Cargo Hook Suspension System

For the
Bell 206 A/B Series With
Talon LC Keeperless
Cargo Hook

Kit Part Numbers

200-268-01, Without Load Weigh
200-269-03, With Load Weigh
Owner's Manual
Owner's Manual Number 120-099-01
Revision 3
September 8, 2015

13915 NW 3rd Court Vancouver Washington 98685 USA

Phone: 360-546-3072 Fax: 360-546-3073 Toll Free: 800-275-0883
www.OnboardSystems.com
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 Record of Revisions

Revision Date Page(s) Reason for Revision

0 07/19/11 All Initial Release.

1 05/20/13 1-3, 2-7, 5-2, Added load indicator P/N 210-095-02, changed P/N
5-9, 5-10 210-095-00 to optional. Updated definition of
external load operations.
2 11/18/13 5-12 & 5-13 Added suspension re-assembly instructions including
caution for tightening nut on pin load cell.
3 09/08/15 1-3, 1-4, 5-4 Added pin load cell P/N 210-301-01 and link
thru 5-11 assembly P/N 232-061-01.

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ii
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CONTENTS
Section 1 General Information
Introduction, 1-1
Safety Labels, 1-1
Specifications, 1-2
Bill of Materials, 1-3
Inspection, 1-4
Theory of Operation, 1-4

Section 2 Installation Instructions

Cargo Hook Suspension System Removal, 2-1
Cargo Hook Suspension System Installation, 2-1
Load Weigh System Internal Harness Installation, 2-7
C-39 Cockpit Indicator Installation, 2-7
Indicator Internal Back Light, 2-7
Indicator Hook-Open Warning Installation, 2-8
Remote Analog Meter Installation, 2-8
Electrical Connections, 2-9
Installation Check-Out, 2-10
Component Weights, 2-11
Cargo Hook Location, 2-11
Paper Work, 2-11

Section 3 Load Weigh System Operation Instructions

Indicator Front Panel, 3-1
The Run Mode, 3-2
To Zero or Tare the Display, 3-3
To Un-Zero the Display, 3-3
Error Codes, 3-4
The Setup Mode, 3-5
Indicator Dampening, 3-7
To look at, or change the dampening level, 3-7
Indicator Calibration, 3-7
To look at or change the calibration code, 3-8
Installation Zero, 3-9
To run the installation zero routine, 3-9
Calibration by Lifting a Known Weight, 3-9
To run calibration by known weight routine, 3-10
Setting the Scale on a Remote Analog Meter, 3-11
To look at or change the scale, 3-11
Select KG or LB Units, 3-12
To look at or change the units, 3-12
Indicator Version, 3-13

iii
CONTENTS, continued
Section 4 Cargo Hook Operation Instructions
Operating Procedures, 4-1
Cargo Hook Loading, 4-3
Cargo Hook Rigging, 4-3

Section 5 Maintenance
Lubrication, 5-1
Inspection, 5-2
Cargo Hook Suspension System Parts, 5-5
Cargo Hook Suspension System Inspection, 5-10
Trouble Shooting, 5-11
Cargo Hook Suspension System Reassembly, 5-12
Instructions for Returning a System to the Factory, 5-13

Section 6 Certification
FAA STC, 6-1
Transport Canada STC, 6-3
EASA STC, 6-5

iv
Section 1
General Information
Introduction
The 200-268-01 and 200-269-03 Suspension System Kits are approved for
installation on the Bell Model 206 A & B series helicopters. These kits
replace the Bell 206-072-900-1, -101 or -103 Auxiliary Equipment Kit-
Cargo Hook. It must be installed with the Bell part number 206-706-335-3, -
5, -105 or -109 Auxiliary Equipment Kit- Cargo Hook Provisions.
The 200-269-03 suspension system kit is the same as the 200-268-01
suspension system kit except it includes a load weigh system.

Safety Labels
The following definitions apply to the symbols used throughout this manual
to draw the reader’s attention to safety instructions as well as other
important messages.
Indicates a hazardous situation which, if not
avoided, will result in death or serious injury.

Indicates a hazardous situation which, if not

avoided, could result in death or serious injury.

Indicates a hazardous situation which, if not

avoided, could result in minor or moderate injury.

Draws the reader’s attention to important or

unusual information not directly related to safety.

Used to address practices not related to personal

injury.

General Information 1-1

Specifications
Table 1-1 Suspension System Specifications
Design load 1,500 lb. (680 kg.)
Design ultimate strength 5,625 lb. (2,550 kg.)
Unit Weight P/N 200-268-01 17.5 lb. (7.9 kg.)
Unit Weight P/N 200-269-03 18.6 lb. (8.4 kg.)

