Kong KARS User manual

ZZV05854 REV.2

Instructions for use of the “K.A.R.S. - Kong Anti Rotation System”
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WARNING
The issue date and any corrections are in the following table:
Version
NOTES
DATE
ZZV05854 REV.2
Wing mechanical release button correction
10/09/2014
ZZV05854 REV.1
Technical data adjustment
03/07/2014
ZZV05854 REV.0
issue
25/05/2014
This publications consists of a total of 40 Pages

Instructions for use of the “K.A.R.S. - Kong Anti Rotation System”
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TABLE OF CONTENTS
CHAPTER 1 –DESCRIPTION AND MAIN CHARACTERISTICS
1.1 Purpose Page 5
1.2 Applicability Page 5
1.3 Limitation of Liability Page 5
1.4 Disposal Page 6
1.5 Labelling Page 7
1.6 Statement of Ownership Page 7
1.7 General description Page 8
1.8 Components list Page 9
1.9 Components description Page 9
1.9.1 KARS waterproof body Page 10
1.9.2 Stabilizer wing Page 11
1.9.3 Connection tube Page 11
1.10 Accessories list Page 13
1.11 Accessories description Page 13
1.11.1 Waterproof container (Carrying case) Page 13
1.11.2 Battery charger Page 14
CHAPTER 2 –INFORMATION FOR USE
2.1 General information Page 15
2.2 Specific information Page 16
2.2.1 Technical data Page 16
2.2.2 Reference Standards Page 16
2.2.3 Environmental conditions Page 16
2.3 Operating instructions Page 18
2.3.1 Preparation Page 18
2.3.2 Switching on at the bench Page 18

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2.3.3 Tube connection Page 21
2.3.4 Switching on during a rescue operation Page 23
2.3.5 Switching off Page 24
2.3.6 Wing mechanical release Page 24
2.3.7 Information provided by the LEDs Page 25
2.3.8 Battery charging procedure Page 27
2.3.9 Stabilizer wing replacement Page 30
CHAPTER 3 –MAINTENANCE AND REPAIR
3.1 General information Page 34
3.2 Maintenance Page 34
3.3 Extraordinary maintenance Page 35
3.4 Repair Page 35
CHAPTER 4 –SHIPMENT AND STORAGE
4.1 Shipment Page 36
4.2 Storage Page 36
CHAPTER 5 - INSPECTIONS
5.1 Inspections before and after use Page 37
5.2 Periodic inspections Page 37
CHAPTER 6 –PRODUCT LIFE AND GUARANTEE
6.1 Product life Page 39
6.2 Guarantee Page 39
6.3 Legal obligations Page 39
CHAPTER 7 –INSPECTION SHEET
7.1 Inspection Sheet Page 40

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CHAPTER 1
DESCRIPTION AND MAIN CHARACTERISTICS
1.1 –PURPOSE
The purpose of this document is to describe and provide the necessary information for the correct
use of the
K.A.R.S. Kong Anti Rotation System
P/N 882000000KK
This document must be kept for the life of the device, near to it and especially free from any
element or substance which may affect the perfect readability.
1.2 –APPLICABILITY
This document is applicable to the
K.A.R.S. Kong Anti Rotation System
P/N 882000000KK
For any kind of information concerning the correct interpretation of this manual, the installation,
use, maintenance and return of the product, contact Kong Customer Service , phone + 39 0341
630506 or e-mail to in[email protected] or write to Kong S.p.A., Via XXV Aprile no. 4, 23804 Monte
Marenzo (Lecco) Italy. In order to facilitate the assistance operations always indicate or
communicate the batch number found on the product. See paragraph 1.5.
1.3 –LIABILITY
Users must read and perfectly understand the information provided by this manual before using
the product.

