Owner's Manual Dual Cargo Hook System

3.12 Installation Check-out..................................................................................... 87 3.13 Component Weights ...................................................................................... 89 3.14 Paperwork...................................................................................................... 90 4.0 Maintenance................................................................................................................. 91 5.0 Instructions for Returning Equipment to the Factory ............................................... 91 Owner’s Manual Document Number 120-155-00 Revision 7 Date 11/10/26 Page 4 of 91 This document is proprietary to Onboard Systems Int’l. Disclosure or reproduction is not allowed. © 2026 Onboard Systems Int’l., all rights reserved. 1.0 Introduction 1.1 Scope This manual contains instructions for installation of the Dual Cargo Hook System on Bell 206L, 206L-1, 206L-3, 206L-4 and 407 aircraft. 1.2 Capability The instructions contained in this document are provided for the benefit of experienced aircraft maintenance personnel and facilities that can carry 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. Owner’s Manual Document Number 120-155-00 Revision 7 Date 11/10/26 Page 5 of 91 This document is proprietary to Onboard Systems Int’l. Disclosure or reproduction is not allowed. © 2026 Onboard Systems Int’l., all rights reserved. 2.0 System Overview 2.1 Introduction The Dual Cargo Hook System is approved for carrying Human External Cargo (HEC) on the Bell 206L series and 407 model helicopters. The Dual Cargo Hook System includes: 1. A primary cargo hook and a secondary cargo hook to which a supplied Y- rope is connected to for carrying of HEC. These cargo hooks are Onboard Systems 528-028 series of cargo hooks with hydraulic release. Figure 2.1 Cargo Hook Overview Secondary Cargo Hook Y-rope Primary Cargo Hook Owner’s Manual Document Number 120-155-00 Revision 7 Date 11/10/26 Page 6 of 91 This document is proprietary to Onboard Systems Int’l. Disclosure or reproduction is not allowed. © 2026 Onboard Systems Int’l., all rights reserved. 2. Separate backup quick release sub-systems (BQRS) for the primary and secondary cargo hook. These systems are independently actuated by release levers installed on the cyclic (reference Figure 2.2) 3. A complete primary quick release sub-system (PQRS) for the secondary cargo hook including a release push button switch integrated into the secondary cargo hook release lever on the cyclic. 4. For the 407 model: a complete primary quick release sub-system (PQRS) for the primary cargo hook except for the release push button switch. The PQRS interfaces with the existing Bell cargo release switch integrated into the cyclic grip. For the 206L series models: the dual cargo hook system requires that the Bell fixed provisions including the primary cargo hook electrical release system is installed. Figure 2.2 Cargo Hook Controls Overview 5. Secondary Hardpoint. The secondary hardpoint is the internal structure installed in the foot well of the passenger seats; it provides the means to attach the secondary cargo hook to the aircraft. 6. Y-rope. The Y-rope is required as it provides a controlled interface between the two cargo hooks and the long line. 7. An optional Long Line Assembly designed to interface with the Y-rope and includes Lanyard Assemblies to connect to a personnel harness. secondary cargo hook's PQRS pushbutton switch primary cargo hook's BQRS lever Secondary cargo hook's BQRS lever primary cargo hook's PQRS pushbutton switch (existing TC switch) View Looking Aft and Inboard View Looking Forward and Outboard Owner’s Manual Document Number 120-155-00 Revision 7 Date 11/10/26 Page 7 of 91 This document is proprietary to Onboard Systems Int’l. Disclosure or reproduction is not allowed. © 2026 Onboard Systems Int’l., all rights reserved. 2.2 Specifications Table 2.1 P/N 232-800-00 Attach Point (Secondary) Specifications Rated Load* 800 lbs (363 kgs) Design Ultimate Strength 3,000 lbs (1,361 kgs) *Use of the secondary (forward) Attach Point is limited to dual cargo hook (HEC) operations with the slack line of the Y-rope attached to it. Do NOT exceed the rated load of 800 lbs with this configuration. Table 2.2 P/N 232-606-00 Beam Assembly (Primary) Specifications Rated Load** 2,650 lbs (1202 kgs) Design Ultimate Strength 9,938 lbs (4,508 kgs) **P/N 232-606-00 Beam Assembly is the previously approved configuration for NHEC operations under STC SR01943SE and this rated load remains applicable with the load attached ONLY to this attach point. Table 2.3 Cargo Hook P/N 528-028-00, 528-028-03 Specifications Rated load (P/N 528-028-00) 3,500 lbs. (1,580 kg.) Rated load (P/N 528-028-03) 800 lbs. (363 kg)*** Design ultimate strength 13,125 lbs. (5,953 kg.) Electrical release capacity 8,750 lbs. (3,970 kg.) Mechanical release capacity 8,750 lbs. (3,970 kg.) Force required for mechanical release at 3,500 lbs. 14 lbs max. @ Master Cylinder Electrical requirements 22-32 VDC 6.9 – 10 amps Minimum release load 0 lbs. Unit weight 3.0 lbs. (1.35 kg.) Mating electrical connector PC05A8-2S *** Cargo Hook P/N 528-028-03 is the secondary (forward) cargo hook and is a dedicated HEC cargo hook thus is limited to 800 lbs. (363 kg). Load ratings given are specific to the equipment described only. Loading limits for the helicopter still apply. Consult the basic flight manual issued by the TC holder and the flight manual supplement provided with the dual cargo hook system for limits. Owner’s Manual Document Number 120-155-00 Revision 7 Date 11/10/26 Page 8 of 91 This document is proprietary to Onboard Systems Int’l. Disclosure or reproduction is not allowed. © 2026 Onboard Systems Int’l., all rights reserved. 