120-137-00 - Onboard Systems International
Contents
1. The illustration is a typical hook load reading The display is 3 500 pounds note the last digit is not displayed Load Weigh System Operation Instructions To Zero or Tare the Display The zero feature is used to zero or tare the weight on the Cargo Hook that is not wanted such as the weight of a cargo net or long line The Right button is used to zero the Indicator reading When the Right button is pressed the display is zeroed The zero legend is turned on and the zeroed number is stored in memory If the Right button is pressed again before the Un zero button is pressed the display blinks in response to the button closure Zero is only available in the Run Mode Figure 4 4 Zeroing the Display Hook Load Zero Legend x 10 7 Un Zero Legend To Un Zero the Display The Left button is used to add the zeroed value back into the current Indicator reading or Un zero the display When the Left button is pressed the number previously zeroed is added to the current display and the Un zero legend is turned on If the Left button is again pressed before the zero button is pressed the display blinks in response to the button closure Un Zero is only available in the Run Mode Load Weigh System Operation Instructions 4 3 4 4 Error Codes Error Codes are the result of difficulties discovered during the Indicator diagnostic tests Diagnostic tests occur at power up and during the execution of certain routines Listed be2. 125 3 2 mm min Installation Instructions 2 3 Manual Release Cable and Cargo Hook Installation continued o Re install the washers and nut onto the cargo hook attach bolt or if installing the load weigh system install the washers and nut onto the pin load cell o Tighten nut on cargo hook attach bolt or pin load cell until fully seated finger tight only Back off nut to previous castellation if needed when aligning cotter pin for installation Install and secure cotter pin Do not tighten nut on pin load cell more than finger tight Overtightening will damage load cell Figure 2 3 6 Pin Load Cell Tightening O Installation Instructions 2 11 2 4 Electrical Wiring to Cargo Hook 2 12 o Route the electrical release wiring 3 and 4 wires with the manual release cable to the cargo hook o Route as far as possible the load cell assembly harness with the manual release cable and electrical release wiring o Secure the wiring to the manual release cable with ty wraps at approximately 12 intervals o Connect the cargo hook electrical release harness connector to the cargo hook Listed below is the pin out for the cargo hook connector Safety wire the connector Table 2 4 1 Cargo Hook Connector E rower The Cargo Hook is equipped with a suppression diode that will be damaged if the Cargo Hook electrical connections are reversed Installation Instructions 2 5 Electrical Re
3. Write the RMA number on the outside of the box or on the mailing label e 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 e 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 5 1 This page intentionally left blank Section 6 Certification FAA STC Hnit States of America Bepartment of Troneportation Federal Aviation Administration Supplemental Cope Certificate Number SRO1808SE This certificate issued to Onboard Systems International 13915 N W 3 Court Vancouver WA 98685 certifies that the change in the lype design for the following product with the limitations and conditions therefore as yrecified hereon meets the airworthiness requirements of Part 27 ofi the Federal Aviation Regulations Original Product Type Certificate Number H11NM Make Robinson Model R44 R44 II Description of the Type Design Change Fabrication of Onboard Systems International Model 200 324 00 and Model 200 326 00 12V cargo hook kits Model 200 325 00 and 200 327 00 28V cargo hook kits Model 200 325 01 and 200 327 01 28V cargo hook kits with Load Weigh and Model 200 340 00 Load Weigh Kit in accordance with Federal Aviation Administration FAA approved Onboard Systems International Master
4. 1 _ Bolt P N 511 076 00 superseded P N 290 505 00 These parts are interchangeable Kit P N 200 340 00 is a load weigh upgrade kit which is intended for operators using the 200 325 00 kit and would like to add load weighing It converts the P N 200 325 00 kit to a P N 200 325 01 kit Suspension Assembly P N 232 292 01 supersedes P N 232 292 00 Suspension Assembly P N 291 108 00 Pillow Block and P N 291 107 00 Pin Inspect the kit items for evidence of damage corrosion and security of lock wire and fasteners If damage is evident do not use the items until they are repaired Specifications 1 4 Table 1 2 Specifications Kit P N 200 324 00 300 324 00 200 325 01 Design load 800 lb 363 kg Design ultimate strength 3 000 Ib 1 361 kg Cargo hook electrical release 8 750 Ibs 3 969 kg capacity Cargo hook mechanical release 8 750 Ibs 3 969 kg capacity Force required for mechanical E rel ase at 3 600 Ib 8 lb Max 400 travel electrical requirements P N 528 029 00 electrical requirements Cargo hook mating electrical PCO6P8 2S connector 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 an external manual release cable and a manual release lever provide the means for unlatching
5. 2 2 Electrical Release Wiring Installation 2 3 2 3 Manual Release Cable and Cargo Hook Installation 2 6 2 4 Electrical Wiring to Cargo Hook 2 12 2 5 Electrical Release Switches Installation 2 13 2 6 Optional Left Seat Release Switch Installation 2 20 2 7 Load Weigh System Installation 2 21 2 8 Placards 2 24 2 9 Installation Check Out 2 25 2 10 Component Weights 2 25 2 11 Cargo Hook Location 2 25 2 12 Paper Work 2 25 Section 3 Operation Instructions Operating Procedures 3 1 Optional Flight Configuration 3 1 Cargo Hook Rigging 3 2 Un Commanded Release Due to Too Large of a Load Ring 3 4 Load Hang Up Due to Small Load Ring or Multiple Load Rings 3 5 Un Commanded Release Due to Nylon Type Straps 3 6 Un Commanded Release Due to Cable or Rope Type Straps 3 7 Contents continued Section 4 Load Weigh System Operation Instructions Indicator Front Panel 4 1 The Run Mode 4 2 To Zero or Tare the Display 4 3 To Un Zero the Display 4 3 Error Codes 4 4 The Setup Mode 4 5 Indicator Dampening 4 7 To look at or change the dampening level 4 7 Indicator Calibration 4 8 To look at or change the calibration code 4 8 Installation Zero 4 9 To run the installation zero routine 4 9 Calibration by Lifting a Known Weight 4 9 To run calibration by known weight routine 4 10 Setting the Scale on a Remote Analog Meter 4 11 To look at or change the scale 4 11 Select KG or LB Units 4 12 To look at or change the units 4 12 Indic
6. solder the wire from the cargo hook switch to pin H Connect the cable shield wire to airframe ground as close to the cargo hook as possible at the cargo hook end of the cable ONLY 2 23 Installation Instructions 2 8 Placards Install the following placards Table 2 8 1 Placards DECAL NUMBER DECAL DESCRIPTION LOCATION P N 215 110 00 CARGO RELEASE Mount adjacent to the cyclic release switch in clear view of the pilot see Figure 2 5 3 Figure 2 5 6 or Figure 2 5 9 P N 215 110 00 CARGO RELEASE Mount adjacent to the left seat release switch in clear view of the pilot See Figure 2 6 1 P N 215 110 00 CARGO RELEASE Mount adjacent to the manual release in clear view of the pilot See Figure 2 3 1 P N 215 111 00 PULL Mount adjacent to the manual release in clear view of the pilot See Figure 2 3 1 P N 215 112 00 CARGO Mount adjacent to the cargo hook circuit breaker in clear view of the pilot P N 215 114 00 CLASS B ROTORCRAFT Mount on the instrument panel in clear view of the pilot P N 215 115 00 FAR PART 133 35 A OPERATIONS Mount on the instrument panel in clear view of the pilot P N 215 119 00 EXTERNAL LOAD LIMIT 800 LBS 363 KGS 2 24 Mount on the belly of the aircraft adjacent to the cargo hook attachment point in clear view of the ground support personnel Installation Instructions 2 9 Instal
7. 1S cOM FOR r ONBOARD SYSTE ys com or THIS MANI UAL WW cK WEB SIT V TE p AT WWW JASE cae CATEST BE VISION Owners Manual For the Cargo Hook Suspension System on the Robinson R44 Series Helicopter Kit Part Numbers 200 324 00 200 325 00 200 325 017 200 340 00 Owner s Manual Number 120 137 000 Revision 7 0227 14 Z lt ONBOARD 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 Record of Revisions Revision Date Reason for Revision 11 06 07 Initial Release 02 04 09 Added Load Weigh Kit P N 200 325 01 and accompanying installation and operation instructions Re arranged installation instructions 10 12 09 1 1 1 2 5 1 Changed Cargo Hook Service Manual for kit P N 200 324 00 to 122 001 00 was 122 013 00 Clarified kit applicability in Introduction paragraph 06 11 10 Section 1 2 1 2 6 2 Corrected cargo hook location listed in Table 2 11 1 9 2 11 2 21 2 24 from 92 2 to 93 9 Replaced Warnings Cautions Section 3 4 8 4 9 amp and Notes section with Safety Labels sections 4 12 Updated safety label format throughout document 07 27 10 1 3 1 4 2 1 2 2 Added new suspension assembly configuration P N 232 292 01 03 17 11 1 3 amp 5 1 Added External Load Limit 800 Decal P N 215 119 00 to Bill Of Materia
