INSTALLATION

OF

7600 ELECTRICAL

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 TABLE OF CONTENTS

ITEM # COMPONENT INSTALLATION PAGE

TABLE OF CONTENTS 1
REVISION CONTROL PAGE 2
1 SWITCH BOX 3
2 SWITCH BOX 4
3 RELAY BOX 5, 6, 7
4 INDICATOR BOX 7, 8, 9
5 RPM METER / FLOW METER 9,10
6 SYSTEM CANNON PLUG 11, 12,13, 14
7 RPM METER / FLOW METER CANNON PLUG 14
8 ELECTRICAL SCHEMATIC RPM METER / FLOW METER 15
9 4056-001 RELAY BOX ELECTRICAL SCHEMATIC 16
10 OPTIONAL 206 & 206l SERIES 17, 18
11 CIRCUIT BREAKER 19
12 DOUBLER PLATES 20, 21
13 WEIGHT AND BALANCE 22

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 REVISION CONTROL PAGE

REV. DATE PAGES EFFECTED COMMENTS APPROVAL

A 10/06/88 COVER PAGE ADDITION

COMPONENT INDEX, 14 -
19
09/18/92 6, 13, 16, 17, 18 REPLACEMENT
B 03/22/94 1, 3, 5, 10, 11, 12, 13 REPLACEMENT
C 07/15/97 COVER PAGE, II,1, 3, 5, REPLACEMENT
9,14
D 08/05/97 ALL ADDITION
E 09/27/99 PAGE 17, 20 CORRECTION
OF STA. & W.L.
AND 4-40 TO
8-32 SCREW
FOR LARGE
CONNECTOR

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 INSTALLATION OF 7600 ELECTRICAL

Electrical Component Installation is to be in compliance with AC 43.13-1A chapter 11.

1. Switch Box

Install Switch Box on the helicopter cyclic (Ref. to Figure 1). Attach the
switch mounting bracket to cyclic, the switch box to mounting bracket if not
already mounted. Route wire bundle from the Switch box down the cyclic to
the Relay box. Tie wrapping approximately every eight inches. Connect the
plug to the Relay box securing in place with over center locking clips.

Switch Box Assembly P/N

Bell 206 / 206L, . . . . . . . . . . . . . . . . . 7764
Hughes / McDonnell Douglas 500N
Hughes / McDonnell Douglas 269 / 369 Series . . . . 7765
Bell / Soloy, Bell 47 Series, Hiller FH1100,
Hiller UH-12 Series, Hiller / Soloy UH-12 Series . . . . 7766
Aerospatiale 315 / 316 / 350 Series . . . . . . . . . 7767

FIGURE #1

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 INSTALLATION OF 7600 ELECTRICAL

Electrical Component Installation is to be in compliance with AC 43.13-1A chapter 11.

2. Switch Box

Install Switch Box on the helicopter cyclic (Ref. to Figure 2). Attach the
switch mounting bracket to cyclic, the switch box to mounting bracket if not
already mounted. Route wire bundle from the Switch box down the cyclic to
the Relay box. Tie wrapping approximately every eight inches. Connect the
plug to the Relay box securing in place with over center locking clips.

Switch Box Assembly P/N’s

OH-58 Series . . . . . . . . . . . . 7764 (SWICTH BOX)
4086-002 (MOUNTING BRACKET)
7605 (SWITCH BOX)
113014 (SCREW)
113456 (SCREW)
111150 (LOCK-NUT)

FIGURE #2

INSTALLATION OF 7600 ELECTRICAL

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3. Relay Box

Install the Relay box in the helicopter according to the appropriate reference drawing for
your helicopter. Attach the Relay box through the tabs in base of box using AN6-32 or
equivalent mounting hardware. After the relay box is mounted connect the switch box 15
Pin plug and secure with over center locking clips.

