Aw139 Hoist Td-03-008 Rev A

TD-03-008
Revision A
TO: HOLDERS OF BREEZE-EASTERN FLIGHT LINE OPERATION

AND MAINTENANCE MANUAL FOR HS-20200-421 SERIES
RESCUE HOIST SYSTEMS, TD-03-008, ORIGINAL RELEASE.
THIS IS TO INFORM YOU OF THE RELEASE OF

TD-03-008, REVISION A, DATED OCTOBER 10, 2011.
HIGHLIGHTS
Revision A replaces in its entirety the original release of TD-03-008, dated September 17,
2004. Please discard the original and replace it with Revision A. Thereafter, indicate on the
Record of Revisions page the date of this action, as well as the initials of the individual
performing this task.
PARAGRAPH DESCRIPTION OF CHANGE
All General Manual Revision and Logo Change.

All Incorporated applicable service bulletins, letters, TPDR’s etc.
All Changed cable orange paint to orange stain. Added white stain
to cable at drum flange attach point.
Section 1 Desc. & Op. Added Flight Line & Ground Handling
Guidelines.
Section 101 Added harness electrical continuity check.
Section 301 Added potentiometer instructions.
Section 501 General revision. Overhaul periodicity to 10 years.
Section 701 Added cartridge shipping instructions. Added cartridge
torque from tag. Added clocking information if
applicable. Added potentiometer instructions.
Section 1001 Revised Illustrated Parts List.
NOTE: BREEZE-EASTERN CORPORATION HAS MOVED ITS CORPORATE AND

MANUFACTURING FACILITY TO: 35 MELANIE LANE, WHIPPANY, NJ
07981-1638 FROM 700 LIBERTY AVENUE, UNION, NJ 07083.
NEW MAIN PHONE 973-602-1001, 800-929-1919.
25-61-00
Page H-1
October 10, 2011
TD-03-008
Revision A
FLIGHT LINE
OPERATION AND MAINTENANCE MANUAL
With
Illustrated Parts List
Rescue Hoist System
BREEZE-EASTERN PART NUMBER
HS-20200-421 SERIES
SAFETY WARNING
For your own safety and the safety of all others, read and understand all of the procedures and information in this document before
installing, operating, and / or maintaining any components of the rescue hoist system covered herein.
EXPORT CONTROLLED WARNING
This manual may contain information that is subject to the International Traffic in Arms Regulations (ITAR) or the Export
Administration Regulations (EAR), and may not be exported, released, or disclosed to foreign nationals, either in the United States or
overseas, without first complying with the export requirements / regulations of the ITAR and / or EAR. The recipient is responsible
for complying with all such export requirements / regulations. Include this notice with any reproduced portions of this document.
PROPRIETARY RIGHTS NOTICE
This manual contains information that is proprietary to Breeze-Eastern Corporation, is an unpublished work protected under
applicable copyright laws and constitutes trade secrets for the purpose of the Trade Secret and Freedom of Information Acts. It is
delivered on the express conditions that it is not to be used, disclosed or reproduced, in any manner, in whole or in part without prior
written authorization of Breeze-Eastern Corporation, 35 Melanie Lane, Whippany, NJ 07981-1638, USA. Nothing contained herein
shall limit any rights granted by Breeze-Eastern Corporation under contract. This legend shall be included on any reproduction hereof
All rights are reserved. Any act in violation of applicable law may result in civil and / or criminal penalties.
25-61-00
Page T-1
October 10, 2011
TD-03-008
Revision A
FLIGHT LINE OPERATION AND MAINTENANCE MANUAL
HS-20200-421 SERIES RESCUE HOIST SYSTEM
RECORD OF REVISIONS
Retain this record in the front of the manual. On receipt of revisions, insert revised pages in the
manual, and enter revision number, date inserted, and initials.
