Flight Line Operation and Maintenance Manual Chs-9000-3 Cargo Hook System

TD-01-007
Revision B
FLIGHT LINE OPERATION AND MAINTENANCE MANUAL
CHS-9000-3 CARGO HOOK SYSTEM
TO: HOLDERS OF BREEZE-EASTERN FLIGHT LINE OPERATION AND MAINTENANCE

MANUAL FOR CHS-9000-3 CARGO HOOK SYSTEM, TD-01-007
REVISION B OF TD-01-007, DATED MARCH 4, 2011 IS RELEASED.
Revision B, dated March 4, 2011 replaces Revision A, dated December 7, 2007 in its entirety. Please
replace Revision A with the new manual provided. Indicate on the Record of Revisions the date of this
action, as well as the initials of the individual performing this task.
SECTION, PAGE DESCRIPTION OF CHANGE
All Revised standard format into manual, which includes, but are not limited to the
following:
ALL - Changed Header and Release Date

Description and Operation revised as necessary.
Section 501. Changed Cargo Hook System overhaul schedule in accordance with Service
Information Letter 02 Maintenance.
Added Apex Fitting information. Removed reference to load rings.
Added Cartridge Storage Information and shipping information.
Revised IPL as necessary.
General manual revision.
HIGHLIGHTS
Page H-1
March 4, 2011
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Revision B
FLIGHT LINE
OPERATION AND MAINTENANCE MANUAL
With
Illustrated Parts List
BREEZE-EASTERN
CARGO HOOK SYSTEM PART NUMBER CHS-9000-3
SAFETY WARNING
For your own safety and the safety of all others, read and understand all of the procedures and information in this component
maintenance manual before installing, operating, and/or maintaining any components of the cargo hook systems covered
herein.
EXPORT CONTROLLED – WARNING
This manual may contain information that is subject to the International Traffic in Arms Regulations (ITAR) or the Export
Administration Regulations (EAR), and may not be exported, released, or disclosed to foreign nationals, either in the United
States or overseas, without first complying with the export requirements / regulations of the ITAR and / or EAR. The
recipient is responsible for complying with all such export requirements / regulations. Include this notice with any reproduced
portions of this document.
PROPRIETARY RIGHTS NOTICE
This manual contains information that is proprietary to Breeze-Eastern Corporation, is an unpublished work protected under
applicable copyright laws and constitutes trade secrets for the purpose of the Trade Secret and Freedom of Information Acts. It
is delivered on the express conditions that it is not to be, used, disclosed or reproduced, in any manner, in whole or in part
without the prior written authorization of Breeze-Eastern Corporation, 35 Melanie Lane, Whippany, NJ 07981-1638, USA.
Nothing contained herein shall limit any rights granted by Breeze-Eastern Corporation under contract. This legend shall be
included on any reproduction hereof. All rights are reserved. Any act in violation of applicable law may result in civil and / or
criminal penalties.
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RECORD OF REVISIONS
Retain this record in the front of the manual. On receipt of revisions, insert revised pages in the
manual and enter revision number, date inserted, and initials.
REVISION REVISION DATE DATE REVISION REVISION DATE DATE

NUMBER FILLED BY NUMBER FILLED BY
Original February 14, 2005 - -
A December 7, 2007
B March 4, 2011
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RECORD OF TEMPORARY REVISIONS
Retain this record in the front of the manual. On receipt of temporary revisions, insert the temporary
revision pages in the manual and enter revision number, issue date, date inserted, and initials of
individual incorporating temporary revision. Upon receipt of revision that replaces the temporary
revision, insert removal date and initials of individual removing temporary revision.
REV. ISSUE DATE REMOVAL INCORPORATOR’S REMOVER’S

NO. DATE INSERTED DATE INITIALS INITIALS
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SERVICE BULLETIN LIST
Retain this record in the front of the manual. On receipt of Alert Service Bulletins (ASB’s), Service
Bulletins (SB’s), Service Information Letters (SIL’s), Technical Publication Deficiency Reports
(TPDR’s), Engineering Change Orders (ECO’s), etc., attach a copy of the document to the back of
the manual, and enter document type and issue date. When the intent of the bulletin is incorporated
into the manual via a revision, Breeze-Eastern will enter the date terminated.
OPERATOR
DOCUMENT TYPE REVISION BREEZE-EASTERN
SUBJECT INCORPORATION
AND NUMBER AND DATE TERMINATION DATE
DATE
SIL05 Maintenance Pilot & Crew Control Panels Original, - December 07, 2007
& Electronics Cleaning 05/15/07
Advisory
SIL01 FE7590-173-1 Cargo Hook Calibration Revision B, - March 04, 2011
Confirmation 10/19/10
SIL01 FE7590-173-2 Cargo Hook Calibration Revision B, - March 04, 2011
Confirmation 10/19/10
TPDR012810001 On Condition Maintenance Original, - March 04, 2011
for the Load Indicator 01/28/10
SIL02 Maintenance B-E Cargo Hook Original, - March 04, 2011
Maintenance Concept 06/30/10
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LIST OF EFFECTIVE PAGES
*Indicates pages revised, added, or deleted in latest revision.
Description Page Date
Highlights H-1 March 4, 2011
25-51-50, Title Page T-1 March 4, 2011
Record of Revisions RR-1 March 4, 2011
Record of Temporary Revisions RTR-1 March 4, 2011
Service Bulletin List SBL-1 March 4, 2011
List of Effective Pages LEP-1 March 4, 2011
LEP-2 March 4, 2011
LEP-3 March 4, 2011
Table of Contents T/C-1 March 4, 2011
T/C-2 March 4, 2011
T/C-3 March 4, 2011
T/C-4 March 4, 2011
T/C-5 March 4, 2011
Introduction INTRO-1 March 4, 2011
Description and Operation 1 March 4, 2011
2 March 4, 2011
3 March 4, 2011
4 March 4, 2011
5 March 4, 2011
6 March 4, 2011
7 March 4, 2011
8 March 4, 2011
9 March 4, 2011
10 March 4, 2011
11 March 4, 2011
12 March 4, 2011
13 March 4, 2011
14 March 4, 2011
Testing and Troubleshooting 101 March 4, 2011
102 March 4, 2011
103 March 4, 2011
104 March 4, 2011
105 March 4, 2011
106 March 4, 2011
107 March 4, 2011
108 March 4, 2011
109 March 4, 2011
110 March 4, 2011
111 March 4, 2011
112 March 4, 2011
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Testing and Troubleshooting (Continued) 113 March 4, 2011
114 March 4, 2011
115 March 4, 2011
116 March 4, 2011
117 March 4, 2011
118 Blank
Schematics & Wiring Diagrams 201 March 4, 2011
202 March 4, 2011
203 March 4, 2011
204 March 4, 2011
Disassembly 301 March 4, 2011
302 March 4, 2011
303 March 4, 2011
304 March 4, 2011
305 March 4, 2011
306 March 4, 2011
307 March 4, 2011
308 March 4, 2011
Cleaning 401 March 4, 2011
402 March 4, 2011
403 March 4, 2011
404 Blank
Checks and Inspections 501 March 4, 2011
502 March 4, 2011
503 March 4, 2011
504 March 4, 2011
505 March 4, 2011
506 March 4, 2011
507 March 4, 2011
508 March 4, 2011
Repair 601 March 4, 2011
602 March 4, 2011
603 March 4, 2011
604 March 4, 2011
Assembly 701 March 4, 2011
702 March 4, 2011
703 March 4, 2011
704 March 4, 2011
705 March 4, 2011
706 March 4, 2011
707 March 4, 2011
708 March 4, 2011
709 March 4, 2011
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Assembly (Continued) 710 March 4, 2011
711 March 4, 2011
712 Blank
Fits and Clearances 801 March 4, 2011
802 March 4, 2011
803 March 4, 2011
804 March 4, 2011
Special Tools, Fixtures and Equipment 901 March 4, 2011
902 March 4, 2011
Illustrated Parts List 1001 March 4, 2011
1002 March 4, 2011
1003 March 4, 2011
1004 March 4, 2011
1005 March 4, 2011
1006 March 4, 2011
1007 March 4, 2011
1008 March 4, 2011
1009 March 4, 2011
1010 Blank
Technical Publication Discrepancy Report
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TABLE OF CONTENTS
Section/Paragraph Title Page
Section H-1 25-51-50, Highlights Page ....................................................... H-1
Section T-1 25-51-50, Title Page ................................................................. T-1
Section RR-1 Record of Revisions .............................................................. RR-1
Section RTR-1 Record of Temporary Revisions ......................................... RTR-1
Section SBL-1 Service Bulletin List ............................................................ SBL-1
Section LEP-1 List of Effective Pages ........................................................ LEP-1
Section T/C-1 Table of Contents ................................................................. T/C-1
Section INTRO-1 Introduction .................................................................... INTRO-1
Paragraph 1 General ............................................................................. INTRO-1
Paragraph 2 Proprietary Status and Liability ........................................ INTRO-1
Paragraph 3 Verification ....................................................................... INTRO-2
Paragraph 4 Digital Pictures ................................................................. INTRO-2
Section 1 Description and Operation ............................................................ 1
Paragraph 1 Description ................................................................................... 1
Paragraph 1A Repair Station Contacts ................................................................ 2
Paragraph 1B Cargo Hook System ...................................................................... 3
Paragraph 2 Proprietary Status and Liability .................................................... 7
Paragraph 3 Leading Particulars for Cargo Hook System ................................ 8
Paragraph 4 Operation ...................................................................................... 9
Paragraph 4A Recommendation of Rigging Hardware ..................................... 10
Paragraph 4B Applying Power to System ........................................................ 12
Paragraph 4C Load Attachment ....................................................................... 13
Paragraph 4D Load Release ............................................................................. 13
Section 101 Testing and Troubleshooting .................................................... 101
Paragraph 1 Testing ...................................................................................... 101
Paragraph 2 Test Equipment and Materials .................................................. 101
Paragraph 3 Test Conditions ......................................................................... 101
Paragraph 4 Performance Tests .................................................................... 101
Paragraph 4A Electrical Tests ......................................................................... 102
Paragraph 4B Pilot Load Release Test ............................................................ 107
Paragraph 4C Manual Load Release Test ....................................................... 108
Paragraph 4D Emergency Load Release Test ................................................. 108
Paragraph 4E Relatch Test .............................................................................. 111
Paragraph 4F Load Weigh System Test and Standard Calibration (Full) ...... 111
Paragraph 4G Calibrate with Resistor Calibration Number (RCAL) .............. 115
Paragraphs 4H and 5 Troubleshooting Procedures ..................................................... 116
Section 201 Schematics and Wiring Diagrams ............................................ 201
Section 301 Disassembly .............................................................................. 301
Paragraph 1 General ..................................................................................... 301
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TABLE OF CONTENTS (CONTINUED)
Section 301 Disassembly (Continued)
Paragraph 2 Cargo Hook System .................................................................. 301
Paragraph 3 Removal of Cargo Hook Assembly .......................................... 301
Paragraph 4 Removal and Disassembly of Cargo Hook Support ................. 302
Paragraph 5 Removal of Load Indicator ....................................................... 303
Paragraph 6 Disassembly of Cargo Hook Assembly .................................... 304
Paragraph 6A Removal of Pressure Cartridge Assembly ................................ 304
Paragraph 6B Removal of Load Arm .............................................................. 305
Paragraph 6C Removal of Keeper Assembly .................................................. 306
Paragraph 6D Removal of Load Cell .............................................................. 307
Paragraph 6E Removal of Electrical Housing Cover (for switch adjustment) 307
Paragraph 6F Removal of Release Handle Spring and Spring Bracket .......... 308
Paragraph 6G Removal of Expiration Plate, Electrical Schematic Decal,
And Nameplate .......................................................................... 307
Section 401 Cleaning .................................................................................... 401
Section 501 Checks and Inspections ............................................................ 501
Paragraph 2 Inspections ................................................................................ 502
Paragraph 2A Overhaul / Refurbishment of Cargo Hook System .................. 502
Paragraph 2B Functional Test ......................................................................... 504
Paragraph 2C Preflight Inspection .................................................................. 504
Paragraph 2D Post Flight Inspection ............................................................... 504
Paragraph 2E Cartridge ................................................................................... 505
Paragraph 2F Inspection of Wiring .................................................................. 506
Paragraph 2G General ..................................................................................... 506
Paragraph 2H Compliance Information............................................................ 507
Section 601 Repair ....................................................................................... 601
Paragraph 2 Refinish .................................................................................... 602
Paragraph 3 Minor Surface Repair (Damage with no exposed metal) ......... 602
Paragraph 4 Major Surface Repair (Damage with exposed metal) .............. 604
Paragraph 5 Application of Top Coat ........................................................... 604
Section 701 Assembly .................................................................................. 701
Paragraph 2 Vital Point Inspection ................................................................ 701
Paragraph 3 Installation of Cargo Hook System .......................................... 701
Paragraph 4 Assembly of Cargo Hook Assembly ........................................ 702
Paragraph 4A Installation of Release Handle Spring and Spring Bracket ...... 702
Paragraph 4B Installation of Keeper Assembly .............................................. 702
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TABLE OF CONTENTS (CONTINUED)

Section 701 Assembly (Continued)
Paragraph 4C Installation of Load Arm .......................................................... 702
Paragraph 4D Installation of Load Cell ........................................................... 705
Paragraph 4E Installation of Pressure Cartridge Assembly ............................ 705
Paragraph 4F Installation of Cover on Electrical Housing ............................. 707
Paragraph 4G Installation of Expiration Plate, Electrical Schematic Decal,
And Nameplate ......................................................................... 707
Paragraph 5 Assembly and Installation of Cargo Hook Support .................. 707
Paragraph 6 Installation of Cargo Hook Assembly ...................................... 709
Paragraph 7 Installation of Load Indicator ................................................... 710
Paragraph 8 Storage ...................................................................................... 711
Paragraph 9 Shipping..................................................................................... 711
Section 801 Fits and Clearances ................................................................... 801
Section 901 Special Tools, Fixtures, and Test Equipment ........................... 901
Section 1001 Illustrated Parts List ................................................................ 1001
Paragraph 1 Introduction ............................................................................ 1001
Paragraph 2 Notes ....................................................................................... 1002
LIST OF TABLES
Table Title Page
1 Leading Particulars for Cargo Hook System ..................................................................... 8
2 Definitions ........................................................................................................................ 10
101 Continuity Check with Load Arm in Closed and Open Positions ................................. 103
102 Continuity Check for Cartridge Wire Assembly ........................................................... 105
103 Troubleshooting Procedures .......................................................................................... 117
401 Materials Required For Cleaning .................................................................................... 401
501 Inspection Requirements ................................................................................................ 501
502 SIL01 FE7590-173-1 & SIL01 FE7590-173-2 Cargo Hook Calibration Confirmation 508
601 Allowable Material Removal ......................................................................................... 603
701 Materials Required for Assembly .................................................................................. 701
801 Dimensional Limits for Cargo Hook System ................................................................. 801
901 Special Tools, Fixtures, and Test Equipment List ......................................................... 901
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LIST OF FIGURES
Figure Title Page
1 Cargo Hook System (Sheet 1 of 2) .................................................................................. 1
2 Side View of Cargo Hook Assembly ............................................................................... 3
3 New Cargo Hook Support Shipped from B-E’s Mfg. Facility with Loose Safety Wire .. 6
4 Cargo Hook Support Rectangular Aluminum Frame ...................................................... 6
5 Cargo Hook Load Indicator ............................................................................................. 7
6 Apex Fitting and Correct Rigging Position on Load Arm .............................................. 11
7 Front Display of Load Indicator .................................................................................... 13
101 Cargo Hook Assembly Wiring Diagram ...................................................................... 104
102 Limit Switch Locations ................................................................................................ 106
103 Emergency Release Test Set Up With Pressure Cartridge Simulator .......................... 110
104 Relatch Test ................................................................................................................. 111
105 Front Display of Load Indicator .................................................................................. 112
106 Adjustment Screw Locations for “ZERO” and “SPAN” Potentiometers .................... 113
107 Nameplate with New RCAL Number Inserted ............................................................ 114
201 Cargo Hook Assembly Wiring Diagram........................................................................ 202
202 Cargo Hook System Interconnect Wiring Diagram (Sheet 1 of 2) ................................ 203
301 Cargo Hook Assembly Mounted in Hook Support (shown removed from Helicopter) 302
302 Mounting Screws for Aft Flange ................................................................................. 303
303 Load Indicator .............................................................................................................. 304
304 Typical Electrical Connector Set-Up for Load Indicator ............................................. 304
305 Pressure Cartridge Installed in Pressure Cartridge Assembly ..................................... 305
306 Load Arm Bolt Removal .............................................................................................. 306
307 Load Arm Removal ...................................................................................................... 306
308 Load Arm and Subassembly Removal ......................................................................... 306
309 Top View of Load Cell (shown without cotter pins) ................................................... 307
310 Side View of Load Cell (shown without cotter pins) .................................................. 307
311 Electrical Housing Assembly ....................................................................................... 308
501 Pressure Cartridge Assembly Location .......................................................................... 506
701 Load Arm, and Subassembly Installation .................................................................... 704
702 Teflon Washer Installation ........................................................................................... 704
703 Load Arm Spring Installation ...................................................................................... 704
704 Load Arm Installation .................................................................................................. 704
705 Load Arm Bolt Installation .......................................................................................... 704
706 Top View of Load Cell (shown without cotter pins) ................................................... 705
707 Side View of Load Cell (shown without cotter pins) .................................................. 705
708 Pressure Cartridge Installation and Assembly ............................................................. 706
709 Electrical Housing Assembly ....................................................................................... 708
710 Typical Electrical Connector Set-Up for Load Indicator ............................................. 710
801 Installation of Cargo Hook Assembly Support (Sheet 1 of 2) ..................................... 802
802 Installation of Cargo Hook Assembly .......................................................................... 804
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LIST OF FIGURES (CONTINUED)
Figure Title Page
901 Pressure Cartridge Simulator ....................................................................................... 901
902 Test Box Assembly ...................................................................................................... 902
1001 Cargo Hook System ................................................................................................... 1003
1002 Cargo Hook Assembly Left Side / Forward View (Sheet 1 of 2) ............................... 1004
1003 Cargo Hook Support .................................................................................................. 1008
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INTRODUCTION
1. General
The instructions in this manual provide the information necessary to perform flight line level
maintenance functions ranging from simple checks to replacement of wear items, to maintain the
Cargo Hook System in a safe and serviceable condition.
The manual is divided into separate sections:
1. Title Page 7. Introduction 13. Checks and Inspections