Table 1-2 P/N 528-029-00 Cargo Hook Specifications

Design load 3,600 lb. (1,580 kg.)
Design ultimate strength 13,500 lb. (6,123 kg.)
Electrical release capacity 9,000 lb. (4,082 kg.)
Mechanical release capacity 9,000 lb. (4,082 kg.)
Force required for mechanical 8 lb. Max.(.600” travel)
release at 3,600 lb.
Electrical requirements 22-32 VDC 6.9 – 10 amps
Minimum release load 0 pounds
Unit weight 3.0 pounds (1.35 kg.)
Mating electrical connector PC06A8-2S SR

1-2 General Information

Bill of Materials
The following items are included with the Cargo Hook Kits. If shortages
are found contact the company from whom the system was purchased.
Table 1-3 Kit Bill of Materials
200-268-01 200-269-03
Part No. Description W/out Load With Load
Weigh Weigh
210-301-01*** Pin Load Cell Assembly - 1
210-095-00** C-39 Indicator, 28V Lights - opt
210-095-02** C-39 Indicator, 5V Lights 1
215-010-00 Placard - 2
215-012-00 Placard - 1
235-035-00 QD Bracket - 1
270-048-04 Load Weigh Internal Harness - 1
512-001-00 Ty-Wrap - 10
400-048-00 Power Switch - 1
510-028-00 Screw - 6
510-029-00 Nut - 6
510-062-00 Washer - 8
215-117-00* Decal-Limit Load 2 2
232-047-00* Frame Assembly 1 1
232-061-01* Link Assembly 1 1
232-062-00* Bungee Cord Assembly 1 1
268-015-00* Manual Release Cable 1 1
270-074-01* Electrical Release Cable 1 1
290-331-00* Release Fitting 1 1
290-332-00* Attach Bolt 2 1
290-431-00* Fitting Tube End 2 2
290-489-00* Bumper Bushing 2 2
510-042-00* Washer 6 6
510-102-00* Nut 2 2
511-073-00* Bolt 2 2
510-170-00* Nut 2 2
510-174-00* Washer 2 2
510-178-00* Cotter Pin 2 2
510-183-00* Washer 3 2
510-223-00* Bolt 2 2
510-227-00* Nut 2 2
510-257-00* Bolt 2 2
510-261-00* Washer 2 2
510-295-00* Quick Release Pin 2 2
512-010-00* Adel Clamp 2 2

General Information 1-3

Bill of Materials continued
Table 1-3 Kit Bill of Materials continued
200-268-01 200-269-03
Part No. Description W/out Load With Load
Weigh Weigh
531-016-00* Nicopress Sleeve 4 4
528-029-00* Cargo Hook 1 1
531-010-00* Lanyard Cable, 7.5” lg. 2 2
600-006-00* Quick Disconnect 1 1
120-099-01 Owner’s Manual 1 1
121-009-01 RFM Supplement 1 1
122-017-00 CMM, Cargo Hook 1 1
600-006-00 Release Cable Disconnect 1 1
* These items are shipped assembled together as the cargo hook suspension system. If necessary,
refer to Section 5 for part identification.
** Indicators 210-095-00 and 210-095-02 are both compatible with kit 200-269-03. Verify
Indicator voltage matches aircraft lighting system voltage.
*** Supersedes P/N 210-226-01.

Theory of Operation
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 the load beam.
The load is attached to the load beam by passing the cargo sling ring into the
throat of the load beam and pushing the ring against the upper portion of the
load beam throat, which will initiate the hook to close. In the closed
position, a latch engages the load beam and latches it in this position.
To release the load, the latch is disengaged from the load beam. With the
latch disengaged, the weight of the load causes the load beam to swing to its
open position, and the cargo sling slides off the load beam. The load beam
then remains in the open position awaiting the next load.
A load release can be initiated by three different methods. Normal release is
achieved by pilot actuation of the push-button switch in the cockpit. When
the push-button 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.

1-4 General Information

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.

Cargo Hook Suspension System Removal

If the aircraft is equipped with an Auxiliary Equipment Kit- Cargo Hook
supplied by Bell Helicopters, remove it.

Cargo Hook Suspension System Installation

1. Open the cargo hook release circuit breaker and position the battery
switch to the off position.
2. If a Bell provisions kit is not already installed, install the Bell Helicopter
provisions kit (206-706-335-3, -5, -105, or –109) as outlined in the Bell
kit instructions.
3. Place the aft pin of the 232-047-00 Frame Assembly into the aft hard
point at Station 130.0. Align the forward attach fittings with the forward
airframe hard points and insert the 510-295-00 Quick Release Pins. See
Figure 2-2.
4. Attach the 268-015-00 mechanical release cable end ball to the 600-006-
00 coupler (see Figure 2-1). Attach the coupler to the cable end ball on
the Bell Provisions Installation.
Figure 2-1 Mechanical Release Cable Connection
Coupler
2. Insert Cable Ball End