REVISION REVISION DATE DATE REVISION REVISION DATE DATE

LETTER FILLED BY LETTER FILLED BY
Original September 17, 2004 - -
A October 10, 2011 - -
25-61-00
Page RR-1
October 10, 2011
Breeze-Eastern Confidential – Use or disclosure of data contained on this sheet or subsequent sheets is subject to the restrictions on the cover page.
TD-03-008
Revision A
RECORD OF TEMPORARY REVISIONS
Retain this record in the front of the manual. On receipt of temporary revisions, insert the temporary
revision pages in the manual, and enter revision number, issue date, date inserted and initials of
individual incorporating temporary revision. Upon receipt of revision that replaces the temporary
revision, insert removal date and initials of individual removing temporary revision.
REV. ISSUE DATE REMOVAL INCORPORATOR’S REMOVER’S

NO. DATE INSERTED DATE INITIALS INITIALS
25-61-00
Page RTR-1
October 10, 2011
TD-03-008
Revision A
SERVICE BULLETIN LIST
Retain this record in the front of the manual. On receipt of Alert Service Bulletins (ASB) / Service
Bulletins (SB), Technical Publication Deficiency Reports (TPDR), Engineering Change Orders
(ECO), etc., attach a copy of the document to the back of the manual, and enter document type and
issue date. When the intent of the bulletin is incorporated into the manual via a revision,
Breeze-Eastern will enter the date terminated.
DOCUMENT TYPE SUBJECT REVISION OPERATOR BREEZE-EASTERN

AND NUMBER AND DATE INCORPORATION TERMINATION DATE
DATE
SB Wire Rope Cables Changes Mandatory Replacement to Original October 10, 2011
Recommended Replacement of 06/02/06
Wire Rope Cable at 1,500 Cycles
SIL01 Maintenance Breeze-Eastern Rescue Hoist and Rev. C October 10, 2011
Cargo Winch Maintenance Concept 04/30/10
SIL03 Maintenance Breeze-Eastern Rescue Hoist Original October 10, 2011
System Cable Foul Indicator 08/12/02
SIL05 Maintenance Pilot and Crew Control Panels and Original October 10, 2011
Electronics Cleaning Advisory 05/15/07
TPDR031805001 Revise motor assembly and tension Original October 10, 2011
roller shaft assembly part numbers 03/18/05
TPDR072710003 Clarify cartridge and refire kit part Original October 10, 2011
numbers 07/27/10
SIL07 Maintenance Improved Wire Rope Cable Original October 10, 2011
Marking 04/21/11
SIL01 BL-7720 Bumper Assy. Product Original October 10, 2011
Improvement 05/11
CO 28646 Pliobond #35 replaces #30, because 06/16/11 October 10, 2011
of MEK phase out
SIL08 Maintenance Information about greases, oils, Original October 10, 2011
coatings, and sealants for B-E 08/11/11
products.
25-61-00
Page SBL-1
October 10, 2011
TD-03-008
Revision A
LIST OF EFFECTIVE PAGES
Description Page Date
Highlights Page H-1 October 10, 2011
25-61-00, Title Page T-1 October 10, 2011
Record of Revisions RR-1 October 10, 2011
Record of Temporary Revisions RTR-1 October 10, 2011
Service Bulletin List SBL-1 October 10, 2011
List of Effective Pages LEP-1 October 10, 2011
LEP-2 October 10, 2011
Table of Contents T/C-1 October 10, 2011
T/C-2 October 10, 2011
Introduction INTRO-1 October 10, 2011
INTRO-2 October 10, 2011
Description and Operation 1 October 10, 2011
2 October 10, 2011
3 October 10, 2011
4 October 10, 2011
5 October 10, 2011
6 October 10, 2011
7 October 10, 2011
8 October 10, 2011
9 October 10, 2011
10 October 10, 2011
11 October 10, 2011
12 October 10, 2011
13 October 10, 2011
14 October 10, 2011
Testing and Troubleshooting 101 October 10, 2011
102 October 10, 2011
103 October 10, 2011
104 October 10, 2011
105 October 10, 2011
106 October 10, 2011
107 October 10, 2011
25-61-00
Page LEP-1
October 10, 2011
TD-03-008
Revision A
LIST OF EFFECTIVE PAGES (continued)
Testing and Troubleshooting (continued) 108 October 10, 2011
109 October 10, 2011
110 October 10, 2011
111 October 10, 2011
112 October 10, 2011
113 October 10, 2011
114 October 10, 2011
115 October 10, 2011
116 October 10, 2011
117 October 10, 2011
118 Blank
Schematics and Wiring Diagrams 201 October 10, 2011
202 October 10, 2011
203 October 10, 2011
204 October 10, 2011
205 October 10, 2011
206 October 10, 2011
Disassembly 301 October 10, 2011
302 October 10, 2011
303 October 10, 2011
304 October 10, 2011
305 October 10, 2011
306 October 10, 2011
307 October 10, 2011
308 October 10, 2011
309 October 10, 2011
310 October 10, 2011
311 October 10, 2011
312 October 10, 2011
313 October 10, 2011
314 Blank
Cleaning 401 October 10, 2011
402 October 10, 2011
403 October 10, 2011
404 October 10, 2011
405 October 10, 2011
406 Blank
Checks and Inspections 501 October 10, 2011
502 October 10, 2011
25-61-00
Page LEP-2
October 10, 2011
TD-03-008
Revision A
Checks and Inspections (continued) 503 October 10, 2011
504 October 10, 2011
505 October 10, 2011
506 October 10, 2011
507 October 10, 2011
508 October 10, 2011
509 October 10, 2011
510 October 10, 2011
511 October 10, 2011
512 October 10, 2011
513 October 10, 2011
514 October 10, 2011
515 October 10, 2011
516 October 10, 2011
