Onboard Systems Bell 206L Series, Bell 407 Series Cargo Hook Kit Owner's Manual

Cargo Hook Kit

For The

Bell 206L Series Helicopter

Bell 407 Series Helicopters

Part Number 200-215-00

Owner's Manual

Owner's Manual Number 120-046-00

Revision 13

September 15, 2009

13915 NW 3 rd

Court, Vancouver Washington, 98685

Phone: 360-546-3072 Fax: 360-546-3073 Toll Free: 800-275-0883 www.OnboardSystems.com

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Revision

6

7

8

9

10

11

12

13

Date

10-31-00

RECORD OF REVISIONS

Page(s) Reason for Revision

1-1

2-2

Added Talon LC Service Manual to BOM and New

STC dated July 27, 2000

Revised instructions of manual release cable installation and Figure 2-2.

5-30-01

12-10-02

07-19-05

2-1

3-5

RFMS Pg. 2

Replaced hook picture to show new cover and S/N plate.

Replaced hook picture to show new cover and S/N plate.

Replaced hook picture to show new cover and S/N plate

Title, 4-3 Address Change

Section 4 Removed maintenance information and replaced with reference to Service Manual 122-001-00.

08-18-06

11/20/06

1-1, 2-4,

Section 5

Removed RFMS from manual. A separate document,

121-036-00, has been created for it.

1-1 & 2-4 Changed Cargo Hook P/N 528-010-00 to 528-010-04 per service bulletin 159-017-00.

Added paragraph to address Release Fitting (290-331-

00) in Maintenance section.

10/01/07 TOC, Section 1,

2-3 & Section 3

Added explanation or warnings, cautions and notes to general information section. Updated warnings, cautions and notes throughout document.

09/15/09 1-2,1-3,2-2 Added Release Cable Assembly (P/N 268-004-01) to kit.

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CONTENTS

Section 1 General Information

Introduction, 1-1

Warnings, Cautions and Notes, 1-2

Bill of Materials, 1-2

Inspection, 1-2

Specifications, 1-3

Theory of Operation, 1-3

Section 2 Installation Instructions

Cargo Hook Removal, 2-1

Cargo Hook Installation, 2-1

Suspension System Installation Check-Out, 2-4

Component Weights, 2-4

Cargo Hook Location, 2-4

Paper Work, 2-4

Section 3 Operation Instructions

Operating Procedures, 3-1

Cargo Hook Rigging, 3-2

Section 4 Maintenance

Instructions for Returning a System to the Factory, 4-1

Section 5 Certification

STC, 5-1

Canadian STC, 5-3

EASA STC, 5-4

i

CONTENTS, continued

Figures

2-1 Suspension System Overview, 2-1

2-2 Manual Release Cable Rig, 2-2

2-3 Un-commanded Release From Incorrectly Secured Cable, 2-3

3-1 Examples of Correct and Incorrect Cargo Hook Rigging, 3-3

3-2 Un-commanded Release Due to Large Load Ring, 3-4

3-3 Load Hang-Up, Too Small or Multiple Load Rings, 3-5

3-4 Un-Commanded Release Due to Nylon Straps, 3-6

3-5 Un-Commanded Release Due to Cable or Rope Straps, 3-7

Tables

1-1 Specifications, 1-3

2-1 Cargo Hook Connector, 2-2

2-2 Cargo Hook Location, 2-4

ii

Section 1

General Information

Introduction

The 200-215-00 Cargo Hook Kit is approved for installation on the following Bell helicopters:

Model Serial Numbers

206L

206L-1

206L-3

206L-4

45001-45153

45154 and on

51001 and on

52001 and on

407 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 528-010-04 Cargo Hook 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 Cargo Hook P/N

17149-6

17149-2

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

120-046-00

121-036-00

122-001-00

290-331-00

528-010-04

268-004-01

Owner’s Manual

RFMS

Talon LC Cargo Hook Service Manual

Release Fitting

Cargo Hook

Release Cable Assembly

Quantity

1

1

1

1

1

1

Kits manufactured after 9/15/09 include Release

Cable Assembly P/N 268-004-01.

1-2

General Information

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 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

3,500 lb. (1,580 kg.)

15,750 lb. (7,140 kg.)

8,750 lb. (3,970 kg.)

8,750 lb. (3,970 kg.)

8 lb. Max.(.400” travel)

22-28 VDC 9 amps

7 pounds

3 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 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 electrically or mechanically. 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 lever. A manual release cable attached to the lever operates the internal mechanism of the cargo hook to unlatch the load beam.

