Owners Manual Eurocopter AS350 Swing 120-106-02
Contents
1. us com FOR pOARDSYSTEMS COM or THIS MANUAL ab Li 1 4 TW ww W 7p SITE eg ATE ST RE VISION PL ASE Owner s Manual 3 600 Pound Keeperless Cargo Hook Kit on the Eurocopter AS350B3 Part Number 200 281 03 Owner s Manual Number 120 106 02 Revision 0 October 20 2009 Z CENBOARD SYSTEMS I N T E R NATIONAL 13915 NW 3 Court Vancouver WA 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 10 20 09 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 Section 6 General Information Introduction 1 1 Warnings Cautions and Notes 1 1 Specifications 1 2 Inspection 1 2 Bill of Materials 12. 2 5 Cargo Hook Installation continued The cargo hook is equipped with a suppression diode that will be damaged if the cargo hook electrical connection is 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 Un commanded cargo hook release will happen if the manual release cable is improperly restrained The cable must not be the stops that prevent the Cargo Hook from swinging freely in all directions If the Cargo Hook loads cause the hook to strain against the manual release cable the swaged end of the cable may separate allowing the inner cable to activate the cargo hook manual release mechanism The result is an un commanded release Ensure that no combination of cyclic stick or cargo hook position is restrained by the manual release cable Figure 2 8 Un Commanded Release From Incorrectly Secured Cable 1 Cargo hook rotates and strains against the manual release cable conduit 2 The strain on the conduit exceeds the pull off force between the swaged fitting and the conduit ENT 3 The swaged joint fails and allows the inner cable to activate the hook s mechanical release mechanism and the hook opens 4 The load ring falls free in an un commanded load release OS Installation Instructions Installation Check Out After installation of the cargo hook
3. COVER LINES ON THE COVER AS SHOWN ABOVE Operation Instructions 3 1 Cargo Hook Rigging 3 2 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 Figure 3 2 shows the recommended rigging but is not intended to represent all rigging possibilities 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 Nylon Type Straps and Rope Nylon type straps or similar material or rope must not be used directly on the cargo hook load beam If nylon straps or rope must be used they Should be first attached to a steel primary ring Verify that the ring will freely slide off the load beam when it is opened Only the primary ring Should be in contact with the cargo hook load beam Operation Instructions Cargo Hook Rigging continued Figure 3 2 Example of Recommended Cargo Hook Rigging Primary Ring secondary Ring Operation Instructions 3 3 Cargo Hook Loading The cargo hook can easily be loaded with one hand A load is attached to the hook by pushing the ring upward against the upper portion of the load beam throat as illustrated in Figure 3 3 until an internal latch engages the load beam and latches it in the closed positi
4. design fe the following s product witk the limitations and conditions therefore as specified hereon meets the airworthiness requirements of Fat 27 ofthe Federal Aviation Regulations Original Product Tyre Coriificate Num ter H9EU Make Eurocopter France Medel AS350B AS350B1 AS350B2 AS350B3 AS350BA and AS350D Description of the Type Design Change Fabrication of Onboard Systems Model 200 281 00 200 281 01 200 281 02 and 200 281 03 Cargo Hook Kits in accordance with FAA approved Onboard Systems Master Drawing List No 155 088 00 Revision 13 dated October 30 2009 or later FAA approved revision Installation of the systems in accordance with FAA approved Onboard Systems Owner s Manual No listed in the table below or later FAA approved revision This modification must be inspected and maintained in accordance with Section 5 of the FAA approved Onboard Systems Instructions for Continued Airworthiness ICA and Onboard Systems Cargo Hook Service Manual listed in the table below or later FAA approved revision See Continuation Sheet on Page 3 Limitations and Conditions Approval of this change in type design applies to the Eurocopter AS350 model rotorcraft listed above that are equipped with the Eurocopter 1400kg Cargo Swing System as installed per Eurocopter Service Bulletin 25 00 62 This approval should not be extended to other rotorcraft of these models on which other previously approved modifications are incorporated unless it i
