTERY switch is in OFF position and connect plug (P 605) to receptacle. (3). In sert free end of hook manual release cable through elongated hole adjacen t to electrical receptacle (Ref. Figure 402). Push manual release cable up int o fuselage and ins ert cable thr ough hole in pilot's floor. ( 4) . Loosely atta ch harn ess a nd manua l r elease cable u si ng clamps (Ref. Figure 402) screws, washers, and nut s. Adjust h a rn ess a nd cable to allow sufficient slack for hook to swing 30 degrees conically from cente rlin e without creating strain on harness an d cable. Arrange harness and cable to form smooth flow to cutouts in fu se lage skin; tighten clamps. Install tie st r aps app r ox im ate ly as shown (Ref. Figur e 402). NOTE: The 600N helicopt er s eq uipp ed with e mergency floats re quir e the manua l r e- l ease handl e to be mount ed on the co llective st i ck (Ref. Fi g ur e 406). (5). Loosely attac h manua l release cable to cyclic stick wi th clamps, screws, was hers, a nd n uts (Ref. Figure 401). (6). Engage approximately half of the thre ads on the manua l release cable ad ju stme nt nut shaft into the bracket portion of the manua l r el ease lever assembly (Ref. Figure 405). (7). En gage swaged ball on release cable in lever bushi ng (Ref. Figure 405). Sec ur e bushing wi th washer a nd cotter pin. (8). Attach m anua l release l ever assembly to cyclic stick wi th clamp and screws. Adjust cable and /or r el ease lever as shown (Re f. Fig u re 405). 25-50-00 P age 401 Revision 23 CSP-HMI-2 MD Helicopters, Inc. NUUNTENANCEMANUAL (9). Tighten three sets of clamp s securing release cable to cyclic stick. (10). Do the adjustment / test of cargo hook install ation. (11). Readjust cable lever (Ref. Figure 405) as required to obtain smooth consistent release of hook. NOTE: The manual release lever clamp can beloosened and the lever assembly moved on cyclic stick to simp lify adjustment, provid- ing the 2. 00-2.50 inch (5.08-6.35 em) di- mension limit is maintained (Ref. Figure 405). Page 402 Revision 23 25-50-00 (12). In sta ll grommet (Ref. Figure 401) in crew compartment floor cutout. (13). Install grommet (Ref. Figure 402 ) in elon gated hole in fuselage lower skin and doubler. (14). Safetywire manual release lever clamp screws with lockwire (Ref. Figure 405). MD Helicopte rs , Inc. MAINTENANCE MANUAL C LAM P ~ SCREW~ ~ _.-·-· - · ~ - ~ ~ PILOT'S CYCLIC STI CK v CANTED STATION 64.365 j i /CLAMP A CLAMP IN STALLATION W QYP -THREE PLACES) ---· --·- -·-----·---i·-i ~-CR'W COMPARTMENT FLO OR i j I i GROMMET i/ j ji MANUAL RELEASE CABLE i ! j ! i ! . I i i I --·-·-·- I i ~ ELECTRICAL RECEPTACLE (J605) / -·-t·- -., -- ·--·-- j i ·-· -· - ·- ·- ·-· - ·-·- · - ·- ·- FUSELAG E SKIN LI NE I ~ ! ELE CTRI CA L PLU G (P605) STA63 Figure 401. Manual Release Cable Routing - Interior 25-50-00 CS P-HM I-2 G25-5000 Page 403 Revi si on 23 CSP-HMI-2 MD Helicopters, Inc. MAINTENANCE MANUAL NOTES: e EXTERIOR ATTACHMENT OF MANUAL RELEASE CABLE AND ELECTRICAL WIRE HARNESS 1. LEFT HAND COMMAND ILLUSTRATED. RIGHT HAND COMMAND DIMENSIONS THE SAME EXCEPT ON OPPOSITE SIDE. 2. EXISTING RIVET LOCATION AT STATION 84.79. 3. P4 HUCK RIVET MAY BE USED INSTEAD AT STATION 84.79. 4. HARNESS AND CABLE TIED TOGETHER MIDWAY BETWEEN STATION 84.79 AND HOOK ASSEMBLY. 5. MAINTAIN SUFFICIENT SLACK IN NOTED SECTION OF CABLE AND HARNESS TO ALLOW HOOK TO SWING 30 DEGREES CONICALLY FROM CENTERLINE WITHOUT CREATING STRAIN ON CABLE AND HARNESS. STATION 84.79 NOTE4 MANUAL RELEASE CABLE WASHER I CLAMP (ELECTRICAL) @(~ I CLIP / ~~~~ CLAMP (!) 