Owner's Manual

Talon LC Hydraulic
Cargo Hook Kit
on the

Airbus Helicopters AS350

Part Number 200-281-01, 200-281-02

Owner's Manual Number 120-106-01

Revision 8
September 11, 2017

13915 NW 3rd Court, Vancouver, WA 98685 USA

Phone: 360-546-3072 Fax: 360-546-3073 Toll Free: 800-275-0883
www.OnboardSystems.com
This page intentionally left blank.
 RECORD OF REVISIONS

Revision Date Page(s) Reason for Revision

0 06/16/06 All Original issue.

1 01/14/08 2-10, 2-11 Added “Remove rubber bumpers from swing
assembly” instruction and updated Figure 2.2.4.
Removed color labels from wiring diagram Figure
2.2.3.
2 02/10/09 5-3 & 5-6 Corrected P/N 232-240-00 to 232-241-00 on 232-222-
00 illustrated parts list. Updated illustrated parts list to
show P/N 232-240-01 used on P/N 232-241-00.
3 09/29/09 2-3, 2-7, 3-1 Updated Figure 2.1.3 to show complete collective,
added note on page 2-7 to allow alternative routing,
clarified Figure 3.1.
4 08/03/10 Replaced P/N 212-014-00 with 212-014-01 and
updated hydraulic fluid filling instructions to use new
Section 1
kit. Updated warnings, cautions and notes section to
through 4
safety label section. Updated safety label format
throughout document.
5 12/19/11 5-7 Replaced Cup Seal (P/N 556-038-00) with Quad Ring
(P/N 556-097-00) inside Slave Cylinder Assembly.
6 10/11/13 5-6 Replaced Slave Cylinder Plumbing P/N 232-240-01
with P/N 232-240-02.
7 05/14/14 2-2, 3-2, 3-3 Updated cargo hook rigging section, changed
recommended minimum bend radii of hose to 1.5
inches.
8 09/11/17 1-1, 2-14 Clarified Introduction section including eligible
installations. Changed supplied bleed kit to P/N 212-
014-02, includes MIL-PRF-87257 hydraulic fluid.
Register Your Products for Automatic Notifications
Onboard Systems offers a free notification service via fax or email for product alerts and documentation
updates. By registering your Onboard Systems products at our website, we will be able to contact you if a
service bulletin is issued, or if the documentation is updated.
You can choose to receive notices on an immediate, weekly, or monthly schedule via fax, email or both
methods. There is no charge for this service. Please visit our website at
www.onboardsystems.com/notify.php to get started.

ii
This page intentionally left blank.
CONTENTS
Section 1 General Information
Introduction, 1-1
Safety Labels, 1-1
Specifications, 1-2
Inspection, 1-2
Bill of Materials, 1-3
Theory of Operation, 1-4

Section 2 Installation Instructions

2.1 Hydraulic Release System Installation, 2-1
2.2 Cargo Hook Installation, 2-9
2.3 Installation Check-Out, 2-12
2.4 Component Weights, 2-13
2.5 Cargo Hook Location, 2-13
2.6 Paper Work, 2-13
2.7 Filling Hydraulic Release System, 2-14

Section 3 Operation Instructions

Operating Procedures, 3-1
Cargo Hook Loading, 3-2
Cargo Hook Rigging, 3-2

Section 4 Maintenance
Instructions for Returning Equipment to the Factory, 4-1

Section 5 System Part Numbers

200-281-01 Cargo Hook Replacement Kit, 5-1
200-281-02 Cargo Hook Replacment Kit, 5-2
232-222-00 Cargo Hook/Link Assembly, 5-3
232-146-00 Link Assembly, 5-4
232-166-00, 232-166-01 Master Cylinder Assembly, 5-5
232-241-00 Slave Cylinder Assembly w/ Plumbing, 5-6
232-169-00 Slave Cylinder Assembly, 5-7