2.3 Bill of Materials – 407 Dual Cargo Hook System The following is a breakdown of the kits of the Dual Cargo Hook System for the 407 model. The Dual Cargo Hook System is broken down into several kit configurations to accommodate existing Onboard Systems cargo hook STC installations in the field, i.e. - if a cargo hook system is installed per Onboard Systems STC SR01943SE, most of this system can be used with an exception being the hydraulic release system must be replaced by the dual release system. The Onboard Systems trolley beam (per STC SR00898SE) and Bell’s TC trolley beam are not approved for use in the Dual Cargo Hook System. These installations must be upgraded to the fixed beam. An operator with a fixed beam with hydraulic hook per STC SR01943SE requires 200-459-00 or 200-459-01 Fixed Provisions, Secondary Hook (depending on LH or RH PIC) and 200-460-00 Removable Provisions, Secondary Hook. A Bell 407 operator with no cargo hook provisions would purchase a 200-456-00 (407 w/ LH PIC) or 200-456-01 (407 w/ RH PIC). Table 2.4 Bill of Materials – Dual Cargo Hook System P/N 200-456-XX Part No. Description Qty -00 -01 200-459-00 Fixed Provisions, Secondary Hook, LH PIC 1 - 200-459-01 Fixed Provisions, Secondary Hook, RH PIC - 1 200-460-00 Removable Provisions, Secondary Hook 1 1 200-461-00* Fixed Provisions, Primary Hook 1 1 200-395-00 Removable Provisions, Primary Hook 1 1 200-464-00 Pin Load Weigh Kit, C-40 Opt. Opt. *If the aircraft is equipped with an Onboard Systems trolley beam per STC SR00898SE or the Bell TC trolley beam kit, P/N 200-461-00 should be replaced by P/N 200-463-00 Pillow Block Kit which provides the structural mounts (Pillow Blocks) for connecting the fixed beam to the internal structural provisions. P/N 200-463-00 includes just the Pillow Blocks (P/N 232-188-01 for LH and P/N 232- 189-01 for RH) and their mounting hardware from kit P/N 200-461-00. If the aircraft is equipped with the Onboard Systems Fixed Provisions Kit P/N 200-328-00 or Bell P/N 206-706-341-111, -117, or -123 Auxiliary Equipment Kit – Cargo Hook Provisions, the P/N 200-461-00 kit should be replaced by P/N 200- 463-00 Pillow Block Kit. To verify the Pillow Block configuration present, refer to Section 3.6 for figures showing Pillow Blocks. Owner’s Manual Document Number 120-155-00 Revision 7 Date 11/10/26 Page 9 of 91 This document is proprietary to Onboard Systems Int’l. Disclosure or reproduction is not allowed. © 2026 Onboard Systems Int’l., all rights reserved. The parts included with the P/N 200-459-00 and 200-459-01 fixed provisions kits for the secondary cargo hook are listed below. These kits include the Dual Master Cylinder with Plumbing which includes the backup release provisions for both the primary cargo hook and secondary cargo hook. P/N 200-459-00 includes hydraulic release system components for installation for left hand PIC while P/N 200-459-01 is for installation for right hand PIC. Installation of the backup release levers on the left side does not constitute approval for left crew seat pilot-in-command operations. There must be provisions made to ensure that equipment originally intended to be operated by the pilot from the right crew seat is equally operable from the left crew seat with similar controls and left crew seat pilot-in-command operation must be approved. Table 2.5 Bill of Materials – Fixed Provisions Kits 200-459-00 & 200-459-01 Part No. Description Qty -00 -01 200-516-003 Cyclic Balance Adjustment Kit 1 1 212-014-02 Hydraulic Bleed Kit 1 1 215-390-00 External Load Limit Decal 1 1 215-399-00 MS27039-1-06 Decal 2 2 232-782-011,2 Forward Bulkhead Fitting Assy, 407 1 1 232-782-021,2 Aft Bulkhead Fitting Assy, 407 1 1 232-800-00 Secondary Attach Point Assembly 1 1 232-820-00 Dual Master Cylinder with Plumbing, LH 1 - 232-821-00 Dual Master Cylinder with Plumbing, RH - 1 232-826-00 Intermediate Plumbing 2 - 235-293-00 Disconnect Bracket 1 1 235-294-00 Doubler 1 1 235-295-00 Doubler 1 1 270-237-00 Internal Harness 1 1 270-238-00 External Fixed Release Harness 1 1 291-994-00 Bushing 4 4 291-996-00 Reinforced Tunnel, 407 1 1 291-997-01 Load Plate 1 1 410-218-00 Contact, 16/16 1 1 410-258-00 Ring Terminal, 16-14, #10 Stud 1 1 410-309-00 Ring Terminal, 16-14, #6 Stud 1 1 440-007-00 Circuit Breaker, 10A 1 1 Owner’s Manual Document Number 120-155-00 Revision 7 Date 11/10/26 Page 10 of 91 This document is proprietary to Onboard Systems Int’l. Disclosure or reproduction is not allowed. © 2026 Onboard Systems Int’l., all rights reserved. Part No. Description Qty -00 -01 445-005-00 Relay 1 1 500-062-00 Spacer - 2 510-095-00 Washer 53 56 510-100-00 Washer 8 8 510-102-00 Nut 3 4 510-390-00 Screw - 2 510-391-00 Screw 41 40 510-392-00 Screw - 2 510-419-00 Washer 1 1 510-580-00 Screw 2 2 510-644-00 Screw 2 4 510-645-00 Screw 5 5 510-646-00 Spacer 1 3 510-647-00 Spacer 5 7 510-652-00 Screw 2 4 510-688-00 Rivet 16 16 510-700-00 Screw 4 4 511-035-00 Insert 2 2 511-177-00 Bolt, 12-Point 4 4 511-178-00 Bolt, 12 Point 4 4 511-179-00 Nut, 12-Point 8 8 511-183-00 Insert, Molded-In 20 20 511-203-00 Perimeter Nut Plate 1 1 511-221-00 Screw 2 2 512-003-00 Cable Tie - Natural 24 24 512-005-00 Cushioned Loop Clamp 6 6 512-026-00 Cushioned Loop Clamp 6 6 512-028-00 Angle Bracket 1 2 512-034-00 Cushioned Loop Clamp 1 1 512-037-00 Cushioned Loop Clamp 2 6 512-067-00 Loop Clamp 1 1 512-068-00 Loop Clamp 2 2 512-069-00 Loop Clamp 1 1 540-032-00 2 oz. Bottle of Hydraulic Fluid 1 1 590-046-00 Spiral Hose Wrap 3/8 Inch, Black 36" 36" Notes: 1. P/Ns 232-782-02 and 232-782-03 w/ Shims (P/Ns 235-297-00 and 235-298- 00) replaced quantity 2 of P/N 232-782-00 for improved fit with aircraft (June 5, 2020). P/N 232-782-03 w/ shims was an interim configuration (see Note 2). 2. P/N 232-782-01 replaces Bulkhead Fitting Assembly P/N 232-782-03 and Shim P/Ns 235-297-00 and P/N 235-298-00 (September 8, 2020). 3. See Table 2.9 for Bill of Materials. Owner’s Manual Document Number 120-155-00 Revision 7 Date 11/10/26 Page 11 of 91 This document is proprietary to Onboard Systems Int’l. Disclosure or reproduction is not allowed. © 2026 Onboard Systems Int’l., all rights reserved. The parts included with the P/N 200-460-00 Removable Provisions, Secondary Cargo Hook are listed below. This kit includes the Secondary Cargo Hook with the Slave Cylinder w/Plumbing pre-installed, an Electrical Release Harness, and attach hardware. Table 2.6 Bill of Materials – P/N 200-460-00 Part No. Description Qty 232-822-00 Cargo Hook W/ Slave Cylinder 1 270-239-00 External Electrical Harness, Secondary 1 290-332-00 Attach Bolt 1 290-360-01 Bumper, 3.5k Hook 1 510-102-00 Nut 1 510-170-00 Nut 1 510-174-00 Washer 1 510-178-00 Cotter Pin 1 510-183-00 Washer 2 510-244-00 Bolt 1 510-712-00 Bolt 1 512-027-00 Cushioned Loop Clamp 1 512-058-00 Flat Bracket 1 The parts included with the P/N 200-461-00 Fixed Provisions Kits for the primary cargo hook are listed below. Table 2.7 Bill of Materials – P/N 200-461-00 Part No. Description Qty 215-205-00 J180 Decal 1 232-188-01 Pillow Block, Left 1 232-189-01 Pillow Block, Right 1 270-151-00 Electrical