1. Compress spring.
Forward
Existing Fixed Manual Release Cable

Installation 2-1
Cargo Hook Suspension System Installation, continued
Figure 2-2 Cargo Hook Suspension System Installation

STATION 91.9

Electrical Release Cable Assembly

P/N 270-074-01
Quick Disconnect
P/N 600-006-00

Quick Release Pin

P/N 510-295-00
(2 PLACES)

Manual Release Cable

P/N 268-015-00

FWD

LOOKING DOWN

Aft Pin of
Frame Assembly (P/N 232-047-00)
STATION 130.0

2-2 Installation
Cargo Hook Suspension System Installation, continued
5. To check the manual release cable rigging at the cargo hook, remove the
manual release cover from the new cargo hook.
6. Move the manual release lever in the clockwise direction to remove free
play, free play is removed when the hook lock indicator begins to move
(this is felt as the lever moves relatively easily for several degrees
before hitting the internal cam stop). Measure the cable ball end free
play with the manual release handle in the cockpit in the non-release
position. There must be a minimum gap of .125 inches (3.2 mm) of free
play at the fork fitting as shown in Figure 2-3.
7. Re-install the manual release cover.

Manual release cable rigging must be done with

the cargo hook in the closed and locked position.

Mis-rigging of the manual release cable will result

in inadvertent release of load.
Figure 2-3 Manual Release Cable Rigging
Release Lever
Hook Lock Indicator

Cable Ball End

Manual Release Cable

.125 in. min.
(3.2 mm)

Release Lever Fork

Load beam must be closed

and locked for rigging.
8. Connect the 270-074-01 cargo hook electrical release cable connector to
the Bell provisions kit connector mounted on the bottom of the
helicopter. Listed below is the pin out for the cargo hook connector.
Table 2-1 Cargo Hook Connector
Pin Function
A Ground
B Positive

Installation 2-3
 Cargo Hook Suspension System Installation, continued

Early versions of the Cargo Hook were equipped

with a suppression diode that will be damaged if
the Cargo Hook electrical connections are
reversed. Do not attach the electrical connector
until the polarity of the aircraft connector is
determined to be compatible with the connector
listed in Table 2-1.

Route the Manual and the Electrical Release cables as illustrated in Figures
2-4 and 2-5.
Figure 2-4 Manual and Electrical Release Cable Routing, without Load Weigh

2-4 Installation
Cargo Hook Suspension System Installation, continued
Figure 2-5 Manual and Electrical Release Cable Routing, with Load Weigh

LOAD LIMIT 1500 LB

FWD

510-028-00
510-029-00
235-035-00 510-062-00
(6 PLACES)

Installation 2-5
Cargo Hook Suspension System Installation, continued

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 2-6 Un-commanded Release From Incorrectly Secured Cable

2-6 Installation
Load Weigh System Internal Harness Installation
The Internal Harness (P/N 270-048-04) is made up of four cables terminated
to one large connector. The large connector is plugged into the back of the
Indicator. One of the cables is marked “LOAD CELL” and is fitted with a
bulkhead connector. Hardware is provided to attach the bulkhead connector
to the Quick Disconnect Bracket, P/N 235-035-00. Attach the Quick
Disconnect Bracket to the bracket that holds the manual and electrical
release fittings on the skin of the aircraft at the cargo hook area.
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 can be connected to the optional Data Recorder or
Analog Slave Meter. These optional items are not included under this STC.

The data cable may or may not be terminated with

a connector depending on manufacture date.
Route the cables in the most convenient manner. Secure the cables to the
existing wiring bundles with the Ty-wraps. Secure the cables clear of flight
control rods.

C-39 Cockpit 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 2¼" instrument
hole. Connect the Indicator to its Internal Harness, refer to Internal Harness
Installation.

Indicator Internal Back Light

The Indicator is equipped with an Internal Back Lighting System that can be
connected to the aircraft light dimming circuit. Indicator 210-095-02 is
compatible with a 5VDC dimming circuit, while 210-095-00 is compatible
with a 28VDC dimming circuit. Use a 22 gauge, twisted pair, shielded
cable to connect the aircraft dimming circuit to the Internal Harness.
Connect the cable shield wire to airframe ground at the light dimmer end of
the cable ONLY.

Installation 2-7
Indicator Hook-Open Warning Installation
The 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 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.

Remote Analog Meter Installation

The Indicator is equipped with an Analog drive circuit that can be connected
to a remote analog meter. Use a 22 gauge, twisted pair, shielded cable to
connect the Remote Analog Meter to the Indicator. Disassemble the
Indicator mating connector and carefully solder the positive wire, from the
analog meter, to pin G and the common wire to pin F. Connect the cable
shield wire to airframe ground as close to the Analog Meter as possible, at
the Analog Meter end of the cable ONLY.
The indicator can be connected to Onboard System’s Analog Meter, P/N
210-180-00, through the “DATA” cable. This meter gives solid weight
indications without needle bounce. The Analog Meter may be mounted in
any convenient location in a standard 3” instrument hole. Attach connector,
P/N 410-130-00, to data line per pin out in Figure 2-6 to connect the Analog
Slave Meter to the Internal Harness “DATA” cable. If a data connector is
present on the data line use cable, P/N 270-059-00, to connect to Analog
Slave Meter.