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The information relates to the description of the characteristics, services, assembly, disassembly,
cleaning, maintenance and conservation of the product, even if they contain some
recommendations for use, they must not be considered a user manual in operational situations.
For operational situations the user must be trained by experienced persons.
Remember that:
A) This product must be used only by trained and skilled persons, otherwise the user must be
constantly supervised by a trained and skilled person.
B) The user is personally responsible for knowing this product, learning how to use it and all the
safety precautions involved.
C) Carry out all the controls described in this manual before and after use and particularly make
sure that the product is:
- in perfect condition and works well,
- suited to the intended use.
D) The user is responsible for the proper use of this product. Any other usage is forbidden:
Attention, serious danger! Record the results of the controls on the “control card” attached to this
manual and keep it. If you have any doubts about the products safety and working conditions,
replace it immediately. Do not use the product that has undergone a shock (e.g. a fall), as any
internal damage or deformation not visible from outside could have considerably reduced its
strength. Incorrect use, mechanical deformation, device accidental drop from height, wear,
chemical contamination, exposure to heat as well as to weather conditions and unauthorized use
are some examples of other reasons that can reduce, limit and even terminate the service life of
the product.
Your life depends on the constant efficiency of your equipment and its history (use, storage,
controls, etc.).
E) When you intend to combine two (or more) products read carefully the instructions for use of
both products.
G) It is strictly forbidden to modify and/or repair the product: no liability will be recognized by
KONG S.p.A. for damage, injury or death caused by: improper use, changes made to product,
repairs by non-authorized persons or use of non-original parts.
1.4 –DISPOSAL
Once the device is unusable it must be disposed of. Comply with local regulations regarding
disposal. In particular, the batteries must be removed and disposed of separately. When in doubt,
return the product to be scrapped to KONG S.p.A.

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1.5 –LABELLING
The KARS marking shows the logo of the manufacturer, the product model, the CE marking and
the serial number (or batch number). This must never be removed or covered.
The batch number consists of 25 digits and is composed as follows:
XXXXXX production batch (in FIG.1: 141709)
YY production year (in FIG.1: 14)
ZZZZ progressive identification number (in FIG. 1: 0012)
WWWWW/WW electronic components identification (in FIG.1: 15156/014)
The marking also includes the degree of protection IP68 (depth up to 3 metres) according to IEC
60529. (in the example Water proof 3m)
FIG. 1 KARS Marking
1.6 –STATEMENT OF OWNERSHIP
The content of this information cannot be used and reported in part or whole without citing the
source and without the written permission of Kong S.p.A. who is the owner.

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1.7 -GENERAL DESCRIPTION
The "K.A.R.S. Kong Anti Rotation System", hereinafter called only "KARS", is an automatic
electromechanical device designed and constructed to automatically reduce or eliminate the
rotation of a suspended load induced by the air flow generated by the rotors of a helicopter.
The system is particularly useful in helirescue maneuvers during the ascent and/or descent
phases of a stretcher while the helicopter is in slow flight or "hovering".
The KARS is constituted by:
no. 1
Waterproof container (Carrying case)
P/N
ZCOM0550
no. 1
Waterproof body
P/N
882000000K
no. 1
Stabilizer Wing (assembled to the body)
P/N
882020000KK
no. 1
Connection tube to the hanging load
P/N
CPB010LA
no. 1
Battery charger
P/N
882010000KK
no. 1
Instructions for use
P/N
ZZV05854
FIG.2 –K.A.R.S. “Kong Anti Rotation System”

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1.8 -COMPONENTS LIST
The "K.A.R.S. Kong Anti Rotation System” is constituted by:
no.
1
Waterproof body
P/N
882000000K
no.
1
Stabilizer Wing
P/N
882020000KK
no.
1
Connection tube to the hanging load
P/N
CPB010LA
1.9 -COMPONENTS DESCRIPTION
1.9.1 –KARS WATERPROOF BODY
The KARS body is made of anodized aluminium (class 6082), surmounted by an aerodynamic
nylon profile.
The aluminium box contains the hardware and the power battery of the device.
The box sealed in the factory has IP68 degree of protection against dust and water with sealing
up to 3 meters of depth.
The device marking is printed on its side (fig.1 and 3).
On the front are assembled: the ON/OFF switch (fig. 4-A), the power-ON LED (fig. 4-B), the plug
with watertight cover for connection to the battery charger and other accessories (fig. 4-C), the
malfunction warning LED (fig. 4-D), the battery charge level LED (fig. 4-E), the maintenance
warning LED (fig. 4-F).
The wing mechanical release button is assembled on the upper part of the KARS body (fig. 4-G).
When the button is pressed it locks in the pressed position. The stabilizer wing of the device is
disengaged from the motor spindle and becomes neutral, i.e. it is no longer linked to the hardware
of the device.
For the operator’s comfort the release can occur even remotely pulling the cordolet (Figure 4-H)
connected to the button.