Section 6 Certification
STC, 6-1
Canadian Approval, 6-3

iii
This page intentionally left blank.
Section 1
General Information
Introduction
The 200-281-01 and 200-281-02 Cargo Hook Kits are approved for use on
Airbus Helicopters AS350 series equipped with a B3 type swing system
with Siren P/N AS21-5-7 cargo hook or Onboard Systems P/N 528-023-51
cargo hook installed.
P/N Manufacturer
AS 21-5-7 Siren
528-023-51 Onboard Systems
The B3 type swing systems are installed on AS350B3 models and can be
retrofitted to earlier models with Cargo Swing fixed parts installed per
Airbus Helicopters Service Bulletin 25.00.62.
The 200-281-02 Cargo Hook Kit is approved for installation on the
AS350B3 model. The 200-281-01 is approved for installation on the
AS350B2 and earlier models.

Safety Labels
The following definitions apply to Safety Labels 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.

General Information 1-1

Specifications
Table 1-1 P/N 528-028-00 Cargo Hook Specifications
Design load 3,500 lbs. (1,580 kg.)
Design ultimate strength 13,125 lbs. (5,952 kg.)
Electrical release capacity 8,750 lbs. (3,970 kg.)
Mechanical release capacity 8,750 lbs. (3,970 kg.)
Force required for mechanical 12 lbs max. @ Master Cylinder
release at 3,500 lb.
Electrical requirements 22-32 VDC 6.9 – 10 amps
Minimum release load 0 pounds
Unit weight 3.0 pounds (1.35 kg.)
Mating electrical connector PC06P8-2S

Load capacities given are for the equipment

described only. Loading limits for your
particular helicopter model still apply. Consult
your flight manual.

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.

1-2 General Information

Bill of Materials
The following items are included with the Cargo Hook Kit, if shortages are
found contact the company from whom the system was purchased.

Table 1-2 Bill of Materials

Part Quantity Quantity
Number Description 200-281-01 200-281-02
120-106-01 Owner’s Manual 1 1
121-014-01 Flight Manual Supplement 1 1
122-015-00 Cargo Hook CMM 1 1
123-013-01 ICA Maintenance Manual 1 1
212-014-02 Bleed Kit 1 1
215-169-00 AS350 Light Indicator Placard 2 2
232-222-00 Cargo Hook/Link Assembly 1 1
232-165-00 Master Cylinder Assembly 1 -
232-165-01 Master Cylinder Assembly - 1
235-135-00 Disconnect Bracket 1 1
291-105-00 Friction Handle - 1
510-453-00 Bolt 1 1
510-042-00 Washer 1 1
510-102-00 Nut 1 1
512-005-00 Adel Clamp 1 1
500-065-00 Grommet Edging 1 1
505-014-00 Grommet 1 1
590-013-00 Spiral Wrap 48” 48”
450-001-00 1/8” Heat Shrink Tubing, 1/2” Lg. 2 2
450-120-00 ¼” dia. Heat Shrink Tubing, 4” Lg. 1 1
450-113-00 ½” dia. Heat Shrink Tubing, 3” Lg. 1 1
510-486-00 CherryMax Rivet 3 3

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 and an external
manual release cable provide the means for unlatching the load beam.

A 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 the hydraulic release
system. The hydraulic release system is operated via a lever in the cockpit
and actuates 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.

1-4 General Information

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.

2.1 Hydraulic Release System Installation

Remove the swing suspension, external electrical release harness and the
external section of the manual release cable from the helicopter. Remove the
lower cowlings as necessary to access and remove the internal section of the
manual release cable system.
The hydraulic release system installation consists of a fixed section and a
removable section. The fixed section is routed from the release lever at the
collective, underneath the cabin floor, and aft to meet up with the existing cargo
hook electrical release harness (as shown in Figure 2.1.1). Figure 2.1.1 is an
overview of the hose routing and the figures following detail the support
installations at various points.
Figure 2.1.1 Fixed Hydraulic Release System Installation Overview

X 1790.15 X 2700 Centerline of fwd

fuel tank support

Y 400

A/C Centerline

FWD Connector Bracket

Y 400

View Looking Down

See Figure 2.1.3

See Figures 2.1.6 & 2.1.7
See Figure 2.1.4
Fuel Tank Support
See Figure 2.1.5 Frame

