ALERT SERVICE BULLETIN

REVISION NOTICE

Bell Helicopter) i XCi ~1.n nber 9,2002

A Subsidiary of Textron Inc.

TO: All Owners/Operators of Bell 205 Helicopters

SUBJECT: REVISION “A” TO ALERT SERVICE BULLETIN 205-00-78:

CARGO HOOK ONBOARD SYSTEMS P/N 528-002-00

The intent of this revision is to ensure that the attached Onboard Systems International
Service Bulletin No. 159-005-02 is distributed to all Bell Helicopter customers. The
original release of this bulletin distributed Onboard Systems International Service
Bulletin No. 159-005-01. Bell Helicopter has been made aware that another bulletin has
been issued by Onboard Systems International on the same hooks and wishes to
advise all its customers.

AN APPROPRIATE ENTRY SHOULD BE MADE IN THE AIRCRAFT LOG BOOK UPON ACCOMPLISHMENT
IF OWNERSHIP OF AIRCRAFT HAS CHANGED PLEASE FORWARD TO NEW OWNER
 ALERT SERVICE BULLETIN
205-00-78
Bell Helicopter ma No*
3ATE 09-09-02 A Subsldlary of Textron Inc DATE 08-01-00
REV A I PAGE 1 of3

MODEL AFFECTED: 205A-1

SUBJECT: CARGO HOOK, ONBOARD SYSTEMS P/N 528-

002-00

HELICOPTERS AFFECTED: All model 205A-1 helicopters that have installed the
cargo hook under STC SR00277SE and as reflected
in the attached Onboard Systems International A
Service Bulletin No. 159-005-02.

COMPLIANCE: Refer to Onboard Systems Service Bulletin 159- A

005-02. I

DESCRIPTION:

Bell Helicopter Textron has been informed by Onboard Systems International of a

potential for inadvertent or uncommanded cargo hook release. The subject cargo hook
assembly is installed into suspension assembly 200-088-01, -02 and -03 and is
currently supplied by Bell Helicopter Textron as a replacement for suspension
assembly 204-072-915-103. The intent of this bulletin is to ensure that the attached
Onboard Systems International Service Bulletin No. 159-005-02 is distributed to all A
Bell Helicopter customers. The original release of this bulletin distributed Onboard
Systems International Service Bulletin No. 159-005-01. Bell Helicopter has been
made aware that another bulletin has been issued by Onboard Systems International
on the same hooks and wishes to advise all its customers.

APPROVAL:

Refer to Onboard Systems Service Bulletin 159-005-02. I A

MANPOWER:

Refer to Onboard Systems Service Bulletin 159-005-02. I A

AN APPROPRIATE ENTRY SHOULD BE MADE IN THE AIRCRAFT LOG BOOK UPON ACCOMPLISHMENT
IF OWNERSHIP OF AIRCRAFT HAS CHANGED PLEASE FORWARD TO NEW OWNER
205-00-78
Page 2 of 3

MATERIAL:

Refer to Onboard Systems Service Bulletin 159-005-02. A

SPECIAL TOOLS:

Refer to the Onboard Systems Cargo Suspension Manual 120-031-02 for special tool
requirements to accomplish this bulletin. You may contact Onboard Systems A
International should you require a copy of this manual.

WEIGHT AND BALANCE:

Not affected

ELECTRICAL LOAD DATA:

Not affected.

REFERENCES:

Service Instruction BHT-SI-204-3

Onboard Systems Service Bulletin 159-005-02 A

PUBLICATIONS AFFECTED:

None affected.

ACCOMPLISHMENT INSTRUCTIONS:

1. Verify if the cargo hook that is installed on the aircraft, or any spare cargo hook, is
affected by this Alert Service Bulletin by physically checking the P/N and S/N on
A
the data plate. Refer to the attached Onboard Systems International Service
Bulletin No. 159-005-02 for affected hooks.

2. If the hook is affected, remove the cargo suspension assembly from the
helicopter, if installed. Refer to service instruction BHT-SI-204-3.
 205-00-78
Page 3 of 3

3. Accomplish the intent of the attached Onboard Systems International Service

A
Bulletin No. 159-005-02 on the cargo hook.

4. It is recommend that a Component Historical Card be created for the suspension

assembly. Annotate the cargo hook historical card to show compliance with the
attached Onboard Systems International Service Bulletin. Any question regarding
this bulletin should be directed to:

Onboard Systems International

11212 NW St. Helens Road
Portland, Oregon 97231 USA
Phone: (503) 286-4956 or (800) 275-0883 Fax: (503) 286-0370
www.OnboardSystems.com
ONBOARD SYSTEMS
INTERNATIONAL SERVICE BULLETIN
Document No. 159-005-02, Rev 0
Jan. 10, 2002
11212 NW St. Helens Road

Portland, Oregon 97231 Model affected: Bell 204B, 205A, 205A-1, 212, 412, 412EP and Garlick UH-1H
USA

Subject: Cargo Hook enhanced safety.

