Cargo Hook 120-044-00
Cargo Hook 120-044-00
Cargo Hook 120-044-00
Owner's Manual
8 10-30-00 4-7 to 4-10 Rolled dash number on items 33, 80, 82, and 84.
Updated Exploded view drawing.
9 01/08/02 4-9 Added information about items 95-99
10 9/17/02 Title, 4-11 Factory address change.
11 12/10/03 4-5 Corrected conflicting statements regarding overhaul
periods specified on pages 4-1 and 4-5. Changed
statement on 4-5 to “every three years” to match
overhaul period specified on page 4-1.
12 03/13/06 4-8 Corrected part number call-out on page 4-8.
13 04/03/06 4-7 Added solenoid assembly part number 650-021-01 for
spare part usage.
14 10/01/07 TOC, i, Added explanation of warnings, cautions and notes.
Section 1, Updated warnings, cautions and notes throughout.
2-4, 2-7, Changed “daily inspection” to “daily check” in section
Section 3, 4. Updated magnetic particle inspection and penetrant
4-2 & 4-6 inspection specifications.
15 02/06/09 4-7 to 4-9 Added Overhaul Kit P/N 212-016-00 to Illustrated
Parts List.
16 07/16/09 4-8 Corrected Mfg. P/N 650-050-01 to 650-050-00
17 3/2/10 4-1 Changed overhaul frequency criteria.
18 10/06/10 1-2, 4-9 Updated warning, caution and note symbols and
descriptions throughout. Added P/N 215-260-00 to
overhaul kit.
19 03/12/12 4-5 Removed word “Major” from first paragraph.
20 06/25/14 4-1, 4-9, 4- Corrected P/N 650-051-01 to P/N 650-051-00.
11 Updated Return to Factory section. Updated “hours of
external load operations” definition.
21 10/18/16 4-7, 4-9 Updated Illustrated Parts List including addition of
alternatives to P/N 510-214-00, 510-108-00, 510-109-
00.
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CONTENTS
Section 1 General Information
Introduction, 1-1
Explanation of Signal Words and Symbols, 1-2
Bill of Materials, 1-3
Inspection, 1-3
Theory of Operation, 1-4
Section 4 Maintenance
Storage Instructions, 4-1
Shelf Life, 4-1
Overhaul Periods, 4-1
Cargo Hook Inspection, 4-2
Cargo Hook Preventive Maintenance, 4-3
Trouble Shooting, 4-4
Repair, 4-5
Acceptance Test Procedures, 4-5
Illustrated Parts Breakdown, 4-7
Cargo Hook Exploded View, 4-10
Instructions for Returning a System to the Factory, 4-11
i
CONTENTS, continued
Section 5 Assembly & Disassembly Procedures
Introduction, 5-1
Disassembly Procedures, 5-1
Assembly Procedures, 5-3
Section 6 Certification
STC, 6-1
Eligibility List, 6-2
STA, 6-3
Rotorcraft Flight Manual Supplement
Figures
2-1 Suspension System Detail Illustration, 2-2
2-2 Suspension System Manual Release Arrangement, 2-5
3-1 Examples of Correct and Incorrect Cargo Hook Rigging, 3-2
3-2 Un-Commanded Release Due to Too Large of a Load Ring, 3-3
3-3 Load Hang-Up Due to Too Small or Multiple Load Rings, 3-4
3-4 Un-Commanded Release Due to Nylon Type Straps, 3-5
3-5 Un-Commanded Release Due to Cable or Rope Type Straps, 3-6
4-1 Cargo Hook Detail Parts, 4-10
Tables
4-1 Inspection, 4-2
4-2 Detail Parts Inspection, 4-3
4-3 Trouble Shooting, 4-4
4-4 Illustrated Parts Breakdown, 4-7
5-1 Cargo Hook Compatibility (Ref.), 5-1
ii
Section 1
General Information
Introduction
The 528-002-00 (painted gray) or 528-002-01 (painted green) are
approved for installation on the following Bell Helicopter Cargo Hook
Suspension Systems.
204-072-915-1 204-072-915-17
204-072-915-3 204-072-915-25
204-072-915-5 204-072-915-101
204-072-915-7 204-072-915-103
204-072-915-9
204-072-915-11
The 528-002 series Cargo Hooks should not be used as a replacement for
the Breeze-Eastern SP-7109-51 hook on the 204-072-915-15 suspension
system.
