120-096-01 - Onboard Systems International
Contents
1. On ARD ysYSTE ws coM F IS MANUAL yy hi ONBO ee iy ny THE EST 3 600 Pound Keeperless Cargo Hook Kit For The MD Helicopters 369 Series 500N and 600N Models System Part Numbers 200 264 01 200 264 02 Owner s Manual Owner s Manual Number 120 096 01 Revision 0 August 4 2008 Z CONBDARD SYSTEMS I N TERNATIONAL 13915 NW 3 Court Vancouver Washington 98685 USA Phone 360 546 3072 Fax 360 546 3073 Toll Free 800 275 0883 www OnboardSystems com This page intentionally left blank Revision Date Record of Revisions Reason for Revision 08 04 08 Initial Release Register Your Products for Automatic Notifications Onboard Systems offers a free notification service via fax or email for product alerts and documentation updates By registering your Onboard Systems products at our website we will be able to contact you if a service bulletin is issued or if the documentation is updated You can choose to receive notices on an immediate weekly or monthly schedule via fax email or both methods There is no charge for this service Please visit our website at www onboardsystems com notify php to get started This page intentionally left blank CONTENTS Section 1 Section 2 Section 3 Section 4 Section 5 General Information Introduction 1 1 Warnings Cautions and Notes 1 1 Bill of Materials 1 2 Inspection 1 2 Specification2. 1 Cargo Hook rotates and strains the manual release cable conduit 2 The strain on the conduit exceeds the pull off force between the swaged fitting and the conduit 3 The swaged joint fails and allows the inner cable to activate the hooks release mechanism and the hook opens Installation Instructions 4 The load ring falls free in an un commanded load release 2 5 Installation Check Out After installation of the Cargo Hook Kit perform the following functional checks 1 Swing the installed Cargo Hook to ensure that the manual release cable assembly and the electrical release harness have enough slack to allow full swing of the suspension assembly without straining or damaging the cables The cable and harness must not be the stops that prevent the Cargo Hook from swinging freely in all directions 2 With no load on the cargo hook load beam pull the lever operated cargo hook mechanical release the Cargo Hook should release Reset the cargo hook load beam 3 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 4 See the MD Helicopters service instructions for your specific helicopter model for additional installation instructions Component Weights The weight of the Cargo Hook Kit components are listed below
3. Table 2 3 Component Weights Item Weight lbs kgs Cargo Hook 3 0 1 36 Manual Release Cable 1 0 45 Electrical Release Cable 0 5 23 Bumper Pads 0 2 09 Travel Limit Bumper 0 1 05 Cargo Hook Location Table 2 4 Cargo Hook Location Fuselage Station 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 121 006 01 in the Rotorcraft Flight Manual 2 6 Installation Instructions Section 3 Operation Instructions Operating Procedures Prior to each job perform the following 1 Ensure that the Cargo Hook has been properly installed and that the manual release cable and electrical release harness do not limit the movement of the hook Be completely familiar with this manual particularly the Cargo Hook rigging section Be completely familiar with all MD Helicopters cargo hook operating instructions Activate the electrical system and press the release button to ensure the cargo hook electrical release is operating correctly The mechanism should operate smoothly Reset the cargo hook load beam by hand after release If the load beam does not re latch do not use the unit until the difficulty is resolved The release solenoid is intended to be energized only intermittently Depressing the electrical release button continuously in excess of
4. 4 dated September 17 2007 or later FAA approved revision and installation of the 200 264 01 and 200 264 02 kits in accordance with FAA approved Onboard Systems International Owner s Manual No 120 096 01 Revision 0 dated August 4 2008 or later FAA approved revision This modification must be inspected and maintained in accordance with Section ATA 5 of the FAA approved Onboard Systems International Instructions for Continued Airworthiness Document No 123 003 00 Revision 3 dated October 10 2006 or later FAA approved revision and Onboard Systems See Continuation Sheet Page 3 Limitations and Conditions Approval of this change in type design applies to only those MD Helicopter model rotorcraft listed above which were previously equipped with an FAA approved installation of MD Helicopter cargo hook kits and cargo hooks shown on the table on Page 3 of 3 This approval should not be extended to rotorcraft of these models on which other previously approved modifications are incorporated unless it is determined by the installer that the relationship between this change and any of those other previously approved modifications including changes in type design will introduce no adverse effect upon the airworthiness of that rotorcraft Rotorcraft modified in accordance with this STC must be operated in See Continuation Sheet Page 3 his certificate and the Ugporiing data which is the Casts for gywoval shall LENA be fict until sur ren
