Cargo Hook Kit Owner's Manual

mechanism. In an emergency, release can be achieved by operating a mechanical release lever. A manual release cable attached to the lever operates the internal mechanism of the Cargo Hook to unlatch the load beam. The load can also be released by the actuation of a lever located on the side of the cargo hook. This page intentionally left blank. Installation Instructions 2-1 Section 2 Installation Instructions These procedures are provided for the benefit of experienced aircraft maintenance facilities capable of carrying out the procedures. They must not be attempted by those lacking the necessary expertise. Cargo Hook Removal Remove the Schweizer supplied Cargo Hook from the aircraft by disconnecting the electrical release cable from the belly mounted bulk- head type connector. Disconnect the manual release cable from the cargo hook. Remove the NAS1305-26D bolt, AN310-5 nut and cotter pin used to attach the Cargo Hook to the suspension system mounting brackets. Remove the cargo hook from the mounting brackets. Also at this time remove the NAS1304-24 upper bolt, NAS43HT4-81 spacer and MS21042-4 nut from the suspension system mounting brackets. Cargo Hook Installation Verify that the part number of the cargo hook removed is a Breeze-Eastern 2A20B P/N 17149-4. If it is not, do not attempt to use the new cargo hook unless compatibility is determined. Inspect the suspension system mounting brackets and attaching hardware to insure that all components are in serviceable condition. Install the new Cargo Hook to the existing Schweizer suspension system mounting brackets using the hardware supplied with the new hook, as illustrated in Figure 2-1. The cargo hook load beam is to point aft. 2-2 Installation Instructions Cargo Hook Installation, continued Figure 2-1 Attach Hardware Installation 510-318-00 BOLT (NAS6604-27) 517-029-00 SPACER (NAS43HT4-93) 510-100-00 WASHER (AN960-416L) 510-227-00 NUT (MS21042L4) 510-319-00 BOLT (NAS6605D29) 510-239-00 WASHER (NAS1149F0532P) 2 PLCS 528-010-00 CARGO HOOK 290-548-00 BUSHING 510-320-00 NUT (SN310-5) 510-115-00 COTTER PIN (MS24665-136) VIEW A-A A A Installation Instructions 2-3 Cargo Hook Installation, continued Connect the manual release cable to the Cargo Hook by first removing the cargo hook manual release cover. Locate the swaged end of the manual release cable assembly, the other end is the cable adjuster. Thread the swaged end of the manual release cable all the way into the hook and tighten against the hook. Place the cable ball end fitting into the hook manual release fork fitting as illustrated in Figure 2-2. Connect the Cargo Hook electrical release cable harness connector to the cargo hook and the belly mounted bulk-head receptacle and safety wire the connector. Listed below is the pin out for the cargo hook and the bulkhead connector. Cargo Hook Connector Bulkhead Connector Pin Function Pin Function A Ground A Power B Power B Ground C Not used Figure 2-2 Manual Release Cable Rig 2-4 Installation Instructions Secure the Release Cables Un-commanded cargo hook release will happen if the manual and electrical release cables are improperly restrained. The cables must not be the stops that prevent the Cargo Hook from swinging freely in all directions. If the Cargo Hook loads cause the hook to strain against the manual release cable the swaged end of the cable may separate allowing the inner cable to activate the cargo hook manual release mechanism. The result is an un-commanded release. Ensure that no combination of cyclic stick or Cargo Hook position is restrained by the manual or electrical release cables. Figure 2-3 Un-commanded Release From Incorrectly Secured Cable Installation Instructions 2-5 Installation Check-Out After installation of the Cargo Hook, perform the following functional checks. 1. Swing the installed Cargo Hook Ensure that the manual release cable assembly and the electrical release cable have enough slack to allow full swing of the suspension assembly without straining or damaging the cables. The cables must not be the stops that prevent the Cargo Hook from swinging freely in all directions. 2. Apply 10 - 20 pounds to the cargo hook load beam and squeeze the lever operated cargo hook mechanical release, the cargo hook should release. 