The 528-002 series Cargo Hooks are suitable as a replacement for the
following cargo hooks when used on one of the applicable Bell Helicopter
Cargo Hook Suspension Systems listed above.
Inspection
Inspect the Cargo Hook for evidence of damage, corrosion and security of
lock wire and fasteners. If damage is evident, do not use the unit until it
has been repaired.
Measure the clearance of the lower control cable ball terminal to the cargo
hook lever as shown in the previous section. Measurement shall be 0.12 to
0.18 inches when hook is rigged and load beam is latched. If adjustment is
made to the stop bolt in order to obtain proper clearance, recheck
adjustment of control cable and conduit.
With the cargo hook release pedal against the FORWARD stop, check for
the following conditions:
Ensure that the spring assembly 204-070-998, does not bottom. If the
spring assembly should bottom, return the cargo hook pedal to the aft
stop and check control cable tension. Cable tension should be 20 to 24
pounds.
Check the operation of the mechanical release with at least 20 pounds
load on the cargo hook load beam.
Ensure the swing arm is full up. Ensure lever is not stopped by the
bottom end of the control cable outer housing.
Ensure cargo hook load beam unlocks.
Release the cargo hook pedal and ensure that both the upper and lower
manual release cables return to the locking position.
See the Bell Helicopter service instructions that cover the original
cargo hook suspension system for additional instructions.
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.
Correct Rigging
Load
Keeper Beam
Load
Load Load
Keeper Beam Keeper Beam
Jammed Ring
Sling Load
Jammed Rings
Sling Load
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.
Shelf Life
Provided the unit has been packed by the appropriate method, the unit can
be stored indefinitely. The primary concern during storage is corrosion.
When unit is returned to service, visually inspect for corrosion. If no
corrosion is noted the unit may be installed and checked for proper
function per page 2-7. If evidence of corrosion is present, follow overhaul
instructions for disassembly, inspection of parts and acceptance testing.
Overhaul Periods
Time Between Overhaul (TBO): 1000 hours of external load operations or
5 years, whichever is less.
Maintenance 4-1
Cargo Hook Inspection
The inspection of the Cargo Hook shall be in accordance with the tables
below.
Table 4-1 Inspection
4-2 Maintenance
Cargo Hook Inspection, continued
Table 4-2 Detail Parts Inspection
Maintenance 4-3
Trouble Shooting
Table 4-3 Trouble Shooting
4-4 Maintenance
Repair
It is recommended that only minor repairs be attempted by the operator.
The Cargo Hook should be returned to the factory for overhaul or when
the Cargo Hook is in need of repair.
Maintenance 4-5
Acceptance Test Procedures, continued
Press the release switch. The load beam should release the load and
relatch.
4-6 Maintenance
Illustrated Parts Breakdown
This section lists the assemblies and parts of the Cargo Hook.
