Cargo Hook Kit Owner`s Manual - Onboard Systems International
Contents
1. pLEASE CHEC 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 Z CONBOARD SYSTEMS I N T E RN ATION A L 13915 NW 3 Court Vancouver Washington 98685 Phone 360 546 3072 Fax 360 546 3073 Toll Free 800 275 0883 www OnboardSystems com This page intentionally left blank RECORD OF REVISIONS Revision Date Page s Reason for Revision 10 31 00 1 1 Added Talon LC Service Manual to BOM and New STC dated July 27 2000 2 2 Revised instructions of manual release cable installation and Figure 2 2 5 30 01 2 1 Replaced hook picture to show new cover and S N 3 5 plate 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 12 10 02 Title 4 3 Address Change 07 19 05 Section 4 Removed maintenance information and replaced with reference to Service Manual 122 001 00 08 18 06 1 1 2 4 Removed RFMS from manual A separate document Section 5 121 036 00 has been created for it 11 20 06 1 1 amp 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 33 1 00 in Maintenance section 10 01 07 TOC Section 1 Added explanation or warnings cautions and notes to 2 3 amp Section 3 general informatio2. 00 215 00 Cargo Hook Kit in accordance with FAA approved Onboard Systems Owner s Manual 120 046 00 Revision 11 dated November 20 2006 or later FAA approved revision Inspect Cargo Hook Kit in accordance with Onboard Systems Owner s Manual 120 046 00 Revison 11 dated November 20 2006 or later FAA approved revision Limitations and Conditions Approval of this change in type design applies to only those Bel model rotorcraft listed above which were previously equipped with an FAA approved installation of Bell cargo hook suspension systems 206 706 341 5 206 706 341 101 206 706 341 109 and either Breeze Eastern cargo hooks 17149 2 or 17149 6 See Continuation Sheet Page 3 This certificate and the supporting data which is the basis for approval shalt remain ia offect until surrendered suspended revoked or a termination dale is otherwise sttablished uy the Haministretor of the Date of aplication May 31 1996 Dale reitdued Late of sisuanrce August 26 1996 Bute amended 7 11 1997 5 10 2000 7 27 2000 1 13 2003 9 8 2006 2 6 2007 By direction of the Helmanis Any alteration of this certificate is punishable by a fine of not ex 1 000 or imonsonment not exceeding I years or Doth This certificate may be transferred in accordance with FAR 21 47 FAA FORM 8110 2 10 68 Certification STC continued Ported States of Armoricx Bepartinent of Trapporiation Frera Aviation Atuinistration Supplemental Type Certificate N
3. 1 3 2 3 3 3 4 3 5 1 1 2 1 2 2 Suspension System Overview 2 1 Manual Release Cable Rig 2 2 Un commanded Release From Incorrectly Secured Cable 2 3 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 Specifications 1 3 Cargo Hook Connector 2 2 Cargo Hook Location 2 4 Section 1 General Information Introduction General Information The 200 215 00 Cargo Hook Kit is approved for installation on the following Bell helicopters Model Serial Numbers 206L 45001 45153 206L 1 45154 and on 206L 3 51001 and on 206L 4 52001 and on 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 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 o
4. 26 2000 or later FAA approved revision FAA approved Onboard Systems Service Manual n 122 001 00 dated June 13 2000 or later FAA approved revision FAA approved Onboard Systems Rotorcraft Flight Manual Supplement n 121 036 00 dated September 7 2006 or later FAA approved revision Limitations and Conditions 1 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 systems 206 706 341 5 206 706 34 1 101 206 706 341 109 and either Breeze Eastern cargo hooks 17149 2 or 17146 6 This STC is approved only for the product configuration as defined in the approved design data referred to in the paragraph Description Compatibility with other aircraft engine configurations shall be determined by the installer This certificate shall remain valid unless otherwise surrendered or revoked For the European Aviation Safety Agency Date of Issue 27 September 2006 P Naaj Le Jolen Massimo Mazzoletti Certification Manager Rotorcraft Balloons amp Airships STC EASA IM R S 01166 Onboard Systems International Certification 5 5
5. Aircraft Engine Type or Model BELL 206L 206L 1 206L 3 206L 4 407 Canadian Type Certificate or Equivalent H 92 Description of Type Design Change Installation of Onboard Systems Model 200 215 00 Cargo Hook Kit in accordance FAA STC No SR00369SE Installation Operating Data Required Equipment and Limitations Installation of Onboard Systems Model 200 215 00 Cargo Hook Kit is to be carried out in accordance with FAA approved Onboard Systems Owner s Manual No 120 046 00 Revision 11 dated November 20 2006 Fabrication of Onboard Systems Model 200 215 00 Cargo Hook Kit is to be in accordance with FAA approved Onboard Systems Master Drawing List No 155 029 00 Revision 14 dated November 30 2006 Inspection of this cargo hook must be in accordance with Onboard Systems Owner s Manual No 120 046 00 Revision 11 dated November 20 2006 Modified rotorcraft must be operated in accordance with an FAA approved copy of Onboard Rotorcraft Flight Manual Supplement RFMS No 121 036 00 dated September 7 2006 Limitations 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 Systems 206 706 341 5 206 706 341 101 206 706 341 109 and either Breeze Eastern cargo hooks 17149 2 or 17149 6 or later FAA approved revisions End Conditions This approval is only applicable to the type mod
6. el 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 Paul Arnell For Minister of Transport Canad Certification 5 3 EASA STC European Aviation Safety Agency SUPPLEMENTAL TYPE CERTIFICATE EASA IM R S 01166 This certificate established in accordance with Regulations EC No 1592 2002 and EC No 1702 2003 and issued to Onboard Systems International 13915 NW 3 Court Vancouver WA 98685 United States certifies that the change in the type design for the product listed below with the limitations and conditions specified meets the applicable type certification basis and environmental protection requirements when operated within the conditions and limitations specified below Original Product Type Certificate number FAA TCDS No H2SW Manufacturer Bell Helicopter Textron Canada Ltd Model 206L 206L 1 206L 3 206L 4 and 407 Original STC Number FAA STC SROO369SE Description of Design Change Cargo hook installation n 200 215 00 5 4 Certification EASA STC continued Associated Technical Documentation FAA approved Onboard Systems Master Drawing List n 155 029 00 dated June 26 2000 or fater FAA approved revision FAA approved Onboard Systems Owner s manual n 120 046 00 dated June