2. Record of Revision 8. Description and Operation 14. Repair
3. Record of Temporary Revisions 9. Testing and Troubleshooting 15. Assembly
4. Service Bulletin List 10. Schematics and Wiring Diagrams 16. Fits and Clearances
5. List of Effective Pages 11. Disassembly 17. Special Tools
6. Table of Contents 12. Cleaning 18. Illustrated Parts List
Refer to the Table of Contents for the page location of applicable sections. An asterisked flag note
*( ) in place of the page number indicates that no special instructions are provided since the
function can be performed using standard industry practices.
The beginning of the REPAIR section includes a list of the separate repairs (if appropriate).
An explanation of the use of the Illustrated Parts List is provided in the introduction to that
section.
All weights and measurements in the manual are in English units with metric equivalents in
parenthesis, unless otherwise noted.
This manual will be revised as necessary to reflect current information and customer input
through the use of the Technical Publication Deficiency Report (TPDR). Attached to the back of
this manual is a copy of a blank TPDR for use by the customer, plus copies of any Service
Bulletins, Service Letters, Change Orders, and TPDR’s written against the manual for
incorporation into the next revision.
2. Proprietary Status and Liability
This Flight Line Operation and Maintenance Manual contains proprietary data, which is the
property of Breeze-Eastern Corporation. Neither this manual, nor any part thereof, shall be
duplicated, used, or disclosed – in whole or in part – for any purpose other than those relating to
the operation and flight line maintenance of the Cargo Hook System by the owner / operator /
maintenance facility.
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Any activity involving the operation, maintenance, and testing of the Cargo Hook System shall be
performed in accordance with the procedures defined in this manual. Furthermore, all
maintenance requiring new components shall be performed utilizing only the parts identified in
this manual, which are all readily available from Breeze-Eastern Corporation. Any and all
actions taken by owners / operators / maintenance facilities that deviate from the
procedures contained herein, or actions taken utilizing parts not identified in this manual,
shall not be the responsibility of Breeze-Eastern Corporation.
3. Verification:
Testing/Troubleshooting: TBD
Disassembly: TBD
Assembly: TBD
4. Digital Pictures
It is recommended that the technician take digital pictures of eash assembly and subassembly, to
be used as a visual reference for Section 701 Assembly, prior to disassembling the cargo hook
system components.
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DESCRIPTION AND OPERATION
1. Description
This publication explains the operation of the Cargo Hook System (See Figure 1), as well as
provides flight line maintenance instructions. These instructions are used to maintain the Cargo
Hook System, with selected subassembly removals, in a serviceable condition while installed on
the helicopter.
Cargo Hook Assembly (Manual Release Side)
Cargo Hook Assembly (Solenoid Side)

Figure 1. Cargo Hook System (Sheet 1 of 2)
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Load Indicator
Cargo Hook Support (shown with hook installed)

Figure 1. Cargo Hook System (Sheet 2 of 2)
A. Operators are encouraged to coordinate all repair / overhaul work with Breeze-Eastern, or
their authorized Service Centers. Breeze-Eastern is a Federal Aviation Administration (FAA)
and a European Aviation Administration (EASA) FAR / EASA Part 145 approved Repair
Station (FAA Repair Station No. BZ7R167O, EASA -145 Acceptance Certificate Reference
No. EASA.5454), and can repair / overhaul all components of the Rescue Hoist System at
competitive prices and lead-times. Please contact Breeze-Eastern Customer Services for any
of these services listed above as follows:
Breeze-Eastern Corporation
35 Melanie Lane
Whippany, New Jersey 07981-1638
Attention: Customer Service / Care
Phone: (973) 602-1001, Ext. 1083 or 1090, or 1-800-929-1919, (US and Canada only).
Fax: (973) 739-9344
E-mail: customerservice@breeze-eastern.com
Web site: www.breeze-eastern .com
Revision status of the Breeze-Eastern technical manuals is listed on the web site referenced
above.
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B. The Cargo Hook System
The Cargo Hook System is designed to carry a rated load of 9,000 lb. (4,082 kg.) while
attached to the helicopter (Note: Compare cargo hook system versus the helicopter design
lift limitations). The CHS-9000-3 Cargo Hook System consists of a FE7590-173-1 Cargo
Hook Assembly (consisting of PN FE7590-173-2 Cargo Hook Assembly and CH-9016-1
Pressure Cartridge Assembly for initial shipping purposes only), CH-9020-1 Hook Support
Frame, and Y-1240-9-1 Load Indicator.
(1) Cargo Hook Assembly
The Cargo Hook Assembly consists of a load arm, which supports the load, with a keeper
to retain the load, refer to Figure 2. The keeper is redundantly secured, in the closed
position, by two springs, which prevent an inadvertent release of the load. The load arm is
attached to two (2) side plates, and is secured with a nut and bolt, about which the load
arm pivots when releasing the load. The side plates are bolted to two (2) Mount Support
Assemblies, located at the fore and aft ends of the Cargo Hook Assembly. These mount
support assemblies attach to bushings in the Hook Support Frame.
Figure 2. Side View of Cargo Hook Assembly

(a) Load Arm, Latch Arm, and Latch Assembly
The load arm is held closed by a series of mechanisms between the side plates. The
load arm is physically held closed by the latch arm. The latch arm is held in place by
a bolt, about which it pivots, attached to the side plates. The latch arm is physically
held closed by the latch assembly. The latch assembly is held in place by a bolt,
about which it pivots, attached to the side plates. The latch assembly is physically
held closed by the lock. The lock is held in place by a bolt, about which it pivots,
attached to one of the side plates, as well as the shaft of the solenoid.
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(b) Lock
The lock holding the latch assembly closed can be opened in three ways. One way to
open the lock is by electrically energizing the rotary solenoid circuit, which rotates
the solenoid shaft, opening the lock. The switch to energize the solenoid is located in
the cockpit, and controlled by the pilot. The solenoid circuit is de-energized when
the lock rotates upward and actuates a limit switch, which opens the circuit. Another
way to open the lock is by manually turning the release handle, located on the Cargo
Hook Assembly, which is only accessible by personnel on the ground. A third way
to release the load is by electrically firing a pressure cartridge, installed in the Cargo
Hook Assembly, which is controlled by the pilot. When the cartridge is fired, a
piston is driven out against the lock to rotate the linkage opening the load arm.
(c) Electrical Interface
The solenoid and the switches are connected to the helicopter through an electrical
cable (supplied by Breeze-Eastern) mounted on the electrical housing of the Cargo
Hook Assembly. This cable interfaces with either a wiring harness (not supplied by
Breeze-Eastern), or is attached directly to a connector, on the helicopter.
The electrical connector for the pressure cartridge, located in the forward mounting
support assembly of the Cargo Hook Assembly, is connected to the helicopter with a
wiring harness (not supplied by Breeze-Eastern).
The load cell is connected to the helicopter through an electrical cable (supplied by
Breeze-Eastern), mounted on the aft mounting support assembly of the Cargo Hook
Assembly, which interfaces with either a wiring harness (not supplied by Breeze-
Eastern), or is connected directly to the helicopter, which interfaces with the Load
Indicator in the cockpit.
(d) Switches
A safety switch, included in the Cargo Hook Assembly (see the Section 201
Schematics and Wiring Diagrams in Figures 201 and 202), is actuated by a cam,
mounted on the solenoid shaft, and thereby interrupts power to the solenoid when the
lock is disengaged. This interruption of power prevents damage to the solenoid from
excessive current flow. Since the load arm is returned to its closed position
automatically after load release, the solenoid is again energized if the pilot’s push-
button switch is still closed. The solenoid will be energized, and de-energized,
repeatedly, as long as the push-button switch is held closed, resulting in the continuous
opening and closing of the internal mechanism and load arm of the Cargo Hook
Assembly. Without a safety switch in the solenoid circuit, the solenoid would be
energized continuously, rather than intermittently, as long as the push-button switch is
closed. The resultant continuous flow of current would damage the solenoid. Also,
included in this circuit is a diode to provide additional protection by increasing the
time to re-energize the solenoid, thereby slowing down the repeated opening and
closing of the internal mechanism and load arm in the Cargo Hook Assembly.
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Also, a switch is included in the Cargo Hook Assembly to send a signal to the pilot
showing that the load arm is open. The cam on the solenoid shaft actuates the “Hook
Open” switch when the lock is disengaged from the latch assembly.
(e) Cartridge
WARNING: THE CARTRIDGE IS AN EXPLOSIVE DEVICE AND MUST BE SHIPPED,
STORED, AND HANDLED IN COMPLIANCE WITH ALL LOCAL
STANDARDS, AND REGULATORY PRACTICES.
WARNING: BEFORE INSTALLING THE CARTRIDGE IN THE CARGO HOOK ASSEMBLY,
BE SURE THAT ALL ELECTRICAL ACTUATING CIRCUITS ARE OPEN.
WARNING: DO NOT PERFORM RESISTANCE CHECKS ON THE CARTRIDGE EITHER
PRIOR TO, OR AFTER, INSTALLATION IN THE CARGO HOOK ASSEMBLY.
NOTE: CARTRIDGE SERVICE LIFE IS 5 YEARS, STARTING WHEN INSTALLED ON
THE HELICOPTER. CARTRIDGE LIFE (COMBINED SHELF AND SERVICE
LIFE) IS 13 YEARS, STARTING FROM THE DATE OF MANUFACTURE,
WHICH CAN BE FOUND IN THE LOT NUMBER ON THE IDENTIFICATION
PLATE. THE LOT NUMBER STARTS WITH THE FIRST THREE LETTERS
“ESD,” FOLLOWED BY TWO DIGITS, IDENTIFYING THE YEAR OF
MANUFACTURE (EXAMPLE: 11 IS 2011), AND ONE LETTER, IDENTIFYING
THE MONTH OF MANUFACTURE, AS FOLLOWS:
A) JANUARY B) FEBRUARY C) MARCH D) APRIL
E) MAY F) JUNE G) JULY H) AUGUST
J) SEPTEMBER K) OCTOBER L) NOVEMBER M) DECEMBER
The Cargo Hook System is equipped with an emergency release, controlled by the
pilot, located internally to the Cargo Hook Assembly. It consists of an electrically
fired pressure cartridge (squib), a squib housing, and piston.
In an emergency, the pilot fires the squib extending a piston, which activates the hook
release (lock) mechanism. At 28 VDC, the minimum all-fire current of the cartridge is
5.0 amperes per bridge wire. The cartridge is contained in a pressure cartridge kit,
which is supplied separately, and can be installed at the flight line level after the cargo
hook is removed from the cargo hook support frame on the helicopter.
Never ship the cargo hook assembly PN FE7590-173-2 with the Pressure Cartridge
Assembly PN CH-9016-1 installed. When shipping the cargo hook to Breeze-Eastern
the Pressure Cartridge Assembly (Figure 1001, Item 12) shall be removed and
properly stored, or disposed of, by the operator in accordance with your local
regulatory authority laws and regulations. If the shipment to Breeze-Eastern contains
an explosive and the packaging does not meet US Department of Transportation /
International Air Transport Association regulations and standards, Breeze-Eastern is
required to report the situation. Additionally, you will be charged a minimum fee of
$500 USD for the proper disposal of the explosive
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(2) Cargo Hook Support
New Cargo Hook Supports shipped directly from the Breeze-Eastern’s
Manufacturing Facility have forward flange retention screws (Refer to Figure 1003,
Item 30) and split bushing attach screws (Refer to Figure 1003, Item 60) with safety
wire attached, but not tied for installation purposes. Ensure screws are safety wired
after installation on the helicopter. See Figure 3.
New Cargo Hook Support

Shipped from Breeze-
Eastern’s Manufacturing
Facility With Loose Safety
Wire
Figure 3. New Cargo Hook Support Shipped From Breeze-Eastern
The Cargo Hook Support is a rectangular aluminum frame consisting of forward and aft
flanges, and left and right side channels. The forward and aft flanges support the Cargo
Hook Assembly. The forward flange has an internal bushing to support the forward
mount of the Cargo Hook. It is designed to slide out of the frame to allow for cargo hook
mount installation. The aft flange incorporates a split bushing for ease of cargo hook
mount installation. The left and right side channels are bolted to the helicopter. Left and
right struts, between the left and right side channels and aft flange, have been added for
strength. The flanges, side channels, and struts are bolted together and safety wired for
redundant retention. On the right channel, a U-bolt is installed for securing the Cargo
Hook Assembly in the stowed position when not in use, refer to Figure 4.
Right Channel Aft Flange (has split bushing)

Left Channel
Right Strut U-Bolt
(Used only for Cargo Hook Storage)
Forward Flange Left Strut
Figure 4. Cargo Hook Support Rectangular Aluminum Frame
(3) Load Indicator

The load indicator, installed in the cockpit, is connected through helicopter wiring to the
load cell in the Cargo Hook Assembly. The indicator displays the load on the Cargo Hook
Assembly in increments of 10 lb., or 10 kg., and is capable of being calibrated (Full and
RCAL) per the procedure in Section 101, Testing and Troubleshooting, refer to Figure 5.
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Figure 5. Cargo Hook Load Indicator

2. Proprietary Status and Liability
This Flight Line Operation and Maintenance Manual contains proprietary data, which is the
property of Breeze-Eastern. Neither this manual, nor any part thereof, shall be duplicated, used, or
disclosed - in whole or in part - for any purpose other than those relating to the operation and
flight line maintenance of the Cargo Hook System by the owner / operator / maintenance facility.
Any activity involving the operation, maintenance, and testing of this Cargo Hook System shall
be performed in accordance with the procedures defined in this manual. Furthermore, all
maintenance requiring new components shall be performed utilizing only the parts identified in
this manual, which are readily available from Breeze-Eastern. Any and all actions taken by
owners / operators / maintenance facilities that deviate from the procedures contained
herein, or actions taken utilizing parts not identified in this manual, shall not be the
responsibility of Breeze-Eastern.
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3. Leading Particulars for Cargo Hook System
Cargo Hook
Rated Operating Capacity ....................... 9,000 lb. (4,082 kg.) – Note Helicopter Lift
Limitations
Limit Load .............................................. 22,500 lb. (10,206 kg.)
Ultimate Load ......................................... 33,750 lb. (15,309 kg.)
Allowable Rotation to Vertical ............... 30°
Operating Temperature Range ................ -40°F to 122°F (-40°C to 50°C)
Electrical Requirements for solenoid ...... 18 to 29 VDC (14 to 24 amps)
Electrical Requirements for cartridge ..... 18 to 29 VDC (5 amps, minimum)
Methods of Release:
• Electrical release (Actuated by the pilot)
• Manual release handle (Force required on handle for release: 10 lb. [4.5 kg.], max.)
• Emergency release (Cartridge in Cargo Hook Assembly actuated by the pilot)
Weight (Cargo Hook Assembly) ............ 23.3 lb. (10.6 kg.) maximum
Cargo Hook Support
Construction ............................................ Rectangular, Aluminum Frame
Weight ..................................................... 24.1 lb. (10.9 kg.) maximum
Load Indicator
Load Indicator (Digital) .......................... 0 to 9,000 lb. (4,082 kg.), English / Metric Selectable
Electrical Requirements .......................... 22 to 30 VDC (0.5 amp maximum power)
Weight ..................................................... 1.0 lb. (0.5 kg.) maximum
Table 1. Leading Particulars for Cargo Hook System
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4. Operation
WARNING: TRANSPORT OPERATIONS UTILIZING A CARGO HOOK SYSTEM CAN
RESULT IN LOSS OF LOAD, AND / OR HELICOPTER, AND CAN RESULT IN
INJURY, OR DEATH. ONLY PROPERLY TRAINED PERSONNEL MUST
UTILIZE APPROPRIATE OPERATION, MAINTENANCE, AND INSPECTION
PROCEDURES TO MINIMIZE THE HAZARDS INHERENT IN THE USE OF
ALL CARGO HOOK SYSTEMS.
WARNING: DURING TRANSPORT OPERATIONS, STAY CLEAR OF DROP AREA
UNDERNEATH LOAD AND HELICOPTER.
WARNING: KEEP HANDS, BODY, AND CLOTHING AWAY FROM CARGO HOOK
ASSEMBLY, SPECIFICALLY “PINCH POINTS,” WHERE THE LOAD ARM,
APEX FITTING, AND KEEPER CONTACT.
WARNING: THE OPERATOR MUST WEAR WORK GLOVES AND EYE PROTECTION
WHENEVER HANDLING THE CARGO HOOK SYSTEM TO PREVENT INJURY
FROM LOADS, AND DEBRIS.
WARNING: OPERATING THE CARGO HOOK SYSTEM IN A DAMAGED, OR DEGRADED,
CONDITION CAN CAUSE LOSS OF LOAD, AND / OR HELICOPTER AND CAN
RESULT IN INJURY, OR DEATH. THE CAUSE OF ANY DEGRADATION
MUST BE DETERMINED, AND THE PROBLEM CORRECTED, PRIOR TO THE
CARGO HOOK SYSTEM BEING RESTORED TO AN OPERATIONAL
CONDITION.
WARNING: THE HELICOPTER WILL BUILD UP STATIC ELECTRICITY. ENSURE THE
HELICOPTER HAS DISSIPATED THE STATIC ELECTRICITY VIA A
GROUNDING WAND, OR EQUIVALENT, PRIOR TO MANUALLY
ATTACHING, OR DETACHING, LOADS TO THE CARGO HOOK SYSTEM.
FAILURE TO DO SO CAN RESULT IN GROUND PERSONNEL BEING THE
ELECTRICAL GROUND, RESULTING IN INJURY, OR DEATH.
NOTE: PRIOR TO TURNING POWER ON, THE CARGO HOOK SYSTEM
COMPONENTS MUST BE VISUALLY INSPECTED FOR SOUND
STRUCTURAL INTEGRITY, AND PROPER INTEGRATION.
NOTE: BREEZE-EASTERN SERVICE INFORMATION LETTER SIL04 MAINTENANCE
TITLED, “BREEZE-EASTERN COMMERCIAL CARGO HOOK LOAD RING
SELECTION / PROCEDURE AND RECOMMENDED RIGGING METHODS” IS
NOT APPLICABLE TO THIS CARGO HOOK. AN APEX FITTING SHALL BE
USED IN LIEU OF LOAD RINGS AS DIRECTED BELOW.
Safe operation of the Cargo Hook System involves use of an Apex Fitting, as well as using proper
procedures during the lifting of loads for transport operations. Breeze-Eastern recommends using
the following operating procedures, and the inspections and maintenance procedures contained
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throughout this manual, prior to, during, and after transport operations using this Cargo Hook
System.
A. Recommendation of Rigging Hardware
It is recommended that an Apex Fitting be utilized on the load arm in lieu of a primary ring(s),
due to the unavailability of the proper diameter load ring / load arm combination for this
cargo hook. Secondary members that attach to the Apex Fitting such as; sling legs, rings, etc.
is solely the responsibility of the helicopter rigger / operator. In all cases the operator is
responsible for the proper selection, and use, of hardware to attach the load to the cargo hook
assembly.
(1) Definitions
Definitions typically used in rigging loads to hooks are listed in Table 2 below.
Terms Description
Apex Fitting An aluminum fitting whose uppermost point

gathers the slung tension members and attaches to
the cargo hook.
Apex Fitting Pin A headed pin that extends through the two ends of
the apex fitting clevis and retained in place by a
(1.125 inch [28.575 mm]
bolt, nut, and cotter pin.
diameter)
Apex Fitting Spacer Aluminum hour glass shaped bushing that fits over
the apex fitting pin and causes the apex fitting to
stay centered on the cargo hook.
Load Arm The cargo hook structural member that the Apex
Fitting sits upon.
Keeper The device on the cargo hook that is intended to

keep the primary ring on the load arm under slack
conditions.
Table 2. Definitions
(2) Correct and Incorrect Rigging Techniques.
NOTE: THE OPERATOR IS RESPONSIBLE FOR PROPER SELECTION, AND USE, OF
HARDWARE TO ATTACH THE LOAD TO THE APEX FITTING ON THE
CARGO HOOK ASSEMBLY.
Guidelines for proper Apex Fitting positioning to support a load is provided in Figure 6.
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NOTE: IT IS IMPERATIVE THAT

