122-017-00 r13 3.6kk service manual

Service Manual for

3.6KK Talon LC Keeperless Cargo Hook

Applicable P/Ns

528-027-01 528-029-00 528-029-60

Service Manual Number 122-017-00 Revision 13

March 29, 2011

13915 NW 3rd Court Vancouver Washington 98685 USA Phone: 360-546-3072 Fax: 360-546-3073 Toll Free: 800-275-0883

www.OnboardSystems.com

This page intentionally left blank.

ii

RECORD OF REVISIONS

Revision

Date

Page(s)

Reason for Revision

4 06/09/09 2-6, 4-1, 4-2 Changed manual release cover P/N from 290-898-00

to 232-376-00 (ref. Service Bulletin 159-026-00). 5 07/27/09 2-6, 2-8, 2-9, 4-

1 & 4-2 Changed manual release cover P/N from 232-376-00 to 290-898-01. Added screw P/N 510-755-00 to figure and parts list. Added safety wire instructions to cargo hook assembly procedure.

6 10/19/09 1-1, 1-2, 2-3, 2-4, 2-7, 4-3

Added electrical schematic and connector and diode assembly detail, added special tools section, changed cargo hook overhaul schedule.

7 12/04/09 4-1 & 4-2 Added rigging warning decal (P/N 215-240-00). 8 03/10/10 4-2 & 4-7 Replaced Manual Release Lever Assembly, P/N 232-

195-00 with P/N 232-195-01. Added attach hole inspection and bushing installation instructions.

9 06/02/10 1-1, 1-2, 2-9, 3-1, 3-2, 4-2, 4-3

Added cargo hook P/N 528-029-60, updated format of signal words and symbols. Clarified ATP instructions.

10 09/17/10 4-3 Replaced P/N 215-192-00 with P/N 215-253-00 on P/N 232-212-00.

11 10/06/10 2-9, 4-2 Added P/N 215-260-00 to overhaul kit. 12 12/01/10 Section 1,

Section 2, Section 4 & 5-1

Added Cargo Hook, P/N 528-027-01, to manual. Updated figure 4-1 and table 4-1 as required. Updated table 4-7.

13 03/29/11 4-3 Changed washer 510-100-00 to 510-983-00 on 528-027-01.

Current revision levels of all manuals are posted on Onboard Systems Int'l website at www.onboardsystems.com. Hard copies of all manuals are also available from the factory.

RECORD OF SERVICE BULLETINS

SB No.

Date Description

159-026-00 07/29/09 Changed manual release cover from P/N 290-898-00 to P/N

290-898-01 to prevent potential binding of manual release cable.

iii

LIST OF EFFECTIVE PAGES

Title Pages Revision Date Record of Revisions i 13 03/29/11 List of Effective Pages ii 13 03/29/11 Contents iii, iv 13 03/29/11 Section 1 - General Information 1-1 through 1-3 13 03/29/11 Section 2 - Maintenance 2-1 through 2-9 13 03/29/11 Section 3 - Acceptance Test Procedures 3-1, 3-2 13 03/29/11 Section 4 - Cargo Hook Parts 4-1 through 4-11 13 03/29/11 Section 5 - Instructions for Storage and Return to Factory 5-1 13 03/29/11

iv

CONTENTS Section 1 General Information

Introduction, 1-1 Safety Labels, 1-1 Specifications, 1-2 Theory of Operation, 1-3

Section 2 Maintenance Preventive Maintenance, 2-1 Inspection, 2-1 Trouble Shooting, 2-2 Cargo Hook Overhaul Schedule, 2-3 Special Tools, 2-3 Cargo Hook Disassembly Procedure, 2-4 Cargo Hook Overhaul Inspection, 2-5 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 Return to Factory, 5-1

General Information 1-1

Section 1 General Information Introduction

This Service Manual contains instructions for inspection, repair, overhaul and return to service of Cargo Hook P/N 528-027-01, 528-029-00 and 528-029-60. 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.

Explanation of Signal Words and Symbols The following definitions apply to the symbols used throughout this manual to draw the reader’s attention to safety instructions as well as other important messages.

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.