2-8 Installation
Electrical Connections
Connect the Internal Harness (P/N 270-048-04) to the Indicator and route
the other end to a convenient location for the Indicator power switch part
number 400-048-00. The cable is supplied extra long, cut off the excess
cable and use as needed to connect the switch and circuit breaker. Connect
the white (red wire, if wire harness 270-048-00 is installed) wire in the
power cable 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. Connect the white/blue (black wire, if wire harness
270-048-00 is installed) wire to the ground bus. The bare wire (present on
harness P/N 270-048-00 only) should be cut off as it is not needed at this
end of the wire. Install the placard 215-010-00 “ELECTRONIC
WEIGHING SYSTEM” next to the power switch and circuit breaker.
Install the placard 215-012-00 “TURN THE WEIGHING SYSTEM OFF
WHEN NAVIGATION EQUIPMENT IN USE” “NO AIRCRAFT
OPERATION SHOULD BE PREDICATED ON THE READING OF THE
ONBOARD WEIGHING SYSTEM” next to the Indicator.

If the C-23 Printer is being utilized with the C-20

or C-30 Data Recorder, a 5 amp circuit breaker
should be used.
Figure 2-7 Wiring Arrangement
POWER SWITCH
(SUPPLIED)
1 AMP CIRCUIT BREAKER
(OPERATOR SUPPLIED) CUT OFF THE BARE WIRE (IF PRESENT),
DO NOT CONNECT IT TO GROUND.
White (Red)
TO 28 VDC
TO AIRFRAME GROUND White/Blue (Black)
POWER CABLE

BACK LIGHT POTENTIOMETER

(OPERATOR SUPPLIED)

INTERNAL HARNESS ASSEMBLY

White (Red) LIGHT CABLE (WITH OPTIONAL CABLE INSTALLED)
TO 28 VDC
TO AIRFRAME GROUND White/Blue (Black)

DATA RECORDER/
ANALOG METER CABLE
TO OPTIONAL EQUIPMENT
DEPENDING ON MFG DATE OR DASH
NUMBER THIS CABLE MAY TERMINATE
IN A CONNECTOR

OPTIONAL EQUIPMENT CONNECTORS

TO LOAD CELL

DATA RECORDER CONNECTOR

P/N 410-011-00, 410-057-00
& 410-020-00
ANALOG METER CONNECTOR PIN COLOR FUNCTION
P/N 410-130-00
MFG: ANY MFG P/N:MS3126F10-6P 1 WH/BL (Black) Ground
PIN COLOR FUNCTION 3 WH (Red) Power
A WH (Red) Power 5 Shield Shield
B WH/GN (Green) Clock 7 WH/GN (Green) Clock Signal
C WH/OR (White) Data 9 WH/OR (White) Data Signal
D WH/BL (Black) Ground 4 Red* Flight Switch
E Shield Shield 2 Purple* Cap. Switch
*Optional

Installation 2-9
Installation Check-Out
After installation of the Cargo Hook Suspension System, perform the
following functional checks.
1. Swing the installed Cargo Hook to its full extremes 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 handle operated
cargo hook mechanical release located in the cockpit, the Cargo Hook
should release. Reset the cargo hook load beam.

3. Close the cargo hook release circuit breaker and position the battery
switch to the ON position. With no load on the cargo hook load beam,
depress the cargo hook electrical release button, the Cargo Hook should
release. Reset the cargo hook load beam
4. See the Bell Helicopter service instructions for your specific helicopter
model for additional installation instructions.
5. Perform an EMI ground test per AC 43.13-lb section 11-107. For
equipment that can only be checked in flight an EMI flight test may be
required.

The cargo hook and load cell are of a class of

equipment not known to have a high potential for
interference. This class of equipment does not
require special EMI installation testing (i.e.
FADEC) as required in paragraphs 7 and 8 of FAA
policy memorandum ASW-2001-01.
6. Power on the Indicator and allow to warm up for 5 minutes (with no load
on the hook). Press both Indicator buttons at the same time to go to the
Setup Mode. Scroll through the menu until the symbol “0 in” is
displayed, then press the right button. Remove any weight that is not to
be zeroed out and press either button to complete the procedure.