Bell / Soloy
Bell 47 Series
Figure #2

Hiller FH1100
Hiller / Soloy UH-12 Series
Hiller UH-12 Series
Figure #3

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 INSTALLATION OF 7600 ELECTRICAL

3. Relay Box (cont.)

Relay box to be mounted on lower right hand side of console

Bell 206/206L Series

OH-58 Series
Figure #4.

Hughes / McDonnell Douglas 500N

Hughes / McDonnell Douglas 269/369 Series
Install relay box in the right side foot-well (forward).

Figure #5

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 INSTALLATION OF 7600 ELECTRICAL

3. Relay Box (cont.)

Aerospatiale 315 / 316 / 350 Series

Figure #6

4. Indicator Box

Install the Indicator box mounting bracket on the console of the helicopter and mount
Indicator box in bracket.
Refer to the appropriate figure for your helicopter.

Figure #7

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 INSTALLATION OF 7600 ELECTRICAL

4. Indicator Box (cont.)

Hiller FH1100
Bell / Soloy Hiller / Soloy UH-12 Series
Bell 47 Series Hiller UH-12 Series
Figure #8 Figure #9

Hughes / McDonnell Douglas

Bell 206 / 206L Series 269 / 369 Series and 500N
Figure #10 Figure #11

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 INSTALLATION OF 7600 ELECTRICAL

4. Indicator Box (cont.)

Aerospatiale 315 / 316 / 350 Series

Figure #12

5. RPM Meter / Flow Meter (Optional)

( Refer to Manufactures Manual )

Step 1. The RPM Meter / Flow Meter is mounted above the Indicator Box using
bracket extensions.

Figure #13

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 INSTALLATION OF 7600 ELECTRICAL

5. RPM Meter / Flow Meter (cont.)

Step 2. The RPM Meter / Flow Meter is connected to the 28 VDC helicopter
power source (battery) with a Black and a Red wire. a 1.5 amp fuse
is required in the power line from the battery for component
protection.

NOTE: TO AVOID ELECTRICAL PROBLEMS, POWER CONNECTIONS MUST BE

MADE AT THE BATTERY.

WIRE ARRANGEMENT

Step 3. Installation Checks:

1. Insure the voltage regulator is set at the manufacturer’s
recommended level, over or under voltage will prevent the
computer from operating correctly.
2. Do not make connections at relays.

Connect to the negative post of battery

with a minimum 18 gage wire.

Absolutely do not connect to the

airframe.

Connect to the positive post of the

battery through 1.5 amp fuse.

Figure #14

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 INSTALLATION OF 7600 ELECTRICAL

6. System Cannon Plug

Step 1. Mount the skin doubler in approximate location indicated in Figure 13

for your helicopter. Drill out existing rivets whose remaining holes can
be used to mount doubler. Drill a matching hole pattern in skin doubler
and mount the doubler using aircraft sealant and longer rivets. Actual
mounting locations may vary.

Figure #15

STA. 90.20 RH Side 4” off Centerline

Bell / Soloy Bell 47 Series

Figure #16

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 INSTALLATION OF 7600 ELECTRICAL

6. System Cannon Plug (cont.)

Step 1. (cont.)

STA. 45.00 RH Side 2” off Centerline

Hiller FH1100
Figure #17

STA. 30.75 RH Side 8” off Centerline

Hiller UH-12 Series
Hiller / Soloy UH-12 Series
Figure #18

STA. 45.22 RH Side 1 1/2” off Centerline

Bell 206 / 206L, OH-58 Series
Figure #19

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 INSTALLATION OF 7600 ELECTRICAL

6. System Cannon Plug (cont.)

Step 1. (cont.)

NOTE: When installing the 7600 electrical for use with the Model 8500 spray
tank. Position the 8500 spray tank under the helicopter. Locate cannon
plug in the right side footwell area between STA. 44.65 and STA.
50.50. Adjust location as necessary so as not to interfere with existing
wiring, avionics equipment or spray tank before cutting hole.