THE SPACER IS
INSTALLED AND
SECURED PROPERLY
FOR SAFE OPERATION.
Figure 6. Apex Fitting and Correct Rigging Position on Load Arm.
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(3) Assemble the Apex Fitting - Each Apex fitting consists of an aluminum clevis, aluminum
pin, aluminum spacer (hour glass), castellated nut, and cotter pin. Align the spacer
between the apex clevis holes and secure with pin through the center inside diameter.
Secure pin with a .375 inch (9.525 mm) bolt, self locking castellated / slotted nut, and
cotter pin. Refer to Figure 7.
(4) The Apex Fitting can be checked during preflight inspection on the ground by opening the
load arm and verifying that the Apex Fitting with a load of 25 lb. (11.4 kg.) drops free.
It is recommended that the operators rigging, which attaches to the Apex Fitting, be
checked on the ground prior to use to preclude the possibility of becoming tangled upon
helicopter lift-off resulting in a jammed condition. The load arm should then be
commanded open. If the rigging becomes jammed at all, and the Apex Fitting does not
drop free from the load arm, then it should not be used.
(5) Apex Fitting Information:
NOTE: BREEZE-EASTERN DOES NOT SUPPLY, STOCK, OR DISTRIBUTE APEX
FITTINGS. THE OPERATOR IS RESPONSIBLE FOR PURCHASING /
OBTAINING AN APEX FITTING FOR PROPER OPERATION OF THE CARGO
HOOK SYSTEM.
The referenced information below is for the aluminum version utilized by the United
States Military 10,000 pound (4536 kg.) Sling Set, used for UH-60 applications).
National Stock Number: 4030-01-048-4045
Part Number: 38850-00004-045
CAGE 56646, 81337, & 81996
B. Applying Power to System

NOTE: PRIOR TO APPLYING POWER TO THE CARGO HOOK SYSTEM, ENSURE
THE LOAD INDICATOR HAS BEEN CALIBRATED PER THE PROCEDURE IN
SECTION 101, TESTING AND TROUBLESHOOTING.
Prior to performing transport operations, apply power to the Cargo Hook Assembly and the
Load Indicator by pushing in applicable circuit breakers. When power is applied to the Load
Indicator, “18880” will be displayed momentarily. If no load is on the Cargo Hook Assembly,
“0” ± 20 lb. (± 40 kg.) then should be displayed. If not, push the “ZERO” button on the face
of the Load Indicator below the display, refer to Figure 7 below.
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Figure 7. Front Display of Load Indicator
C. Load Attachment
NOTE: INSTALLATION OF THE APEX FITTING ONTO THE LOAD ARM DOES NOT
REQUIRE MANUAL RELEASE OF THE CARGO HOOK SYSTEM. PUSH THE
APEX FITTING PAST THE KEEPER UNTIL THE KEEPER CLOSES SECURING
THE APEX FITTING ON THE LOAD ARM.
To attach the load to the Cargo Hook Assembly, install the Apex Fitting over the snout (end)
of the load arm. Ensure the conical spacer of the Apex Fitting is centered on the cargo hook
load arm and is secured by the spring-loaded keeper in the throat of the Cargo Hook.
D. Load Release
WHENEVER HANDLING THE CARGO HOOK SYSTEM, TO PREVENT
INJURY FROM LOADS, AND DEBRIS.
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HELICOPTER HAS DISSIPATED THE STATIC ELECTRICITY VIA A STATIC
DISCHARGE (GROUNDING) WAND, OR EQUIVALENT, PRIOR TO
MANUALLY ATTACHING, OR DETACHING, LOADS TO THE CARGO HOOK
SYSTEM. FAILURE TO DO SO CAN RESULT IN GROUND PERSONNEL
BEING THE ELECTRICAL GROUND, RESULTING IN INJURY, OR DEATH.
NOTE: WHEN ELECTRICALLY RELEASING THE LOAD ARM WITH NO LOAD, IT
MAY BE REQUIRED TO APPLY HAND PRESSURE TO THE LOAD ARM TO
OPEN IT.
(1) Normal Release
Load release can be initiated electrically in flight. A master switch in the cockpit must
first be closed, which provides power to the solenoid in the Cargo Hook Assembly. Then
the pilot presses a push-button switch to release the load. Only momentary push-button
switch operation is required. When the push-button switch is depressed, the solenoid is
energized in the Cargo Hook Assembly. When the solenoid is energized, the solenoid
shaft, on which the lock is mounted, rotates, and opens the lock. With the lock
disengaged, the latch assembly releases the latch arm. With the latch arm released, the
weight of the load causes the load arm to swing open, and the load slides off the load arm.
A spring in the Cargo Hook Assembly then positions the load arm back to its closed, and
latched, position after load release and release of the push-button switch.
(2) Emergency Release
Load release also can be initiated electrically in an emergency if normal release fails. An
explosive cartridge is actuated in the Cargo Hook Assembly when the pilot depresses a
guarded push-button switch in the cockpit. The energy from the cartridge forces a pin
down to disengage the lock. With the lock disengaged, the latch assembly releases the
latch arm. With the latch arm released, the weight of the load causes the load arm to swing
open, and the load will slide off the load arm.
(3) Manual Release
In addition, personnel on the ground can initiate load release manually. A hand actuated
release handle, external to the Cargo Hook Assembly, is connected to the lock. Rotating
the handle up disengages the lock. With the lock disengaged, the latch assembly releases
the latch arm. With the latch arm released, the weight of the load causes the load arm to
swing open, and the load will slide off the load arm.
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TESTING AND TROUBLESHOOTING
1. Testing
This section covers testing, adjustment, fault isolation, and implementation of corrective actions
on the Cargo Hook System utilizing troubleshooting procedures. The test procedures contained in
this section are to be performed for fault isolation, as required by actions accomplished in Checks
and Inspections, Section 501, and as required by the procedures in Assembly, Section 701.
Reference numbers in parenthesis refer to IPL in Section 1001.
2. Test Equipment and Materials
The recommended method for testing the System at the flight line level is to perform the
procedures identified in this section with the equipment identified below, or suitable equivalent.
A. Electrical Power: 28 VDC, 40 amperes minimum.
B. Load Source: The load applied to the Cargo Hook Assembly during testing shall be
by use of calibrated weights with values of 25 lb. (11 kg.), 100 lb. (45
kg.), 500 lb. (227 kg.), 2,000 (907 kg.), 4,500 lb. (2,041 kg.), 6,000
(2,721 kg.), and 9,000 lb. (4,082 kg.).
C. Torque Wrench: Minimum Range, 0 - 25 in.-lb. (0 - 288 mm.-kg.).
D. Multimeter: Fluke Model 77, or equivalent (minimum range, 0 - 30 VDC, 0 - 40
ohms, 0 - 10 amps).
E. Tie Wire: MS20995NC32.
3. Test Conditions
The preferred test condition is with the Cargo Hook System installed on the helicopter. There are
cases whereby it will be difficult for operators. Therefore, it is allowable to remove the cargo
hook / support and conduct tests off the helicopter, when applicable. All tests shall be conducted
between ambient temperature of 60°F to 104°F (16°C to 40°C), and relative humidity of 95
percent maximum.
4. Performance Tests
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CONDITION.
NOTE: SOLENOID SAFETY AND HOOK OPEN INDICATOR SWITCHES MUST BE
OPERATING, AND SET PROPERLY, PRIOR TO PERFORMING LOAD
TESTING.
A. Electrical Tests (see Figure 101 and Section 201 for wiring diagrams)
(1) Continuity Check.
(a) Remove the Cargo Hook Assembly from the helicopter per Disassembly, Section 301.
(b) Cable Assembly EC-10498 use a milliohm meter, measure the resistance between the
backshell of the connector MS3459W14S-5P and metal body of the Y-1146-187-1
fitting. The resistance shall not exceed 20 milliohms.
(c) Cable Assembly FE7590-140 use a milliohm meter, measure the resistance between
the backshell of the connector MS3116P8-4S and connector M83723/85W1005N. The
resistance shall not exceed 20 milliohms.
(d) Conduct the following continuity check across the pins of connector
MS3459W14S-5P, with the load arm in the closed and open positions, using a
multimeter for pin to pin test or Test Box Assembly PN TE-135-1, Refer to Table 101.
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NOTE: FOR THIS CHECK, THE HOOK SHOULD BE UNLOADED AND THE LOAD
ARM SHOULD BE UP AND LATCHED.
NOTE: PIN CONTINUITY IS TESTED BY DEPRESSING THE “PUSH TO TEST
BUTTON.”
NOTE: AN OPTIONAL TEST BOX ASSEMBLY PN TE-135-1 CAN BE USED AS AN
ALTERNATIVE TO THE MULTIMETER PIN TO PIN TEST STATED BELOW.
Optional Test Box - The following initial switch settings must be made on the Test Box
PN TE-135-1 prior to running the test.
(S2) Hook Open Light Switch OFF Position

(S4) Pilot Release Switch NEUTRAL Position
(S1) Emergency Release Switch TEST Position
(S3) Main Power Switch- CONT. Position
Pin Continuity Check
Check Continuity Check with Load Arm in Closed Position
Pins Condition Pins Condition Pins Condition

A to A Continuity B to B Continuity C to D Discontinuity
A to B Continuity B to C Discontinuity C to E Discontinuity
A to C Discontinuity B to D Discontinuity D to D Continuity
A to D Discontinuity B to E Discontinuity D to E Discontinuity
A to E Discontinuity C to C Continuity E to E Continuity
Check Continuity Check with Load Arm in Open Position
Pins Condition
B to E Continuity
C to D Continuity
Table 101. Continuity Check with Load Arm in Closed and Open Positions
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Figure 101. Cargo Hook Assembly Wiring Diagram

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STORED, AND HANDLED IN COMPLIANCE WITH ALL LOCAL STANDARDS
AND REGULATORY PRACTICES.
WARNING: BEFORE INSTALLING THE CARTRIDGE IN THE CARGO HOOK ASSEMBLY,
MAKE SURE THAT ALL ELECTRICAL ACTUATING CIRCUITS ARE OPEN.
PRIOR TO, OR AFTER, INSTALLATION IN THE CARGO HOOK ASSEMBLY.
(e) Per Disassembly, Section 301, remove the pressure cartridge assembly (20, Figure
1002, Sheets 1 and 2), and remove connector from the cartridge. Cable Assembly
FE7590-140 use a multimeter, and check the continuity between the pins in the
connector disconnected from the cartridge and the pins in the support assembly
connector. The results must be as listed in Table 102:
Pins Condition Pins Condition

A to 1 Continuity C to 2 Continuity
A to 2, 3, 4, and 5 Discontinuity D to 1, 2, 4, and 5 Discontinuity
B to 1, 2, 3, and 5 Discontinuity D to 3 Continuity
B to 4 Continuity A, B, C, D to Case Discontinuity
C to 1, 3, 4, and 5 Discontinuity 1, 2, 3, 4, 5 to Case Discontinuity
Table 102. Continuity Check for Cartridge Wire Assembly

(f) Attach the connector to the cartridge, and install the pressure cartridge assembly (20,
Figure 1002, Sheet 1 and 2) per Assembly, Section 701.
(g) Install the Cargo Hook Assembly per Assembly, Section 701.
(2) Operational Check
(a) Using hand pressure to push down on the load arm to simulate a load, open the load
arm with the manual release handle, and check for continuity between pins B and E in
connector MS3459W14S-5P (see Figure 101, hardwired to Electrical Housing). If
discontinuity is found adjustment of the anti-cycling switch (Switch 2, Figure 102, and
Item 420, Figure 1002, Sheet 2, View A) is required or the anti-cycling switch is
faulty.
(b) Using hand pressure to push down on the load arm to simulate a load, open the load
arm with the manual release handle, and check for continuity between pins C and D in
connector MS3459W14S-5P (see Figure 101, hardwired to Electrical Housing). If
discontinuity is found, adjustment of the linkage safe switch (Switch 1, Figure 102,
and Item 410, Figure 1002, Sheet 2, View A) is required or the linkage safe switch is
faulty.
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Figure 102. Limit Switch Locations
(c) If either of the switches is inoperative, refer to Table 103 for Troubleshooting
Procedures. If the setting for either of the switches is not correct, adjust limit switches
to obtain required setting as follows:
1) To set either of the limit switches, remove the cover in the electrical housing per
Section 301, Disassembly.
2) Loosen screws (390, Figure 1002, Sheet 2, View A) holding lock plate assembly
(400).
3) Pull up on manual release lever to rotate cam counterclockwise, and reposition
lock plate assembly (400, Figure 1002, Sheet 2, View A) accordingly so switches
(410, and 420) actuate properly. Switch 1, for hook open light, should actuate as
soon as manual release lever is pulled up, and load arm opens. Switch 2, for
solenoid protection, should actuate as soon as load arm swings down to full open.
Move lock plate assembly down and closer to the solenoid to allow the switches to
actuate sooner. Move lock plate assembly up and away from the solenoid to allow
the switches to actuate later.
4) Torque screws (390) from 20 to 25 in.-lb. (2.60 to 2.82 Nm.) to secure lock plate
assembly (400).
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5) Recheck position of switches (410, and 420) by pulling up on manual release lever
to rotate cam. If repositioning of the lock plate assembly cannot set switches,
loosen screws (430), and rotate solenoid (440). Rotate solenoid counterclockwise
to allow the switches to actuate sooner, clockwise to allow the switches to actuate
later.
6) Torque screws (390) and (430) from 20 to 25 in.-lb. (230 to 288 mm.-kg.) to
secure lock plate assembly (400) and solenoid (440).
7) After cam properly actuates switches (410, and 420), check torque on screws (390)
securing lock plate assembly (400) in electrical housing.
8) Install and secure cover in electrical housing with screws per Section 701,
Assembly.
B. Pilot Load Release Test (for Maximum Operating Load– Note lift limitation of the helicopter)
NOTE: THE PILOT LOAD RELEASE TEST REQUIRES TESTING OF THE CARGO
HOOK SYSTEM ON THE HELICOPTER.
(1) Install Cargo Hook Assembly into Cargo Hook Support on Helicopter per Section 701,
Assembly.
(2) Apply 100 lb. (45 kg.) load to Cargo Hook Assembly for a minimum of 10 seconds.
(3) Energize the electrical release circuit, and release the load.
(4) After load release, the load arm must automatically relatch, and the “hook open” light
must not be illuminated.
(5) Apply 25 lb. (11.34 kg.) load to Cargo Hook Assembly for a minimum of 10 seconds.
(7) After load release, the load arm must automatically relatch, and the “hook open” light
(8) Optional Pilot Load Release Test - Apply the rated cargo hook lifting load capability of
the helicopter to the Cargo Hook Assembly for 10 seconds, minimum.
(10)After load release, the load arm must automatically relatch, and the “hook open” light
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C. Manual Load Release Test
NOTE: THE MANUAL LOAD RELEASE TEST REQUIRES TESTING OF THE CARGO
HOOK SYSTEM ON THE HELICOPTER.
Assembly.
(2) Apply 100 lb. (45 kg.) to the Cargo Hook Assembly for a minimum of 10 seconds.
(3) Using a torque wrench with a 9/16-inch (14.288 mm) adapter, apply torque (not to exceed
25 in.-lb. [2.82 N-m.]) to nut on manual release lever, and release load.
(4) Apply 25 lb. (11 kg.) to the Cargo Hook Assembly for a minimum of 10 seconds.
(5) Using a torque wrench, apply torque (not to exceed 25 in.-lb. [2.82 N-m.]) to nut on
manual release lever, and release load.
(6) If a hook “Open” light is installed, it shall remain illuminated during the full manual
release lever travel and shall be illuminated after the lever is released.
(7) If loads do not release with torque applied to lever, Cargo Hook Assembly is binding, and
should be replaced.
D. Emergency Load Release Test
NOTE: THE EMERGENCY LOAD RELEASE TEST REQUIRES TESTING OF THE
CARGO HOOK SYSTEM ON THE HELICOPTER WITH THE CARTRIDGE
ASSEMBLY REMOVED.
(1) Remove cartridge assembly from Cargo Hook Assembly per Section 301, Disassembly.
(2) Install pressure cartridge simulator, P/N VW-F-1094-24, connected to a source of nitrogen
with regulator gauge (set at 200 psi ± 20 psi [13.8 bar ± 1.4 bar] outlet pressure), and
valve (in the closed position, see Figure 103).
Assembly.
(4) Apply a load of 500 lb. (227 kg.) to the Cargo Hook Assembly, and then open the nitrogen
valve, and hold for a 10 second period.
NOTE: ACTUATION OF PRESSURE CARTRIDGE ASSEMBLY, OR SIMULATOR,
MAY CAUSE MARK, OR BLEMISH, ON TOP SIDE OF LOCK. THIS
CONDITION IS NORMAL, AND ACCEPTABLE.
NOTE: ACTUATION OF PRESSURE CARTRIDGE ASSEMBLY, OR SIMULATOR,
PERMANENTLY EXTENDS A PIN AGAINST THE LOCK, AND PREVENTS
THE LOAD ARM FROM RELATCHING. THIS CONDITION IS NORMAL, AND
ACCEPTABLE.
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(5) The load arm must open, release the load, and not relatch until the initiating device is
replaced.
(6) If a hook “Open” light is installed, it shall remain illuminated until the EED is removed.
(7) After completion of the test, close the valve, remove the pressure cartridge simulator, and
install the cartridge assembly into the Cargo Hook Assembly per Section 701, Assembly.
Prior to using the pressure cartridge simulator again, depress the pin manually into the
pretest, or normal, position.
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Figure 103. Emergency Release Test Set Up With Pressure Cartridge Simulator
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E. Relatch Test (See Figure 104)
(1) Install Cargo Hook Assembly into Cargo Hook Support on Helicopter per Section
701, Assembly.
(2) Measure 1.00 +0/-0.10 inch (25.4 +0/-2.5 mm.) from the normally closed position of
the load arm at the point where the keeper intersects the load arm (see Figure 104).
Release the load arm using the manual release, and by hand deflect the load arm this
distance.
(3) Release load arm.
(4) Load arm shall automatically relatch into Cargo Hook Assembly.
(5) If a hook “Open” light is installed, it shall remain illuminated when the load arm is
unlatched, and go out after relatch.
Figure 104. Relatch Test

