Big Mouth Cargo Hook Kit - Onboard Systems International
Contents
1. COM FOR 1S a yww ONBO or TH rre ATW CHECK iapa REVISION THE LA PL JASE Big Mouth Cargo Hook Kit for the Bell 206 A amp B Series Kit Part Number 200 232 00 Owner s Manual Owner s Manual Number 120 074 00 Revision 8 September 14 2010 Z CONBDARD SYSTEMS IN TERNATIONAL 13915 NW 3 Court Vancouver Washington 98685 USA Phone 360 546 3072 Fax 360 546 3073 Toll Free 800 275 0883 www OnboardSystems com This page intentionally left blank Revision Date RECORD OF REVISIONS Page s Reason for Revision 3 9 00 4 8 4 9 Added additional location option of connector plug on solenoid cover 6 26 00 2 1 2 2 2 5 amp Section 4 Figure 2 1 changed washer part number and added Torque value to AN Nut Figure 2 2 added torque value Page 2 2 added Hook location table Removed overhaul instructions from Section 4 and moved information to the new Service Manual 122 002 00 9 17 02 Title 4 3 Factory address change 01 18 07 2 2 2 3 amp 2 4 Section 4 Updated figures to show new knob configuration Updated maintenance information to refer to service manual 122 002 00 04 12 07 TOC Section 1 2 4 amp Section 3 Updated Warnings Cautions and Notes format to current standards 06 16 10 TOC amp Sections 1 4 Added Manual Release Cable P N 268 015 00 to parts list Added installation instructions for manual re2. on Primary Ring Rotorcraft Fli ght Document Number BOARD Manual Supplement 120 074 00 SYSTEMS Page INTERNATIONAL Cargo Hook a oo Ill PROCEDURES continued Un Commanded Release Due to Too Large of a Load Ring WARNING Load rings that are too large will cause an un commanded release The ring will flip over the end of the load beam and flip the keeper up and then fall free Only correctly sized load rings must be used See examples below Figure 2 Un commanded release due to load rings that are too large Load Ring flips over the Load Beam and gyrates The flip over often occurs with long line operations during landing and take offs Load Ring moves inward and bears against the keeper The Keeper is forced to rotate allowing the Ring to slip off Rotorcraft Fli ght Document Number BOARD Manual Supplement 120 074 00 SYSTEMS me iNTERNATI ONAL Cargo Hook a oo Ill PROCEDURES continued Load Hang Up Due to Too Small of a Load Ring or Multiple Load Rings WARNING Load rings that are too small or multiple load rings will hang on the load beam when the load is released Only correctly sized load rings must be used See examples below Figure 3 Load hang up due to load rings that are too small or using multiple load rings Load hang up due to multiple rings on load beam Z Rotorcraft Flight H CONBOARD Manual Supplement 120 074 00 SYSTEMS Page INTERNATIONAL Cargo Hook ea oo
3. Ill PROCEDURES continued Un Commanded Release Due to Nylon Type Straps WARNING Nylon type straps or similar material must not be used directly on the cargo hook load beam as they have a tendency to creep under the keeper and fall free If nylon straps must be used they should first be attached to a correctly sized primary ring Only the primary ring should be in contact with the cargo hook load beam See examples below Figure 4 Un commanded release due to nylon type straps Nylon type strap on the Load Beam lS SSK Nts SOKS RRS S OOK KK a SRK Me 9 9 0 x we S ee lt gt anes lt gt lt gt lt gt PUM KKK RKKKKY SISS RRS w L RSS ROLL Kk RS As the load swings the strap fibers work their way under the keeper ZRII ZRELE 199o S SSS NANNA ISO S LSS S I QS Oe ee X gt C00 OQI SSL LLS S 9S 18032222S PRR The strap works its way off of the load beam RLR RRR RRM Z Rotorcraft Flight H CONBOARD Manual Supplement 120 074 00 SYSTEMS e INTERNATIGONAL Cargo Hook ee i Ill PROCEDURES continued Un Commanded Release Due to Cable or Rope Type Straps WARNING Cable or rope type straps must not be used directly on the cargo hook load beam Their braided eyes will work around the end of the load beam and fall free If cable or rope is used they should first be attached to a correctly sized primary ring Only the primary ring should be i
