Instructions for Continued Airworthiness

25.16.1 Slave Cylinder Assembly Removal, Section 25 Page 12 25.16.2 Forward Connector Bracket, Section 25, Page 13 25.16.3 Release Lever Removal, Section 25, Page 14 25.16.4 Electrical Module Assembly, Section 25, Page 15 25.16.5 Load Weigh Indicator Enclosure Removal, Section 25, Page 16 25.16.6 Load Weigh Indicator Removal, Section 25, Page 16 25.17.1 Suspension Frame Assembly Installation, Section 25, Page 18 25.17.2 Cargo Hook Attachment Hardware, Section 25, Page 19 25.17.3 Slave Cylinder Assembly Installation, Section 25, Page 20 25.17.4 Hose & Electrical Harness Routing, Section 25 Page 21 25.17.5 Release Lever Installation, Section 25 Page 22 25.17.6 Hydraulic Hose Attachment, Section 25 Page 23 25.17.7 Lever Adjustment, Section 25 Page 24 25.17.8 Pin Load Cell Attach Hardware, Section 25 Page 26 Tables 0.4.1 Primary Fixed Provisions Kit Components, Section 0 Page 2 0.4.2 Cargo Hook Suspension Kit Components, Section 0 Page 3 0.4.3 Primary Pin Load Weigh Kit Components, Section 0 Page 3 5.1.1 Suspension Assembly Parts, Section 5 Page 4 5.1.2 Trunnion Assembly Parts, Section 5 Page 5 5.1.3 Forward and Aft Hard Point Parts, Section 5 Page 6 5.1.4 Suspension System Inspection Criteria, Section 5 Page 7 11.1.1 Cargo Hook Suspension System Placards, Section 11 Page 1 25.1.1 Cargo Hook Connector, Section 25 Page 1 25.5.1 Component Weights and CGs, Section 25 Page 3 25.15.1 Troubleshooting, Section 25 Page 4 Instructions for Continued Airworthiness 123-036-00 Revision 0 00-00-00 Page 1 05/05/11 Section 0 Introduction 0.4 Scope This ICA contains maintenance instructions for cargo hook kit P/N’s 200-355-00, 200-356-00, 200-357-00, and 200-369-00 on the Agusta A109E, A119, AW119 MkII model helicopters. These kits, when installed, provide the means for the helicopter to carry external loads. Kit P/N 200-356-00 must be installed with Kit P/N 200-355-00 (on the A109E) or with Kit P/N 200-369-00 (on the A119 and AW119 MkII models) and Kit P/N 200- 357-00 is an optional load weigh kit which can be installed in addition to these kits. Kit P/N 200-355-00 and 200-369-00 are fixed provisions kit. P/N 200-355-00 is for the A109E model and P/N 200-369-00 is for the A119 and AW119 MkII models. These kits include the internal electrical release wiring harnesses, fixed manual release system including the release lever for actuation, support brackets and hard points which support the cargo hook suspension, and miscellaneous brackets and hardware. The primary kit components are shown below. Figure 0.4.1 Fixed Provisions Kit Overview 14 M405A16 M390A16N M405A16 M390A16N J8505 270-179-00 P8505 270-180-00 CB8505 CB8505 M362A16 M364A20 3 15 4 2 9 18 16 17 10 8 6 5 7 12 11 13 215-255-00 CARRYING OF EXTERNAL LOADS 1 Instructions for Continued Airworthiness 123-036-00 00-00-00 Page 2 Revision 0 05/05/11 0.4 Scope continued Table 0.4.1 Primary Fixed Provisions Kit Components ITEM PART NO. DESCRIPTION QTY 1 215-255-00 A109/A119 Information Decals 1 2 220-043-00 Fwd Connector Bracket Fairing 1 3 232-453-00 Fwd Hard Point Assembly 2 4 232-463-00 Fwd Connector Bracket Assembly 1 5 232-464-00 Intermediate Hose Assembly 1 6 232-465-00 Release Lever Assembly w/ Plumbing 1 7 232-466-00 Electrical Module Assembly 1 8 232-474-00 Barrel Nut Assembly 4 9 232-475-00 Aft Connector Bracket Assembly 1 10* 235-177-00 Landing Gear Lock 1 11 270-178-00 Intermediate Electrical Harness 1 12 270-179-00 Internal Electrical Harness 1 13 270-180-00 Electrical Harness 1 14 291-361-00 Aft Hard Point 2 15 291-363-00 Support Bracket 2 16 291-365-00 Peel Shim 1 17 291-367-00 Peel Shim 1 18 291-617-00 Angle Bracket 1 * Included with Kit P/N 200-355-00 only. Kit P/N 200-356-00 is a cargo hook suspension kit and includes the cargo hook and its external electrical release and manual release components which mate with the associated fixed provision kit components, and a frame assembly which supports the cargo hook and spans the hard points on the belly of the helicopter. It requires that a helicopter be equipped with the Onboard Systems Fixed Provisions Kit P/N 200- 355-00 or 200-369-00 (see above). Figure 0.4.2 Cargo Hook Suspension Kit Overview 1 3 2 Instructions for Continued Airworthiness 123-036-00 Revision 3 00-00-00 Page 3 08/24/15 0.4 Scope continued Table 0.4.2 Cargo Hook Suspension Kit Components ITEM PART NO. DESCRIPTION QTY 1 210-244-00 Cargo Hook/Frame