1-2 General Information

Specifications Table 1-1 Cargo Hook Specifications (P/N 528-027-01, 528-029-00 and P/N 528-029-60) Design load 3,600 lb. (1,632 kg.) Design ultimate strength 13,500 lb. (6,122 kg.) Electrical release capacity 9,000 lb. (4,081 kg.) Mechanical release capacity 9,000 lb. (4,081 kg.) Force required for mechanical release at 3,600 lb. 8 lb. Max.(.600” travel)

Electrical requirements 22-32 VDC 6.9 - 10 amps Minimum release load 0 pounds Unit weight 3.1 pounds (1.4 kg.) Mating electrical connector PC07A8-2P

Table 1-2 Cargo Hook Connector

Pin Function

A Ground

B Power

Earlier versions of the cargo hook were equipped with a suppression diode that can be damaged if the cargo hook electrical connections are reversed. Do not attach the electrical connector until polarity of the aircraft connector is determined to be compatible with the Cargo Hook connector listed in Table 1-2.

Figure 1-1 Cargo Hook Electrical Schematic

B

ASolenoid

DiodeConnectorPC07A-8-2P

General Information 1-3

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 manual 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 the 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 the actuation of a lever located on the side of the Cargo Hook.

Maintenance 2-1

Section 2 Maintenance Preventive Maintenance

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 salt water, monthly application of a corrosion preventative compound such as ACF-50 is required. Spray exterior of hook with corrosion preventative compound and wipe off excess.

Inspection The inspection of the Cargo Hook shall be in accordance with the table below.

Table 2-1 Inspection

Daily Check Rejection Criteria Remedy

1. Check all mounting fasteners to ensure that they are secure.

Visible loose fasteners or missing locking pins

Re-torque and reinstall locking pins per installation instructions

2. Visually check the electrical connector for looseness.

Visible loose electrical connector Re-tighten connector

3. Check the cargo hook case and covers for cracks and corrosion.

Visible cracks or corrosion. Remove cargo hook from service and replace discrepant parts per this Service Manual.

4. Check the load beam for gouges and cracks.

Visible cracks. Gouges or wear deeper than .090

Remove cargo hook from service and replace discrepant parts per this Service Manual.

5. Cycle the electrical and manual release mechanisms to ensure proper operation.

Failure to open or re-lock properly.

Remove cargo hook from service. Consult trouble-shooting chart in this manual for guidance.

2-2 Maintenance

Trouble Shooting Table 2-2 Trouble Shooting

DIFFICULTY PROBABLE CAUSE CORRECTIVE ACTION Cargo hook does not operate electrically; manual cable release operates normally.

Open electrical circuit, faulty wiring, circuit breaker, switch or solenoid

Disconnect cable from electrical connector on Cargo Hook. Using multimeter, check for 3.0 to 4.0 ohms 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.

Cargo hook does not operate electrically or manually.

Defective internal mechanism Disassemble hook and inspect internal mechanism for binding, jamming, and worn or broken parts. Repair as required.

Cargo hook operates electrically, but not manually.

Defective manual release cable Defective manual release system

Check manual release cable and cable connection to Cargo Hook. Correct any defects. Disassemble hook and inspect internal mechanism for binding, jamming, and worn or broken parts. Repair as required.

Load beam fails to relatch after being reset.

Defective latch mechanism Disassemble hook and inspect internal mechanism. Replace defective part.

Cargo hook manual release cable pull-off force exceeds 8 Lbs. (at the hook).

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 contact surfaces between latch and load beam

Circuit breaker opens when the Cargo Hook is energized.

Short in the system, faulty wiring, circuit breaker or solenoid

Check for shorts to ground. Check solenoid resistance, repair or replace defective parts.

Maintenance 2-3

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 is defined as the time in which a helicopter is engaged in external load operations. This includes time between loads on the cargo hook.

Special Tools The following special tools are required for the overhaul of the cargo hook. • Torque wrench (25 in-lbs required) • Multi-meter • Digital force gauge • 9,000 lb capacity test stand • Power supply capable of supplying 22 to 28 VDC.

2-4 Maintenance

Cargo Hook Disassembly Procedure Refer to Figure 4-1 for the Cargo Hook sub-assemblies and parts referenced below. For sub-assembly parts refer to Figures 4-2 through 4-8.