F. Load Weigh System Test and Standard Calibration (Full)
(1) Install Cargo Hook Assembly into the Cargo Hook Support per Section 701,
Assembly.
(2) Apply power to the Cargo Hook System. Observe the test sequence and check that all
LCD segments function. Check that the display (see Figure 105) on the Load Indicator
reads “18880” during the initial test sequence after applying power.
NOTE: STAY STANDARD WHEN ADJUSTING THE INDICATOR TO LBS OR KG.
ENSURE YOU DO NOT INTERCHANGE THE VALUES DURING
ADJUSTMENT OR YOUR VALUES WILL BE OFF.
(3) Depending on the operator’s preference, use the front panel LB / KG switch (see
Figure 105) to set the Load Indicator to read in pounds (lb.), or kilograms (kg.). Use
the front panel LB / KG switch to toggle between LB and KG.
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(4) Load the hook up to 9000 lbs, and hold for 5 seconds to make sure the hook is fully
seated in the frame. Bring the load back to zero.
(5) With no weight on the Cargo Hook Assembly, adjust the “ZERO” potentiometer
adjustment screw on back of the Load Indicator (see Figure 106) with a small
screwdriver until display (see Figure 105) reads 0 ± 20 lb. (9 kg.).
(6) Apply a load of 9,000 lb. +/- 10 lbs. (4,082 kg. +/- 4.5 kg.) to the Cargo Hook
Assembly, and adjust the “SPAN” potentiometer adjustment screw on the back of the
Load Indicator (see Figure 106) with screwdriver until the display (see Figure 105)
reads 9,000 lb. +/- 10 lbs. (4,082 kg. +/- 4.5 kg.).
Figure 105. Front Display of Load Indicator
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Note:
Adjustment
screws are
located under
the ZERO &
SPAN Phillip
Head Screws.
Use a
jeweler’s
screwdriver,
or equivalent,
to adjust.
Figure 106. Adjustment Screw Locations for “ZERO” and “SPAN” Potentiometers
(7) Remove the load from the Cargo Hook Assembly. If the display (see Figure 105) reads
between ± 80 lb. (36 kg.), use the “ZERO” switch on the front of the panel to reset the
Load Indicator to “ZERO.” Otherwise, repeat steps 4 and 5 above until no further
adjustments are necessary to the “ZERO,” or “SPAN,” potentiometer adjustment
screws (see Figure 106).
(8) Apply a load of 2,000 lb. (907 kg.) to the Cargo Hook Assembly, and check if the
display (see Figure 105) reads 2,000 lb. +250/-50 lb. (907 kg. +113/-23 kg.). If the
display reads within the allowable limits, continue to step 9. If the display does not
read within the allowable limits, repeat steps 4 through 6 above until no further
screws (see Figure 106), then repeat step 7.
(9) Apply a load of 4,500 lb. (2,041 kg.) to the Cargo Hook Assembly, and check if the
display (see Figure 105) reads 4,500 lb. +350/-50 lb. (2,041 kg. +159/-23 kg.). If the
screws (see Figure 106), then repeat steps 7, and 8.
(10) Apply a load of 6,000 lb. (2,721 kg.) to the Cargo Hook Assembly, and check if the
display (see Figure 105) reads 6,000 lb. +400/-50 lb. (2,721 kg. +181/-23 kg.). If the
screws (see Figure 106), then repeat steps 7, 8, and 9.
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NOTE: IF HELICOPTER LOAD LIMITATIONS PREVENT USE OF 9,000 LB. (4,082 KG.)
PROCEED TO STEP 12.
(11) Apply a load of 9,000 lb. (4,082kg.) to the Cargo Hook Assembly, and check if the
display (see Figure 105) reads 9,000 lb. +500/-50 lb. (4,082kg. +227/-23 kg.). If the
display reads within the allowable limits, calibration is completed. If the display does
not read within the allowable limits, repeat steps 4 through 11 above until no further
screws (see Figure 106), then repeat steps 7, 8, 9, and 10.
NOTE: RECORD THE RCAL NUMBER WHEN DISPLAYED IN STEP (10) BELOW.
THIS IS THE RCAL NUMBER THAT WILL BE STAMPED ON THE
NAMEPLATE. REFER TO FIGURE 107.
(12) Remove the load from the Cargo Hook Assembly. If the display (see Figure 105)
reads between ± 100 lb. (45 kg.), push the “ZERO” and the LB / KG switches
simultaneously, and after “18880” is displayed and disappears, the RCAL value will
be displayed immediately (see Figure 106). Otherwise, repeat steps 4 through 11 above
until no further adjustments are necessary to the “ZERO,” or “SPAN,” potentiometer
adjustment screws (see Figure 106), then repeat step 10.
(13) Use the “ZERO” switch on the front of the panel (see Figure 105) to reset the Load
Indicator to “ZERO.”
(14) If a new cargo hook / nameplate stamp this RCAL number in the nameplate RCAL
block. If this procedure was accomplished due to maintenance, then it is permissible to
cross out the existing RCAL number on the existing nameplate and stamp (or
equivalent) the new RCAL number in the nameplate RCAL position (see Figure 107),
or use a new label after transferring all the nameplate information. Also, record this
value in the maintenance logbook for the Cargo Hook System, and Helicopter.
STAMP, OR EQIVALENT,
NEW RCAL NUMBER
HERE, WHEN
APPLICABLE.
Figure 107. Nameplate with RCAL Number Inserted.
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G. Calibrate the indicator to the cargo hook using the Resistor Calibration Number (RCAL).
NOTE: RCAL CALIBRATION CAN BE USED IF THE STANDARD CALIBRATION
CANNOT BE CONDUCTED, PROVIDED THAT THE LOAD WEIGH
TRUNNION / MOUNTING BLOCKS HAVE NOT BEEN REMOVED OR
REPLACED DURING MAINTENANCE). THIS PROCEDURE SYNCHRONIZES
THE INDICATOR DISPLAY TO THE RCAL NUMBER STAMPED ON THE
CARGO HOOK NAMEPLATE.
NOTE: STAY STANDARD WHEN ADJUSTING THE INDICATOR TO LBS OR KG.
ENSURE YOU DO NOT INTERCHANGE THE VALUES DURING
ADJUSTMENT OR YOUR VALUES WILL BE OFF.
NOTE: SERVICE INFORMATION LETTER (SIL) 01 FE7590-173-1 AND FE7590-173-2
REQUIRED CARGO HOOK SERIAL NUMBERS B2026, B2027, B2028, B2029,
B1978, B1979, B1980, B1981, B1982, B1983, B1984, B1985, 1268, 1269, 1270,
1271, 1272, 1273, 1572, 1573, 1574, 1575, 1576, 1577, 1706, 1707, 1708, 1709,
1710, 1711, 1713, 1714, 1715, 1716, 1717, 1718, 1782, 1783, 1784, 1785, 1786,
1787, 1788, 1789, 1790, 1791, 1792, 1793, 1794, 1795, 1796, 1797, 1823, 1824,
1825, 1826, 1827, 1828, 1829, 1830, 1831, 1832, 1833, 1834, AND 1835 TO BE
SENT BACK TO BREEZE-EASTERN FOR RECALIBRATION
CONFIRMATION. ONCE ACCOMPLISHED AN “R” WAS ANNOTATED
AFTER THE DATA PLATE SERIAL NUMBER. CHECK TO ENSURE THIS SIL
WAS TERMINATED.
(1) Make note of the last RCAL number stamped on the cargo hook nameplate.
(2) Turn off the cargo hook weigh system circuit breaker.
(3) Remove the four front panel mountings screws and place the Indicator in a position,
which permits access to the rear panel controls.
(4) Remove the seal screws to access the adjustment screws on the rear panel, labeled
“ZERO” and “SPAN,” refer to Figure 106. Retain screws for assembly.
(5) Apply power to the indicator. Observe the test sequence and insure that all LCD
segments function. The numeric digits should display “18880.”
(6) With no weight on the cargo hook, zero the indicator by adjusting the zero pot with a
small screwdriver to within 20 lb. / 20 kg. The indicator will display to the nearest 10
lb. / 10 kg. increment. There is no decimal in the display.
(7) Start the test sequence by pressing and releasing the ZERO and LBS / KGS buttons
simultaneously. After the segments on / segments off sequence, the RCAL number
immediately displays. Immediately press and hold the ZERO and LBS / KGS buttons
simultaneously to lock on the RCAL value.
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(8) While holding the ZERO and LBS / KGS buttons simultaneously, adjust the SPAN
pot until the display matches the RCAL number recorded in step (1) above. Release
the ZERO and LBS / KGS buttons to return to normal operation.
(9) If the indicator returns to zero, the RCAL calibration is complete. If not repeat steps
(6 – 9) until no further adjustments are necessary.
(10) Replace the seal screws covering the Zero and Span pots. Remount the indicator.
(11) Record this value in the maintenance logbook for the Cargo Hook System, and
Helicopter.
H. If the System fails to meet any of the test parameters identified in Paragraphs 4A through
4F above, refer to Table 103 for Troubleshooting Procedures.
5. Troubleshooting Procedures
Troubleshooting is the process of using a logical sequence to locate and eliminate a System
malfunction. The troubleshooting process relies heavily on the abilities of qualified
technicians. Refer to Table 103 for Troubleshooting Procedures.
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Trouble Probable Cause Remedy
Load does not release Loss of Power Check Aircraft Power is on
during normal
(electrical) release Connector not attached to aircraft Check connector
Connector pins damaged, or missing Check connector pins
Loose connection on terminal board Tighten connection
Broken wire/damaged connector, or cable Replace wire/cable
Defective solenoid Replace Cargo Hook Assembly
Damaged mechanical components Replace Cargo Hook Assembly
Load Arm does not open Load Arm has no load Use hand to open Load Arm
during normal
(electrical) release
Load does not release Damaged mechanical components Replace Cargo Hook Assembly
during manual release
Load does not release Defective cartridge assembly (or simulator) Replace cartridge assembly (or simulator)
during emergency
Defective cartridge or timed out cartridge Replace cartridge and packing
release
Connector not attached to cartridge (or pressure line Check connector (or pressure line)
not connected simulator)
Connector pins damaged, or missing Replace connector pins
Damaged, or jammed, mechanical components Replace Cargo Hook Assembly
Load arm does not Broken, or damaged, torsion spring Replace Spring, and Load Arm
relatch after normal, or
manual, release Damaged mechanical components Replace Cargo Hook Assembly
No continuity between Improper switch bracket adjustment Readjust

pins B and C during
Broken wire Replace wire/cable
release
Connector pins damaged Replace connector pins
Damaged switch Replace switch
Continuity between pins Improper switch bracket adjustment Readjust
B and C during Relatch
Load arm relatches after Broken, or missing, piston in cartridge (or simulator) Replace cartridge assembly (or simulator)
emergency release (pin
Damaged mechanical components Replace Cargo Hook Assembly
prevents relatch)
Support moves while Missing Hardware Replace Hardware
Cargo Hook Assembly
Defective Support Replace Support
supports load
Table 103. Troubleshooting Procedures
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Trouble Probable Cause Remedy
Support/Cargo Hook Improperly torqued Hardware Torque Hardware properly
Assembly moves
Missing Hardware Replace Hardware
excessively while
supporting load Missing, or improperly installed, Split Bushing Check installation of, or Replace, Split
Bushing
Defective Support (i.e., elongated holes) Replace Support
Load Indicator display Loss of Power Check Power is on
not illuminated
Connectors not attached from Load Cell to Check connectors
Helicopter, or to Load Indicator
Broken wire/damaged connector or cable Replace wire/cable
Defective Load Indicator Replace Load Indicator
Load Indicator reading Incorrect Units (lb., or kg.) selected Change Units on display
inaccurate, or
Load Indicator requires calibration Calibrate Load Indicator
varies/oscillates greatly
Support not attached securely Check Support condition and hardware
Defective Load Indicator Replace Load Indicator
Defective load cell in Cargo Hook Assembly Replace load cell
Table 103. Troubleshooting Procedures (continued)

If defect cannot be corrected, contact Breeze-Eastern Customer Services at:
35 Melanie Lane
Fax: (973) 739-9344
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SCHEMATICS AND WIRING DIAGRAMS
1. General
This section provides all schematic diagrams, wiring, and interconnecting diagrams of the
applicable components of the Cargo Hook System. These schematics and wiring diagrams
are provided for use during disassembly, assembly, installation, and troubleshooting of the
CHS-9000-3 Cargo Hook System.
2. Contents of this Section
Figure Description Page
Figure 201 Cargo Hook Assembly Wiring Diagram 202
Figure 202 Cargo Hook System Interconnect Wiring Diagram 205
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Figure 201. BL Cargo Hook Assembly Wiring Diagram
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Figure 202. Cargo Hook System Interconnect Wiring Diagram (Sheet 1 of 2) 25-61-00
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Figure 202. Cargo Hook System Interconnect Wiring Diagram (Sheet 2 of 2)
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DISASSEMBLY
1. General
Use the Testing and Troubleshooting procedures, in Section 101, to establish the condition of the
Cargo Hook System, or most probable cause for its malfunction. These procedures are to be
followed to determine the extent of disassembly required for repair of the Cargo Hook System, and
to limit the amount of maintenance required for returning it to a serviceable condition.
2. Cargo Hook System
Disassemble the Cargo Hook System in accordance with the following instructions. Reference
numbers in parenthesis refer to IPL in Section 1001. Special Tools and general information are listed
in Section 901. All mention of applying, and disconnecting, power to the System should be
accomplished using Helicopter circuit breakers, or equivalent acceptable means.
RESULT IN LOSS OF LOAD, AND/OR HELICOPTER, AND CAN RESULT IN
INJURY, OR DEATH. ONLY PROPERLY TRAINED PERSONNEL MUST UTILIZE
APPROPRIATE OPERATION, MAINTENANCE, AND INSPECTION PROCEDURES
TO MINIMIZE THE HAZARDS INHERENT IN THE USE OF ALL CARGO HOOK
SYSTEMS.
WARNING: KEEP HANDS, BODY, AND CLOTHING AWAY FROM HOOK ASSEMBLY,
SPECIFICALLY “PINCH POINTS,” WHERE THE LOAD ARM, APEX FITTING,
AND KEEPER CONTACT.
WARNING: THE OPERATOR MUST WEAR WORK GLOVES, AND EYE PROTECTION
CONDITION CAN CAUSE LOSS OF LOAD, AND/OR HELICOPTER, AND CAN
RESULT IN INJURY, OR DEATH. THE CAUSE OF ANY DEGRADATION MUST
BE DETERMINED, AND THE PROBLEM CORRECTED, PRIOR TO THE CARGO
HOOK SYSTEM BEING RESTORED TO AN OPERATIONAL CONDITION.

DISCHARGE (GROUNDING) WAND, OR EQUIVALENT, PRIOR TO MANUALLY
ATTACHING, OR DETACHING, LOADS TO THE CARGO HOOK SYSTEM.
FAILURE TO DO SO CAN RESULT IN GROUND PERSONNEL BEING THE
ELECTRICAL GROUND, RESULTING IN INJURY, OR DEATH.
3. Removal of Cargo Hook Assembly
Remove Cargo Hook Assembly (Item 10, Figure 1001, [Item 10 consists of Items 11 and 12 for
shipping purposes only] from Cargo Hook Support and Helicopter as follows, refer to Figure 301]):
A. Disconnect power to Cargo Hook Assembly (10) by pulling applicable circuit breakers.
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B. Disconnect jumper (180, Figure 1003) from Cargo Hook Assembly by removing screw (10,
Figure 1002, Sheet 2) and washer (20), and electrical connectors from Helicopter to cartridge,
load cell, and solenoid.
Figure 301. Cargo Hook Assembly Mounted in Hook Support (shown removed from Helicopter)
C. Remove tie wire, screws (30, Figure 1003), and washers (40) securing forward flange (50) to
Cargo Hook Support (20, Figure 1001). Do not remove forward flange at this time. Discard tie
wire, and retain screws, and washers for inspection, and future use.
D. Remove tie wire, screws (60, Figure 1003), and washers (70) securing split bushings (80) to
Cargo Hook Support (20, Figure 1001). Discard tie wire, and retain screws, and washers for
inspection, and future use.
E. Remove forward flange (50, Figure 1003), split bushings (80), and Cargo Hook Assembly (10,
Figure 1001) by sliding all parts forward, and out of the Cargo Hook Support (20).
F. Separate forward flange (50, Figure 1003), and split bushings (80) from Cargo Hook Assembly
(10, Figure 1001). Retain split bushings, and forward flange for inspection, and future use.
4. Removal and Disassembly of Cargo Hook Support
Remove, and disassemble, Cargo Hook Support (20, Figure 1001) from Helicopter as follows
(accomplish removal instructions identified in paragraph 3 [removal of Cargo Hook Assembly])
above prior to performing the steps below):
A. Remove screws (10, Figure 1003) and washers (20) securing Cargo Hook Support (20, Figure
1001) to Helicopter. Retain hardware for inspection, and future use.
B. Remove Cargo Hook Support from Helicopter.
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C. Remove tie wire, screws (90, and 100, Figure 1003), and washers (70) securing left strut (110)
and right strut (120) between aft flange (130), right channel (140), and left channel (150).
Remove struts, discard tie wire, and retain struts, screws and washers for inspection, and future
use.
D. Remove screws (160, and 190), washers (170), jumper (180), and nut (200) securing bumper
(210) to aft flange (130) and right channel (140). Remove bumper (210) from assembly, and
remove grommet (220) from bumper. Retain grommet, bumper, screws, nuts, and washers for
E. Remove nuts (230), and washer (240) securing U-bolt (250) with sleeving (260) to left channel
(150), and remove U-bolt. Retain U-bolt, nuts, and washers for inspection, and future use.
F. Remove tie wire, screws (30), and washers (40) securing aft flange (130) to right channel (140)
and left channel (150), and remove aft flange (130), and left and right channels. Discard tie wire,
and retain channels, flange, screws, and washers for inspection, and future use (see Figure 302).
Figure 302. Mounting Screws for Aft Flange

G. Remove nameplate (270), if necessary, as follows:
(1) All typed-in information on nameplates should be recorded prior to removal. This
information will be required when nameplate is installed during assembly. If nameplate is
illegible, or missing, contact Breeze-Eastern with all known information concerning Cargo
Hook Support for original, or new data.
(2) Remove nameplate by using a sharp knife, razor blade, or equivalent.
(3) Remove any residual adhesive from where the nameplate was installed by using similar
means as removing the nameplate.
5. Removal of Load Indicator
Remove Indicator (30, Figure 1001) from Helicopter as follows:
A. Disconnect power to Indicator (30) by pulling applicable circuit breakers.
B. Remove hardware (not shown in IPL, and not supplied by Breeze-Eastern) securing Indicator to
Helicopter. Retain hardware for inspection, and future use.
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C. Access the electrical connectors attached to the Indicator by lifting out the Indictor from the
panel. Detach the electrical connectors to back of Indicator, and remove Indicator (see Figures
303, and 304).
Figure 303. Load Indicator Figure 304. Typical Electrical Connector Set-Up
for Load Indicator
6. Disassembly of Cargo Hook Assembly
Disassemble Cargo Hook Assembly (10, Figure 1001) as follows:
A. Removal of Pressure Cartridge Assembly
STORED, AND HANDLED IN COMPLIANCE WITH ALL LOCAL STANDARDS,
AND REGULATORY PRACTICES. TAKE PROPER ESD PRECAUTIONS TO
AVOID SETTING OFF THE CARTRIDGE DURING HANDLING DUE TO
ELECTRICAL SHOCK FROM ELECTROSTATIC DISCHARGE.
WARNING: BEFORE REMOVING THE CARTRIDGE, ENSURE THAT ALL ELECTRICAL
CIRCUITS TO THE CARGO HOOK ASSEMBLY ARE OPEN.
PRIOR TO, OR AFTER, REMOVAL FROM CARGO HOOK ASSEMBLY.
NOTE: CARTRIDGE SERVICE LIFE IS 5 YEARS, STARTING WHEN INSTALLED ON
THE HELICOPTER. CARTRIDGE LIFE (COMBINED SHELF AND SERVICE LIFE)
IS 13 YEARS, STARTING FROM THE DATE OF MANUFACTURE, WHICH CAN
BE FOUND IN THE LOT NUMBER ON THE IDENTIFICATION PLATE. THE LOT
NUMBER STARTS WITH THE FIRST THREE LETTERS “ESD,” FOLLOWED BY
TWO DIGITS, IDENTIFYING THE YEAR OF MANUFACTURE (EXAMPLE: 11 IS
2011), AND ONE LETTER, IDENTIFYING THE MONTH OF MANUFACTURE, AS
FOLLOWS:
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When shipping the cargo hook to Breeze-Eastern the Pressure Cartridge Assembly
(Figure 1001, Item 12) shall be removed and properly stored, or disposed of, by the
operator in accordance with your local regulatory authority laws and regulations. If the
shipment to Breeze-Eastern contains an explosive and the packaging does not meet US
Department of Transportation / International Air Transport Association regulations and
standards, Breeze-Eastern is required to report the situation. Additionally, you will be
charged a minimum fee of $500 USD for the proper disposal of the explosive
Remove the pressure cartridge assembly as follows (see Figure 1002):
(1) Remove quick release pin (30, Figure 1002, Sheets 1, and 2) securing pressure cartridge
assembly (70) to Cargo Hook Assembly. If quick release pin is damaged, separate pin from
lanyard assembly (60, Figure 1002, Sheet 1), and discard quick release pin. If lanyard
assembly is damaged, remove cotter pin (40), nut (50), and lanyard assembly with quick
release pin, and separate lanyard assembly from quick release pin. Discard cotter pin, and
retain nut, and quick release pin for inspection, and future use.
(2) Lift off pressure cartridge assembly (70, Figure 1002, Sheets 1, and 2), and detach electrical
connector to the pressure cartridge (80).
CAUTION: DO NOT USE TAPE, OR METAL CAP, IN PLACE OF PROTECTIVE SHIPPING
CAP DURING REMOVAL OF CARTRIDGE.
NOTE: SPRING SHUNT, AND PROTECTIVE PLASTIC CAP, SAVED DURING
INSTALLATION, SHOULD BE USED DURING REMOVAL OF CARTRIDGE.
(3) Install shunt, or equivalent, into connector of pressure cartridge (80, Figure 1002, Sheets 1,
and 2) to short all pins together, and install protective cap to secure shunt in connector.
(4) Remove pressure cartridge (80) with packing (90). Remove packing from pressure cartridge,
and discard packing (see Figure 305).
Figure 305. Pressure Cartridge Installed in Pressure Cartridge Assembly