5. perform the following functional checks 1 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 2 With no load on the cargo hook load beam pull the manual release lever on the collective and verify the cargo hook releases Reset the cargo hook load beam 3 With no load on the cargo hook load beam depress the cargo hook electrical release button the cargo hook must release Reset the cargo hook load beam Component Weights The weight of the Cargo Hook Kit components are listed below Table 2 2 Component Weights Cargo Hook Kit 4 7 pounds includes Cargo Hook Link Assembly and 2 2 kgs Manual Release Cable Cargo Hook Location See the Eurocopter provided Flight Manual Supplement for external load weight and balance data Paper Work In the US fill in FAA form 337 for the initial installation This procedure may vary in different countries Make the appropriate aircraft log book entry Insert the Rotorcraft Flight Manual Supplement P N 121 014 02 in the Rotorcraft Flight Manual Installation Instructions 2 7 This page intentionally left blank Section 3 Operation Instructions Operating Procedures Daily prior to the first cargo hook use of the d
6. 2 Theory of Operation 1 2 Installation Instructions Cargo Hook Removal 2 1 Cargo Hook Installation 2 1 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 Rigging 3 2 Cargo Hook Loading 3 4 Maintenance Instructions for Returning a System to the Factory 4 1 System Part Numbers 200 281 03 AS 350 Hook Replacement Kit 5 1 232 146 00 Link Assembly 5 2 232 148 00 Link Bumper Assembly 5 3 Certification STC 6 1 Canadian Approval 6 3 EASA Approval 6 4 iii This page intentionally left blank Section 1 General Information Introduction The 200 281 03 Cargo Hook Kit is approved as a replacement for the following cargo hook on Eurocopter AS350 Series helicopters equipped with a B3 type swing system The B3 type swing systems are installed on AS350 B3s and can be retrofitted to earlier models via Eurocopter Service Bulletin 25 00 62 AS 21 5 7 528 023 01 Onboard Systems 528 023 51 Onboard Systems 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 NOTE Draws the reader s attention to info
7. art Numbers 200 281 03 Cargo Hook Replacement Kit TNT K 2568 02702 ITEM Part Number DESCRIPTION QTY 1 232 149 00 Link Bumper Assembly 1 2 528 029 00 3 5K Keeperless Cargo Hook 1 3 230 077 00 Connector Assembly 1 4 268 024 02 Manual Release Cable Assembly 1 5 215 169 00 AS350 Light Indicator Placard 2 System Part Numbers 5 1 System Part Numbers continued 232 146 00 Link Assembly CE oY Item Part Number Description Qty 1 290 771 00 Adapter Link 2 517 052 00 Bushing 3 290 364 00 Bushing p nu 5 2 System Part Numbers System Part Numbers continued 232 149 00 Link Bumper Assembly ITEM P N DESCRIPTION QTY 1 510 178 00 Cotter Pin 1 2 510 170 00 Nut 1 3 510 174 00 Washer 1 4 510 183 00 Washer 2 5 290 775 00 Attach Bolt 1 6 232 146 00 Link Assembly 1 7 290 773 00 Replacement Bumper 1 System Part Numbers 5 3 This page intentionally left blank Section 6 Certification STC United States uf Americ Department of Cransportation Federal Aviation Administration Supplemental Cype Certificate Number SRO1166SE This certificate issued to Onboard Systems International 13915 NW 3 Court Vancouver WA 98685 certifies hat the change in the Le
8. ay perform the following Refer to the Eurocopter manuals for additional instructions 1 Activate the electrical system and press the Cargo Hook release button to ensure the cargo hook electrical release is operating correctly The mechanism should operate smoothly and the Cargo Hook must release Reset the hook by hand after the release If the hook does not release or re latch do not use the unit until the difficulty is resolved The cargo hook release solenoid is intended to be energized only intermittently Depressing the electrical release button continuously in excess of 20 seconds will cause the release solenoid to overheat possibly causing permanent damage 2 Activate the manual release lever to test the cargo hook manual release mechanism The mechanism should operate smoothly and the Cargo Hook must release Reset the load beam by hand after release Verify that the hook lock indicator on the side of the hook returns to the fully locked position If the hook does not release or re latch do not use the unit until the problem is resolved In the fully locked position the hook lock indicator must align with the lines on the manual release cover see Figure 3 1 Figure 3 1 Hook Lock Indicator Cover Lock Indicator Lock Indicator ACCEPTABLE NOT ACCEPTABLE LOCK INDICATOR DIAMOND LOCK INDICATOR DIAMOND IS NOT VISIBLE OR IS IS ALIGNED WITH ENGRAVED VISIBLE BUT IS NOT ALIGNED WITH ENGRAVED LINES ON THE