1. Remove manual release cover (14) by removing two screws (27).

2. For P/N 528-027-01 cargo hook only - remove manual release guard cover (9) by removing screw (31), nut (17) and spring (34).

3. Remove cotter pin (22), nuts (21 and 24) and washers (19 and 20).

4. Remove bolts (16) and (25) and guard base (10).

5. Remove Solenoid Assembly (7).

6. Remove nut (21) and bolt (26) and armor plates (11 and 12).

7. Remove cotter pin (23), nut (18) and washer (28) securing manual release lever.

8. Remove Manual Release Lever Assembly (6) and springs (33).

9. The hook frame halves can now be separated by removing the Side Plate Assembly (5) from the remaining 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 (item 2, Figure 4-7) may be removed from the cover by removing two nuts and two washers. Note the orientation of connector, diode and solenoid wires. Do not typically unsolder the wires at the connector and diode. Note the orientation of solenoid cam and remove three screws and washers.

11. Remove the attach bushings by pressing them out of the side plates.

12. Other bushings and bearings may be removed from detail parts by conventional means.

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-lit room.

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 the latest revision of ASTM-E1444 and MIL-STD-1907, Grade A on the parts listed below. No cracks are permitted in any of these parts.

Toggle (Item 1 in Figure 4-4)

Load Beam (Item 1 in Figure 4-2)

Solenoid Cam (Item 3 in Figure 4-7)

Cam (Item 1 in Figure 4-3)

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 Side (Item 1 in Figure 4-5).

Side Plate, Solenoid Side (Item 1 in Figure 4-8).

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

Side Plates and Covers 290-898-01 290-897-00 290-941-00 290-942-00

corrosion minor, less than .005” deep

Blend at 10:1 ratio as required to provide smooth transitions and remove pitting

Touch up with alodine and zinc chromate primer

Side Plates and Covers 290-898-01 290-897-00 290-941-00 290-942-00

dents, gouges and scratches

minor, less than .005” deep

Blend at 10:1 ratio as required to provide smooth transitions.

Touch up with alodine and zinc chromate primer

Side Plates 290-897-00, 290-942-00

Oversized attach holes.

See table 2-4.

Hook attach lugs (part of Side Plates 290-897-00 and 290-942-00).

cracks visible Remove and replace

Hook attach lugs (part of Side Plates 290-897-00 and 290-942-00).

corrosion visible Remove and replace

Hook attach bushings 290-294-00, inside diameter

wear .520 max diameter Remove and replace

2-6 Maintenance

Cargo Hook Overhaul Inspection continued

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

Load Beam 290-831-00

Wear from contact with load rings (no sharp notches)

.070” deep Remove and replace. This part is 15-5PH, passivated. No touch up finish required.

Load Beam 290-831-00

gouges and nicks .050” deep Blend at 10:1 ratio as required to provide smooth transitions and assure load rings will not hang up on load beam during release.

This part is 15-5PH, passivated. No touch up finish required.

Armor Plate 290-643-00, 290-644-00.

gouges and nicks .050” deep Blend at 10:1 ratio as required to provide smooth transitions.

This part is 15-5PH, passivated. No touch up finish required

Armor Plate 290-643-00, 290-644-00

deformation or bending

.060” or when ability to retain load ring is affected.

Remove and replace.

Armor Plate 290-643-00, 290-644-00

cracks Visible Remove and replace

Bumper, Load Beam 514-031-00

cuts and abrasions .060” deep or if rubbing on Load Beam

Remove and replace

Cam 290-832-00

Wear on cam surfaces and dents on bearing area

Visible denting Remove and replace

Threaded fasteners

Replace all threaded fasteners at each overhaul

N/A Remove and replace

Nameplate Mutilation or illegibility

Illegible Remove and replace

Springs Cracks and deformation

Visible defects Remove and replace

Solenoid Burning or shorting, check resistance with multi-meter.