3. Close the cargo hook release circuit breaker and position the battery switch to the ON position. Apply 10 - 20 pounds to the cargo hook load beam and depress the cargo hook electrical release button, the cargo hook should release. 4. See the Schweizer service instructions for your specific helicopter model for additional installation instructions. Component Weights The weight of the cargo hook components are listed in Table 2-1. Table 2-1 Component Weight Item Weight lbs (kgs) Cargo Hook 3.0 (1.36) Electrical Release Cable 0.5 (.23) Paper Work Remove the Flight Manual Supplement from the back of this manual and place it into the Rotorcraft Flight Manual. In the US, fill in FAA form 337 for the initial installation. This procedure may vary in different countries. Make the appropriate aircraft log book entry. This page intentionally left blank. Operation Instructions 3-1 Section 3 Operation Instructions Operating Procedures Prior to each job perform the following: 1. Ensure that the Cargo Hook has been properly installed and that the manual and electrical release cables do not limit the movement of the hook. 2. Be completely familiar with this manual, particularly the Cargo Hook rigging section. 3. Be completely familiar with all Schweizer cargo hook operating instructions. 4. Activate the electrical system and press the release button to ensure the cargo hook electrical release is operating correctly. The mechanism should operate smoothly and the Cargo Hook must relatch after release. If the hook does not relatch do not use the unit until the difficulty is resolved. The release solenoid is intended to be energized only intermittently. Depressing the electrical release button continuously in excess of 20 sec. will cause the release solenoid to overheat, possibly causing permanent damage. 5. Activate the release lever assembly located on the cyclic stick to test the cargo hook manual release mechanism. The mechanism should operate smoothly and the Cargo Hook must relatch after release. If the hook does not relatch do not use the unit until the difficulty is resolved. See the Cargo Hook Service Manual 122-001-00 and the aircraft’s service instructions that cover the original Cargo Hook installation for additional instructions. 3-2 Operation Instructions Cargo Hook Rigging Extreme care must be exercised in rigging a load to the Cargo Hook. If the load ring is too big it may work its way around the end of the load beam and be supported for a time on the keeper and then fall free. If the load ring is too small it may jam itself against the load beam during an attempted release. The following illustrations show recommended configurations and potential difficulties that must be avoided. The examples shown are not intended to represent all problem possibilities. It is the responsibility of the operator to assure the hook will function properly with the rigging. Operation Instructions 3-3 Cargo Hook Rigging, continued Figure 3-1 Examples of Correct and Incorrect Cargo Hook Rigging Se c onda ry R ing or Sha c kle 5/8" M a x. c ros s s e c tion Loa d Prima ry R ing In co rrect Rig g in g In co rrect Rig g in g Co rrect Rig g in g M ultiple R ings on Loa d B e a m M ultiple R ings on Prima ry R ing 1.50"Prima ry R ing I.D . 1.87" 3-4 Operation Instructions Un-Commanded Release Due to Too Large of a Load Ring Load rings that are too large will cause an un- commanded release. The ring will flip over the end of the load beam and flip the keeper up and then fall free. Only correctly sized load rings must be used. See examples below. Figure 3-2 Un-Commanded Release Due to Too Large of a Load Ring Load Ring flips over the Load Beam and gyrates. The flip over often occurs with long line operations during landings and take offs. Load Ring moves inward and bears against the keeper The Keeper is forced to rotate allowing the Ring to slip off Operation Instructions 3-5 Load Hang-Up Due to Too Small of a Load Ring or Multiple Load Rings Load rings that are too small or multiple load rings will hang on the load beam when the load is released. Only correctly sized load rings must be used. See examples below. Figure 3-3 Load Hang-Up Due to Too Small a Load Ring or Multiple Load Rings Jammed Ring Sling Load Sling Load Jammed Rings Load Hang-Up Due to Multiple Rings on Load Beam 3-6 Operation Instructions Un-Commanded Release Due to Nylon Type Straps Nylon type straps (or similar material) must