Assembly 1 2 215-256-00 External Load Limit Decal 1 3 215-258-00 External Load Limit Decal 1 Kit P/N 200-357-00 is a load weigh kit which includes a pin load cell, internal electrical harness, and load weigh indicator. When this kit is installed, the pin load cell assembly replaces the cargo hook attach bolt within the cargo hook suspension assembly. The primary kit components are shown below. Figure 0.4.3 Pin Load Weigh Kit Overview 1 5 4 6 LOAD CELL 7 3 2 Table 0.4.3 Primary Pin Load Weigh Kit Components ITEM PART NO. DESCRIPTION QTY 1 210-095-02 C-39 Indicator Assembly 1 2 210-301-02* Pin Load Cell Assembly 1 3 232-451-00 Bracket Assembly 1 4 232-452-00 Mounting Plate Assembly 1 5 235-198-00 Outer Cover 1 6 270-177-00 Load Weigh Internal Harness 1 7 270-182-00 Jumper Assembly 1 *Supersedes P/N 210-226-02, these P/Ns are interchangeable in this installation. Instructions for Continued Airworthiness 123-036-00 00-00-00 Page 4 Revision 0 05/05/11 0.5 Purpose The purpose of this Instructions for Continued Airworthiness (ICA) manual is to provide the information necessary to inspect, service, and maintain in an airworthy condition the P/N 200-355-00, 200-356-00, 200- 357-00, and 200-369-00 Cargo Hook kits. 0.6 Arrangement This manual contains instructions for the service, maintenance, inspection and operation of the P/N 200-355-00, 200-356-00, 200-357-00, and 200- 369-00 Cargo Hook Kits. The manual is arranged in the general order that maintenance personnel would use to install, maintain and operate the Cargo Hook Kits in service. The arrangement is: Section 0 Introduction. Section 4 Airworthiness limitations (None apply to this System.) Section 5 Inspection and overhaul schedule Section 11 Placards and Markings Section 12 Servicing Section 25 Equipment and Furnishings 0.7 Applicability These Instructions for Continued Airworthiness are applicable to Cargo Hook Kits P/N 200-355-00, 200-356-00, 200-357-00 and 200-369-00 for the Agusta A109E, A119, and AW119 MkII helicopters. Refer to the appropriate Agusta maintenance documentation for instructions regarding parts of the aircraft that interface with these cargo hook kits. 0.9 Abbreviations FAA Federal Aviation Administration CFR Code of Federal Regulations ICA Instructions for Continued Airworthiness Instructions for Continued Airworthiness 123-036-00 Revision 2 00-00-00 Page 5 12/02/13 0.12 Precautions The following definitions apply to precaution flags used in this manual. Indicates a hazardous situation which, if not avoided, will result in death or serious injury. Indicates a hazardous situation which, if not avoided, could result in death or serious injury. Indicates a hazardous situation which, if not avoided, could result in minor or moderate injury. Draws the reader’s attention to important or unusual information not directly related to safety. Used to address practices not related to personal injury. 0.19 Distribution of Instructions for Continued Airworthiness Before performing maintenance ensure that the Instructions for Continued Airworthiness (ICA) in your possession is the most recent revision. Current revision levels of all manuals are posted on Onboard Systems Int'l web site at www.onboardsystems.com. Onboard Systems offers a free notification service via fax or e-mail for product alerts and documentation updates. By registering Onboard Systems products on the web site, we will be able to contact you if a service bulletin is issued, or if the documentation is updated. Notices can be chosen to be received on an immediate, weekly, or monthly schedule via fax, email or both methods. There is no charge for this service. Please visit the Onboard Systems web site at www.onboardsystems.com/notify.php to get started. Instructions for Continued Airworthiness 123-036-00 00-00-00 Page 6 Revision 0 05/05/11 THIS PAGE INTENTIONALLY LEFT BLANK Instructions for Continued Airworthiness 123-036-00 Revision 0 04-00-00 Page 1 05/05/11 Section 4 Airworthiness Limitations 4.2 No airworthiness limitations The Airworthiness Limitations section is FAA approved and specifies inspections and other maintenance required under Secs. 43.16 and 91.403 of the Federal Aviation Regulations unless an alternative program has been FAA approved. No airworthiness limitations are associated with this type design change. Instructions for Continued Airworthiness 123-036-00 04-00-00 Page 2 Revision 0 05/05/11 THIS PAGE INTENTIONALLY LEFT BLANK Instructions for Continued Airworthiness 123-036-00 Revision 4 05-00-00 Page 1 10/10/17 Section 5 Inspection and Overhaul Schedule 5.1 Cargo Hook Suspension System Inspection 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 kits per the following. Refer also to Component Maintenance Manual (CMM) 122-015-00 for the cargo hook for additional instructions. 