8. 4A wires from wire harness P N 270 090 00 up through the horizontal tube and out the end of the grip assembly 4 Slide a piece of heat shrink P N 450 001 00 over the 2A and 4A wires ref Figure 2 5 3 5 Prep and solder using a lap splice the 2A wire from up through the cyclic to one of the wires from the switch and the 4A wire from the cyclic to the other wire from the switch 6 Slide the heat shrink over the respective solder joints and shrink in place using a heat gun Figure 2 5 3 Grip Assembly C058 Screw and Nut Removal R44 Cyclic Grip E O Cyclic Switch Housing Assembly P N 232 114 01 O OO Heat Shrink 1 2 Lg P N 450 001 00 CARGO Install Placard RELEASE P N 215 110 00 here VIEW A A 7 Install the Switch Housing Assembly into the end of the grip assembly and secure with the Screw P N MS27039C0806 removed earlier The Nut P N MS21042L08 removed earlier will not be re used for this installation and can be discarded 8 Check the cyclic for freedom of motion throughout its complete travel range and ensure the wires are not chafing on any components 2 15 Installation Instructions 2 5 2 Release Switch Installation Robinson Grip Assembly C058 R44 II 2 16 1 Remove nut P N B227 4 from start switch P N B227 2 and remove switch Mount P N D443 2 from end of grip assembly Figure 2 5 4 Start Switch Removal R
9. Drawing List MDL No 155 124 00 Revision 6 dated October 16 2009 or later FAA approved revision See Continuation Sheet Page 3 of 3 Limitations and Conditions Approval of this change in type design applies only to those Robinson rotorcraft models listed above which are equipped with Robinson hard point tie down block part number P N D134 1 Cargo Hook Kit models 200 324 00 and 200 326 00 are eligible for installation on R44 only Cargo Hook Kit models 200 325 00 200 325 01 200 327 00 200 327 01 and 200 340 00 are eligible for installation on R44 II only 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 See Continuation Sheet Page 3 of 3 This certificate and lhe Jufypeortirng data which ti the Casts Por approval shall remain in offect until surrendered suspended zevoked ora termination date i otherwise eialbished by the Administrator fe the Federal Aviation Administration Date fe application October 08 2007 Date reissued Date of issuance January 10 2008 Date amended April 09 2009 August 11 2009 December 30 2009 By direction of the Administrator Signature Acting Manager Seattle Airc
10. Instructions for Continued Airworthiness Section ATA 5 document number 123 030 00 Revision 2 dated June 09 2009 or later FAA approved revision Onboard Systems International Cargo Hook Component Maintenance Manual No 122 001 00 Revision 9 dated October 16 2009 or later FAA approved revision for cargo hook kit P N 200 324 00 P N 200 325 00 and P N 200 325 01 Onboard Systems International Cargo Hook Service Manual No 122 018 00 Revision 3 dated June 9 2009 or later FAA approved revision for cargo hook kit P N 200 326 00 or Onboard Systems International Cargo Hook Service Manual No 122 017 00 Revision 0 dated March 23 2006 or later FAA approved revision for cargo hook kit P N 200 327 00 and P N 200 327 01 Limitations and Conditions continued Modified rotorcraft must be operated in accordance with an FAA approved Onboard Systems International Rotorcraft Flight Manual Supplement RFMS RFMS No 121 051 00 Revision 1 dated February 25 2009 or later FAA approved revision for the 200 324 00 200 325 00 and 200 325 01 cargo hook kits or RFMS No 121 048 00 Revision 2 dated July 01 2009 or later FAA approved revision for the 200 326 00 200 327 00 and 200 327 01 cargo hook kits A copy of this Certificate Owner s Manual Component Maintenance Manual or Service Manual Instructions for Continued Airworthiness and FAA approved RFMS must be maintained as part of the permanent records of the modified rotorcraft If the ho
11. N 290 332 00 Washer P N 510 183 00 Washer P N 510 174 00 Cotter Pn i P N 510 178 00 Nut P N 510 170 00 Washer P N 510 183 00_ Washer Nut P N 510 174 00 P N 510 170 00 Pin Load Cell Assembly P N 210 226 01 Cotter Pin P N 510 178 00 Installation Instructions 2 9 2 3 2 10 Manual Release Cable and Cargo Hook Installation continued O Place the inner cable of the manual release cable through the slot of the release lever fork as shown in Figure 2 3 3 Rotate the release lever in the clockwise direction to remove free play and hold the free play is removed when the hook lock indicator begins to move This is also readily felt as the lever rotates easily for several degrees as the free play is removed Measure the gap between the release lever fork and the cable ball end with the manual release handle in the cockpit in the non release position The gap should measure a minimum of 125 3 2 mm If the gap does not measure at least 125 make adjustments at the cargo hook This is done by removing the cargo hook from the suspension and rotating the cargo hook in the required direction When correct setting is achieved tighten the jam nut securely against the cargo hook Re install the manual release cover on the cargo hook with the two screws removed Safety wire the screws Figure 2 3 5 Manual Release Cable Rigging Manual release lever Manual release ea Ball End Fitting
12. are too large will cause an un commanded release The ring will flip over the end of the load beam and flip the keeper up and then fall free Only correctly sized load rings must be used See examples below Figure 3 2 Un Commanded Release Due to Too Large of a Load Ring Load Ring flips over the Load Beam and gyrates The flip over often occurs with long line operations during landings and take offs Load Ring moves inward and bears against the keeper The Keeper is forced to rotate allowing the Ringto slip off 3 4 Operation Instructions Load Hang Up Due to Too Small of a Load Ring or Multiple Load Rings Load rings that are too small or multiple load rings will hang on the load beam when the load is released Only correctly sized load rings must be used See examples below Figure 3 3 Load Hang Up Due to Too Small of a Load Ring or Multiple Load Rings Sling Load Load hang up due to multiple rings on load beam Jammed Rings Sling Load wey Operation Instructions 3 5 Un Commanded Release Due to Nylon Type Straps Nylon type straps or similar material must not be used directly on the cargo hook load beam as they have a tendency to creep under the keeper and fall free If nylon straps must be used they should be first attached to a correctly sized primary ring Only the primary ring should be in contact with the cargo hook load beam S
13. from the P N 268 014 01 manual release cable o Place the 268 014 01 manual release cable inside the tunnel and route the output end of the cable through the cutout in the forward belly panel Insert the forward end of the cable into the cyclic control cover plate and install the face nut and T handle as shown in Figure 2 3 1 Install the adel clamp as shown install on same side as T handle and secure the release cable to it Verify that the release cable does not interfere with push pull control rods and electrical components in the tunnel and that there is sufficient clearance between these items to allow for motion and account for any slack o Route the 3 and 4 electrical release wires through the cutout and route aft as shown in Figure 2 3 2 and secure them and the manual release cable with adel clamps 2 6 Installation Instructions 2 3 Manual Release Cable and Cargo Hook Installation continued Figure 2 3 1 Manual Release Cable Installation CIRCUIT BREAKER PANEL 2 ELT SWITCH 38 63 1 00 I I LEN peca 1 25 13 P N 215 110 00 1 aila EN ADEL CLAMP P N 215 111 00 P N 512 010 00 WASHER P N 510 209 00 SCREW P N 510 297 00 NUT CYCLIC CONTROL COVER P N 510 286 00 SPACER P N 500 066 00 KEEL PANEL REE FWD m SECTION B B MANUAL RELEASE CABLE Te P N 268 014 01 I I BOTTOM SKIN sL MEASURE FROM FORWARD 2 375 PANEL OPENING SECTION A A Installation