4. Remove the cargo hook manual release cover and connect the manual release cable Place the cable ball end fitting into the hook manual release fork fitting as illustrated in Figure 2 4 Check that there is a minimum of 125 of free play at the fork fitting as shown in Figure 2 4 Figure 2 4 Manual Release Cable Rig MANUAL RELEASE KNOB SAFETY WIRE MANUAL RELEASE CABLE FORK FITTING BALL END FITTING 125 FREE PLAY a Attach the supplied adel clamps through the end loops of the cargo hook restraining shock cord Route the shock cord through the eyelet and over the threaded rod as illustrated in Figures 2 4 and 2 5 Secure the adel clamps to the screws on the cargo hook manual release cover as illustrated and safety wire Figure 2 5 Adel Clamp and Shock Cord Installation ADEL CLAMP SHOCK CORD MANUAL RELEASE KNOB SIDE OF HOOK Installation Instructions 2 3 Cargo Hook Installation continued Figure 2 6 Cargo Frame Assembly Overview Cargo Frame Assembly TN i o N J Universal Assembly Lh 7 Threaded Rod a fi Link Adapter q ae Hook Retracted Shock Cord Cargo Hook in Extended Postion Connect the cargo hook electrical release cable connector to the Cargo Hook Listed below is the pin out for the cargo hook connector Table 2 1 Cargo Hook Conne
5. load rings must be used See examples below Figure 3 3 Load Hang Up Due to Too Small a Load Ring or Multiple Load Rings Load hang up due to multiple rings on load beam Operation Instructions Un Commanded Release Due to Nylon Type Straps Nylon type straps or similar material must not be used directly on the cargo hook load beam as they have a tendency to creep under the keeper and fall free If nylon straps must be used they should be first attached to a correctly sized primary ring Only the primary ring should be in contact with the cargo hook load beam See examples below Figure 3 4 Un Commanded Release Due to Nylon Type Straps Nylon type strap on the Load Beam As the load swings the strap fibers work their way under the keeper x XS Ke 2S XXX RRS oe OOOO 32299 IIRS 222030309000000 SS Kx ies xe Me KXXX ISSIS OS SISOS SISS RSS S SS SS R X Me SKY 2S 39292 ALA QQS The strap works its way off of the load beam LEQ Q D LRA 3 6 Operation Instructions Un Commanded Release Due to Cable or Rope Type Straps Cable or rope type straps must not be used directly on the cargo hook load beam Their braided eyes will work around the end of the load beam and fall free If cable or rope is used they should be first attached to a correctly sized primary ring Only the primary ring should be in contact with the cargo hook load beam See examples b
6. 5 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 1 Inspect for splitting of the outer black conduit and heat shrink in this area and separation of the conduit from the steel end fitting Figure 4 1 Manual Release Cable Inspection Pay close attention to this area of the manual release cable Maintenance Inspection continued 6 Visually inspect for corrosion on the exterior of cargo hook and suspension system components Corrosion on the cargo hook side plates is cause for immediate overhaul Additionally any exfoliation corrosion in the upper attach lug area of the cargo hook is cause for immediate replacement of the side plate Refer to the Cargo Hook Service Manual 122 002 00 for instructions Adapter Link Overhaul Time Between Overhaul TBO 1000 hours of external load operations or 5 years whichever comes first Refer to Service Manual 122 002 00 for overhaul information for the Cargo Hook Remove adapter link from the helicopter and inspect per the following instructions refer to Figure 4 2 for parts breakdown o Inspect the bushing ID surfaces for wear and corrosion Pitting corrosion or excessive wear is cause for rejection Maximum permissible bushing clearance is 010 on diameter If bushing P N 290 364 00 needs to be replaced press in new bushing with wet zinc chr
7. 5 039 00 dated June 26 2000 or later FAA approved revisions and Installation of this system in accordance with FAA approved Onboard Systems Owner s Manual No 120 074 00 dated June 20 2000 or later FAA approved revisions Inspect cargo hook kit in accordance with Onboard Systems Service Manual No 122 002 00 dated June 20 2000 or later FAA approved revisions Basis of Certification as defined in the applicable Type Certificate Data Sheets Rotorcraft equipped with the Onboard Systems Model 200 232 00 Cargo Hook Kit must be operated in accordance with FAA approved Rotorcraft Flight Manual Supplement RFMS No 120 074 00 dated July 27 1998 or later FAA approved revisions Approval of this change in type design applies to only those Bell model rotorcraft listed above which were equipped with an FAA approved installation of Bell Cargo Hook Suspension Assembly P N 206 706 335 1 101 or 103 Bell Cargo Hook Provisions Kit P N 206 706 335 3 5 or 105 and Breeze Eastern Cargo Hook P N SP 4232 4 5 or 5L End Conditions This approval is only applicable to the type model of aeronautical product specified therein Prior to incorporating this modification the installer shall establish that the interrelationship between this change and any other modification s incorporated will not adversely affect the airworthiness of the modified product W Wong Aircraft Certification Engineer For Minister of Transport Cana
