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Component Maintenance Manual,

Cargo Hook

Onboard Systems International

13915 NW 3rd Court
Vancouver, WA 98685 United States of America
Cage Code: 1Y921

Toll Free Phone: (800) 275-0883

Phone: (360) 546-3072
Fax: (360) 546-3073

Applicable Equipment Part Numbers

528-027-01
528-029-00
528-029-01
528-029-02
528-029-04
528-029-60

Please check our web site www.onboardsystems.com

for the latest revision of this manual.

This document is proprietary to Onboard Systems Int’l. Disclosure or reproduction is not allowed. © 2022 Onboard Systems Int’l., all rights reserved.
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RECORD OF REVISIONS

Revision Date Page(s) Reason for Revision

Changed solenoid in 528-029-01 to 455-007-00. Added
18 08/06/13 5, 6, 8, 22 requirement to maintain record of all cargo hook activity (pg 5).
Added Storage and Inactivity section. Added Section 6.3.
19 12/10/13 16-17 Added toggle pin installation warning.
20 03/03/14 12 & 14-26 Added Cam Bearing deburr warning and Figure 9.2.
Updated disassembly & assembly instructions and added photos.
21 03/24/15 9-10 & 16-25
Added 215-253-10 and 215-254-10 to Table 13.1 notes.
4, 10, 11, 13,
Added cargo hook P/N 528-029-02 (includes Surefire Release) and
22 01/26/16 23, 24, 25 -
associated instructions and parts. Removed Cam from NDT list.
33
Clarified disassembly instructions (sections 8.10 thru 8.13) and P/N
23 11/30/17 10, 13, 28
applicability of Surefire functionality and parts.
Removed NDT requirement for Solenoid Cam (7.2), Manual
24 01/19/18 10, 12 Release Lever (6.1) and Cam Roller Pin (13). Added inspection
criteria for Solenoid Cam and Release Lever to Table 9.1.
Added Connector Cap (item 7.15, applicable to cargo hook P/N
25 02/01/18 30, 32, 33
528-027-01 only) to Figure 13.1 and Table 13.1
Replaced NDT inspection of Toggle (4.2) and Load Beam
Assembly (2.2, 2.1) with magnified visual inspection; moved
26 01/14/20 6, 11
inspection step to Table 9.1. Changed item 1 of section 4.5 to
require a functional check rather than full ATP.
Added 528-029-04 and associated instructions. Added 212-072-00
27 06/08/22 All overhaul kit. Added load beam axial migration inspection step to
Table 9.1. Added -04 specific load beam damage criteria.
Added grace period to maintenance and overhaul schedule.
28 07/15/22 5, 8 Specified that calendar time is sufficient for -04 hook interval.
Added sections references for overhaul and maintenance.
29 07/19/22 4.3, 6.1 Maintenance grace period wording standardized.
Specified to inspect exterior for cracks, specified table 9.1 for
30 07/05/22 4.3, 10.26 inspection criteria. Added install instructions for manual release
guard.
Remove requirement to remove -04 hook from aircraft from annual
31 10/19/22 4.3, 4.4 inspection. Remove requirement to lubricate attach hardware from
annual inspection. Add biennial inspection for -04 hook only.

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1.0 Introduction
1.1 Scope. This component maintenance manual contains instructions for inspection,
maintenance and overhaul.
1.2 Capability. The instructions contained in this document are provided for the benefit of
experienced aircraft maintenance personnel and facilities that are capable of carrying out the
procedures.
1.3 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.
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2.0 Referenced Documents

180-172-00 Acceptance Test Procedure – Cargo Hook P/N 528-027-01, 528-029-00, 528-
029-02, 528-029-04, 528-029-60
180-180-00 Acceptance Test Procedure – Cargo Hook P/N 528-029-01

3.0 Service Bulletins/Amendments

3.1 This component is subject to the following service bulletins. Service bulletin documents may
be obtained from the Onboard Systems website. Verify compliance with all service bulletins
prior to maintenance.

Service Bulletin Description P/N Applicability S/N Applicability

159-026-00 Replace Manual Release 528-029-00 All

Cover P/N 290-898-00 with 528-029-01
P/N 290-898-01
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4.0 Maintenance
4.1 Maintain a record of ALL cargo hook activities including aircraft installation and removal,
inspections, repair and overhaul as well as inactivity and storage events.

Failure to follow all equipment maintenance

instructions and component inspection criteria
may result in serious injury, death or immediate
loss of flight safety.
4.2 Cleaning and Preventative Maintenance
1. As needed per visual condition, remove accumulated soils from exterior with a soft bristle
brush and mild solvent/cleaner.
2. As needed per visual condition, in salt water environments, apply a corrosion
preventative compound such as ACF-50 to all exterior surfaces.
4.3 Annual Inspection
1. Annually*, or 100 hours of external load operations, whichever comes first, remove the
Cargo Hook from the aircraft*. Thoroughly clean the exterior with a soft bristle brush and
mild solvent/cleaner and visually inspect exterior for cracks, gouges, dents, nicks,
corrosion, and missing or loose fasteners. See Table 9.1 for inspection criteria. A one-
month or 10-hour grace period can be applied if needed. No additional extension is
allowed beyond this grace period.
2. Lubricate the Cargo Hook Attach Bolt or the Pin Load Cell*. Recommended lubricants
are Mobilgrease 28 or AeroShell 7 grease.
*Cargo Hook P/N 528-029-04:
• Calendar time alone can be used to determine maintenance inspection intervals.
• Hook does not need to be removed from the aircraft for annual inspection.
• Attach hardware does not need to be lubricated at annual inspection.