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FIG.3 KARS waterproof body
FIG.4 KARS front panel

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1.9.2 STABILIZER WING
A wing profile (stabilizer wing) is mechanically connected to the KARS body fig.5. The wing is
assembled on the KARS shaft and becomes integral with it through a spline. It is held in place by a
bracket with safety spring pin and an internal magnet. (Fig.5)
The wing, driven by the KARS motor which in turn is controlled by a gyroscope, has the stabilizer
function opposing the rotation of the suspended load induced by the air flow of the helicopter
rotors.
The wing is made of synthetic material and is removable without the use of tools from the KARS
body if it must be replaced.
FIG.5 Stabilizer wing and connection fork
1.9.3 CONNECTION TUBE
The L bent aluminium tube supplied with the KARS is specific for use with Kong Kit Everest
stretcher (P/N 855.SET.12 - 855.SET.13.) of which it ensures an optimal position during the
operational phases. (Fig.6)
The tube is inserted in the KARS through an automatic lock with double safety device (short side)
and to the stretchers (long side) by inserting it into the coupling on the spinal axis of the stretcher.

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The tube is provided with a slotted cable (FIG.6) that, by pulling it, allows the release of the KARS
from Kong Kit Everest stretcher.
On request it is possible to provide different connections for linking to other devices. When
combined with other devices, the user must ensure their compatibility with the KARS.
FIG.6 KARS connection tube to the Kong Kit Everest stretcher

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1.10 -ACCESSORIES LIST
no.
1
Waterproof container (Carrying case)
P/N
ZCOM0550
no.
1
Battery charger
P/N
882010000KK
1.11 –ACCESSORIES DESCRIPTION
1.11.1 WATERPROOF CONTAINER (CARRYING CASE)
The waterproof polypropylene carrying case protects the KARS from possible impacts during its
transport. Inside the carrying case there are suitably shaped housings used to immobilize all
components of the KARS and the battery charger.
In any case, handling and storage must be made with all the necessary precautions and as
specified in Chapter 4.
FIG. 7 Waterproof container (Carrying case)

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1.11.2 BATTERY CHARGER
The battery charger (FIG.8) is a voltage adapter/stabilizer with two-pin plug for connection to the
power supply (Input 110-220 V AC, 50-60HZ) and cable with a specific connector for connection to
the KARS.
To recharge the KARS battery, use exclusively the battery charger supplied. The use of any other
battery charger may cause permanent damage to the device. If a battery charger other than the
one supplied with the device is used, the warranty becomes void.
FIG.8 KARS battery charger

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CHAPTER 2
INFORMATION FOR USE
2.1 –GENERAL INFORMATION
The product must be operated only by personnel trained in the use of this specific device and not
of others comparable or similar.
•Before carrying out any operation on the device (such as training, installation, operation),
operators must carefully read the instructions contained in this publication, with particular
attention to the appropriate safety precautions and the methods of installation and use.
•In case of doubt on the correct interpretation of the instructions, consult Kong S.p.A. to obtain
the necessary clarifications.
•Do not allow untrained persons to operate during the use of the device, as this may cause
damage or injury to yourself or others.
•Carry out the prescribed maintenance and comply with the life time specified by KONG S.p.A.
in this publication.
•Before each use, always check the integrity of the device as specified in this publication. In
case of malfunction or damage that may compromise the functionality and safety of the
device and the operator, it is necessary to remove the device immediately from service and
contact Kong S.p.A.
•It is forbidden to use the device for any other use other than that described in this manual.
•Do not alter or modify the device and/or its components; the change could result in improper
operation and damage to operators.
•The device must not undergo any tampering (modification, remodelling, addition, repair),
otherwise the company declines any liability on the correct operation or on any damage
caused by the device; in addition the product warranty and certifications become null and
void.
•This product can be used combined with non-invasive medical devices conforming to
Directive 93/42/EEC when compatible with the relevant information of the product. When you
intend to combine two (or more) products read carefully the instructions for use of both
products to check their compatibility.
•Record and retain these instructions: the batch number, the date and place of purchase, date
of first use, the date of the checks, the name of the users (possibly), and comments.
•The assistance of qualified personnel must be guaranteed while using the device.
•Do not store the device under other materials more or less heavy, which could damage the
structure of the device.
•Store in a dry, cool place, away from light. Avoid exposure to sunlight or any other source of
direct heat.
•Store and transport the device in its original packaging (waterproof carrying case) properly
positioned.
•The device must not be exposed to, or come into contact with thermal ignition sources,
flammable agents and chemicals.