not be used directly on the cargo hook load beam as they have a tendency to creep under the keeper and fall free. If nylon straps must be used they should be first attached to a correctly sized primary ring. Only the primary ring should be in contact with the cargo hook load beam. See examples below. Figure 3-4 Un-Commanded Release Due to Nylon Type Straps Operation Instructions 3-7 Un-Commanded Release Due to Cable or Rope Type Straps Cable or rope type straps must not be used directly on the cargo hook load beam. Their braided eyes will work around the end of the load beam and fall free. If cable or rope is used they should be first attached to a correctly sized primary ring. Only the primary ring should be in contact with the cargo hook load beam. See examples below. Figure 3-5 Un-Commanded Release Due to Cable or Rope Type Straps This page intentionally left blank. Maintenance 4-1 Section 4 Maintenance Refer to Component Maintenance Manual 122-001-00 for detailed maintenance information for the Cargo Hook. Inspection The inspection of the Cargo Hook Kit shall be in accordance with the table below. Table 4-1 Inspection Part Number Daily Check At Overhaul Interval* 528-010-04 Cargo Hook Refer to Service Manual 122-001-00. Refer to Service Manual 122-001-00. 290-364-00 Bushing Visually check for excessive wear. Inspect to the requirements of this manual (see below) at cargo hook overhaul interval. 290-548-00 Adapter Bushing Visually check for excessive wear. Inspect to the requirements of this manual (see below) at cargo hook overhaul interval. 270-093-00 Electrical Release Wire Harness 1. Check for security of attachment, damaged wires and connectors. Replace if damaged. Most system problems will be the result of damaged wires. Keep the cables clean and ensure that they are not chafing. Replace if the insulation or shield is damaged. All fasteners 1. Inspect for cracks, excessive wear and security or attachment. If worn excessively or cracked, replace part. Replace fasteners at cargo hook overhaul interval. * Refer to Service Manual 122-001-00 for overhaul interval for the Cargo Hook. Bushing Overhaul Inspect the bushing and bearing surfaces for wear and corrosion. Pitting, corrosion or excessive wear is cause for rejection. Maximum permissible bushing clearance is .010” on diameter. 4-2 Maintenance Instructions for Returning Equipment to the Factory If an Onboard Systems product must be returned to the factory for any reason (including returns, service, repairs, overhaul, etc.) obtain an RMA number before shipping your return. An RMA number is required for all equipment returns. • To obtain an RMA, please use one of the listed methods. • Contact Technical Support by phone or e-mail (Techhelp@OnboardSystems.com). • Generate an RMA number at our website: http://www.onboardsystems.com/rma.php • After you have obtained the RMA number, please be sure to: • Package the component carefully to ensure safe transit. • Write the RMA number on the outside of the box or on the mailing label. • Include the RMA number and reason for the return on your purchase or work order. • Include your name, address, phone and fax number and email (as applicable). • Return the components freight, cartage, insurance and customs prepaid to: Onboard Systems International 13915 NW 3rd Court Vancouver, Washington 98685 USA Phone: 360-546-3072 Certification 5-1 Section 5 Certification STC 5-2 Certification Canadian STC Canadian Approval was granted on September 17, 1999 by familiarization of FAA STC SR00711SE. Refer to the following letter. Certification 5-3 EASA STC 5-4 Certification EASA STC continued Page 1 Rotorcraft Flight Manual Supplement Cargo Hook Document Number 120-081-00 FAA APPROVED ROTORCRAFT FLIGHT MANUAL SUPPLEMENT Schweizer 269C R/N __________________ S/N __________________ Page 2 Rotorcraft Flight Manual Supplement Cargo Hook Document Number 120-081-00 INTRODUCTION This supplement must be attached to the appropriate approved Schweizer Rotorcraft Flight Manual when an Onboard Systems 200-244-00 Cargo Hook Kit is installed in accordance with Supplemental Type Certificate (STC) NO. SR00711SE. The information contained herein supplements or supersedes the basic manual only in those areas listed herein. For limitations, procedures and performance information not contained in this supplement, consult the basic Rotorcraft Flight Manual. I. LIMITATIONS The basic Flight Manual remains applicable. When an Onboard Systems 200-244-00 Cargo Hook Kit is installed, the following placard applies: • Mounted on bottom of Cargo Hook. II. PERFORMANCE The basic Flight Manual remains applicable. III. PROCEDURES Before each Cargo Hook use perform the following procedures. If the procedures are not successful do not use the equipment until the problem has been corrected. 