5. Conditions continued accordance with FAA approved Onboard Systems International Rotorcraft Flight Manual Supplement RFMS No 121 006 00 Revision 4 dated June 18 2008 or later FAA approved revision for the 200 264 00 cargo hook kit or Onboard Systems International RFMS No 121 006 01 Revision 0 dated October 23 2008 or later FAA approved revision for the 200 264 01 or 200 264 02 Cargo Hook Kit A copy of this Certificate FAA approved RFMS and Maintenance Manual must be maintained as part of the permanent records of the modified rotorcraft Cargo Hook 369H92105 501 369H90072 505 517 519 369H92105 501 369H92105 501 369H90072 505 511 519 369H92105 501 369H92105 501 369H92105 501 369H92105 501 369H92105 501 369H90072 525 529 CT 600N_ 369H92105 503 505 If the holder agrees to permit another person to use this certificate to alter the product the holder shall give the other person written evidence of that permission END Any alteration of this certificate is punishable by a fine of not exceeding 1 000 or imprisonment not exceeding 3 years or both This certificate may be transferred in accordance with FAR 21 47 FAA FORM 8110 2 1 10 69 5 2 Certification Canadian Approval Transport Transports had sds Canada Cer lLLJLCULLOTL Aviation Aviation Suite 620 Your file Votre r f rence a pee e z T Our file Notre r f rence o P 01 014 V6Z 2J8 April 20 2001 Mr Ron Pirtle Onboa
6. 20 seconds will cause the release solenoid to overheat possibly causing permanent damage Activate the release lever assembly located on the cyclic stick to test the cargo hook manual release mechanism Reset the cargo hook load beam by hand after release If the load beam does not re latch do not use the unit until the difficulty is resolved See the Service Manual 122 017 00 and the MDHC service instructions that cover the original Cargo Hook installation for additional instructions Operation Instructions 3 1 Cargo Hook Loading Cargo Hook Rigging 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 1 until an internal latch engages the load beam and latches it in the closed position Figure 3 1 Cargo Hook Loading 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 but is not intended to represent all rigging possibilities 3 2 Some combinations of small primary rings and large secondary rings could cause fouling during release It is the responsibility of the operator to assure the cargo hook will function properly with each rigging Operation Instructions Cargo Hook Rigging continued Nyl
7. Hook is 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 Table 2 1 Cargo Hook Connector Table 2 2 Bulkhead Receptacle Pin Function Pin Function A Ground A Power B Positive B Ground C Shield Installation Instructions Secure the Release Cable Secure the cargo hook manual and electrical release harness following the MD Helicopters Installation and Maintenance Instructions Publication No CSP 005 or later approved source The first clamp used to secure the manual release to the A C skin should not be less than 23 inches from the hook Un commanded cargo hook release will happen if the manual and electrical release cables are improperly restrained The cables 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 or electrical release cables Figure 2 5 Un commanded Release From Incorrectly Secured Cable
8. MA 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 Maintenance 4 1 This page intentionally left blank Section 5 Certification FAA STC United States of Arnett Departinent of Cremeportution Federad Aviston Administration Supplemental Type Certificate Number R00892SE This certificate issued to Onboard Systems International 13915 NW 3rd Court Vancouver WA 98685 certifies lhat the change in the type design for the following product with the Cnitations and conditions therefor as Precified hereon meets the airworthiness POGMMMENELMS of Fart 27 of the Federal Aviation Keegulations OQigtnal Product Type Certificate Number H3WE Make MD Helicopters Inc Model 369D 369E 369F 369FF 369HE 369HM 369HS 500N and 600N Description of the Type Design Change Fabrication of Onboard Systems International Model 200 264 00 200 264 01 and 200 264 02 Cargo Hook Kits in accordance with FAA Approved Onboard Systems International Master Drawing List No 155 061 00 Revision 8 dated August 27 2008 or later FAA approved revision Installation of the 200 264 00 kit in accordance with FAA approved Onboard Systems International Owner s Manual No 120 096 00 Revision
