BHT-407-CR&O-V

CHAPTER 25

EQUIPMENT AND FURNISHINGS

COMPONENT BELL P/N VENDOR P/N VENDOR NAME

Fixed Beam Cargo 232-188-01 Onboard Systems International 1
Suspension System 232-189-01
Talon LC Keeperless Cargo 528-023-01 Onboard Systems International 1
Hook
NOTE:

1 Refer to www.onboardsystems.com for the latest information from Onboard Systems International.

25-00-00
9 MAR 2010 Rev. 2 Page 1/2
 Document Number Revision
Component 122-021-00 1
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Manual August 28, 2007 1 of 17
Title Name Date Approved
Document Approved By: Owner – Engineering Mark Hanson Aug. 28, 2007

Maintenance Manual,
Fixed Beam Cargo Suspension System

Onboard Systems International

13915 NW 3rd Court
Vancouver, WA 98685 United States of America
Cage Code: 1Y921

Toll Free Phone: (800) 275-0883

Phone: (360) 546-3072
Fax: (360) 546-3073

Applicable Equipment Part Numbers

Onboard Systems: 200-296-00

232-188-01
232-189-01

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TABLE OF CONTENTS

SECTION & TOPIC PAGE

1.0 Introduction .................................................................................................................................... 3
2.0 Referenced Documents .................................................................................................................. 4
2.0 Inspection........................................................................................................................................ 4
4.0 Maintenance..................................................................................................................................... 5
5.0 Overhaul........................................................................................................................................... 5
6.0 Disassembly & Re-assembly Instructions...................................................................................... 10

APPENDIX PAGE
Revision History .......................................................................................................................................... 16

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1.0 Introduction
1.1 Scope. This component maintenance manual contains instructions for inspection,
maintenance and overhaul of the Fixed Beam Cargo Suspension System 200-296-00.

1.2 Capability. The instructions contained in this document are provided for the benefit of
experienced aircraft maintenance personnel and facilities that are capable of carrying
out the procedures.

1.3 Warnings, Cautions and Notes. The following definitions apply to Warnings, Cautions
and Notes used in this manual.

Means that if this information is not observed,

serious injury, death or immediate loss of flight
safety could occur.

Means that there is a risk of injury or degradation

in performance of equipment if this information is
not observed.

Draws the reader’s attention to information

which may not be directly related to safety,
but which is important or unusual.

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2.0 Referenced Documents

122-005-00 3.5KK Cargo Hook Service Manual

3.0 Inspection
3.1 Scheduled Check & Inspection. The scheduled inspection intervals noted below are
maximums and are not to be exceeded. If the Fixed Beam Cargo Suspension System is
subjected to unusual circumstances, extreme environmental conditions, etc., it is the
responsibility of the operator to perform the inspections more frequently to ensure
proper operation.
Daily Check
1. Visually check for damage and/or corrosion on the exterior of the Cargo Hook
(item 1) and suspension system components.
2. Move the Cargo Hook (item 1) and the Main Beam (item 3) throughout their
ranges of motion and observe the Manual Release Cable (item 15) and
Electrical Release Harness (item 16) to ensure that they have enough slack.
The Manual Release Cable (item 15) and Electrical Release Harness (item 16)
must not be the stops that prevent the Cargo Hook (item 1) or Main Beam (item
3) from moving freely in all directions.
3. Rotate the Main Beam (item 3) and Cargo Hook (item 1) about their pivot points
to verify that they rotate freely.
4. Visually check the Manual Release Cable (item 15) and its connections for
damage and security.
5. Visually check the Electrical Release Harness (item 16) and its connections for
damage and security.
Annual Inspection
1. Visually inspect for damage and/or corrosion on the exterior of Cargo Hook
(item 1) and suspension system components (refer to Table 5.1 for acceptable
limits).
2. Move the Cargo Hook (item 1) and the Main Beam (item 3) throughout their
ranges of motion and observe the Manual Release Cable (item 15) and
Electrical Release Harness (item 16) to ensure that they have enough slack.
The Manual Release Cable (item 15) and Electrical Release Harness (item 16)
must not be the stops that prevent the Cargo Hook (item 1) or Main Beam (item
3) from moving freely in all directions.
3. Rotate the Main Beam (item 3) and Cargo Hook (item 1) about their pivot points
to verify that they rotate freely.
4. Visually inspect the Manual Release Cable (item 15) and its connections for
damage and security.
5. Visually inspect the Electrical Release Harness (item 16) and its connections for
damage and security.

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4.0 Maintenance
4.1 Lubrication of the Fixed Beam Cargo Suspension system is recommended every 200
hours of operation. To obtain maximum life under severe duty conditions such as
logging or seismic work, it is recommended to lubricate every 100 hours.

4.2 To lubricate, remove the Trunnion Pins (item 4) and Cargo Hook Attach Bolt (item 14)
and lubricate wear surfaces. Recommended lubricants are Mobilgrease 28 or AeroShell
17.

5.0 Overhaul
5.1 Overhaul Frequency. Overhaul the suspension system at the time of the cargo hook
overhaul. Refer to the 3.5KK Cargo Hook Service Manual for appropriate time-between-
overhaul.

Failure to follow all equipment maintenance

instructions and component inspection criteria may
result in serious injury, death or immediate loss of
flight safety.

5.2 Suspension System Overhaul Instructions

Remove the suspension system from the helicopter per the following:

1. Disconnect the Electrical Release Harness (item 16) connector from its connection
at the belly of the helicopter.
2. Remove the Manual Release Cable (item 15) from its junction fitting at the belly of
the helicopter.
3. Remove the bolts that secure the Pillow Blocks (items 2 and 9) to the hard points
and remove suspension system from the helicopter.

Disassemble the suspension system per the following instructions.