Harness 1 270-152-00 Electrical Harness 1 291-144-00 Bulkhead Fitting 2 291-145-00 Radius Block, Left 2 291-146-00 Radius Block, Right 2 291-152-00 Shim 1 410-243-00 Splice 2 440-007-00 Circuit Breaker, 10a 1 510-095-00 Washer 20 510-102-00 Nut 1 510-234-00 Nut 4 510-419-00 Washer 1 510-624-00 Screw 4 510-633-00 Screw 1 510-644-00 Screw 16 510-648-00 Washer 4 510-725-00 Bolt 4 512-003-00 Cable Tie - Natural 2 Owner’s Manual Document Number 120-155-00 Revision 7 Date 11/10/26 Page 12 of 91 This document is proprietary to Onboard Systems Int’l. Disclosure or reproduction is not allowed. © 2026 Onboard Systems Int’l., all rights reserved. The parts included with the optional P/N 200-464-00 Pin Load Weigh Kit are listed below. Table 2.8 Bill of Materials – P/N 200-464-00 Part No. Description Qty 210-282-01 Pin Load Cell Assembly 1 210-293-01* C-40 Load Weigh Indicator 1 215-010-00 Electronic Load Weigh Placard 1 270-241-00 Load Weigh Internal Harness 1 410-199-00 Shield Termination 1 410-255-00 Connector 1 410-446-00 Strain Relief Clamp 1 450-005-00 Heat Shrink 1/4" Black 2:1 1.5" 510-029-00 Nut 4 510-062-00 Washer 4 510-170-00 Nut 1 510-174-00 Washer 1 510-178-00 Cotter Pin 1 510-183-00 Washer 1 510-481-00 Screw 4 511-211-00 Screw 4 512-001-00 Cable Tie 3.5 In 10 512-026-00 Cushioned Loop Clamp 6 *C-40 Indicator P/N 210-293-01 replaces P/N 210-293-00 in new productions kits as of October 2023, these are interchangeable except for software compatibility. Refer to C-40 Owner’s Manual 120-152-00 for specific software versions. Installation of the Dual Master Cylinder on the cyclic on an aircraft with dual controls may require modification and replacement of some of the existing cyclic balancing components. Cyclic Balance Adjustment Kit P/N 200-516-00 is included with Fixed Provisions Kits 200-459-00 and 200-459-01 for the 407 model and is to be used if necessary. Table 2.9 – Bill of Materials - Cyclic Balance Adjustment Kit P/N 200-516-00 Part No. Description Qty 514-145-00 Spring 1 511-417-00 Insert 2 510-644-00 Screw 1 510-785-00 Washer 1 Owner’s Manual Document Number 120-155-00 Revision 7 Date 11/10/26 Page 13 of 91 This document is proprietary to Onboard Systems Int’l. Disclosure or reproduction is not allowed. © 2026 Onboard Systems Int’l., all rights reserved. 2.4 Bill of Materials – 206L Dual Cargo Hook System This section includes the kits of the Dual Cargo Hook System for the 206L series models. A 206L model must be equipped with the Bell fixed provisions including the electrical release wiring and the internal structural provisions for the primary cargo hook. The Onboard Systems trolley beam (per STC SR00898SE) and Bell’s TC trolley beam are not approved for use in the Dual Cargo Hook System. These components must be upgraded to the fixed beam. Table 2.10 lists the kits for the Dual Cargo Hook System installation on the 206L, of which all are required except for the optional Pin Load Weigh Kit. P/N’s 200- 395-00, 200-460-00, and 200-464-00 are the same as for the 407 model and their parts lists are included in 2.3 Table 2.10 Bill of Materials – Dual Cargo Hook System P/N 200-465-00 Part No. Description Qty 200-395-00 Removable Provisions, Primary Hook 1 200-460-00 Removable Provisions, Secondary Hook 1 200-462-00 Fixed Provisions, Secondary Hook 1 200-463-00 Pillow Block Kit 1 200-464-00 Pin Load Weigh Kit, C-40 Opt. Owner’s Manual Document Number 120-155-00 Revision 7 Date 11/10/26 Page 14 of 91 This document is proprietary to Onboard Systems Int’l. Disclosure or reproduction is not allowed. © 2026 Onboard Systems Int’l., all rights reserved. The parts included with the P/N 200-462-00 Fixed Provisions kit for the secondary cargo hook are listed in Table 2.11 below. This kit includes the Dual Master Cylinder with Plumbing which includes the backup release provisions for both the primary cargo hook and secondary cargo hook. Table 2.11 Bill of Materials – Kit P/N 200-462-00 Part No. Description Qty 212-014-02 Hydraulic Bleed Kit 1 215-390-00 External Load Limit Decal 1 232-783-00 Fwd Bulkhead Fitting Assy, 206L 1 232-784-00 Aft Bulkhead Fitting Assy, 206L 1 232-800-00 Secondary Attach Point Assembly 1 232-821-00 Dual Master Cylinder With Plumbing, RH 1 235-293-00 Disconnect Bracket 2 235-294-00 Relay Mount Doubler 40 235-295-00 Doubler 8 270-237-00 Internal Harness 4 270-238-00 External Fixed Release Harness 2 291-993-00 Reinforced Tunnel 46 291-994-00 Bushing 2 291-997-01 Load Plate 4 410-218-00 Contact, 16/16 5 410-258-00 Ring Terminal, 16-14 AWG, #10 Stud 3 410-309-00 Lug, Ring, 16-14 AWG, #6 Stud 7 440-007-00 Circuit Breaker, 10a 4 445-005-00 Relay 16 500-062-00 Spacer 4 510-095-00 Washer 2 510-100-00 Washer 4 510-102-00 Nut 4 510-390-00 Screw 8 510-391-00 Screw 2 510-392-00 Screw 10 510-644-00 Screw 18 510-645-00 Screw 1 510-646-00 Spacer 4 510-647-00 Spacer 24 510-652-00 Screw 6 510-688-00 Rivet 6 510-700-00 Screw 2 511-035-00 Insert 1 511-177-00 Bolt, 12-Point 6 511-178-00 Bolt, 12 Point 1 511-179-00 Nut, 12-Point 2 511-180-00 Screw 1 511-183-00 Insert, Molded-In 36" Continued on following page Owner’s Manual Document Number 120-155-00 Revision 7 Date 11/10/26 Page 15 of 91 This document is proprietary to Onboard Systems Int’l. Disclosure or reproduction is not allowed. © 2026 Onboard Systems Int’l., all rights reserved. Part No. Description Qty 511-184-00 Washer 1 511-203-00 Perimeter Nut Plate 1 511-221-00 Screw 1 512-003-00 Cable Tie - Natural 1 512-005-00 Cushioned Loop Clamp 1 512-026-00 Cushioned Loop Clamp 2 512-028-00 Angle Bracket 40 512-034-00 Cushioned Loop Clamp 8 512-037-00 Cushioned Loop Clamp 4 512-067-00 Loop Clamp 2 512-068-00 Loop Clamp 46 512-069-00 Loop Clamp 2 540-032-00 2 oz. Bottle of Hydraulic Fluid 1 590-046-00 Spiral Hose Wrap 3/8 Inch, Black 4 Owner’s Manual Document Number 120-155-00 Revision 7 Date 11/10/26 Page 16 of 91 This document is proprietary to Onboard Systems Int’l. Disclosure or reproduction is not allowed. © 2026 Onboard Systems Int’l., all rights reserved. 