See Figure 2.1.8

Installation Instructions 2-1

2.1 Hydraulic Release System Installation continued
Observe the following precautions (ref. Figure 2.1.2) when routing the hydraulic
hose.
 Use care to avoid kinking the hose.
 Recommended minimum hose bend radii is 1.5 inches. Avoid abrupt change
in direction of the hose just outside the end fittings. Provide gradual
transitions where possible.
 Verify that the hose routing is clear of and cannot be deflected into chafe
points.
Figure 2.1.2 General Hose Routing Practices
Maximize bend radii
Use cushioned loop clamp and
bracket (shown), ty-raps, or other
suitable means to secure hose
at various points.
Suspend clear of if possible
or add anti-chafe strip.
X

Provide as gradual a transition

as possible at end fittings

2-2 Installation Instructions

2.1 Hydraulic Release System Installation continued
The hydraulic release system is supplied dry. It is recommended that the system
be filled and bled on the bench before installing on the helicopter. Refer to
section 2.7 for filling and bleeding instructions.
 Mount the Release Lever Assembly (P/N 232-165-00) to the collective stick
with the Clamp Half (P/N 290-753-00) and two screws (P/N 510-390-00)
provided pre-assembled on the assembly, as illustrated below.
Figure 2.1.3 Release Lever Installation

Screws
P/N 510-390-00

Release Lever Assembly

If installing kit P/N 200-281-02 (for the AS350B3

model) a shorter friction adjustment knob for the
collective is required because of interference with
the master cylinder assembly reservoir. This item
is supplied as P/N 291-105-00. See below for
installation instructions.
Figure 2.1.4 B3 Collective

Friction Knob

Installation Instructions 2-3

2.1 Hydraulic Release System Installation continued
 Remove the collective to the extent necessary to remove the friction knob.
Refer to Airbus Helicopters maintenance manual for removal and re-
installation instructions.
 Replace the OEM friction knob with the friction knob P/N 291-105-00
provided.
 Re-install collective per Airbus Helicopters maintenance manual
instructions.
 Mount the Release Lever Assembly (P/N 232-165-01) to the collective with
the Clamp Half (P/N 290-753-00) and two screws (P/N 510-390-00)
provided pre-assembled on the assembly, as illustrated below.

Locate the Release Lever Assembly on the

collective shaft as close as possible to the throttle
twist grip (as shown in Figure 2.1.5).
 Adjust the Friction Knob to its outermost position and verify that there is
clearance with the reservoir on the release lever assembly.
Figure 2.1.5 AS350B3 Release Lever Installation

Release Lever Assembly

The lever position is to be adjusted, if necessary,

at installation check out, after the system is filled
and bled.

2-4 Installation Instructions

2.1 Hydraulic Release System Installation continued
 Route the hose to underneath the cabin floor through the existing slot
(through which the manual release cable was routed through) to the right of
the base of the collective.
 Underneath the floor, route the hydraulic hose through an existing hole in
the frame immediately aft of the collective. Secure the hose at this point
with an loop clamp (P/N 512-005-00). Fasten the loop clamp to the existing
bracket (Airbus Helicopters P/N 350A86-0020-33) with hardware as
illustrated below.

Figure 2.1.6 Hose Routing Through Frame

Cabin Floor

A/C Centerline
Bolt P/N 510-453-00
Washer P/N 510-042-00
A Nut P/N 510-102-00

Loop Clamp
P/N 512-005-00

AH P/N 350A86-0020-33
A A-A
View Looking Aft

Installation Instructions 2-5

2.1 Hydraulic Release System Installation continued
 Aft of the frame, route the hose along the top of the structural member
(shown below) and secure with loop clamp (P/N 512-005-00) at location
shown.
Figure 2.1.7 Loop Clamp Installation

Loop clamp from

Figure 2.1.6 is behind
this.

Route the hose to this beam and

secure with loop clamp. Enlarge
hole to .196 dia. (if necessary) to
fit loop clamp screw.