8. 706 335 1 101 or 103 Bell cargo hook provisions kit P N 206 706 335 3 5 or 105 and Breeze Eastern cargo hook P N SP 4232 4 5 or 5L This approval should not be extended to helicopters of these models on which other previously approved modifications are incorporated unless it is determined by the installer that the relationship between this change and any of those other previously approved modifications including changes in type design will introduce no adverse effect upon the airworthiness of that helicopter Modified rotorcraft must be operated in accordance with an FAA approved copy of Onboard Rotorcraft Flight Manual Supplement RFMS No 120 074 00 dated July 27 1998 or later FAA approved revision See Continuation Sheet Page 3 of 3 This certificate and the supporting data which is the basis for approval shall remain in fect until sur rendered suspended revoked or a termination date ti otherwise established ly the Adninistralor of the SZederatl Aviation Administration Date of application May 28 1998 Date of idduanoe Signature Acting Manager Seattle Aircraft Certification Office Title Any alteration of this certificate is punishable by a fine of not exceeding 1 000 or imprisonment not exceeding 3 years or both This certificate may be transferred in accordance with FAR 21 47 FAA FORM 8110 2 10 68 Certification 5 1 5 2 United States of America Bepartment of Transportation Federal Aviation
9. AN Washer 2 PLCS P N 510 183 00 AN 960 816L AN Nut P N 510 170 00 AN 320 C6 Manual Release Knob Side of Hook Cargo Hook P N 528 017 00 Installation Instructions 2 1 Cargo Hook Kit Installation continued 2 2 Attach the Cargo Hook assembly to the cargo frame assembly using the Bell supplied hardware that was previously used to attach the universal assembly to the Cargo Hook The cargo hook load beam should point to the right Figure 2 2 Cargo Hook Assembly to Cargo Frame Assembly Installation Cargo Frame Assembly Universal Assembly MS Cotter Pin B ae a ks ae MS24665 283 ira OD _ Bushing supplied xj aa with Link Adapter MS Nut MS 17825 6 A INSTALLATION TORQUE AO ae y A AN Bolt 95 110 IN LBS N i AN176 21 _AN Washer AN960 616 AN Washer AN960 616 eo Manual Release Knob Side of Hook Attach the manual release cable to the cargo suspension assembly as illustrated below Figure 2 3 Manual Release Cable Installation MANUAL RELEASE CABLE P N 268 015 00 Installation Instructions Cargo Hook Installation continued Thread the release fitting P N 290 426 00 into the cargo hook
10. Administration Supplemental Cope Certificate Continuation Sheet Minler SR00538SE Limitations and Conditions continued A copy of this Certificate and the RFMS must be maintained as part of the permanent records of the modified helicopter If the holder agrees to permit another person to use this certificate to alter the product the holder shall give the other person written evidence of that permission END Any alteration of this certificate is punishable by a fine of not exceeding 1 000 or imprisonment not exceeding 3 years or both FAA FORM 8110 2 1 10 69 This certificate may be transferred in accordance with FAR 21 47 PAGE 3 OF 3 PAGES Certification STA i Transport Canada Transports Canada Department of Transport Supplemental Type Certificate This approval is issued to Number SH98 48 Onboard Systems Issue No 2 11212 NW St Helens Road Approval Date September 14 1998 Portland OREGON Issue Date October 24 2000 97231 UNITED STATES OF AMERICA Responsible Office Pacific Aircraft Engine Type or Model Bell 206A and 206B Canadian Type Certificate or Equivalent H 92 Description of Type Design Change Fabrication and Installation of Onboard Systems Cargo Hook Kit per FAA STC SRO0538SE Instailation Operating Data Required Equipment and Limitations Fabrication of Onboard Systems Model 200 232 00 Cargo Hook Kit in accordance with FAA approved Onboard Systems Master Drawing List No 15
11. at they are tight Visually inspect the electrical connector for loose or damaged pins and sockets Operate the keeper manually and check that it snaps back to its normal position on the load beam Inspect the case and covers for cracks and damage Inspect the load beam for gouges and cracks Cycle the manual release mechanisms to ensure proper operation Cycle the electrical release mechanisms to ensure proper operation Rotorcraft Fli ght Document Number BOARD Manual Supplement 120 074 00 SYSTEMS Page Daa CugoHook a Joo Ill PROCEDURES continued Cargo Hook Rigging Extreme care must be exercised in rigging a load to the Cargo Hook If the load ring is too big it may work its way around the end of the load beam and be supported for a time on the keeper and then fall free If the load ring is too small it may jam itself against the load beam during an attempted release The following illustrations show recommended configurations and potential difficulties that must be avoided WARNING The examples shown are not intended to represent all problem possibilities It is the responsibility of the operator to assure the hook will function properly with the rigging Figure 1 Examples of correct and incorrect cargo hook rigging Correct Rigging 150 5 S Ap 9 95 Primary Ring D Primary Ring AA T 1 2 Max Cross Section _ secondary Ring or Shackle Multiple Rings 7 Multiple Rings on Load Beam