517 October 10, 2011
518 October 10, 2011
519 October 10, 2011
520 October 10, 2011
521 October 10, 2011
522 October 10, 2011
523 October 10, 2011
524 October 10, 2011
525 October 10, 2011
526 October 10, 2011
Repair 601 October 10, 2011
602 October 10, 2011
603 October 10, 2011
604 October 10, 2011
605 October 10, 2011
606 October 10, 2011
607 October 10, 2011
608 October 10, 2011
Assembly 701 October 10, 2011
702 October 10, 2011
703 October 10, 2011
704 October 10, 2011
705 October 10, 2011
706 October 10, 2011
707 October 10, 2011
25-61-00
Page LEP-3
October 10, 2011
TD-03-008
Revision A
Assembly (continued) 708 October 10, 2011
709 October 10, 2011
710 October 10, 2011
711 October 10, 2011
712 October 10, 2011
713 October 10, 2011
714 October 10, 2011
715 October 10, 2011
716 October 10, 2011
Fits and Clearances 801 October 10, 2011
802 October 10, 2011
F = Foldout F 803 / 804 October 10, 2011
805 October 10, 2011
806 October 10, 2011
Special Tools, Fixtures, and Equipment 901 October 10, 2011
902 October 10, 2011
Illustrated Parts List 1001 October 10, 2011
1002 October 10, 2011
1003 October 10, 2011
1004 October 10, 2011
1005 October 10, 2011
1006 October 10, 2011
1007 October 10, 2011
F = Foldout F 1008 / 1009 October 10, 2011
1010 October 10, 2011
1011 October 10, 2011
1012 October 10, 2011
1013 October 10, 2011
1014 October 10, 2011
Technical Publication Deficiency Report
25-61-00
Page LEP-4
October 10, 2011
TD-03-008
Revision A
TABLE OF CONTENTS
Section/Paragraph Title Page
Highlights Page ........................................................................... H-1
25-61-00, Title Page ................................................................... T-1
Record of Revisions ................................................................ RR-1
Record of Temporary Revisions .......................................... RTR-1
Service Bulletin List ............................................................. SBL-1
List of Effective Pages .......................................................... LEP-1
Table of Contents ................................................................... T/C-1
Introduction Introduction ....................................................................... INTRO-1
Paragraph 1 General ............................................................................. INTRO-1
Paragraph 2 Proprietary Status and Liability ....................................... INTRO-2
Paragraph 3 Verification ...................................................................... INTRO-2
Paragraph 4 Digital Pictures ................................................................. INTRO-2
Section 1 Description and Operation ............................................................ 1
Paragraphs 1A through 1C Description .................................................................................... 1
Paragraph 1D Rescue Hoist System ..................................................................... 2
Paragraph 1E Rescue Hoist Assembly ................................................................ 2
Paragraph 1F Wire Rope Cable ........................................................................... 3
Paragraph 1G Hook Assembly ............................................................................. 3
Paragraph 1H Tension Roller ............................................................................... 3
Paragraph 1I Cycle Counter ............................................................................... 4
Paragraph 1J Limit Switches .............................................................................. 4
Paragraph 1K Cable Cutter .................................................................................. 5
Paragraph 1L Cable Foul Assembly .................................................................... 6
Paragraph 1M Variable Speed Controller ............................................................. 6
Paragraph 1N Control Pendant Assembly ............................................................ 7
Paragraph 1O Leading Particulars for Rescue Hoist System ............................... 8
Paragraph 2 Operation ........................................................................................ 9
Paragraph 3 Flight Line / Ground Handling Operation Guidelines ...................13
Section 101 Testing and Troubleshooting ..................................................... 101
Paragraph 1 Testing ........................................................................................ 101
Paragraph 2 Test Equipment and Materials ................................................... 101
Paragraph 3 Test Conditions .......................................................................... 101
Paragraph 4 Test ............................................................................................. 101
Paragraph 4A Limit Switch Test ....................................................................... 102