Table 4-4 Illustrated Parts Breakdown (Ref. Figure 4-1)
Overhaul Kit
ITEM PART NO. DESCRIPTION UNITS / SYSTEM
P/N 212-016-00
1* 528-002- Cargo Hook -- --
2* 650-001-01 . Case and cover assembly 1 -
3 510-212-00 Screw, AN23-23A 2 2
4 510-095-00 Washer, AN960-10 2 2
5 510-213-00 Nut, AN364-1032 2 2
6** 510-214-00 Bolt, AN27-36 1 1**
7** 510-108-00 Nut, AN320-7 1 1**
8** 510-109-00 Washer, AN960-716L 1 1**
9 510-067-00 Cotter Pin, AN380-3-4 1 1
10 Not used - -
{11*} 650-002-00 . . Case Assembly 1 -
{12} 650-003-00 . . . Case 1 -
13 650-004-00 . . . Support, spring 1 -
14 Not used - -
15 650-006-00 . . . Pin stop 1 -
16 650-007-00 . . . Post, microswitch 3 -
17 650-008-00 . . . Post, microswitch 2 -
18 650-009-00 . . . Pin, switch actuator 1 -
19 650-010-00 . . . Dowel pin 2 -
20 650-011-00 . . . Dowel pin 1 -
21 650-012-00 . . . Pin, shoulder 1 -
22 Not used - -
{23*} 650-013-00 . . Cover Assembly 1 -
{24} 650-014-00 . . . Cover 1 -
25 650-015-00 . . . Shaft support 1 --
26 Not used - -
27 650-017-00 . Lever, latch and shaft assembly 1 -
28 Not used - -
29 Not used - -
30 Not used - -
31 Not used - -
32 Not used - -
33* 650-018-01 . Cover assembly, solenoid 1 -
34 510-215-00 Screw, AN 500A8-7 3 3
35 290-270-00 . . Cover 1 -
36 410-132-00 . . Connector, MS 3102E-16S-5P 1 -
37 510-216-00 Screw, AN 500A4-7 4 4
38 Not used - -
39 Not used - -
Maintenance 4-7
Illustrated Parts Breakdown, continued
Table 4-4 Illustrated Parts Breakdown, continued
Overhaul Kit
ITEM PART NO. DESCRIPTION UNITS / SYSTEM
P/N 212-016-00
40*** 650-021-00 . Solenoid assembly 1 -
41 650-022-00 . Manual release arm assembly 1 -
42 Not used - -
43 Not used - -
44 650-025-00 . . Screw BS A218/A 1 -
45 650-026-00 . . Washer BS SP11A 1 -
46 650-027-00 . Load beam return assy, arm, pin & 1 -
trunnion
47 Not used - -
48 Not used - -
49 510-217-00 1/8” x 5/8” long, roll pin 1 1
50 Not used - -
51 Not used - -
52 290-269-00 . Plate assembly, pivot, LH 1 -
53 290-268-00 . Plate assembly, pivot,RH 1 -
54 650-034-00 . Spring, keeper, LH 1 1
55 650-035-00 . Spring, keeper, RH 1 1
56 650-036-00 . Beam, load 1 -
57 650-037-00 . Keeper, load beam 1 -
58 650-038-00 . Retainer, solenoid 1 -
59 650-039-00 . Plunger, trunnion 1 -
60 650-040-00 . Spring, trunnion 1 1
61 Not used - -
62 650-017-00 . Latch, Lever, Shaft & Arm Assembly 1 -
63 Not used - -
64 510-218-00 3/32” x 3/8” long, roll pin 1 -
65 650-043-00 Grooved bushing 1 -
66 650-058-00 . Solenoid link 1 -
67 650-059-00 . Solenoid linkage pin 1 -
68 650-060-00 . Solenoid linkage pin 2 -
69 650-044-00 . Indicator, release 1 -
70 650-045-00 . Cover, release 1 -
71 Not used - -
72 650-046-00 . Spacer, release cover 3 -
73 650-047-00 Screw 3 3
74 650-048-00 . Spring release arm 1 1
75 650-049-00 . Spring, load beam return 1 1
76 Not used - -
77 Not used - -
78 Not used - -
79 Not used - -
* Item not illustrated
{} Indicates items not sold as spares
*** For spare part usage P/N 650-021-00 has been superseded by P/N 650-021-01. When installing 650-021-01,
item 85 bushings must be discarded. They are replaced by the bushings included with the –01 solenoid
assembly.
4-8 Maintenance
Illustrated Parts Breakdown, continued
Table 4-4 Illustrated Parts Breakdown, continued
Overhaul Kit
ITEM PART NO. DESCRIPTION UNITS / SYSTEM
P/N 212-016-00
80 650-050-00 . Bumper, beam 1 1
81 Not used - -
82 650-051-00 . Bumper, latch 1 1
83 650-052-00 . Microswitch, safety ITB1-1 1 -
84 650-053-01 . Actuator, safety switch 1 -
85 650-054-00 . Bushing, solenoid 2 -
86 Not used - -
87 650-055-00 . Rubber stop 1 1
88 650-056-00 . Data plate, modification 1 -
89 510-262-00 . Rivet 4 4
90 215-075-00 . Serial Number Plate 1 1
91 215-074-00 . Wiring Diagram Decal 1 1
92 215-096-01 . Load Ring Limits Decal 1 1
93 510-309-00 . Rivet 4 4
94**** 650-066-00 . Spring, Toggle 1 -
95 650-064-00 Screw 2 2
96 650-062-00 Actuator auxiliary switch 1 -
97 650-065-00 Spacer safety microswitch 2 2
98 650-063-00 Nut 2 2
99**** 650-069-00 Spring, toggle 1 1
100* 215-260-00 Overhaul Label - 1
* Item not illustrated
{} Indicates items not sold as spares
****Cargo Hooks S/N CAL 1135 and on, Item 99 is used. Item 99 replaces Item 63 and Item 94. (See
Service Bulletin 159-005-01 and 159-005-02)
Maintenance 4-9
Cargo Hook Exploded View
Figure 4-1 Cargo Hook Detail Parts
4-10 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.