Hughes / McDonnell Douglas 269 / 369 Series and 500N

Figure #20

STA. 91.94 RH Side 2” off Centerline

Aerospatiale 315 / 316 / 350 Series

Figure #21

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 INSTALLATION OF 7600 ELECTRICAL

Step 2.

Attach Indicator / Relay harness to the Relay control unit and the Indicator
box. Route wiring harness to doubler location and cut harness wires long
enough to reach the skin doubler hole for mounting the System Cannon Plug.
Remark harness wires for easy identification. Strip wires 1/4” and slide cable
clamp with boot P/N 115702 (MS 3057-20A) over wires. Slide heat shrink
over wires, solder appropriate wires to pins (A wire to A pin) in the 23 slot
connector P/N 106019 (MS3100A32-6S). Cover solder connections with heat
shrink. Mount System Cannon Plug on the inside of helicopter, with cap and
chain P/N 106012 (MS25043-32D) on out side of helicopter.

7. RPM Meter / Flow Meter Cannon Plug

Attach RPM Meter / Flow Meter harness to the RPM Meter / Flow Meter box.
Route wiring harness to doubler location and cut harness wires long enough
to reach the skin doubler hole for mounting the RPM Meter / Flow Meter
Cannon Plug. Remark harness wires for easy identification. Strip wires 1/4”
and slide cable clamp with boot P/N 115760 (MS3057-12A) over wires. Slide
heat shrink over wires, solder appropriate wires to pins (A wire to A pin) in the
11 slot connector P/N 106025 (MS3100A20-33S) . Cover solder connections
with heat shrink. Mount Cannon Plug on the inside of helicopter, with cap and
chain P/N 106008 (MS25043-20D) on out side of helicopter.

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ELECTRICAL WIRING SCHEMATICS

8. RPM METER / FLOW METER

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9. FOR 4056-001 RELAY BOX

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10. OPTIONAL 206 AND 206L, OH-58 SERIES
ELECTRICAL COMPONENT MOUNTING

RELAY BOX

Install the relay box on the left side of the console at STA. 16.2 and W. L. 24.1. Attach
the relay box through the tabs using 8-32 or equivalent mounting hardware. Use nut
plates on the inside of the console. (Figure 22).

VIEW LOOKING INBOARD

Figure #22

Cut a hole 2” diameter in the left side of console at STA. 27.77 and W. L. 29.23. Cut
hole so that it is in the same panel as the relay box mounting only. See Figure 22. Run
all wires to and from the relay box through this hole. Protect the wires by installing trim
material around the hole.

Route the extension cable P/N 7015 through the console to the right side. Cut out per
Figure 23 at STA. 48.72 and W. L. 23.13. Mount using AN4-40 hardware or equivalent.

Figure #23 INDICATOR BOX

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10. OPTIONAL 206 AND 206L, OH-58 SERIES (cont.)

When the indicator box is in use on a spray system the labels for the lights and dials not
in use maybe covered by decals as shown in Figure 24.

Figure #24

When mounting the indicator box and the RPM Meter / Flow Meter option, the indicator
box and RPM meter / Flow meter are mounted side by side on the top of the console.
Use the attaching bracket P/N 157566 for the indicator and flow meter / RPM meter
boxes as templates for mounting hardware. Use 10-32 mounting hardware or
equivalent. Remove the vent button on top of the console and replace with the
appropriate size of grommet. Route the wiring harnesses from the flow meter / RPM
meter and indicator box through the vent hole.
(Figure 25 and 26)

Figure #25

Figure #26

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11. CIRCUIT BREAKER

The circuit breaker maybe installed on the right side of the console at STA. 6.93 and W.
L. 30.25. A 25/32 diameter hole is used for clearance of the circuit breaker button. Use
the circuit breaker as a template for the two (2)
.191 diameter, drill #11 holes for mounting. Use AN10-32 mounting hardware or
equivalent. (Figure 27).