6 (MANUAL) NUT "" (J) I ~~ SCREW RIVET (NOTES 1, 2)-----.._fi . ~~ A CLAMP ATTACHMENT \:1 !IYEICAll G25 -5001 Figure 402. Manual Release Cable and Electrical Wire Harness Routing - Exterior Page 404 Revision 23 25-50-00 HOOK RELEASE DECAl STANDARD GRIP EQUIP MENT GRIP MD Helicopters, Inc. MAINTENANCE MANUAL AUDIO RAO ALT @0~ I -COMU- 2® ~ 001-NAV-2 00@ AOF XPt iOR OATIERY EXT P\'n:l CSP-HMI-2 CARGO HOOI< RELEASE CIRCUIT BREA KER CARGO / I l OOK~ @ O 00HOOK FLOATS b 369D LEFT-HAND COMMAND CONFIGURATION CARGO HOOK RELEASE • ~ 0CIRCUIT BREAKER IT ~ ~ \I 369E/FF "T~E" PANEL LEFT-HAND COMMAND CONFIGURATION GCIRCUIT BREAKER PANEL CARGO HOOK RELEASE SWITCH RELEASE SWITCH CARGO HOOK RELEASE CIRCUIT BREAKER 0 PILOT'S CYCLIC STICK GRIP RIGHT -HAND COMMAND WITH CENTER ELECTRICAL CONSOLE CONFIGURATION G 25-5002 Figure 403. Cargo Hook Electrical Equipment Installation 25 - 50-00 Page 405 Revision 23 CSP-HMI-2 ELECTRICAL WIRE HARNES S ~ MANUAL RELEAS E CABLE NOTE: PADS PREVEN T FUSELAGE SKIN DAMAGE AT HOOK CONTACT POINTS. Page 406 Revision 23 MD Helicopters, Inc. MAINTENANCE MANUAL EXTERNAL REL EASE ~ (TURN CLOCKWISE) HOOK (LOAD BEAM) 2.00 ±0.121N. (5.08 ±0.3048 CM) STA99.325 Ii i LATERAL CENTERLINE OF 4-HOLE LAYOUT A-A Figure 404. Hook and Pad - Installation 25-50-00 3.75±0. 121N . (9.525 ±0.3048 CM) (2 PLCS) G25-5003A NOTES: MD Helicopters, Inc. MAINTENANCE MANUAL CARGO HOO K MAN UAL RELEASE LEVE R ASSEMBLY~ SLOTIE D BUSHING LOOKING AFT AND DOWN CARGO HOOK RmASE CABLE1 BALL TERMINAL (NOTE 1) 1. CABLE BALL TERMINAL RETAINED IN SLOTIED BUSHING OF RELEASE LEVER. CSP-HMI-2 POSITIONING LEVER ON STI CK HOOK-ENGAGED LEVER POSITION (NOTES 3, 6) CARGO HOOK ~ RELEASE LEVER 2. APPROXIMATE ANGULAR POSITION OF LEVER REQUI RED FOR CONVENIENCE AND RELEASE OF CARGO HOOK. 3. CABLE BALL TERMINAL AFT TRAV EL SHOULD BE APPROXIMATELY 1/2 1NCH TO RELEASE HO OK. RELEASE BRACKET 4. WITH LOCKING NUT LOOSENED , TURN ADJUSTMENT NUT TO PULL RELEASE LEVER TO FULL FORWARD (HOOK ENGAGED) POSITION WITH SLIGHT TENSION ON CABLE; TIGHTEN LOCKING NUT. IF REQUIRED, ADJUST POSITION OF LEVER ASSEMBLY ON CYCLIC STICK. 5. BUSHING 369 H92631 MAY BE USED AS ALTERNATE. 6. LEVER SHOULD NOT MOVE FROM HOOK-ENGAGED POSITION WHEN CYCLIC STICK IS MOVED THROUGH FULL TRAVE L IN ALL DIRECTIONS. \ LO OK ING INBOARD FROM LEFT SIDE OF HELICOPTER G25-5004 Figure 405. Cargo Hook Manual Release Lever - Installation 25-50-00 Page 407 Revision 23 CSP-HMI-2 MD Helicopters, In c. MAINTENANCE MANUAL CARGO HOOK MECHANICAL RELEA SE CARGO HOOK ELECTRICAL RELEASE "' CYCLIC-MOUNTED ELECTRICAL HOOK RELEASE STANDARD CYCLIC-MOUNTED MECHANICAL HOOK RELEASE CARGOHOOK~MECHANICAL RELEASE CARGO HOOK RELEASE CAB LE COLLECTIVE-MOUNTED MECHANICAL HOOK RELEASE (NOTE) NOTE: FOR 600N MODEL HELICOPTERS EQUIPPED WITH THE OPTIONAL EMER GENCY FLOAT IN STA LLATION , STC# SR00471 LA . Page 408 Revision 23 Figure 406. Cargo Hook Release for 600N Helicopters 25-50-00 60-052-1 MD Helicopters, In c. CSP -H M I- 2 N.UUNTENANCEMANUAL CARGO HOOK INSPECTION/CHECK 1. Cargo Hook Operational Check Do the fo llow ing operational check procedure whenever it is nece ssa ry to verify that the cargo hook system is operatin g prop er l y: (1) . Place b attery swit ch in BATTERY position. (2). Check that CARGO HOOK/HOOK cir cuit breaker is pr essed to full in position (Ref. Figure 402 ). NOTE: Cargo load ring s (or eq ui va l ent ch eck tool) with a maximum cross-section t hi ck- nes s of 3/4 in ch can be u sed for test ing or for cargo transport operations. (3) . Pu sh cargo load ring forward into hook thro at (Ref. Figure 404); keeper should permit easy e ntr ance to hook throat. (4) . Pull aft and downward on lo ad ring; hook mu st r em ain in locked position. (5) . Rotate external release knob located on left side of ca rgo h oo k body, whil e pulling downward on load ring; hook (load beam) b ar should drop and rel ease load ring. (6) . Reinsert load rin g in hook throat. PullCARGO HOOK EMER G EN CY RE- LE AS E (man u al release) lever on pilot's cyclic stick while load ring is being p ulled downward; hook (load beam) should rel ease lo ad ring. Reins ert load ring a nd move pi lot's cyclic st ick to all ex tr eme positions; CARGO HOOK EMERGENCY RELEASE lever mustnot move from hook-enga ged position and hook load beam must r ema in inlocked posit ion. (7) . Pres s CARGO HOOK switch on pilot's cyclic st ick gT ip (Ref. Figure 403) while load rin g is being pulled downward; hook lo ad beam sh ou ld release l oad ring. I I Cargo hook mu st remain yvARNING closed while moving through all positions of extreme travel fore and aft as well as si de -t o -si de. (8 ). Grasp lo ad r ing and pull downward while mo ving cargo hook manua lly full t ra vel side- to-side. Ensure hook (load beam) remains in lock ed position. 2. Adjustment Adjust the manual r el ease cable so that the 2.00--2.50 in ch ( 5. 08 5-6.35 em) dimension sh own (Re f. Figure 405) is maintained . 3. Exter ior Components Inspection I I On cargo hooks, manufac - yvARNING tured by Breeze-Eastern, Model 2A20B, PIN - 17149-1 thru - 5, en- sure Warning Plate PIN 13830-1 is at- tached to the manual r el ease side of the cargo hook. If Wa1·nin g Plate is not in s talled, contact Breeze-Eastern forWarning Plate and in st a llation instruc-tions. (1). Make certain that neoprene pads (Ref. Fi gu r e 404 ) are securely bonded to skin. Check p ads for excessive wear. (2). Verify se curity of fo ur bolts attach in g hook assembly to fuselage (Ref. Figure 404); exam in e hook assembly for dam age or excessive wear. Check that hook body swi vels freely in all direc- tions. (3). Verify secur it y of clips and clamps attaching electrical wire harness and manual relea se cable housing to fu se lage (Ref. Figur e 402). (4). Ve rify presence and secu rit y of gTom- met (R ef . Figure 401) through which manual release cable passes at fuselage skin. (5). Check electric al wire harn ess for cuts, wear, and skinned insu lation. (6). Examin e m anua l r elease cable housin g for nicks, cuts, kinks , dents, or gener al 25-50-00 Page 601 Revision 23 CSP-HMI-2 MD Helicopters, Inc. MUUNTENANCEMANUAL damage that would r estrict movement of cable within housing . 4. Interior Components Inspection (1). Verify security of electrical receptacle (J605) at fuselage connection (Ref. Figure 401). (2) . Examine electrical wire harness for cuts, wear, or skinned insulation. (3). Check manual release cable hou sing for nicks, cuts, kinks, dents, or genera l damage that wou ld restrict movement of cable within housing . (4) . Verify presence and security of grom- met where manual release cable passes through pilot's floor (Ref. Figure 401). (5). Check security of manual release cab le housing adjustment nut; verify that