14. in the Run Mode and select the digit to be changed in the Setup Mode e The Left button is used to Un Zero the display in the Run Mode and scroll the selected digit in the Setup Mode Figure 4 1 Front Panel Calibration amp ero amp Un Zero Legend 7 Hook Logd Dampening Unit Legend Left Button Load Weigh System Operation Instructions 4 1 The Run Mode 4 2 The C 39 Indicator has two operating modes Run and Setup The Run Mode is used to display the cargo hook weight and the Setup Mode is used to setup or configure the Indicator to the helicopter and to the Load Cell When powered up the Indicator always comes to life in the Run Mode After the Indicator has been correctly installed power it up by activating the Load Weigh Circuit Breaker The Indicator will go through a self diagnostic routine During this routine the display will display all of the digits and legends If a problem is found during the routine an Error Code will be displayed For an explanation of Error Codes see the section Error Codes After the diagnostic routine the display should look like this Figure 4 2 After Diagnostic Routine Hook Load x 10 CAL I SETUP UN ZERO ZERO Clee The illustration is of the Indicator in the Run Mode with no load on the hook Note the LB legend displayed Figure 4 3 LB Legend Displayed Hook Load x 10 LB 5 al
15. the DC solenoid in the Cargo Hook opening the hook and releasing the cargo A schematic for the electrical system is shown below in Figure 2 2 1 Figure 2 2 1 Electrical Schematic Optional Left NG c Cyclic Switch ALNET P N 400 059 00 P N 400 059 00 2B 4A 22G 5 Airframe ground Connector P N 410 131 00 ai CE Circuit Breaker 16G 10 amp A A P N 440 006 00 16G B sz ps 16G Q h 6G 16G Cargo Hook Wire Harness PCO7A 8 2P P N 270 090 00 Spade Connectors 4 Places Relay P N 445 002 00 12V or P N 445 003 00 28V Installation Instructions 2 3 2 2 Electrical Release Wiring Installation continued 2 4 Figure 2 2 2 Wire Harness and Relay Installation o Install the relay P N 445 002 00 if installing kit P N 200 326 00 or P N 445 003 00 if installing kit P N 200 327 00 on the keel panel below the existing relay installation reference Figure 2 2 2 using the hardware as shown o Place the main wire harness P N 270 090 00 into the tunnel on top of the existing wire bundle 1 75 4 75 Circuit Breaker P N 440 006 00 Use existing available location amp 4 4 4 4 4 4 POO 4 Wire Harness P N 270 090 00 Wires 2B amp 4B to optional left seat switch Decal
16. 1 108 00 and Pin P N 291 107 00 perform the following the Suspension Assembly P N can be determined by checking the underside of the Pillow Block P N 232 292 01 Suspension Assembly has a 01 on the underside of the Pillow Block O Grease the Pin P N 291 107 00 with Mobilgrease 28 or equivalent before assembly Partially insert the Pin into the Pillow Block Hold the Suspension Assembly P N 232 292 00 in the orientation as shown in Figure 2 1 2 position it within the slot of the Pillow Block and slide the Pin through the Suspension Assembly and into the other side of the pillow block 2 1 2 1 2 2 Cargo Hook Suspension Assembly Installation continued Figure 2 1 1 Suspension Assembly Installation P N 232 292 01 Pillow Block Suspension Assembly o P N 232 292 01 A a le J Forward Cap Screw P N 290 505 00 or 511 076 00 Identification of Pillow Block P N 291 108 01 Engraved 01 Figure 2 1 2 Suspension Assembly Installation P N 232 292 00 Suspension Assembly P N 232 292 00 Pillow Block P N 291 108 00 Pin P N 291 107 00 Cap Screw P N 290 505 00 or 511 076 00 2 Installation Instructions 2 2 Electrical Release Wiring Installation The electrical release system is powered from the bus through a 10 amp circuit breaker to a relay in the center tunnel Switches on the cyclic and co pilots seat support control the relay and energize
17. 162 00 provided Secure the power wire to the existing wire harnesses with tie wraps The 2A and 4A wires are routed to the cyclic switch which is installed per Section 2 5 If the optional co pilot s seat switch is to be installed the 2B and 4B wires are routed to the outboard side of the co pilot s seat otherwise cap and stow these two wires The co pilot s seat switch is installed per section 2 6 The 3 and 4 electrical wires are to be routed out the same hole in the forward belly panel as the manual release cable This hole is created during the manual release cable installation reference section 2 3 2 5 2 3 Manual Release Cable and Cargo Hook Installation NOTICE Install the manual release T handle on the cyclic control cover in the location shown in Figure 2 3 1 If due to configuration changes by Robinson Helicopters this location is not available locate it as near as_ possible IMPORTANT Before proceeding with drilling hole for T handle verify there is clearance beneath the cyclic control cover for the release cable to extend down o Drill a 38 inch 9 6 mm diameter hole through the left aft corner of the cyclic control cover and box assembly as shown in Figure 2 3 1 o Locate and drill the hole for the cable clamp in the tunnel keel panel as shown o Make a cutout in the forward belly panel as shown in Figure 2 3 2 and install the P N 500 065 00 edge grommet o Remove the T handle and first nut
18. Instructions 2 7 2 3 Manual Release Cable and Cargo Hook Installation continued Figure 2 3 2 Manual Release Cable Routing 1 00 in 25 mm Forward Belly Panel Grommet P N 500 065 00 EE E A eee Caia Forward L__ Right Aft Belly Panel TS CE e am ie Ea View Looking Down anual Release Cable Electrical Wiring Adel Clamp 3 P N 512 027 00 2 8 Installation Instructions 2 3 Manual Release Cable and Cargo Hook Installation continued o Remove the manual release cover from the cargo hook o Remove the cargo hook from the suspension assembly and screw the manual release cable into the cargo hook by holding the cable and turning the cargo hook o Temporarily install the cargo hook to the suspension assembly If in possession of kit P N 200 324 00 or P N 200 325 00 temporarily install the cargo hook P N 528 010 04 or P N 528 010 06 to the suspension assembly using the hardware as shown in Figure 2 3 3 If installing kit P N 200 325 01 remove the attach bolt from the cargo hook and temporarily install the cargo hook with the Pin Load Cell Assembly and hardware as shown in Figure 2 3 4 The cargo hook load beam must point forward NOTICE Do not tighten nut and install cotter pin until after the manual release cable rigging is completed Figure 2 3 3 Cargo Hook Installation Washer P N 510 183 00 Attach Bolt P
19. P N 215 112 00 Grommet P N 505 01 1 00 E P N 445 002 00 or View Looking Down P N 445 008 00 0 00 2 00 l ia Nut P N 510 279 00 Screw P N 510 277 00 Washer B P N 510 278 00 Aire 002 00 Serine or P N 445 003 00 2 PLCS View A A Looking Outboard o Connect wire numbers 1 2 and 3 from the main wire harness to the relay terminals A B and 7 as shown in the electrical system schematic Connect jumper wire 6 to relay terminal 5 o Connect the ground lead of wire number 5 to any convenient existing ground location in the tunnel o Secure the wire harness with wire ties as required Installation Instructions 2 2 Electrical Release Wiring Installation continued Installation Instructions O Remove the circuit breaker cover panel and install the 10 amp circuit breaker P N 440 006 00 in an available location On some early models it may be necessary to remove the panel and make a hole for the additional circuit breaker Open the circuit breaker to disarm the cargo hook release circuit Use the wire assembly P N 270 089 00 and a ring terminal P N 410 162 00 as a jumper to power the input side of the circuit breaker in compliance with AC 43 13 Feed the 1 wire of the main wire bundle from the tunnel into the circuit breaker bay using the existing wire harness access hole Connect the wire to the output side of the circuit breaker using the other ring terminal P N 410
20. The R44 maintenance and parts manuals should be available throughout the installation as various R44 components will be referred to by name and part number The part numbers for Robinson components are provided for reference and are subject to change by Robinson All equipment removed and replaced shall be done in accordance with the R44 maintenance manual All installed hardware shall be torqued in accordance with standard torques of AC43 13 unless noted otherwise Apply torque stripe where applicable 2 1 Cargo Hook Suspension Assembly Installation Installation Instructions O O O Insert the cap screws P N 290 505 00 or 511 076 00 into the two holes in the Robinson hardpoint block and screw in to ensure thread integrity Some re work of access holes in skin may be required to allow bolt installation Remove the two cap screws Apply sealant to the side of the Suspension Assembly P N 232 292 01 Pillow Block which is to be installed against the belly skin Orient the Suspension Assembly as shown in Figure 2 1 1 and secure it to the helicopter with the two P N 290 505 00 or 511 076 00 cap screws refer to Figure 2 1 1 NOTICE Install the Suspension Assembly so that the engraved F is forward and the engraved A is aft as shown in Figure 2 1 1 Torque screws to 26 ft lbs Safety wire the cap screws to the ears on the pillow block Tf installing Suspension Assembly P N 232 292 00 Pillow Block P N 29