2.5 Bill of Materials – Long Line Kit Table 2.12 lists the items included with the Long Line Kit P/N 200-458-XX. This kit provides the required Y-rope and all components, including a lanyard, to connect to a human harness. The Y-rope is the only mandatory P/N of the Long Line Kit as it interfaces with the cargo hooks. Locally approved alternate components to connect to the Y-rope may be used. The kit P/N is completed by replacing the XX by a two-digit number which is multiplied by 10 to define the length of the included long line, for example – kit P/N 200-458-10 includes a 100-foot-long line (P/N 490-015-10), Kit P/N 200-458- 15 would include a 150-foot-long line (P/N 490-015-15), etc. Table 2.12 Bill of Materials – Long Line Kit (P/N 200-458-10 listed) Part No. Description Qty 292-017-00 Rigging Plate 1 490-019-00 Y-Rope 1 490-015-10 Long Line, 100 ft 1 490-017-00 25 LB Long Line Weight Bag 1 490-018-00 Lanyard 1 530-031-00 Carabiner 2 Owner’s Manual Document Number 120-155-00 Revision 7 Date 11/10/26 Page 17 of 91 This document is proprietary to Onboard Systems Int’l. Disclosure or reproduction is not allowed. © 2026 Onboard Systems Int’l., all rights reserved. 3.0 Installation These installation instructions 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. The installation instructions are separated into the following sections and cover a complete installation. If the aircraft is equipped with an existing cargo hook installation, some of these sections can be skipped as noted. 1. Installation of the support structure for the secondary cargo hook (i.e. – secondary hardpoint) is addressed in section 3.1 for the 407 model and section 3.2 for the 206L model. 2. Installation of the internal support structural fittings for the primary cargo hook is covered in section 3.3. These fittings are present on an aircraft with a cargo hook previously installed. 3. Section 3.4 includes instructions for the installation of the fixed side hydraulic release system including creating of a hole in the belly panel under the seat and installation of Doublers. 4. Section 3.5 addresses installation of the fixed electrical wiring for the primary cargo hook (this wiring will be present with an existing cargo hook installation), the secondary cargo hook, and the optional load weigh system. 5. Sections 3.6 and 3.7 provide instructions for installation of the primary cargo hook and the secondary cargo hook respectively. Owner’s Manual Document Number 120-155-00 Revision 7 Date 11/10/26 Page 18 of 91 This document is proprietary to Onboard Systems Int’l. Disclosure or reproduction is not allowed. © 2026 Onboard Systems Int’l., all rights reserved. 3.1 Secondary Hardpoint Installation - 407 The secondary hardpoint includes structure that is installed in the passenger foot well, replacing the existing cover over the fuel lines (see Figure 3.1). It provides the aircraft structural attachment means for the secondary cargo hook. For a 206L series model, refer to Section 3.2. If the aircraft is already equipped with the secondary hardpoint installed per STC SR02651LA then skip to section 3.3. Figure 3.1 Secondary Hardpoint Installation Overview Reinforced Tunnel Bulkhead Fittings Load Plate Secondary Attach Point Assembly passenger footwell aft bulkhead Owner’s Manual Document Number 120-155-00 Revision 7 Date 11/10/26 Page 19 of 91 This document is proprietary to Onboard Systems Int’l. Disclosure or reproduction is not allowed. © 2026 Onboard Systems Int’l., all rights reserved. The following hardware is included with kit P/N 200-459-00 and P/N 200-459-01 for installing the secondary hardpoint fittings. P/N Description Qty 510-095-00 Washer 44 510-100-00 Washer 8 510-391-00 Screw 40 510-580-00 Screw 2 511-177-00 Bolt, 12 Point 4 511-178-00 Bolt, 12 Point 4 511-179-00 Nut, 12 Point 8 511-183-00 Insert, Molded-in 20 511-221-00 Screw 2 At the bulkhead panels at each end of the foot well use caution to not break through and damage the fuel tanks behind each panel. 1. Remove existing rivets and the three angle brackets (that supported the removed Bell tunnel) from the forward bulkhead (FS 100). For the row of five rivets supporting the horizontal bracket, the three from the left (circled below) support a bracket which supports a fuel line fitting. The tails of the two outer of these three rivets cannot be removed and can be left in place. 2. Replace the center rivet of these three rivets with a blind countersunk head rivet (CR3212 series with grip length as needed) to secure the bracket. Figure 3.2 Brackets and Rivets to Remove (Forward Bulkhead) Owner’s Manual Document Number 120-155-00 Revision 7 Date 11/10/26 Page 20 of 91 This document is proprietary to Onboard Systems Int’l. Disclosure or reproduction is not allowed. © 2026 Onboard Systems Int’l., all rights reserved. 3. If in possession of Bulkhead Fitting Assembly P/N 232-782-00 or P/N 232- 782-03 use shims (P/N 235-297-00 and 235-298-00) to accommodate the several different layers/surfaces on the forward bulkhead. Match drill (Ø0.201”) the lower row of 5 holes in P/N 232-782-00 or middle row of 5 holes in P/N 232-782-03 through shims as applicable. Fwd Bulkhead Fitting P/N 232-782-01 does not use shims; it is machined to fit the “stepped” surfaces of the forward bulkhead. 4. Position the Fwd Bulkhead Fitting on the forward bulkhead panel. Center it over the opening for the fuel lines. Figure 3.3 Forward Bulkhead Fitting Location 5. Match drill fastener pattern from the bulkhead fitting into the outer skin of forward bulkhead panel using a #7 drill (10 places total). For P/N 232-782-03, the lower row of 5 holes is not used. Use the two upper rows. 6. Remove the bulkhead fitting and enlarge the holes to Ø.561/.566” for the NAS1832-3 inserts (P/N 511-183-00). Deburr all holes. Fwd Bulkhead Fitting Assembly P/N 232-782-01* Forward bulkhead panel (FS 100) of passenger footwell fuel line *supersedes 232-782-00 and 232-782-03 This row of fasteners is present on P/N 232-782-03 only. Owner’s Manual Document Number 120-155-00 Revision 7 Date 11/10/26 Page 21 of 91 This document is proprietary to Onboard Systems Int’l. Disclosure or reproduction is not allowed. © 2026 Onboard Systems Int’l., all rights reserved. 7. Install the inserts per Bell manual BHT-206-SRM-1, Chapters 3-2-11 and -12 (Figure 3-4) using a Bell C-317 adhesive. Follow manufacturer instructions for handling and curing. Allow adhesive to fully cure. 8. Secure the bulkhead fitting to the forward bulkhead panel using the 10 screws (P/N 510-391-00) and washers (P/N 510-095-00) provided. At the aft bulkhead: 9. Position the Aft Bulkhead Fitting Assembly (P/N 232-782-02) or Bulkhead Fitting Assembly (P/N 232-782-00) on the aft bulkhead panel at FS 121. Center it over the opening for the fuel lines in the bulkhead panel. Verify there is clearance with the fuel lines. The bracket supporting the fuel line has slots which may provide some downward adjustment. Ensure there is clearance with fuel line and fuel line fitting. 