Paragraph 4B Control Pendant Digital Readout Test ....................................... 108
Paragraph 4C Cable Foul Assembly Test ......................................................... 110
Paragraph 4D Electrical Continuity Test .......................................................... 111
Paragraph 4E Rated Load Test ......................................................................... 111
Paragraph 4F Hook Load Test .......................................................................... 113
25-61-00
Page T/C-1
October 10, 2011
TD-03-008
Revision A
TABLE OF CONTENTS (continued)
Section 101 Testing and Troubleshooting (continued)
Paragraph 4G Bumper Assembly and Full In Limit Switch Test ..................... 113
Paragraph 5 Troubleshooting ......................................................................... 114
Section 201 Schematics and Wiring Diagrams .............................................. 201
Section 301 Disassembly ............................................................................... 301
Paragraphs 1 and 2 General ....................................................................................... 301
Paragraph 3 Removal of Hoist From Helicopter............................................. 301
Paragraph 4 Removal of Variable Speed Controller ...................................... 302
Paragraph 5 Removal of Control Pendant and Pendant Cable Assembly ....... 303
Paragraph 6 Removal and Disassembly of Hook Assembly .......................... 303
Paragraph 7 Removal and Disassembly of Bumper Assembly ...................... 304
Paragraph 8 Removal and Disassembly of Limit Switch Cover Assembly .... 304
Paragraph 9 Removal of Cable ...................................................................... 305
Paragraph 10 Removal of Cable Cutter ........................................................... 306
Paragraph 11 Removal of Cable Guide ............................................................ 307
Paragraph 12 Removal of Follower ................................................................. 308
Paragraph 13 Removal of Cable Pressure Roller Assemblies ......................... 308
Paragraph 14 Removal of Tension Roller ........................................................ 308
Paragraph 15 Removal of Overrunning Clutch ................................................ 309
Paragraph 16 Removal of Chain ...................................................................... 309
Paragraph 17 Removal of Motor ...................................................................... 310
Paragraph 18 Removal of Identification Plate and Labels ............................... 311
Paragraph 19 Removal of Electrical Components ........................................... 311
Paragraph 19A Removal of Full Out S2 and Intermediate Limit Switches S1.....311
Paragraph 19B Removal of Potentiometer R1 .................................................... 312
Paragraph 19C Removal of Full In Limit Switches S3 ....................................... 312
Paragraph 19D Removal of Cable Foul Assembly Switches .............................. 312
Section 401 Cleaning ..................................................................................... 401
Paragraph 1 General ....................................................................................... 401
Paragraph 1A through 1J General ....................................................................................... 402
Paragraph 1K Cable (if exposed to lubricants) ................................................. 403
Paragraph 1L Hoist, Hook and / or Cable (if exposed to saltwater) ................. 403
Paragraph 1M Forward and Aft Cowling Windows ...........................................405
Paragraph 1N Wiring Harness Assembly ..........................................................405
Section 501 Checks and Inspections .............................................................. 501
Paragraph 2 Inspections ................................................................................. 502
Paragraph 2A Overhaul of Rescue Hoist .......................................................... 502
Paragraph 2B General ....................................................................................... 503
25-61-00
Page T/C-2
October 10, 2011
TD-03-008
Revision A
Section 501 Checks and Inspections (continued)
Paragraph 2C Tension Roller ............................................................................ 504
Paragraph 2D Overrunning Clutch Assembly and Tension Roller
Clutch Assembly ........................................................................ 507
Paragraph 2E Wire Rope Cable ........................................................................ 508
Paragraph 2F Hook Assembly .......................................................................... 513
Paragraph 2G Cable Guide ............................................................................... 515