4.4 Biennial Inspection (528-029-04 Only)

1. Biennially (every 24 months), or 200 hours of external load operations, whichever comes
first, remove the Cargo Hook from the aircraft. Thoroughly clean the exterior with a soft
bristle brush and mild solvent/cleaner and visually inspect exterior for cracks, gouges,
dents, nicks, corrosion, and missing or loose fasteners. See Table 9.1 for inspection
criteria. A two-month or 20-hour grace period can be applied if needed. No additional
extension is allowed beyond this grace period. Calendar time alone can be used to
determine maintenance inspection intervals.
2. Lubricate the Cargo Hook Attach Bolt. Recommended lubricants are Mobilgrease 28 or
AeroShell 7 grease.
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4.5 Overhaul
1. Overhaul the Cargo Hook in accordance with the overhaul schedule and instructions
contained in sections 7 and 9.
4.6 Storage and Inactivity
1. The Cargo Hook may be stored in its original factory sealed bag and box for up to 2 years
from its date of manufacture or last factory overhaul. If stored in its original factory sealed
bag and box for less than 2 years, it may be used without any additional activity. If the
period of storage in its original packaging is greater than 2 years, the Cargo Hook must
be subjected to a functional check before being used. Perform the functional check per
the instructions in section 11.7 through 11.9 of the acceptance test procedures (ATP)
herein.
2. If the Cargo Hook has been installed on an aircraft and subsequently removed from
service, store it in a reasonably protected indoor, dry, heated storage area for up to 6
months. If stored in this condition for less than 6 months, it may be used without any
additional activity. If it is to be stored longer than 6 months, perform the following
activities. Prepare the Cargo Hook for storage by thoroughly cleaning and drying the
exterior, liberally applying ACF-50 corrosion preventative compound inside and out,
sealing it in a plastic bag with a desiccant, and labeling it with the date of storage. If
stored in this condition for less than 2 years, it may be placed in service without any
additional activity. If the period of storage exceeds 2 years the Cargo Hook must be
subjected to the ATP described herein before being placed in service.
3. If the Cargo Hook has been installed on the aircraft and subsequently removed from
service but not stored in accordance with the instructions above, the Cargo Hook must
be subject to the ATP described herein before being placed in service.
4.7 Repair
1. Repair the Cargo Hook in accordance with the repair instructions contained here-in.
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5.0 Repair Instructions

5.1 It is recommended that only minor repairs be attempted by anyone other than the factory.
The following procedures and information 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 and suitable equipment to perform the acceptance
test procedures on the Cargo Hook after maintenance. See Section 14 for instructions for
returning equipment to the factory.
5.2 Reference numbers throughout this manual shown in parentheses ( ) refer to Table and
Figure 13.1.
5.3 Follow these steps to repair the Cargo Hook, referring to the applicable sections in this
manual:
1. Disassemble as required.
2. Inspect disassembled parts.
3. Obtain required replacement parts.
4. Reassemble.
5. Acceptance test.
6. Inspect for return to service.
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6.0 Overhaul Schedule

6.1 The Cargo Hook shall be overhauled every 1000 hours of external load operations or 5
years*, whichever comes first. A six-month or 100-hour grace period can be applied if
needed. No additional extension is allowed beyond this grace period.
6.2 Hours of external load operations should be interpreted to be (1) anything is attached to the
primary cargo hook (whether or not a useful load is being transported) and (2) the aircraft is
flying. If these conditions are not met, time does not need to be tracked. If a C-40 Load
Weigh Indicator is used in conjunction with the Cargo Hook, it can be used to track external
load hours.
6.3 The 5-year period is from the initial installation date when the Cargo Hook is new or newly
overhauled, regardless of storage or inactivity periods. If initial installation date is unknown,
then 5-year period is from date of manufacture as indicated on the Cargo Hook data plate or
5 years from date of last overhaul indicated on the overhaul sticker.
*Cargo Hook P/N 528-029-04: Calendar time alone can be used to determine maintenance,
inspection and overhaul intervals.
7.0 Overhaul Instructions
7.1 It is recommended that only minor repairs be attempted by anyone other than the factory.
The following procedures and information 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 and suitable equipment to acceptance test the
Cargo Hook after maintenance. See Section 14 for instructions for returning equipment to
the factory.
7.2 Overhaul kit P/N 212-024-00* is recommended to complete the Cargo Hook overhaul. The
overhaul kit contains all recommended items to be replaced at time of overhaul. Table 13.1
lists detail parts contained in the overhaul kit.
*For 528-029-04 use kit P/N 212-072-00
7.3 Follow these steps to overhaul the Cargo Hook, referring to the applicable sections in this
manual:
1. Obtain appropriate overhaul kit.
2. Completely disassemble.
3. Discard all items that are to be replaced by an item in the overhaul kit as listed in table
13.1.
4. Inspect disassembled parts.
5. Obtain any required replacement parts.
6. Reassemble.
7. Acceptance test.
8. Inspect for return to service.
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8.0 Disassembly Instructions

8.1 Remove manual release cover (14) by removing two screws (27).
8.2 For P/Ns 528-027-01 and 528-029-04 only - remove manual release guard cover (9) by
removing screw (31), nut (17) and spring (34).
8.3 Remove cotter pin (21), nuts (24 and 20) and washers (19 and 23).
8.4 Remove bolts (16) and (25) and for P/Ns 528-027-01 and 528-029-04 only – remove guard
base (10).