10. To check alignment with the forward bulkhead fitting set the Reinforced Tunnel in place. 11. Remove the Reinforced Tunnel. 12. Match drill fastener pattern from the bulkhead fitting into the outer skin of the aft bulkhead panel using a #7 drill (10 places total). At the bulkhead panels at each end of foot well use caution to not break through and damage the fuel tanks behind each panel. 13. Remove the bulkhead fitting and enlarge the holes to Ø.561/.566” for the NAS1832 inserts (P/N 511-183-00). Deburr all holes. 14. Install the inserts per Bell manual BHT-206-SRM-1, Chapters 3-2-11 and -12 (Figure 3-4) using a Bell C-317 adhesive. Follow manufacturer instructions for handling and curing. Allow adhesive to fully cure. 15. Match drill Ø.201” the Bulkhead Fitting to the existing lower insert locations in the aft bulkhead on each side of the opening for the fuel lines (refer to Figure 3.4). Deburr the holes. Owner’s Manual Document Number 120-155-00 Revision 7 Date 11/10/26 Page 22 of 91 This document is proprietary to Onboard Systems Int’l. Disclosure or reproduction is not allowed. © 2026 Onboard Systems Int’l., all rights reserved. Figure 3.4 New Holes in Aft Bulkhead Fitting 16. Secure the Bulkhead Fitting to the aft bulkhead panel using twelve (12) screws (P/N 510-391-00) and washers (P/N 510-095-00). 17. Position the Reinforced Tunnel (P/N 291-996-00) between the two bulkhead fittings, referring to Figure 3.5 for orientation. The Reinforced Tunnel is NOT symmetrical; it must be oriented such that the 4-hole pattern (which supports the secondary cargo hook) is closer to the forward bulkhead of the footwell (refer to Figure 3.5). 18. Transfer the threaded inserts pattern in the floor (used to attach the Bell cover) to each of the lower flanges (a “hole finder” tool is suggested). Drill Ø.201” diameter (14 places) through the lower flanges. Aft Bulkhead Fitting Assembly P/N 232-782-02* Aft bulkhead panel (FS 121) of passenger footwell Transfer these hole locations from inserts in bulkhead panel. *supersedes 232-782-00 Owner’s Manual Document Number 120-155-00 Revision 7 Date 11/10/26 Page 23 of 91 This document is proprietary to Onboard Systems Int’l. Disclosure or reproduction is not allowed. © 2026 Onboard Systems Int’l., all rights reserved. Figure 3.5 Orientation of Reinforced Tunnel 19. Mark and match drill Ø.201” each end (4 places each end, 8 places total) of the Reinforced Tunnel with the Bulkhead Fittings fastener pattern (see Figure 3.6). Transfer hole locations from floor inserts. (14 places) Forward View Looking Down Passenger Footwell 4 hole pattern must be closer to forward bulkhead Owner’s Manual Document Number 120-155-00 Revision 7 Date 11/10/26 Page 24 of 91 This document is proprietary to Onboard Systems Int’l. Disclosure or reproduction is not allowed. © 2026 Onboard Systems Int’l., all rights reserved. Figure 3.6 Bulkhead Fitting Locations to Transfer to Tunnel 20. Temporarily secure the Reinforced Tunnel in position to match drill through the floor. 21. With the Reinforced Tunnel secured drill Ø.25” through the floor using the 4- hole pattern (shown in Figure 3.5). 22. Remove the Reinforced Tunnel and ream the holes in the floor to Ø.375” for the bushings (P/N 291-994-00). 23. Dry fit the bushings; the bushings should be flush or protrude slightly (.010” max.) past top and bottom skins. 24. Prep the floor panel with core removal per Bell SRM Section 3-2-11. 25. Install bushings wet with a Bell C-317 adhesive. 26. Reinstall the Tunnel with fourteen (14) screws (P/N 510-391-00) and washers (P/N 510-095-00) through its lower flanges into the floor inserts and two (2) of these screws and washers into each vertical flange of each bulkhead fitting. Transfer these four (4) hole locations to Tunnel (both ends) Owner’s Manual Document Number 120-155-00 Revision 7 Date 11/10/26 Page 25 of 91 This document is proprietary to Onboard Systems Int’l. Disclosure or reproduction is not allowed. © 2026 Onboard Systems Int’l., all rights reserved. 27. Use two (2) P/N 510-580-00 (MS27039-1-06) screws and washers (P/N 510- 095-00) at the aft end of the top horizontal surface of the Reinforced Tunnel into the horizontal flange of the aft Bulkhead Fitting (P/N 232-782-02). Apply decal P/N 215-399-00 to the top surface adjacent to each of these screw heads. If Bulkhead Fitting P/N 232-782-00 (has nutplates under horizontal flange) is installed, use two (2) P/N 511-221-00 (MS27039-1-09) screws and washers (P/N 510-095-00). Modify the decal to indicate the -09 screw. Do not substitute screws that secure the Reinforced Tunnel to the Bulkhead Fittings. Longer screws may contact the fuel line and/or fuel line fittings. If longer screws are used, verify that they do not contact the fuel lines. Figure 3.7 Screws for Attaching Tunnel to Bulkhead Fitting 28. Use two (2) P/N 510-580-00 (MS27039-1-06) screws at the forward end of the top horizontal surface of the Reinforced Tunnel into the horizontal flange of the Forward Bulkhead Fittings. Aft Bulkhead Fitting Use P/N 511-221-00 (MS27039-1-09) screws, on both sides Use P/N 510-580-00 (MS27039-1-06) screws if tapped holes are present on bulkhead fitting flange. Use P/N 511-221-00 (MS27039-1-09) screws if nutplates are present. Decal P/N 215-399-00 Owner’s Manual Document Number 120-155-00 Revision 7 Date 11/10/26 Page 26 of 91 This document is proprietary to Onboard Systems Int’l. Disclosure or reproduction is not allowed. © 2026 Onboard Systems Int’l., all rights reserved. 29. Referring to Figure 3.8 place four screws (P/N 511-177-00) in the inner four counterbored-hole pattern of the Load Plate (P/N 291-997-01) and secure the Secondary Hardpoint Assembly (P/N 232-800-00) with its bolt head oriented forward to the Load Plate (refer to engraved arrow on it) with washers (P/N 510-100-00) and nuts (P/N 511-179-00). Torque the nuts to 50-70 in-lbs. 30. Remove the paint from the aircraft skin that will mate with the Load Plate to create an electrical bond. Apply a MIL-DTL-5541 chemical conversion coating (Alodine 1001 or Alodine 1201 or similar) to the exposed bare metal. 