1. Activate the electrical system and press the Cargo Release button to ensure the cargo hook electrical release system is operating correctly. With no load on it the cargo hook must open. Reset the hook by hand after release. 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 hydraulic release system by pulling the release lever on the cyclic. The lever should operate smoothly and the cargo hook must open. Return the load beam to its closed and locked position by hand after release. Verify that the hook lock indicator on the side of the hook returns to the fully locked position. In the fully locked position the hook lock indicator must align with the lines on the cover (see Figure 5.1.1). If the hook does not release or re-latch, do not use the unit until the problem is resolved. Figure 5.1.1 Hook Lock Indicator Hook Lock Indicator ACCEPTABLE Hook Lock Indicator Instructions for Continued Airworthiness 123-036-00 05-00-00 Page 2 Revision 4 10/10/17 5.1 Cargo Hook Suspension System Inspection continued 3. Move the cargo hook throughout its full range of motion and observe the hydraulic hose and electrical harnesses to ensure that they have enough slack. The hose or harnesses must not be the stops that prevent the cargo hook from moving freely in all directions. 4. Move all pivoting joints to ensure that they rotate freely throughout their range of motion. 5. Visually inspect for presence and security of fasteners. 6. Visually inspect the external electrical harnesses and their connectors at the forward and aft connector brackets for damage and security. 7. Visually inspect the external hydraulic hose and its connection to the cargo hook and the fittings at the forward and aft connector brackets on the belly of the helicopter for damage and security. 8. Visually inspect for cracks in suspension frame assembly and the forward and aft hard points. 9. Visually inspect for security of C-39 load weigh indicator mounting (if load weigh system is installed). 10. Visually check for oil leaks in the hydraulic release system. Some seeping or dampness is acceptable at the cargo hook, but if drips or areas cleaned by oil leaking are present the hook must not be used until the condition is repaired. See troubleshooting section to determine the course of action. 11. Check the fluid level in the master cylinder on the cyclic. The master cylinder features a transparent lid through which the fluid level can be checked. Hydraulic fluid must be visible over the baffle surface (reference Figure 12.1.1). 12. Check the hydraulic release system for air by pulling the lever firmly until it bottoms out. Check the push rod position (reference Figure 12.2.5). If some of the green ring on the push rod is visible, the system is adequately bled. If some of the green on the push rod is NOT visible with the lever completely pulled, the system has too much air in it and must be bled, see Section 12.2 for bleeding instructions. 13. Check function of cargo hook stowage bracket. Rotate cargo hook up to the left and into the bracket. Ensure cargo hook is retained by the bracket and can be released. In the stowed position visually inspect the hose and harness for chafing points. Instructions for Continued Airworthiness 123-036-00 Revision 3 05-00-00 Page 3 08/24/15 5.1 Cargo Hook Suspension System Inspection continued Every 1000 hours of external load operations or 5 years, whichever comes first, remove the suspension assembly and the hard points from the helicopter (see section 25.17), disassemble, and inspect the component parts per the following instructions. o Remove the two loop clamps which secure the wiring harness and hydraulic hose to the suspension assembly. o Cut safety wire and remove the two bolts at each Center Bar Tube (item 8). o Slide the forward Center Bar Tube out of the forward Cross Tube of the Frame Assembly (item 3) and remove the Cargo Hook (item 35) and Trunnion Assembly (item 2). o Slide the aft Center Bar Tube out of the aft Cross Tube. o Separate the Cargo Hook from the