3,600 Pound Keeperless
Cargo Hook Kit
for the
Bell 206L & 407
Series Helicopters
Kit Part Number 200-260-01
Owner's Manual
Owner's Manual Number 120-093-01
Revision 0
September 30, 2009
13915 NW 3 rd
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
0
Date
09/30/09
Page(s)
All Initial Release
Reason for Revision
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CONTENTS
Section 1 General Information
Introduction, 1-1
Warnings, Cautions and Notes, 1-2
Bill of Materials, 1-2
Inspection, 1-3
Specifications, 1-3
Theory of Operation, 1-3
Section 2 Installation Instructions
Cargo Hook Removal, 2-1
Cargo Hook Installation, 2-1
Manual Release Cable Installation, 2-2
Electrical Connection, 2-5
Cargo Hook Installation, Warning, 2-6
Installation Check-Out, 2-7
Component Weights, 2-7
Cargo Hook Location, 2-7
Paper Work, 2-7
Section 3 Operation Instructions
Operating Procedures, 3-1
Cargo Hook Loading, 3-2
Cargo Hook Rigging, 3-2
Section 4 Maintenance
Instructions for Returning a System to the Factory, 4-1
Section 5 Certification
STC, 5-1
STA, 5-2
EASA STC, 5-3
ANAC CST, 5-5
iii
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Section 1
General Information
Introduction
The 200-260-01 Cargo Hook Kit is approved for installation on the following Bell helicopters:
Model
206L
206L-1
206L-3
206L-4
407
Serial Numbers
45001-45153
45154 and on
51001 and on
52001 and on all
Equipped with one of the following Bell Helicopter Cargo Hook
Suspension Systems:
206-706-341-109
206-706-341-5
206-706-341-101
The 528-029-00 Cargo Hook included in the 200-260-01 kit is suitable as a replacement for the following cargo hooks when used on one of the applicable Bell Helicopter Cargo Hook Suspension Systems listed above.
Breeze-Eastern P/Ns
17149-6
17149-2
Onboard Systems P/Ns
528-010-04
528-023-01
General Information
1-1
Warnings, Cautions and Notes
The following definitions apply to Warnings, Cautions and Notes used in this manual.
Means that if this information is not observed, serious injury, death or immediate loss of flight
safety could occur.
Means that there is a risk of injury or degradation in performance of equipment if this information is not observed.
Draws the reader’s attention to information which may not be directly related to safety, but which is important or unusual.
Bill of Materials
The following items are included with the Cargo Hook, if shortages are found contact the company from whom the system was purchased.
Part Number Description
528-029-00 3.6K Keeperless Hook
290-331-00 Release Fitting
268-004-01 Release Cable Assembly
290-332-00 Attach Bolt
510-174-00 Washer
510-183-00 Washer
510-170-00 Nut
510-178-00 Cotter Pin
120-093-01
Owner’s Manual
121-002-01 RFMS
122-017-00 Cargo Hook Service Manual
123-001-01 ICA
Quantity
1
1
1
1
1
1
1
1
2
1
1
1
General Information
1-2
Inspection
Inspect the cargo hook for evidence of damage, corrosion and security of lock wire and fasteners. If damage is evident, do not use the unit until it has been repaired.
Specifications
Table 1-1 Cargo Hook P/N 528-029-00 Specifications
Design load
Design ultimate strength
Electrical release capacity
Mechanical release capacity
Force required for mechanical release at 3,500 lb.
Electrical requirements
Minimum release load
Unit weight
Mating electrical connector
3,600 lb. (1,633 kg.)
13,500 lb. (6,123 kg.)
9,000 lb. (4,082 kg.)
9,000 lb. (4,082 kg.)
8 lb. Max.(.600” travel)
22-32 VDC 6.9 - 10 amps
0 pounds
3.0 pounds (1.35 kg.)
PC06A8-2S SR
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 and an external manual release cable 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.
General Information
1-3
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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 Removal
Verify that the part number of the cargo hook to be removed matches one of the numbers on the list in the Applicability section of this manual. If it does not, do not attempt to use the new cargo hook, contact the factory for clarification.
To remove the existing cargo hook from the suspension system, disconnect the electrical and manual release cables from the cargo hook.
Remove the cargo hook retaining bolt and separate the cargo hook from the suspension system.
Cargo Hook Installation
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.
Inspect the suspension system to ensure that all components are in serviceable condition before installing the new cargo hook to the suspension system.
Attach the Cargo Hook (P/N 528-029-00) to the suspension system as illustrated in Figure 2.1. The Cargo Hook load beam must point to the right side of the helicopter when looking from the rear.
