Techtest

Limited

Crash Position Indicator

System
Ty p e 1 5 - 5 0 3 - 1 3 4 - 1

Maintenance Manual

Techtest
L i m i t e d
Preface

This manual is a controlled document, and as such is subject to amendment.

It is in the interest of the user to register this manual with Techtest Ltd. to
ensure receipt of any amendments.

Any unsatisfactory feature of this manual should be addressed to:

Customer Support

Techtest Limited
Street Court
Kingsland
Leominster
Herefordshire
HR6 9QA
U.K.

Tel No. +44 (0) 1568 708 744

Fax No. +44 (0) 1568 708 713
E-mail: sales@hr-smith.com
Amendments Record

No. Changed By Date C/N Reference

1 M.Thompson 20/05/03 TT 770

2 M.Thompson 07/10/03 TT 808
3 M. Thompson 19/12/03 TT 828
4 M. Thompson 24/03/04 TT 854
5 G. Probert 25/10/04 TT 896
6 G. Probert 31.03.05 TT 956
7 G. Probert 24.10.05 TT 1072
8 G. Probert 09.11.06 TT1419

Issue Number
8.
Issue Date
09.11.06
Document Number
HRS 1026-05-03
C/N Number
TT 1419
Contents

Section Title Page No.

Preface
Amendment Record
Contents

1. System Description 1
2. Maintenance Guidelines 2
2.1. General 2
2.2. Required Equipment 2
2.3 System Testing 2
3. Maintenance Procedure 3
3.1. Crash Position Indicator Beacon 503-16 3
3.1.1 Cleaning 3
3.1.2 Fitting and Removal 3
3.1.2.1 Detaching Beacon 3
3.1.2.2 Re Attaching Beacon 3
3.1.3 Scheduled Maintenance 4
3.1.3.1 Battery 4
3.1.4 On Condition Maintenance 4
3.1.4.1 CPI Beacon 4
3.1.4.2 Sealing Gasket 4
3.2. Beacon Release Unit 503-21 5
3.2.1 Scheduled Maintenance 5
3.2.1.1 Actuator 5
3.2.2 On Condition Maintenance 5
3.2.2.1 Sealing Gasket 5
3.3. System Interface Unit 503-24 Series 5
3.3.1 Scheduled Maintenance 5
3.3.1.1 Battery 5
3.3.2 On Condition Maintenance 6
3.3.2.1 Sealing Gasket 6
3.4. Cockpit Control Panel 503-22 Series 6
3.5. Water activated Switch 503-23 Series 6
3.6. Configuration Unit 503-40 6
4. Post Maintenance Testing 7
4.1 General Maintenance 7
4.2 LRU Maintenance 7
4.3 Built in Test Failure 8
5 Illustrated Parts Catalogue 9
5.1 503-22 Cockpit Control Unit 10
5.2 503-40 Configuration Unit 10
5.3 503-24 System Interface Unit 11
5.4 503-23 Water Activated Switch 12
5.5 503-21 Beacon Release Unit 13
5.6 503-16 CPI Beacon 14
 1. System Description
The Techtest Crash Position Indicator (CPI) System is a primary radio loca-
tion aid to alert Search and Rescue authorities and assist location in the
event of an aircraft distress situation. The system is designed for installation
in helicopters and fixed wing aircraft and features a locator beacon contain-
ing the transmitter and antenna. The beacon, which can be both manually
and automatically activated, is deployed from the aircraft in the event of
a crash, providing full emergency frequency operation at 121.5 MHz and
406.025 MHz.

The CPI system consists of the Beacon, a Beacon Release Unit, System
Interface Unit, Cockpit Control Panel, Water Activated Switch and an Air-
craft Identification Device (A schematic, detailing the constituent parts of the
system is shown at Figure 1).

An Installation drawing of each Line Replaceable Unit can be found in sec-

tion 5, Illustrated Parts Catalogue.