Trunnion Assembly by removing the cotter pin (item 18), nut (item 16), and washers (items 17 and 19) from the Attach Bolt (item 6). o Remove the Attach Bolt and remaining washers. o The aft pins are installed with sealant in addition to the hardware shown and are not typically disassembled from the frame unless damage is observed. Figure 5.1.2 Suspension Parts Instructions for Continued Airworthiness 123-036-00 05-00-00 Page 4 Revision 3 08/24/15 5.1 Cargo Hook Suspension System Inspection continued Table 5.1.1 Suspension Assembly Parts ITEM PART NO. DESCRIPTION QTY 1 215-150-00 Serial Number Decal 1 2 232-433-00 Trunnion Assembly 1 3 232-434-00 Frame Assembly 1 4 232-482-00* Slave Cylinder Plumbing Assembly 1 5 270-181-00* Electrical Release Harness Assembly 1 6 290-332-00** Attach Bolt 1 7 291-500-00 Aft Pin 2 8 291-504-00 Center Bar Tube 2 9 291-555-00 Stowage Clip 1 10 291-556-00 Stowage Clip Rod 1 11 291-558-00 Quick Release Pin 2 12 291-612-00 Bushing 2 13 450-001-00* Heat Shrink AR 14 510-095-00 Washer 12 15 510-102-00 Nut 5 16 510-170-00 Nut 1 17 510-174-00 Washer 1 18 510-178-00 Cotter Pin 1 19 510-183-00 Washer 2 20 510-213-00 Nut 2 21 510-452-00 Bolt 1 22 510-455-00 Bolt 1 23 510-531-00 Screw 2 24 510-565-00 Safety Pin 2 25 510-712-00 Bolt 2 26 510-836-00 Bolt 2 27 510-934-00 Bolt 1 28 510-935-00 Eye Bolt 1 29 510-949-00 Bolt 4 30 512-011-00 Ty-wrap 1 31 512-026-00 Loop Clamp 1 32 512-027-00 Loop Clamp 1 33 512-028-00 Angle Bracket 1 34 514-100-00 Spring 1 35 528-028-00 Cargo Hook 1 36 531-010-00 Lanyard Cable 2 37 531-016-00 Crimp Sleeve 4 38 590-013-00* Spiral Wrap AR * Not shown in figure. ** Replaced by pin load cell (P/N 210-226-02 or P/N 210-301-02) if load weigh system is installed. Instructions for Continued Airworthiness 123-036-00 Revision 0 05-00-00 Page 5 05/05/11 5.1 Cargo Hook Suspension System Inspection continued Figure 5.1.3 Trunnion Assembly Parts Table 5.1.2 Trunnion Assembly Parts ITEM PART NO. DESCRIPTION QTY 1 290-364-00 Bushing 1 2 291-501-00 Trunnion 1 3 291-575-00 Radius Filler 2 Instructions for Continued Airworthiness 123-036-00 05-00-00 Page 6 Revision 0 05/05/11 5.1 Cargo Hook Suspension System Inspection continued Figure 5.1.4 Forward and Aft Hard Point Parts 1 2 3 4 Table 5.1.3 Forward and Aft Hard Point Parts ITEM PART NO. DESCRIPTION QTY 1 290-788-00 Bushing 2 2 291-364-00 Forward Hard Point 1 3 291-361-00 Aft Hard Point 1 4 232-474-00 Barrel Nut Assembly 2 Instructions for Continued Airworthiness 123-036-00 Revision 5 05-00-00 Page 7 12/17/18 5.1 Cargo Hook Suspension System Inspection continued o Return the Pin Load Cell Assembly (P/N 210-226-02 or 210-301-02) to the factory for inspection and calibration. The factory will inspect the condition of the load cell and perform acceptance test procedures including calibration and zero balance, repairing as necessary. o In addition, carefully inspect, and if necessary repair, the detail parts in accordance with the instructions in Table 5.1.4. Inspect the parts in a clean, well-lit room. Perform a thorough visual inspection of the Frame Assembly including the aft pins (item 7) for cracks and damage. The large Cross Tubes of the Frame Assembly are assembled onto the longitudinal side frames using a structural adhesive in addition to the eight screws at each end thus these joints should not be disassembled. Remove the screws in order to remove the covers so that the insides of the Cross Tubes can be visually inspected for damage including corrosion. Table 5.1.4 Suspension System Inspection Criteria Component Damage Permitted without Repair Repair Maximum Damage which Causes Replacement Frame Assembly P/N 232-434-00 (item 3, Figure 5.1.2) Dents, gouges, corrosion and scratches less than .010” deep except on the four raised pads on the bottom of the assembly’s side frames which have a tolerance of less than .070” deep. Blend at 20:1 ratio, length to depth, to provide smooth transitions. Protect bare surface with Alodine (MIL- PRF-5541), zinc chromate primer (MIL- PRF-23377 or similar) and topcoat (MIL- PRF-85285 or similar). Dents, gouges, corrosion and scratches greater than .030” deep except on the four raised pads on the bottom of the assembly’s side frames which have a tolerance of greater than .080” deep. Visual cracks. Trunnion P/N 291-501-00 (item 2, Figure 5.1.3) Dents, gouges, corrosion and scratches less than .010” deep. Blend at 20:1 ratio, length to