31. Position the Load Plate on the belly with the FWD arrow pointing forward and secure it to the belly through the Tunnel with the four bolts (P/N 511-178-00), washers (P/N 510-100-00), and nuts (P/N 511-179-00). Torque the nuts to 50-70 in-lbs. 32. Torque stripe the eight nuts. Figure 3.8 Load Plate and Secondary Hardpoint Assembly Installation Reinforced Tunnel Load Plate P/N 291-997-00 Bolt P/N 511-178-00 4X Bolt P/N 511-177-00 4X Nut P/N 511-179-00 4X Attach Point Assembly P/N 232-800-00 Nut P/N 511-179-00 4X Washer P/N 510-100-00 4X Aircraft belly panel not shown Forward Bolt head oriented forward Washer P/N 510-100-00 4X Owner’s Manual Document Number 120-155-00 Revision 7 Date 11/10/26 Page 27 of 91 This document is proprietary to Onboard Systems Int’l. Disclosure or reproduction is not allowed. © 2026 Onboard Systems Int’l., all rights reserved. 3.2 Secondary Hardpoint Installation – 206L Models The secondary hardpoint is installed in the passenger foot well, replacing the existing cover over the fuel lines. If the aircraft is already equipped with the secondary hardpoint installed per STC SR02651LA then skip to section 3.3. Install the components per the following. The following hardware is provided with kit P/N 200-462-00 for installing the secondary hardpoint. P/N Description Qty 510-095-00 Washer 28 510-100-00 Washer 8 510-391-00 Screw 46 511-177-00 Bolt, 12 Point 4 511-178-00 Bolt, 12 Point 4 511-179-00 Nut, 12 Point 8 511-180-00 Screw, C’Sink 2 511-183-00 Insert, Molded-in 10 511-184-00 Washer, Reduced OD 18 511-221-00 Screw 4 At the bulkhead panels at forward and aft ends of foot well use caution to not break through and damage the fuel tanks behind each panel. 1. Match drill Ø.201” in the Forward Bulkhead Fitting (P/N 232-783-00) using the existing fastener pattern in the forward bulkhead panel at FS 96.44 (ref. Figure 3.9) The Bulkhead Fitting should be centered over the opening for the fuel lines in the bulkhead panel. Deburr all holes. 2. Match drill the horizontal flanges of the Forward Bulkhead Fitting using the existing insert pattern in the floor (ref Figure 3.9). Deburr all holes. Owner’s Manual Document Number 120-155-00 Revision 7 Date 11/10/26 Page 28 of 91 This document is proprietary to Onboard Systems Int’l. Disclosure or reproduction is not allowed. © 2026 Onboard Systems Int’l., all rights reserved. Figure 3.9 Forward Bulkhead Fitting Installation 3. Secure the Forward Bulkhead Fitting to the bulkhead panel using ten screws (P/N 510-391-00) and washers (510-095-00) and to the floor inserts using four of these same screws and washers. 4. Position the Aft Bulkhead Fitting at the aft bulkhead panel with it centered over the opening for the fuel lines. Ensure clearance with fuel lines. Alignment with the Fwd Bulkhead Fitting can be checked by setting the Reinforced Tunnel in place. 5. Match drill fastener pattern from the Aft Bulkhead Fitting (P/N 232-784-00) into the outer skin of aft bulkhead panel using a #7 drill (10 places total). Do not break through and damage fuel tank. 6. Remove the bulkhead fitting and enlarge the holes to Ø.561/.566” for the NAS1832 inserts (P/N 511-183-00). Deburr all holes. 7. Install the inserts per Bell manual BHT-206-SRM-1, Chapters 3-2-11 and -12 (Figure 3-4) using a Bell C-317 adhesive. Follow manufacturer instructions for handling and curing. Allow adhesive to fully cure. 8. Match drill Ø.201” and 100° countersink the Bulkhead Fitting to the existing dome nut locations on each side of the opening for the fuel lines (refer to Figure 3.10). Deburr the holes. Forward bulkhead panel (FS 96.44) of passenger footwell fuel line Forward Bulkhead Fitting Assembly P/N 232-783-00 Drill ten (10) holes in vertical flange to match insert locations in bulkhead panel. Drill two (2) holes in each lower flange to match insert locations in floor. Owner’s Manual Document Number 120-155-00 Revision 7 Date 11/10/26 Page 29 of 91 This document is proprietary to Onboard Systems Int’l. Disclosure or reproduction is not allowed. © 2026 Onboard Systems Int’l., all rights reserved. Figure 3.10 Match Drill Locations on Bulkhead Fitting 9. Secure the Aft Bulkhead Fitting to the bulkhead panel using ten screws (P/N 510-391-00) and washers (P/N 510-095-00) and two screws (P/N 511-180- 00) at the countersunk locations. 10. Position the Reinforced Tunnel (P/N 291-993-00) between the two bulkhead fittings with it oriented as shown in Figure 3.11 and transfer the threaded inserts pattern in the floor to each of the lower flanges (a “hole finder” tool is suggested). Drill Ø.201” diameter (18 places) through the lower flanges and spot face .406” around holes to fit washers. Bulkhead Fitting Assembly P/N 232-782-00 Aft bulkhead panel of passenger footwell Drill Ø.201 hole and 100° C'sink to match the existing dome nut locations (2 places). Owner’s Manual Document Number 120-155-00 Revision 7 Date 11/10/26 Page 30 of 91 This document is proprietary to Onboard Systems Int’l. Disclosure or reproduction is not allowed. © 2026 Onboard Systems Int’l., all rights reserved. Figure 3.11 Orientation of Reinforced Tunnel 11. Mark and match drill each end of the Reinforced Tunnel with the Bulkhead Fittings fastener pattern. Figure 3.12 Bulkhead Fitting Hole Locations to Transfer to Tunnel 12. Temporarily secure the Reinforced Tunnel in position in order to match drill through the floor. Forward Bulkhead Fitting Orient Tunnel so the end with the step is over the forward bulkhead fitting flange. Transfer these four (4) hole locations to Tunnel (both ends) Owner’s Manual Document Number 120-155-00 Revision 7 Date 11/10/26 Page 31 of 91 This document is proprietary to Onboard Systems Int’l. Disclosure or reproduction is not allowed. © 2026 Onboard Systems Int’l., all rights reserved. 13. With the Reinforced Tunnel secured drill Ø.25” through the floor using the 4- hole pattern (shown in Figure 3.5 for the Tunnel on the 407). 14. Remove the Reinforced Tunnel and ream the holes in the floor to .375” for the bushings (P/N 291-994-00). 15. Dry fit the bushings; the bushings should be flush or protrude slightly (.010” max.) past top and bottom skins. 16. Install bushings wet with a Bell C-317 adhesive. 17. Re-install the Reinforced Tunnel with eighteen (18) screws (P/N 510-391-00) and washers (P/N 511-184-00) through its lower flanges into the floor inserts and four (4) of these P/N 510-391-00 screws and P/N 510-095-00 washers into the vertical flanges of the bulkhead fittings (two (2) at each bulkhead fitting). 18. Use two (2) P/N 511-221-00 screws at each end of the top horizontal surface of the Reinforced Tunnel into the nutplates in the horizontal flange of the Bulkhead Fittings (two (2) at each Bulkhead Fitting). For the following refer to Figure 3.8 (the 206L installation is the same as the 407). 