1 1. Cockpit Control Panel

2.Aircraft ID Configuration Unit
2 3. System Interface Unit
4.Beacon Release Unit
3 5. Water Activated Switch
6.Beacon
4
5
6

Figure 1

1
2. Maintenance Guidelines
In order to maintain a safe working environment, it is recommended that the
following guidelines are adhered to when working on the CPI system.

2.1 General
All maintenance work, as detailed in this publication, should be performed by
suitably qualified personnel. In the absence of suitably qualified personnel,
the equipment can be returned to Techtest for any maintenance work.

Before engaging in any maintenance work it is essential that the CPI system
is isolated, and powered down by switching the ARM switch on the SIU (Part
No. 503-24) to OFF. The system should be left for at least 5 seconds to fully
discharge before beginning any work.

NOTE:
The system has a re-chargeable back-up battery. If the battery is
charged, removing the circuit breaker on the aircraft, without setting
the ARM Switch to OFF will not deactivate the system.

If at any time the CPI Beacon Part No. 503-16 is removed from the Beacon
Release Unit Part No. 503-21, the Protective Cover Plate (Part No. 0881)
should be attached to the Beacon Release Unit, and remain in place until the
CPI Beacon is re attached.

2.2 Required Equipment

If maintenance is to be performed by the end user, or a third party, the fol-
lowing test equipment is recommended to confirm the system is fully func-
tional.

Equipment Techtest Part No

Portable SARSAT Beacon Test Set 12-503-1
Programming Test Set (optional) 12-503-5
CPI Programming Adaptor (optional) 12-503-14
CPI Programming Adaptor - USB port (optional) 12-503-14-USB
Beacon Activation Testset 12-503-16
Beacon Firing Unit 12-503-17

2.3 System Testing

The CPI system has a Built in Test which can be used to assess the sys-
tem’s integrity (Section 4). If there is a fault in the system it will also indicate
the location so the correct maintenance work can be performed (Section
4.3)

2
3. Maintenance Procedure
Before engaging in any maintenance work it is essential that the CPI system
is isolated, and powered down by switching the ARM switch on the SIU (Part
No. 503-24) to OFF, the system should be left for at least 5 seconds to fully
discharge before beginning any work.

Important - This system has a re-chargeable back-up battery. If the

battery is charged, removing the circuit breaker on the aircraft will not
de-activate the system.

3.1 Crash Position Indicator Beacon: 503-16

3.1.1. Cleaning
At regular service intervals, and upon removal for maintenance, the beacon
should be cleaned to remove surface contamination due to exhaust gas
residue. This is to prevent the likelihood of degradation of the surface
lacquer or underlying ABS moulding. The recomended cleaning agent is
methylated spirit.

3.1.2. Fitting and Removal

3.1.2.1. Detaching Beacon

Before any maintenance work can be carried out on the Beacon, it must be
removed from the Beacon Release Unit as directed below.

3.1.2.1.1.
P/N 503-16
Remove the M6 Fixing Bolt (Part No. 0862) M6 Spring Washer (Part No. NC-
00-110) and Lock Plate (Part No. 0863) which sit in the recess on the front of
the CPI Beacon. Once removed the beacon will not be fixed to the release
unit, care should be taken to support the Beacon to prevent it from falling.
The Beacon can be carefully drawn off the release unit.

P/N 503-16 MOD 1 & 2

Remove the M6 Fixing Bolt (Part No. 0862/1), and Lock Plate (Part No. 0863)
which sit in the recess on the front of the CPI Beacon. Once removed the
beacon will not be fixed to the release unit, care should be taken to support
the Beacon to prevent it from falling. The Beacon can be carefully drawn off
the release unit.

3.1.2.1.2
The Release Unit Cover (Part No. 0881), should be fixed to the Release
Unit using 2 M5x30 Pan Head screws and should remain in place until the
Beacon is to be re attached.