Paragraph 2H Chain .......................................................................................... 515
Paragraph 2I Cable Foul Assembly ................................................................. 517
Paragraph 2J Pressure Roller Assemblies ........................................................ 518
Paragraph 2K Level Wind Shaft and Follower ................................................. 518
Paragraph 2L Pre-Flight Inspection .................................................................. 519
Paragraph 2L.(5) Check Oil Level and Oil Change Instructions ........................... 520
Paragraph 2M Post-Flight Inspection ................................................................ 522
Paragraph 2N Cable Cutter ............................................................................... 522
Paragraph 2O Detailed Inspection of Rescue Hoist End Flanges ..................... 523
Paragraph 2P Inspection of Wiring .................................................................. 523
Paragraph 2Q Inspect Integrity of Limit Switches (Every 5 year period only) 524
Section 601 Repair ......................................................................................... 601
Paragraph 2 Refinish ...................................................................................... 603
Paragraph 3 Minor Surface Repair ................................................................. 604
Paragraph 4 Major Surface Repair ................................................................. 605
Paragraph 5 Application of Top Coat ............................................................ 605
Paragraph 6 Application of Coating (Orange Stain) on Cable ....................... 605
Paragraph 7 Cable Foul Removal .................................................................. 606
Paragraph 8 Cable Alignment Inspection / Adjustment ................................. 607
Paragraph 9 General Wiring Harness Connector Pin Replacement ............... 607
Section 701 Assembly .................................................................................... 701
Paragraph 2 Assembly of Rescue Hoist System ............................................ 702
Paragraph 3 Installation of Electrical Components ........................................ 702
Paragraph 3A Installation of Full In Limit Switch S3 ....................................... 702
Paragraph 3B Installation of Full Out S2 and Intermediate
S1 Limit Switches .......................................................................703
Paragraph 3C Installation of Potentiometer R1 ................................................ 703
Paragraph 3D Installation of Cable Foul Assembly Limit Switches ................ 703
Paragraph 4 Installation of Motor .................................................................. 704
Paragraph 5 Installation of Chain ................................................................... 704
25-61-00
Page T/C-3
October 10, 2011
TD-03-008
Revision A
Section 701 Assembly (continued)
Paragraph 6 Installation of Overrunning Clutch Assembly ............................ 704
Paragraph 7 Installation of Tension Roller .................................................... 705
Paragraph 8 Installation of Roller Assemblies and Follower ......................... 706
Paragraph 9 Installation of Cable Guide ........................................................ 707
Paragraph 10 Installation of Limit Switch Cover Assembly ........................... 707
Paragraph 11 Installation of Cable Cutter ........................................................ 707
Paragraph 12 Installation of Cable ................................................................... 708
Paragraph 13 Assembly and Installation of Bumper Assembly ....................... 710
Paragraph 14 Assembly and Installation of Hook Assembly ........................... 710
Paragraph 15 Installation of Labels onto Limit Switch Cover ......................... 712
Paragraph 16 Installation of Hoist .................................................................... 712
Paragraph 17 Installation of Variable Speed Controller .................................. 713
Paragraph 18 Installation of Control Pendant and Pendant Cable Assembly ... 713
Paragraph 19 Installation of Cartridge ............................................................. 713
Paragraph 20 Storage Instructions ................................................................... 714
Paragraph 21 Shipping Instructions ...................................................................715
Section 801 Fits and Clearances .................................................................... 801
Section 901 Special Tools, Fixtures, and Equipment .................................... 901
Section 1001 Illustrated Parts List ................................................................. 1001