12. ations release at 3 500 lb Minimum release load Mating electrical connector PCO06A8 2S SR General Information Theory of Operation General Information 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 and an external manual release cable provide the means for unlatching the load beam The load beam is normally returned to its closed position after release of the load by a spring in the internal mechanism In the closed position a latch engages the load beam and latches it in this position The load is attached to the load beam by passing the cargo sling ring into the throat of the load beam past a spring loaded keeper which secures the load 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 A spring in the internal mechanism then drives the load beam back to its closed and latched position 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 achieve
13. cables The cables must not be the stops that prevent the Cargo Hook from swinging freely in all directions 2 Apply 10 20 pounds to the cargo hook load beam and pull the handle operated cargo hook mechanical release the Cargo Hook should release 3 Close the cargo hook release circuit breaker and position the battery switch to the ON position Apply 10 20 pounds to the cargo hook load beam and depress the cargo hook electrical release button the Cargo Hook should release 4 See the Bell Helicopter service instructions for your specific helicopter model for additional installation instructions Component Weights The weight of the cargo hook components are listed in Table 2 2 Table 2 2 Component Weights Item Weight Ibs kgs Cargo Hook 5 75 2 61 Link Adapter assembly 1 0 45 Manual Release Cable 25 11 Cargo Hook Location Table 2 3 Cargo Hook Location Fuselage Station 108 5 Paper Work Remove the Flight Manual Supplement from the back of this manual and place it into the Rotorcraft Flight Manual 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 2 6 Installation Instructions Section 3 Operation Instructions Operating Procedures Prior to each job perform the following 1 Ensure that the Cargo Hook has been properly installed and that the manual and electrical release cables do not limit the
14. ctor Pe rover 2 4 Installation Instructions Cargo Hook Installation continued Un commanded cargo hook release will happen if the manual and electrical release cables are improperly restrained The cables 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 or electrical release cables Figure 2 7 Un commanded Release From Incorrectly Secured Cable HOOK ROTATES AND STRAINS AGAINST __ THE MANUAL RELEASE CONDUIT THE STRAIN ON THE CONDUIT EXCEEDS THE PULL OFF FORCE BETWEEN THE SWAGED FITTING AND THE CONDUIT THE SWAGED JOINT FAILS AND ALLOWS THE INNER CABLE TO ACTIVATE THE HOOK S MECHANICAL RELEASE MECHANISM AND THE HOOK OPENS N THE LOAD RING FALLS FREE IN AN UN COMMANDED RELEASE Installation Instructions 2 5 Installation Check Out After installation of the Cargo Hook perform the following functional checks 1 Swing the installed Cargo Hook to ensure that the manual release cable assembly and the electrical release cable have enough slack to allow full swing of the suspension assembly without straining or damaging the
15. d by operating a mechanical release cable The manual 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 knob located on the side of the Cargo Hook 1 3 This page intentionally left blank Section 2 Installation Instructions These procedures are provided for the benefit of experienced aircraft maintenance facilities capable of carrying out the procedures They must not be attempted by those lacking the necessary expertise Cargo Hook and Manual Release Cable Removal Disconnect the manual and electrical release cables from the Cargo Hook Remove the Cargo Hook from the universal assembly leaving the universal assembly attached to the cargo suspension assembly Disconnect and remove the manual release cable from the cargo suspension assembly Cargo Hook Kit Installation Inspect the cargo frame assembly to insure that all components are in serviceable condition Attach the link adapter assembly to the Cargo Hook using the hardware supplied as illustrated below Torque AN nut 510 170 00 to 50 in lbs then rotate nut to next castellation not to exceed 110 in lbs Install and secure cotter pin 510 178 00 Figure 2 1 Link Adapter Assembly Installation NAS Washer P N 510 174 00 Link Adapter Assembly NAS 1149F0663P P N 210 164 00 MS Cotter Pin P N 510 178 00 MS24665 302 Load Bolt P N 290 332 00