1. Loosen jam nut and remove the Manual Release Cable (item 15) from the Cargo
Hook (item 1).
2. Disconnect the Electrical Release Harness (item 16) from the Cargo Hook (item 1).
3. See the instructions in the Illustrated Parts List section for disassembly procedures
of the detail parts.

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Inspect and repair the detail parts in accordance with the instructions in Table 5.1.
Repair or replace parts as outlined. Perform magnetic particle inspection in accordance
with ASTM-E1444 and MIL-STD-1907, Grade A on the parts listed below. No cracks are
permitted in any of these parts.

• Main Beam (Item 3)

• Pillow Blocks (items 2.1 and 9.1)
• Trunnion Pin (item 4)

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Table 5.1, Suspension System Inspection Criteria

Component Damage Permitted without Repair Repair Maximum Damage which Causes
Replacement
Main Beam, Dents, gouges, and scratches less than Blend at 20:1 ratio, length to depth, to Dents, gouges and scratches greater than
P/N 290-852-01 .030” deep outside lug areas of Zones A provide smooth transitions. .060” deep outside lug areas of Zones A and B
Item 3 and B (see Figure 5.1).
Dents, gouges, and scratches greater than
Protect affected surfaces with MIL-PRF- .030” deep around lugs in Zones A and B
Dents, gouges, and scratches less than
.010” deep around lugs in Zones A and 23377 Type 1 epoxy primer or equivalent
Cracks.
B (see Figure 5.1). and MIL-PRF-85285 Type 1 polyurethane
coating or equivalent.
Pillow Blocks Dents, gouges, and scratches less than Blend at 20:1 ratio, length to depth, to Dents, gouges and scratches greater than
P/N 290-853-01, .030” deep outside lug area of Zone A provide smooth transitions. .060” deep outside lug area of Zone A
P/N 290-883-01 (see Figure 5.2).
Items 2.1, 9.1 Protect affected surfaces with MIL-PRF- Dents, gouges, and scratches greater than
23377 Type 1 epoxy primer or equivalent .030 in. deep around lug in Zone A
and MIL-PRF-85285 Type 1 polyurethane
Cracks.
coating or equivalent.
Trunnion Pin Wear on outside diameter, diameter None. Wear on outside diameter, diameter less than
P/N 290-854-00 greater than .363”. .363”.
Item 4
Cracks.
Thrust Bearing Wear on ends of bearing, thickness None. Wear on ends of bearing, thickness less than
P/N 290-881-00 greater than .125” .125”
Item 8
Bushing Wear on inside diameter, diameter less None. Wear on inside diameter, diameter greater than
P/N 290-364-00 than .520”. .520”.
Item 7
Shaft Bushing Wear on inside diameter, diameter less None. Wear on inside diameter, diameter greater than
P/N 290-882-00 than .393”. .393”.
Items 2.3, 9.3

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Table 5.1, Suspension System Inspection Criteria continued

Component Damage Permitted without Repair Repair Maximum Damage which Causes
Replacement
Attach Bolt, Wear on outside diameter, diameter None. Wear on outside diameter, diameter less than
P/N 290-332-00 greater than .495”. .495”.
Item 14
Cracks.
Bearing, None. None. Damage to Teflon liner.
P/N 517-012-00 Binding or seizing.
Items 2.2, 9.2

Threaded None. None. Replace threaded fasteners at overhaul except

fasteners 290-332-00 (item 14).

Manual Release Dents, gouges, and scratches less than Blend at 20:1 ratio, length to depth, to Dents, gouges, and scratches greater than
Cable .020” deep on end fittings. provide smooth transitions. .060” deep on end fittings.
P/N 268-031-00
Item 15 Superficial scratches, nicks, and Cracks, scratches, and nicks in the outer
scrapes on outside of release cable conduit, which expose the longitudinal wires
conduit. underneath.
Electrical Superficial scratches, nicks, and None. Broken or missing pins on connectors.
Release Harness scrapes on outside of electrical harness
P/N 270-130-01 sleeving.
Item 16

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Figure 5.1, Main Beam Inspection Zones

Zone A Zone A

Zone B

Figure 5.2, Pillow Block Inspection Zone

Zone A

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6.0 Disassembly & Re-assembly Instructions

6.1 The instructions following provide Illustrated Parts Lists, disassembly and re-assembly
instructions.
Figure 6.1, Fixed Cargo Suspension System Parts

4
6
2

15
5

16
10
11
12
8

13
17
6

1
8

7
13

14
3

17
9

5
4

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Table 6.1, Suspension System Parts (Refer to Figure 6.1)

Item Part No. Description Qty Notes

1 528-023-01 Cargo Hook 1
2 232-188-01 Pillow Block Assembly, Left 1 See Figure 6.5
3 290-852-01 Main Beam 1
4 290-854-00 Trunnion Pin 2
5 510-523-00 Bolt 2
6 510-500-00 Nut 2
7 290-364-00 Bushing 1
8 290-881-00 Thrust Bearing 2
9 232-189-01 Pillow Block Assembly, Right 1 See Figure 6.6
10 510-178-00 Cotter Pin 1
11 510-170-00 Nut 1
12 510-174-00 Washer 1
13 510-183-00 Washer 2
14 290-332-00 Attach Bolt 1
15 268-031-00 Manual Release Cable 1
16 270-130-01 Electrical Release Harness 1
17 31-054-64DFHF Decal 2 Supplied by Bell
Helicopter

Disassembly
1. Remove Cotter Pin (item 10), Nut (item 11), Washers (items 12 and 13), and Attach Bolt
(item 14) and remove cargo hook (item 1) from Main Beam (item 3). Refer to Figure 6.1 for
item numbers.
2. Remove Nuts (item 6), Bolts (item 5), and Trunnion Pins (item 4) from each end of the
Main Beam to remove the Pillow Block Assemblies (items 2 and 9) and Thrust Washers
(item 8) from the Main Beam (item 3).
3. Press out Bushing (item 7) from Main Beam (item 3).