Maintenance 4-11
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Section 5
Assembly & Disassembly Procedures
Introduction
Table 5-1 is a Cargo Hook compatibility reference chart. This table is for
reference only.
Table 5-1 Cargo Hook Compatibility (Ref.)
Onboard Bell Helicopter Bell Hook Part Breeze Hook Helicopters Used Cargo hook
Systems P/N Suspension Number Part Number On Differences
528-002- Cargo System 204-072-
Hook 915 Dash Number
Compatibility
-1, -3, -5, -7, -9, 204-072-924-1 SP7109-11 or 204B, 205 GRC,
Yes -11 SP7109-1 UH-1D, 205FRG,
205A, UH-1N
No -13 204-072-924-3 SP7109-12
No -15 204-072-924-5 SP7109-51 UH-1N (N/M) Military
wiring
-17, -25, -101, 204-072-924-7 SP7109-62 204B, 205A-1, New bolts,
Yes -103 212, 205A, UH- PMA plate
HRS, UN-1N,
205, 412, 412NB,
UH-1H
Disassembly Procedures
1. Cut and remove all lockwire.
2. Remove name plate if mutilated or illegible
3. Remove pivot plates (52 and 53) by removing bolt (6), nut (7), washer
(8) and cotter pin (9).
4. Remove pivot springs (54 and 55) note the pivot springs are left and
right, keep the pivot springs with the appropriate pivot. Remove the
keeper (57).
5. Remove bolts (3), nuts (5), and washers (4).
6. Remove connector (36) from solenoid cover (35) by removing screws
(37), disconnect lead wires from connector contact pins (36).
7. Remove solenoid cover (35) by removing screws (34).
8. Lift the cover (24) carefully from case (12)
9. Disconnect pink leadwires from terminals of switch (83). Remove
wiring including both switches from the case.
10. Remove switch actuator (84).
Certification 6-1
Eligibility List
6-2 Certification
STA
Certification 6-3
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MANUFACTURE SUPPLIED
Document Number
Rotorcraft Flight
120-044-00
Manual Supplement
Page
Cargo Hook 1
INTRODUCTION
This supplement must be attached to the appropriate approved Bell Rotorcraft Flight Manual
when an Onboard Systems 528-002-00 or 528-002-01 Cargo Hook is installed in accordance
with Supplemental Type Certificate (STC) NO. SR00277SE. 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.
Ensure that the following placard is mounted in the location shown in full view of the cargo
hook operator.
WARNING. USE
LOAD RING WITH 4.0
+0.0 -1.0 INCH
NOMINAL INTERNAL
DIMENSION ONLY.
OTHER RINGS CAN
SLIP OFF OR HANG
UP.
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.
Document Number
Rotorcraft Flight
120-044-00
Manual Supplement
Page
Cargo Hook 2
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
Correct Rigging
Load
Keeper Beam
Load
Load Load
Keeper Beam Keeper Beam
Document Number
Rotorcraft Flight
120-044-00
Manual Supplement
Page
Cargo Hook 3
III. PROCEDURES, continued
Document Number
Rotorcraft Flight
120-044-00
Manual Supplement
Page
Cargo Hook 4
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
Jammed Rings
Sling Load
Document Number
Rotorcraft Flight
120-044-00
Manual Supplement
Page
Cargo Hook 5
III. PROCEDURES, continued
Document Number
Rotorcraft Flight
120-044-00
Manual Supplement
Page
Cargo Hook 6
III. PROCEDURES, continued
Document Number
Rotorcraft Flight
120-044-00
Manual Supplement
Page
Cargo Hook 7
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