16. da Certification 5 3 This page intentionally left blank FAA APPROVED ROTORCRAFT FLIGHT MANUAL SUPPLEMENT Bell Helicopter Models 206A amp 206B ax FAA Approved ae Manager Special Certification Branch Seattle Aircraft Certicification Office pate Aly 27 9 9b ed Revis Z Rotorcraft Flight H CONBOARD Manual Supplement 120 074 00 SYSTEMS INTRODUCTION This supplement must be attached to the appropriate approved Bell Rotorcraft Flight Manual when an Onboard Systems 200 232 00 Cargo Hook Kit is installed in accordance with Supplemental Type Certificate STC NO SROOS538SE The information contained herein supplements or supersedes the basic manual only in those areas listed herein For limitations procedures and performance information not contained in this supplement consult the basic Rotorcraft Flight Manual I LIMITATIONS The basic Flight Manual remains applicable When an Onboard Systems 200 232 00 Cargo Hook Kit is installed the following placard applies e Mounted on bottom of Cargo Hook WARNING USE LOAD RING WITH 1 5 25 INCH NOMINAL INTERNAL DIMENSION I PERFORMANCE The basic Flight Manual and Bell Rotorcraft Flight Manual Supplement Cargo Hook remains applicable HI PROCEDURES Before each Cargo Hook use perform the following procedures If the procedures are not successful do not use the equipment until the problem has been corrected Inspect all mounting fasteners to ensure th
17. e The following illustrations show recommended configurations and potential difficulties that must be avoided The examples shown are not intended to represent all problem possibilities It is the responsibility of the operator to assure the hook will function properly with the rigging Operation Instructions Cargo Hook Rigging continued Figure 3 1 Examples of Correct and Incorrect Cargo Hook Rigging Correct Rigging j i 1 50 2 25 T Primary Ring I D Multiple Rings f l Multiple Rings on Load Beam on Primary Ring Operation Instructions 3 3 Un Commanded Release Due to Too Large of a Load Ring Load rings that are too large will cause an un commanded release The ring will flip over the end of the load beam and flip the keeper up and then fall free Only correctly sized load rings must be used See examples below Figure 3 2 Un Commanded Release Due to Too Large of a Load Ring Load Ring flips over the Load Beam and gyrates The flip over often occurs with long line operations during landing and take offs Load Ring moves inward and bears against the keeper The Keeper is forced to rotate allowing the Ring to slip off 3 4 Operation Instructions Load Hang Up Due to Too Small of a Load Ring or Multiple Load Rings Load rings that are too small or multiple load rings will hang on the load beam when the load is released Only correctly sized
18. e Instructions 4 1 Preventive Maintenance 4 1 Inspection 4 1 Adapter Link Overhaul 4 3 Instructions for Returning a System to the Factory 4 4 iii CON T EN T S continued Section 5 Certification STC 5 1 STA 5 3 Rotorcraft Flight Manual Supplement Figures Tables 2 1 2 2 2 3 2 5 1 1 2 1 2 2 2 3 Manual Release Cable Installation 2 1 Link Adapter Assembly Installation 2 2 Cargo Hook Assembly to Cargo Frame Assembly 2 2 Manual Release Cable Rig 2 3 Adel Clamp and Shock Cord Installation 2 3 Cargo Frame Assembly Overview 2 4 Un commanded Release 2 5 Examples of Correct and Incorrect Cargo Hook Rigging 3 3 Un commanded Release Due to Large Load Ring 3 4 Load Hang Up Too Small or Multiple Load Rings 3 5 Un Commanded Release Due to Nylon Straps 3 6 Un Commanded Release Due to Cable or Rope Straps 3 7 Link Assembly Parts 4 2 Cargo Hook Specifications 1 1 Cargo Hook Connector 2 3 Component Weights 2 5 Cargo Hook Location 2 5 Section 1 General Information Introduction Safety Labels The P N 200 232 00 Cargo Hook kit is approved for installation on the 206A and 206B The kit replaces the Breeze Eastern hooks SP4232 4 5 and 5L when used as part of the Bell Cargo Hook Suspension Assembly P N 206 706 335 1 10lor 103 The helicopter must also be equipped with the Bell Cargo Hook Provisions Kit P N 206 706 335 3 5 or 105 The following definitions apply to the sy