Phone: 503-286 -4956

Fax: 503-286-0370 Helicopters Affected: All aircraft with Onboard Systems part number 528-002-00
Toll Free: 800-275-0 883 Cargo Hook, Serial Number CAL829 to CAL1135 inclusive and all affected
hooks in spares.
www.OnboardSystems.com
These hooks may be installed on aircraft with the Bell manufactured suspension
system with P/N 528-002-00 hook installed per STC SR00277SE or Canadian
STA SH96-77. Also included are aircraft with Onboard Suspension Systems P/N
200-088-01, -02 and -03 or 200-089-01, -02 and -03 that have been installed per
STC SH5707NM or Canadian STA SH93-50. These suspension systems had
several possible hook part numbers installed. Only the systems equipped with
Onboard hook part number 528-002-00 are affected.

Compliance: Mandatory. 300 hours time in service from the effective date, or 90
days, whichever comes first. The effective date is Jan 25, 2002.

Description: In August of 1999 Onboard issued Service Bulletin 159-005-001

that required replacement of an internal extension spring. The purpose of the
spring replacement was to decrease the possibility of uncommanded load releases
by increasing the tension on the release mechanism. A fatigue failure of the
replacement spring P/N 650-066-00 has been reported from the field. The field
failure was on a hook being used as the lower hook on a long line, so it could
accumulate more cycles in a shorter time than would be typical of a primary belly
hook application. Subsquent testing on our test stand shows that the spring can
fail with as little as 14,000 release cycles on the hook In estimating the number of
cycles on a particular hook please be aware that each full motion of the release
mechanism counts as a cycle. This applies whether or not the hook is empty or
loaded when cycled. The “machine gunning” of the mechanism that is part of the
preflight test also counts against the total at the rate of 10-20 cycles per second.

This bulletin provides for the installation of a redesigned spring that has an
enhanced service life.

Approval: The engineering design aspects of this bulletin are FAA/DER

approved.
ONBOARD SYSTEMS
Manpower: Approximately 1.0 man-hours will be required to install the kit, after
INTERNATIONAL the hook is removed from the aircraft. Man-hours are based on hands-on time and
may vary with personnel and facilities available. If the hook is already
11212 NW St. Helens Road disassembled for scheduled inspection or overhaul, the kit installation will take no
Portland, Oregon 97231 additional time. No machining operations are required. Installation consists of
USA removing and replacing parts.

Phone: 503-286 -4956 Required Material: The following material is required for accomplishment of this
Fax: 503-286-0370
bulletin and may be obtained from Onboard Systems:
Toll Free: 800-275-0883
Part number 650-069-00 Spring Assy, Toggle Quantity 1
Grease (MIL-G-23827)
www.OnboardSystems.co
Cotter Pins for hook attach bolts

Special Tools: Test Stand for performing ATP on reassembled hook. (18,000 lbs.
capacity)

Weight and Balance: Not affected

Electrical Load Data: Not affected

References: TBD

Publications affected: Onboard Systems 6,000 lb Cargo Hook Owners Manual,

P/N 120-044-00 and Onboard Systems UH-1 Cargo Hook Suspension System
Manual P/N 120-031-01.

Accomplishment Instructions:
1. Prepare helicopter for maintenance and disconnect main battery.
2. Remove the P/N 528-002-00 hook from the suspension system. Refer to
appropriate maintenance manual instructions.
3. Disassemble P/N 528-002-00 hook as required to split the case halves. Refer
to appropriate maintenance manual, 120-031-01 or 120-044-00 for
instructions.
4. Remove P/N 650-066-00 or 650-041-00 Spring, Toggle and replace with P/N
650-069-00 Spring Assy, Toggle. Do not remove the plastic cover from
spring. Refer to figure 1 for correct orientation of spring installation. End of
spring with plastic cover can be pushed over roll pin in toggle assy without
removing roll pin and then hook the opposite end of spring over pin in case.
5. Reassemble hook per maintenance manual instructions.
6. Perform Acceptance Test Procedure in accordance with Section 8 of manual
120-031-01 or Section 4 of manual 120-044-00, as appropriate.
7. Stamp or clearly vibro-engrave “MODS.” plate on side of hook with SB6 in
any available box on the right side of the plate, to identify that the service
bulletin has been complied with.
ONBOARD SYSTEMS
8. Reassemble hook onto suspension system and reinstall suspension onto
INTERNATIONAL aircraft per maintenance manual instructions. Check rigging.
9. Make logbook entry.
11212 NW St. Helens Road

Portland, Oregon 97231

USA Figure 1 Cargo Hook , Spring Assembly showing orientation of plastic spring cover.

Phone: 503-286 -4956

Fax: 503-286-0370

Toll Free: 800-275-0883

www.OnboardSystems.co