9. accordance with ATA Chapter 5 of For the 200 264 00 Cargo Hook Kit Onboard Systems International Instructions for Continued Airworthiness Document No 123 003 00 Revision 3 dated October 10 2006 or later EASA approved revision and Onboard Systems International Cargo Hook Service Manual No 122 005 00 Revision 12 dated July 18 2008 or later EASA approved revision EASA Ferm 91 Issue 1 5 4 Certification EASA STC continued al European Aviation Safety Agency For the 200 264 01 or 200 264 02 Cargo Hook Kits Onboard Systems international Instructions for Continued Airworthiness Document No 123 003 01 Revision 0 dated August 4 2008 or later EASA approved revision and Onboard Systems International Cargo Hook Service Manual No 122 017 00 Revision 2 dated June 4 2008 or later EASA approved revision Operation Rotorcraft modified in accordance with this STC must be operated in accordance with For the 200 264 00 Cargo Hook Kit Onboard Systems International Rotorcraft Flight Manual Supplement RFMS No 121 006 090 Revision 4 dated June 18 2008 or later EASA approved revision For the 200 264 01 or 200 264 02 Cargo Hook Kit Onboard Systems International RFMS No 121 006 01 Revision 0 dated October 23 2008 or later EASA approved revision Limitations and Conditions 1 Prior to installation of this modification the installer must determine that the interrelationship between thi
10. dered suspended revoked or a termination date ts otherwise estal hashed by the Administrator ofi the Federal Aviation Administration Late of application September 22 2000 Date reissued Date of issuance March 20 2001 Date amended January 13 2003 November 3 2008 Acting Manager Seattle Aircraft Certification Office Title Any alteration of this certificate is punishable by a fine of not exceeding 1 000 or imprisonment not exceeding 3 years or both This certificate may be transferred in accordance with FAR 21 47 FAA FORM 8110 2 10 68 PAGE 1 OF 3 PAGES Certification 5 1 FAA STC continued Tnit Stes of America Pepartment of Cransportition Federal Aviation Administration Supplemental Type Certificate Continuation Sheet Number SR00892SE Onboard Systems Reissued Amended January 13 2003 November 3 2008 Deseription of the Type Design Change continued nternational Cargo Hook Service Manual No 122 005 00 Revision 12 dated July 18 2008 or later FAA approved revision for the 200 264 00 Cargo Hook Kit or section ATA 5 of the FAA approved Onboard Systems international Instructions for Continued Airworthiness Document No 123 003 01 Revision 0 dated August 4 2008 or later FAA approved revision and Onboard Systems international Cargo Hook Service Manual No 122 017 00 Revision 2 dated June 4 2008 or later FAA approved revision for the 200 264 01 or 200 264 02 Cargo Hook Kits Limitations and
11. er helps protect the aircraft skin and the release cables from excessive hook movement Do not use the cargo hook without the travel limit bumper in place Figure 2 1 Travel Limit Bumper Installation Travel Limit Bumper Travel Limit Bumper incorrectly installed correctly installed 2 1 Cargo Hook Installation continued Install the cargo hook to the attach point using the Attach Bolt washers nut and cotter pin as illustrated in Figure 2 2 The cargo hook load beam must point aft Figure 2 2 Attach Hardware Installation Existing Attach Point Washer P N 510 183 00 WE Washer U_ C y EAE 00 P N 510 174 00 O Cotter Pin Wa c P N 510 178 00 ax 4 Nut P N 510 170 00 Attach Bolt 7 P N 290 332 00 Cargo Hook Tighten nut on Attach Bolt to finger tight then rotate to next castellation to install and secure cotter pin Remove any existing hook bumper pads that may be attached to the A C skin Install the supplied P N 290 361 00 Bumper Pads to the airframe skin in the location illustrated in Figure 2 3 with 3M trim cement Figure 2 3 Bumper Pads Installation BUMPER PAD P N 290 361 00 QTY 2 CARGO HOOK MOUNTING BRACKET VIEW LOOKING UP FROM BELOW AIRCRAFT SKIN Installation Instructions Cargo Hook Installation continued Remove the manua
12. ion EC No 1702 2003 to Onboard Systems International 13915 NW 3rd Court WA 98685 Vancouver United States and certifies that the change in the type design for the product listed below with the limitations and conditions specified meets the applicable Type Certification Basis and environmental protection requirements when operated within the conditions and limitations specified below Original Product Type Certificate Number FAA TC H3WE Type Certificate Hoider McDonnell Douglas MD Helicopters 369D 369E 369F Model 369FF 369HE 369HM 369HS SOON 600N Original STC Number FAA STC SROO892SE Description of Design Change installation of Onboard Systems International Model 200 264 00 200 264 01 and 200 264 02 Cargo Hook Kits in accordance with Onboard Systems International Master Drawing List No 155 061 00 Revision 8 dated August 27 2008 or later EASA approved revision Associated Technical Documentation Installation Installation of the 200 264 00 kit should be done in accordance with Onboard Systems International Owner s Manual No 120 096 00 Revision 4 dated September 17 2007 or later EASA approved revision Installation of the 200 264 01 and 200 264 02 kits should be done in accordance with Onboard Systems International Owner s Manual No 120 096 01 Revision 0 dated August 4 2008 or later EASA epproved revision Inspection and Maintenance The modification must be inspected and maintained in