 Aft of the loop clamp installed above, route the hose inboard and aft across
the airframe centerline to the identical structural member on the left side of
the airframe. Secure hose to fitting on top of structural member with ty-wrap
as shown below. Ensure the hose is secured so that it does not interfere with
the control rods.
Figure 2.1.7 Hydraulic Hose Routing

Tie off hose at this fitting.

2-6 Installation Instructions

2.1 Hydraulic Release System Installation continued
 Route the hose under the airframe support (as shown below) and secure the
hose to the fitting on top of the structural member aft of the airframe
support. Install grommet edging (P/N 500-065-00) as necessary to protect
hydraulic hose from chafing.
Figure 2.1.8 Routing under Airframe

Cut and install grommet

edging in this area to prevent
chafing of hydraulic hose.

 Route the hose up through the rear cabin bulkhead as shown in Figure 2.1.9.
Split and install grommet (P/N 505-014-00) after hose is routed through.

If this hole is not available, route the hose

outboard to the existing electrical harness and
route with electrical harness to the connector
bracket. Space hydraulic hose off of electrical
harness or apply protective wrap over hose to
prevent it from rubbing on wires.
Figure 2.1.9 Hose Routing through Rear Cabin Bulkhead

Install grommet in this hole.

View Looking Aft

Installation Instructions 2-7

2.1 Hydraulic Release System Installation continued
 Aft of the rear cabin bulkhead pick up existing electrical harness and secure
hydraulic hose to it. Prevent the hose from rubbing on the wires by spacing it
off or applying protective wrap. The hose will route outboard of Y400 and
follow the electrical release harness to the connector bracket.
 Temporarily remove the Airbus Helicopters connector 55M from the
existing connector bracket.
 Remove existing connector bracket by drilling out the three rivets.
 Locate the provided connector bracket as shown below and drill out pilot
holes in the supplied connector bracket to 0.129/0.132” (3.2/3.4 mm)
diameter and drill fuel tank support to match.
 Secure Connector Bracket to fuel tank support with three rivets (P/N 510-
486-00).
 Insert the hydraulic hose end fitting through the hole and slide it aft to the
end of the slot and tighten jam nut.
Figure 2.1.10 Connector Bracket Installation

Hydraulic Connector

5.75/6.00 in.
Eurocopter (146/152 mm)
55M Connector
VIEW A-A A

A
Connector Bracket .63/.75
(16/19 mm)

Y=0
VIEW LOOKING FORWARD

2-8 Installation Instructions

2.2 Cargo Hook Installation
The cargo hook assembly includes an electrical pigtail which must be spliced into
the Airbus Helicopters Y harness. Splice per the following instructions.
o Cut the leg of Y harness that goes to the cargo hook off within 1.50/2.00” from
the Y junction.
o Cut the electrical pigtail from the cargo hook to a length which provides for
optimal routing when spliced with the Y harness.
o Strip the outer heat shrink, wire jacket and shield back 1”. Prep the individual
wires.
o Slide the 3” long piece of ½” dia. heat shrink P/N 450-113-00 and 4” long piece
of ¼” dia. heat shrink P/N 450-120-00 over the cargo hook pigtail and a ½”
long piece of heat shrink tubing P/N 450-001-00 over the two individual wires.
o Prep the wires on the Airbus Helicopters harness and solder the wires from the
cargo hook pigtail to them, referring to the wiring diagram (see Figure 2.2.3).
Figure 2.2.1 Wiring Harness Modification
Heat Shrink
P/N 450-113-00

To C
argo
Hoo
k
1.50/2.00

Heat Shrink
P/N 450-001-00

o Slide the heat shrink tubing over the individual solder joints and shrink in
place using heat gun. Cap and stow the remaining three wires.
o Slide the 4” long piece of ¼” dia. heat shrink over the solder joints and
shrink in place.
o Slide the 3” long piece of ½” dia. heat shrink over the convoluted tubing so
that it overlaps it by approximately 1” and shrink in place.
Figure 2.2.2 Wiring Harness Modification - completed