19. elow Figure 3 5 Un Commanded Release Due to Cable or Rope Type Straps Cable or rope type line flips over the Load Beam The flip over oftens occurs with long line operations during landings and take offs Load Ring moves inward and bears against the keeper The keeper rotates allowing the Ring to slip off Cargo Hook Suspension System Operation Instructions 3 7 This page intentionally left blank Section 4 Maintenance Storage Instructions Clean the Cargo Hook thoroughly before packaging Pack the unit in a heat sealable package If the unit is to be stored for long periods in a tropical climate it should be packed in a reliable manner to suit local conditions Refer to relevant MIL specifications After the Cargo Hook has been repaired or stored for an extended period of time it must be subjected to the Acceptance Test Procedure per service manual 122 002 00 Package the unit in a suitable fiberboard box and cushion the unit to prevent shifting Seal the fiberboard box with tape and mark the box with the contents and date of packaging Preventive Maintenance Inspection Maintenance Remove caked on dirt from the Cargo Hook with a brush and clean exposed surfaces with a mild solvent Thoroughly dry all surfaces The scheduled inspection intervals noted below are maximums and are not to be exceeded If the cargo hook is subjected to unusual circumstances extreme enviro
20. lease cable Replaced warnings cautions and notes section with safety labels section Updated safety labels throughout document Updated inspection and overhaul information 09 14 10 Added Figure 4 4 added Link Assembly bushing installation instructions updated bushing wear criteria Register Your Products for Automatic Notifications Onboard Systems offers a free notification service via fax or email for product alerts and documentation updates By registering your Onboard Systems products at our website we will be able to contact you if a service bulletin is issued or if the documentation is updated You can choose to receive notices on an immediate weekly or monthly schedule via fax email or both methods There is no charge for this service Please visit our website at www onboardsystems com notify php to get started ii This page intentionally left blank CONTENTS Section 1 Section 2 Section 3 Section 4 General Information Introduction 1 1 Safety Labels 1 1 Bill of Materials 1 2 Inspection 1 2 Specifications 1 2 Theory of Operation 1 3 Installation Instructions Cargo Hook and Manual Release Cable Removal 2 1 Cargo Hook Kit Installation 2 1 Installation Check Out 2 6 Component Weights 2 6 Cargo Hook Location 2 6 Paper Work 2 6 Operation Instructions Operating Procedures 3 1 Cargo Hook Rigging 3 2 Cargo Hook Rigging Illustrations 3 3 Maintenance Storag
21. mbols 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 T D AN G i R 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 N O C E unusual information not directly related to safety General Information Used to address practices not related to personal injury 1 1 Bill of Materials Inspection Specifications 1 2 The following items are included with the Cargo Hook Kit if shortages are found contact the company from whom the system was purchased Part Number Description Quantity 120 074 00 Cargo Hook Kit Owner s Manual 122 002 00 Big Mouth Hook Service Manual 210 164 00 Adapter Link Assembly 268 015 00 Manual Release Cable 290 426 00 Release Fitting 510 252 00 Jam Nut 512 010 00 Adel Clamp 528 017 00 Cargo Hook NOTICE Kits sold after June 16 2010 include the Manual Release Cable prior to this the kit utilized the existing OEM release cable Inspect the kit items for evidence of damage corrosion and security of lock wire and fasteners If damage is evident do not use the items until they are repaired Table 1 1 Cargo Hook Specific
22. movement of the hook 2 Be completely familiar with this manual particularly the Cargo Hook rigging section 3 Be completely familiar with all Bell Helicopter Cargo Hook operating instructions 4 Activate the electrical system and press the release button to ensure the cargo hook electrical release is operating correctly The Cargo Hook must relatch after release If the hook does not relatch 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 solenoid to overheat possibly causing permanent damage 5 Activate the manual release knob to test the cargo hook manual release mechanism The mechanism should operate smoothly and the Cargo Hook must relatch after release If the hook does not relatch do not use the unit until the difficulty is resolved See the trouble shooting table in Section 4 and the Bell service instructions that cover the original Cargo Hook installation for additional instructions Operation Instructions 3 1 Cargo Hook Rigging 3 2 Extreme care must be exercised in rigging a load to the Cargo Hook If the load ring is too big it may work its way around the end of the load beam and be supported for a time on the keeper and then fall free If the load ring is too small it may jam itself against the load beam during an attempted releas