13. l release cover from the cargo hook Thread the swaged end of the manual release cable into the cargo hook manual release boss on the hook side plate and tighten against the hook Place the cable ball end fitting into the hook manual release lever fork as illustrated in Figure 2 4 Rotate the release lever in the clockwise direction to remove free play and hold in this position the free play is taken up when the hook lock indicator begins to move Measure the cable ball end free play with the manual release handle in the cockpit in the non release position Adjust the manual release cable system for a minimum of 125 inches 3 2 mm of free play at the fork as shown in Figure 2 4 Figure 2 4 Manual Release Cable Rigging Release Lever Hook Lock Indicator Cable Ball End A Manual Release Cable E m 125 MIN Release Lever Fork Route the electrical release harness and manual release cable and rig the cyclic stick release lever assembly following the MD Helicopters Installation and Maintenance Instructions Publication No CSP 005 or later approved source Replace the cargo hook manual release cover Installation Instructions 2 3 2 4 Cargo Hook Installation continued Connect the cargo hook electrical release harness connector to the Cargo Hook and belly mounted bulk head receptacle and safety wire the connector Listed below is the pin out for the cargo hook connector and bulkhead receptacle The Cargo
14. m 122 017 00 Cargo Hook Service Manual 123 003 01 ICA Maintenance Manual Inspection Inspect the cargo hook for evidence of damage corrosion and security of lock wire and fasteners If damage is evident do not use the unit until it has been repaired Specifications Table 1 1 Specifications 528 029 00 Cargo Hook release at 3 600 lb 1 2 General Information Theory of Operation General Information The primary elements of the Cargo Hook are the load beam the internal mechanism and a DC solenoid The load beam supports the load and is latched through the internal mechanism The DC solenoid and an external manual release cable provide the means for unlatching the load beam The load is attached to the load beam by passing the cargo sling ring into the throat of the load beam and pushing the ring against the upper portion of the load beam throat which will initiate the hook to close In the closed position a latch engages the load beam and latches it in this position To release the load the latch is disengaged from the load beam With the 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 s
15. nual release cable in the MD Helicopters 369H92105 501 cargo hook assembly The 200 264 02 cargo hook kit is approved for installation with MD Helicopter 600N models which use the 369H92105 503 or 369H92105 505 cargo hook assembly Warnings Cautions and Notes General Information The following definitions apply to Warnings Cautions and Notes used in this manual Means that if this information is not observed serious injury death or immediate loss of flight safety could occur Means that there is a risk of injury or degradation in performance of equipment if this information is not observed NOTE Draws the reader s attention to information which may not be directly related to safety but which is important or unusual 1 1 Bill of Materials The following items are included with the Cargo Hook Kit if shortages are found contact the company from whom the system was purchased Partno Description unt Quatt Part No Description Quantity Quantity 270 073 00 Electrical Release Harness 1 270 073 02 Electrical Release Harness 1 268 005 01 Manual Release Cable 1 268 005 02 Manual Release Cable 1 290 360 01 Travel Limit Bumper 1 1 290 361 00 Bumper Pas 2 2 510 178 00 Cotter Pin 1 1 Soro e e o 510 174 00 Washer 1 1 510 183 00 Washer 2 2 121 006 01 RFM Supplement 1 N m m N NLR m m N m
16. on 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 Figure 3 2 Examples of Recommended Cargo Hook Rigging Operation Instructions 3 3 This page intentionally left blank Section 4 Maintenance Refer to Cargo Hook Service Manual 122 017 00 for the cargo hook and Instructions for Continued Airworthiness 123 003 01 for additional detailed maintenance information for the cargo hook kit 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 NOTICE An RMA number is required for all equipment returns e To obtain an RMA please use one of the listed methods Contact Technical Support by phone or e mail Techhelp OnboardSystems com e Generate an RMA number at our website http Awww onboardsystems com rma php e 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 R