To C
argo
Hoo
k

Installation Instructions 2-9

2.2 Cargo Hook Installation continued
Figure 2.2.3 Wiring Diagram
Existing Airbus Helicopters' Harness

24M 32M
white
A K
ME5E
blue
B J
ME93NF C
Cap and stow ME88G B
these wires
ME89G A

Early versions of the cargo hook were equipped

with a suppression diode that will be damaged if
the cargo hook electrical connections are
reversed. See table 2.1 for cargo hook connector
pin function.
Table 2.1 Cargo Hook Connector
Pin Function
A Ground
B Power

2-10 Installation Instructions

2.2 Cargo Hook Installation continued
Attach the Cargo Hook and Bumper Assembly (P/N 232-222-00) to the existing
load cell, re-using the Airbus Helicopters hardware (see below). The cargo hook
load beam should point to the left side of the aircraft. Remove rubber bumpers
from swing assembly.
Figure 2.2.4 Swing Mount Cargo Hook Installation Assembly
AS350B3 Swing Assembly

Rubber Bumper
(remove)

AS350B3 Load Cell

Forward
Re-use hardware

Cargo Hook

te the hydraulic hose to the left, outside the swing frame tubes and up as shown
below. Connect it to the fixed quick disconnect fitting installed previously.
Install the supplied spiral wrap (P/N 590-013-00) over the hose and trim excess.
Figure 2.2.5 Hose Routing at Frame

Forward Add Spiral Wrap (P/N 590-013-00) over hose.

View Looking Down

Installation Instructions 2-11

2.3 Installation Check-Out
After installation of the cargo hook, perform the following checks.
1. Verify that the hydraulic hose routing does not have kinks and is clear of
chafing points.
2. Ensure that the collective has full movement and is not restricted by the
hydraulic hose routing.
3. Swing the installed cargo hook to ensure that the hydraulic hose assembly and
the electrical release harness have enough slack to allow full swing of the
suspension assembly without straining or damaging the hose or harness. The
hose and harness must not be the stops that prevent the cargo hook from
swinging freely in all directions.
4. With no load on the cargo hook load beam, pull the release lever on the
collective and verify the cargo hook releases. Reset the cargo hook load beam.
5. With no load on the cargo hook load beam, depress the cargo hook electrical
release button, the cargo hook must release. Reset the cargo hook load beam.
6. Actuate the release lever on the collective and observe its range of motion.
Ensure that it is accessible and that there is no interference throughout its range
of motion (refer to Figure 2.3.1). If necessary adjust the lever position by
loosening the set screw and turning the lever adjustment screw (ref. Figure
2.3.2) in the required direction. Re-tighten set screw.
Figure 2.3.1 Lever Position
Adjust lever position to approximately
center its range of motion within this
area. Ensure access and clearance is
present at its starting and ending positions.

Release Lever Assembly

Figure 2.3.2 Lever Adjustment

Set Screw

Lever Adjustment Screw

DETAIL A
A

2-12 Installation Instructions

2.4 Component Weights
The weights and cgs of the Cargo Hook kit components are listed below. When
performing weight and balance calculations remember to deduct equipment
removed, such as manual release cable, etc.
Table 2.2 Weights and CGs – 200-281-01
Item Weight Station

Removable Provisions* 5.1 lbs (2.3 kgs) 133 in (3375 mm)

Fixed Provisions** 1.0 lb (.45 kgs) 110 in (2794 mm)
Total 6.1 lbs (2.8 kgs) 129.2 in (3282 mm)
Table 2.3 Weights and CGs – 200-281-02
Item Weight Station

Removable Provisions* 5.1 lbs (2.3 kgs) 133 in (3375 mm)

Fixed Provisions** 1.2 lb (.54 kgs) 110 in (2794 mm)
Total 6.3 lbs (2.9 kgs) 128.6 in (3266 mm)
* The removable provisions include the hook, external hydraulic release hose,
bumper, and electrical release harness. These items are easily removed if they are
not needed on the helicopter’s mission.
** The fixed provisions are those items of the kit that remain on the aircraft. The
only fixed item in this kit is the Master Cylinder with hydraulic hose.