Paragraph 1 Introduction .............................................................................. 1001
Paragraph 1A Purpose ..................................................................................... 1001
Paragraph 1B Explanation and Usage of Section ........................................... 1001
Paragraph 1C Vendors .................................................................................... 1002
Paragraph 2 Notes ........................................................................................ 1002
LIST OF TABLES
Table Title Page
1 Rescue Hoist System Configuration Matrix ................................................................ 2
2 Leading Particulars for Rescue Hoist System .............................................................. 8
101 Electrical Continuity Test ......................................................................................... 111
102 Troubleshooting Procedures ..................................................................................... 114
401 Materials Required for Cleaning .............................................................................. 401
501 Inspection Requirements ........................................................................................... 501
601 Materials Required for Repair ................................................................................. 601
602 Allowable Material Removal ................................................................................... 602
25-61-00
Page T/C-4
October 10, 2011
TD-03-008
Revision A
LIST OF TABLES (continued)

Table Title Page
701 Materials Required for Assembly ............................................................................ 701

801 Allowable Limit Values ............................................................................................ 801
901 Special Tools, Fixtures, and Test Equipment List / Matrix ...................................... 901
LIST OF FIGURES
Figure Title Page
1 HS-20200-421 Series Rescue Hoist System ................................................................ 1
2 Limit Switch Actuation Positions ................................................................................ 4
3 Approximate Dimensions of Orange Stain on Wire Rope Cable .............................. 11
101 Locations of Limit Switches and Potentiometers on the Cyclocentric Assembly ... 103
102 Limit Switch Actuation Positions ............................................................................ 104
103 Cable Guide Pin ....................................................................................................... 107
104 Cable Foul Assembly Inspection and Adjustment ................................................... 110
105 Deflection of Bumper Assembly with Hook at Full In Position .............................. 113
201 Typical Circuit Used to Drive the Cable Foul Indicator .......................................... 201
202 BL-20200-421 Rescue Hoist Assembly Wiring Diagram ....................................... 202
203 HS-20200-421-01 Rescue Hoist System Wiring Diagram ...................................... 203
204 HS-20200-421-02 Rescue Hoist System Wiring Diagram ...................................... 204
205 EC-14170-1 Control Pendant Cable Assembly Wiring Diagram ............................ 205
206 BL-16016-1 Cable Foul Sensor Wiring Diagram .................................................... 206
301 Cable Cutter Cartridge in Cable Guide Assembly ................................................... 302
302 Limit Switch Cover .................................................................................................. 305
303 Full Out Limit Switch (S2) on Cyclocentric Assembly ........................................... 306
304 Cable Guide Assembly with Cable Guide ............................................................... 308
305 Chain, Sprocket, Follower, and Attaching Hardware .............................................. 310
306 Motor Support with Attaching Hardware ................................................................ 311
307 Cable Foul Assembly ............................................................................................... 313
308 Cable Foul Assembly (Left Side View) .................................................................... 313
401 Example of Corrosion on Hook Assembly Parts ..................................................... 404
402 Example of Corrosion on Drum ............................................................................... 404
501 Examples of Unacceptable Damage to Gear ........................................................... 504
502 Tension Roller and Overrunning Clutch Assemblies .............................................. 505
503 Tension Roller Replacement Criteria ....................................................................... 506
504 Overrunning Clutch Assembly ................................................................................ 507