VIEW LOOKING OUTBOARD AT RIGHT SIDE CONSOLE

Figure #27

The fuse for the flow meter / RPM meter maybe substituted for the equivalent in a circuit
breaker. Mount the circuit breaker on the right side of the console at STA. 5.62 and W.
L. 29.86. (Figure 27).

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12. DOUBLER PLATES

The electrical plugs for the belly tank can be mounted at STA. 46.90 and R.B.L.
.70 for the large plug, STA. 53.75 and R.B.L. .70. Use doubler plates P/N 7631 and
P/N 7629.
For the large plug going to the spray tank drill a 2 1/2 diameter hole at STA. 46.90,
R.B.L. .70. Push the honeycomb back .20 of an inch all the way around the 2 1/2 hole.
Install EPON 934 or equivalent to seal the honeycomb .20 inches thick in the 2 1/2
diameter hole. Be sure that the small holes are left clear of adhesive in order for the 8-
32 hardware is accessible for mounting the plug. Carefully strip all paint in these areas
to the bare metal. Areas that have been stripped need to be roughed up, use 80-120 grit
sand paper lightly. After sanding thoroughly clean the areas with acetone or alcohol,
prior to applying glue. Install the doubler plate P/N 7631 using 6 MS20600A4W-2 rivets.
Apply adhesive between the doubler plate and the skin of the helicopter. (Figure 28 and
29).

Figure #28 Figure #29

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12. DOUBLER PLATES (cont.)

For the small plug going to the flow meter drill a 1.65 diameter hole at STA. 53.75,
R.B.L. .70. Push the honeycomb back .20 of an inch all the way around the 1.65 hole.
Install EPON 934 or equivalent to seal the honeycomb .20 inches thick in the 1.65
diameter hole. Be sure that the hole is left clear of adhesive in order for the AN4-40
hardware for mounting the plug is accessible. Carefully strip all paint in these areas to
the bare metal. Areas that have been stripped need to be roughed up, use 80-120 grit
sand paper lightly. After sanding thoroughly clean the ares with acetone or alcohol, prior
to applying glue. Install the doubler plate P/N 7629 using 6 MS20600A4W-2 rivets.
Apply adhesive between the doubler plate and the skin of the helicopter. (Figure 30 and
31).

Figure #30 Figure #31

When the spray system is not in use disconnect or pull open the circuit breakers to the
battery. The wire L in the plug on the indicator box does not need to be connected.
When wiring the circuit breakers the flow meter / RPM meter needs to be on the
incoming side of the circuit breaker for the relay box.

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13. WEIGHT AND BALANCE

206/206L, OH-58 SERIES

Component Weight (1bs) Arm (in) Moment (in-
1bs)

Relay Box 4 17.0 68

Indicator Box 1 36.2 36.2
RPM Meter / Flow Meter 1.25 36.2 45.3
Total 6.25 23.92 149.5

Hughes / McDonnell Douglas 269/369 series and 500N

Relay Box 4 50.0 202

Indicator Box 1 49.5 49.5
RPM Meter / Flow Meter 1.25 49.5 62
Total 6.25 50.16 313.5

Hiller FH1100, Hiller / Solov UH-12 series, Hiller UH-12 series

Relay Box 4 18 72
Indicator Box 1 19.2 19.2
RPM Meter / Flow Meter 1.25 19.2 24
Total 6.25 18.43 115.2

Bell / Solov, Bell 47 series

Relay Box 4 13.2 52.8

Indicator Box 1 16.5 16.5
RPM Meter / Flow Meter 1.25 16.5 20.6
Total 6.25 14.38 115.2

Aerospatiale 315, 316, 350 series

Relay Box 4 120 480

Indicator Box 1 17.9 17.9
RPM Meter / Flow Meter 1.25 17.9 22.4
Total 6.25 83.25 520.3

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