B. Removal of Load Arm
Remove load arm as follows (see Figure 1002, Sheets 1, and 2):
(1) Remove cotter pin (100, Figure 1002, Sheets 1, and 2), nut (110), washers (120), and bolt
(130) securing load arm to Cargo Hook Assembly (see Figure 306). Discard cotter pin, and
nut, and retain washers, and bolt for inspection, and future use.
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CAUTION: WHEN REMOVING THE LOAD ARM FROM THE CARGO HOOK ASSEMBLY
ENSURE THE TEFLON WASHERS POSITIONED ON EACH SIDE OF LOAD ARM
BORE ARE ACCOUNTED FOR DURING REMOVAL TO PREVENT THE
WASHERS FROM FALLING INSIDE THE ASSEMBLY.
(2) Remove the load arm (140) and Teflon washers (150) located on each side of the load arm
bore by working it out by hand (see Figures 307, and 308). Retain washers, and load arm for
Figure 306. Load Arm Bolt Removal Figure 307. Load Arm Removal
Teflon plugs (part of load arm)
Spring (part of load arm)
Teflon Washer
Bushing (part of load arm)
Teflon Washer

Bushing (Loose)
Load Arm
Figure 308. Load Arm and Subassembly Removal
(3) Remove Teflon plugs (160, Figure 1002, Sheets 1, and 2), and loose bushing (170), which
will slide out of the load arm center bore. Retain load arm, which contains pressed in
bushings (180, and 190) that captures spring (200), and loose bushing (170) for inspection,
and future use (see Figure 308).
C. Removal of Keeper Assembly
Remove keeper assembly as follows (see Figure 1002, Sheets 1, and 2):
(1) Remove cotter pin (210, Figure 1002, Sheets 1, and 2), nut (220), and bolt (230) securing
keeper to Cargo Hook Assembly. Discard cotter pin, and retain nut, and bolt for cleaning,
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(2) Remove keeper (240), and springs (250). Retain keeper, and springs for cleaning, inspection,
and future use.
D. Removal of Load Cell
Remove load cell as follows (see Figure 1002):
(1) Remove cotter pins (260, and 290, Figure 1002, Sheet 1), nuts (270, and 300), and bolts (280,
and 310, Figure 1002, Sheet 2) securing load cell in Cargo Hook Assembly. Discard cotter
pins, and retain nuts, and bolts for inspection, and future use (see Figures 309, and 310).
Figure 309. Top View of Load Cell Figure 310. Side View of Load Cell
(shown without cotter pins) (shown without cotter pins)
(2) Remove load cell (320, Figure 1002, Sheets 1, and 2).
E. Removal of Electrical Housing Cover (for switch adjustment)
Remove cover of electrical housing (for switch adjustment) as follows (see Figure 1002, Sheets
1, and 2):
(1) Remove screws (330, and 340) securing cover (350) with gasket (360) to electrical housing
(370).
(2) Remove cover (350) with gasket (360) from electrical housing assembly (370). If necessary,
remove harness assembly (380) from electrical housing assembly (370). If necessary, remove
diode assembly (445) from electrical housing assembly by removing screws from terminal
board and carefully lifting out diode assembly (see Figure 311).
(3) Proceed to Section 101, Testing and Troubleshooting for adjustment procedure involving
screws (390, Figure 1002, Sheet 2, View A), lock plate assembly (400), hook open indicator
light switch (410), anti-cycling relay switch (420), screws (430), and solenoid (440).
F. Removal of Release Handle Spring and Spring Bracket (see Figure 1002, Sheet 1)
(1) Remove nut (450, Figure 1002, Sheet 1) securing spring bracket (460) to Cargo Hook
Assembly, and remove bracket. Retain nuts, and bracket for inspection, and future use.
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(2) Remove bolt (470) securing spring (480) to release handle (490), and remove spring. Retain
bolt, and spring for inspection, and future use.
G. Removal of Expiration Plate, Electrical Schematic Decal, and Nameplate
Remove expiration plate (500, Figure 1002, Sheet 1), electrical schematic decal (510, Figure
1002, Sheet 2), and nameplate (520, Figure 1002, Sheet 1) as follows:
Figure 311. Electrical Housing Assembly

(1) All typed-in information on expiration plate and nameplate should be recorded prior to
removal. This information will be required when expiration plate, or nameplate, is installed
during assembly. If expiration plate, or nameplate, is illegible, or missing, contact Breeze-
Eastern with all known information on Cargo Hook Assembly to obtain original or new data.
(2) Remove expiration plate (500), electrical schematic decal (510), and nameplate (520) by
using a sharp knife, razor blade, or equivalent.
(3) Remove any residual adhesive from where the expiration plate, electrical schematic decal,
and nameplate was installed by using similar means as removing the label.
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CLEANING
1. General
Cleaning instructions for the components of the Cargo Hook System are provided in this section.
To ensure satisfactory results, each cleaning procedure should be performed as described.
Materials required for the cleaning procedures are listed in Table 401. All dust, dirt, corrosion,
soot, rust, and moisture must be removed, as these destructive agents will eventually cause
operational failure.
Equipment / Material Name
ASTM-D3699 Kerosene
TT-I-735 Isopropyl Alcohol
- Soft Bristle Brush (commercially available)
- Vacuum Cleaner (commercially available)
Table 401. Materials Required for Cleaning
Cleaning will require maintenance personnel to wear gloves when handling these materials, or
when applying them in an air exhausted partially covered tank. If the tank is not exhausted, or
uncovered, the maintenance personnel should wear gloves, respirator, and goggles.
AND KEEPER CONTACT.
CONDITION.
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WARNING: KEROSENE AND ISOPROPYL ALCOHOL ARE COMBUSTIBLE. DO NOT USE

NEAR OPEN FLAMES, NEAR WELDING AREAS, OR ON HOT SURFACES.
PROLONGED CONTACT OF VAPOR WITH SKIN CAN IRRITATE NOSE AND
THROAT AND CAN CAUSE DIZZINESS. IF ANY LIQUID CONTACTS SKIN,
OR EYES, IMMEDIATELY FLUSH AFFECTED AREA THOROUGHLY WITH
WATER. REMOVE SATURATED CLOTHING. IF VAPORS CAUSE DIZZINESS,
GO TO FRESH AIR.
WARNING: DO NOT HOSE WATER SOAK THE ELECTRONICS; SUCH AS PILOT
CONTROLS, CREW CONTROLS, PENDANTS, WIRING HARNESSES, ETC., OR
ELECTRICAL SHORTS MAY OCCUR.
NOTE: LIMIT SWITCHES MUST BE OPERATING, AND SET PROPERLY PRIOR TO
PERFORMING LOAD TESTING.
A. Clean all metal parts with kerosene, isopropyl alcohol, or equivalent. Remove caked-on dirt
with a stiff-bristle, non-metallic brush and solvent.
WARNING: COMPRESSED AIR USED FOR CLEANING CREATES AIRBORNE PARTICLES
THAT MAY ENTER THE EYES. PRESSURE SHALL NOT EXCEED 15 PSIG (1.0
BAR). EYE PROTECTION IS REQUIRED.
B. Thoroughly dry parts with a lint-free cleaning cloth. Blow off extra cleaning materials from
hard-to-reach areas with moisture-free compressed air.
C. Wipe parts using a clean, lint-free cloth to prevent contamination of parts.
D. Place cleaned parts on a clean dust-free surface.
E. Wipe switches, receptacles, and connectors with a clean cloth, and isopropyl alcohol, or
equivalent non-flammable, non-corrosive volatile solution suitable for electrical cleaning
applications.
F. Do not attempt to clean painted parts in a vapor degreaser, as paint will be removed.
NOTE: DO NOT ALLOW BEARINGS TO SPIN WHEN DRYING WITH COMPRESSED
AIR.
G. For cleaning of non-sealed bearings, thoroughly clean all bearings with soft-bristle brush and
kerosene, or isopropyl alcohol. Dry the bearing with clean, dry compressed air at a maximum
pressure of 15 psig (1.0 bar), or with a clean, lint-free cloth. Do not attempt to clean sealed
bearings in solvent. Breeze-Eastern recommends replacement of all sealed bearings at
overhaul, or as necessary during flight line maintenance.
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H. Prior to installation of label, or nameplate, clean surface with isopropyl alcohol to remove any
adhesive, dirt, dust, or grease, prior to assembly. Dry surface with clean, dry compressed air at
a maximum pressure of 15 psig (1.0 bar), or with a clean, lint-free cloth.
I. For all faying, or mating surfaces, specifically where gaskets are to be installed, clean with
isopropyl alcohol to remove any dirt, dust, soot, or grease, prior to assembly. Dry surface with
clean, dry compressed air at a maximum pressure of 15 psig (1.0 bar), or with a clean, lint-
free cloth.
J. After each day of use, it is recommended to wash the Hook Assembly (specifically the keeper
and load arm) to remove all contaminants. If any corrosion is visible, remove corrosion and
re-treat affected area per Repair (Section 601). Wash Cargo Hook Assembly and Frame
Assembly with clean, fresh water as specified below.
NOTE: DO NOT RINSE OFF CARGO HOOK ASSEMBLY AND FRAME ASSEMBLY
WITH FRESH WATER UNDER HIGH PRESSURE. HIGH PRESSURE
WATER MAY WASH OUT LUBRICATION IN CARGO HOOK ASSEMBLY.
USE LOW PRESSURE WATER TO RINSE OFF HOOK ASSEMBLY
(RECOMMENDED PRESSURE OF WATER SUPPLY IS NO GREATER
THAN 5 PSI [0.3 BAR]).
(1) Rinse off Cargo Hook Assembly and Frame Assembly so that all sand, dust, saltwater, and
all other contamination have been thoroughly washed off.
(2) Wipe off excess water from Hook Assembly after washing.
(3) The application of corrosion preventative compounds; such as WD-40, ACF-50,
Corrosion-X, or equivalent, on external metallic parts is acceptable if applied in
accordance with the manufacturer’s instructions.
K. Wipe off the front of the Load Indicator using a clean, lint free cloth lightly dampened with
isopropyl alcohol.
L. Wiring Harness Cleaning.
(1) Remove any loose contamination by hand.
(2) Using a small vacuum, remove dust, dirt, and grime accumulations on the wiring harness
assembly.
(3) Use a soft bristle brush to loosen accumulations of dust, dirt, soot, and grime that remain,
and vacuum the area again.
(4) Remove any remaining dust, dirt, soot, and grime by wiping with isopropyl alcohol and a
clean cloth.
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INTENTIONALLY
LEFT BLANK
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CHECKS AND INSPECTIONS
1. General
The items listed in Table 501 shall be inspected in accordance with the procedures contained in
this section at the recommended frequency. Inspections can be made more frequently, depending
on the operator’s environment, and usage, but it is not recommended to make these inspections
less frequently. In addition, a maintenance log must be maintained for each Cargo Hook
System in order to keep track of maintenance actions, and inspections. All preflight inspections
must be performed at the beginning of the day before the first flight of the helicopter. All post
flight inspections must be performed at the end of the day after the last flight of the helicopter.
Recommended Frequency of Part Name Figure and Inspection Required

Inspections Section, Paragraph Item No.
At the beginning of the mission day Sec. 501, Para. 2.C 1001-1 Preflight Inspection
- Inspect Cargo Hook and Support for damage,
dirt, and corrosion
- Check for secure, or missing hardware,
elongated side plate holes, and mounting points
- Verify all connectors are secure
- Check operation of Cargo Hook (electrical and
manual release) and display of Load Indicator
- Check Cargo Hook pivots properly in Support
At the end of the mission day Sec. 501, Para. 2.D 1001-1 Post Flight Inspections
- Wash Cargo Hook and Support
- Inspect Cargo Hook and Support for damage,
dirt, and corrosion
- Check for secure, or missing hardware,
elongated side plate holes, and mounting points
- Verify all electrical connectors are secure
- Check operation of Cargo Hook (electrical and
manual release), and display of Load Indicator
Annually (per Section 101) Sec. 501, Para. 2.B 1001-1 Functional Test
- Performance and Electrical Tests
- Pilot, Manual, and Emergency Load Release
Test
- Relatch Test
Sec. 501, Para. 2 F Wiring Inspection

Overhaul – The first of 5 years, 3,000 Cargo Hook System 1001-11 Overhaul – The first of 5 years, 3,000 cycles, or
cycles, or 1,000 hours of external load Sec. 501, Para. 2.A 1001-20 1,000 hours of external load operations from date
operations from date of installation on of installation on the helicopter - Overhaul Cargo
the helicopter (to be documented in Hook Assembly PN FE7590-173-2 and Cargo
maintenance log) Hook Support
The Load Indicator is classified as “On 1001-30 On Condition – Load Indicator
Condition” maintenance / overhaul
5 years service life (from date of Cartridge 1002-80 Mandatory Replacement
helicopter installation) / 13 years shelf Sec. 501, Para. 2.E
life (from date of manufacture)
Table 501. Inspection Requirements

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2. Inspections
AND KEEPER CONTACT.
CONDITION CAN CAUSE LOSS OF LOAD, AND/OR HELICOPTER AND CAN
MUST BE DETERMINED, AND THE PROBLEM CORRECTED PRIOR TO THE
CONDITION.
NOTE: LIMIT SWITCHES MUST BE OPERATING, AND SET PROPERLY PRIOR TO
PERFORMING LOAD TESTING.
A. Overhaul / Refurbishment of Cargo Hook System:
Breeze-Eastern’s Cargo Hook Time Between Overhaul (TBO) period is the first of 5 years,
3,000 cycles, or 1,000 hours of external load operations from date of installation on the
helicopter. Overhaul the Cargo Hook Assembly PN FE7590-173-2 and Cargo Hook Support
PN CH-9020-1. The Load Indicator is maintained “On Condition.” Refer to the following
clarification notes below:
NOTES:
1. Definitions:
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a. Cargo Hook “Cycle” is defined as any unlatch and relatch of the load beam
whether loaded or unloaded.
b. Hours of external load operation is defined as the time the helicopter is engaged
in external load operations, including time between loads on the hook.
2. If operators consistently utilize the Cargo Hook in adverse environmental conditions /
extremes or consistently use at the Cargo Hook maximum rated load (particularly
releases at maximum rated load), it is the operator’s responsibility to increase the
scope and frequency of all Cargo Hook maintenance actions to ensure safe operation
of the equipment.
More frequent inspections can be made, but inspections cannot be accomplished less
frequently.
3. Tracking of calendar time, number of cycles, or hours of external load operations is
dependent on the operator’s helicopter records / cargo hook usage logs.
4. If a Breeze-Eastern supplied load weigh indicator is included in the design it is
considered “On-Condition” maintenance and not bound by the defined overhaul
requirements in this section.
5. The Breeze-Eastern supplied load carrying frame / support is included in the design
the TBO as defined in paragraph 2.A above applies.
6. The application of corrosion preventative compounds; such as WD-40, ACF-50,
Corrosion-X, or equivalent, on external metallic parts is acceptable if applied in
accordance with the manufacturer’s instructions.
7. Operators are encouraged to coordinate all repair / overhaul work with Breeze-Eastern,
or their authorized Service Centers. Breeze-Eastern is a Federal Aviation
Administration (FAA) and a European Aviation Administration (EASA) FAR / EASA
Part 145 approved Repair Station (FAA Repair Station No. BZ7R167O, EASA -145
Acceptance Certificate Reference No. EASA.5454), and can repair / overhaul all
components of the Cargo Hook System at competitive prices and lead-times. Please
contact Breeze-Eastern Customer Services for any of these services listed above as
follows:
35 Melanie Lane