2.5 Cargo Hook Location

See the Airbus Helicopters provided Flight Manual Supplement for external load
weight and balance data.

2.6 Paper Work

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. Insert
the Rotorcraft Flight Manual Supplement P/N 121-014-01 into the Rotorcraft
Flight Manual.

Installation Instructions 2-13

2.7 Filling Hydraulic Release System
Each hydraulic system is typically shipped dry. Proper bleeding is critical to the
operation of the hydraulic release system. An improperly bled system will not
release the cargo hook mechanism.
If there is a need to fill and/or bleed the system, follow the procedures listed below.
If you need to remove and repair any items in the hydraulic system, refer to the
Instruction for Continued Airworthiness manual.
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
fluid and the other to observe the reservoir.
A reservoir seal is installed beneath the reservoir lid. This seal serves to prevent
hydraulic fluid left over from the testing process from leaking during shipping.

The reservoir seal is for shipping purposes only

and must be removed and discarded before
bleeding or installation of the hydraulic system.
Bleeding procedure:
1. Assemble the supplied bleed kit P/N 212-014-02 (or optional P/N 212-014-01)
by press fitting each of the kit’s components together as shown in Figure 2.5.1.
This kit also includes 2 ounces of MIL-PRF-87257 fluid (kit P/N 212-014-01
includes MIL-PRF-5606 fluid).

MIL-PRF-5606 and MIL-PRF-87257 fluids are

both compatible with the hydraulic system. These
fluids are interchangeable and miscible.
Figure 2.5.1 Hydraulic Hook Bleed Kit

bleed adapter

PVC tubing

female X barb fitting

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.

2-14 Installation Instructions

2.7 Filling Hydraulic Release System continued

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 2.7.2.
Figure 2.7.2 Hose Arrangements

Good Hose Arrangement

Poor Hose Arrangement

4. Remove screws, reservoir lid, reservoir seal, and baffle from the master cylinder
reservoir as shown in Figure 2.7.3 (the reservoir seal is supplied for shipping
purposes only, after removal discard reservoir seal).

Installation Instructions 2-15

2.7 Filling Hydraulic Release System continued
Figure 2.7.3 Reservoir Disassembly

Screw (2)

Reservoir Lid
Baffle
Reservoir Seal

5. Remove the screw and stat-o-seal on the slave cylinder, see Figure 2.7.4.
Figure 2.7.4 Screw and Stat-o-seal Removal

Slave Cylinder

Stat-o-seal washer

Screw

6. Fill the syringe with approximately 35 cc of hydraulic fluid and purge any
remaining air in the syringe and tubing. Screw the end of the bleed adapter into
the screw hole on the slave cylinder to create a tight seal. See Figure 2.7.5.
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.

2-16 Installation Instructions

2.7 Filling Hydraulic Release System continued

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.
Figure 2.7.5 Injecting Hydraulic Fluid

Bleed Adapter

Female X Barb Fitting

PVC Tubing

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 bleed adapter from the screw hole. Re-install the Stat-O-Seal (P/N
510-496-00) and screw (P/N 510-493-00), see Figure 2.7.6.

Installation Instructions 2-17

2.7 Filling Hydraulic Release System continued
Figure 2.7.6 Screw Re-installation

Stat-O-Seal

Screw

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 slowly cycle the
lever until there are no more. Actuating the lever releases air trapped within the
master cylinder.

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.

2-18 Installation Instructions

2.7 Filling Hydraulic Release System continued
12. Check the system for air by actuating the lever firmly until it bottoms out.
Check the push rod position (see Figure 2.7.7). 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.
Figure 2.7.7 Checking System for Air

Verify green ring on Lever

push rod is still visible

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 bleed kit with isopropyl alcohol. Allow it
to dry. Not cleaning the kit will render it unusable. Reassemble and store for
next use.