Assembly
1. Press Bushing (item 7) into Main Beam (item 3) with zinc chromate primer, TT-P-1757 or
equivalent.
2. Install cargo hook (item 1) onto Main Beam (item 3) with Attach Bolt (item 14), Washers
(items 13 and 12), and Nut (item 11). Tighten nut finger tight and rotate to next
castellation to install Cotter Pin (10).
3. Install left and right Pillow Block Assemblies (items 2 and 9) onto aircraft hard points, see
Figure 6.2. (Refer to Bell documentation for fastener part numbers and torque
requirements).

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Note that the Pillow Block Assemblies (items 2

and 9) are sensitive to right and left. See Figure
6.2.

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Figure 6.2, Pillow Block Orientation, RH Pillow Block Shown

FORWARD

LEFT

Small cutout must be facing

towards center of aircraft.
Chamfer on outboard side.

4. Assemble Main Beam (item 3) and Cargo Hook (item 1) onto Pillow Block
Assemblies (items 2 & 9) with Thrust Washer (item 8) and Trunnion Pins (item 4)
as shown.

Figure 6.3, Trunnion Pin/Thrust Washer Assembly

Trunnion Pin

Thrust Washer

Large lobe on the beam

must be to the left side
(when looking forward)
of the aircraft.

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5. Secure Trunnion Pin (item 4) with Bolt (item 5) as shown in Figure 6.4. Rotate the
Trunnion Pin (item 4) to align the hole in the pin with the hole in the Main Beam
(item 3). The Bolt (item 5) must pass through the hole in the Trunnion Pin (item 4)
when installed.

For wrench clearances, the Bolt (item 5) can only

be properly installed from one side of the Main
Beam (item 3).

6. Install Nut (item 6) onto Bolt (item 5) and torque to 20-25 in-lbs.

Figure 6.4, Beam/Pillow Block Assembly

Nut

Bolt

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Figure 6.5, Pillow Block Assembly, Left

2.3

2.2

2.1

Item Part No. Description Qty

2 232-188-01 Pillow Block Assembly, Left 1
2.1 290-853-01 Pillow Block, Left 1
2.2 517-012-00 Spherical Bearing 1
2.3 290-882-00 Shaft Bushing 1

Disassembly
1. Press Spherical Bearing (item 2.2) out of Pillow Block (item 2.1).
2. Press Shaft Bushing (item 2.3) out of Spherical Bearing (item 2.2).

Assembly
1. Apply corrosion inhibiting compound, BMS 3-38 or equivalent, to OD of Shaft Bushing (item
2.3) and press into Spherical Bearing (item 2.2).
2. Apply zinc chromate primer, TT-P-1757 or equivalent, to OD of Spherical Bearing (item 2.2)
and press into Pillow Block (item 2.1).

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Figure 6.6, Pillow Block Assembly, Right

9.1

9.2
9.3

Item Part No. Description Qty

9 232-189-01 Pillow Block Assembly, Right 1
9.1 290-883-01 Pillow Block, Right 1
9.2 517-012-00 Spherical Bearing 1
9.3 290-882-00 Shaft Bushing 1

Disassembly
1. Press Spherical Bearing (item 9.2) out of Pillow Block (item 9.1).
2. Press Shaft Bushing (item 9.3) out of Spherical Bearing (item 9.2).

Assembly
1. Apply corrosion inhibiting compound, BMS 3-38 or equivalent, to OD of Shaft Bushing (item
9.3) and press into Spherical Bearing (item 9.2).
2. Apply zinc chromate primer, TT-P-1757 or equivalent, to OD of Spherical Bearing (item 9.2)
and press into Pillow Block (item 9.1).

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APPENDIX A-1 Revision History

Revision Revised
Date Description of Change
Number Section / Page
0 August 22, 2007 All New Issue
Added item 17 to Figure 6.1 and Table 6.1.
Corrected Document Number on pages 9
1 August 28, 2007 All thru 16.
Corrected assembly sequencing and figure
references.

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 Service Manual
for
Talon LC Keeperless
Cargo Hook

528-023-01

Service Manual Number

122-005-00
Revision 16
October 23, 2009

13915 NW 3rd Court Vancouver, Washington 98685 USA

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

Revision Date Page(s) Reason for Revision

9 01/03/06 2-6 Added note about replacement of bolts when bushings
are changed.
2-7 Added Overhaul references for toggle pivot, load
beam roller, cam pivot and interlock roller bushings.
4-2 Changed Item #15 to 290-913-00
4-3 Changed Item #28 to 290-914-00
10 07/27/07 Section 1, 2, 3 Added Warnings, Cautions, and Notes section and re-
formatted these throughout. Re-organized Section 2.
Added annual inspection.
11 06/04/08 2-6, 4-1 & 4-2 Updated solenoid assembly part number to 232-118-
02. Added note explaining solenoid assembly P/N
change. Updated figure 4-1 to show new diode
configuration. Deleted sentence giving max
permissible bushing clearance as inspection criteria is
addressed in table 2-3.
12 07/18/08 2-8 Updated Cargo Hook assembly procedures to include
applying Corban on inside of armor plates. Moved
installation of cotter pin to after torque of solenoid
cover. Moved installation of manual release cover to
after ATP.
13 09/10/08 4-2 & 4-3 Added Overhaul Kit P/N 212-015-00 to parts list.
14 10/01/08 2-1 & 2-8 Added information on Cor-Ban corrosion inhibiting
compound for clarity.
15 04/23/09 2-8, 4-1 & 4-3 Added screw P/N 510-755-00 to figure and parts list.
Added safety wire instructions to cargo hook
assembly procedure.
16 10/23/09 2-8 Added attach hole inspection and bushing installation
instructions.
Current revision levels of all manuals are posted on Onboard Systems Int'l website at
www.onboardsystems.com. Revision levels of all manuals are available from the factory.