9. elease clamps on the belly Be sure to maintain full thread engagement between the manual release cable fitting and cargo hook Re install the manual release cover with the two screws and ensure the manual release cable jam nut is tightened securely against the cargo hook Installation Instructions Cargo Hook Installation continued Connect the electrical harness to the Cargo Hook per the following instructions Cut the hook end connector off of the existing Eurocopter release harness as close to the connector as possible Install the supplied connector and backshell assembly P N 230 077 00 at 24M onto the existing harness using the schematic below Table 2 1 Cargo Hook Connector Existing Eurocopter Harness Pin Function RENNES MESE ME93NF CE Cap and stow ME88G these wires ME89G CN Cap and stow the remaining wires for the load indicator lights from 32M and install INOP placards P N 215 169 00 over the load indicator lights 74M and 75M in the cockpit Route the electrical release cable connector through the slot in the Cargo Hook Bumper see below and connect the new cargo hook electrical release cable connector to the Cargo Hook and secure with safety wire See table 2 1 for connector pin out information Figure 2 7 Cargo Hook Bumper Slot Installation Instructions
10. ese two screws a AAAA ee o Thread the fitting at the end of the manual release cable into the manual release boss on the cargo hook side plate until the threads protrude approximately 125 inches beyond the boss and secure with jam nut as shown in Figure 2 3 Leave the manual release cover off of the cargo hook until the other end of the release cable is connected in order to verify proper setting Figure 2 3 Initial Release Cable Adjustment Manual Release Cable Approx 125 in 3 2mm 2 2 Installation Instructions Cargo Hook Installation continued o Connect the other end of the release cable to the fixed section of the existing AS350 manual release cable by mating the cable end fittings together as shown below slide back the Adapter Fitting to access fitting on removable cable Slide the Adapter Fitting forward and thread it onto the AS350B3 fitting and engage a castellation on the Adapter Fitting with the retaining pin and lock it in place o Snap the Adapter Fitting into the existing clip mounted to the belly of the helicopter Figure 2 4 Manual Release Cable Connection CABLE END FITTINGS FIXED CABLE PA EE fe Q RON er OA RARE IS Ra RN RON PRXKAXN RON MANN RON NUE WARY Ysa ANA EXISTING AS350B3 ADAPTER FITTING ADAPTER FITTING o At the cargo hook ensure the manual release cable is between the two prongs of the release lever fork as illustrated
11. in Figure 2 5 Manual release cable rigging must be done with the cargo hook in the closed and locked position Installation Instructions 2 3 Cargo Hook Installation continued 2 4 O With the cargo hook closed and locked rotate the release lever in the clockwise direction to remove free play the free play is taken up when the hook lock indicator begins to move this is also felt as the lever rotates relatively easily for several degrees as the free play is taken up and measure the gap between the cable ball end and the release lever fork with the manual release lever in the cockpit in the non release position This gap should be a minimum of 125 inches 3 2 mm as shown in Figure 2 5 Figure 2 5 Manual Release Cable Rigging Hook Lock Indicator Manual Release Cable Release Lever Fork Load beam must be closed and locked for rigging o If necessary adjust the manual release cable system to obtain the minimum gap of 125 inches at the release lever fork as shown in Figure 2 5 the maximum gap is limited by the manual release cover i e the release cable must fit within the cover when it is installed The system can be adjusted at the manual release lever on the collective or minor adjustments can be made at the cargo hook by loosening the jam nut and turning the manual release cable in the required direction this requires that the manual release cable be disconnected from the fixed release cable and the quick r