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

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

Verify that the part number of the cargo hook removed matches one of the numbers on the list in section 1 of this manual. If it does not, do not attempt to use the new cargo hook, contact the factory for clarification.

Inspect the suspension system to ensure that all components are in serviceable condition before assembling the new cargo hook to the suspension system and returning the system to service.

Figure 2-1 Suspension System Overview

Install the new cargo hook to the suspension system, in the same manner as the old hook was installed. (The cargo hook load beam should point to the right side of the helicopter). Torque cargo hook attach bolt and nut to

50 in-lbs, then rotate nut to next castellation, not to exceed 110 in-lbs.

Insert and secure cotter pin.

BEAM

CARGO HOOK

ATTACH BOLT

CARGO HOOK

CARRIAGE

CARGO HOOK

LOAD BEAM

Installation Instructions

2-1

Cargo Hook Installation,

continued

Remove the cargo hook manual release cover and connect the manual release cable, P/N 268-004-01. Place the cable ball end fitting into the hook manual release fork fitting as illustrated in Figure 2-1. Check that there is a minimum of .125 inch free play at the fork fitting as shown in

Figure 2-2 with the manual release handle in the cockpit in the full down position.

Figure 2-2 Manual Release Cable Rig

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 Connector

Pin Function

A Ground

B Power

2-2

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 2-3 Un-commanded Release From Incorrectly Secured Cable

Installation Instructions

2-3

Suspension System Installation Check-Out

After installation of the Cargo Hook, perform the following functional checks. Follow any Bell Helicopter instructions for the specific helicopter.

1. 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 cables.

2. Apply 10 - 20 pounds to the cargo hook load beam and pull the 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 that cover the original cargo hook suspension system for additional instructions.

Component Weights

The weight of the 528-010-04 Cargo Hook is 3 pounds (1.36 kgs). This is approximately 1 pound lighter than the cargo hook it replaced.

Cargo Hook Location

Table 2-2 Cargo Hook Location

Fuselage Station 121.0

Paper Work

Insert the Rotorcraft Flight Manual Supplement 121-036-00 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.

2-4

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 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 mechanism should operate smoothly and the Cargo Hook must relatch after release. If the hook does not re-latch do not use the unit until the difficulty is resolved.

The release solenoid is intended to be energized only intermittently. Depressing the electrical release button continuously in excess of 20 sec. will cause the release solenoid to overheat, possibly causing permanent damage.

5. Activate the release lever assembly located on the cyclic stick to test the cargo hook manual release mechanism. The mechanism should operate smoothly and the Cargo Hook must re-latch after release. If the hook does not re-latch do not use the unit until the difficulty is resolved.

See the Bell service instructions that cover the original Cargo Hook installation for additional instructions.

Operation Instructions

3-1

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.

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.

3-2

Operation Instructions

Cargo Hook Rigging, continued

Figure 3-1 Examples of Correct and Incorrect Cargo Hook Rigging

Correct Rigging

Primary Ring

5/8" M ax. cross section

1.50" Primary Ring I.D.

1.87"

Secondary Ring or Shackle

Incorrect Rigging

Load

Incorrect Rigging

M ultiple Rings on Primary Ring

M ultiple Rings on Load Beam

Operation Instructions

3-3

Un-Commanded Release Due to Too Large of a Load Ring

Load rings that are too large will cause an uncommanded 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 flip s over the Load Beam and gyrates.

The flip over often occurs with long line op erations during landings and take offs.

Load Ring moves inward and bears against the keeper

3-4

The Keeper is forced to rotate allowing the

Ring to slip off

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 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

Jammed Ring

Sling Load

Operation Instructions

Load Hang-Up Due to

Multiple Rings on Load

Beam

Jammed Rings

Sling Load

3-5

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

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 below.

Figure 3-5 Un-Commanded Release Due to Cable or Rope Type

Straps

Operation Instructions

3-7

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Section 4

Maintenance

Cargo Hook Kit P/N 200-215-00 includes the Cargo Hook and the Release

Fitting (P/N 290-331-00). The Release Fitting threads into the cargo hook manual release side and interfaces with the helicopter’s existing manual release cable. It requires no maintenance other than a check, prior to external load operations, for damage and security.

For detailed maintenance of the Cargo Hook refer to Cargo Hook Service

Manual 122-001-00.

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.

Maintenance

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

4-1

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Section 5

Certification

STC

Certification

5-1

STC

continued

5-2

Certification

Canadian STC

Certification 5-3

EASA STC

5-4

Certification

EASA STC

continued

Certification 5-5