RECORD OF SERVICE BULLETINS

SB No. Date Description

159-011-00 October 9, 2003 This service bulletin replaces the return spring in the hook
with one of greater force and changes the hook part number
from 528-023-00 to 528-023-01.

ii
CONTENTS
Section 1 General Information
Introduction, 1-1
Warnings, Cautions, and Notes, 1-1
Specifications, 1-2
Theory of Operation, 1-2
Definitions, 1-2
Section 2 Maintenance
Consumables
Preventive Maintenance, 2-1
Trouble Shooting, 2-1
Inspection, 2-2
Cargo Hook Overhaul Schedule, 2-4
Cargo Hook Disassembly Procedure, 2-5
Cargo Hook Overhaul Inspection, 2-6
Cargo Hook Assembly Procedures, 2-8
Section 3 Acceptance Test Procedures
Proof Load Test, 3-1
Minimum Load Release Test, 3-2
Electrical Load Release Test, 3-2
Manual Load Release Test, 3-2
Section 4 Cargo Hook Parts
Cargo Hook Parts, 4-1
Section 5 Instructions for Storage and Return to Factory
Instructions for Storage, 5-1
Instructions for Return to Factory, 5-1
Figures
2-1 Spring Assembly Installation, 2-8
4-1 Cargo Hook Parts, 4-1
Tables
1-1 Specifications, 1-2
1-2 Cargo Hook Connector, 1-2
2-1 Consumables, 2-1
2-2 Trouble Shooting, 2-1
2-3 Cargo Hook Overhaul Inspection, 2-6
2-4 Side Plate Attach Hole Bushing Inspection, 2-8
4-1 Cargo Hook Parts, 4-2

iii
Section 1
General Information
Introduction
This Service Manual contains instructions for repair, overhaul and return to
service of Cargo Hook P/N 528-023-01. These procedures are provided for
the benefit of experienced aircraft maintenance facilities capable of carrying
out the procedures. They must not be attempted by those lacking the
necessary expertise or equipment. It is recommended that only minor
repairs be attempted by anyone other than the factory. It is recommended
that the Cargo Hook be returned to the factory for overhaul in accordance
with the overhaul schedule or when any of the components are in need of
major repair.

Warnings, Cautions and Notes

The following definitions apply to Warnings, Cautions and Notes used in
this manual.

Means that if this information is not observed,

serious injury, death or immediate loss of flight
safety could occur.

Means that there is a risk of injury or degradation

in performance of equipment if this information is
not observed.

Draws the reader’s attention to information which

may not be directly related to safety, but which is
important or unusual.

General Information 1-1

Specifications
Table 1-1 Specifications for Cargo Hook 528-023-01
Design load 3,500 lbs. (1,587 kgs.)
Design ultimate strength 15,750 lbs. (7,142 kgs.)
Electrical release capacity 8,750 lbs. (3,968 kgs.)
Mechanical release capacity 8,750 lbs. (3,968 kgs.)
Force required for mechanical 8 lbs. Max.(.600” travel)
release at 3,500 lb.
Electrical requirements 22-32 VDC 6.9 - 10 amps
Minimum release load 0 lbs
Unit weight 3.0 lbs (1.35 kgs.)
Mating electrical connector PC06A8-2S SR
Table 1-2 Cargo Hook Connector
Pin Function
A Ground
B Power

Theory of Operation
The primary elements of the Cargo Hook are the load beam, the internal
mechanism, and a DC solenoid. The load beam supports the load and is
latched through the internal mechanism. The DC solenoid provides the
normal means for unlatching the load beam. A manual release cable and a
mechanical release lever also provide means for unlatching the load beam.
The load is attached to the load beam by passing the cargo sling ring into the
throat of the load beam and pushing the ring against the upper portion of the
load beam throat, which will initiate the hook to close. In the closed
position, a latch engages the load beam and latches it in this position.
To release the load, the latch is disengaged from the load beam. With the
latch disengaged, the weight of the load causes the load beam to swing to its
open position and the cargo sling slides off the load beam. The load beam
then remains in the open position awaiting the next load.
A load release can be initiated by three different methods. Normal release is
achieved by pilot actuation of a push-button switch in the cockpit. When the
push-button switch is pressed, it energizes the DC solenoid in the Cargo
Hook, and the solenoid opens the latch in the internal mechanism. In an
emergency, release can be achieved by operating a mechanical release cable.
The release cable operates the internal mechanism of the Cargo Hook to
unlatch the load beam. The load can also be released by ground personnel
by the actuation of a lever located on the side of the Cargo Hook.

Definitions
Hours of External Load Operations. Time in which a helicopter is
engaged in external load operations including time between loads on the
hook.