19. Place four screws (P/N 511-177-00) in the inner four counterbored-hole pattern of the Load Plate (P/N 291-997-01) and secure the Secondary Hardpoint Assembly (P/N 232-800-00) with its bolt head oriented forward to the Load Plate (refer to engraved arrow on it) with washers (P/N 510-100-00) and nuts (P/N 511-179-00). Torque the nuts to 50-70 in-lbs. 20. Remove the paint from the aircraft skin that will mate with the Load Plate to create an electrical bond. Apply a MIL-DTL-5541 chemical conversion coating (Alodine 1001 or Alodine 1201 or similar) to the exposed bare metal. 21. Position the Load Plate on the belly with the FWD arrow pointing forward and secure it to the belly through the Tunnel with the four bolts (P/N 511-178-00), washers (P/N 510-100-00), and nuts (P/N 511-179-00). Torque the nuts to 50-70 in-lbs and apply torque stripe. Owner’s Manual Document Number 120-155-00 Revision 7 Date 11/10/26 Page 32 of 91 This document is proprietary to Onboard Systems Int’l. Disclosure or reproduction is not allowed. © 2026 Onboard Systems Int’l., all rights reserved. 3.3 Bulkhead Fitting Installation – 407 Model The two bulkhead fittings (P/N 291-144-00) support the primary cargo hook beam and are installed on the passenger seat bulkhead (FS 121.44). These fittings are included with kit P/N 200-461-00. If these are already installed, skip to the next section; otherwise install them per the following instructions. For the 206L series models, the bulkhead fittings from Bell are required to be installed. 1. Remove 16 screws at RBL 8.00 and LBL 8.00 from the passenger seat bulkhead. 2. At these locations remove the four screws and nuts and eight washers from the floor panel. 3. Place the bulkhead fittings at these locations and temporarily attach each to the bulkhead with eight screws (P/N 510-644-00) and washers (P/N 510-095-00). 4. Peel shims (P/N 291-152-00) and insert between the bottom of the bulkhead fittings and inside of floor panel to establish a gap of 0.000/0.003 inches (0.00/0.07 mm). 5. Temporarily remove the shims. Figure 3.13 Bulkhead Fitting Fasteners 6. Working from underneath the helicopter, transfer the four hole locations in the floor to the bulkhead fittings (two at each bulkhead fitting). Shim P/N 291-152-00 Screw P/N 510-644-00 Washer P/N 510-095-00 8 Places Bulkhead Fitting P/N 291-144-00 BL 8.00 Owner’s Manual Document Number 120-155-00 Revision 7 Date 11/10/26 Page 33 of 91 This document is proprietary to Onboard Systems Int’l. Disclosure or reproduction is not allowed. © 2026 Onboard Systems Int’l., all rights reserved. 7. Remove the bulkhead fittings and drill a Ø0.250/0.255-inch hole through the flanges at the marked locations. The bulkhead fittings are heat-treated steel thus it is recommended that they be clamped securely in a vise and that a drill press and new drill bits be used. 8. Place the four radius blocks in position on the lower flanges of the bulkhead fittings. Figure 3.14 Radius Blocks 9. Mark the four radius blocks with locations to match the holes in the flanges of the bulkhead fittings. 10. Drill Ø.250/.255 holes in the radius blocks at these locations. 11. Check the radius blocks for fit by inserting bolts through them and the bulkhead fittings. Minor filing may be necessary to obtain proper fit and alignment. 12. Align the shims with the bottom of the bulkhead fittings and transfer the hole locations to them and drill through the shims. Radius Block P/N 291-145-00 Radius Block P/N 291-146-00 Owner’s Manual Document Number 120-155-00 Revision 7 Date 11/10/26 Page 34 of 91 This document is proprietary to Onboard Systems Int’l. Disclosure or reproduction is not allowed. © 2026 Onboard Systems Int’l., all rights reserved. 13. In preparation for bonding, remove primer and clean the mating surfaces of the radius blocks, bulkhead fittings, shims, and the floor panel using MEK or similar cleaner. 14. Align the holes and bond the shims to the floor panel with Magnobond 6398 adhesive (Bell P/N 299-947-100 Type II, Class 2). 15. Install the bulkhead fittings onto the seat bulkhead with the sixteen screws and washers. 16. Apply the Magnobond 6398 adhesive and position the four radius blocks onto the flanges of the bulkhead fittings. Temporarily install pillow blocks (or work aid) until adhesive cures. Instructions for installing the pillow blocks are in section 3.6. Owner’s Manual Document Number 120-155-00 Revision 7 Date 11/10/26 Page 35 of 91 This document is proprietary to Onboard Systems Int’l. Disclosure or reproduction is not allowed. © 2026 Onboard Systems Int’l., all rights reserved. 3.4 Fixed Hydraulic Release System Installation The fixed hydraulic release system installation consists of mounting the Dual Master Cylinder P/N 232-820-00 (for LH PIC on the 407) or P/N 232-821-00 (for RH PIC on the 206L and 407) to the cyclic, mounting the Connector Bracket on the belly of the aircraft (near the primary cargo hook location), and routing the hoses between these items. A complete hardware set is provided for routing both hoses to the connector bracket thus if an existing cargo hook is installed there will be extra hardware. Installation of the Dual Master Cylinder may result in a cyclic balance condition requiring adjustment with a modification using new parts when dual controls are utilized. The cyclic control balance should also be evaluated with the single control configuration. After completing the installation of the hydraulic release system and filling it with fluid, see Section 3.11. Install the Dual Master Cylinder per the following, referring to Figure 3.15. 1. If installed, remove the Master Cylinder used for the single cargo hook installation and its hydraulic line to the connector bracket on the belly. Retain the hardware as some of this can be re-used including the spacers and loop clamps along the belly. If installing the kit on a 206L series with an existing cargo hook installation remove the manual release cable from the center console down to the connector bracket. This instruction is also applicable to 407 models with an existing cargo hook installation with the cable style backup release. Cover the hole in the center console through which the T-handle was installed. 