2-10 Installation
Component Weights
The weights of the Cargo Hook Suspension System kits are listed below.
Table 2-2 Component Weights
Item Description Weight
200-268-01 Suspension System w/o Load Weigh 17.5 lbs (7.94 kgs)
200-269-03 Suspension System w/ Load Weigh 18.6 lbs (8.44 kgs)

Cargo Hook Location

Table 2-3 Cargo Hook Location
Fuselage Station 108.5

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 121-009-01 into
the rotorcraft flight manual.

Installation 2-11
This page intentionally left blank.
Section 3
Load Weigh System Operation Instructions
Indicator Front Panel
The C-39 Indicator front panel includes the following features.
 The four 7 segment LCD digits show the weight on the Cargo Hook and
displays various Setup information.

 The Legends clarify the digital display. i.e. when the LB Legend is
turned on, the display will be pounds, etc.

 The Right button is used to Zero the display in the Run Mode and select
the digit to be changed in the Setup Mode.

 The Left button is used to Un-Zero the display in the Run Mode and
scroll the selected digit in the Setup Mode.

Figure 3-1 Front Panel

Calibration & Zero & Un-Zero Legend

Dampening
Legend
Unit Legend

Digits

Left Button Right Button

Load Weigh System Operation Instructions 3-1

The Run Mode
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 3-2 After Diagnostic Routine

The illustration is of the Indicator in the Run Mode with no load on the
hook. Note the LB legend displayed.

Figure 3-3 LB Legend Displayed

The illustration is a typical hook load reading. The display is 3,500 pounds,
note the last digit is not displayed.

3-2 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 3-4 Zeroing the Display

Zero Legend

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 3-3

The Run Mode continued
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 below 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 3-1 Indicator Error Codes

POSSIBLE
DISPLAY CAUSE CORRECTIVE ACTION
Err 1 A/D or D/A circuit 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.

Err 2 NV Ram failure Power cycle the Indicator; if

Error Code continues, return
the Indicator to the factory.

Err 3 NV Ram write failure Re-enter data, if Error Code

continues, return the Indicator
to the factory.

Err 4 NV Ram busy failure Power cycle the Indicator, if

Error Code continues return
the Indicator to the factory.

3-4 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 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 3-5

The Setup Mode, continued
Table 3-2 Indicator Setup Routines

MENU FUNCTION DISPLAY

Press the Left button to 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 the Indicator to Display is a combination of load on the
0 in 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
installed Load Cell except the Cargo
when no load is on the Cargo Hook.
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" i.e.; 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 software. be changed.

3-6 Load Weigh System Operation Instructions

The Setup Mode, continued
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 3-5 Changing Dampening Level

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 buttons 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 3-7

The Setup Mode, continued
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 3-6 Changing the CAL Code

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 and 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.

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.

3-8 Load Weigh System Operation Instructions

The Setup Mode, continued
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 Installation 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 3-9

The Setup Mode, continued
To Run the Calibration by Lifting a Known Weight 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 word LOAD
is displayed, then press the Right button. The display should look like this:
Figure 3-7 Running CAL Routine

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 3-8 Entering Load in CAL Routine

3-10 Load Weigh System Operation Instructions

The Setup Mode, continued
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,
power 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, press 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 3-9 Changing the Scale

Load Weigh System Operation Instructions 3-11

The Setup Mode, continued
To Look at or Change the Scale, continued
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.

Select KG or LB Units
The units routine sets the display to read in pounds (LB) or kilograms (KG).

To look at or change the Units

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 3-10 Changing the Units

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
selection has been made, press both the Right and Left button at the same
time to return to Run.

The selected units are displayed when in the Run

Mode.

3-12 Load Weigh System Operation Instructions

The Setup Mode, continued
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 3-11 Looking at Indicator Version

Load Weigh System Operation Instructions 3-13

This page intentionally left blank.
Section 4
Cargo Hook Operation Instructions
Operating Procedures
Prior to a flight involving external load operations perform the following:
1. Activate the electrical system and press the Cargo Hook release button
to ensure the cargo hook electrical release is operating correctly. 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. In the fully locked position the hook lock indicator must align
with the lines on the manual release cover (see Figure 4.1). 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 4.1).
Figure 4.1 Hook Lock Indicator

Operation Instructions 4-1

Operating Procedures continued
3. Visually inspect the manual release cable for damage, paying close
attention to the flexible conduit at the area of transition to the cargo hook
end fitting (refer to Figure 4.2). Inspect for splitting of the outer black
conduit in this area and separation of the conduit from the steel end
fitting.
Figure 4.2 Manual Release Cable Inspection
Pay close attention to this area
of the manual release cable.

Manual release cables are wearable items and

must be replaced as condition requires. Broken or
kinked conduit, inner cable kinks (ref Figure 4.3),
frays, or sticky operation are each cause for
immediate replacement.
Figure 4.3 Manual Release Cable Conditions
Kinked inner cable.

Broken or kinked conduit.