3.1.2.2. Reattaching Beacon

3.1.2.2.1.
The Release Unit Cover should be removed from the Release Unit, by
removing the 2 M5 Pan head screws.

3.1.2.2.2.
Fit the Beacon to the Release Unit, locating the Beacon connector’s guide
pins in to the Release Unit’s floating connector. The Beacon can then be
pressed into position.

3
3.1.2.2.3.
Whilst the Beacon is supported in place, insert the M6 Fixing Bolt, lubricated
with MoS2 or Cu Grease, with the Spring Washer (if applicable) and Lock
Plate and torque tighten to 30-32 lbf-in (3.4-3.6 Nm).

3.1.2.2.4.
Inspect the joint between the Release Unit Sealing Gasket and Beacon,
ensuring the fit is flush and a good seal is formed.

3.1.3 Scheduled Maintenance.

3.1.3.1 Battery

The CPI Beacon has an internal LiS02 battery pack, (Part No. A0936) which
must be replaced every 5 years. This interval is dependent on the Beacon
having not been deployed or set to transmit at any point during the battery’s
installed life. If the Beacon has been set to either of these, the battery should
be replaced immediately. The BIT (Built in Test) is not regarded as either of
these actions.
Note: The CPI Beacon battery cannot be replaced by the user. The
Beacon must be returned to Techtest Ltd. for battery replacement and re-
certification.

3.1.4 On Condition Maintenance

3.1.4.1 CPI Beacon

If, at any time, the CPI Beacon is deployed, it should be returned to Techtest
for inspection.

3.1.4.2 Sealing Gasket

Periodic inspections should be made to the Sealing Gasket (Part No. 01052)
located between the Beacon’s Case and Cover. If there are any noticeable
signs of degradation to the gasket that could affect its operating perform-
ance, it should be replaced as directed below.

3.1.4.2.1
Remove the Beacon’s 12 M4 x 20 Stainless Steel Cap Head socket screws,
12 M4 Shake proof washers and all 3 M4 x 10 Stainless Steel Button Head
socket screws from the Case. Carefully separate the case and cover,
ensuring none of the affixed assembly is damaged.

3.1.4.2.2
Replace the damaged Sealing Gasket with (Part No. 01052).

3.1.4.2.3
Carefully replace the Cover, locating the Case’s pillar in the Cover’s through
hole, ensuring the screw holes of the Gasket, Case and Cover line up, and
secure with screws and washers removed in section 3.1.3.2.1. The screws
should be progressively torque tightened to 10-12 lbf in (1.1-1.3 Nm) working
in a diagonally opposite tightening pattern. The 3 M4 stainless steel Button
Head socket screws should also be tightened to 10-12 lbf in (1.1-1.3 Nm).

Note: The 12 retaining screws can relax after a period of time and the torque
settings should be checked, and the screws re-tightened if neccessary, to the
above setting on every ‘C’ overhaul.

4
3.2 Beacon Release Unit: 503-21
Should the Beacon Release Unit be removed from the Installed system for
shipping, storage etc. the Protective Cover Plate (Part No. 0881) should be
affixed, and remain in place until the unit is to be re installed

3.2.1 Scheduled Maintenance

3.2.1.1 Actuator

The Actuator, contained within the Beacon Release Unit, has an installed life
of ten years, or one Deployment firing. If the Beacon Release Unit has fired
for any reason, or reached its operating life threshold, it should be returned
to Techtest for replacement

3.2.2 On Condition Maintenance

3.2.2.1 Sealing Gasket

Periodic inspections should be made to the Sealing Gasket, (Part No. 0921)
located between the Beacon Release Unit and the CPI Beacon. If there
are any noticeable signs of degradation to the gasket that could affect its
operating performance, and ability to produce a water tight seal it should be
replaced as detailed below.

3.2.2.1.1
Remove the CPI Beacon from its installed location as detailed in section.
3.1.1 .

3.2.2.1.2
Remove the Sealing Gasket from the edge of the Beacon Release Unit and
replace with new part. The BRU’s 4 Countersunk mounting screws will have
to be loosened to allow the gasket to be released.