21. allation Zero Routine With the Indicator powered up and in the Run Mode press both buttons at the same time to go to Setup Scroll through the menu until the symbol 0 in is displayed then press the Right button The CAL legend will be turned on and the current weight on the Cargo Hook will be displayed and blinking Remove any weight that is not to be zeroed out and press either button to complete the procedure and return to the Run Mode Calibration by Lifting a Known Weight Calibration by lifting a known weight is a Setup routine that calculates the Calibration Code for the Load Cell attached to the Indicator It is useful if the load cell Calibration Code is not known or as a cross check to the accuracy of a known Calibration Code The procedure is done by entering the known weight into the Indicator and then lifting the weight This procedure can be done in the shop or on the helicopter The accuracy of the procedure is directly related to the weight of the known load If for example the procedure was done with a 1 000 pound load that was assumed to weigh only 900 pounds all subsequent lifts would be displayed 10 light Be sure to include the weight of everything between the Cargo Hook and the load i e the cable net dirt etc The closer the known load approaches the lifting capacity of the helicopter the more accurate the calculated Calibration Code will be Load Weigh System Operation Instructions 4 9 Calibration by Lif
22. ate NUMERO 2010S12 07 Number LIMITA ES E CONDI ES ions and Conditions The approval of this type design change should not be extended to other aircraft of this model 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 aircraft 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 Operation must be performed in accordance with the applicable FAA approved Rotorcraft Flight Manual Supplement AFMS specified below Document No 121 051 00 Rev 1 dated 25 Feb 2010 or later approved revision for the Onboard Systems 200 324 00 200 325 00 and 200 325 01 Cargo Hook kits or Document No 121 048 00 Rev 2 dated 01 July 2009 or later approved revision for the Onboard Systems 200 326 00 200 327 00 and 200 327 01 Cargo Hook kits Installation of the Cargo Hook Kit in accordance with the following approved documents Owner Manual document No 120 137 00 Rev 4 dated 27 July 2010 or later approved revision for the Onboard Systems 200 324 00 200 325 00 or 200 325 01 Cargo Hook kit Owner s Manual document No 120 132 00 Rev 5 dated 27 J
23. ator Version 4 13 Section 5 Maintenance Instructions for Returning a System to the Factory 5 1 Section 6 Certification FAA STC 6 1 Canadian Approval 6 3 EASA STC 6 5 ANAC Approval 6 8 Section 1 General Information Introduction The P N 200 324 00 200 325 00 and 200 325 01 Cargo Hook Suspension System Kits are approved for use on the Robinson R44 series helicopters These kits include the cargo hook suspension assembly internal electrical wiring including release switches and manual release cable The 200 325 01 includes a load weigh system The P N 200 324 00 kit is eligible for use on the R44 model which has a 14V electrical system The P N 200 325 00 and 200 325 01 kits are eligible for use on the R44 Raven II model which has a 28V electrical system The P N 200 325 00 and 200 325 01 kits also include a different cyclic switch housing assembly than the P N 200 324 00 kit to accommodate the Raven II cyclic configuration The load weigh system for the P N 200 325 01 kit includes a pin load cell assembly at the cargo hook a cockpit mounted C 39 load weigh indicator and the interconnecting wire harness 1 1 General Information Safety Labels The following definitions apply to safety labels used in this manual Indicates a hazardous situation which if not 1 D AN G E R avoided will result in death or serious injury Indicates a hazardous situation which if not avoided could result in death or serious inj
24. d Left buttons at the same time To change the Calibration Code use the Right button to select the digit to be changed then use the Left button to scroll the blinking digit to the desired number When the Calibration Code has been entered press both the Right and Left button at the same time to return to Run NOTICE Depending on the type of Load Cell the Calibration code could be a 3 or 4 digit number If the Calibration Code is a 3 digit number a leading zero 0 must be used For example if a Load Cell had a CAL Code of 395 it would be entered as 0395 If the load cell Calibration Code is not known or as a cross check the Indicator can generate the Calibration Code This is done by entering the weight of a known load into the Indicator LOAD routine and then lifting the load See the section Calibration by Lifting a Known Load Load Weigh System Operation Instructions Installation Zero Installation zero is a routine that matches the Indicator to the INSTALLED Load Cell It adjusts the Indicator reading to compensate for the weight of the Cargo Hook on the Load Cell and whatever zero offset is built into the Load Cell The Installation Zero procedure is not mandatory If done the Indicator will read zero when the Un Zero button is pressed and there is no weight on the Cargo Hook If the Installation Zero is not done the Indicator will show the weight of the Cargo Hook plus the value of the Load Cell zero offset To Run the Inst
25. discussion of their function and how they are programmed A complete discussion of each setup item is presented later in this section To enter the Setup Mode press both the Right and Left buttons at the same time while the Indicator is powered up and in the Run Mode To exit the Setup Mode and return to the Run Mode press both the buttons at the same time If you are in a Setup routine and have started to change an entry but you change your mind before completing the procedure power cycle the Indicator to exit the Setup Mode and then go to the Run Mode without changing the item The Indicator is power cycled by turning the Indicator power off for a few moments Load Weigh System Operation Instructions 4 5 The Setup Mode continued Table 4 2 Indicator Setup Routines MENU FUNCTION DISPLAY Press the Right button to view or change the To return to the Run Mode press both the scroll through the menu menu item Right and Left buttons at the same time Dampening Level sets the pilots preference Blinking display is previously entered DAMP for display dampening Dampening Level Select the desired dampening level by pressing the Left button Calibration Code matches the Indicator to the Display is previously entered CAL Code CODE Load Cell The Code is changed by selecting the digit to be changed with the Right button The selected digit will blink Change the blinking digit by pressing the Left button Installation ZERO matches t
26. ed 17 Sep 2010 or later FAA approved revision for cargo hook kit P N 200 327 00 and 200 327 01 VII Approval of this change in type design applies only to those Robinson rotorcraft models listed above which are equipped with Robinson hard point tie down block part number P N 0134 1 Vill Cargo hook kit models 200 324 00 and 200 326 00 are eligible for installation on R44 only Cargo Hook Kit models 200 325 00 200 325 01 200 327 00 and 200 327 01 are eligible for installation on R44 Il only IX A copy of this Certificate and the Supplement referred on item Ill as applicable above shall be maintained as part of the permanent records of the modified aircraft F 400 01E 08 10 Fi 03 de 03 H 02 3500 0 6 10 Certification
27. ee examples below Figure 3 4 Un Commanded Release Due to Nylon Type Straps Cable or rope type line flips over the Load Beam The flip over often Occurs with long line operations during landings and take offs Load Ring moves inward and bears against the keeper The Keeper rotates allowing the Ring to slip off 360000 Operation Instructions Un Commanded Release Due to Cable or Rope Type Straps Cable or rope type straps must not be used directly on the cargo hook load beam Their braided eyes will work around the end of the load beam and fall free If cable or rope is used they Should be first attached to a correctly sized primary ring Only the primary ring should be in contact with the cargo hook load beam See examples below Figure 3 5 Un Commanded Release Due to Cable or Rope Type Straps Nylon type strap on the Load Beam As the oad swngs the strap fbers work their way under the keeper The strap works its way off of the oad beam Maintenance 3 7 This page intentionally left blank Section 4 Operation Instructions Load Weigh System Indicator Front Panel The C 39 Indicator front panel includes the following features e The four 7 segment LCD digits show the weight on the Cargo Hook and displays various Setup information e The Legends clarify the digital display i e when the LB Legend is turned on the display will be pounds etc e The Right button is used to Zero the display