8.5 Remove Solenoid Assembly (7).

8.6 Remove nut (20) and bolt (26) and armor plates (11 and 12).
8.7 Remove cotter pin (22), nut (18) and washer (28) securing manual release lever.
8.8 Remove Manual Release Lever Assembly (6) and springs (33).
8.9 The Cargo 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.
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8.10 Note the orientation of the solenoid cam (7.2) and remove it by cutting the safety wire and
removing three screws (7.9).

8.11 The solenoid (7.6) may be removed from the cover by removing two nuts (7.7), two washers
(7.8) if applicable, and unsoldering its wires from the connector contacts. If the Surefire
Module (applicable to cargo hook P/N 528-029-02 only) is installed, unsolder the wires from
its terminals and remove the RTV silicone securing the wires to the cover. For 528-029-04
only, remove the connector contacts using the appropriate contact removal tools prior to
unsoldering the pins.
8.12 The Surefire Module (7.10, P/N 528-029-02 only) may be removed by unsoldering the
remaining two wires from its terminals, and removing the nut (7.12) from screw (7.11). The
module is assembled with RTV silicone between it and the solenoid cover so light prying will
be necessary to remove it.
8.13 The connector (7.5) may be removed by removing its nut on the outside of the cover. Note
the connector orientation before removing.
8.14 Remove the attach bushings (5.1 and 8.1) by pressing them out of the side plates.
8.15 Other bushings and bearings may be removed from detail parts by conventional means.
8.16 The load beam shaft (2.1) typically does not need to be disassembled from the load beam
(2.2).
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9.0 Inspection Instructions

9.1 Thoroughly clean all parts to be inspected using standard methods. Parts should be
completely free of surface contaminants, soils or grease before beginning inspections.
9.2 If the Cargo Hook is being overhauled, firstly perform nondestructive inspection on the
following parts to confirm absence of surface cracks which may have developed in service.
Confirmed cracks of any size are cause for part replacement.
For the Side Plate, Solenoid (8.2) and Side Plate, Manual Release (5.2), inspect using:
• Liquid penetrant inspection per ASTM E1417
Mark all indications and then interpret each under 10X magnification. Differentiate surface
cracks from other non-relevant indications such as machine tool marks, scratches, dents or
superficial corrosion.
9.3 Carefully inspect detail parts in accordance with the instructions in Table 9.1. Inspect the
parts in a clean, well-lighted room using standard dimensional measuring tools and visual
methods. Repair parts found within inspection limits. Replace any part found beyond limits.
Table 9.1, Cargo Hook Inspection Criteria
Seq Component Inspection Criteria & Repair Action Finish Recommended
Limit replacement at
overhaul.
1. Load Beam Surface cracks – None. Cracks of any N/A No
Assembly (2), inspect under size are cause for
Toggle (4.2) illuminated part replacement.
magnification
(minimum 2X / 4
diopter).
2. Load Beam Corrosion – 0.006 in. Glass bead blast at Passivate per No
Assembly (2) (0.127 mm) deep less than 30 PSI AMS-QQ-P-35 or
Manual Release (2.11 KGF/CM2) to ASTM A967
Lever (6.1) remove corrosion.
Solenoid Cam
(7.2)
Armor Plate (11,
12)
3. Load Beam Load Beam Shaft has Press out Load N/A No
Assembly (2) moved axially within Beam Shaft, clean
with the Load Beam - mating surfaces,
.393 in. ± .015 (ref. and press in with
Figure 9.3 Loctite 680 retaining
compound to depth
shown in Figure 9.3.
4. Side Plate (5.2, See Figure 9.1 Blend at 10:1 ratio as Apply alodine No
8.2) required to provide (MIL-DTL-5541)
smooth transitions. and zinc
chromate primer
(MIL-PRF-23377
or similar) to
affected surfaces
– see Note 1
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Seq Component Inspection Criteria & Repair Action Finish Recommended

Limit replacement at
overhaul.
5. Side Plate (5.2, Wear or deformation of None N/A No
8.2) top attach bushing hole
ID – 0.6264 in (15.91
mm)
6. Manual Rel. Dents, nicks, cracks, Blend at 10:1 ratio as Apply alodine No
Cover (14) gouges, scratches and required to provide (MIL-DTL-5541)
Solenoid Cover corrosion – 0.020 in. smooth transitions. & zinc chromate
(7.3) (0.50 mm) deep primer (MIL-
PRF-23377 or
similar) to
affected surfaces
– see Note 1.
7. Bearing (3.6, 3.7, Wear – more than 50% None N/A Yes
4.5, 5.5, 6.2, 8.4) copper showing
8. Bearing (4.6) Roughness, binding, None N/A Yes
looseness, or corrosion
9. Attach Bushing Wear on ID – 0.520 in None N/A Yes
(5.1, 8.1) (13.208 mm)
10. Bumper (32) Denting, cuts or None N/A Yes
abrasions – 0.060 in.
(1.27 mm) deep
11. Armor Plate (11, Gouges and nicks – Blend at 10:1 ratio as Passivate per No
12) 0.050 in. (1.27 mm) required to provide AMS-QQ-P-35 or
deep smooth transitions. ASTM A967
12. Cam Assembly See figure 9.2 None N/A No
(3)
13. Cam assembly Roughness, binding or Replace Interlock Pin N/A No
(3) looseness of the (3.4), Roller (3.1),
Interlock Roller 3.1) and Bearings (3.7)
14. Toggle Assembly Roughness, binding or Replace Pin (4.4), N/A No
(4) looseness of the Load Roller (4.1), and
Beam Roller (4.1) Bearings (4.5)
15. Cam roller pin Visible denting, None N/A No
(13) corrosion
16. Manual Release Deformation or None N/A No
Lever (6.1) damage at fork fitting
17. Solenoid Cam Any measurable wear None N/A No
(7.2) to cam surfaces
18. Load Beam (2.2) Wear, gouges and Blend at 10:1 ratio as Passivate per No
nicks – 0.050 in. (1.27 required to provide AMS-QQ-P-35 or
mm) deep smooth transitions ASTM A967
and ensure load
For -04 Cargo Hook rings will not hang up
See figure 9.4 during release.
19. Serial Number Damaged or illegible None N/A No
Plate (7.1)
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Seq Component Inspection Criteria & Repair Action Finish Recommended