Fax: (973) 739-9344
Web site: www.breeze-eastern .com (Note: Revision status of the Breeze-Eastern
technical manuals is listed on the web site).
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B. Functional Test
Perform test procedures in Section 101, Testing and Troubleshooting, as recommended in
Table 501 from the date of installation on the helicopter. If Cargo Hook Assembly has been
removed, perform functional test after reinstallation onto helicopter prior to use.
C. Preflight Inspection
The following procedures are to be performed before each day in which the hoist may be used
for airborne transport operations (including training).
(1) Visually inspect Cargo Hook Assembly and Hook Support Frame Assembly for any
visible external damage i.e. cracks, elongation, etc. If Cargo Hook Assembly is in the
stowed position, remove U-bolt per Section 301, Disassembly, allow Cargo Hook
Assembly to rotate into the operating position, and install U-bolt per Section 701,
Assembly.
(2) Check assemblies for missing, or improperly secured hardware (i.e., missing tie wire).
(3) Verify all electrical connectors are undamaged, attached properly, and secured.
(4) Apply power to the Cargo Hook System by pushing in the applicable circuit breakers,
operate the Cargo Hook Assembly using electrical release switch, and verify load beam
opens, and relatches properly. Also, verify the Load Indicator display is illuminated, and
reads 0000 lb. (0000 kg.) when power is applied to the System.
(5) Operate Cargo Hook Assembly using manual release lever, and verify load arm opens,
and relatches properly. Pull down load arm by hand when manual release lever is
actuated. Release manual release lever, and then release load arm. Check that the load arm
relatches.
(6) Check that the keeper on Cargo Hook Assembly opens, and closes without binding, and
springs are firmly in place.
(7) Check that the Cargo Hook Assembly pivots from side to side in Hook Support Frame
Assembly without binding.
D. Post Flight Inspection
The following procedures are to be performed at the end of each day in which the hoist was
used for airborne transport operations (including training).
(1) As required, specifically after transport operations over salt water thoroughly wash the
Cargo Hook Assembly per Section 401, Cleaning.
(2) Check assemblies for missing, or improperly secured hardware (i.e., missing tie wire,
nuts, cotter pins, etc.).
(3) Verify all electrical connectors are undamaged, attached properly, and secured.
(4) Visually inspect Cargo Hook Assembly and Hook Support Frame Assembly for any
visible external damage i.e. cracks, elongation, etc. If Cargo Hook Assembly is to be
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stowed, remove U-bolt per Section 301, Disassembly, rotate Cargo Hook Assembly up to
allow the U-bolt to capture the load beam, and attach U-bolt to the Support per Section
701, Assembly.
E. Cartridge
STORED, AND HANDLED IN COMPLIANCE WITH ALL LOCAL
STANDARDS, AND REGULATORY PRACTICES. TAKE PROPER ESD
PRECAUTIONS TO AVOID SETTING OFF THE CARTRIDGE DURING
HANDLING DUE TO ELECTRICAL SHOCK FROM ESD.
WARNING: BEFORE REMOVING THE CARTRIDGE, ENSURE THAT ALL
ELECTRICAL CIRCUITS TO THE CARGO HOOK ASSEMBLY ARE OPEN.
PRIOR TO, OR AFTER, REMOVAL FROM CARGO HOOK ASSEMBLY.
NOTE: CARTRIDGE SERVICE LIFE IS 5 YEARS, STARTING WHEN INSTALLED
ON THE HELICOPTER. CARTRIDGE LIFE (COMBINED SHELF AND
SERVICE LIFE) IS 13 YEARS, STARTING FROM THE DATE OF
MANUFACTURE, WHICH CAN BE FOUND IN THE LOT NUMBER ON THE
IDENTIFICATION PLATE. THE LOT NUMBER STARTS WITH THE FIRST
THREE LETTERS “ESD,” FOLLOWED BY TWO DIGITS, IDENTIFYING
THE YEAR OF MANUFACTURE (EXAMPLE: 11 IS 2011), AND ONE
LETTER, IDENTIFYING THE MONTH OF MANUFACTURE, AS FOLLOWS:
The cartridge date of manufacture, and installation must be documented in the maintenance
log, and on the label on the pressure cartridge assembly.
When the cartridge has been actuated during an emergency release (refer to Figure 501),
replace the cartridge per the procedures contained in Disassembly, Section 301, and
Assembly, Section 701, and inspect the lock at the point where the pin in the Pressure
Cartridge Assembly makes contact with the lock. Marks and blemishes are normal, and
acceptable. Visible cracks are not. If cracks are found, send Cargo Hook Assembly to Breeze-
Eastern, or their authorized Service Centers, for repair.
If the cartridge was fired, do not utilize / operate the cargo hook until the emergency release
function has been restored by replacing the Pressure Cartridge Assembly PN CH-9016-1.
Never ship the cargo hook assembly PN FE7590-173-2 with the Pressure Cartridge Assembly
PN CH-9016-1 installed. When shipping the cargo hook to Breeze-Eastern the Pressure
Cartridge Assembly (Figure 1001, Item 12) shall be removed and properly stored, or disposed
of, by the operator in accordance with your local regulatory authority laws and regulations. If
the shipment to Breeze-Eastern contains an explosive and the packaging does not meet US
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Department of Transportation / International Air Transport Association regulations and
standards, Breeze-Eastern is required to report the situation. Additionally, you will be charged
a minimum fee of $500 USD for the proper disposal of the explosive
IF FIRED, REPLACE ENTIRE

PRESSURE CARTRIDGE CARTRIDGE LOCATION
ASSEMBLY, PN CH-9016-1
Figure 501. Pressure Cartridge Assembly Location
F. Inspection of Wiring
Visually inspect wiring for degradation due to wear, vibration, moisture, contamination, and
excessive heat. Check electrical wiring for the following defects:
(1) Wiring that has been subjected to chafing, fraying, or is brittle.
(2) Insulation that is abraded, cracked, over-stressed, or suspected of being penetrated.
(3) Conductors or shields that are broken or exposed.
(4) Clamps or brackets that are loose or missing.
(5) Wiring that is routed incorrectly.
(6) Wiring that is not correctly attached to terminals or connectors.
(7) Backshells that is loose or separated.
(8) Connector pin damage.
(9) Grommets that is loose or cracked.
Replace any wiring found with defects.
G. General
Visually inspect for obvious wear, damage, or corrosion, during all maintenance actions
identified in this manual as specified below:
(1) Check all parts for nicks, cracks, scratches, and corrosion.
(2) Examine threads for stripping, distortion, nicks, and cross threading.
(3) Inspect all mating, and faying surfaces for possible damage.
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(4) Non-Destructive Testing:
(a) STEEL - Perform Magnetic Particle Inspection in accordance with ASTM-E1444 with
the criterion for acceptance/rejection shall be in accordance with MIL-STD-1907. The
applicable tables of MIL-STD-1907 (GRADE “A” LEVEL) shall be utilized to
determine maximum allowable discontinuity sizes and distribution. Surface
indications that are shallow and can be removed by polishing out with emery paper, or
machining without loss of dimensions, shall not be cause for rejection. Parts with
shallow indications removed, shall be reprocessed to the Magnetic Particle Inspection
procedure. Parts shall contain no indications of cracks. Linear indications (with at least
a three to one length to width ratio) are definitely a cause for rejection.
(b) NON-FERROUS - Perform Fluorescent Penetrant Inspection in accordance with
ASTM-E1417 with the criterion for acceptance/rejection shall be in accordance with
MIL-STD-1907. The applicable tables of MIL-STD-1907 (GRADE “A” LEVEL)
shall be utilized to determine maximum allowable discontinuity sizes and distribution.
Surface indications that are shallow and can be removed by polishing out with emory
paper or machining without loss of dimensions shall not be cause for rejection. Parts
with shallow indications removed, shall be reprocessed to the Fluorescent Penetrant
Inspection procedure. Parts shall contain no indications of cracks. Linear indications
(with at least a three to one length to width ratio) are definitely a cause for rejection.
If any defects listed above are detected, perform the necessary corrective actions identified in
Section 601, Repair, or Section 701, Assembly.
H. Compliance Information
Ensure all applicable compliance information sent by Breeze-Eastern / Regulatory Authorities
in the form of Alert Service Bulletins (ASB), Service Bulletins (SB), Service Information
Letters (SIL), Technical Publication Deficiency Reports (TPDR), Change Orders (CO), etc.
are attached on the back of this manual and / or incorporated into this manual.
SIL01 FE7590-173-1 and SIL01 FE7590-173-2 pertaining to Cargo Hook Calibration
Confirmation for the following SN’s should indication a RCAL number on the nameplate.
SIL02 Maintenance Breeze-Eastern Cargo Hook Maintenance Concept pertaining to this
cargo hook system.
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B-E Part Number Ref: AgustaWestland PN

FE7590-173-1 & 2 3G2592V00651
NOTE: IT IS NECESSARY FOR BREEZE-EASTERN TO RECALIBRATE ALL THE UNITS / PER
THIS TABLE / NOT ONLY THE ONES WITHOUT THE RCAL NUMBERS MARKED ON
THE IDENTIFICATION PLATE. ONCE COMPLIED WITH, A RCAL NUMBER WILL BE
STAMPED IN THE RCAL BLOCK OF THE NAMEPLATE TERMINATING THIS SIL01
FE7590-173-1 & SIL01 FE7590-173-2.
NOTE: SERVICE INFORMATION LETTER (SIL) 01 FE7590-173-1 AND FE7590-173-2 REQUIRED
CARGO HOOK SERIAL NUMBERS B2026, B2027, B2028, B2029, B1978, B1979, B1980,
B1981, B1982, B1983, B1984, B1985, 1268, 1269, 1270, 1271, 1272, 1273, 1572, 1573, 1574,
1575, 1576, 1577, 1706, 1707, 1708, 1709, 1710, 1711, 1713, 1714, 1715, 1716, 1717, 1718,
1782, 1783, 1784, 1785, 1786, 1787, 1788, 1789, 1790, 1791, 1792, 1793, 1794, 1795, 1796,
1797, 1823, 1824, 1825, 1826, 1827, 1828, 1829, 1830, 1831, 1832, 1833, 1834, AND 1835 TO
BE SENT BACK TO BREEZE-EASTERN FOR RECALIBRATION CONFIRMATION. ONCE
ACCOMPLISHED AN “R” WAS ANNOTATED AFTER THE DATA PLATE SERIAL
NUMBER. CHECK TO ENSURE THIS SIL WAS TERMINATED.
Table 502. SIL01 FE7590-173-1 & SIL01 FE7590-173-2 Cargo Hook Calibration
Confirmation (Contact Breeze-Eastern for information details).
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REPAIR
1. General
AND KEEPER CONTACT.
WARNING: THE OPERATOR MUST WEAR WORK GLOVES, AND EYE PROTECTION
CONDITION CAN CAUSE LOSS OF LOAD, AND/OR HELICOPTER, AND CAN
CONDITION.
A. Causes of surface corrosion are as follows:
(1) Nicks, dents, scratches, and wear that remove paint and / or plating are the principal
causes of surface corrosion.
(2) Salt water exposure can cause surface corrosion, as well as joint corrosion due to moisture
between dissimilar metals through electrolytic action, when paint and or coating/plating
are removed as described above. This type of corrosion exists due to the use of aluminum
and steel parts in the manufacturing of the rescue hoists.
B. Removal of corrosion on aluminum parts.
(1) Remove mild surface corrosion with 200-300 grit aluminum oxide abrasive cloth, or
abrasive mat (Scotch Brite).
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(2) Remove moderate to heavy corrosion with Vacu-blast, or equivalent, with glass beads
only.
(3) Blend repaired areas. See Table 601 for allowable material removal.
C. Removal of corrosion on steel parts.
(1) Remove mild surface corrosion with a steel wire brush, 100-200 grit abrasive cloth.
(2) Remove moderate to heavy corrosion with fine file, or non-woven abrasive wheel.
(3) Blend repaired areas. See Table 601 for allowable material removal.
D. Superficial damage to primed surfaces may be touched up locally using primer procedures
listed in the refinishing section below.
2. Refinish
A. If primed surfaces of the hoist are worn, or bared, due to repair sanding, refinish using the
following materials:
Primer: MIL-P-7962, or equivalent
Top Coat: MIL-L-19537, or equivalent (2 coats recommended)
B. If primed surfaces of the electronic controller are worn, or bared, due to repair sanding,
refinish using the following materials:
Primer: TT-P-1757, Type I, Color Y
Top Coat: TT-E-527, Color No. 37038 (Black) per FED-STD-595
3. Minor Surface Repair (Damage with no exposed metal)
A. Remove contamination from damaged area using clean cloths moistened with isopropyl
alcohol, or equivalent.
B. Wipe surface area until free of oil, grease, or other contamination.
C. Lightly sand damaged area with 320 grit, or finer, abrasive paper.
CAUTION: AVOID OVER SANDING SURFACE AREA. REMOVE SANDING RESIDUE WITH
CLEAN CLOTH MOISTENED WITH ISOPROPYL ALCOHOL.
D. Mask, or protectively cover, all areas not being treated, or primed.
NOTE: IRIDITE #5025, OR NCP ALSO ACCEPTABLE, FOLLOW MANUFACTURERS
INSTRUCTIONS WHEN USING.
E. Aluminum will not require a surface treatment if primer is applied immediately. If a delay of
more than two hours occurs, use Iridite #14-2 solution (4 ounces per gallon [32 ml. per liter]).
Apply by brush, or swab, at room temperature. A contact time of 15 to 30 seconds will
usually produce a golden yellow color. Rinse thoroughly and dry.
F. Primer application should be accomplished under the following conditions:
Temperature: 50° F (10° C) minimum and Relative Humidity: 85% maximum.
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NOMENCLATURE DAMAGE REPAIR LIMITS

Figure 1001
Cargo Hook Support (20) Surface Corrosion, Clean with Scotch Brite, and protect surface with conductive
Nicks, Blemishes corrosion preventive compound, or paint, as required
Moderate to Heavy Damage greater than 0.002 in. (0.05 mm.), replace
Load Indicator (30) Surface Corrosion, Clean with Scotch Brite, and protect surface with conductive
Nicks, Blemishes corrosion preventive compound, or paint, as required
Figure 1002
Hardware (Nuts, Bolts, None Allowed Replace
Screws, Washers, etc.)
Electrical Connectors (outer Surface Corrosion, Clean with Scotch Brite, and protect surface with conductive
surfaces) Nicks, Blemishes corrosion preventive compound, as required
Electrical Connectors None Allowed Replace
(internal components, i.e.
pins)
Pressure Cartridge Assembly Surface Corrosion, Clean with Scotch Brite, and protect surface with conductive
(70) Nicks, Blemishes corrosion preventive compound, as required
Springs (200, 250 and 460) None Allowed Replace
Load Arm (140), Keeper Surface Corrosion, Clean with Scotch Brite, and protect surface with corrosion
Assembly (240), and Cover Nicks, Blemishes preventive compound, or paint, as required
(350)
Corrosion
Bushings (170, 180, and 190) None Allowed Replace
Load Cell (320, Support Surface Corrosion, Clean with Scotch Brite, and protect surface with conductive
Assembly only) Nicks, Blemishes corrosion preventive compound, as required
Lock Plate Assembly (400), None Allowed Replace
and Switches (410, and 420)
Table 601. Allowable Material Removal
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G. Using a cotton swab, or brush, apply Primer to the affected area and allow to dry. The
minimum drying time prior to service use is 48 hours when cured under 75° F (24° C), and 24
hours when cured above 75° F (24° C).
H. Apply topcoat as specified in paragraph 5 below.
4. Major Surface Repair (Damage with exposed metal)
A. To strip primer, and coating, from damaged area using approved strippers per MIL-R-25134,
or equivalent. The viscosity of this primer is high enough so that it can be applied by brush, or
swab, to the specific area to be stripped without running. It is to be used in the as received
condition at temperatures above 50° F (10° C).
B. Follow procedures 3A through 3H listed in Minor Surface Repair above.
5. Application of Top Coat
A. Top coat application should be accomplished under the following atmospheric conditions:
Temperature: 50° F (10° C) minimum
Relative Humidity: 85% maximum
B. Using a quality natural-bristled paintbrush, apply coating in one direction as much as
practical. Brush the surface to form an even continuous coat. Avoid repeated brushing out of
wet coating that causes pick-up, air bubbles, and voids, which require later touch-up. The
minimum drying time prior to use is 48 hours when cured at a temperature under 75° F (24°
C), and 24 hours when cured above 75° F (24° C).
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ASSEMBLY
1. General
Assemble the Cargo Hook System in accordance with the following instructions. Reference
numbers in parenthesis refer to IPL in Section 1001. All mention of applying and disconnecting
power to the system components should be accomplished using helicopter circuit breakers, or
equivalent acceptable means. Materials Required for Assembly (suitable equivalents acceptable)
are identified in Table 701 below:
Material Name and Application
MS20995NC32 Tie Wire to secure hardware after installation
TT-I-735 Isopropyl Alcohol to activate adhesive on expiration plate,
electrical schematic decal, and nameplates prior to installation
TT-L-58E, Type I, Class I Gloss Lacquer to protect expiration plate, electrical schematic
decal, and nameplates after installation
Table 701. Materials Required for Assembly (suitable equivalents acceptable)
2. All procedures identified with the note VITAL INSPECTION POINT, and parts with their
item numbers identified with the note VP requires a qualified technician, other than the
maintenance technician who performed the operation, to inspect the work completed, due to the
criticality of the operation. This inspection must be documented in either the helicopter, or Cargo
Hook System, maintenance log.
3. Installation of Cargo Hook System
Assemble the Cargo Hook System in accordance with the following instructions and Figures
1001, 1002, and 1003.
CONDITION CAN CAUSE LOSS OF LOAD, AND/OR HELICOPTER AND CAN
SYSTEM BEING RESTORED TO AN OPERATIONAL CONDITION.
AND KEEPER CONTACT.
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4. Assembly of Cargo Hook Assembly

Assemble Cargo Hook Assembly as follows:
A. Installation of Release Handle Spring and Spring Bracket
(1) Install spring (480, Figure 1002, Figure 1) onto release handle (490), and secure with nut
(470). Torque nut from 95 to 105 in.-lb. (10.73 - 11.86 N-meter).
(2) Install spring bracket (460) onto Cargo Hook Assembly, and secure with nuts (450).
Torque nuts from 140 to 150 in.-lb. (15.82 – 16.95 N-meter).
B. Installation of Keeper Assembly
Install keeper assembly as follows (see Figure 1002):
(1) VITAL INSPECTION POINT. To install springs (250, Figure 1002, Sheets 1, and 2
VP ), and keeper assembly (240), compress legs of springs, and position mounting holes
in keeper with mating holes in Cargo Hook Assembly.
(2) Secure spring, and keeper with bolt (230), and nut (220). Install nut finger tight so that
cotter pin can be installed. Do not install cotter pin at this time.
(3) VITAL INSPECTION POINT. Check that keeper operates freely, and install cotter
pin (210 VP ), and bend tabs.
(4) Proceed to Paragraph 6 of this Section for Installation of Cargo Hook Assembly.
C. Installation of Load Arm
Install load arm as follows:
(1) VITAL INSPECTION POINT. Position spring (200, Figure 1002, Sheets 1, and 2)
in load arm (140), and press in bushings (180, and 190), into load arm bore (see Figure
701).
(2) Install Teflon plugs (160) into load arm (140).
CAUTION: WHEN INSTALLING THE LOAD ARM, ENSURE THE TEFLON WASHERS
ARE POSITIONED ON EACH SIDE OF LOAD ARM BORE, AND ARE
RETAINED SO THEY DO NOT FALL INSIDE THE CARGO HOOK ASSEMBLY.
(3) Install bushing (170) into bore of pressed in bushings, position one Teflon washer (150)
on each side of the load arm center bore, and position load arm into Cargo Hook
Assembly (see Figures 701, and 702). While positioning the load arm, grip washers and
load arm to ensure there is no slippage, or misalignment, during installation, and ensure
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load arm spring is routed underneath the bumper seal in the Cargo Hook Assembly (see
Figures 703, and 704).
(4) VITAL INSPECTION POINT. Install bolt (130, Figure 1002, Sheets 1, and 2),
washers (120), and nut (110) to secure load arm (see Figure 705). Torque nut VP from
390 to 420 in.-lb. (44.06 – 47.45 N-meter), install cotter pin (100 VP), and bend tabs.
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Teflon plugs (part of load arm)
Spring (part of load arm)
Teflon Washer
Teflon Washer
Bushing (Loose) Bushing (part of load arm)