4-2 Operation Instructions

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 4.4, until an internal latch engages the
load beam and latches it in the closed position.
Figure 4.4 Cargo Hook Loading

Cargo Hook Rigging

Extreme care must be exercised when rigging a load to the Cargo Hook.
Steel load rings are recommended to provide consistent release performance
and resistance to fouling. The following illustration shows the
recommended rigging and rigging to avoid, 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.

Cargo Hook Operation Instructions 4-3

Cargo Hook Rigging, continued
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.
Figure 4.5 Examples of Cargo Hook Rigging

Recommended Avoid

Primary Ring

Long Line

4-4 Cargo Hook Operation Instructions

Section 5
Maintenance
The following 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. It is
recommended that only minor repairs be attempted by anyone other than the
factory.

Refer to Component Maintenance Manual 122-017-00 for detailed

maintenance information for the Cargo Hook.

Lubrication
Lubrication of the Suspension System is recommended every 500 hours of
external load operations. To obtain maximum life under severe duty
conditions such as logging or seismic work, it is recommended to lubricate
the suspension system pivot points every 200 hours. Recommended
lubricants are AeroShell 17, MIL-G-21164 or Mobilgrease 28, MIL-G-
81322.

Maintenance 5-1
Inspection
The scheduled inspection/overhaul intervals noted below are maximums and
are not to be exceeded. If the system is subjected to unusual circumstances,
extreme environmental conditions, etc., it is the responsibility of the
operator to perform the inspections more frequently to ensure proper
operation.
Annually or 100 hours of external load operations, whichever comes
first, inspect the suspension system per the following instructions (see
Figures 5.2 through 5.4 for part identification and Table 5.2 for
inspection criteria).

Hours of external load operations should be

interpreted to be (1) anything is attached to the
cargo hook (whether or not a useful load is being
transported) and (2) the aircraft is flying. If these
conditions are not met, time does NOT need to be
tracked.
1. Move the cargo hook throughout its full range of motion to ensure the
electrical harness and manual release cable have enough slack. The
harness and cable must not be the stops that prevent the cargo hook from
swinging freely in all directions.
2. Visually inspect the electrical harness strain relief at the load cell (if
installed) for damage.
3. Visually inspect the external electrical harnesses for damage, chafing and
security.
4. Visually inspect the electrical connections of the cargo hook and load cell
(if installed) at the belly of the helicopter for damage and security.
5. Visually inspect the load cell cover for corrosion, damage and security (if
kit 200-269-03 is installed).
6. Visually inspect the load link for corrosion, damage and cracks (refer to
Table 5.2 for inspection criteria).
7. Visually inspect suspension frame assembly for cracks, wear and
corrosion. If worn excessively or cracked, replace parts (refer to Table
5.2 for inspection criteria). Remove corrosion and treat with zinc
chromate primer.

5-2 Maintenance
Inspection continued
8. Activate the electrical system and press the Cargo Hook release button
to ensure the cargo hook electrical release is operating correctly. 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.
9. 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. In the fully locked position the hook lock indicator must align
with the lines on the manual release cover (see Figure 5.1). 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 5.1).
Figure 5.1 Hook Lock Indicator

10. Verify calibration of the load cell (if installed) by lifting a load of
known weight (see Section 3 for instructions).

Maintenance 5-3
Inspection continued
The overhaul interval for the suspension system shall be 5 years or 1000
hours of external load operations, whichever comes first. See
Component Maintenance Manual 122-017-00 for cargo hook overhaul.
At the overhaul interval, in addition to the items listed for the annual/100
hour inspection, perform the following:
1. Disassemble and inspect the suspension system components to the
requirements outlined in Table 5.2. Carefully inspect the detail parts in
a clean, well-lit room. Inspect bushings, bearing surfaces and the pivot
bolts for wear and corrosion. Pitting, corrosion or excessive wear on
pivot bolts is cause for rejection. Maximum permissible bushing
clearances are .015 inches on diameter.
2. Magnetic particle inspect in accordance with ASTM-E1444 and MIL-
STD-1907, Grade A, the following part(s). No cracks are permitted.
 Link Assembly (P/N 232-061-00 or P/N 232-061-01) or Pin Load
Cell Assembly (P/N 210-226-01 or P/N 210-301-01) if kit P/N 200-
269-03 is installed. For the Pin Load Cell Assembly, inspect
shoulder of pin and do not remove cover.
 Frame Assembly (P/N 232-047-00)
3. Inspect internal electrical harness from the load weigh indicator to the
load cell for general condition, security of attachment, and chafing along
the length of wire runs.