Limit replacement at
overhaul.
20. Solenoid (7.6) Shorted or open None N/A No
electrical circuit.
For Cargo Hook P/N
528-029-01, resistance
1.2 to 1.6 ohms. All
other Cargo Hook P/Ns
except P/N 528-029-
02, resistance 3.0 to
4.0 ohms.
21. Surefire Module Bent or corroded None N/A No
(7.10)* terminals.
22. Electrical Loose, missing, or None N/A No
connector (7.5) mutilated contact pins,
cracked case, or worn
insulator
23. Rigging warning Damage or illegible None N/A Yes
decal (1)
24. Springs (33) Cracks or deformation None N/A Yes
25. Electrical wiring Deterioration None N/A No
26. All remaining Wear, corrosion or None N/A Yes
nuts, bolts, roll deterioration
pins, cotter pins,
washers, heli-
coils
Note 1 – For service at Onboard Systems, optional finish: black anodize per MIL-A-8625 Type II, Class 2
after nondestructive inspection. Prepare for anodize by using standard methods.
*Applicable to P/N 528-029-02 only.
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Figure 9.1, Side Plate, Additional Inspection Criteria

Side Plate, Manual (5.2)

Side Plate, Solenoid (8.2)

Inspection Criteria and Limits

Inside dashed circles – NO corrosion allowed.
Inside dashed circles – Dents, nicks, gouges, and scratches – 0.005 in (0.13 mm) deep.
Inside dashed lines – Dents, nicks, gouges, scratches, and corrosion – 0.010 in (0.25 mm) deep.
Outside dashed lines– Dents, nicks, gouges, scratches, and corrosion – 0.020 in (0.50 mm) deep.
(X) Approved metal stamp locations
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Figure 9.2, Cam Assembly (3) Bearing Inspection Criteria

No Repair
Allowed

Inspection Criteria and Limits:

Inside Lines: No wear, dents, corrosion, gouges or nicks allowed.

Thoroughly inspect surfaces inside lines for signs

of visible wear, dents, corrosion, gouges or nicks.
Continued use of a damaged cam may cause
inadvertent load release.

Repair (including filing, deburring and buffing) is

prohibited on all surfaces shown inside lines.
Alterations of these surfaces may cause
inadvertent load release.
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Figure 9.3 Load Beam Shaft Depth Figure 9.4 Load Beam Wear, Gouges, and Nicks*

.393±.015
(9.98±.38 mm)

*Applies to 528-029-04 Cargo Hook only.

Shaded area - Wear, gouges and nicks – 0.050 in. (1.27
mm) deep.
Non-shaded area - Wear, gouges and nicks – 0.010 in.
(0.25 mm) deep.
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10.0 Re-assembly Instructions

10.1 Replace all parts found to be unserviceable or beyond limits.
10.2 Measure the top attach bushing hole of side plates (5.2) and (8.2) with a bore gage to
determine if the standard attach bushing (5.1, 8.1) is appropriate or if an oversize attach
bushing P/N 290-294-01 is required. The oversize attach bushing P/N 290-294-01 may be
distinguished from the standard attach bushing by the presence of a groove on the OD.

10.3 Install correct attach bushing into side plates (5.2) and (8.2) as follows.

If top attach hole Use attach bushing: Installation

measures:

Less than .6257 in P/N 290-294-00 (5.1, 8.1) Install with wet zinc chromate
(15.893 mm) primer using an arbor press.
Ensure a continuous fillet seal of
primer around bushing flange
.6264 - .6270 in after installation.
(15.910 – 15.926 mm) P/N 290-294-01*
* Oversized Attach Bushing
P/N 290-294-01 is identified
by a groove on its OD as
shown.
Groove

.6257 - .6263 in P/N 290-294-00 (5.1, 8.1) Install with Loctite 680 adhesive
(15.893 – 15.908 mm) using an arbor press. Ensure a
continuous fillet seal of adhesive
.6271 - .6285 in
P/N 290-294-01 around bushing flange after
(15.928 – 15.954 mm)
installation.
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10.4 Press bearing (8.4) into side plate (8.2) with wet zinc chromate primer using an arbor press.
Split in bearing must be oriented towards the top of the hook. Press roll pin (8.3) into side
plate using an arbor press.

10.5 Press bearing (5.5) into side plate (5.2) with wet zinc chromate primer using an arbor press.
Split in bearing must be oriented towards the top of the hook.