Burnt smell or if resistance is outside 3.0 to 4.0 ohm range

Remove and replace

Solenoid wiring Deterioration Visible damage Remove and replace solenoid

Electrical connector

Loose, missing, or mutilated contact pins, cracked case, or worn insulator

Visible damage Remove and replace

Roller Bearings Roughness, binding, looseness, or corrosion

N/A Replace N/A

DU Bushings Wear > 50% copper showing

Remove and replace N/A

Maintenance 2-7

Cargo Hook Overhaul Inspection continued

Table 2-4 Side Plate Attach Hole Inspection

If top attach hole measures: Use attach bushing: Installation

Less than .6257 in (15.893 mm)

.6264 - .6270 in (15.910 – 15.926 mm)

P/N 290-294-00 (item 2, Figure 4-5 & Figure 4-8)

P/N 290-294-01*

* Oversized Attach Bushing P/N 290-294-01 is identified by a groove on its OD as shown.

Groove

Install with wet zinc chromate primer using an arbor press. Ensure a continuous fillet seal of primer around bushing flange after installation.

.6257 - .6263 in (15.893 – 15.908 mm)

.6271 - .6285 in (15.928 – 15.954 mm)

P/N 290-294-00 (item 2, Figure 4-5 & Figure 4-8)

P/N 290-294-01

Install with Loctite 680 adhesive using an arbor press. Ensure a continuous fillet seal of adhesive around bushing flange after installation.

2-8 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. Note safety wire installation for solenoid cam screws shown in Figure 2-1.

Figure 2-1 Solenoid Cam Screws Safety Wiring

3. Install bolt (15) through Side Plate Assembly (8) and install Cam Assembly (3) over the bolt and engage cam spring on roll pin.

4. Install Load Beam Assembly (2) by turning the Cam Assembly clockwise and setting the load beam into place.

5. Place the Toggle Assembly (4) and load beam bumper (32) onto Side Plate Assembly.

6. Grease Toggle Assembly needle bearing with MIL-G-23827 grease and install pin (13).

7. Install Side Plate Assembly (5), lining up the bolt (15), roll pin, and the load beam shaft. Install bolt (16) capturing the toggle assembly (4) and on P/N 528-027-01, the guard base (10).

8. If solenoid, diode, and connector were disassembled, solder the solenoid wires to connector pins A and B and then solder the diode across these pins.

9. Install Solenoid Assembly (7) on outside of Side Plate Assembly with bolt (25) while capturing the load beam bumper and the Toggle Assembly pivot bolt.

Solenoid Cam

Safety wire betweenthese two screws

Maintenance 2-9

Cargo Hook Assembly Procedures continued 10. Install a spring (33), Manual Release Lever (6), and then a second

spring over the Manual Release Lever. Install springs per Figure 2-2.

Both springs must be installed.

11. Install washer (28) and nut (18), tighten nut finger tight and turn to next castellation, install cotter pin (23).

12. Install manual release cover (14) with screws (27). 13. Install Armor Plates (11 and 12) with bolt (26) and nut (21). Torque to

20-25 in-lbs. 14. Install washer (28) and nut (18). 15. Torque nut to 15 in-lbs., rotate to next castellation and install cotter pin

(23). 16. Install washer (21) and nut (19). Torque nut to 20-25 in-lbs.

17. For P/N 528-027-01 cargo hook only - install manual release guard cover (9) with screw (31), nut (17) and spring (34).

18. Perform Acceptance Test Procedures as listed in this manual. 19. Safety wire solenoid assembly connector to screw (29) (P/N 528-029-00

and 528-027-01 only). 20. Fill out and affix Overhaul Label (P/N 215-260-00). Install rigging

warning decal (1).

Figure 2-2 Spring Installation

1. Install this end of 1stspring around cam post.

1st Spring

2. Pre-load spring by pullingthis end down until leg hooks around roll pin.

2nd Spring

3. Install manual release lever.

4. Install this end of 2nd spring underneath release lever retention ear. Install other end around rollpin as was done with 1st spring.

ATP 3-1

Section 3 Acceptance Test Procedures

If during repair the Cargo Hook has had the side plates separated or after overhaul it must be subjected to the Acceptance Test Procedure (ATP) 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.

Electrical Check Use a multimeter 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.

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.

Suspend the hook from a test stand capable of loading the Cargo Hook to 9,000 pounds. Use a nylon sling or a steel ring to apply the load to the load beam.

Gradually load the Cargo Hook with the test stand to 9,000 pounds (4,082 kgs). 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 the hook lock indicator on the side of the cargo hook.