12. lenoid 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 A 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 switch is pressed it energizes the DC solenoid in the Cargo Hook and the solenoid opens the latch in the internal mechanism In an emergency release can be achieved by operating a mechanical release cable The release cable operates the internal mechanism of the Cargo Hook to unlatch the load beam The load can also be released by the actuation of a lever located on the side of the Cargo Hook 1 3 This page intentionally left blank Section 2 Installation Instructions These procedures are provided for the benefit
13. ment Onboard No 121 014 00 dated January 15 2003 and revised on July 23 2004 or later approved revisions Limitations and Conditions 1 This STC is approved only for the product configuration as defined in the approved design data referred to in the paragraph Description Compatibility with other aircraft engine configurations shall be determined by the installer This certificate shall remain valid unless otherwise surrendered or revoked For the European Aviation Safety Agency Date of Issue 15 March 2005 Le r Lah Qu Ox ApS M Mazzoletti Certification Manager Rotorcraft Ballons and Airships STC EASA IM R S 00623 Onboard Systems Certification 6 5
14. nstallation on Canadian registered aeronautical products This letter confirms formal acceptance of the referenced STCs by Transport Canada Should you require additional information with regards to this matter or clarification please do not hesitate to contact the undersigned at 604 666 5597 Yours truly Senior Engineer Aircraft Certification for Minister of Transport c c Mr Jeffrey E Duven Acting Manager Seattle ACO ie Canada 1 1 Certification 6 3 EASA Approval European Aviation Safety Agency SUPPLEMENTAL TYPE CERTIFICATE EASA IM R S 00623 This certificate established in accordance with Regulations EC No 1592 2002 and EC No 1702 2003 and issued to Onboard Systems 13915 NW 3rd Court Vancouver WA 98685 USA 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 DGAC TC No 84 Manufacturer Eurocopter France Model Eurocopter AS 350 B3 Helicopter Description of Design Change Cargo Hook Kit installation in accordance with FAA STC No SR1I166SE issued January 22 2003 6 4 Certification EASA Approval continued European Aviation Safety Agency Associated Technical Documentation AS 350 B3 Flight Manual and RFM Supple
15. of experienced aircraft maintenance facilities capable of carrying out the procedures They must not be attempted by those lacking the necessary expertise Cargo Hook Removal Remove the existing cargo hook and manual release cable from the helicopter by disconnecting the hook from the load cell on the swing suspension and the manual release cable at the fitting on the belly of the aircraft Disconnect the electrical release cable at the hook Remove rubber bumpers from the swing assembly Cargo Hook Installation Inspect the swing assembly components to ensure that they are in serviceable condition Attach the new Cargo Hook P N 528 029 00 with Link Bumper Assembly P N 232 149 00 to the load cell re using the Eurocopter hardware see below The cargo hook load beam should point to the left side of the aircraft Figure 2 1 Swing Mount Cargo Hook Installation Assembly AS350B3 SWING ASSEMBLY RUBBER BUMPER REMOVE P AS350B3 LOAD CELL Forward RE USE HARDWARE CARGO HOOK Installation Instructions 2 1 Cargo Hook Installation continued Connect the manual release cable P N 268 024 02 to the cargo hook per the following instructions o Remove the manual release cover from the cargo hook by removing two screws see below Figure 2 2 Manual Release Cover Removal Remove th
16. on Figure 3 3 Cargo Hook Loading 3 4 Operation Instructions Section 4 Maintenance Refer to the Instructions for Continued Airworthiness ICA manual 123 013 02 for maintenance of the cargo hook kit For maintenance specific to the cargo hook refer to Cargo Hook Service Manual 122 017 00 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 e Write the RMA number on the outside of the box or on the mailing label Include the RMA number and reason for the return on your purchase or work order e 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 System P