10.6 Press roll pin (5.3) into side plate using an arbor press. Install two helicoils (5.4) into side
plate. Break and remove helicoil tangs.
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10.7 Assemble toggle (4): Press two bushings (4.5) into load beam roller (4.1) with wet zinc
chromate primer using an arbor press. Press two bushings (4.5) into toggle (4.2) with wet
zinc chromate primer using an arbor press. Press bearing (4.6) into toggle using an arbor
press. Capture load beam roller in toggle using pin (4.4). Ensure pin is installed as shown.
Secure pin with cotter pin (4.3).

10.8 Assemble cam (3): Press two bushings (3.7) into roller (3.1) with wet zinc chromate primer
using an arbor press. Press two bushings (3.6) into cam (3.2) with wet zinc chromate primer
using an arbor press. Capture roller with pin (3.4) and secure with cotter pin (3.3) as shown.
Attach spring (3.5) to cam.

10.9 Press bearing (6.2) into manual release lever (6.1) with wet zinc chromate primer using an
arbor press.
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10.10 Install bolt (15) through side plate (8.2). Apply a light coat of Mil-G-23827 grease to indicated
surfaces of side plate.

10.11 Place cam assembly (3) over the bolt. Extend spring (3.5) over roll pin (8.3).

10.12 Install load beam assembly (2) and bumper (32). Rotate cam (3) clockwise to install load
beam.
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10.13 With the load beam open all the way, install toggle assembly (4).

10.14 Apply Mil-G-23827 grease to bearing (4.6) and install cam roller pin (13).

Ensure that cam roller pin (13) is installed in the

toggle assembly, omitting installation of cam
roller pin will cause cargo hook to not function
properly and be damaged.
10.15 Check for and remove FOD if present
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10.16 Place Side Plate Assembly (5) over the assembly, lining up the bolt (15), roll pin (8.3), and
the load beam shaft (2.1).

10.17 Apply Mil-G-23827 grease to side plate surfaces that will contact the spring and install spring
(33) capturing cam and roll pin.
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10.18 Place manual release lever assembly over bolt (15). Secure using washer (28), nut (18),
and cotter pin (22). Install second spring (33) capturing the roll pin and inserting the looped
end into the slot on the manual release lever assembly (as shown).

Both springs must be installed.

Do not actuate the manual release lever without

the manual release cover installed. Actuating the
manual release lever may result in the spring
being ejected from the hook.
10.19 Apply a corrosion preventative compound to faying surfaces of armor plates (11 and 12)
and install using bolt (26) and nut (20).
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10.20 Install solenoid cam (7.2) onto solenoid using screws (7.9). Apply Loctite 262 to screw
threads. Safety wire screws as shown using .020 - .032 in [0.5 - 0.8 mm] diameter safety
wire. If the diode (7.4) and solenoid leads (7.6) were removed from the connector (7.5) re-
solder/install prior to assembling into cover. Install the connector using the O-ring and nut
included with the connector. Ensure the connector is installed in the proper orientation as
noted on disassembly. Place the solenoid into the solenoid cover (7.3). For cargo hook P/N
528-029-04, torque connector nut to 40-46 in-lb [4.5-5.2 N-m].

10.21 For cargo hook P/N 528-029-02 solder the wires from the solenoid to the inner two terminals
of the Surefire Module (7.10). Route each wire from the connector to the Surefire Module
through a ferrite cable core (7.13) twice. Solder the wire from connector pin B to the INPUT
terminal (terminal located nearest to the connector) of the Surefire Module and solder the
wire from the connector pin A to the GND terminal (terminal located furthest from the
connector), reference schematic below. Use Loctite 598 RTV silicone on the ferrite cable
cores to secure them to the inside of the cover.
If the Surefire Module was removed, apply a small amount of Loctite 598 RTV silicone to its
faying surface with solenoid cover and re-install it with the screw (7.11) and nut (7.12).

Surefire Module
INPUT
SOL +
(+28 VDC)
B
SOL - GND A
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10.22 Apply Loctite 598 RTV silicone to solenoid mounting studs and place S/N Tag (7.1) over
mounting studs and secure with two washers (7.8) where applicable, and nuts (7.7). Torque
nuts to 20-25 in-lb [2.3-2.8 N-m] plus drag torque. Install screw (29) and rigging warning
decal (1) as shown.

10.23 Install solenoid assembly onto cargo hook. Install bolt (16), washer (23), and nut (24).
Torque nut to 15 in-lb [1.7 N-m] then rotate to next castellation and install cotter pin (21).
Install bolt (25), washer (19), and nut (20). Torque to 20-25 in-lb [2.3-2.8 N-m]. For cargo
hook P/N 528-029-00, -01, -02, and -60 the bolt (16) is installed from the same side as the
solenoid assembly (7). On P/Ns 528-027-01 and 528-029-04 bolt (16) is installed from the
side opposite the solenoid assembly and the guard base (10) is captured underneath the
head (as shown in Figure 13.1).

10.24 Install manual release cover (14) using two screws (27). The screws may be loosely
installed as the cover will be removed for the ATP.
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10.25 For P/N 528-029-00, 528-029-01, 528-029-02, 528-029-04, and 528-027-01 hooks only:
safety wire connector nut to cover with .020 - .032 diameter safety wire as shown. Heat
shrink over safety wire is optional.