3-2 ATP

Minimum Load Release Test With no load on the load beam, operate the manual release lever. The load beam should unlatch and fall open. Release the manual release lever. Reset the load beam and ensure it latches in the fully closed and locked position.

Set up an adjustable 22 - 28 VDC supply with a momentary release switch wired into the positive wire. Connect the negative lead to pin A and the positive lead to pin B of the cargo hook connector. Set the voltage to 27.5 VDC, ±0.1.

With no load on the load beam, press the release switch. The load beam should unlatch and fall open. Reset the load beam by hand.

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 3,600 pounds (1,633 kgs) and hold the load for 20 seconds.

Damage to the release solenoid can occur if the release switch is operated for more than 20 seconds continuously.

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. Repeat the test a second time.

Manual Load Release Test Connect a manual release cable to the Cargo Hook and gradually load the Cargo Hook to 3,600 pounds (1,633 kgs). 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. Reset the load beam. Repeat the test a second time.

With no load applied to the load beam, verify that the load beam can be unlatched manually by pulling the manual release cable.

Cargo Hook Parts 4-1

Section 4 Cargo Hook Parts Figure 4-1 Cargo Hook Parts

continued........

4-2 Cargo Hook Parts

Cargo Hook Parts continued

Figure 4-1 Cargo Hook Parts, continued


Cargo Hook Parts continued Table 4-1 Cargo Hook Parts (Refer to Figure 4-1)

Quantity Item Part No. Description

528-

027-

01

528-

029-

00

528-

029-

60

Ove

rhau

l Kit

212-

024-

00

Notes

1 215-240-00 Rigging Warning Decal 1 1 1 1 2 232-161-00 Load Beam Assembly 1 1 1 - See Figure 4-2 3 232-162-00 Cam Assembly 1 1 1 - See Figure 4-3 4 232-185-00 Toggle Assembly 1 1 1 - See Figure 4-4 5 232-194-00 Side Plate Assembly, Manual Release 1 1 1 - See Figure 4-5

232-195-00 Manual Release Lever Assembly 1 - - - See Figure 4-6 6 232-195-01* Manual Release Lever Assembly - 1 1 - See Figure 4-6

232-212-00 Solenoid Assembly - 1 - - See Figure 4-7 232-212-02 Solenoid Assembly - - 1 - See Figure 4-7

7

232-212-03 Solenoid Assembly 1 - - - See Figure 4-7 8 232-213-00 Side Plate Assembly, Solenoid 1 1 1 - See Figure 4-8 9 235-120-00 Guard Cover 1 - - -

10 235-121-00 Guard Base 1 - - - 11 290-643-00 Armor Plate – Solenoid 1 1 1 -- 12 290-644-00 Armor Plate – Manual 1 1 1 - 13 290-896-00 Cam Roller 1 1 1 - 14 290-898-01 Manual Release Cover 1 1 1 - 15 290-901-00 Bolt 1 1 1 1 16 290-913-00 Bolt 1 1 1 1 17 510-029-00 Nut 1 - - - 18 510-082-00 Nut 1 1 1 1 19 510-095-00 Washer 1 1 1 1

510-983-00 Washer 1 - - 1 20 510-219-00 Washer - 1 1 1

21 510-102-00 Nut 2 2 2 2 22 510-115-00 Cotter Pin 1 1 1 1 23 510-125-00 Cotter Pin 1 1 1 1 24 510-259-00 Nut 1 1 1 1 25 510-375-00 Bolt 1 1 1 1 26 510-376-00 Bolt 1 1 1 1 27 510-493-00 Screw 2 2 2 2 28 510-516-00 Washer 1 1 1 1 29 510-755-00 Screw 1 1 - - 30 510-961-00 Screw 1 - - -


Cargo Hook Parts continued Table 4-1 Cargo Hook Parts, continued (Refer to Figure 4-1)


528-

027-

01

528-

029-

00

528-

029-

60

Ove

rhau

l Kit

212-

024-

00

Notes

31 510-963-00 Screw 1 - - - 32 514-031-00 Bumper 1 1 1 1 33 514-058-00 Spring 2 2 2 2 34 514-089-00 Spring 1 - - -

35♠ 215-260-00 Overhaul Label - - - 1

* P/N 232-195-01 supersedes P/N 232-195-00 in 528-029-00 cargo hooks, these P/Ns are interchangeable. ♠ Item not shown.