release lever freely returns to hook-en- gaged position (Ref. Figure 405). Page 602 Revision 23 25-50-00 NOTE: The 600N helicopters equipped with emergency floats require the manual re- lease handle to be mounted on the collective stick (Ref. Figure 406) (6). Verify security of clamps attaching manual release cable housing to pilot's cyclic stick (Ref. Figure 401); check for damage to manual release cable housing that might restrict movement of cable. (7). Check security of manual release lever attachment to pilot's cyclic stick (Ref. Figure 405). (8). Examine decals (Ref. Figure 403) for secure attachment and legibility. (9). Examine cargo hook circuit wiring for damage and/or loose connections. (10). Verify secure installation of CARGO HOOK circuit breaker and HOOK RELEASE push-button switch (Ref. Figure 403). MD Helicopte rs, In c. CSP- HMI- 2 NUUNTENANCEMANUAL CARGO HOOK INITIAL INSTALLATION 1. Cargo Hook Initial Installation Pro cedures in this sect ion can be done at th e operator' s discretion and ar e app licable to 369D/E/FF - 500N helicop ters . These instru c- tions provide for the in s t allation of the cargo hook assembly. A. Preparat ion for Installation Pre paration for installation of the cargo hook assembly includes th e following: (1). Identify all components, including attaching hardwar e, or compone nt s to be removed for access to work ar eas. Protect components from damage and conta min ation until in stalled. (2). Check that all electrical switc he s are in OFF position. (3) . Make ce rtain BATT-OFF-EXT switch is in OFF position. B. Helicopter Equipment Removal (Ref. Figure 404) Prior to in s talling the cargo hook, a limited numb er of it ems must be remo ve d from t he heli copter to accommoda te cargo hook installation. (1 ). Remove plug butt on from cargo switch hole in stick grip; discard plug butt on. (2). Remove passenger/cargo com partm ent left support fairin g. (3). Remove passenger/cargo compartment seat. (4 ). Remove cyclic stick control cove r. (5) . Remove pilot's floor left covering. (6). Remove pilot's floor left access door. C. Modification of Helicopter Modification of the helicopter co n sists of cutouts in the pilot's floor a nd fuselage lower sk in to accommodate rou t in g of the cargo hook manu al control cable and electrical harness. NOTE: Fu se la ge cutouts for l eft and rig ht hand co mm and a re as illu strate d (Ref. Figure 9 01 ). Use applicable dim ensions ac- cording to the model h elicopter being modi- fied . (1) . Make cutouts in t hr ee places as illu strated (Ref. Figur e 901). It em CM318 Consumable Materials (Ref. Section 91 - 00- 00) Nomenclature Primer (2). Deburr cutouts and app ly thin coat ofprim er (CM318) to expo sed bare metal. D. Cargo Hook Provisions Installation (Re f. Fi gure 404) Th e follow in g proce dure involv es installation of the cargo hook provi- sions exclusive of the cargo hook assembly kit. To complete installation of the cargo hook system, both cargo hook provisions, and the cargo h ook assembly kit installations must be accomplished. Hook provision equipment omitted in the fo llowing procedure is included in th e car go hook installation procedure. In st all car go hook provisions as follows: It em CM206 CM228 CM230 CM318 CM418 Consumable Materials (Ref. Section 91-00-00) Nomenclature Chemical coat in g Su rface cleaner Paint remover Prim er Cement, epoxy NOTE: Th e cargo hook a nd provision