10.26 For P/Ns 528-027-01 and 528-029-04 only:

1. Install guard base (9) with bolt (16), nut (24) and washer (23). Torque nut (24) to 15
in-lb [1.7 N-m]. Rotate to next castellation and install cotter pin
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2. Bend two “arms” of the spring (34) inward and install under guard cover (9) using
screw (31) and nut (17) as shown. Torque nut to 10 - 12 in-lb [1.1-1.4 N-m].

10.27 Perform Acceptance Test Procedures as listed in this manual.

10.28 Fill out and affix Overhaul Label (P/N 215-260-00).
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11.0 Acceptance Test Procedure

11.1 When the Cargo Hook is overhauled or the side plates (5.2 and 8.2) are separated, the
Cargo Hook must be subjected to the following acceptance test procedure (ATP) steps
before being returned to service.
11.2 Examine the Cargo Hook externally for security of the lock wire, cotter pins and fasteners.
11.3 Use an appropriate insulation resistance tester to test the resistance between each pin and
the base of the connector (7.5). The readings should not be less than 2 mega-ohms.
11.4 For all configurations except P/N 528-029-02 use a multi-meter to check the resistance
between pins A and B of the electrical connector. Resistance should be:

Applicable P/Ns Resistance

528-027-01, 528-029-00, 528-029-04, and 528-029-60 3 – 4 ohms
528-029-01 1.2 – 1.6 ohms

11.5 Remove the two screws (27) and Manual Release Cover (14) and install a manual release
test cable. Replace the Manual Release Cover and screws.
11.6 Suspend the hook from a test rig capable of loading the Cargo Hook to 9,000 pounds (4082
kg). Use a steel ring to apply the load to the load beam.
11.7 Connect a power supply (see below for required VDC output) with a momentary release
switch wired into the positive wire, to the connector (7.5), and an in-line current meter.
Connect the negative lead to pin A and the positive lead to pin B. Set the voltage as follows:

Applicable P/Ns Voltage

528-027-01, 528-029-00, 528-029-02, 20 VDC + 0.1
528-029-04, 528-029-60
528-029-01 10.25 VDC + 0.1

11.8 With no load on the load beam, operate the manual release lever. The load beam should
fall open and stay in the open position. Push the load beam up and closed. The load beam
should automatically latch. Repeat step.
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11.9 Check the electrical release function of the Cargo Hook.

For all configurations except 528-029-02 perform the following.
With no load on the load beam, release the Cargo Hook with the electrical release. The
load beam should fall open and stay in the open position. Push the load beam up and
closed. The load beam should automatically latch. Repeat step.

Damage to the Cargo Hook release solenoid can

occur if the release switch is operated for more than
20 seconds continuously.
For the 528-029-02 configuration, perform the following.

The 528-029-02 cargo hook includes an electronic

delay of approximately ½ second. It is necessary to
press and hold the release switch.
Actuate the release switch very briefly without holding it down (less than ½ second). The
load beam should remain closed and the mechanism should not audibly cycle.
Actuate and hold the release switch for a few seconds. The load beam should fall to the
open position after approximately ½ second and then should continue to audibly cycle
repeatedly.
11.10 Load a suitable load ring onto the load beam (2.2) and push up load beam until it latches.
Gradually load the Cargo Hook with the test rig to 9,000 pounds (4082 kg). Hold the load
for 1 minute. The load beam should hold the load without unlatching. Reduce the load to
zero.

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.
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11.11 Load the Cargo Hook using a steel ring that is free to drop clear of the load beam. Gradually
load the Cargo Hook to 3,600 pounds (1633 kg). Using a spring scale or equivalent, pull the
manual release cable. The load beam should unlatch and the steel ring should slide off the
load beam. Verify the required release force is between 3.5 pounds (15.5 N) and 8 pounds
(35.5 N). Push the load beam up and closed. The load beam should automatically latch
and the hook lock indicator should align with the line on the manual release cover. Repeat
the test at 2,000 pounds (907 kg) and 600 pounds (272 kg).

Use of a nylon sling is not recommended for load

release tests as recoil may cause damage to the
Cargo Hook.
11.12 Load the Cargo Hook using a steel ring that is free to drop clear of the load beam. Gradually
load the Cargo Hook to 3,600 pounds (1633 kg). Press the electrical release button (press
and hold for P/N 528-029-02 cargo hook). The load beam should unlatch and the steel ring
should slide off the load beam. Push the load beam up and closed. The load beam should
automatically latch and the hook lock indicator should align with the line on the manual
release cover. Verify that the current draw is between 5 and 9 amps*. Repeat the test at
2,000 pounds (907 kg) and 600 pounds (272 kg).
*The 528-029-02 configuration delivers this current in rapid pulses which may register as a
lower current value on some ammeters due to averaging.
11.13 Remove the Cargo Hook from the test stand. Remove the manual release cable and replace
the Manual Release Cover (14) and screws (27).
11.14 End of Acceptance Test Procedure.
11.15 For service at Onboard Systems, optionally use the following Onboard Systems factory
acceptance test procedures:

Acceptance Test Procedure Applicable P/Ns

180-172-00 528-027-01, 528-029-00, 528-029-02, 528-029-04,
528-029-60
180-180-00 528-029-01
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12.0 Troubleshooting
12.1 The following section lists symptoms and probable causes to aid in equipment
troubleshooting.