28. emove nut start switch and switch mount 2 Remove outboard screw MS27039C0806 and nut MS21042L08 as shown in Figure 2 5 5 The nut will not be re used for this installation and can be discarded Figure 2 5 5 Screw and Nut Removal Remove outboard screw and nut 3 Using a lead wire pull the number 2A and 4A wires up through the horizontal tube and out the end of the grip assembly 4 Slide a piece of heat shrink P N 450 001 00 over the 2A and 4A wires 5 Prep and solder using a lap splice the 2A wire from up through the cyclic to one of the wires from the switch and the 4A wire from the cyclic to the other wire from the switch 6 Slide the heat shrink over the respective solder joints and shrink in place using a heat gun Installation Instructions 2 5 2 Release Switch Installation Robinson Grip Assembly C058 R44 II continued Figure 2 5 6 Release Switch Installation R44 Cyclic Grip q Cyclic Switch Housing Assembly P N 232 152 01 Heat Shrink 1 2 Lg a P N 450 001 00 A CARGO Install Placard RELEASE P N 215 110 00 here VIEW A A 7 Insert the Switch Housing Assembly into the end of the C058 cyclic grip while pulling the Robinson start switch through it Re install the Robinson start switch into the Switch Mount P N D443 2 with the nut and secure the Switch Mount by tightening the pre installed set screw in t
29. h a C 30 Data Recorder a 5 amp circuit breaker should be used 2 22 Installation Instructions 2 7 Load Weigh System Installation continued C 39 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 214 instrument hole Connect the Indicator to its Internal Harness refer to Internal Harness Installation 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 The cable shield wire is not grounded at this end of the cable and may be cut off Indicator Hook Open Warning The 210 095 00 Indicator is equipped with a Hook Open Warning feature that can be connected to a cargo hook equipped with a hook open switch Depending on the capabilities of the cargo hook switch the Indicator will flash HOOK OPEN when the cargo hook load beam is open The cargo hook switch must be normally open when the cargo hook load beam is in the closed position When the load beam is open one side of the switch must be grounded and the other side of the switch is to be connected to the Indicator Use a 22 gauge shielded wire to connect the cargo hook switch to the Indicator Disassemble the Indicator mating connector and carefully
30. he Indicator to Display is a combination of load on the Oin the installed Load Cell and to the helicopter Load Cell and normal load cell zero After this procedure the display will be zero offset Remove all weight from the sino lo d ison the Carro Hook installed Load Cell except the Cargo X 8 Hook and press any button to complete the procedure and return to the Run Mode Load is used to calibrate the system by lifting No previous display is shown Enter the LOAD a known load known load using the Right button to select the digit to be changed and Left button to enter the number Known load is entered X 10 ie 5000 kilograms is entered as 500 After the known load is entered press both buttons at the same time and lift the known load When the load is stabilized press either button A new Calibration Code will be calculated and the known load will be displayed This completes the procedure Scale matches the analog output of the Display is previously entered number To Scale Indicator to an optional remote analog meter Change the number use the Right button to select a digit use the Left button to scroll the digit to the desired number Entry is times 10 LB KG Units selects the Indicator units pounds or Display is previously selected unit To kilograms change the unit use the Left button XX V Version is the revision level of the Indicator Version is for information only it cannot hardware and soft
31. he Switch Housing 8 If necessary while inserting the Switch Housing Assembly into the cyclic grip pull excess wire back down the cyclic grip Secure the Switch Housing Assembly into the end of the grip assembly with the MS27039C0806 screw removed earlier Figure 2 5 7 Switch Housing Assembly Installed 9 Install placard P N 215 110 00 as shown in Figure 2 5 6 10 Check the cyclic for freedom of motion throughout its complete travel range and ensure the wires are not chafing on any components Installation Instructions 2 17 2 5 3 Cyclic Release Switch Installation 2 18 1 Remove the cover to the cyclic switch housing and ensure its wires are clear of the areas to be drilled on the horizontal cyclic control handle Drill a 172 inch 4 4 mm diameter hole on the forward side of the cyclic grip as shown in Figure 2 5 8 Use a lead wire and route the number 2A and 4A wires up through the cyclic stick and out the existing wire routing hole Place a length of heat shrink over the wires that will cover the exposed portion similar to the existing com wires Using a lead wire again pull the number 2A and 4A wires up through the cyclic grip and out the 250 hole on the front of the cyclic grip Place a 1 inch 25 4 mm length of heat shrink over each wire to the cyclic switch Prepare each wire end and solder them to the normally open and closed switch terminals as shown in the Figure 2 2 1 wiring schematic Using a heat gun
32. her eon met pplicable airwo mess requirements Original N mero do Certificado de Tipo 9402 ANAC Produto Original duct Type Certificate Fabricante Robinson Manufacturer Modelo s R44 and R44 Il Model s DESCRI O DA MODIFICA O AO PROJETO DE TIPO Description of Type Design Cha Fabrication of Onboard System International Model 200 324 00 and 200 326 00 12V cargo hook kits Model 200 325 00 and 200 327 00 28V cargo hook kits Model 200 325 01 and 200 327 01 28V cargo hook kit with load weight and Model 200 340 00 load weight Kit in accordance with Onboard Systems Master Drawing List MDL No 155 124 00 Rev 7 dated April 9 2010 or later approved revision This CST validates in Brazil the STC SRO1808SE issued by FAA USA LIMITA ES E CONDI ES Limitations and Conditions See continuation sheet for applicable data Dates of mento 17 Sep 2010 Da emiss o 20 Dec 2010 Da reemis ss o Application Issue Reissue N HELIO TARQUINIO J NIOR DINO ISHIKURA j Superintendente de Aeronavegabilidade General Manager Aeronautical Product Certticabon Airworthiness Superintendent F 400 01E 08 10 Ela de 03 H 02 3500 0 6 8 Certification ANAC Approval continued Limita GA y ANAC AG NCIA NACIONAL DE AVIA O CIVIL BRASIL Folha de Continua o ao Continuation Sheet to CERTIFICADO SUPLEMENTAR DE TIPO Supplemental Type Certific
33. lation Check out After installation of the Cargo Hook Suspension System perform the following functional checks l Swing the installed Cargo Hook to ensure that the manual release cable assembly and the electrical release cable have enough slack to allow full swing of the suspension assembly without straining or damaging the cables The cables must not be the stops that prevent the Cargo Hook from swinging freely in all directions Apply 10 20 pounds 4 5 9 kg to the cargo hook load beam and pull the handle operated cargo hook manual release the Cargo Hook must release the load 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 buttons the Cargo Hook should release using the cyclic and left seat electrical release switches Reset the cargo hook load beam 2 10 Component Weights The weight of the system is listed in Table 2 10 1 Table 2 10 1 Component Weights Item Weight Ibs kgs P N 200 324 00 5 3 2 4 P N 200 325 00 5 3 2 4 P N 200 325 01 6 8 3 1 2 11 Cargo Hook Location Table 2 11 1 Cargo Hook Location 2 12 Paper Work Installation Instructions Fuselage Station 93 9 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 Supple
34. lder 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 81 10 2 1 10 69 PAGE 3 OF 3 PAGES 6 2 Certification Canadian Approval Transport Transports Canada Canada Civil Aviation Aviation Civile Suite 620 Your file Votre r f rence 800 Burrard Street Vancouver B C Our file Notre r f rence Z 2J Peay NAPA P 08 0357 RDIMS 4432295 October 09 2008 Mr Mark Hanson Onboard Systems International 13915 NW 3 court Vancouver WA 98685 USA Subject Acceptance of Foreign STC SR01808SE Dear Mr Hanson This is in response to FAA letter requesting Transport Canada approval of the subject STC In accordance with our current policy associated with the review of foreign STCs 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 confirm