depth, to provide smooth transitions. Part is 15-5 stainless steel, no touch up paint required. Dents, gouges, corrosion and scratches greater than .030” deep. Visual cracks. Fwd Hard Point P/N 291-364-00 (item 2, Figure 5.1.4) Dents, gouges, corrosion and scratches less than .010” deep. Blend at 20:1 ratio, length to depth, to provide smooth transitions. Protect bare surface with Alodine (MIL- PRF-5541), zinc chromate primer (MIL- PRF-23377 or similar) and optionally topcoat (MIL-PRF-85285 or similar). Dents, gouges, corrosion and scratches greater than .060” deep. Visual cracks. Instructions for Continued Airworthiness 123-036-00 05-00-00 Page 8 Revision 5 12/17/18 Table 5.1.4 Suspension System Inspection Criteria continued Component Damage Permitted without Repair Repair Maximum Damage which Causes Replacement Bushing P/N 290-788-00 (item 1, Figure 5.1.4) Wear on inside diameter, diameter less than .340”. None. Wear on inside diameter, diameter greater than .340” inclusive. Aft Hard Point P/N 291-361-00 (item 3, Figure 5.1.4) Dents, gouges, corrosion and scratches less than .010” deep. Blend at 20:1 ratio, length to depth, to provide smooth transitions. Protect bare surface with Alodine (MIL- PRF-5541), zinc chromate primer (MIL- PRF-23377 or similar) and optionally topcoat (MIL-PRF-85285 or similar). Dents, gouges, corrosion and scratches greater than .060” deep. Visual cracks. Attach Bolt P/N 290-332-00 (item 6, Figure 5.1.2) or Pin Load Cell P/N 210-226-02 or P/N 210-301-02 Wear on outside diameter, diameter greater than .495” inclusive. None. Wear on outside diameter, diameter less than .495”. Visual cracks Center Bar Tube P/N 291-504-00 (item 8, Figure 5.1.2) Dents, gouges, corrosion and scratches less than .010” deep. Blend at 20:1 ratio, length to depth, to provide smooth transitions. Protect bare surface with Alodine (MIL- PRF-5541) and zinc chromate primer (MIL-PRF-23377 or similar). Dents, gouges, corrosion and scratches greater than .040” deep. Visual cracks. Instructions for Continued Airworthiness 123-036-00 Revision 5 05-00-00 Page 9 12/17/18 Table 5.1.4 Suspension System Inspection Criteria continued Component Damage Permitted without Repair Repair Maximum Damage which Causes Replacement Aft Pin P/N 291-500-00 (item 7, Figure 5.1.2) Dents, gouges, corrosion and scratches less than .010” deep. Blend at 20:1 ratio, length to depth, to provide smooth transitions. Part is 15-5 stainless steel, no touch up required. Dents, gouges, corrosion and scratches greater than .040” deep. Visual cracks. Bushing P/N 291-612-00 (item 12, Figure 5.1.2) These bushings are self-lubricating using a composite liner. Wear on the composite liner, but base metal is not exposed. None. If the composite liner is worn through to the base metal or binding of the Trunnion Assembly pivot when installed. Quick Release Pin P/N 291-558-00 (item 11, Figure 5.1.2) Wear or indentations on outside diameter, diameter greater than or equal to .300” inclusive. None. Wear or indentations on outside diameter, diameter less than .300”. Visual cracks. Instructions for Continued Airworthiness 123-036-00 05-00-00 Page 10 Revision 0 05/05/11 5.1 Cargo Hook Suspension System Inspection Schedule continued Suspension Frame Re-assembly after Inspection Re-assemble the suspension assembly per the following (refer to Figure 5.1.2). 1. Press in new bushings as necessary. 2. Insert the Center Bar Tube (item 8) with bushing (item 12) through aft Cross Tube of Frame Assembly (item 3) and secure with bolts (item 29) and washers (item 14). Torque the bolts to 20-25 in-lbs. Safety-wire the bolts to holes in the tabs on the Center Bar Tube. 3. Ensure Radius Fillers are installed over ends of Trunnion shafts (item 2) and insert the aft Trunnion shaft into the Center Bar Tube. Orient the Trunnion using the FWD indication on the side of it. 4. Align the forward Trunnion shaft with the hole in the forward Cross Tube of the Frame Assembly and insert the other Center Bar Tube with bushing through and capture the forward Trunnion shaft. 5. Secure the forward Center Bar Tube to the forward Cross Tube with bolts (item 29) and washers (item 14). Torque the bolts to 20-25 in-lbs. Safety- wire the two bolts together. 