2. Remove the Clamp from the Dual Master Cylinder by removing the four screws that temporarily secured it. 3. Position the Dual Master Cylinder on the cyclic at approximate location shown below and re-install the four screws, tighten the screws just enough to hold the Dual Master Cylinder in position. Owner’s Manual Document Number 120-155-00 Revision 7 Date 11/10/26 Page 36 of 91 This document is proprietary to Onboard Systems Int’l. Disclosure or reproduction is not allowed. © 2026 Onboard Systems Int’l., all rights reserved. 4. Check this position by actuating the levers and verifying they do not contact the cyclic grip when fully actuated and that they are comfortably reached from the cyclic grip. Adjust the position of the Dual Master Cylinder on the cyclic tube as necessary and then tighten the four screws to 20-30 in-lbs. and safety wire them together in pairs. 5. Each individual lever can also be adjusted by loosening its set screw and using a small flat screwdriver at the end of the Push Rod to turn it. Maintain full thread engagement on the Push Rod. Figure 3.15 Dual Master Cylinder Installation Install the Connector Bracket (P/N 235-293-00) on the belly per the following. 6. If installed, remove the connectors and existing connector bracket on the belly at FS115.00 that is used for the single cargo hook installation. 7. Install the supplied Connector Bracket on the belly of the helicopter using the two existing inserts located left of the centerline at FS 115.00 (ref. Figure 3.16). The inboard insert is located at LBL 9.50. Attach the bracket with screws (P/N 510-644-00) and washers (P/N 510-095-00). 8. As applicable, re-install the primary cargo hook release system and load weigh system electrical connectors (that were removed) into the new Connector Bracket. Push Rod Clamp Set Screw Owner’s Manual Document Number 120-155-00 Revision 7 Date 11/10/26 Page 37 of 91 This document is proprietary to Onboard Systems Int’l. Disclosure or reproduction is not allowed. © 2026 Onboard Systems Int’l., all rights reserved. Figure 3.16 Connector Bracket Installation 3.4.1 Routing – Right Side Cyclic Installation This section describes the routing of the hydraulic release system hoses from the Dual Master Cylinder to the Connector Bracket for right hand PIC on the 206L series and 407. Skip to Section 3.4.2 if installing for left hand PIC (left hand PIC is applicable to the 407 model only). 1. Route the hoses from the Dual Master Cylinder inside the boot and under the seat. On the cyclic tube, secure the hoses and electrical harness (from the switch) with loop clamps and hardware as shown below (the switch harness is terminated above the boot and is connected at a later step). Actuation of the primary release lever (on the right) moves fluid through the hydraulic hose that exits the master cylinder on the left and the secondary hook release moves fluid through the hose on the right. Connector Bracket P/N 235-293-00 Secure with screws (P/N 510-644-00) and washers (P/N 510-095-00) Inboard Forward FS 115.0 View Looking Up LBL 9.50 Owner’s Manual Document Number 120-155-00 Revision 7 Date 11/10/26 Page 38 of 91 This document is proprietary to Onboard Systems Int’l. Disclosure or reproduction is not allowed. © 2026 Onboard Systems Int’l., all rights reserved. Figure 3.17 Routing on Cyclic Figure 3.18 and Figure 3.19 below show an example of routing of the two hoses under the seat on a 206L model. Under the seat the routing may vary depending on equipment installed under the seat and on the exterior of the aircraft. Refer to the following general guidance and precautions when establishing the routing. o Verify the location where the hoses penetrate through to the outside to ensure there is clearance for the Doublers (P/Ns 235-294-00 and 235- 295-00) with any belly mounted equipment, inserts, doublers, etc. o Ensure the hoses do not restrict the movement of the cyclic, provide enough slack between the first support point aft of the cyclic and the clamps securing the hoses to the cyclic. o Ensure the hoses are secured clear of flight controls and are protected from chafing on wires, structure, adjacent equipment, etc. o Support the hoses with cushioned loop clamps every 12 to 16 inches. o Use existing inserts in the belly panel under the seat if possible or install new inserts provided. Loop Clamp P/N 512-069-00 Lever for Primary Cargo Hook Lever for Secondary Cargo Hook NOTE: PRIMARY HOOK RELEASE LEVER ON THE RIGHT (INBOARD) MOVES FLUID THROUGH THE HOSE EXITING LEFT SIDE OF MASTER CYLINDER AND SECONDARY HOOK RELEASE LEVER MOVES FLUID THROUGH THE HOSE ON THE RIGHT. A A View A-A Nut P/N 510-102-00 Washer P/N 510-095-00 Screw P/N 510-652-00 Loop Clamp P/N 512-068-00 (secondary hook hose) Loop Clamp P/N 512-067-00 (for wire harness to switch) Loop Clamp P/N 512-068-00 (primary hook hose) Owner’s Manual Document Number 120-155-00 Revision 7 Date 11/10/26 Page 39 of 91 This document is proprietary to Onboard Systems Int’l. Disclosure or reproduction is not allowed. © 2026 Onboard Systems Int’l., all rights reserved. o If available an existing hole in the belly can be used for routing the hoses to underneath the aircraft provided the above guidance is followed. The installation of the Doublers can be omitted but a bracket will need to be fabricated to mount the relay. The following hardware is provided with kit P/N 200-459-01 and kit P/N 200-462- 00 for routing under the seat. Depending on routing, not all this hardware may be used and different lengths of screws or spacers of the same series may be substituted. P/N Description Qty 500-062-00 NAS43DD3 spacer, 1” long for #10 screw 2 510-646-00 NAS43DD3 spacer 9/16” long spacer for #10 screw. 2 510-647-00 NAS43DD3 spacer 3/4” long spacer for #10 screw. 2 510-095-00 #10 Washer 3 510-102-00 Nut 2 510-390-00 MS27039-1-14 screw 2 510-392-00 MS27039-1-22 screw 2 510-644-00 MS27039-1-08 screw 2 510-652-00 MS27039-1-17 screw 2 511-035-00 Insert 2 512-037-00 MS21919-WDG4 cushioned loop clamp 6 512-028-00 Angle Bracket 2 Owner’s Manual Document Number 120-155-00 Revision 7 Date 11/10/26 Page 40 of 91 This document is proprietary to Onboard Systems Int’l. Disclosure or reproduction is not allowed. © 2026 Onboard Systems Int’l., all rights reserved. Figure 3.18 Example Hose Routing Under Seat on the 206L Remove existing fastener and add Spacer (500-062-00) and longer screw (P/N 510-392- 00) to attach loop clamps (P/N 512-037-00). Use spacer (P/N 510-646-00) and screw (P/N 510-652-00) to secure loop clamps to existing insert or add insert. Hoses Hole to underneath aircraft.