35. lease Switches Installation The table below shows three R44 cyclic configurations refer to the column on the right for installation instructions for the electrical release switch Cyclic Configuration Installation Instructions R44 with C058 Grip Assembly Install Switch Housing P N 232 114 01 included with Kit P N 200 326 00 per Section 2 5 1 R44 II with C058 Grip Assembly Install Switch Housing P N 232 152 01 Start switch installed in end of cyclic included with Kit P N 200 327 00 per grip Section 2 5 2 The Switch Housing for this configuration is not supplied with these kits Contact Onboard Systems to obtain Switch Housing P N 232 063 01 switch P N 400 059 00 cap P N 400 054 00 and screw P N 510 301 00 qty 2 and install per Section 2 5 3 Installation Instructions 2 13 2 5 1 Release Switch Installation Robinson Grip Assembly C058 R44 1 Remove Plug Robinson P N DP 875 and discard as shown in Figure 2 5 1 Figure 2 5 1 Grip Assembly C058 Plug Removal D 3 Y i tes E cm sm q Q 14 Remove plug and discard 2 Remove outboard screw MS27039C0806 and nut MS21042L08 as shown in Figure 2 5 2 Figure 2 5 2 Grip Assembly C058 Screw and Nut Removal Remove outboard screw and nut 2 14 Installation Instructions 2 5 1 Release Switch Installation Robinson Grip Assembly C058 R44 continued 3 Using a lead wire pull the number 2A and
36. lied extra long cut off the excess cable and use as needed to connect the switch and circuit breaker Connect the POWER white wire red if wire harness P N 270 048 00 is installed 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 7 1 Connect the circuit breaker to the 28 VDC bus Connect the white blue wire black if wire harness P N 270 048 00 is installed to the ground bus The cable shield wire is not grounded at this end of the cable and may be cut off Use a minimum of 22 gauge wire to make all connections Secure the connections and protect from corrosion 2 21 2 7 Load Weigh System Installation continued Figure 2 7 1 Wiring Arrangement Power switch 1 amp circuit breaker supplied operator supplied To 28 VDC White Red To airframe ground White Blue Black Power cable Back light potentiometer operator supplied White Cl i To 28 VDC te Clea Light cable To airframe ground White Blue Black To C 39 indicator Data Recorder Cable To optional equipment gt To load cell NOTICE If a C 23 Printer is being utilized wit
37. low is a matrix of the Error Code displays their meaning and possible corrective action Pressing either button will usually bypass the error code however the displayed information may be suspect Table 4 1 Indicator Error Codes POSSIBLE DISPLAY CAUSE CORRECTIVE ACTION A D or D A circuit failure NV Ram failure NV Ram write failure NV Ram busy failure Potential short in the optional analog meter cable Clear short and power cycle the Indicator by turning the power to the Indicator off for a few moments If Error Code continues return the Indicator to the factory Power cycle the Indicator if Error Code continues return the Indicator to the factory Re enter data if Error Code continues return the Indicator to the factory Power cycle the Indicator if Error Code continues return the Indicator to the factory Load Weigh System Operation Instructions The Setup Mode The C 39 Indicator can be used with a wide range of helicopters and load cells The Setup Mode on the Indicator matches the Indicator to the Load Cell and to the helicopter This is done by entering data into the Indicator Entered data includes the load cell Calibration Code the units that the Indicator should read out pounds or kilograms and several other items The Indicator has a group of Setup routines arranged in menu form that are used to configure the Indicator Shown on the next page is a matrix of the Setup routines and a brief
38. ls Updated RMA information 11 18 13 2 11 to 2 25 Update pin load cell installation instructions Updated switch P N 400 053 00 to P N 400 059 00 and switch housing P N 232 063 00 to 232 063 01 02 27 14 1 2 1 3 2 1 2 2 3 Replaced bolt P N 290 505 00 with 511 076 00 2 2 4 2 6 2 7 Loosened tolerances on relay location moved manual release cable T handle location 80 inches inboard to provide clearance with a c structure Updated Notice for locating T handle Current revision levels of all manuals are posted on Onboard Systems Int l web site at www onboardsystems com 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 General Information Introduction 1 1 Safety Labels 1 2 Bill of Materials 1 3 Inspection 1 4 Specifications 1 4 Theory of Operation 1 5 Section 2 Installation Instructions 2 1 Cargo Hook Suspension Assembly Installation 2 1
39. ment 121 051 00 in the Rotorcraft Flight Manual 2 25 This page intentionally left blank 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 and electrical release cables do not limit the movement of the hook 2 Be completely familiar with this manual particularly the Cargo Hook rigging section 3 Be completely familiar with all Cargo Hook operating instructions 4 Activate the electrical system and press the cargo hook release button to ensure the cargo hook electrical release is operating correctly The Cargo Hook should re latch after release If the hook 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 20 seconds may cause the release solenoid to overheat possibly causing permanent damage 5 Activate the manual release lever to test the cargo hook manual release mechanism The mechanism should operate smoothly and the Cargo Hook must re latch after release If the hook does not re latch do not use the unit until the difficulty is resolved Operation Instructions 3 1 Optional Flight Configuration Cargo Hook Rigging 3 2 The aircraft can be operated with the Cargo Hook and gimbal assembly removed This may be accomplished by re
40. moving the Cargo Hook from the 232 292 00 Suspension Assembly Then remove 291 108 00 Pillow Block and 232 292 00 Suspension System together by removing the two Pillow Block mounting fasteners See Figure 2 1 1 Secure the manual release cable and electrical wire bundle to any convenient location on the frame structure using tie wraps Extreme care must be exercised in rigging a load to the Cargo Hook If the load ring is too big it may work its way around the end of the load beam and be supported for a time on the keeper and then fall free If the load ring is too small it may jam itself against the load beam during an attempted release The following illustrations show recommended configurations and potential difficulties that must be avoided The examples shown are not intended to represent all problem possibilities It is the responsibility of the operator to assure the hook will function properly with the rigging Operation Instructions Cargo Hook Rigging continued Figure 3 1 Examples of Correct and Incorrect Cargo Hook Rigging Correct Rigging 875 inch 22 2 mm max cross section 1 50 1 87 inch Primary 38 1 47 5 mm Ring ID Secondary Ring Primary Ring 625 inch 15 9 mm max cross section Incorrect Rigging Incorrect Rigging Multiple rings on Load Beam Multiple rings on Primary Ring Operation Instructions 3 3 Un Commanded Release Due to Too Large of a Load Ring Load rings that
41. nvenient location or use an existing unused hole in the tunnel wall Install Grommet P N 505 011 00 2 Drill a 50 inch hole in the outboard side of the left seat support as shown in Figure 2 6 1 3 Route the number 2B and 4B wires through the grommeted hole and through the left baggage area to the 50 inch hole on the outboard seat support Secure the wires to the forward seat hinge fasteners with two clamps P N 512 018 00 4 Slide the nut provided with the switch P N 400 059 00 over the wires from inside the seat support and feed the wires through the 50 inch hole and through the switch guard P N 290 478 01 5 Place a 50 inch length of heat shrink over each wire to the switch Solder the wires to the switch as shown in the Figure 2 2 1 wiring schematic Use a heat gun and shrink the covering material to final size Place the switch P N 400 059 00 into the switch guard and through the seat as shown in Figure 2 6 1 and secure with nut Figure 2 6 1 Left Seat Release Switch Installation Switch Guard LEFT S EAT P N 290 478 01 1 00 in 25 4 mm Drill 50 in 12 7 mm hole in seat support 1 60 in C A Switch 41 mm P N 400 059 00 CARGO RELEASE SECTIONA A 215 110 00 2 20 Installation Instructions 2 7 Load Weigh System Installation Kit P N 200 327 01 features a load weigh system which includes the load cell an electrical wiring internal harness and a C 39 load weigh indica
42. o hook kits Rotorcraft Flight Manual Supplement RFMS No 121 051 00 Revision 0 dated January 7 2008 For the 200 326 00 and 200 327 00 cargo hook kits RFMS No 121 048 00 Revision 0 dated January 7 2008 3 Installation Kit P N 200 324 00 or 200 325 00 Onboard Systems Owner s Manual No 120 137 00 Revision 0 Kit P N 200 326 00 or 200 327 00 Onboard Systems Owner s Manual No 120 132 00 Revision 0 4 Inspection and maintenance ICA for all kit P N Instructions for Continued Airworthiness document number 123 030 00 Revision 0 Additionally for cargo hook kit P N 200 324 00 Service Manual No 122 013 00 Revision 2 Additionally for cargo hook kit P N 200 325 00 Onboard Systems Cargo Hook Service Manual No 122 001 00 revision 5 Additionally for cargo hook kit P N 200 326 00 Onboard Systems Cargo Hook Service Manual No 122 018 00 revision 0 Additionally for cargo hook kit P N 200 327 00 Onboard Systems Cargo Hook Service Manual No 122 017 00 Revision 0 Or later FAA revisions of the above listed documents STC EASA IM R S 01438 Onboard Systems International 6 6 Certification EASA Approval continued European Aviation Safety Agency Limitations and Conditions 1 Approval of this change in type design applies only to those Robinson Rotorcraft models listed above which are equipped with Robinson hard point tie down block P N D134 1 Prior to installation of this modification