3.2.2.1.3
Tighten the 4 screws to 18-22 lbf in (2.0-2.5 Nm) and replace the CPI
Beacon as detailed in section 3.1.1.

3.3 System Interface Unit: 503-24 Series

3.3.1 Scheduled Maintenance

The SIU contains components with an operational life of 10 years. After 10

years of operation the SIU must be replaced or returned to Techtest Limited
for refurbishment.

3.3.1.1 Battery
The internal battery of the System Interface Unit (Part No. A01011) must be
replaced every 5 years, as detailed below.

3.3.1.1.1
Remove the Battery Cover Panel (Part No. 01005) and Gasket (Part No.
01010) by unscrewing the four M3x8 Pan Head Screws.

3.3.1.1.2
The Battery Removal Tool (Part No.0716) supplied with the replacement
battery, should be inserted into the slot between the Battery and housing
until it clicks into place. The battery can then be drawn out of its housing, and
disposed of safely.
NOTE: The battery ‘O’ ring must also be replaced during this process.

5
3.3.1.1.3
The replacement battery can now be inserted into the housing, and should
be pushed into place until it locates with a click.

3.3.1.1.4
The Battery Cover and gasket should be replaced using the screws removed
in section 3.3.1.1.1

3.3.2 On Condition Maintenance

3.3.2.1 Sealing Gasket
Periodic inspections should be made to the Sealing Gasket (Part No. 01010)
located between the SIU and the battery cover. If there are any noticeable
signs of degradation to the gasket that could affect its sealing capabilities, it
should be replaced as directed below.

3.3.2.1.1
Unscrew the 4 M3x8 screws on the Battery Cover Panel and remove.

3.3.2.1.2
Replace the Sealing Gasket (Part No. 01010), ensuring all holes through
line up.

3.3.2.1.3
The Battery Cover should be replaced, and torque tightened to 15-18 lbf in
(1.7-2.0 Nm) using the screws removed in section 3.3.2.1.1

3.4 Cockpit Control Panel: 503-22-Series

This item is not maintainable by the end user, and in the event of failure
should be returned to Techtest for repair/ replacement as deemed neces-
sary.

3.5 Water Activated Switch: 503-23-Series

This item is not maintainable by the end user, and in the event of failure
should be returned to Techtest for repair/ replacement as deemed neces-
sary.

3.6 Configuration Unit: 503-40

This item is not maintainable by the end user, and in the event of failure
should be returned to Techtest for repair/ replacement as deemed neces-
sary.

6
4.0 Post Maintenance Testing

4.1 General Maintenance

General maintenance work includes Battery and Gasket Replacement or any

work that does not require any LRU’s to be detached from the CPI System.
This does not include removing the Beacon from the Release Unit. Once any
maintenance work has been completed, and units replaced, the following
test procedure should be performed.

4.1.1.
The system must be switched to the ARM position on the SIU switch (Figure
2) before testing can be initiated. The Built in Test (BIT) takes place via the
cockpit control panel.

Figure 2
A Portable SARSAT Beacon Test Set, (Part No.12-503-1) should be used to
take a message reading from the Beacon whilst the BIT is being performed.
Consult the Portable SARSAT Beacon Test Set User Manual for operating
instructions

To test the system, press the Test/Reset button (Figure 3), both the TX/TEST

Figure 3
and BEACON GONE indicators will illuminate (Figure 4). The TX/TEST indi-
cators will then flash in synchronisation with a swept tone (Figure 5).

Both the indicators will then extinguish (Figure 6), signalling that the system
has passed BIT successfully.

Figure 4
If the BIT passes, the reading taken by the Portable SARSAT Beacon Test
Set should be cross checked against the Aircraft information. If there is a dis-
parity in the information, the Configuration Unit can be reprogrammed using
the Programming Test Set, (Part No.12-503-5) or CPI Programming Adapter
(Part No. 12-503-14).