23. n contact with the cargo hook load beam See examples below Figure 5 Un commanded release due to cable or rope type straps Cable or rope type line flips over the Load Beam The flip over oftens occurs with long line operations during landings and take offs Load Ring moves inward and bears against the keeper The keeper rotates allowing the Ring to slip off Rotorcraft Fli ght Document Number BOARD Manual Supplement 120 074 00 SYSTEMS Page Daa CagoHook n Joo
24. nmental 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 cargo hook kit per the following NOTICE Hours of external load operations is defined as the time in which a helicopter is engaged in external load operations This includes time between loads on the hook 1 Activate the helicopter electrical system and press the cargo release button to ensure the cargo hook electrical release is operating correctly The cargo hook must release If the hook does not release or re latch do not use the unit until the problem is corrected 4 1 Inspection continued 4 2 Pressing the cargo electrical release button continuously in excess of 20 seconds will cause the cargo hook electrical release solenoid to overheat possibly causing permanent damage 2 Activate the manual release system by pulling the release handle in the cockpit The cargo hook must release If the hook does not release or re latch do not use the unit until the problem is corrected 3 Move the cargo hook throughout its full range of motion to ensure the manual and electrical release cables have enough slack The cables must not be the stops that prevent the cargo hook from moving freely in all directions 4 Visually check for presence and security of fasteners and electrical connections
25. omate primer o Inspect the link for damage Repair dents gouges nicks scratches and corrosion if less than 030 deep blend out at a ratio of 20 1 length to depth replace Adapter Link Assembly if otherwise damaged o Perform Magnetic Particle Inspection on adapter link P N 290 363 00 in accordance with ASTM E 1444 and MIL STD 1907 Grade A No cracks are permitted Figure 4 2 Link Assembly Parts Link Adapter P N 290 363 00 Bushing Bushing rs P N 290 364 00 P N 290 365 00 Maintenance 4 3 Instructions for Returning Equipment to the Factory If an Onboard Systems product must be returned to the factory for any reason including returns service repairs overhaul etc obtain an RMA number before shipping your return NOTICE An RMA number is required for all equipment returns e To obtain an RMA please use one of the listed methods Contact Technical Support by phone or e mail Techhelp OnboardSystems com Generate an RMA number at our website http Awww onboardsystems com rma php e After you have obtained the RMA number please be sure to 4 4 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 cust
26. oms prepaid to Onboard Systems 13915 NW 3rd Court Vancouver Washington 98685 USA Phone 360 546 3072 Maintenance Section 5 Certification De oes STC Department of Transportation Feeral Aviation Administration Supplemental Cope Certificate Minler SR00538SE Thes certificate issued to Onboard Systems 11212 NW St Helens Road Portland OR 97231 certifies that the change tn the igre deseg for the following peroduct with the limitations and conditions therefor as specified Rereon meets the airworthiness reguirenents of Part of the Civil Air Regulations Ohiginal Poduct Tye Certificate Number H2SW Make Bell Model 206A and 206B Description of the Tyre Design Change Fabrication of Onboard Systems Model 200 232 00 cargo hook kit in accordance with FAA Approved Onboard Systems Master Drawing List No 155 039 00 dated June 26 2000 or later FAA approved revision and installation of this replacement cargo hook in accordance with FAA approved Onboard Systems Owner s Manual No 120 074 00 dated June 26 2000 or later FAA approved revision Inspect this cargo hook kit in accordance with Onboard Systems Service Manual No 122 002 00 dated June 12 2000 or later FAA approved revision Lnitations ard Conditions Approval of this change in type design applies to only those Bell model rotorcraft listed above which were previously equipped with an FAA approved installation of Bell cargo hook suspension assembly P N 206
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