6. Assemble the Cargo Hook onto the Trunnion with Attach Bolt (item 6) and two washers (item 19), washer (item 17), nut (item 16) and cotter pin (item 18). Tighten nut to finger tight and rotate to next castellation to install cotter pin (item 18). Instructions for Continued Airworthiness 123-036-00 Revision 3 05-00-00 Page 11 08/24/15 5.2 Cargo Hook Overhaul Schedule Time Between Overhaul (TBO): 1000 hours of external load operations or 5 years, whichever comes first. Hours of external load operations should be interpreted to be (1) anything is attached to the primary cargo hook (whether or not a useful load is being transported) and (2) the aircraft is flying. If these conditions are NOT met, time does NOT need to be tracked. Overhaul the cargo hook per component maintenance manual 122-015-00. Contact Onboard Systems for guidance in locating authorized overhaul facilities. Instructions for Continued Airworthiness 123-036-00 05-00-00 Page 12 Revision 0 05/05/11 THIS PAGE INTENTIONALLY LEFT BLANK Instructions for Continued Airworthiness 123-036-00 Revision 0 11-00-00 Page 1 05/05/11 Section 11 Placards and Markings 11.1 Placards The Cargo Hook Kits include the following placards shown in Table 11.1.1. Table 11.1.1 Cargo Hook Suspension System Placards Placard part number and appearance Location P/N 215-256-00 or P/N 215-258-00 Depending on model on which the kit is installed. The A109E uses 215-258-00 and A119 and AW119 MkII use P/N 215-256-00. Located on the belly of the aircraft near the cargo hook suspension or on the cargo hook suspension frame in clear view of the ground support personnel. (text is engraved on manual release lever P/N 290-906- 00 shown) Located on the release lever of the hydraulic release master cylinder assembly. Master cylinder assembly is located on the cyclic. Instructions for Continued Airworthiness 123-036-00 11-00-00 Page 2 Revision 0 05/05/11 11.1 Placards continued Table 11.1.1 Cargo Hook Suspension System Placards continued Placard part number and appearance Location P/N 215-255-00 CARRYING OF EXTERNAL LOADS In the cockpit in a location visible to the pilot. Instructions for Continued Airworthiness 123-036-00 Revision 4 12-00-00 Page 1 10/10/17 Section 12 Servicing 12.1 Maintenance of the Hydraulic Release System The system is filled with fluid at installation and does not consume fluid unless it leaks out. If any leakage is detected, the fluid level should be immediately checked. MIL-PRF-5606 and MIL-PRF-87257 fluids are both compatible with the hydraulic system. These fluids are interchangeable and miscible. To check the fluid level: 1. Position the collective against the lower stop. 2. The Master Cylinder features a transparent lid through which the fluid level can be checked. Hydraulic fluid must be visible over the baffle surface (see Figure 12.1.1). 3. Remove lid and add hydraulic fluid as required until the baffle surface is partially or fully submerged. Figure 12.1.1 Checking Hydraulic Fluid Level Baffle surface If leakage is noted around any plumbing fittings, the fittings may be tightened until the leakage quits. If leakage is noted around the pistons in either the master or slave cylinders the leaking cylinder must be repaired. See the instructions for repair in this section. Instructions for Continued Airworthiness 123-036-00 12-00-00 Page 2 Revision 4 10/10/17 12.1 Maintenance of the Hydraulic Release System continued Master Cylinder Repair If fluid is leaking around the piston, the only repair is to remove and replace the cup seal and O-ring. The master cylinder must be disassembled, inspected and then re- assembled with new seals. Disassembly: 1. Remove snap ring. Use caution when removing snap ring since the piston is spring loaded against the washer and snap ring. The piston will pop out of the housing when the snap ring is removed. Use the lever to put pressure on the piston while removing snap ring. 2. Loosen the set screw and disconnect barrel nut on lever from the push rod. See Figure 12.1.2. 3. Remove the piston and spring. See Figure 12.1.3 for parts breakdown. 4. Inspect the master cylinder bore for scratches. If any scratches or gouges are visible in the bore, the master cylinder must be replaced. Re-assembly: 1. If the bore condition is acceptable, replace the lip seal and O-ring on the piston assembly. Maintain orientation as shown in Figure 12.1.4. Stretch seals over piston into grooves. 2. To assemble the master cylinder, lubricate the piston seals and cylinder bore generously with hydraulic fluid. 3. Place the spring in the cylinder bore. 4. Pass the push rod through the washer. 