Onboard Systems AS350 528-023-01, 528-029-00 cargo hook Service Bulletin

Service Bulletin
Document: 159-039-00
Revision: 0 Date: 11/16/16
SERVICE BULLETIN
Subject:
upgrade.
AS350 Cargo Hook replacement kits—manual release cable & bumper
Helicopters Affected: Airbus Helicopters AS350 series.
Parts Affected: Cargo Hook replacement kits installed under kit P/Ns listed in Table 1
below:
Table 1 – Affected Cargo Hook Replacement Kits
Kit P/N
Cargo Hook P/N
STC
200-261-00
528-023-01
SR00886SE
200-261-01
528-029-00
SR00886SE
Compliance: Recommended.
Ownership: Please review this information and determine if the equipment is still in
your possession. If this equipment is no longer in your possession, please forward this
notice to the current owner or to your customer, as applicable.
Description: Onboard Systems has received a report of an inadvertent load release
with a cargo hook using a manual release cable with a barrel-shaped inner cable
termination (see Figure 1). The large cable termination can potentially bind on the
manual release cover and prevent the cargo hook from completely re-latching—
resulting in an inadvertent load release.
Action: To comply with this bulletin, perform the following:
1) Check manual release cable configuration. Check the configuration of the
manual release cable installed. Onboard Systems release cables can be identified
by the part number marking on the cable housing. If P/N 268-024-00 or 268-024-02
is already installed, skip to step 3.
2) Replace manual release cable. If the configuration of the manual release cable
installed is any other than P/N 268-024-00 or 268-024-02, obtain manual release
cable P/N 268-024-02 and remove and replace the manual release cable per the
instructions in this Service Bulletin.
Page 1 of 8
Service Bulletin
Document: 159-039-00
Revision: 0 Date: 11/16/16
Figure 1 - Manual Release Cable Terminations
MS20664 cable ball
end on Onboard
Systems 268-024-00 &
268-024-02
Barrel-style termination
on non-Onboard
Systems release cable
3) Check for Cargo Hook bumper on Cargo Swing installation. The 200-261-00
and 200-261-01 kits can be installed in two basic configurations on the AS350
series, a Cargo Swing and Cargo Sling installation. See Figures 2 and 3.
If the cargo hook kit is installed on a Cargo Swing, check for presence of the cargo
hook bumper (see Figure 2). The bumper prevents damage to the manual release
cable as the cargo hook moves. This damage could cause the manual release
cable’s conduit to kink or separate from the fitting at the cargo hook and result in an
inadvertent load release.
If the bumper is not present, obtain the bumper kit P/N 232-155-00 and install per
the instructions in this Service Bulletin. The bumper is not necessary, nor adds
value to a Cargo Sling installation.
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Service Bulletin
Document: 159-039-00
Revision: 0 Date: 11/16/16
Figure 2 - AS350 Cargo ‘Swing’
Figure 3 - AS350 Cargo ‘Sling’
LB Rated Capacity
Model No. 528S/N
Date
CAGE Code 1Y921 Form 215-154-00
Portland, OR USA
Page 3 of 8
Service Bulletin
Document: 159-039-00
Revision: 0 Date: 11/16/16
Manpower: Approximately 1.0 man-hour(s) will be required.
Required Materials: Depending on which components are installed, one or both of the
following items are required for accomplishment of this bulletin.
Table 1 Materials
Part No.
Description
Quantity
268-024-02
Manual Release Cable
1
232-155-00*
Bumper Kit
1
*Bumper kit includes all attach hardware shown in figure 7 required for installation.
Special Tools: None
Weight and Balance: Not affected
Electrical Load Data: Not affected
References: None
Publications Affected: The following publications can be downloaded from the
company web site by visiting the following link:
http://www.onboardsystems.com/Support/Manuals_and_Documents.php
Owner’s Manuals: 120-094-00 and 120-094-01
ICA(s): 123-002-00 and 123-002-01
Contact Information: Technical support questions regarding this bulletin can be
addressed through the following contact methods:
Onboard Systems
13915 NW 3rd Court
Vancouver, WA 98685 USA
Phone: 360-546-3072
Fax: 360-546-3073
E-mail: [email protected]
Web: www.onboardsystems.com
Disposition of Parts Removed: Discard.
Material/Part availability: Contact Onboard Systems for pricing and availability of
replacement parts.
Page 4 of 8
Service Bulletin
Document: 159-039-00
Revision: 0 Date: 11/16/16
Accomplishment Instructions:
Section 1 of the accomplishment instructions provides instructions for replacing the
existing Manual Release Cable with Manual Release Cable P/N 268-024-02. Section 2
provides instructions for installing the Bumper Kit P/N 232-155-00 onto the cargo hook.
Section 1 – Manual Release Cable Replacement
Remove existing manual release cable
1. Disconnect the manual release cable from the fixed manual release cable at the
bracket on the belly of the helicopter and remove it from supporting clips on the belly
of the aircraft.
2. Remove the manual release cover from the cargo hook by removing two screws (see
Figure 4) and disengage the inner cable from the fork fitting in the cargo hook.
Unthread and remove the manual release cable.
3. Loosen the jam nut and unthread the Manual Release Cable Adapter and discard as it
will not be used with Manual Release Cable P/N 268-024-02.
Figure 4 - Manual Release Cover Removal (Cargo Hook P/N 528-023-01 shown)
manual release cover screws
Manual Release Cable Adapter
Install new manual release cable P/N 268-024-02
4. Thread the fitting at the end of the Manual Release cable P/N 268-024-02 into the side
plate until the threads extend through the boss (see Figure 6) and secure with jam nut.
5. Connect the other end of the manual release cable to the fixed manual release cable
by mating the cable end fittings as shown below. Slide the adapter fitting forward and
thread it onto the mating adapter fitting of the fixed manual release cable.
Page 5 of 8
Service Bulletin
Document: 159-039-00
Revision: 0 Date: 11/16/16
Figure 5 - Manual Release Cable Connection to Fixed Cable
Cable end fittings
AS350 fixed cable
Adapter fitting
of P/N 268-024-02
AS350 adapter fitting
6. At the cargo hook insert the inner cable through the fork fitting (see Figure 6).
7. Check the rigging of the Manual Release Cable by rotating the manual release lever in
the clockwise direction to remove free play (this is felt as the lever rotates relatively
easily for several degrees before free play is taken up) and measure the gap between
the cable ball end and the fork fitting as shown in Figure 6. This gap should be a
minimum of .125 inches (3.2 mm). If it is less than .125 inches, adjustments can be
made at the cargo hook by loosening the jam nut and threading the manual release
cable end fitting further. Adjustments can also be made at the Airbus release lever on
the collective.
Refer also to the applicable ICA for detailed information on the Manual Release Cable
rigging.
Failure to appropriately set the manual
release cable free play will result in
uncommanded release of load.
Page 6 of 8
Service Bulletin
Document: 159-039-00
Revision: 0 Date: 11/16/16
Figure 6 - Cargo Hook Rigging (Cargo Hook P/N 528-023-01 shown)
Ensure threads are flush or
extend past inside of boss.
manual release lever
fork
boss
cable ball end
.125" min.
(3.2 mm)
inner cable
Load beam must be
closed and locked
when rigging.
Adjustment of the manual release cable
free play must be accomplished with the
cargo hook load beam in the closed and
locked position.
8. Re-install manual release cover and secure screws with safety wire.
9. Move the cargo hook throughout its range of motion and verify that the manual release
cable is not pulled tight in any possible position of the cargo hook.
10. Verify manual release system function by pulling the release lever in the cockpit and
ensuring the cargo hook load beam falls open.
For safe operation of manual release
cable  Route to avoid strain