1-2 General Information

Section 2
Maintenance
Consumables
Preventive Maintenance
Trouble Shooting
Table 2-2 Trouble Shooting
DIFFICULTY
Cargo hook does not operate
electrically; manual cable
release operates normally.
Cargo hook does not operate
electrically or manually.
Cargo hook operates
electrically, but not manually.
Load beam fails to relatch
after being reset.
Cargo hook manual release
cable pull-off force exceeds 8
lbs. (at the hook).
Circuit breaker opens when
Cargo Hook is energized.
Maintenance
Table 2-1 Consumables
Consumable Material Recommended Product(s)
Solvent Isopropyl alcohol
Lubricant AeroShell Grease #7 (MIL-PRF-23827)
Corrosion Preventative ACF-50
Compound Cor-Ban 27L (BMS 3-38) corrosion
inhibiting compound
Remove caked-on dirt from the Cargo Hook with a brush and clean exposed
surfaces with a mild solvent. Thoroughly dry all surfaces.
In highly corrosive environments such as a salt-laden atmosphere, monthly
application of a corrosion preventative compound such as ACF-50 is
required. Spray exterior of hook with the corrosion preventative compound
and wipe off excess.
PROBABLE CAUSE CORRECTIVE ACTION
Open electrical circuit, faulty Disconnect electrical connection at Cargo Hook.
wiring, circuit breaker, Using multimeter, check for 3.0 to 4.0 ohms
switch or solenoid. between pins A and B of electrical connector. If
open indication is obtained, check solenoid for
3.0 to 4.0 ohms resistance, replace solenoid if
required.
Defective internal mechanism. Disassemble hook and inspect internal
mechanism for binding, jamming, and worn or
broken parts. Repair as required.
Defective manual release cable, Check manual release cable and its connection to
Defective manual release Cargo Hook. Correct any defects.
system. Disassemble hook and inspect internal
mechanism for binding, jamming, and worn or
broken parts. Repair as required.
Defective latch mechanism. Disassemble hook and inspect internal
mechanism. Replace defective parts.
Friction in internal mechanism. Check operation of unit using manual release
lever. Disassemble hook and inspect internal
mechanism. Check pivot points for excessive
friction and lubricate. Check for denting in roller
contact surfaces in internal mechanism.
Short in the system, faulty wiring, Check for shorts to ground. Check solenoid
circuit breaker or solenoid resistance, repair or replace defective parts.
2-1
Inspection
Cargo Hook Daily Check
Prior to each cargo hook use perform the following. The pilot may
accomplish this.
1. Activate the electrical system and press the Cargo Release button to
ensure the cargo hook electrical release system is operating correctly.
The cargo hook must release. Reset the hook by hand after release. If
the hook does not release or re-latch, do not use the unit until the
problem is fixed.

Depressing the electrical release button

continuously in excess of 20 seconds will cause the
cargo hook release solenoid to overheat, possibly
causing permanent damage.

2. Activate the manual release system by pulling the release lever in the
cockpit. The mechanism should operate smoothly and the cargo hook
must release. Reset the hook by hand after release. If the hook does not
release or re-latch, do not use the unit until the problem is resolved.
3. Visually check for presence and security of fasteners and electrical
connection.
4. Visually check the load beam for damage, gouges and cracks. Refer to
Table 2-3 for limits.
5. Visually check the cargo hook case and covers for damage, cracks and
corrosion. Refer to Table 2-3 for limits.

2-2 Maintenance
 Cargo Hook Inspection Schedule
The scheduled inspection intervals noted below are maximums and are not
to be exceeded. If the cargo hook is subjected to unusual circumstances,
extreme environmental conditions, etc., it is the responsibility of the
operator to perform the inspections more frequently to ensure proper
operation.
Annually or 100 hours of external load operations, whichever comes
first, inspect the cargo hook per the following.
1. Visually inspect for corrosion on the exterior of cargo hook. Corrosion
on the cargo hook side plates is cause for immediate overhaul.
Additionally, any exfoliation corrosion in the upper attach lug area of
the cargo hook is cause for immediate replacement of the side plate.
2. Visually inspect for presence and security of fasteners and electrical
connection.
3. Visually inspect the load beam for damage, gouges and cracks. Refer to
Table 2-3 for limits.
4. Visually inspect the cargo hook case and covers for damage, cracks and
corrosion. Refer to Table 2-3 for limits.
5. Activate the helicopter’s electrical system and press the Cargo Release
button to ensure the cargo hook electrical release system is operating
correctly. The cargo hook must release. Reset the hook by hand after
release. If the hook does not release or re-latch, do not use the unit until
the problem is fixed.

Depressing the electrical release button

continuously in excess of 20 seconds will cause the
cargo hook release solenoid to overheat, possibly
causing permanent damage.
6. Activate the manual release system by pulling the release lever in the
cockpit. The mechanism should operate smoothly and the cargo hook
must release. Reset the hook by hand after release. If the hook does not
release or re-latch, do not use the unit until the problem is resolved.

In highly abrasive environments such as desert operations, annually or

500 hours of external load operations, whichever comes first, perform
the following.
1. Disassemble, inspect, clean, re-lubricate, re-assemble, and test the cargo
hook per this Service Manual.

Maintenance 2-3
Cargo Hook Overhaul Schedule
The overhaul of the Cargo Hook shall be in accordance with the guidelines below.
The examples below are intended as general guidelines and do not represent all
conditions or types of operations. If the severity of use is not readily classified, the
overhaul interval shall be determined on the basis of the operator’s evaluation of the
operating environment. It is the operator’s responsibility to decide which profile is
closest to his actual usage. If the helicopter is used for mixed missions the operator
will schedule overhaul based on the most severe mission profile in his operation.

1. Air taxi or similar operations:

This helicopter is typically stored in a hangar and only occasionally used for hook
work. Overhaul every 1000 hours of external load operations or 5 years, whichever
comes first.

2. Oil field support, firefighting, construction:

Typically more than average external load flight hours and loads near lift capacity.
This operator rarely releases the hook with the load off the ground. Check for
external corrosion annually, and overhaul every 1000 hours of external load
operations or 5 years, whichever comes first.

3. Logging:
The same as oil field support and firefighting but with the added factor of the hook
being subjected to shock loading from the load shifting and jerking when landing or
taking off. This application is also subject to many load cycles per hour as the turn
time will often be less than a minute. For this operator, overhaul every 500 hours of
external load operations or 5 years, whichever comes first.