5. Thread the push rod into the barrel nut until approximately 1/16” of thread is visible through the opposite side of the barrel nut. 6. Insert the small spring into the piston assembly and insert the piston assembly into the master cylinder bore using a firm rocking motion. 7. Use the lever to compress the spring and hold the piston in place. 8. Use snap ring pliers to install the snap ring. 9. Secure push rod threads by tightening set screw. Figure 12.1.2 Master Cylinder Lever Disconnect Push Rod Barrel Nut Snap Ring Washer Set Screw Turn until Barrel Nut is disconnected from push rod. Instructions for Continued Airworthiness 123-036-00 Revision 1 12-00-00 Page 3 12/16/11 12.1 Maintenance of the Hydraulic Release System continued Master Cylinder Repair continued Figure 12.1.3 Master Cylinder Piston Removal Spring Piston Assembly Spring Push Rod Washer Snap Ring Figure 12.1.4 Master Cylinder Piston Seal Orientation Cup Seal (P/N 556-048-00) Note seal orientation. O-ring (P/N 556-047-00) Piston (P/N 290-814-01) Slave Cylinder Repair If the slave cylinder is leaking oil around the piston rod, the only repair possible is to remove and replace the quad ring or cup seal (earlier production units of the slave cylinder assembly used a cup seal instead of the quad ring). Disassembly: 1. Remove cap, piston, and seal (see Figure 12.1.5). 2. Inspect bore of slave cylinder for scratches or gouges. If any are present the assembly must be replaced. 3. Remove bushing in cap by pressing it out. 4. Remove quad ring (or cup seal) by stretching it over the piston. Re-assembly: 1. Press new bushing into cap. 2. Stretch new quad ring over piston into groove. 3. Clean and lubricate cylinder bore and piston seal with hydraulic fluid. 4. Insert piston into cylinder taking care not to damage edges of quad ring. 5. Screw on cap and torque to 50-60 in-lbs. Instructions for Continued Airworthiness 123-036-00 12-00-00 Page 4 Revision 1 12/16/11 12.1 Maintenance of the Hydraulic Release System continued Slave Cylinder Repair continued Figure 12.1.5 Slave Cylinder Piston Removal Piston (P/N 290-805-00) Quad Ring (P/N 556-097-00) Cylinder Cap (P/N 290-802-00) Bushing (P/N 517-040-00) Instructions for Continued Airworthiness 123-036-00 Revision 4 12-00-00 Page 5 10/10/17 12.2 Bleeding Hydraulic System Filling and bleeding the hydraulic release system is most easily accomplished on the bench, prior to installation on the aircraft. This process may also be accomplished after the system is installed. Filling and bleeding requires two persons, one to inject hydraulic fluid through the system and the other to observe the reservoir. Following is the procedure: 1. Obtain the hydraulic hook bleed kit, 212-014-02. This kit consists of 2 ounces of MIL-PRF-87257 fluid, a syringe, a female barb fitting, a length of PVC tubing, and a bleed adapter fitting. The bleed kit is included in new hydraulic hook kits. Assemble the bleed kit by pressing the fittings into the tubing and threading the female barb fitting into the syringe. 2. If the system is already installed on the aircraft, place an absorbent towel under the master cylinder. If the master cylinder is not installed on the aircraft, lightly clamp the master cylinder in a vise to hold it in a vertical position and position the slave cylinder so that its level is below the level of the master cylinder. Use best shop practices to keep foreign material out of the hydraulic system. FOD will plug orifices, damage seals and/or scratch sealing surfaces necessitating system rebuild. Use only clean hydraulic fluid from sealed containers. 3. Connect the master cylinder assembly to the slave cylinder assembly if not already done. If filling or bleeding on the bench, as much as possible, arrange the hoses uncoiled, straight and running uphill. See Figure 12.2.1. Figure 12.2.1 Hose Arrangement Good Hose Arrangement Poor Hose Arrangement Instructions for Continued Airworthiness 123-036-00 12-00-00 Page 6 Revision 4 10/10/17 12.2 Bleeding Hydraulic System continued 4. Remove screws, reservoir lid, and baffle from the master cylinder reservoir as shown in Figure 12.2.2. Figure 12.2.2 Reservoir Disassembly Screw (2) Reservoir Lid Baffle 5. Remove the screw and stat-o-seal on the slave cylinder, see Figure 12.2.3. Figure 12.2.3 Screw and Stat-o-seal Removal Stat-o-seal Screw Slave Cylinder Assembly 6. Fill a syringe with approximately 35 cc of hydraulic fluid. Screw the end of the syringe into the screw hole on the slave cylinder to create a tight seal. See Figure 12.2.4. 