Cargo Hook Parts continued Figure 4-2 Load Beam Assembly Parts

Table 4-2 Load Beam Assembly Parts

Item Part No. Description Qty Qty included in Overhaul Kit

P/N 212-024-001 290-831-00 Load Beam 1 - 2 290-640-00 Load Beam Shaft 1 -

1

2



Figure 4-3 Cam Assembly Parts

Table 4-3 Cam Assembly Parts


P/N 212-024-001 290-832-00 Cam 1 - 2 290-603-00 Interlock Roller 1 - 3 517-031-00 Bearing 2 2 4 517-009-00 Bearing 2 2 5 510-495-00 Clevis Pin 1 1 6 510-417-00 Cotter Pin 1 1 7 514-032-00 Extension Spring 1 1

5

63

3

2

14

4

7


Cargo Hook Parts continued Figure 4-4 Toggle Assembly Parts

Table 4-4 Toggle Assembly Parts


P/N 212-024-001 290-838-00 Toggle 1 - 2 517-060-00 Bearing 1 1 3 290-438-00 Load Beam Roller 1 - 4 517-021-00 Bearing 4 4 5 510-494-00 Clevis Pin 1 1 6 510-417-00 Cotter Pin 1 1

3

5

4

6

4

4

4

2

1



Figure 4-5 Side Plate Assembly, Manual Release Side, Parts Table 4-5 Side Plate Assembly, Manual Release Side, Parts


P/N 212-024-001 290-897-00 Side Plate, Manual Release 1 - 2 290-294-00 Attach Bushing 1 1 3 517-010-00 Bearing 1 1 4 510-210-00 Self-Locking Helicoil 2 2 5 510-203-00 Roll Pin 1 1

1

2

3

4

5


Cargo Hook Parts continued Figure 4-6 Manual Release Lever Assembly Parts

Table 4-6 Manual Release Lever Assembly Parts


-00 -01

Qty included in Overhaul Kit

P/N 212-024-00

290-899-00 Manual Release Lever 1 - - 1 290-899-01 Manual Release Lever - 1 -

2 517-054-00 Bearing 1 1 1


Cargo Hook Parts continued Figure 4-7 Solenoid Assembly Parts

AB

5

2

3

6

8

7

14

Connector/Diode Assembly Detail

Diode (item 9)

Connector (item 5)

9

Table 4-7 Solenoid Assembly Parts


-00 -02 -03

Qty included in Overhaul Kit

P/N 212-024-00

1 290-941-00 Solenoid Cover 1 1 1 -

2 455-003-00 Solenoid 1 1 1 -

3 290-835-00 Solenoid Cam 1 1 1 -

215-192-00 Serial Number Plate - 1 - -

215-253-00 528-029-00 Serial Plate 1 - - - 4

215-264-00 528-027-01 Serial Plate - - 1 -

5 410-139-00 Connector 1 1 1 -

6 510-379-00 Screw 3 3 3 1

7 510-206-00 Nut 2 2 2 1

8 510-209-00 Washer 2 2 2 1

9 340-035-00** Diode 1 1 1 -

10^ 410-310-00 Cap - - 1 -

** Diode P/N 340-035-00 supersedes diode P/N 340-027-00. These P/N’s are interchangeable.

^ Cap not shown.



Figure 4-8 Side Plate Assembly, Solenoid Side, Parts

Table 4-8 Side Plate Assembly, Solenoid Side, Parts


P/N 212-024-001 290-942-00 Side Plate, Solenoid 1 -

2 290-294-00 Attach Bushing 1 1

3 517-010-00 Bearing 1 1

4 510-202-00 Roll Pin 1 1

1

2

34

Instructions for Storage and Return to Factory 5-1

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.

Return to Factory If an Onboard Systems product must be returned to the factory for any reason (including returns, service, repairs, overhaul, etc.), please contact Technical Support by phone or email to obtain an RMA number before returning it. For more information, please refer to our website. 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 13915 N. W. 3rd Court Vancouver, Washington 98685 USA

122-017-00 r13 3.6kk service manual

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