43. on has been made press both the Right and Left button at the same time to return to Run NOTICE The selected units are displayed when in the Run Mode Load Weigh System Operation Instructions Indicator Version The Version routine displays the Indicator s hardware and software revision levels Version is set at the factory and cannot be changed Figure 4 11 Looking at Indicator Version Hook Load x 10 CAL LB KG UN ZERO Load Weigh System Operation Instructions 4 13 This page intentionally left blank Section 5 Maintenance Refer to the Instructions for Continued Airworthiness ICA manual 123 030 00 for maintenance of the cargo hook suspension system For maintenance of cargo hook P N 528 010 04 and P N 528 010 06 refer to Cargo Hook Service Manual 122 001 00 In 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 Generate an RMA number at our website http www onboardsystems com rma php e After you have obtained the RMA number please be sure to e Package the component carefully to ensure safe transit
44. r cycle the Indicator It is not possible to return to the Run Mode by using the buttons on the Indicator front panel without changing the Calibration Code If you wish to proceed lift the known load and when it is stabilized press either button to complete the procedure The Indicator will display the load This ends the procedure The Indicator is now calibrated to the Load Cell It is a good practice to go to the Code routine and record the new Calibration code for later reference Setting the Scale for a remote analog meter The Scale routine is used when a user supplied analog meter is connected to the Indicator It is used to match or calibrate the analog meter to the Indicator The Indicator outputs a 0 to 5 VDC analog signal which is proportional to the Load Cell load The Scale number tells the Indicator at what point in pounds or kilograms it should reach the 5 VDC output If for example a 5 volt analog meter is used and its full scale reading is 10 000 pounds the number entered into the Indicator Scale routine would be 1000 the number is entered X 10 This number tells the Indicator that it should output the proportional 0 to 5 VDC signal between zero pounds and 10 000 pounds The Scale number does not affect Onboard Slave Meters P N 210 106 00 or 210 180 00 This number only affects user supplied instruments connected to the analog out signal To Look at or Change the Scale With the Indicator powered up and in the Run Mode pre
45. raft 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 Certification 6 1 FAA STC continued Hnit States of America Department of Transportition Federal Aviation Administration Supplemental Cype Certificate Continuation Sheet Number SRO1808SE Onboard Systems International Iisued January 10 2008 Amended April 09 2009 August 11 2009 December 30 2009 Description fi the Type Design Change continued Installation of the Onboard Systems International Cargo Hook Kits Model 200 324 00 200 325 00 or 200 325 01 in accordance with FAA approved Onboard Systems international Owner s Manual No 120 137 00 Revision 1 dated February 04 2009 or later FAA approved revision Installation of the Onboard Systems International Cargo Hook Kits Model 200 326 00 200 327 00 or 200 327 01 is in accordance with FAA approved Onboard Systems International Owner s Manual No 120 132 00 Revision 3 dated June 09 2009 or later FAA approved revision Installation of the Model 200 340 00 Load Weigh Kit is in accordance with the above identified Onboard Systems International Owner s Manual for either the Model 200 325 01 or 200 327 01 cargo hook kit as applicable This modification must be inspected and maintained in accordance with Onboard Systems International
46. s formal acceptance of the referenced STC by Transport Canada Yours truly Paul Arnell For Regional Manager Aircraft Certification Cc Seattle Aircraft Certification Office Certification 6B 6 4 This page intentionally left blank Certification EASA Approval European Aviation Safety Agency SUPPLEMENTAL TYPE CERTIFICATE EASA IM R S 01438 This certificate established in accordance with Regulations EC No 216 2008 and EC No 1702 2003 and issued to Onboard Systems 13915 NW 3rd Court Vancouver WA 98685 United States 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 EASA IM R 121 Manufacturer Robinson Helicopter Comp Model R44 R44 IT Original STC Number FAA STC SROI808SE Description of Design Change Cargo Hook Suspension Systems Description The installation provides for different optional Cargo Hook System kits depending on aircraft voltage system and the respective cargo hook in accordance with FAA STC SRO1808SE Certification 6 5 EASA Approval continued European Aviation Safety Agency Associated Technical Documentation 1 Definition MDL 155 124 00 2 Flight Manual Supplements For the 200 324 00 and 200 325 00 carg
47. shrink the covering material to final size Figure 2 5 8 Cyclic Switch Wire Routing Existing holes Cyclic A REF 172 Drilled in step 2 Looking Aft Install the 400 059 00 switch in the 232 063 01 cyclic switch housing assembly using needle nose pliers to hold the switch Install the completed switch housing assembly with the hardware as shown in Figure 2 5 9 Remove the existing switch housing screws and replace them with the longer 510 301 00 screws and retain one of the removed nuts as shown in Figure 2 5 9 Installation Instructions 2 5 3 Cyclic Release Switch Installation continued 7 Re install the com switch housing and wires 8 Check the cyclic for freedom of motion throughout its complete travel range and ensure the wires are not chafing on any components Figure 2 5 9 Cyclic Release Switch Installation Switch P N 400 059 00 Switch Housing Assembly P N 232 063 01 RN Z d Retain Nut N K ESN Decal CARGO 7 P N 215 110 00 RELEASE Screw a P N 510 301 00 2 PLCS Installation Instructions 2 19 2 6 Optional Left Seat Release Switch Installation If the left seat release switch installation is not desired cap and stow wires 2B and 4B per AC 43 13 and skip this section 1 Drill a 250 inch hole in the left side of the tunnel wall above the main wire bundle in a co
48. ss both buttons at the same time to go to Setup Scroll through the menu until the word SCALE is displayed then press the Right button The display should look like this Figure 4 9 Changing the Scale Hook Load x 10 CAL or Load Weigh System Operation Instructions 4 11 To Look at or Change the Scale continued Select KG or LB Units The CAL legend is turned on and the previously set Scale number is displayed To return to Run without changing the Scale press both the Right and Left button at the same time To change the Scale number use the Right button to select a digit to be changed then use the Left button to scroll the blinking digit to the desired number When the complete Scale number has been entered press both the Right and Left button at the same time to return to Run The units routine sets the display to read in pounds LB or kilograms KG To look at or change the Units 4 12 With the Indicator powered up and in the Run Mode press both buttons at the same time to go to Setup Scroll through the menu until the word LB or KG is displayed then press the Right button The display should look like this Figure 4 10 Changing the Units Hook Load x 10 CAL LB KG The CAL legend is turned on and the previously set unit is displayed To return to Run without changing the units press both the Right and Left button at the same time To change the units press the Left button When the selecti
49. the installer must determine that the interrelationship between this 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 This certificate shall remain valid unless otherwise surrendered or revoked For the European Aviation Safety Agency Date of Issue 23 April 2008 Massimo MAZZOLETTI Certification Manager Rotorcraft Balloons Airships STC EASA IM R S 01438 Onboard Systems International Certification 6 7 ANAC Approval x A ANAC AG NCIA NACIONAL DE AVIA O CIVIL BRASIL CERTIFICADO SUPLEMENTAR DE TIPO Supplemental Type Certificate NUMERO 2010S12 07 Number itido com base na Lei n 7565 C digo Brasileiro de Aeron utica de 19 de dezembro de cado em 1986 This certificate Teloos in the basis of the Law No 7565 C digo Brasileiro de Aeron utica dated 19 December 1986 conferido ao Onboard Systems International e grain baia 13915 NW 3rd Court Vancouver WA 98685 USA r ter a modifica o ao projeto de tipo do produto abaixo citado observadas as limita es e condi es for having the change to the type design of the product mentioned below with the limitations and conditions theretor as especificadas satisfeito 20s requisitos de aeronavegabilidade aplicaveis specitied