Installation Instructions 2-19

This page intentionally left blank.
Section 3
Operation Instructions
Operating Procedures
Prior to a flight involving external load operations perform the following.
1. Ensure that the hydraulic hose and electrical release harnesses do not
limit the movement of the cargo hook.
2. Be completely familiar with this manual, particularly the Cargo Hook
rigging section.
3. Be completely familiar with all Airbus Helicopters Cargo Hook
operating instructions and the ICA 123-013-01.
4. Activate the electrical system and press the cargo hook release button to
ensure the cargo hook electrical release is operating correctly. The
Cargo Hook must release. Reset the load beam by hand. If the hook
does not release or re-latch, do not use the unit until the problem is
resolved.

Depressing the electrical release button

continuously in excess of 20 seconds will cause
the release solenoid to overheat, possibly
causing permanent damage.
5. Activate the manual release lever in the cockpit to test the cargo hook
manual release mechanism. The mechanism should operate smoothly
and the Cargo Hook must release. Reset the load beam by hand. 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 manual release cover (see Figure 3.1). If
the hook does not release or re-latch, do not use the unit until the
problem is resolved.
Figure 3.1 Hook Lock Indicator
Hook Lock Indicator Hook Lock Indicator

ACCEPTABLE

Operation Instructions 3-1

Cargo Hook Loading
The cargo hook can easily be loaded with one hand. A load is attached to
the hook by pushing the ring upward against the upper portion of the load
beam throat, as illustrated in Figure 3.2, until an internal latch engages the
load beam and latches it in the closed position.
Figure 3.2 Cargo Hook Loading

Cargo Hook Rigging

Extreme care must be exercised when rigging a load to the Cargo Hook.
Steel load rings are recommended to provide consistent release performance
and resistance to fouling. Figure 3.3 shows the recommended rigging and
rigging to avoid, but is NOT intended to represent all rigging possibilities.

It is the responsibility of the operator to assure

the cargo hook will function properly with each
rigging.

Nylon type straps (or similar material) or rope

must not be used directly on the cargo hook load
beam. If nylon straps or rope must be used they
should be first attached to a steel primary ring.
Verify that the ring will freely slide off the load
beam when it is opened. Only the primary ring
should be in contact with the load beam.

3-2 Operation Instructions

Cargo Hook Rigging, continued
Figure 3.3 Examples of Cargo Hook Rigging

Recommended Avoid

Primary Ring

Long Line

Operation Instructions 3-3

This page intentionally left blank.
Section 4
Maintenance
Refer to the Instructions for Continued Airworthiness (ICA) manual 123-
013-01 for maintenance of the cargo hook kit. For maintenance specific to
the cargo hook refer to Cargo Hook Component Maintenance Manual 122-
015-00.

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
([email protected]).
 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
13915 NW 3rd Court
Vancouver, Washington 98685
USA
Phone: 360-546-3072

Maintenance 4-1
This page intentionally left blank.
Section 5
System Part Numbers
200-281-01 Cargo Hook Replacement Kit

Item Part No. Description Qty

1 232-222-00 Cargo Hook/Link Assembly 1
2 232-165-00 Master Cylinder Assembly 1
3 235-135-00 Disconnect Bracket 1
4 215-169-00 AS350 Light Indicator Placard 2
5* 510-453-00 Bolt 1
6* 510-042-00 Washer 1
7* 510-102-00 Nut 1
8* 512-005-00 Adel Clamp 1
9* 500-065-00 Grommet Edging 1
10* 505-014-00 Grommet 1
11* 450-001-00 1/8” Heat Shrink Tubing, 1” Lg. 2
12* 510-486-00 CherryMax Rivet 3

* Item not shown in Figure.

System Part Numbers 5-1

System Part Numbers continued
200-281-02 Cargo Hook Replacement Kit

Item Part No. Description Qty

1 232-222-00 Cargo Hook/Link Assembly 1
2 232-165-01 Master Cylinder Assembly 1
3 235-135-00 Disconnect Bracket 1
4 215-169-00 AS350 Light Indicator Placard 2
5 291-105-00 Friction Knob 1
6* 510-453-00 Bolt 1
7* 510-042-00 Washer 1
8* 510-102-00 Nut 1
9* 512-005-00 Adel Clamp 1
10* 500-065-00 Grommet Edging 1
11* 505-014-00 Grommet 1
12* 450-001-00 1/8” Heat Shrink Tubing, 1” Lg. 2
13* 510-486-00 CherryMax Rivet 3

* Item not shown in Figure.