Rig with proper free play

Replace as condition requires
Page 7 of 8
Service Bulletin
Document: 159-039-00
Revision: 0 Date: 11/16/16
Section 2 – Bumper Kit Installation
Install the cargo hook bumper kit per the following.
1. Remove the cotter pin from the cargo hook’s attach bolt and remove the nut, washers,
and the attach bolt.
2. Disassemble the hardware that is provided pre-assembled onto the bumper and place
the bumper over the cargo hook in the orientation shown in Figure 7. The bumper is
an interference fit and it may be necessary to use a mallet to tap it into a position
where the attach bolt can be inserted.
3. Re-assemble the hardware through the bumper, cargo hook and the load cell as
shown below. Rotate the nut finger tight until fully seated. Back nut off to previous
castellation, if needed, when aligning cotter pin for installation.
Figure 7 - Cargo Hook Bumper Attachment to Cargo Hook
AS350 Swing Load Cell
Attach Bolt
P/N 290-775-00
Washer
P/N 510-183-00
Washer
P/N 510-174-00
Nut
P/N 510-170-00
Washer
P/N 510-183-00
Bumper
P/N 290-773-00
Cotter Pin
P/N 510-178-00
Cargo Hook
P/N 528-023-01 (shown)
or P/N 528-029-00
4. Make logbook entry as appropriate.
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