50. 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 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 A secondary release button is also provided on the left seat lower outboard support In an emergency release can be achieved by operating a manual 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 5 This page intentionally left blank 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
51. ting a Known Weight continued To Run the Calibration by Lifting a Known Weight Routine 4 10 With the Indicator powered up and in the Run Mode press both buttons at the same time to go to Setup Scroll through the menu until the word LOAD is displayed then press the Right button The display should look like this Figure 4 7 Running CAL Routine Hook Load x 10 CAL CUO SETUP UN ZERDO ZERO The CAL legend is turned on and the first digit is blinking The previous load is not displayed At this point if you wish to return to the Run Mode without changing the Calibration Code power cycle the Indicator At this point it is not possible to return to the Run Mode without changing the Calibration Code by using the buttons on the Indicator front panel To proceed with the procedure use the Right button to select the digit to be changed then use the Left button to scroll the blinking digit to the desired number Note that the known weight is entered X 10 a 1000 pound load is entered as 100 When the known load has been entered press both the Right and Left button at the same time The display will look like this Figure 4 8 Entering Load in CAL Routine Hook Load x 10 CAL Load Weigh System Operation Instructions Calibration by Lifting a Known Weight continued The CAL legend and the digits will be blinking Again at this point if you wish to return to the Run Mode without changing the Calibration Code powe
52. tor If this kit is not being installed skip to section 2 8 Load Weigh Internal Harness Installation Installation Instructions The Load Weigh Harness is made up of four cables terminated to one connector 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 is connected to an optional Data Recorder and C 23 printer The load cell cable can be routed with the hook electrical release harness to the cargo hook area The load cell connector should be mounted in a location close enough to the load cell to ensure the load cell cable is not strained when the cargo hook is moved to its furthermost point but far enough away to minimize excess cable which may be snagged Secure the connector with the screws P N 510 028 00 and nuts P N 510 029 00 provided Route the harness to the electrical bus and to the Indicator mounting location Secure the cables to the existing wiring bundles with the ty wraps Secure the cables clear of flight control rods Electrical Connections Install the supplied power switch P N 400 048 00 The POWER cable on the Internal Harness is supp
53. ttons at the same time To change the dampening number use the Left button to scroll the blinking digit to the desired number After the selection has been made press both the Right and Left buttons at the same time to return to Run Indicator Calibration The Calibration Code or CAL code is a mandatory input The Indicator will not accurately display the load without the correct Calibration Code The Calibration Code scales the signal from the Load Cell If the C 39 Indicator was supplied as part of a Load Weigh System the Calibration Code will have been entered into the Indicator by the factory however it should be confirmed If the Indicator is to be mated to a different Load Cell it must be calibrated before use Calibration can be done by entering a known Calibration Code or by lifting a known load and having the Indicator calibrate itself Both options are discussed below Load Weigh System Operation Instructions 4 7 4 8 To Look at or Change the Calibration Code With the Indicator powered up and in the Run Mode press both buttons at the same time to go to Setup Scroll through the menu until the word CODE is displayed then press the Right button The display should look like this Figure 4 6 Changing the CAL Code Hook Load X 10 CAL j SETUP The CAL legend is turned on and the previously entered or computed Calibration Code is displayed To return to Run without changing the CAL Code press both the Right an
54. uly 2010 or later approved revision for the Onboard Systems 200 326 00 200 327 00 or 200 327 01 Cargo Hook kit Installation of the 200 340 00 Load Weight Kit in accordance with above identified Onboard System International Owner s Manual for either the model 200 325 01 or 200 327 01 cargo hook kit as applicable Jo F 400 01E 08 10 Fl 02 de 03 H 02 3500 0 Certification 6 9 ANAC Approval continued gt ANAC AGENCIA NACIONAL DE AVIACAO CIVIL BRASIL Folha de Continua o ao Continuation Sheet to CERTIFICADO SUPLEMENTAR DE TIPO Supplemental Type Certificate N MERO 2010S12 07 Number LIMITA ES E CONDI ES Limitations and Gonditions VI This modification must be Inspected and Maintained in accordance with Onboard Systems International Instruction for Continued Airworthiness Section ATA 5 document No 123 030 00 Rev 04 dated 23 July 2010 or later FAA approved revision Onboard Systems International Cargo Hook Component Maintenance Manual document No 122 001 00 Rev 13 dated 13 Sep 2010 or later FAA approved revision for cargo hook kit P N 200 324 00 P N 200 325 00 and P N 200 325 01 Onboard Systems International Cargo Hook Service Manual document No 122 018 00 Rev 7 dated 17 Sep 2010 or later FAA approved revision for cargo hook kit P N 200 326 00 and Onboard Systems International Cargo Hook Service Manual document No 122 017 00 Rev 10 dat
55. ury Indicates a hazardous situation which if not avoided could result in minor or moderate injury Draws the reader s attention to important or N O C i unusual information not directly related to safety Used to address practices not related to personal injury 1 2 General Information Bill of Materials The following items are included with the Cargo Hook Suspension System Kits If shortages are found contact the company from whom the system was purchased Table 1 1 Suspension System Bill of Materials Part No Description 200 324 00 200 325 00 200 325 01 200 340 12V 28V 28V 00 120 137 00 Owner s Manual J 1 14 14 J 121 051 00 RFM Supplement 1 f 1 1 f FE 2568 0141 R44 Manual Release Assembly 1 Relay Washer Heat Shrink 4 Lg continued ES EE E a od ae EC Es ES ea EE Los RE pee ed ea i ER Er Es ES ES ES ss ES E ee E Et El ES o EE General Information 1 3 Bill of Materials continued Inspection Table 1 1 Suspension System Bill of Materials continued Part No Description 200 324 00 200 325 00 200 325 01 200 340 12V 28V 28V 00 215 010 00 Pd e 1 e a 215 012 00 Placard o oo o a a E 510 028 00 Screw o o o a oa E 510 029 00 Nut i o o o fo 4 T A E 510 17800 CoterPin dP ddd Sworo ES o E S o e S a E 510 17400 Washer dP ddd 510 18500 Washer Do Do
56. ware be changed 4 6 Load Weigh System Operation Instructions Indicator Dampening The Damp or dampening routine allows the pilot to adjust the Indicator dampening level to his preference The dampening routine is a program that stabilizes the Indicator reading It offers a trade off between Indicator responsiveness and stability Ten dampening levels are available from 0 through 9 At level 0 the display responds to the slightest change in weight However if the load bounced even slightly the display digits would respond instantly making the display look unstable With a dampening level of 9 the display would be stable under the most turbulent conditions however it would take several seconds for the display to respond to a change in weight The ideal dampening level will depend on the flying conditions A mid range setting of 5 or 6 is usually adequate To Look at or Change the Dampening Level With the Indicator powered up and in the Run Mode press both buttons at the same time to go to Setup Scroll through the menu using the Left button until the word DAMP is displayed To look at or change the Dampening Level press the Right button The display should look like this Figure 4 5 Changing Dampening Level Hook Load x 10 CAL DAMP The CAL and the DAMP legend is turned on and the previously set dampening level is displayed To return to Run without changing the current dampening level press both the Right and Left bu
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