kits are supplied with as many p arts assembl ed as practical , h owever, some parts mig ht re- quir e assembly at in sta llation. Th e operator should omit those ste ps which can have al- r eady been accomplished. (1). I nstall cargo hook neoprene p ads as follows: 25-50-00 P ag e 901 Revision 23 CSP-HMI-2 MD Helicopters, In c. NUUNTENANCEMANUAL (a). Remove paint from fuselage skin in pad installation areas as shown; use paint remover (CM230). (b). Clean metal in areas where paint as removed; use surface cleaner (CM228). (c). Bond neoprene pads to skin at locations shown; use adhesive (CM418). (2). Prime and touch-up border areas around pads as follows: (a). Wash affected area with solution of mild soap and fresh water. Rinse area with clean water and wipe dry with clean lint - free cloth. (b). Using swab, liberally apply chemical film (CM206). (c). Allow solution to remain on surface for 1 to 3 minutes, or until surface becomes amber to brown in color. NOTE: Avoid letting chemical mixture dry on surface. If it has dried, re-wet surface with solution. (d). Rinse treated surface with clean water. After rinsing, wipe off excess moisture with clean lint-free cloth. Allow area to dry completely at room temperature for 1 hour. · (e). Wipe surface clean with thinner and dry off immediately. (f) . Apply primer (CM318) and allow to dry for 30 minutes. (g). Apply lacquer to match original factory finish color. NOTE: Installation of the cargo hook manual release lever assembly and clamp assem- blies is accomplished during installation of the cargo hook kit. Page 902 Revision 23 25-50-00 E. Electrical Components and Wiring Installation (Left and Right Hand Command) Consumable Materials (Ref. Section 91 - 00- 00) Item Nomenclature CM404 Adhesive, epoxy CM614 Sleeving, heat-shrink CM704 Tie strap, nylon NOTE: The order and manner of installation for left or right hand command is the same. Refer to dimensions given in applicable fig- ures, for model of helicopter being modified. (1). Make certain BATTERY switch is in OFF position. (2). Disconnect battery connector. (3). Connect cargo hook switch to existing wires according to stick grip and model helicopter being modified. Insulate wires and contacts on switch with sleeving (CM614). Ref. Table 901 and applicable wiring diagrams (Ref. Figure 101). (4). Install switch guard on switch. Apply small amount of adhesive (CM404) to O.D. of switch . (5) . Install switch in grip. Allow minimum cure time of 24 hours ±30 minutes. (6). Install relay on bracket with screws, washers, and nuts (Ref. Figure 902). Table 901. Cargo Hook Relay Installation Re lay Model K201 D Location 369A2519 Bulkhead K20 1 E/FF 369H2500 Bulkhead Remarks Sli m console T-Panel (7). Locate existing mounting holes accord- ing to model of helicopter being modi- fied. (Ref. Table 901 and Figure 902). Using relay bracket as a template, mark and drill attachment hole(s) 0.165-0.177 inch (4.191-4.4958 mm) in bulkhead as required. MD Helicopters, Inc. MAINTENANCE MANUAL 10.00 LBL r --- 5.00 ±0.25 IN . (12.7 ±0.635 CM) L )- ·- __ -::fr._ - C HANNEL : tf O ( 1 l.795:r---- P IL OT'S FLOOR O - ·-* GROM ME T . · ~ C LI P 1 . 0.555-0.562 IN . 0.881N. ~i 1- (14.0970-14.2748 MM) (22.352 MM) HOLE o.88IN.~1 (22.352 MM) CSP-HMI - 2 PILOT'S FLOOR GROMMET A CREW COMPARTMENT FLOOR CUTOUT ~ (LEFI - HANDCOMMANDl A CREW COMPARTMENT FL OOR CUTOUT ~(RIGHT-HAND COMMAND) GROMMET ~ , ------------- ------- --- 12.05 LBL - __ Q_9 ____ ;- .9 _________ _ \I I ~ o 0.68X 1 .18 1 N.