5-4 Maintenance
Cargo Hook Suspension System Parts
Figure 5.2 Cargo Hook Suspension System Parts

Maintenance 5-5
Cargo Hook Suspension System Parts, continued
Figure 5.3 Cargo Hook Suspension System Parts without Load Weigh

5-6 Maintenance
Cargo Hook Suspension System Parts, continued
Figure 5.4 below shows the suspension system with load weigh (P/N 200-269-03) with pin
load cell P/N 210-226-01. Pin load cell P/N 210-226-01 has been superseded by P/N 210-
301-01, the configuration is the same with P/N 210-301-01 except with changes as shown in
Figure 5.5.
Figure 5.4 Cargo Hook Suspension System Parts With Load Weigh

Figure 5.5 Cargo Hook Suspension with Pin Load Cell P/N 210-301-01

Maintenance 5-7
Cargo Hook Suspension System Parts, continued
Figure 5.6 Cargo Hook Suspension System Parts With Load Weigh continued
31

35

34
36

37

5-8 Maintenance
Cargo Hook Suspension System Parts, continued
Table 5.1 Cargo Hook Suspension System Parts
Item Part No. Description 200-268-01 200-269-03
1 528-029-00 Cargo Hook 1 1
2 290-331-00 Release Fitting 1 1
3 232-047-00 Frame Assembly 1 1
4 510-223-00 Bolt 2 2
5 510-261-00 Washer 2 2
6 510-227-00 Nut 2 2
71 290-431-00 Fitting - Tube End 2 2
8 290-489-00 Bumper Bushing 2 2
9 510-627-00 Bolt 2 2
10 510-042-00 Washer 6 6
11 510-102-00 Nut 2 2
12 232-062-00 Bungee Cord Assembly 1 1
13 510-295-00 Pin - Quick Release 2 2
14 531-010-00 Lanyard Cable 2 2
15 531-016-00 Nicopress Sleeve 4 4
3
16 232-061-00 Link Assembly opt opt
232-061-01 Link Assembly 1 1
17 290-332-00 Attach Bolt 2 1
18 510-174-00 Washer 2 2
19 510-170-00 Nut 2 2
20 510-178-00 Cotter Pin 2 2
21 268-015-00 Manual Release Cable 1 1
22 270-074-01 Electrical Release Cable 1 1
23 215-117-00 Decal - Limit Load 2 2
24 512-010-00 Cushioned Loop Clamp 2 2
25 600-006-00 Quick Disconnect 1 1
26 290-507-00 Frame Bumper See note 4 See note 4
27 510-257-00 Bolt 2 2
28 510-183-00 Washer 3 2
29 510-145-00 Nut - 1
30 510-067-00 Cotter Pin - 1
31 210-095-002 C-39 Indicator Assy, 28V - opt
31 210-095-022 C-39 Indicator Assy, 5V - 1
32 235-035-00 QD Bracket - 1
33 270-048-04 Load Weigh Internal Harness - 1
34 215-012-00 Placard - 1
35 215-010-00 Placard - 2
36 400-048-00 Power Switch - 1
37 512-001-00 Ty-Wrap - 10
38 510-028-00 Screw - 6
39 510-029-00 Nut - 6
40 510-062-00 Washer - 8

Maintenance 5-9
Cargo Hook Suspension System Parts, continued
Table 5.1 Cargo Hook Suspension System Parts
Item Part No. Description 200-268-01 200-269-03
41 210-226-013 Pin Load Cell Assembly - 1
42 510-068-00 Bolt - 1
43 510-183-00 Washer 2 3
1
Optionally use P/N 290-431-01, consult the factory for additional guidance.
2
Indicator P/Ns 210-095-00 and 210-095-02 are both compatible with kit 200-269-03. Verify Indicator
voltage matches aircraft lighting system voltage.
3
Pin Load Cell Assembly P/N 210-226-01 is superseded by P/N 210-301-01. If using Pin Load Cell
Assembly P/N 210-301-01 it must be installed with Link Assembly P/N 232-061-01 rather than Link
Assembly P/N 232-061-00 (see Table 5.2 below for identification of Link Assemblies) and must not be
used with the Frame Bumper P/N 290-507-00. Replace item 9 bolts with P/N 511-073-00 bolts.
Table 5.2 Link Assembly Identification
Link Assembly P/N 232-061-00 (shown below) Link Assembly P/N 232-061-01 (shown below)
for use with Pin Load Cell Assembly P/N 210- for use with Pin Load Cell Assembly P/N 210-
226-01 and Frame Bumper P/N 290-507-00. 301-01 and without Frame Bumper P/N 290-507-
00.

4
Use Frame Bumper Assembly only with Link Assembly P/N 232-061-00 (see Table 5.2 above for
identification of Link Assembly P/N).