1. Inspect all mounting fasteners to ensure that they are tight. 2. Visually inspect the electrical connector for loose or damaged pins and sockets. 3. Operate the keeper manually and check that it snaps back to its normal position on the load beam. 4. Inspect the case and covers for cracks and damage. 5. Inspect the load beam for gouges and cracks. 6. Cycle the manual release mechanisms to ensure proper operation. 7. Cycle the electrical release mechanisms to ensure proper operation. Page 3 Rotorcraft Flight Manual Supplement Cargo Hook Document Number 120-081-00 III. PROCEDURES, continued Cargo Hook Rigging Extreme care must be exercised in rigging a load to the Cargo Hook. If the load ring is too big it may work its way around the end of the load beam and be supported for a time on the keeper and then fall free. If the load ring is too small it may jam itself against the load beam during an attempted release. The following illustrations show recommended configurations and potential difficulties that must be avoided. WARNING: The examples shown are not intended to represent all problem possibilities. It is the responsibility of the operator to assure the hook will function properly with the rigging. Figure 1 Examples of correct and incorrect cargo hook rigging Se c onda ry R ing or Sha c kle 5/8" M a x. c ros s s e c tion Loa d Prima ry R ing In co rrect Rig g in g In co rrect Rig g in g Co rrect Rig g in g M ultiple R ings on Loa d B e a m M ultiple R ings on Prima ry R ing 1.50"Prima ry R ing I.D . 1.87" Page 4 Rotorcraft Flight Manual Supplement Cargo Hook Document Number 120-081-00 III. PROCEDURES, continued Un-Commanded Release Due to Too Large of a Load Ring WARNING: Load rings that are too large will cause an un-commanded release. The ring will flip over the end of the load beam and flip the keeper up and then fall free. Only correctly sized load rings must be used. See examples below. Figure 2 Un-commanded release due to load rings that are too large Load Ring flips over the Load Beam and gyrates. The flip over often occurs with long line operations during landings and take offs. Load Ring moves inward and bears against the keeper The Keeper is forced to rotate allowing the Ring to slip off Page 5 Rotorcraft Flight Manual Supplement Cargo Hook Document Number 120-081-00 III. PROCEDURES, continued Load Hang-Up Due to Too Small of a Load Ring or Multiple Load Rings WARNING: Load rings that are too small or multiple load rings will hang on the load beam when the load is released. Only correctly sized load rings must be used. See examples below. Figure 3 Load hang-up due to load rings that are too small or using multiple load rings Jammed Ring Sling Load Sling Load Jammed Rings Load Hang-Up Due to Multiple Rings on Load Beam Page 6 Rotorcraft Flight Manual Supplement Cargo Hook Document Number 120-081-00 III. PROCEDURES, continued Un-Commanded Release Due to Nylon Type Straps WARNING: Nylon type straps (or similar material) must not be used directly on the cargo hook load beam as they have a tendency to creep under the keeper and fall free. If nylon straps must be used they should first be attached to a correctly sized primary ring. Only the primary ring should be in contact with the cargo hook load beam. See examples below. Figure 4 Un-commanded release due to nylon type straps Page 7 Rotorcraft Flight Manual Supplement Cargo Hook Document Number 120-081-00 III. PROCEDURES, continued Un-Commanded Release Due to Cable or Rope Type Straps WARNING: Cable or rope type straps must not be used directly on the cargo hook load beam. Their braided eyes will work around the end of the load beam and fall free. If cable or rope is used they should first be attached to a correctly sized primary ring. Only the primary ring should be in contact with the cargo hook load beam. See examples below. Figure 5 Un-commanded release due to cable or rope type straps