~ \ \ v\Q; o (17.272X ~ I 0 0 29.972 MM (NOTE 11 \ 0 ! 0 F' ·-; ~ ------- o ~-c J 1- ---a '? .... o .a9a-~ 2 ~~J J~~ ·- - .. T .l., __ ____ .. i , 22.8854 MMI \ \ i I (NOTE2 · I 1 i i 0.381N.~j i- (9.652 MM) DOUBLER ~ DOUBLER IN STA L LAT I ON \:1 (L EFT - HAND COMMAN D) ~: 1. SLOT IN SK IN TO MATCH SLOTIN DOUBLER. 2. H OLE IN SK IN TO M ATCH HOLE IN DOUBLER. GROMMET Figure 901. Fuselage Skin Cutouts 25-50-00 G25-5006A Page 903 Revision 23 CSP-HMI-2 MD He li copters, Inc. MAINTENANCE MANUAL (8). Attach relay bracket to bulkhead withscrews, washers and nuts. Identify relay as indicated (Ref. Table 902), using a suitab le contrasting perman e nt ink. (9). On left hand command helicopters, remove edgelighted panel from lower switch and circuit breaker panel: loosen lower c ircuit breaker panel. Remove hole cover button; install circuit breaker (CB603) (Ref. Figure 402). (10). On right hand command helicopters with center electrical console, remove edgelighted panel from circuit breaker panel located on the pilot's collective pitch stic k cover; loosen circuit breaker panel remove hole cover button; in sta ll circuit breaker (Ref. Figure 402). (11). On right or left hand command helicop- ters with standard cyclic stick grip, install module and cover on TB3. (12). Install cargo hook circuit wiring; see app licable wiring diagram (Ref. Figure 101). For wire termination and t e rminal hardware, refer to Table 102. (13). Install cargo hook electrical connector with washer and connector nut. Install prot ective cap on receptacle if cargo hook kit is not being in stalled concur- r e nt w ith provisions. (14). Secure cargo hook circuit w irin g with tie-straps (CM704) as required . Check that wires and termi n als are not stressed. (15). Check all wiring for correct install at ion and security of attachment. (16). Connect battery connector. F. Cargo Hook Installation Consumable Materials (Ref. Section 91-00 - 00) Item Nomenclature CM429 Sealing compound, silicone CM702 Lockwire CRES CM704 Tie strap, nylon ' he cargo hook installation consi sts of attaching the hook and emergency electl'ical/ Page 904 Revision 23 25-50-00 manual release cabl es on the underside of the helicopter, routing and sec urin g the ma nual release cab le , and installation and adjustmentof the manual release lever. (1). Secure base of cargo hook assembly to fuselage underside with bolts andwashers (Ref. Figur e 404). (2). If installed, remove protective cap from cargo hook electrical receptacle (J605); check that BATTERY switch is in OFF position and connect plug (P 605) to . receptacle. (3). Insert free end of hook manual release cable through elongated hole adjacent to electrical receptacle; pu sh manual release cable up into fuselage and insert cable through hole in pilot's floor (Ref. Figure 401). (4). Install electrical harn ess and manual release cable clamp (provision) clips with ri vets (Ref. Figure 402). (5). Loosely attach harness an d cable clamps with screws, w ashers and nuts; adjust harne ss and cable to allow sufficient slack for hook to swing 30 degTees conically from centerline without creating strain on harness andcable. Arrange harness and cable to form smooth flow to cutouts in fuselage skin; tighten clamps. Install tie straps(CM704) approximately as shown (Ref. Figure 402). (6). Loosely attach manual release cable to cyclic