Load Arm
Figure 701. Load Arm, and Subassembly Installation
Load Arm
Spring
Figure 702. Teflon Washer Installation Figure 703. Load Arm Spring Installation
Figure 704. Load Arm Installation Figure 705. Load Arm Bolt Installation
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D. Installation of Load Cell
Install load cell (part of aft support assembly) as follows:
(1) Position mounting holes in load cell (320, Figure 1002, Sheets 1, and 2) with mating holes
in Cargo Hook Assembly.
(2) VITAL INSPECTION POINT. Install bolts (280, and 310, Figure 1002, Sheet 2),
and nuts (270, and 300, Figure 1002, Sheet 1) to secure load cell (320, Figure 1002,
Sheets 1, and 2). Torque nuts (270, VP) from 390 to 420 in.-lb. (44.06 – 47.45 N-meter),
and nut (300, VP) from 390 to 420 in.-lb. (44.06 – 47.45 N-meter). Secure with cotter
pins (260 and 290, Figure 1002, Sheet 1, VP) (see Figures 706, and 707).
Figure 706. Top View of Load Cell Figure 707. Side View of Load Cell
(Shown without cotter pins) (Shown without cotter pins)
(4) A Load Weigh System Test and Standard Calibration (Full) is necessary in accordance
with Section 101, Testing and Troubleshooting, Paragraph 4F after installation in the
frame, or equivalent testing means.
E. Installation of Pressure Cartridge Assembly
WARNING: THE PRESSURE CARTRIDGE IS AN EXPLOSIVE DEVICE AND MUST BE
SHIPPED, STORED, AND HANDLED IN COMPLIANCE WITH ALL LOCAL
STANDARDS, AND REGULATORY PRACTICES. TAKE PROPER ESD
PRECAUTIONS TO AVOID SETTING OFF THE CARTRIDGE DURING
HANDLING DUE TO SHOCK FROM ELECTROSTATIC DISCHARGE.
WARNING: BEFORE REMOVING THE PRESSURE CARTRIDGE, ENSURE THAT ALL
ELECTRICAL CIRCUITS TO THE CARGO HOOK ASSEMBLY ARE OPEN.
WARNING: DO NOT PERFORM RESISTANCE CHECKS ON THE PRESSURE CARTRIDGE
EITHER PRIOR TO, OR AFTER, REMOVAL FROM CARGO HOOK
ASSEMBLY.
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NOTE: SERVICE LIFE IS 5 YEARS, STARTING WHEN INSTALLED ON THE
HELICOPTER. CARTRIDGE LIFE (COMBINED SHELF AND SERVICE LIFE) IS
13 YEARS, STARTING FROM THE DATE OF MANUFACTURE, WHICH CAN
BE FOUND IN THE LOT NUMBER ON THE IDENTIFICATION PLATE. THE
LOT NUMBER STARTS WITH THE FIRST THREE LETTERS “ESD,”
FOLLOWED BY TWO DIGITS, IDENTIFYING THE YEAR OF MANUFACTURE
(EXAMPLE: 11 IS 2011), AND ONE LETTER, IDENTIFYING THE MONTH OF
MANUFACTURE, AS FOLLOWS:
Install pressure cartridge assembly as follows:
(1) VITAL INSPECTION POINT. Install new packing (90, Figure 1002, Sheets 1, and
2) onto new pressure cartridge (80), and thread new pressure cartridge into pressure
cartridge assembly (70). Torque cartridge VP from 60 to 85 in.-lb. (6.78 - 9.60 N-meter)
(see Figure 708).
Pressure Cartridge O-ring
Pressure Cartridge Assembly
Figure 708. Pressure Cartridge Installation and Assembly

NOTE: SPRING SHUNT AND PROTECTIVE PLASTIC CAP, SHOULD BE SAVED FOR
USE DURING REMOVAL OF PRESSURE CARTRIDGE.
(2) Remove cap and shunt from connector of pressure cartridge (80), and retain for future use.
(3) Install connector to pressure cartridge (80).
(4) Position pressure cartridge assembly (70) on Cargo Hook Assembly, and install quick
release pin (30).
(5) Connect quick release pin to lanyard assembly (60, Figure 1002, Sheet 1), and secure
lanyard assembly to Cargo Hook Assembly with nut (50), and cotter pin (40).
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F. Installation of Cover on Electrical Housing
Install cover of electrical housing as follows:
(1) If necessary, install diode assembly (445) into electrical housing assembly (370) and
secure with screws from terminal board (See Figure 709).
(2) After adjustment of switches (410, and 420, Figure 1002, Sheet 2, View A), secure lock
plate assembly (400) by tightening screws (390) to a torque of 30 to 40 in.-lb. (3.39 – 4.52
N-meter). Position holes in gasket (360, Figure 1002, Sheets 1, and 2) and cover (350)
with mating holes in electrical housing assembly (370).
(3) Secure gasket and cover with screws (330, and 340). Torque screws from 20 to 25 in.-lb.
(2.26 - 2.82 N-meter).
(4) If necessary, install harness assembly (380) onto connector on side of electrical housing
assembly (370).
G. Installation of Expiration Plate, Electrical Schematic Decal, and Nameplate
Install expiration plate (500, Figure 1002, Sheet 1), electrical schematic decal (510, Figure
1002, Sheet 2), and nameplate (520, Figure 1002, Sheet 1) as follows:
NOTE: ALL SURFACES SHALL BE CLEANED PRIOR TO INSTALLATION OF
EXPIRATION PLATE / ELECTRICAL SCHEMATIC DECAL / NAMEPLATES.
SEE SECTION 401 FOR CLEANING INSTRUCTIONS.
(1) On new plates, all typed information shall be added on expiration plate (500, [PN, Mfg.
Date, Unseal Date, Assy. Date]) and nameplate (520), if not already included, from
previously recorded data obtained during disassembly. If information on nameplate was
illegible when removed, contact Breeze-Eastern with all known information concerning
cargo hook assembly (part number, serial number, etc., if known) for original or new data.
(2) Remove backing of expiration plate (500, Figure 1002, Sheet 1) / electrical schematic
decal (510, Figure 1002, Sheet 2) / nameplate (520, Figure 1002, Sheet 1) to expose
adhesive.
(3) Apply TT-I-735 Isopropyl Alcohol on back of expiration plate / electrical schematic decal
/ nameplate to activate adhesive, install, and allow drying for 1 hour.
(4) Coat expiration plate / electrical schematic decal / nameplate with TT-L-58E, Type I,
Class I Gloss Lacquer.
5. Assembly and Installation of Cargo Hook Support
Assemble, and install Cargo Hook Support on Helicopter as follows (see Figure 1003):
A. VITAL INSPECTION POINT. Position mounting holes in right, and left channels (140,
and 150) with mating holes in aft flange (130), install washers (40), and screws (30) to secure
channels to flange. Torque screws VP from 300 to 330 in.-lb. (33.90 – 37.29 N-meter), and
tie wire screws per MS33540 with MS20995NC32.
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Figure 709. Electrical Housing Assembly

B. Install U-bolt (250) with sleeving (260) into right channel (140). Secure with washers (240)
and nuts (230). Torque nuts from 12-15 in.-lb. (1.36 – 1.69 N-meter) and then 30-40 in.-lb.
(3.39 – 4.52 N-meter) after the cargo hook is installed / stored.
C. Install grommet (220) into bumper (210), position mounting holes in bumper with mating
holes in aft flange (130) and left channel (150), and install washers (170), jumper (180),
screws (160, and 190), and nut (200) to secure bumper. Torque screw (160) from 20 to 25 in.-
lb. (2.26 – 2.82 N-meter), and torque screw (190) from 30 to 40 in.-lb. (3.39 – 4.52 N-meter).
NOTE: DO NOT TIE WIRE SCREWS ON AFT FLANGE SECURING STRUTS AT THIS
TIME. THESE SCREWS ARE TO BE TIE WIRED TO THE SPLIT BUSHING
SCREWS WHEN INSTALLED.
D. VITAL INSPECTION POINT. Position mounting holes in left, and right struts (110,
and 120) with mating holes in aft flange (130), and right and left channels (140, and 150).
Install washers (70), and screws (90, and 100) to secure struts (110 and 120). Torque screws
VP (90) from 150 to 180 in.-lb. (16.95 – 20.34 N-meter). Torque screws (100) from 210 to
240 in.-lb. (23.73 – 27.12 N-meter). Tie wire screws per MS33540 with MS20995NC32 on
left and right channels.
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NOTE: DO NOT INSTALL SPLIT BUSHINGS, AND FORWARD FLANGE AT THIS
TIME. THESE PARTS WILL BE INSTALLED WHEN CARGO HOOK
ASSEMBLY IS INSTALLED.
E. VITAL INSPECTION POINT. Position mounting holes in Cargo Hook Support with
mating holes on Helicopter, and install washers (20), and cap screws (10) to secure Cargo
Hook Support. Torque cap screw to 150 to 165 in.-lb. (16.95 - 18.64 N-meter)
F. Proceed to Paragraph 6 of this Section for Installation of Cargo Hook Assembly.
G. Installation of Nameplate
Install nameplate (270) as follows (see Figure 1003):
NOTE: ALL SURFACES SHALL BE CLEANED PRIOR TO INSTALLATION OF
NAMEPLATE. SEE SECTION 401 FOR CLEANING INSTRUCTIONS.
(1) All typed information should be added on nameplate (270) from previously recorded data
obtained during disassembly. If information on nameplate was illegible when removed,
contact Breeze-Eastern with all known information concerning cargo hook assembly (part
number, serial number, etc., if known) for original or new data.
(2) Remove backing of nameplate (270) to expose adhesive.
(3) Apply TT-I-735 Isopropyl Alcohol on back of nameplate to activate adhesive, install, and
allow drying for 1 hour.
(4) Coat nameplate with TT-L-58E, Type I, Class I Gloss Lacquer.
6. Installation of Cargo Hook Assembly
Install Cargo Hook Assembly into Cargo Hook Support as follows:
A. Install forward flange (50, Figure 1003) onto forward support assembly on Cargo Hook
Assembly.
B. Install forward flange (50, Figure 1003), and Cargo Hook Assembly into Cargo Hook Support
by sliding aft support assembly of Cargo Hook Assembly into center mating hole in aft flange
(130), and by sliding forward flange (50) into opening in right, and left channels (140, and
150).
NOTE: TIE WIRE SCREWS SECURING SPLIT BUSHINGS IN AFT FLANGE TO
SCREWS SECURING STRUTS.
C. VITAL INSPECTION POINT. Install split bushings (80) between aft support assembly
of Cargo Hook Assembly hole in aft flange of Cargo Hook Support. Secure split bushings
(80) with washers (70) and screws (60). Secure forward flange with washers (40) and screws
(30). Torque screws (30) for forward flange (50) from 95 to 110 in.-lb. (10.73 – 12.43 N-
meter), and torque screws (60) for split bushings from 60 to 85 in.-lb. (6.78 – 9.60 N-meter),
and tie wire screws per MS33540 with MS20995NC32.
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D. Secure jumper (180) to Cargo Hook Assembly with washer (20, Figure 1002, Sheet 2) and
screw (10).
E. Connect electrical connectors from Helicopter to cartridge, load cell, and solenoid of Cargo
Hook Assembly.
F. Connect power to Cargo Hook Assembly by pushing in applicable circuit breakers.
G. VITAL INSPECTION POINT. Test Cargo Hook Assembly per Paragraphs 4B through
4E in Testing and Troubleshooting, Section 101.
7. Installation of Load Indicator
Install Load Indicator onto Helicopter as follows:
A. Connect electrical connectors to back of Load Indicator (30, Figure 1001, and Figure 710).
Figure 710. Typical Electrical Connector Set-Up for Load Indicator

B. Position mounting holes in Load Indicator (30, Figure 1001) with mating holes in Helicopter.
C. VITAL INSPECTION POINT. Install hardware (not shown in IPL, and not supplied by
Breeze-Eastern) to secure Load Indicator to Helicopter.
D. Connect power to load indicator by pushing in applicable circuit breakers.
E. VITAL INSPECTION POINT. Test and calibrate Load Indicator per Paragraph 4F or
4G (when applicable) in Testing and Troubleshooting, Section 101.
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8. Storage
A. If the Cargo Hook System, or any part of the system, is removed from the Helicopter for more
than twenty-four (24) hours, it is recommended that the component(s) be prepared for storage
with packaging and preservation as follows:
(1). The component(s) shall be stored in a clean, dry, climate controlled environment where
the relative humidity does not exceed 85 percent, and the temperature does not exceed a
low temperature of 50° F (10° C), and a high temperature of 86° F (30° C).
(2). If the component(s) cannot be stored in a controlled climate as stated above, they shall be
packaged with sufficient desiccant in a suitable container that meets the best commercial
practices to withstand normal handling and storage practices, and to withstand a low
temperature of –67° F (–55° C) and a high temperature of 185° F (85° C).
B. If the Cargo Hook System remains in storage / inactive for more than a year it is
recommended that after installation the tests in Section 101, Testing and Troubleshooting be
conducted to ensure its operational integrity.
C. Store the Pressure Cartridge Assembly (Reference: U.N Number UN0276, U.N Classification
Code 1.4C) in approved magazines only. Storage and handling must conform to appropriate
quantity / distance requirements, barricading, grounding and personnel material limits. Keep
the cartridge shunted until installed with protective caps installed. Avoid high temperature,
store in a cool and dry place.
Effective shielding is recommended for personnel when handling these devices. Humidity
control (i.e. higher relative humidity > 60%) reduces or prevents static electricity build-up.
Explosion –proof equipment is required when operating with exposed explosive materials.
9. Shipping
From Breeze-Eastern Manufacturing Facility:
When Breeze-Eastern ships the Cargo Hook Assembly (Item 10, Figure 1001) from the
manufacturing facility it consists of (Items 11 and 12). The Cargo Hook Assembly is configured
this way because the Pressure Cartridge Assembly (Item 12), which contains an explosive and
must be shipped separately in accordance with local and government regulatory authority
requirements. Once the items are received by the operator, they can be reassembled.
To Breeze-Eastern from the Operators / Field
When shipping the cargo hook to Breeze-Eastern the Pressure Cartridge Assembly (Figure 1001,
Item 12) shall be removed and properly stored, or disposed of, by the operator in accordance with
your local regulatory authority laws and regulations. If the shipment to Breeze-Eastern contains
an explosive and the packaging does not meet US Department of Transportation / International
Air Transport Association regulations and standards, Breeze-Eastern is required to report the
situation. Additionally, you will be charged a minimum fee of $500 USD for the proper disposal
of the explosive.
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THIS PAGE
INTENTIONALLY
LEFT BLANK
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FITS AND CLEARANCES
1. Table 801 identifies the allowable limits for close tolerance parts for the Cargo Hook System.
These limits are to be applied when any doubt exists concerning the serviceability of a part as a
result of visual inspection for wear, or from an improper fit during assembly and installation of
the hoist. When this condition exists the affected part(s) shall be dimensionally inspected in
accordance with Checks and Inspections Section 501. Replace parts that do not meet the limits,
and for which rework is not applicable.
2. The values given in the “Dimension Limits” column in Table 801 are the applicable minimum, or
maximum, permitted to ensure proper functioning for the components of the system. If parts fail
to meet these requirements, one, or more, of the parts must be replaced, unless rework of the part
is applicable. The dimensional limits should be used as a guide for assembling and installing
reworked parts.
3. The values shown in Table 801 are applicable to the components of the Cargo Hook System. See
Figures 801 and 802 for items referenced. Other dimensions shown on Figures 801 and 802 are
for reference only.
Fig. No. Description of Location for Dimensional Check Dimension Limits in Inches
(and Item (Millimeters)
No., if Minimum Maximum
applicable)
Figure 801 Diameter of Frame Assembly Mounting Holes 0.384 (9.75) 0.391 (9.93)
Figure 801 Distance between Mounting Holes (Forward to Aft) 11.79 (299.5) 11.81 (300.0)
Figure 801 Distance between Mounting Holes (Side to Side) 20.46 (519.7) 20.48 (520.2)
Figure 802 Diameter of Forward and Aft Supports 1.974 (50.140) 1.976 (50.190)
Figure 802 Diameter of Flange Mounting Holes for Supports 1.995 (50.673) 2.000 (50.800)
Figure 802 Diameter of Flange on Aft Support 2.490 (63.246) 2.510 (63.754)
Figure 802 Length of Harness for Load Cell 55.3 (1404.62) 57.3(1455.42)
Figure 802 Length of Harness for Electrical Housing 59 (1499) 61 (1549)
Table 801. Dimensional Limits for Cargo Hook System
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Figure 801 (Sheet 1 of 2). Installation of Cargo Hook Assembly Support (dimensions in inches [millimeters])
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Figure 801 (Sheet 2 of 2). Installation of Cargo Hook Support (dimensions in inches [millimeters])
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Figure 802. Installation of Cargo Hook Assembly (dimensions in inches [millimeters])

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SPECIAL TOOLS, FIXTURES AND TEST EQUIPMENT
Note: Equivalent substitutes may be used for listed items.
Tool/ Equipment No. Nomenclature Use and Application Test
VW-F-1094-24 Pressure Cartridge Simulator To perform Emergency Load Release Test X
(See Figure 901)
TE-135-1 Test Box Assembly (See Option / Alternative to the Multimeter X
Figure 902) Pin to Pin Test
Table 901. Special Tools, Fixtures, and Test Equipment List
Item No. Description Qty. Part Number

1 Squib Housing 1 FE7590-94
2 Top Shield 1 VW-F-1094-24-1
3 Piston 1 FE7590-96
4 Screw 2 FF9635-0305-157
5 O-Ring 1 22558-9
6 Spring 1 Y-1182-44-1
7 Washer 1 FE7590-143
8 Adapter 1 202701-5-6S
9 Plug 1 FE7590-132
10 Decal 1 FE8222-1
Figure 901. Pressure Cartridge Simulator
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Figure 902. TE-135-1 Test Box Assembly
NOTE: For information on the acquisition of special tools, fixtures, and test equipment contact:
35 Melanie Lane

Fax: (973) 739-9344
Revision status of the Breeze-Eastern technical manuals is listed on the web site referenced above.
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ILLUSTRATED PARTS LIST

1. Introduction
A. Purpose
This section provides illustrations and parts breakdown of all parts of the assemblies shown that
can be disassembled, repaired, replaced, and reassembled.
B. Explanation and Usage of Section
(1) Assembly Order Indenture System
(a) This indenture system used in the parts list shows the relationship of one part to another.
For a given item, the number of indentures depicts the relationship of the item to the
associated next higher assembly as follows:
1 2 3 4
Assembly
• Detail Parts for Assembly
• • Subassembly
• • • Detail Parts for Subassembly
(2) Part Numbering System
The part numbering system consists of each part number identifier by which a part may be
ordered or procured.
(3) Effectivity Code
Reference letters (A through Z except I and O) are assigned to the EFF CODE column to
each top assembly in each IPL figure. The reference letter of the applicable top assembly is
also shown in EFF CODE column for detailed parts and subassemblies used on all top
assemblies. If only one assembly is shown in the IPL figure, then no reference letters will
be entered in the corresponding EFF CODE column.
(4) Parts Replacement Data
The interchangeability between parts is identified in the NOMENCLATURE column of the
parts list. A list of terms used to show interchangeability and their definition is as follows:
Term Abbreviation Definition
Alternate ALT Alternate designates a definitive sequence of parts. The part is
optional to, and interchangeable with, other parts in the same
number variant group, or other item number as designated.
Preferred PREF When an alternate part is listed, the preferred part will be
identified in the same item number variant group, or other item
number, as designated.
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(5) Units per Assembly