5-10 Maintenance
Cargo Hook Suspension System Inspection
Table 5.3 Cargo Hook Suspension Inspection Criteria
Item Part Inspect for: Repair
1 Frame Assembly Dents, nicks, cracks, Repair dents, gouges, nicks, scratches and
P/N 232-047-00 gouges, corrosion or corrosion if less than .030” deep, blend out at a
(item 3) scratches in the welded ratio of 20:1, length to depth, replace assembly if
frame structure. otherwise damaged. Touch up with zinc chromate
primer.
2 Link Assembly Dents, nicks, cracks, Repair dents, gouges, nicks, scratches and
P/N 232-061-00 or gouges, corrosion or corrosion if less than .030” deep, blend out at a
P/N 232-061-01 scratches in structural link. ratio of 20:1, length to depth, replace link if
(item 16) otherwise damaged. Touch up with zinc chromate
primer.
Wear on inside diameter If copper is visible over more than 50% of the
of upper bushing. bushing wear area, remove and replace the
bushing.
Wear on inside diameter Replace bushing if inside diameter exceeds 0.520
of lower bushing. in. (13.21 mm).
3 Attach Bolt Wear on outside diameter. Replace bolt if outside diameter is less than 0.485
P/N 290-332-00 in. (12.32 mm).
(item 17)
Qty 2
4 Pin Load Cell Wear on outside diameter Replace if outside diameter is less than .487 in.
Assembly of shoulder. (12.37 mm).
P/N 210-226-01 or
P/N 210-301-01
(item 41)
Qty 1

Maintenance 5-11
Trouble Shooting
Table 5.3 Trouble Shooting
DIFFICULTY PROBABLE CAUSE CORRECTIVE ACTION
Circuit breaker opens when Short in the system, faulty Repair or replace defective
the circuit to Load Weigh System circuit breaker or switch. wiring, circuit breaker and switch.
is energized.
Load Weigh Indicator does not Faulty wiring, circuit breaker or Check the power switch, circuit breaker
light up. switch. and wiring. If this doesn’t help, return the
unit to the factory.
Where Am I? Turn the Indicator power off for a few
moments. When it comes to life it will be
in the Run mode.
Displayed load is incorrect. Incorrect Calibration Code. Insure the correct Calibration Code has
been entered.
Displayed load is not stable. Dampening level is too small. Adjust the Dampening level to a larger
number.
Displayed load takes too long to Dampening level is too large. Adjust the Dampening level to a smaller
change the reading when the load number.
is changed.
Do not recognize the displayed NV Ram failure, A/D or D/A Refer to Error Codes in section 3.
numbers on the Indicator. circuit failure.
Load Weigh Indicator does not Defective load cell or Check for damaged internal harness,
change with changing hook damaged internal harness. replace load cell.
loads.

5-12 Maintenance
Cargo Hook Suspension System Reassembly
1. Assemble the Cargo Hook onto the Link Assembly (16) with the Attach
Bolt (17), two washers (28, one on each side of the cargo hook), washer
(18), nut (19) and cotter pin (20). If using the load weigh system, the
pin load cell replaces the Attach Bolt and one of the washers (28) is
omitted (do not install one on the pin load cell cover side of the cargo
hook).
2. Tighten the nut on the pin load cell or attach bolt until fully seated,
finger tight only. Back off nut to previous castellation, if needed, to
insert cotter pin. Install and secure cotter pin.

Do not tighten nut on pin load cell more than

finger tight. Over-tightening will damage load
cell.
Figure 5.5 Pin Load Cell Tightening

3. Install Link Assembly to frame using Attach Bolt (17), washer (18), and
nut (19).
4. Tighten nut (19) finger tight and back off to previous castellation, if
needed, to insert cotter pin (20).

Maintenance 5-13
Cargo Hook Suspension System Reassembly continued
5. Install the two Bumper Bushings (8) and Frame Bumper (26) using two
bolts (9), four washers (10) and two nuts (11).

If using Link Assembly P/N 232-061-01 (see

Table 5.2 for identification), do not install the
Frame Bumper and use the shorter bolts (P/N
511-073-00) to secure the Bumper Bushings (8).
6. Attach release fitting (2) to cargo hook.
7. Secure Manual Release Cable (21) to Frame Assembly (3) bracket and
to cargo hook.
8. Verify manual release cable rigging per Section 2.

5-14 Maintenance
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.

An RMA number is required for all equipment

returns.
 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
 After you have obtained the RMA number, please be sure to:
 Package the component carefully to ensure safe transit.
 Write the RMA number on the outside of the box or on the
mailing label.
 Include the 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).
 Return the components freight, cartage, insurance and customs
prepaid to:
Onboard Systems
13915 NW 3rd Court
Vancouver, Washington 98685
USA
Phone: 360-546-3072

5-14 Maintenance
Section 6
Certification
FAA STC

Certification 6-1
FAA STC continued

6-2 Certification
Transport Canada STC

Certification 6-3
Transport Canada STC continued

6-4 Certification
EASA STC

Certification 6-5
EASA STC continued

6-6 Certification