17. raft 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 ooo 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 PAGE 3 OF 3 PAGES 6 2 Certification Canadian Approval ivi Transport Transports Canada Canada Aviation Aviation Aircraft Certification Branch 620 800 Burrard Street Vancouver BC V6Z 2J8 Your file Votre r f rence 190S 03 169 Our file Notre r f rence March 24 2003 Onboard Systems 13915 NW 3 Court Vancouver WA 98685 USA Attention Mr Ron Pirtle Subject Acceptance of Foreign STCs SR01164SE SRO1165SE and SRO1166SE Dear Sir This is in response to your letters dated February 25 2003 making application for Canadian approvals of the subject STCs In accordance with our current policy associated with the review of foreign STCs some STCs applicable to certain categories of rotorcraft 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 STCs fall within these criteria These STCs will be entered in the national index of STCs that have been reviewed and accepted by Transport Canada for i
18. rmation which may not be directly related to safety but which is important or unusual 1 1 Specifications Table 1 2 P N 528 029 00 Cargo Hook Specifications Design load 3 600 Ib 1 633 kg Design ultimate strength 13 500 Ib 6 123 kg Electrical release capacity 9 000 Ib 4 082 kg Mechanical release capacity 9 000 Ib 4 082 kg Force required for mechanical 8 lb max 600 travel release at 3 500 Ib Mating electrical connector Load capacities given are for the equipment described only Loading limits for your particular helicopter model still apply Consult your flight 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 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 Table 1 2 200 281 03 Bill of Materials 121 014 02 Flight Manual Supplement 1 232 149 00 Link Bumper Assembly ol 1 1 1 1 1 1 1 2 230 077 00 Connector Assembly 528 029 00 Cargo Hook 215 169 00 AS350 Light Indicator Placard ES Eater Lt _268 024 02 Manual Release Cable Assembly 1 EE Pa si 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 so
19. s 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 accordance with a copy of an FAA approved Onboard Systems Rotorcraft Flight Manual Supplement RFMS listed in the table below or later FAA approved revisions See Continuation Sheet on Page 3 This certificate and the Uypporting data which is the hasis fer approval shall remain We flect until surrendered sugende L revoked or a termination date is otherwise established hy lhe Administrator cf the Federal Aviation Adininistration Date fe application August 15 2002 Date reissued Date of issuance January 22 2003 Yate amended December 21 2007 April 15 2010 By direction of the Administrator Signature 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 6 1 STC continued United States of Americ Bepartnent of Transportation Federal Aviation Administration Supplemental Type Certificate Continuation Sheet Number SRO1166SE Onboard Sy
20. stems International Sisued January 22 2003 Ketisuedk January 2001 Ano Or Amended December 21 2007 April 15 2010 Description fi the Type Design Change continued SYSTEM PART NUMBER OwNER S MANUAL No INSTRUCTIONS FOR CONTINUED AIRWORTHINESS AND CARGO HOOK SERVICE MANUAL 200 281 00 200 281 01 200 281 02 120 106 00 Revision 8 dated January 11 2008 123 013 00 Revision 3 dated July 01 2005 122 005 00 Revision 15 dated April 23 2009 120 106 01 Revision 3 dated September 29 2009 123 013 01 Revision 1 dated October 25 2007 122 015 00 Revision 7 dated January 30 2009 120 106 01 Revision 3 dated September 29 2009 200 281 03 120 106 02 Revision 0 dated October 20 2009 123 013 01 Revision 1 dated October 25 2007 122 015 00 Revision 7 dated January 30 2009 123 013 02 Revision 0 dated March 05 2010 122 017 00 Revision 5 dated July 27 2009 Limitations and Conditions continued SYSTEM PART NUMBER ROTORCRAFT FLIGHT MANUAL SUPPLEMENT 200 281 03 200 281 00 121 014 00 Revision 1 dated July 23 2004 200 281 01 121 014 01 Revision 0 dated December 13 2007 200 281 02 121 014 01 Revision 0 dated December 13 2007 121 014 02 Revision 0 dated March 04 2010 A copy of this certificate FAA approved RFMS ICA and Service Manual must be maintained as part of the permanent records of the modified rotorc
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