The UNITS PER ASSEMBLY column shows that total quantity required per assembly, per
subassembly, and per sub-subassembly as applicable. For bulk items, the letters AR
indicate “as required.” The letters RF indicate the item is listed for reference purposes.
(6) Items Not Illustrated
Items not illustrated are indicated by a dash (-) ahead of the item number in the FIG. &
ITEM NO. Column.
(7) Alpha Variant Item Numbers
(a) Alpha variants A through Z (except I and O) are assigned to existing item number when
necessary to show:
1) Added items.
2) Service bulletin modifications.
3) Configuration differences.
4) Optional or alternate parts.
5) Product improvement parts (non-service bulletin).
(b) Alpha variant item numbers are not shown on the exploded views when the appearance
and location of these items are the same as the basic items.
2. Notes:
CAUTION: THE CABLE CUTTER CARTRIDGE IS AN EXPLOSIVE DEVICE AND MUST
BE SHIPPED, STORED, AND HANDLED IN COMPLIANCE WITH ALL
LOCAL STANDARDS, AND REGULATORY PRACTICES.
NOTE: WHEN SHIPPING THE CARGO HOOK TO BREEZE-EASTERN THE
PRESSURE CARTRIDGE ASSEMBLY (FIGURE 1001, ITEM 12) SHALL BE
REMOVED AND PROPERLY STORED, OR DISPOSED OF, BY THE
OPERATOR IN ACCORDANCE WITH YOUR LOCAL REGULATORY
AUTHORITY LAWS AND REGULATIONS. IF THE SHIPMENT TO
BREEZE-EASTERN CONTAINS AN EXPLOSIVE AND THE PACKAGING
DOES NOT MEET US DEPARTMENT OF TRANSPORTATION /
INTERNATIONAL AIR TRANSPORT ASSOCIATION REGULATIONS AND
STANDARDS, BREEZE-EASTERN IS REQUIRED TO REPORT THE
SITUATION. ADDITIONALLY, YOU WILL BE CHARGED A MINIMUM FEE
OF $500 USD FOR THE PROPER DISPOSAL OF THE EXPLOSIVE.
A. Pressure Cartridge Assembly (70, Figure 1002) can be purchased, and is shipped, as a spare
part. The pressure cartridge (80) and packing (90) is shipped as part of item (70, Figure 1002).
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10
11
12
20
30
Figure 1001. Cargo Hook System
NUMERICAL PARTS LIST INDEX

FIG. AND PART NOMENCLATURE USABLE UNITS PER
ITEM NO. NUMBER 1234 ON CODE ASSY.
1001-
1 CHS-9000-3 CARGO HOOK SYSTEM REF
10 FE7590-173-1 • Cargo Hook Assembly 1
(See IPL Figure 1002 for Detailed Breakdown)
11 FE7590-173-2 •• Cargo Hook Assembly, without Pressure Cartridge REF
Assembly (For Shipping Purposes Only)
12 CH-9016-1 •• Pressure Cartridge Assembly (Refer to Notes Page REF
1002) (Refer to Figure 1002, Item 70)
20 CH-9020-1 • Support, Cargo Hook 1
(See IPL Figure 1003 for Detailed Breakdown)
30 Y-1240-9-1 • Indicator, Load 1
ATTACHING HARDWARE
- MS16998-77 • Screw, Cap (Refer to Fig. 1003, Item 10) REF
- Y-1407-3-2 • Washer, Flat (Refer to Figure 1003, Item 20) REF
- (Not Illustrated)
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Figure 1002. Cargo Hook Assembly – Left Side / Forward View (Sheet 1 of 2)
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Figure 1002. Cargo Hook Assembly – Right Side / Aft View (Sheet 2 of 2)
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FIG. AND PART NUMBER NOMENCLATURE USABLE UNITS

ITEM NO. 1234 ON PER
CODE ASSY.
1002-
-1 FE7590-173-2 CARGO HOOK ASSEMBLY RF
10 MS16998-26 • Screw, Cap 1
20 AN960C10L • Washer, Flat 1
30 FF9631-422 • Pin, Quick Release 1
40 MS24665-155 • Pin, Cotter 1
50 AN310-4 • Nut, Castellated 1
60 AC6000425 • Lanyard Assembly 1
70 CH-9016-1 • Pressure Cartridge Assembly (See Page 1002) 1
80 FE7590-95 • • Cartridge, Pressure (See Page 1002) 1
90 MS28775-011 • • O-Ring (See Page 1002) 1
100 MS9245-66 • Pin, Cotter 1
110 MS21083N10 • Nut, Self-Locking 1
120 AN960KD1016L • Washer, Flat 2
130 AN180-25 • Bolt, Hex Head 1
140 FE7590-27 • Load Arm 2
150 FF9652-03 • Washer, Teflon 2
160 FE7590-45 • Plug, Teflon 2
170 FE7590-10-1 • Bushing 1
180 FE7590-74-2 • Bushing 1
190 FE7590-74-1 • Bushing 1
200 FE7590-75 • Spring, Load Arm 1
210 MS24665-155 • Pin, Cotter 1
220 AN310-5 • Nut, Castellated 1
240 FE7590-114 • Keeper Assembly 1
250 FE7590-39 • Spring, Keeper 2
260 MS9245-46 • Pin, Cotter 3
290 MS9245-47 • Pin, Cotter 1
320 500388-0002 • Load Weigh Assembly 1
330 MS35190-287L • Screw, Flat Head 2
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NUMERICAL PARTS LIST INDEX (continued)
ITEM NO. 1234 ON PER
CODE ASSY.
1002-
340 MS24694-S124 • Screw, Flat Head 2
350 FE7590-15 • Cover 1
360 FE7590-23 • Gasket 1
370 FE7590-82-1 • Electrical Housing Assembly 1
380 EC-10498-1 • • Harness Assembly 1
390 MS35276-261 • • Screw 3
400 FE7590-33 • • Lock Plate Assembly 1
410 FF9637-01 • • Switch, Hook Open Indicator Light (S1) 1
420 FF9637-01 • • Switch, Anti-Cycling Relay (S2) 1
430 FF9231-01-1004S • • Screw, Hex, Soc Button Head 2
440 FE7590-6 • • Solenoid 1
445 BL-8163-5 • • Diode Assembly 1
460 FE7590-91 • Bracket, Release Handle Spring 1
470 FE7590-93 • Bolt 1
480 FE7590-92 • Spring 1
490 FE7590-21 • Handle, Release 1
500 FE7590-162 • Plate, Expiration 1
510 FE7590-14 • Decal, Electrical Schematic 1
520 FE7590-176-2 • Nameplate, Cargo Hook 1
- (Not Illustrated)
25-51-50
Page 1007
March 4, 2011
TD-01-007
Revision B
Figure 1003. Cargo Hook Support

NUMERICAL PARTS LIST INDEX
ITEM NO. 1234 ON CODE PER ASSY.
1003-
-1 CH-9020-1 SUPPORT, CARGO HOOK RF
10 MS16998-77 • Screw 4
20 Y-1407-3-2 • Washer 4
30 MS24678-46 • Screw, Cap, Drilled 16
40 CH-9031-1 • Washer, Flat 16
50 CH-9023-1 • Flange, Forward 1
70 Y-1407-3-1 • Washer, Flat 8
80 CH-9027-1 • Bushing, Split 2
110 CH-9026-1 • Strut, Left 1
120 CH-9025-1 • Strut, Right 1
25-51-50
Page 1008
March 4, 2011
TD-01-007
Revision B
NUMERICAL PARTS LIST INDEX (continued)

ITEM NO. 1234 ON CODE PER ASSY.
1003-
130 CH-9024-1 • Flange, Aft 1
140 CH-9021-1 • Channel, Right 1
150 CH-9022-1 • Channel, Left 1
160 MS16995-36 • Screw, Cap 1
170 AN960C10L • Washer, Flat 3
180 MS25083-2BB10 • Jumper, Electrical, Bonding 1
190 MS16996-10 • Screw, Cap 1
200 MS21083C3 • Nut, Self-Locking 1
210 CH-9029-1 • Bumper 1
220 MS35489-6 • Grommet, Synthetic, Rubber 1
230 MS17830-4C • Nut, Self-Locking 2
240 AN960C416 • Washer, Flat 2
250 Y-1409-1-1 • U-Bolt 1
260 CH-9020-10 • Sleeving, Shrink 1
270 BL-12890-1 • Nameplate 1
- (Not Illustrated)
25-51-50
Page 1009
March 4, 2011
TD-01-007
Revision B
THIS PAGE
INTENTIONALLY
LEFT BLANK
25-51-50
Page 1010
March 4, 2011
TECHNICAL PUBLICATION DEFICIENCY REPORT
Page 1 of 1
B-E Tracking Number:
Customer: Date:
Type: O&M Type: CMM Manual Type:
Manual: Type:
Manual: Revision: O&M
Number: Number: CMM
Number: Number:
Section: Page: Section:
Figure: Table: Figure:
Discrepancy (Provide as much detail as possible):
Initiator: Title:
Submit to: B-E Customer Services.
via email Customerservices@breeze-eastern.com or FAX (973)-739-9344
Breeze Eastern Use Only

Engineering Services Disposition:
Engineering Services: Date:

Customer Services: Date:
35 Melanie Lane
Whippany, New Jersey 07981-1638 USA
Phone: Local calls use 973-602-1001, Ext. 1083 or 1090.
In the USA (except New Jersey) and Canada call toll free 1-800-929-1919.
Fax : 973-739-9344
E-mail Address: customerservices@breeze-eastern.com
Web Site: www.breeze-eastern.com
QC1334 Rev.A 04/28/10

CAGE CODE 08484
SIL08 Maintenance
Original Release, 08/11/11
Page 1 of 2
SERVICE INFORMATION LETTER
Information about Greases, Oils, Coatings, and Sealants
SUBJECT: Information on current grease, oils, coatings, and sealants for

B-E products.
I. PLANNING INFORMATION.
A. Reason.
To provide the operators of Breeze-Eastern products with updated information on

consumables due to component obsolescence, compatibility, compliance, and / or product
improvement.
B. Summary.
The following table lists alternate consumables for B-E products.
Consumable Replaced by / Alternate Remarks

Amovis 8-X Tribolube-9 grease Note 1
MIL-G-46886 A-A-59173 grease Note 2
DC-33 grease A-A-59173 grease Note 2
MIL-PRF-7808 oil MIL-PRF-23699 oil Note 3
Iridite #14-2 Iridite NCP, Iridite #525 Note 5
Pliobond 30 Pliobond 35 Note 6
Table 1. Alternate Consumables.
C. Notes.
1. Tribolube-9 grease, made by Aerospace Lubricants Inc., replaces the discontinued

Amoco Amovis No. 8-X grease.
NOTE: DO NOT MIX TRIBOLUBE-9 AND AMOVIS 8-X GREASE. CLEAN

COMPONENTS BEFORE APPLYING TRIBOLUBE-9.
PROPRIETARY RIGHTS NOTICE: This Service Information Letter contains information that is proprietary to Breeze-Eastern Corporation, is an
unpublished work protected under applicable copyright laws and constitutes trade secrets for the purpose of the Trade Secret and Freedom of Information
Acts. It is delivered on the express conditions that it is not to be used, disclosed or reproduced, in any manner, in whole or in part without prior written
authorization of Breeze-Eastern Corporation, 35 Melanie Lane, Whippany, NJ 07981-1638, USA. Nothing contained herein shall limit any rights granted by
Breeze-Eastern Corporation under contract. This legend shall be included on any reproduction hereof All rights are reserved. Any act in violation of
applicable law may result in civil and / or criminal penalties
EXPORT CONTROLLED – WARNING This Service Information Letter may contain information that is subject to the International Traffic in Arms
Regulations (ITAR) or the Export Administration Regulations (EAR), and may not be exported, released, or disclosed to foreign nationals, either in the
United States or overseas, without first complying with the export requirements/regulations of the ITAR and/or EAR. The recipient is responsible for
complying with all such export requirements/regulations. Include this notice with any reproduced portions of this document.
CAGE CODE 08484
SIL08 Maintenance
Page 2 of 2
2. A-A-59173 silicone grease replaces MIL-G-46886. Any A-A-59173 spec compliant

grease is interchangeable with DC-33 grease.
3. MIL-PRF-23699 oil is an acceptable alternate for MIL-PRF-7808 Grade 3 oil

EXCEPT for the side gearbox of two-speed BL-20200 series hoists.
NOTE: DRAIN HOIST COMPLETELY BEFORE REFILLING WITH NEW OIL.
Recommended Oil Minimum Operating Temperature.

MIL-PRF-7808 Below -40° F (-40° C)
MIL-PRF-23699 Over -40° F (-40° C)
Table 2. Recommended Oil for Minimum Operating Temperatures
4. MIL-PRF-7808 oil is an acceptable alternate for MIL-PRF-7870 oil.
5. Iridite NCP, Iridite #525, or any MIL-DTL-5541 Class 1A compliant coating is

interchangeable with Iridite #14-2.
6. Pliobond 35 sealant replaces Pliobond 30. Pliobond 35 is a Volatile Organic

Compound (VOC) regulation compliant adhesive.
D. Effectivity.
Wherever mentioned in B-E documentation, Table 1. Alternate Consumables applies.
Service Information Letter - Maintenance ATA 100 Format

Use or disclosure of data contained on this sheet is subject to the restriction on the title page of this Service Information Letter.
CAGE CODE 08484
SIL08 Maintenance
Page 1 of 2
SUBJECT: Information on current grease, oils, coatings, and sealants for

B-E products.
I. PLANNING INFORMATION.
A. Reason.
To provide the operators of Breeze-Eastern products with updated information on

consumables due to component obsolescence, compatibility, compliance, and / or product
improvement.
B. Summary.
The following table lists alternate consumables for B-E products.
Consumable Replaced by / Alternate Remarks

Amovis 8-X Tribolube-9 grease Note 1
MIL-G-46886 A-A-59173 grease Note 2
DC-33 grease A-A-59173 grease Note 2
Iridite #14-2 Iridite NCP, Iridite #525 Note 5
Pliobond 30 Pliobond 35 Note 6
Table 1. Alternate Consumables.
C. Notes.
1. Tribolube-9 grease, made by Aerospace Lubricants Inc., replaces the discontinued

Amoco Amovis No. 8-X grease.
NOTE: DO NOT MIX TRIBOLUBE-9 AND AMOVIS 8-X GREASE. CLEAN

COMPONENTS BEFORE APPLYING TRIBOLUBE-9.
PROPRIETARY RIGHTS NOTICE: This Service Information Letter contains information that is proprietary to Breeze-Eastern Corporation, is an
unpublished work protected under applicable copyright laws and constitutes trade secrets for the purpose of the Trade Secret and Freedom of Information
Acts. It is delivered on the express conditions that it is not to be used, disclosed or reproduced, in any manner, in whole or in part without prior written
authorization of Breeze-Eastern Corporation, 35 Melanie Lane, Whippany, NJ 07981-1638, USA. Nothing contained herein shall limit any rights granted by
Breeze-Eastern Corporation under contract. This legend shall be included on any reproduction hereof All rights are reserved. Any act in violation of
applicable law may result in civil and / or criminal penalties
EXPORT CONTROLLED – WARNING This Service Information Letter may contain information that is subject to the International Traffic in Arms
Regulations (ITAR) or the Export Administration Regulations (EAR), and may not be exported, released, or disclosed to foreign nationals, either in the
United States or overseas, without first complying with the export requirements/regulations of the ITAR and/or EAR. The recipient is responsible for
complying with all such export requirements/regulations. Include this notice with any reproduced portions of this document.
CAGE CODE 08484
SIL08 Maintenance
Page 2 of 2
2. A-A-59173 silicone grease replaces MIL-G-46886. Any A-A-59173 spec compliant

grease is interchangeable with DC-33 grease.
3. MIL-PRF-23699 oil is an acceptable alternate for MIL-PRF-7808 Grade 3 oil

EXCEPT for the side gearbox of two-speed BL-20200 series hoists.
Recommended Oil Minimum Operating Temperature.

MIL-PRF-7808 Below -40° F (-40° C)
MIL-PRF-23699 Over -40° F (-40° C)
Table 2. Recommended Oil for Minimum Operating Temperatures
4. MIL-PRF-7808 oil is an acceptable alternate for MIL-PRF-7870 oil.
5. Iridite NCP, Iridite #525, or any MIL-DTL-5541 Class 1A compliant coating is

interchangeable with Iridite #14-2.
6. Pliobond 35 sealant replaces Pliobond 30. Pliobond 35 is a Volatile Organic

Compound (VOC) regulation compliant adhesive.
D. Effectivity.
Wherever mentioned in B-E documentation, Table 1. Alternate Consumables applies.
Service Information Letter - Maintenance ATA 100 Format

Use or disclosure of data contained on this sheet is subject to the restriction on the title page of this Service Information Letter.

Flight Line Operation and Maintenance Manual Chs-9000-3 Cargo Hook System

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TD-01-007

TO: HOLDERS OF BREEZE-EASTERN FLIGHT LINE OPERATION AND MAINTENANCE

ALL - Changed Header and Release Date

REVISION REVISION DATE DATE REVISION REVISION DATE DATE

REV. ISSUE DATE REMOVAL INCORPORATOR’S REMOVER’S

FLIGHT LINE OPERATION AND MAINTENANCE MANUAL

FLIGHT LINE OPERATION AND MAINTENANCE MANUAL

FLIGHT LINE OPERATION AND MAINTENANCE MANUAL

Description Page Date

TABLE OF CONTENTS (CONTINUED)

1. Title Page 7. Introduction 13. Checks and Inspections

Cargo Hook Assembly (Manual Release Side)

Cargo Hook Assembly (Solenoid Side)

Cargo Hook Support (shown with hook installed)

Figure 2. Side View of Cargo Hook Assembly

New Cargo Hook Support

Figure 3. New Cargo Hook Support Shipped From Breeze-Eastern

Right Channel Aft Flange (has split bushing)

Figure 4. Cargo Hook Support Rectangular Aluminum Frame

(3) Load Indicator

Figure 5. Cargo Hook Load Indicator

3. Leading Particulars for Cargo Hook System

Table 1. Leading Particulars for Cargo Hook System

Apex Fitting An aluminum fitting whose uppermost point

Keeper The device on the cargo hook that is intended to

NOTE: IT IS IMPERATIVE THAT

Figure 6. Apex Fitting and Correct Rigging Position on Load Arm.

B. Applying Power to System

Figure 7. Front Display of Load Indicator

(S2) Hook Open Light Switch OFF Position

Check Continuity Check with Load Arm in Closed Position

Pins Condition Pins Condition Pins Condition

Check Continuity Check with Load Arm in Open Position

Figure 101. Cargo Hook Assembly Wiring Diagram

Pins Condition Pins Condition

Table 102. Continuity Check for Cartridge Wire Assembly

Figure 102. Limit Switch Locations

Figure 104. Relatch Test

Figure 105. Front Display of Load Indicator

Figure 107. Nameplate with RCAL Number Inserted.

No continuity between Improper switch bracket adjustment Readjust

Table 103. Troubleshooting Procedures

Table 103. Troubleshooting Procedures (continued)

SCHEMATICS AND WIRING DIAGRAMS

2. Contents of this Section

Figure Description Page

Figure 201 Cargo Hook Assembly Wiring Diagram 202

Figure 202 Cargo Hook System Interconnect Wiring Diagram 205

Figure 201. BL Cargo Hook Assembly Wiring Diagram

Figure 202. Cargo Hook System Interconnect Wiring Diagram (Sheet 2 of 2)

WARNING: THE HELICOPTER WILL BUILD UP STATIC ELECTRICITY. ENSURE THE

Figure 302. Mounting Screws for Aft Flange

Figure 305. Pressure Cartridge Installed in Pressure Cartridge Assembly

Bushing (part of load arm)

Figure 311. Electrical Housing Assembly

WARNING: KEROSENE AND ISOPROPYL ALCOHOL ARE COMBUSTIBLE. DO NOT USE

Recommended Frequency of Part Name Figure and Inspection Required

Sec. 501, Para. 2 F Wiring Inspection

Table 501. Inspection Requirements

Attention: Customer Service / Care

IF FIRED, REPLACE ENTIRE

Figure 501. Pressure Cartridge Assembly Location

B-E Part Number Ref: AgustaWestland PN