Figure 5
Should the indicators remain illuminated (Figure 7) and six beeps are heard
from the cockpit control panel, the BIT has failed. The TEST/RESET button
should be pressed (Figure 3), and the BIT re-initiated to overcome possible
battery passivation

Figure 6
If, after three attempts, the indicators remain illuminated, the BIT has failed.
Reference should then be made to section 4.3

It is recommended that testing of the system should be minimised, since

testing does use battery capacity. Figure 7

4.2 LRU Maintenance

LRU maintenance includes any work which requires LRU’s to be replaced
and/or returned to Techtest for repair/ replacement. When the system has
been reinstalled it is recommended that its operational performance be
verified utilising the System Installation Test Set, (Part No. 12-503-16).

Reference should be made to the System Installation Test Set Operating

Manual in order to carry out these tests.

7
4.3 Built in Test Failure
4.3.1. Power-up BIT Fail
When the system starts, it attempts to read the distress massage and the g-
activation levels for the aircraft from the ID unit. If it fails to read this message
both enunciators will illuminate momentarily, and the system will restart and
re-attempt to read from the ID box. A persistant fail will characterize itself as
the enunciators continually flashing at a very slow rate.
If the system initializes successfully there will be 2 beeps, and no enunciators
will illuminate.

4.3.1. Diagnostic BIT

In the event that the CPI System BIT indicates a FAIL, a diagnostic test
should be performed as follows.

Switch the System to OFF at the SIU. Switch the SIU to ARM whilst the
Test/Reset button is depressed. The system will beep once, signalling test
initiation, followed by two swept tones and a beep. There will then be a string
of beeps, the number being dependent on the type of fault. The list below
can be used to identify the fault.

No. Beep Train Beeps

1 SIU Access to Beacon Fail 2
2 SIU Accelerometer 1 3
3 SIU Accelerometer 2 4
4 SIU Accelerometer 3 5
5 Beacon Battery 7
6 Beacon rf Failure 8
7 Beacon Tests Completed 9

Fault No.1
If fault 1 is indicated then the cables between the SIU and beacon should be
checked, ensuring they are attached and in good working order. If the fault
persists, contact Techtest Limited.

Fault No.2,3,4
If any of these are indicated, the SIU is at fault and should be replaced or the
system shut down and Techtest Limited Informed.

Fault 5
If fault 5 is indicated the Beacon’s Battery should be replaced, and the system
retested. The BIT may have to be performed up to 3 times to overcome
possible battery passivation.If the fault persists, contact Techtest Limited.

Fault 6.
If fault 6 is indicated the Beacon is at fault and the supplier should be
contacted

Fault 7
If fault 7 is indicated the system is at fault and the supplier should be
contacted.

If any of these faults are not immediatly rectified the system should be set
to OFF at the SIU, and the Beacon removed from the aircraft (Section 3.1.1)
until the system is repaired.

8
5. Illustrated Parts Catalogue

9
Cockpit Control Unit 503-22-Series

Configuration Unit 503-40

10
 1.

2.

3.

4.

5.

6.

System Interface Unit 503-24-Series

No. Part No. Qty. Description

1. NA-00-37 4 Screw, Pan Head
2. NA-00-017 4 Spring Washer

3. NA-00-015 4 Washer

4. 01005 1 Battery Cover

5. 01010 1 Gasket

6. A01011 1 Ni-Cad Battery

11
Water Activated Switch 503-23-Series

12
 1.

Beacon Release Unit 503-21

No. Part No. Qty. Description

1. 0921 1 Sealing Gasket

13
 1. 2. 3.

Beacon 503-16 Beacon 503-16 MOD 1 & 2

No. Part No. Qty. Description No. Part No. Qty. Description
1. 0863 1 Lock Plate 1. 0863 1 Lock Plate
2. NC-00-110 1 M6 Spring Washer 2. N/A 0 M6 Spring Washer
3. 0862 1 Special Bolt 3. 0862/1 1 Special Bolt

14