5-2 System Part Numbers

System Part Numbers continued
232-222-00 Cargo Hook/Link Assembly
13 12

11

7
9

10

6
5
1

10

2
1
SLAVE CYLINDER ASSEMBLY INSTALLATION
BUMPER NOT SHOWN FOR CLARITY

Item Part Number Description Qty

1 528-028-00 Cargo Hook 1
2 232-241-00 Slave Cylinder Assembly w/ Plumbing 1
3 510-531-00 Screw 2
4 512-003-00 Ty-wrap 1
5 290-940-00 Bumper 1
6 270-138-00 Electrical Release Harness 1
7 510-170-00 Nut 1
8 290-775-00 Attach Bolt 1
9 510-174-00 Washer 1
10 510-183-00 Washer 1
11 232-146-00 Link Assembly 1
12 512-011-00 Ty-wrap 2
13 510-178-00 Cotter Pin 1

System Part Numbers 5-3

System Part Numbers continued
232-146-00 Link Assembly
1

Item Part Number Description Qty

1 290-771-00 Adapter Link 1
2 517-052-00 Bushing 1
3 290-364-00 Bushing 1

5-4 System Part Numbers

System Part Numbers continued
232-166-00, 232-166-01 Master Cylinder Assembly

11

22 21

10
15
2 5
14
24
13

12 25
4 1

1 20
18 16
6
2 17
7
23 19

ITEM P/N DESCRIPTION QTY

1 290-810-01 Master Cylinder 1
2 290-753-00 Clamp Half 1
3 290-811-00** Lever 1
4 290-816-00 Shaft 1
5 290-812-00 Barrel Nut 1
6 290-814-01 Piston 1
7 290-813-00 Push Rod 1
8 290-921-00 Reservoir Lid 1
9 556-044-00 O-Ring 1
10 510-390-00 Screw 2
11 510-157-00 #6-32 x ½” Button Head Cap Screw 2
12 510-487-00 Bolt 1
13 510-082-00 Nut 1
14 510-095-00 Washer 1
15 510-125-00 Cotter Pin 1
16 556-048-00 Cup Seal 1
17 556-047-00 O-Ring 1
18 514-055-00 Compression Spring 1
19 510-532-00 Washer – Piston Stop 1
20 515-008-00 Snap Ring 1
21 510-248-00 Helicoil 2
22 235-118-00 Master Cylinder Baffle 1
23 514-060-00 Compression Spring 1
24 510-530-00 #8-32 x 3/16” Nylon Tip Set Screw 1
25 510-042-00 Washer 1
** 232-166-01 (included with kit P/N 200-281-02) uses lever P/N 290-811-01.

System Part Numbers 5-5

System Part Numbers continued
232-241-00, Slave Cylinder Assembly with Plumbing

Item Part Number Description Qty

1 232-169-00 Slave Cylinder Assembly 1
2 232-240-021 Slave Cylinder Plumbing Assembly 1
3 560-006-00 Quick Disconnect 1
4 556-041-00 O-Ring 2
5 558-031-00 Banjo Bolt 1
1
This item supersedes P/N 232-240-00 & 232-240-01. These assemblies are interchangeable.

5-6 System Part Numbers

System Part Numbers continued
232-169-00, Slave Cylinder Assembly
1

6
7
5
3
2

Item Part Number Description Qty

1 290-803-00 Slave Cylinder 1
2 290-802-00 Cylinder Cap 1
3 290-805-00 Piston 1
4 517-040-00 Bushing 1
5 510-496-00 Stat-O-Seal 1
6 510-493-00 Screw 1
7 556-097-00 Quad Ring 1

System Part Numbers 5-7

This page intentionally left blank.
Section 6
Certification
FAA STC

Certification 6-1
FAA STC continued

6-2 Certification
Canadian Approval

Certification 6-3
EASA STC

6-4 Certification
EASA STC continued

Certification 6-5