4. Aerial release of loads.

When loads are released with weight on the hook, the opening shock and
instantaneous rebound of the hook operating mechanism will accelerate wear.
Therefore, significant restrictions apply for aerial release of loads. This occurs when
the pilot releases the load from the primary hook with the load not on the ground.
This section does not apply to aerial releases from a remote hook. This application
is not common and the primary hook is not designed for continuous use in this way.
The hook is designed to withstand occasional occurrences. In this case the time
between overhauls should be determined by counting cycles. The load weight at
release determines the allowable cycles before overhaul. Following are the
guidelines.
less than 113 kgs (250 lbs.) no limit and no need to record releases
113 - 453 kgs (250 - 1000 lbs.) 2000 releases
454 – 1134 kgs (1001 - 2500 lbs) 100 releases
over 1134 kgs (2500 lbs) 20 releases
Releases in excess of the release limits will require overhaul. The release counts
will be re- zeroed after overhaul.

2-4 Maintenance
Cargo Hook Disassembly Procedure
Refer to Figure 4-1
1. Cut and remove all lockwire.
2. Remove manual release cover (7) by removing two screws (6).
3. Remove the manual and electrical release cables from the Cargo Hook.
4. Remove cotter pin (8), nuts (9 and 11) and washers (10 and 12) from the
solenoid side of the hook.
5. Remove Solenoid Assembly (13).
6. Remove bolts (14) and (15).
7. Remove nut (11) and bolt (16) and armor plates (17 and 18).
8. Remove cotter pin (8), nut (18) and washer (19) securing manual release
lever.
9. Remove manual release lever (20), spring retainer (31), and spring (21).
Lay assembly on the bench with the manual release side up. The frame
can now be split by lifting the Side Plate (22) from the assembly. The
internal mechanism can now be viewed and cycled to check for smooth
operation. All of the internal parts may be removed at this time.
10. The solenoid may be removed from the cover by unsoldering or cutting
the wires at the connector (13.8) and removing two nuts (13.1).
11. Remove the attach bushings (22.2) by pressing them out of the side
plates.
12. Other bushings and bearings may be removed from detail parts by
conventional means. When disassembling the toggle (23) press out the
load beam roller pin (23.3) in the direction shown on the exploded parts
view. The toggle (23.1) has stepped holes, which only allow removal in
the correct direction.

Maintenance 2-5
Cargo Hook Overhaul Inspection
(This page may be copied and used as an inspection record sheet)
Carefully inspect and repair the detail parts in accordance with the
instructions in Table 2-3. Inspect the parts in a clean, well-lighted room.

If the toggle pivot and cam pivot bushings are

being replaced, bolt P/N 510-373-00 must be
replaced with P/N 290-913-00 and bolt P/N 510-
374-00 must be replaced with P/N 290-914-00.
Inspect bearings and the shafts they run on for wear and corrosion. Pitting,
corrosion or roller dents on shafts is cause for rejection.
Perform magnetic particle inspection in accordance with ASTM E1444 and
MIL-STD-1907, Grade A on the parts listed below. No cracks are permitted
in any of these parts.
Toggle (23.1) Solenoid Cam (13.7)
Load beam (25.1) Cam (24.1)
Attach Bolt (5)
Perform penetrant inspection per ASTM E1417 and MIL-STD-1907, Grade
A on the parts listed below. No cracks are permitted in any of these parts.
Side Plate, Manual Release (22.1) Side Plate, Solenoid (27.1)

Table 2-3 Cargo Hook Overhaul Inspection

Component Damage Tolerance Remedy Finish

Side Plates and Covers Corrosion Minor if less Blend at 10:1 ratio as Touch up with alodine
290-636-00, 290-637-00, than .005 deep required to provide smooth and zinc chromate
290-646-00, 290-633-00 transitions and remove primer
pitting.
Side Plates and Covers Dents, gouges and Minor if less Blend at 10:1 ratio as Touch up with alodine
290-636-00, 290-637-00, scratches than .005 deep required to provide smooth and zinc chromate
290-646-00, 290-633-00 transitions. primer
Side Plates Oversized attach See table 2-4.
290-636-00, 290-637-00, holes.
Hook attach lugs Cracks visible Remove and replace
Hook attach lugs Corrosion visible Remove and replace
Hook attach bushings 290- Wear .520 max Remove and replace
294-00, inside diameter diameter
Load Beam 290-639-00 Wear from contact .070 deep Remove and replace. This part is 15-5PH,
with load rings. passivated. No touch
Sharp notches up finish required.
Load Beam 290-639-00 Gouges and nicks .050 deep Blend at 10:1 ratio as This part is 15-5PH,
required to provide smooth passivated. No touch
transitions and assure load up finish required.
rings will not hang up on
load beam during release.

Load Beam 290-639-00 Cracks visible Remove and replace

2-6 Maintenance
Cargo Hook Overhaul Inspection continued
Table 2-3 Cargo Hook Overhaul Inspection continued
Component Damage Tolerance Remedy Finish