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Despite all efforts, laboratory tests, inspections, and instructions for use, the standards are not
always able to reproduce what actually happens in practice, so the performances under real
conditions when using the product in a natural environment can often differ considerably. The best
instructions can be gained by continual practice under the supervision of skilled and qualified
personnel.
The KARS must always be kept and managed by skilled personnel.
2.2 –SPECIFIC INFORMATION
2.2.1 TECHNICAL DATA FIG.9
Height (mm) 250.00 mm
Width (mm) 80.00 mm
Length (mm) 343.50 mm
Weight (g) 1630 g
Battery charger weight (g) 180 g
Degree of protection IP68 for dust and water. Seal verified with immersion up to 3 m.
2.2.2 REFERENCE STANDARDS
IEC 529:1989 +A1 Degree of protection provided by enclosures (IP Code)
EN 60529:1991 +A1 Degree of protection provided by enclosures (IP Code)
RTCA DO160G Environmental conditions and test procedures for airborne equipment:
§ 4.5 temperature tests
§ 20 Radio Frequency Energy
§ 21 Emission of Radio frequency Energy
§ 25 electrostatic discharge
CEI CLC/TR 50538 Guide to EMC Directive conformity of equipment designed for military
purposes.

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2.2.3 ENVIRONMENTAL CONDITIONS
Operating temperature: -55° C* + 85°C
Storage temperature: +5 °C + 45°C
Storage relative humidity: less than 85%
* At a temperature below -30°C the battery may not provide sufficient power to the circuit.
FIG.9 Drawing of KARS overall dimensions

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2.3 –OPERATING INSTRUCTIONS
2.3.1 PREPARATION
Upon receipt of the product:
•Unpack and place the material in a visible way.
•Check that there are all the items listed in paragraph 1.4.
•Fill in the table at the end of this document.
Keep this manual duly completed. We advise to make a copy to keep attached to the product and
keep the original in a lockbox. In this case, remember to fill in both manuals as regards all the
checks, maintenance and repairs (see chap. 3 and 5)
The device must be checked before each start-up, in order to detect malfunctions and/or damage
due to transportation and/or storage.
When the device is off, check:
•Components integrity
•Absence of deformations, bends or cracks.
•Make sure that the mechanical release button of the wing is operated (by pushing or pulling
the cordolet, the button must lock in the pressed position) and can be reset (by turning a
quarter turn clockwise, the inner spring must let out the button without difficulty). The
operation must occur freely and without difficulty.
•Once the mechanical release button is reset verify that the wing pin of the KARS shaft is
properly inserted in the engagement seat of the stabilizer wing. The control is visual or
manual by slightly actuating the stabilizer wing.
•Verify that the KARS connection buttons with the tube are working. (when pressed they must
return immediately in the out position)
•Check that the tube coupling button is working properly. (pulling the cable the button must
return in - releasing the cable the button must come out)
2.3.2 SWITCHING ON AT THE BENCH
- Before turning on the KARS check that the cover of the charge connector, with bayonet
coupling, is securely locked and tight. Fit it axially centering the pins in their seats, press and turn
until it locks.
When the connector cover is not locked the impermeability of KARS is not guaranteed. Also
during the operational phase the powder may clog the contacts.
•Check that in the operating range of the stabilizer wing there are no obstacles that prevent
free movement.

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•Activate the mechanical release button of the KARS wing turning it clockwise. Check that it is
in the working position and that the wing is properly engaged to the pin of the shaft.
FIG.10 Wing mechanical release button reset –shaft pin engagement detail
•Verify that the KARS is placed flat and firmly gripped. Do not switch on the KARS when it is
resting horizontally on the ground or on a worktop.
•With the mechanical release button of the wing activated and the KARS off, rotate the
stabilizer wing through an angle of 360°, making sure that there are no hard points during the
rotation
•The switch is equipped with a safety device to prevent accidental operation. To use is, pull the
lever outwards, bring it to the ON position and release the lever. The switch is locked in the
ON position. (FIG.11)
FIG.11 ON/OFF switch activation.

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•When the switch is in the ON position, the blue LED must be lit.
•Within a second, the service LED and the battery LED (see § 2.3.5) will flash once. This
indicates that the KARS has carried out all the communication checks between hardware and
software components.
•The wing will perform a rotation of 20° to the left, followed by a rotation of 40° to the right, and
then by a subsequent rotation of 20° to the left which will bring the wing upright Fig. 12.
FIG.12 Stabilizer wing movement when switched on.
•Turning the Kars on the vertical axis laterally to the right and left for no more than 20°, without
rotating it in the horizontal axis, the wing must remain vertical. (FIG.13)
FIG.13 Verticality of the wing during the +/- 20° movement of the waterproof body