Symptom Probable Cause Remedy

Failure to operate Damaged or defective Check for proper resistance across
electrically diode (7.4) or Surefire connector pins A and B per section
Module (7.10) or solenoid 11.4. If out of tolerance, remove the
(7.6). Solenoid Assembly (7) and
(diode is applicable to all disconnect the diode. Re-check for
hooks except P/N 528- proper resistance. Replace diode or
029-02, Surefire Module is solenoid as necessary.
used in P/N 528-029-02 For P/N 528-029-02, remove the
only). Solenoid Assembly from the Cargo
Hook and check the resistance
across the (+) and (-) Solenoid
terminals of the Surefire Module for
3 – 4 ohms. Replace Surefire
Module or solenoid (as necessary).
Damaged or loose wiring. Check for proper continuity across
connector pins A and B per table
9.1. Remove the Solenoid
Assembly (7) and repair wiring.
Release switch not held Hold the release switch for a longer
down long enough (P/N time. The 528-029-02 cargo hook
528-029-02 only). includes a Surefire Module (7.10)
which incorporates an electronic
delay of approximately ½ second
after which time the hook solenoid
will activate repeatedly. If the
release switch is not held down
long enough the solenoid will not
activate.
During the Friction in internal Check operation of unit using the
Acceptance Test mechanism. manual release lever. Disassemble
Procedure, the manual and inspect internal mechanism.
release cable force Check all bearing joints for free
exceeds requirements movement. Check cam assembly
(3) for denting/ damage. Check
toggle roller and pin for denting/
damage. Replace as necessary.
 13.0

3.4
Illustrated Parts List

3.1
3.6
3.7
Figure 13.1 Cargo Hook Parts

3.3

3.5
3.2
32
3.6
5.1 Surefire Components of P/N 528-029-02
5.2
30 19
20 8.3
8.4
Manual

5.4
Component

5.3 5.5
Maintenance

4.2
33
6.1 4.5
6.2
33
22
Date

13 4.6 4.4

4.5

12 4.1
28 4.3
20
27 4.5
18
31
10/19/22
Document Number

14
122-017-00

2.1

27 2.2

9
Page
31
Revision

32 of 36
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Table 13.1, Cargo Hook Parts

Overhaul Kit

Overhaul Kit
528-029-00

528-029-01

528-029-02

528-029-60

528-029-04

528-027-01

212-024-00

212-072-00
Item Part No. Description
1 215-240-00 Rigging Warning Decal 1 1 1 1 1 1 1 1
21 232-161-00 Load Beam Assembly 1 1 1 1 - 1 - -
21 232-161-02 Load Beam Assembly - - - - 1 - - -
2.1 290-640-00 Load Beam Shaft 1 1 1 1 - 1 - -
2.1 290-640-01 Load Beam Shaft - - - - 1 - - -
2.2 290-831-00 Load Beam 1 1 1 1 1 1 - -
31 232-162-00 Cam Assembly 1 1 1 1 1 1 - -
3.1 290-603-00 Roller 1 1 1 1 1 1 - -
3.2 290-832-00 Cam 1 1 1 1 1 1 - -
3.3 510-417-00 Cotter Pin 1 1 1 1 1 1 1 1
3.4 510-495-00 Pin 1 1 1 1 1 1 1 1
3.5 514-032-00 Spring 1 1 1 1 1 1 1 1
3.6 517-009-00 Bushing 2 2 2 2 2 2 2 2
3.7 517-031-00 Bushing 2 2 2 2 2 2 2 2
41 232-185-00 Toggle Assembly 1 1 1 1 - 1 - -
41 232-185-01 Toggle Assembly - - - - 1 - - -
4.1 290-438-00 Load Beam Roller 1 1 1 1 1 1 - -
4.2 290-838-00 Toggle 1 1 1 1 1 1 - -
4.3 510-417-00 Cotter Pin 1 1 1 1 1 1 1 1
4.4 510-494-00 Pin 1 1 1 1 - 1 1 -
4.4 509-004-00 Pin - - - - 1 - - 1
4.5 517-021-00 DU Bushing 4 4 4 4 4 4 4 4
4.6 517-060-00 Bearing 1 1 1 1 1 1 1 1
51 232-194-00 Side Plate Assembly, Manual Release 1 1 1 1 1 1 - -
5.1 290-294-00 Attach Bushing 1 1 1 1 1 1 1 1
5.2 290-897-00 Side Plate, Manual Release 1 1 1 1 1 1 - -
5.3 510-203-00 Roll Pin 1 1 1 1 1 1 1 1
5.4 510-210-00 Helicoil 2 2 2 2 2 2 2 2
5.5 517-010-00 Bearing 1 1 1 1 1 1 1 1
61,3 232-195-00 Manual Release Lever Assembly - - - - 1 1 - -
61,3 232-195-01 Manual Release Lever Assembly 1 1 1 1 - - - -
6.1 290-899-00 Manual Release Lever - - - - 1 1 - -
6.1 290-899-01 Manual Release Lever 1 1 1 1 - - - -
6.2 517-054-00 Bearing 1 1 1 1 1 1 1 1
71 232-212-00 Solenoid Assembly 1 - 1 - - - - -
71 232-212-01 Solenoid Assembly - 1 - - - - - -
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Overhaul Kit