Armor Plate Gouges and nicks. .050 deep Blend at 10:1 ratio as This part is 15-5PH,
290-643-00, required to provide passivated. No touch
290-644-00. smooth transitions. up finish required
Armor Plate Deformation or .060 or when Remove and replace.
290-643-00, bending. keeper function
290-644-00. is affected
Armor Plate Cracks Visible Remove and replace
290-643-00,
290-644-00.
Bumper, Load Beam Cuts and abrasions .060 deep or if Remove and replace
514-031-00 rubbing on Load
Beam
Cam Wear on cam Visible denting Remove and replace
surfaces and dents
on bearing area
Toggle pivot bushings Wear > 50% copper Remove and replace
showing
Load beam roller bushings Wear > 50% copper Remove and replace
showing
Cam pivot bushings Wear > 50% copper Remove and replace
showing
Interlock roller bushings Wear > 50% copper Remove and replace
showing
Attach Bolt 290-332-00 Wear .495 min. Remove and replace
diameter
Attach Bolt 290-332-00 Cracks, gouges or visible Remove and replace
nicks
Threaded parts, all fasteners Replace all threaded N/A Remove and replace
except 290-332-00 parts at each
overhaul
Nameplate Mutilation or Illegible Remove and replace
illegibility
Springs Cracks and Visible defects Remove and replace
deformation
Solenoid Burning or shorting, Burnt smell or if Remove and replace
check resistance resistance is
with ohmmeter outside 3.0 to
4.0 ohm range
Electrical wiring Deterioration Visible damage Remove and replace
Electrical connector Loose, missing, or Visible damage Remove and replace
mutilated contact
pins, cracked case,
or worn insulator

Maintenance 2-7
 Table 2-4 Side Plate Attach Hole Inspection
If top attach hole measures:
Less than .6257 in (15.893
mm)
.6264 - .6270 in (15.910 –
15.926 mm)
.6257 - .6263 in (15.893 –
15.908 mm)
.6271 - .6285 in (15.928 –
15.954 mm)
2-8
Use attach bushing:
P/N 290-294-00 (22.2)
P/N 290-294-01*
* Oversized Attach Bushing
P/N 290-294-01 is identified
by a groove on its OD as
shown.
Groove
P/N 290-294-00 (22.2)
P/N 290-294-01
Installation
Install with wet zinc chromate
primer using an arbor press.
Ensure a continuous fillet seal
of primer around bushing
flange after installation.
Install with Loctite 680
adhesive using an arbor press.
Ensure a continuous fillet seal
of adhesive around bushing
flange after installation.
Maintenance
Cargo Hook Assembly Procedures
1. Replace all roll pins, bearings and bushings that have been removed at
disassembly.
2. Replace all parts found to be damaged with serviceable parts.
3. Install bolt (28), toggle (23), cam (24), load beam bumper (26) and load
beam (25) into side plate (27), sliding cam over bolt (28).
4. Grease toggle needle bearing (23.5) with MIL-G-23827 and install pin
(23.6).
5. Slide cam spring (24.6) over roll pin (27.4).
6. Install side plate (22) over loaded side plate (27).
7. Install bolt (15) by aligning toggle pivot bearing and sliding bolt in to
assembly.
8. Install bolt (14).
9. Install spring (per Figure 2-1) (21), spring retainer (31), and manual
release lever (20).
10. Install washer (19) and nut (30), tighten nut finger tight and turn to next
castellation.
11. Apply thin film of Cor-Ban 27L corrosion inhibiting compound to
inside of Armor Plates (17 and 18), and install using bolt (16) and nut
(11).
Torque to 20-25 in-lbs.
12. Install solenoid assembly (13) Safety wire solenoid assembly connector
to screw (32).
13. Install washer (10) and nut (9).
14. Torque nut to 15 in-lbs, rotate to next castellation and install cotter pin
(8).
15. Install washer (12) and nut (11). Torque nut to 20-25 in-lbs. Install
cotter pin (8) into manual release lever nut (30).
16. Perform Acceptance Test Procedures as listed in this manual.
17. Install manual release cover (7) and screws (6).
Figure 2-1 Spring Assembly Installation

Maintenance 2-9
Section 3
Acceptance Test Procedures
If during repair the Cargo Hook has had the side plates separated or has
been stored in excess of five years it must be subjected to the Acceptance
Test Procedure below. Minor repairs that do not involve splitting the side
plates such as removing and replacing the solenoid will not require a full
ATP. The daily functional check is sufficient.
Examine the Cargo Hook externally for security of the lockwire, cotter pins
and fasteners.
Use an appropriate insulation resistance tester to test the resistance between
each pin and the base of the connector. The readings should not be less than
2 mega-ohms. Using a multimeter, check continuity between pins A and B
of the electrical connector. Resistance value should be 3.0 to 4.0 ohms.
Suspend the hook from a test rig capable of loading the Cargo Hook to
8,750 pounds. Use a nylon sling or a steel ring to apply the load to the load
beam.

Proof load test

Perform a proof load test as follows:

Do not release the proof test load electrically or

manually. Decrease the load gradually, using the test
machine, after completion of the proof load test.
Gradually load the Cargo Hook with the test rig to 8,750 pounds. Hold the
load for 1 minute. The load beam should hold the load without unlatching.
Reduce the load to zero.
Ensure that the unit is correctly locked by observing that the nose of the load
beam is secure in the latch.

ATP 3-1
Minimum load release test
With no load on the load beam, operate the manual release lever. The load
beam should unlatch and the load should slide off the load beam. Release
the manual release lever. Reset the load beam and ensure it latches in the
fully locked position.
Connect an adjustable 22 - 28 VDC supply with a momentary release switch
wired into the positive wire, to the connector located on top of the solenoid
housing. Connect the negative lead to pin A and the positive lead to pin B.
Press the release switch. The load beam should release the load. Reset the
load beam by hand after release.

Electrical load release test

Use a nylon sling or steel ring that is free to drop clear of the load beam.
Gradually load the Cargo Hook to 3,500 pounds and hold the load for 20
seconds.

Depressing the electrical release button continuously

in excess of 20 seconds will cause the cargo hook
release solenoid to overheat, possibly causing
permanent damage.
With the power supply operating voltage set at 22 VDC, press the release
button. The load beam should unlatch and the nylon sling or the steel ring
should slide off the load beam. Reset the load beam by hand after release.
Repeat the test a second time.