17. rd Systems International 11212 N W St Helens Road Portland OR USA 97231 Dear Mr Pirtle Subject Acceptance of FAA STC SR00892SE This is in response to the FAA Seattle ACO letter dated April 9 2001 requesting Transport Canada approval of the subject STC In accordance with our current policy associated with the review of foreign STC s some STCs applicable to certain categories of aircraft may be accepted solely on the basis of their foreign certification and do not require the issue of a corresponding certificate by Transport Canada The subject STC falls within these criteria This STC will be entered in the national index of STCs that have been reviewed and accepted by Transport Canada for installation on Canadian registered aeronautical products This letter confirms formal acceptance of the referenced STC by Transport Canada Yours truly ail Henry Wong for Regional Manager Aircraft Certification c c Ms Dorenda Baker Acting Manager Seattle Aircraft Certification Office od 1 1 Canada EASA STC European Aviation Safety Agency SUPPLEMENTAL TYPE CERTIFICATE EASA IM R S 01167 Revision 1 This Supplemental Type Certificate is issued by EASA acting in accordance with Regulation EC No 216 2008 on behalf of the European Community its Member States and of the European third countries that participate in the activities of EASA under Article 66 of that Regulation and in accordance with Commission Regulat
18. s 1 2 Theory of Operation 1 3 Installation Instructions Cargo Hook Removal 2 1 Cargo Hook Installation 2 1 Secure the Release Cables 2 5 Installation Check Out 2 6 Component Weights 2 6 Cargo Hook Location 2 6 Paper Work 2 6 Operation Instructions Operating Procedures 3 1 Cargo Hook Loading 3 2 Cargo Hook Rigging 3 2 Maintenance Inspection 4 1 Instructions for Returning a System to the Factory 4 2 Certification FAA STC 5 1 Canadian Approval 5 3 EASA STC 5 4 iii CONTENT S continued Figures Tables 2 1 2 2 2 3 2 4 2 5 3 1 3 2 1 1 2 1 2 2 2 3 2 4 4 1 Travel Limit Bumper Installation 2 1 Attach Hardware Installation 2 2 Bumper Pads 2 2 Manual Release Cable Rig 2 3 Un commanded Release From Incorrectly Secured Cable 2 5 Cargo Hook Loading 3 2 Examples of Recommended Cargo Hook Rigging 3 3 Specifications 1 2 Cargo Hook Connector 2 4 Bulkhead Receptacle 2 4 Component Weight 2 6 Cargo Hook Location 2 6 Inspection 4 1 Section 1 General Information Introduction The 200 264 01 cargo hook kit is approved for installation with the following MD Helicopter models which use the 369H92105 501 cargo hook assembly The 528 029 00 Cargo Hook 270 073 00 Electrical Release Cable and 268 005 01 Manual Release Cable included in this 200 264 01 cargo hook kit are suitable as replacements for the cargo hook Breeze Eastern P N 17149 4 electrical release cable and ma
19. s modification and any other previously installed modification will introduce no adverse effect upon the airworthiness of the product The installation of this modification by third persons is subject to written permission of the approval holder and holding and disposal of the approved appropriate documentation 2 Approval of this change In type design applies to only those MD Helicopter model rotorcraft identified here which were previously equipped with an FAA approved installation of MD Helicopter cargo hook kits and cargo hooks shown on the table below Helicopter Model 369H90072 501 505 507 515 519 369D l 369H92105 501 369H90072 505 517 519 _ 369E 369H92105 501 369H90072 505 3569F 369H92105 501 369H90072 519 523 369H92105 501 369H90072 501 369H92105 501 369H92105 501 369H90072 501 369H92105 501 369H90072 525 529 600N _ 369H92105 503 This Certificate shall remain valid unless otherwise surrendered or revoked For the European Aviation Safety Agency Date of issue 15 July 2009 Mohaka fs Miaa Certification Manager STC EASA IM R S 01167 Revision 1 Onboard Systems International EASA form 91 Issue 1
20. witch 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 1 3 This page intentionally left blank Section 2 Installation Instructions Cargo Hook Removal 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 If present remove the MD Helicopters supplied Cargo Hook from the aircraft by disconnecting the electrical release cable from the belly mounted bulk head type connector Disconnect the manual release cable from the cyclic stick release lever assembly and remove it from the attaching clamps along its entire length Remove the single bolt used to attach the Cargo Hook to the airframe mounting bracket and separate the Cargo Hook from the aircraft Cargo Hook Installation Installation Instructions Inspect the helicopter s cargo hook attach point and attaching hardware to ensure that all components are in serviceable condition Install the P N 290 360 01 travel limit bumper to the Cargo Hook as illustrated in Figure 2 1 The Travel Limit Bump
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