7. While observing the reservoir, slowly push on the syringe plunger to force fluid through the slave cylinder, hydraulic hose, and up to the master cylinder reservoir. There will be some resistance during filling—this is normal. Injecting the fluid into the system too rapidly may cause the fluid to spray up and out of the master cylinder reservoir. Wear safety glasses when observing fluid reservoir while filling. Instructions for Continued Airworthiness 123-036-00 Revision 0 12-00-00 Page 7 05/05/11 12.2 Bleeding Hydraulic System continued Figure 12.2.4 Injecting Hydraulic Fluid Bleed Adapter PVC tubing Female X Barb Fitting Syringe 8. Continue to force fluid into the master cylinder reservoir until the reservoir is approximately half full. If bleeding an already filled system, you may need to draw fluid from the master cylinder reservoir during this step to prevent overflow. 9. Remove the syringe from the screw hole. Re-install the stat-o-seal (P/N 510- 496-00) and screw (P/N 510-525-00), see Figure 12.2.3. 10. Allow the system to rest for several minutes. This will allow any air to rise through the system. 11. Very slowly pull the release lever on the master cylinder and watch for bubbles. If bubbles are observed rising within the reservoir, continue to cycle the lever until there are no more. Actuating the lever releases trapped air in the system. Pull the lever very slowly! When the reservoir is not baffled and capped, a hard pull will cause fluid to erupt over the edge of the reservoir. 12. Check the system for air by actuating the lever firmly until it bottoms out. Check the push rod position (see Figure 12.2.5). If the green area on the push rod is visible, proceed to step 13. If the green on the push rod is not visible with the lever completely pulled, the system has too much air in it and needs further bleeding. To do this, repeat steps 5 – 11. Instructions for Continued Airworthiness 123-036-00 12-00-00 Page 8 Revision 0 05/05/11 12.2 Bleeding Hydraulic System continued Figure 12.2.5 Checking System for Air Some of the green ring must be visible. Release Lever Master Cylinder Reservoir 13. After the system is properly bled, verify that the reservoir is approximately half full of hydraulic fluid. Fluid should be visible above the baffle. 14. Re-install the baffle, and the reservoir lid. 15. Check the system for proper operation. Fully actuate the release lever. The hook must open and the lever must have a firm feel. 16. Disassemble and thoroughly clean the syringe with isopropyl alcohol. Allow it to dry. Not cleaning the syringe will render it unusable. Reassemble and store for next use. Instructions for Continued Airworthiness 123-036-00 Revision 0 12-00-00 Page 9 05/05/11 12.3 Lubrication Information Lubrication of Cargo Hook Suspension system is required every 500 hours of hook operation. To obtain maximum life under severe duty conditions such as logging or seismic work, it is recommended to lubricate the suspension system approximately every 250 hours. Lubricate the Cargo Hook attach bolt (or Pin Load Cell shoulder if load weigh kit is installed) as noted in Figure 12.3.1. Recommended lubricants are AeroShell 17, MIL-PRF-21164 or Mobilgrease 28, MIL-PRF-81322. Re-assemble the attach hardware and tighten the nut to finger tight and then rotate nut to next castellation to install the cotter pin. Figure 12.3.1 Lubrication Points Lubricate Attach Bolt shoulder. Lubricate quick release pin shanks. Instructions for Continued Airworthiness 123-036-00 12-00-00 Page 10 Revision 0 05/05/11 12.3 Lubrication Information, continued Hook Corrosion Prevention In marine or other corrosive environments the life of the hook can be increased by periodically treating with a corrosion preventative compound such as ACF-50. Spray exterior of hook with corrosion preventative compound and wipe off excess with a rag. The amount and frequency of application will vary depending on climate. In dry dusty environments it is not recommended to treat for corrosion since the oily residue on the inside of the hook that cannot be wiped off could attract and retain dust and sand. In addition corrosion is not likely to be a problem in these conditions. For offshore or coastal operations, treatment should be done every two weeks.