Tighten nut P/N 510-170-00 on bolt P/N 290-332-00 to finger tight, then rotate nut to next castellation to install and secure cotter pin P/N 510-178-
00.
Installation Instructions 2-1
Cargo Hook Installation
continued
Figure 2.1 Cargo Hook Installation
Manual Release Cable Installation
Remove the manual release cover from the cargo hook by removing two screws.
Figure 2.2 Manual Release Cover Removal
Remove these two screws.
2-2
Installation Instructions
Manual Release Cable Installation
continued o Thread the manual release cable adapter, P/N 290-331-00 into the cargo hook side plate and tighten until firmly against the side plate.
Figure 2.3 Manual Release Cable Adapter
Manual Release
Cable Adapter o Connect the manual release cable, P/N 268-004-01, to the adapter. o At the cargo hook, place the cable ball end fitting into the manual release lever fork as illustrated in Figure 2.4.
Manual release cable rigging must be done with the cargo hook in the closed and locked position.
o Rotate the release lever in the clockwise direction to remove free play
(the free play is taken up when the hook lock indicator begins to move, this is also readily felt as the lever rotates relatively easily for several degrees as the free play is taken up) and measure the gap between the release lever fork and cable ball end with the manual release lever in the cockpit in the non-release position. Adjust the manual release cable system to obtain a minimum gap of .125 inches
(3.2mm) at the release lever fork as shown in Figure 2.4.
Installation Instructions 2-3
Manual Release Cable Installation
continued
Figure 2.4 Manual Release Cable Rigging
Release Lever
Hook Lock Indicator
Manual Release Cable
Cable Ball End
.125 in. min.
(3.2 mm)
Release Lever Fork
Load beam must be closed and locked for rigging.
o Re-install the manual release cover with the two screws.
2-4
Installation Instructions
Electrical Connection
Connect the existing cargo hook electrical release harness connector to the
Cargo Hook. Listed below is the pin out for the cargo hook connector.
Table 2-1 Cargo Hook Connector
Pin Function
A Ground
B Power
The cargo hook is equipped with a suppression diode that will be damaged if the cargo hook electrical connection is reversed. Do not attach the electrical connector until polarity if the aircraft connector is determined to be compatible with the Cargo Hook connector listed in Table 2-
1.
Installation Instructions
2-5
Cargo Hook Installation, Warning
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 2.5 Un-commanded Release From Incorrectly Secured Cable
2-6
Installation Instructions
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 and the electrical release harness have enough slack to allow full swing of the cargo hook and suspension assembly without straining or damaging the cable or harness. The release cable or harness 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, 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.
Component Weights
The weight of the Cargo Hook Kit components are listed below.
Table 2-2 Component Weights
Item Weight
Cargo Hook w/ attach hardware & release fitting
Manual Release Cable
3.25 lbs (1.47 kgs)
0.31 lbs (0.14 kgs)
Total 3.56 lbs (1.61 kgs)
Cargo Hook Location
Table 2-3 Cargo Hook Location
Fuselage Station
Paper Work
121.0
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 121-002-01 in the aircraft Flight Manual.
Installation Instructions 2-7
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Section 3
Operation Instructions
Operating Procedures
Daily, prior to the first cargo hook use of the day, perform the following:
1. Ensure that the manual release cable and electrical release harnesses do not limit the movement of the cargo hook.
2. Activate the electrical system and press the Cargo Hook release button to ensure the cargo hook electrical release is operating correctly. The mechanism should operate smoothly and 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.
Operation Instructions
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.
3. 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. 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 3.1).
Figure 3.1 Hook Lock Indicator
3-1
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 3.2, until an internal latch engages the load beam and latches it in the closed position.
Figure 3.2 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. Figure 3.3 shows the recommended rigging, 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.
3-2
Operation Instructions
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 3.3 Examples of Recommended Cargo Hook Rigging
Operation Instructions
3-3
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Section 4
Maintenance
Refer to the Instructions for Continued Airworthiness (ICA) manual 123-
001-01 and Cargo Hook Service Manual 122-017-00 for 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
([email protected]).
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
Maintenance
4-1
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Section 5
Certification
FAA STC
Certification
5-1
FAA STC
continued
5-2
Certification
Canadian STC
Certification
5-3
Canadian STC
continued
5-4
Certification
EASA STC
Certification
5-5
EASA STC
continued
5-6
Certification
ANAC CST
Certification
5-7
ANAC CST
continued
5-8
Certification
ANAC AML
Certification
5-9