7. er 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 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 Removal To remove the existing cargo hook from t
8. f equipment if this information is NOTE 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 Quantity 120 046 00 121 036 00 122 001 00 Talon LC Cargo Hook Service Manual 528 010 04 Cargo Hook 268 004 01 Release Cable Assembly 290 33 1 00 Release Fitting NOTE Kits manufactured after 9 15 09 include Release Cable Assembly P N 268 004 011 1 2 General Information Inspection Specifications 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 Table 1 1 Specifications Force required for mechanical 8 lb Max 400 travel release at 3 500 lb Electrical requirements 22 28 VDC 9 amps Minimum release load 3 pounds 1 35 kg Mating electrical connector PCO6A8 2S SR 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 aft
9. he 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 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 Figure 2 1 Suspension System Overview ern CARGO HOOK ATTACH BOLT CARGO HOOK x LOAD BEAM Installation Instructions 2 1 Cargo Hook Installation continued 2 2 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 m
10. ing 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 Operation Instructions Cargo Hook Rigging continued Figure 3 1 Examples of Correct and Incorrect Cargo Hook Rigging Correct Rigging N 1 50 Primary Ring I D coal Secondary Ring or Shackle Incorrect Rigging Multiple Rings 4 Multiple Rings an i on Primary Ring 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 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 landings and take offs Load Ring moves inward and bears against the keeper The Keeper i
11. inimum 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 Manual Release Lever Manual Release Cable Fork Fitting Ball End Fitting 125 Free Play 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 Pa rower Installation Instructions Cargo Hook Installation continued Installation Instructions 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 Hook rotates and stra ns aga nst the manua reease condut Be The stra n on the condu t exceeds the pu off force between the swaged VV ftt ng and the condu t The swaged jo nt fa s and a ows the nner cab e to act vate
12. n RMA number at our website http Awww onboardsystems com rma php e 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 e Include the RMA number and reason for the return on your purchase or work order e Include your name address phone and fax number and email as applicable e 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 This page intentionally left blank Section 5 Certification STC Separhnent ot Uraeportation sedtern Au Anetra Supplemental Type Certificate Number SR00369SE This certificate issued to Onboard Systems 13915 NW 3rd Court Vancouver WA 98685 certifies that the change in the type design for the following product with the limitations and conditions therefor as specifued hereon meets the airworitiness reguiements of Fart 6 of the Civil Ait Regulations Ouuginal Produet ppe Certificate Number H2SW Make Bell Model 206L 206L 1 206L 3 206L 4 and 407 Dusergntion of the Type Design Change Fabrication of Onboard Systems Model 200 215 00 Cargo Hook Kit in accordance with FAA Approved Onboard Systems Master Drawing List No 155 029 00 Revision 14 dated November 30 2006 or later FAA approved revision and Installation of the 2
13. n 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 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 This page intentionally left blank CONTENTS Section 1 Section 2 Section 3 Section 4 Section 5 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 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 Operation Instructions Operating Procedures 3 1 Cargo Hook Rigging 3 2 Maintenance Instructions for Returning a System to the Factory 4 1 Certification STC 5 1 Canadian STC 5 3 EASA STC 5 4 CONTENTS continued ii Figures Tables 2 1 2 2 2 3 3
14. ould 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 Cable or rope type line flips over the Load Beam The flip over often 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 Operation Instructions 3 7 This page intentionally left blank 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 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 e Generate a
15. s 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 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 mee Load Hang Up Due to Multiple Rings on Load Beam Jammed Rings Sling Loa Operation Instructions 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 Nylon type strap on the Load Beam As the load swings the strap fibers work their way under the keeper The strap works its way off of the load beam 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 sh
16. the hook s mechan ca re ease mechan sm and the hook opens 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 Ins
17. tructions 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 Be completely familiar with this manual particularly the Cargo Hook rigging section Be completely familiar with all Bell Helicopter cargo hook operating instructions 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 re latch 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 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 3 1 Operation Instructions Cargo Hook Rigging 3 2 Extreme care must be exercised in rigg
18. umber R00369SE Onboard Systems Amended February 6 2007 Limitations and Conditions Continued This approval should not be extended to rotorcraft 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 rotorcraft Modified rotorcraft must be operated in accordance with a copy of the FAA approved of Onboard Rotorcraft Flight Manual Supplement RFMS No 121 036 00 dated September 7 2006 or later FAA approved revision A copy of this Certificate and the FAA approved RFMS must be maintained as part of the permanent records of the modified rotorcraft 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 e e e _ ee Any iteration of this certificate is FAA FORM 6110 2 10 68 5 2 Certification Canadian STC Department of Transport Supplemental Type Certificate This approval is issued to Number SH97 21 Onboard Systems Issue No 3 13915 North West 3rd Court Approval Date May 01 1997 Vancouver Washington Issue Date June 07 2007 United States of America 98685 i 7 D Transport Canada Transports Canada Responsible Office Pacific
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