stick with clamps, screws, washers, and nuts (Ref. Figure 401). (7). Engage swaged ball on release cable inlever bushing; secure bushing with washer and cotter pin (Ref. Figure 405). (8). Attach manual r el ease lever assemb ly to cyclic st ick with clamp and screws; adjust cable and / or release lever asshown (Ref. Figure 401). (9). Tighten three sets of clamps securing release cable to cyclic stick. (10). Check that hook does not release when cyclic st ick is moved to extremes in all directions . EXISTING HOLE S MD Helicopter s, Inc. MAINTENANCE MANUAL ~,· ""· ~,' WASHER SCREW CSP-HMI-2 WASHER ~ K312 RELAY IN STALLATION \1:1 (369E/FF 500N) Figure 902. Relay and Bracket Installation Pilots Floor (3690/E/FF) 25-50-00 G25-5007A Pag·e 905 Revision 23 CSP-HMI-2 MD Helicopters, Inc. · NUUNTENANCEMANUAL (11). Pull manual rel ease l ever ; check that hook load beam opens. Repeat opera- tion several times to ensure proper release of hook. (12). Re-adjust cable/lever as required to obtain smooth consistent release of hook. NOTE: The manual release lever clamp can be loosened and the lever assembly moved on cyclic stick to simplify adjustment, provid- ing the 2.00--2.50 inch (5.085-6.350 em) dimension limit is maintained (Ref. Figure 405). (13). Install grommet in crew compartment floor cutout (Ref. Figure 401). Fill any voids between grommet and cable. Use sealant (CM429). (14). Install grommet in elongated hole in fuselage lower skin and doubler (Ref. Figure 402). Fill any voids between grommet and manual release cable. Use sealant (CM429). (15) . Safety manual release lever clamp screws with lockwire (CM702), (Ref. Figure 405). (16). Install HOOK RELEASE decal on left or right hand cyclic stick grip (Ref. Figure 403). (17). Install CARGO HOOK EMERGENCY RELEASE decal on cyclic stick (Ref. Figure 405). (18) . Install EXTERNAL LOAD LIMIT 2000 POUNDS decal (Ref. Figure 404). Table 902. VNE Card Installation Part Number Model Effectivity 369029571 0 003-523 -17,-19 -21,-23 0/E 0 524 & Subs E 001 & Subs 3690292588 FF 001 & Subs (19). Replace VNE card on instrum ent panel as applicable (Ref. to Table 903). G. Helicopter Equipment Installation Reinstall equipment initially removed in reverse order of removal. NOTE: At completion of installation, do the an operational check of cargo hook installation. Table 903. Cargo Hook Switch Installations - Stick Grip Part Number 369H90153-BSC -3 369027133 3690297846-BSC -3 369H92805 Page 906 Revision 23 Model 0/E/FF D/E/FF 0/E/FF 0 0 0 Remarks For models equipped with emergency floats, left or right hand command (Ref . Figure 403). For models equipped with hoist, left or right hand command (Ret. Figure 403) . Standard grip, left hand command (Ref. Figure 403). Center electrical console, "T" grip right hand command (Ref. Figure 403) . Center electrical conso le, "T" grip right hand command (Ref. Figure 403). Center electrical conso le, "T" grip right hand command (Re f. Figure 403). 25-50-00 MD Helicopters, Inc. CSP-HMI-2 MAINTENANCE MANUAL H. Weight and Balance Data Weight and balance changes resulting from installation of the cargo hook are listed in Table 904. After installation of the cargo hook incorporate changes in helicopter weight and balance record as instructed. Table 904. Weight and Balance Data Added Weight Pounds (kg) +6.3 (+2.858) I ·Arm Inches (em) +87.0 (+220.98) 25 - 50 - 00 Moment in-lb (kg em) +548.1 (+631.48) Page 907 Revision 23