Overhaul Kit
528-029-00

528-029-01

528-029-02

528-029-60

528-029-04

528-027-01

212-024-00

212-072-00
Item Part No. Description
71 232-212-02 Solenoid Assembly - - - 1 - - - -
71 232-212-03 Solenoid Assembly - - - - - 1 - -
71 232-872-00 Solenoid Assembly - - - - 1 - - -
7.1 215-192-00 SN Plate - - - 1 - - - -
7.15 215-253-00 SN Plate 1 - 1 - - - - -
7.15 215-254-00 SN Plate - 1 - - - - - -
7.1 215-264-00 SN Plate - - - - - 1 - -
7.1 215-435-00 SN Plate - - - - 1 - - -
7.2 290-835-00 Solenoid Cam 1 1 1 1 1 1 - -
7.3 290-941-00 Solenoid Cover 1 1 1 1 - 1 - -
7.3 292-119-00 Solenoid Cover - - - - 1 - - -
7.44 340-035-00 Diode 1 1 - 1 1 1 - -
7.5 410-139-00 Connector 1 1 1 1 - 1 - -
- 556-045-00 O-ring - - - - - - 1 -
7.5 410-475-00 Connector - - - - 1 - - -
7.6 455-003-00 Solenoid 1 - 1 1 1 1 - -
7.6 455-007-00 Solenoid - 1 - - - - - -
7.7 510-206-00 Nut 2 2 2 2 2 2 2 2
7.8 510-209-00 Washer 2 2 2 2 - 2 2 -
7.9 510-379-00 Screw 3 3 3 3 3 3 3 3
7.10 232-727-00 Surefire Module - - 1 - - - - -
7.11 511-118-00 Screw - - 1 - - - 1 -
7.12 510-922-00 Nut - - 1 - - - 1 -
7.13 320-028-00 Ferrite Cable Core - - 2 - - - - -
7.14 420-088-00 M22759/34 18 ga. Wire - - AR - - - - -
7.156 410-310-00 Connector Cap w/ Chain - - - - - 1 - -
81 232-213-00 Side Plate Assembly, Solenoid 1 1 1 1 1 1 - -
8.1 290-294-00 Attach Bushing 1 1 1 1 1 1 1 1
8.2 290-942-00 Side Plate, Solenoid 1 1 1 1 1 1 - -
8.3 510-202-00 Roll Pin 1 1 1 1 1 1 1 1
8.4 517-010-00 Bearing 1 1 1 1 1 1 1 1
9 235-120-00 Guard Cover - - - - 1 1 - -
10 235-121-00 Guard Base - - - - 1 1 - -
11 290-643-00 Armor Plate, Solenoid Side 1 1 1 1 1 1 - -
12 290-644-00 Armor Plate, Manual Side 1 1 1 1 1 1 - -
13 290-896-00 Cam Roller Pin 1 1 1 1 1 1 - -
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Overhaul Kit

Overhaul Kit
528-029-00

528-029-01

528-029-02

528-029-60

528-029-04

528-027-01

212-024-00

212-072-00
Item Part No. Description
14 290-898-01 Manual Release Cover 1 1 1 1 1 1 - -
15 290-901-00 Bolt 1 1 1 1 - 1 1 1
15 509-003-00 Bolt - - - - 1 - - 1
16 290-913-00 Bolt 1 1 1 1 - 1 1 -
16 509-002-00 Bolt - - - - 1 - - 1
17 510-029-00 Nut - - - - 1 1 - -
18 510-082-00 Nut 1 1 1 1 1 1 1 1
19 510-095-00 Washer 1 1 1 1 1 1 1 1
20 510-102-00 Nut 2 2 2 2 2 2 2 2
21 510-115-00 Cotter Pin 1 1 1 1 1 1 1 1
22 510-125-00 Cotter Pin 1 1 1 1 1 1 1 1
23 510-100-00 Washer - - - - 1 - - 1
23 510-219-00 Washer 1 1 1 1 - - 1 -
23 510-983-00 Washer - - - - 1 1 - -
23 540-796-00 Washer - - - - 1 - - 1
24 510-259-00 Nut 1 1 1 1 - 1 1 1
24 510-796-00 Nut - - - 1 - - 1
25 510-375-00 Bolt 1 1 1 1 1 1 1 1
26 510-376-00 Bolt 1 1 1 1 1 1 1 1
27 510-493-00 Screw 2 2 2 2 2 2 2 2
28 510-516-00 Washer 1 1 1 1 1 1 1 1
29 510-755-00 Screw 1 1 1 1 - 1 1 -
30 510-961-00 Screw - - - - 1 1 - -
31 510-963-00 Screw - - - - 1 1 - -
32 514-031-00 Bumper 1 1 1 1 1 1 1 1
33 514-058-00 Torsion Spring 2 2 2 2 2 2 2 2
34 514-089-00 Spring - - - - 1 1 - -
35 215-336-00 Surefire Notice Decal - - 1 - - - 1 -
362 215-260-00 Overhaul Label - - - - - - 1 1
1 Item not illustrated as an assembly.
2 Item not illustrated.
3 P/N 232-195-01 supersedes P/N 232-195-00 these parts are interchangeable.
4 Diode P/N 340-035-00 supersedes diode P/N 340-027-00.
5 For field installation use 215-253-10 (for 528-029-00) or 215-254-10 (for 528-029-10). Steel stamp or
engrave data in blank fields.
6 Connector Cap w/ Chain is optional and can be removed from cargo hook (applicable to P/N 528-027-01
only).
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14.0 Instructions for Returning Equipment to the Factory

14.1 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 International, LLC
13915 NW 3rd Court
Vancouver, Washington 98685
USA
Phone: 360-546-3072