Manual load release test

With no load applied to the load beam, verify that the load beam can be
unlatched manually using the release mechanism.
Connect a manual release cable to the Cargo Hook and gradually load the
Cargo Hook to 3,500 pounds. Hold the load for 30 seconds. Perform a
manual release by pulling the manual release cable. The required release
force shall not be less than 3.5 lbs and not exceed 8 lbs. Repeat the test a
second time.

3-2 ATP
Section 4
Cargo Hook Parts
Figure 4-1 Cargo Hook Parts

Cargo Hook Parts 4-1

Cargo Hook Parts, continued
Table 4-1 Cargo Hook Parts (Refer to Figure 4-1)
Item Part No. Description Qty Included in
Overhaul Kit
P/N 212-015-00
1 510-178-00 MS24665-302 Cotter Pin 1 1
2 510-170-00 AN320-C6 Nut 1 1
3 510-174-00 NAS1149F-663P Washer 1 1
4 510-183-00 NAS1149F0832P Washer 2 2
5 290-332-00 Attach Bolt 1 -
6 510-377-00 MS35265-46 Screw 2 2
7 290-646-00 Manual Release Cover 1 -
8 510-115-00 MS24665-136 Cotter Pin 2 2
9 510-259-00 AN320-4 Nut 1 1
10 510-219-00 NAS1149F0463P Washer 1 1
11 510-102-00 MS21042-3 Nut 2 2
12 510-042-00 NAS1149F0363P Washer 1 1
* 13 232-118-01** Solenoid Assembly 1 -
13.1 510-206-00 AN365-832 Nut 2 2
13.2 510-209-00 NAS1149FN832P Washer 2 2
13.3 290-633-00 Solenoid Cover 1 -
13.4 455-003-00 Solenoid 1 -
13.5 420-033-00 Lockwire 1 -
13.6 510-379-00 MS35265-26 Screw 3 3
13.7 290-634-00 Solenoid Cam 1 -
13.8 410-139-00 PC07A-8-2P Cannon Plug 1 -
- 556-045-00 O-Ring - 1
13.9 340-035-00 Diode 1 -
13.10 215-191-00 S/N Plate 1 1
14 510-375-00 NAS6203-38 Bolt 1 1
15 290-913-00 Bolt 1 1
16 510-376-00 NAS6203-10 Bolt 1 1
17 290-643-00 Armor Plate – Solenoid Side 1 -
18 290-644-00 Armor Plate – Manual Side 1 -
19 510-085-00 AN970-3 Washer 1 1
* 20 232-119-00 Manual Release Lever Assembly 1 -
20.1 290-635-00 Manual Release Lever 1 -
20.2 517-032-00 Bearing, Manual Release Lever 1 1
* Item not illustrated as an assembly
** P/N 232-118-00 was changed to 232-118-02 to replace diode P/N 340-027-00 with 340-035-00. These
P/N’s are interchangeable.

4-2 Cargo Hook Parts

Cargo Hook Parts, continued
Table 4-1 Cargo Hook Parts, continued (Refer to Figure 4-1)
Item Part No. Description Qty Included in
Overhaul Kit
P/N 212-015-00
21 514-056-00 Spring Assembly, Cam 1 1
* 22 232-116-00 Side Plate Assembly, Manual 1 -
22.1 290-637-00 Side Plate, Manual 1 -
22.2♠ 290-294-00 Bushing, Attach 2 2
22.3 517-010-00 Bearing, Load Beam Pivot 2 2
22.4 510-210-00 Helicoils 2 2
* 23 232-112-00 Toggle Assembly 1 -
23.1 290-638-00 Toggle 1 -
23.2 517-021-00 Bearing, 4 2
23.3 290-645-00 Pin, Load Beam Roller 1 -
23.4 290-438-00 Load Beam Roller 1 -
23.5 517-037-00 Bearing, Cam Roller 1 1
23.6 290-439-00 Pin, Cam Roller 1 -
* 24 232-113-00 Cam Assembly 1 -
24.1 290-632-00 Cam 1 -
24.2 517-009-00 Bearing, Cam 2 2
24.3 517-031-00 Bushing, Interlock 2 -
24.4 290-603-00 Roller, Interlock 1 -
24.5 290-450-00 Pin, Interlock 1 -
24.6 514-032-00 Spring, Cam Backup 1 1
* 25 232-117-00 Load Beam Assembly 1 -
25.1 290-639-00 Load Beam 1 -
25.2 290-640-00 Shaft, Load Beam 1 -
26 514-031-00 Bumper, Load Beam 1 1
* 27 232-115-00 Side Plate Assembly- Solenoid 1 -
27.1 290-636-00 Side Plate – Solenoid 1 -
27.2 510-202-00 Roll Pin 1 1
28 290-914-00 Bolt 1 1
30 510-082-00 AN320-3 Nut 1 1
31 290-819-00 Spring Retainer 1 -
32 510-755-0 Screw 1 -
* Item not illustrated as an assembly
♠ Optionally P/N 290-294-01 may be used, see Table 2-4.

Cargo Hook Parts 4-3

Section 5
Instructions for Storage and Return to Factory
Instructions for Storage
Clean the Cargo Hook components thoroughly before packaging. Pack the
unit in a heat-sealable package. If the unit is to be stored for long periods in
a tropical climate it should be packed in a reliable manner to suit local
conditions. Refer to relevant MIL specifications.

Package the unit in a suitable fiberboard box and cushion the unit to prevent
shifting. Seal the fiberboard box with tape and mark the box with the
contents and date of packaging.

Instructions for Returning a System to the Factory

If a component must be returned to the factory:

to:

Onboard Systems
13915 NW 3rd Court
Vancouver Washington 98685
USA

Instructions for Storage and Return to Factory 5-1