25-61-00
Page T/C-5
October 10, 2011
TD-03-008
Revision A
LIST OF FIGURES (continued)
Figure Title Page
505 Example of Broken Strands in Wire Rope Cable .................................................... 509

506 Example of Abrasion of Wire Rope Cable .............................................................. 509
507 Example of Kink in Wire Rope Cable ..................................................................... 510
508 Example of Bird Caging in Wire Rope Cable ......................................................... 510
509 Hook Assembly Attachment to Wire Rope Cable ................................................... 511
510 Example of Knot Wire Rope Cable .......................................................................... 511
511 Examples of Wire Rope Cable Looseness ................................................................ 512
512 Example of a Raised Strand in a Wire Rope Cable ................................................. 513
513 Hook Assembly ........................................................................................................ 514
514 Required Terminal Clamp Orientation .................................................................... 514
515 Level Wind Chain Drive with Hoist Horizontal ...................................................... 515
516 Chain Tension Check with Hoist Horizontal ........................................................... 516
517 Chain Tension Check with Hoist Vertical ............................................................... 517
518 Roller Replacement Criteria ......................................................................................518
519 Dimensional Inspection of Level Wind Follower and Shaft ................................... 519
520 Oil Fill Location ....................................................................................................... 520
521 Deflection of Bumper Assembly with Hook at Full In Position .............................. 522
522 Cable Foul Limit Switch Locations ......................................................................... 525
601 Wire Rope Cable Orange Stain Lengths .................................................................. 604
602 Cable Fouls On Recue Hoists .................................................................................. 606
701 Tension Roller and Overrunning Clutch Assemblies .............................................. 706
702 Safety Tie Wire Installation and Roller Replacement ...............................................707
703 Cutaway of Correct Cable Cutter Orientation ...........................................................708
704 Correct and Incorrect Wire Rope Cable Attachment Drum.......................................709
705 Required Terminal Clamp Orientation .................................................................... 711
706 Hook Assembly Setscrew Correct vs. Incorrect Assembly .......................................712
707 Improper Clocking Results and Proper Clocking Installation Instructions Of The
Cartridge / Wiring Harness (For Reference) ..............................................................714
801 Rescue Hoist Assembly Illustration ......................................................................... 803
802 Variable Speed Controller Illustration ..................................................................... 805
803 Control Pendant Assembly Illustration .................................................................... 806
901 Retaining Ring Installation Tool, PN BLT-10300-V .............................................. 901
902 TE-120-1, Weights with TE-120-3 Cart .................................................................. 902
903 TE-132-1, Clevis Mount Maintenance Fixture ........................................................ 902
1001 Rescue Hoist System .............................................................................................. 1004
1002 Hook Assembly ...................................................................................................... 1006
1003 Rescue Hoist Assembly ......................................................................................... 1008
25-61-00
Page T/C-6
October 10, 2011
TD-03-008
Revision A
INTRODUCTION
1. General
The instructions in this manual provide the information necessary to perform flight line level
maintenance functions ranging from simple checks, to replacement of wear items, to maintaining
the hoist in an operational condition.
The manual is divided into separate sections:

H Highlights Page
T Title Page
RR-1 Record of Revisions
RTR-1 Record of Temporary Revisions
SBL-1 Service Bulletin List
LEP List of Effective Pages
T/C Table of Contents
INTRO Introduction
1 Description and Operation
101 Testing and Troubleshooting
201 Schematic and Wiring Diagrams
301 Disassembly
401 Cleaning
501 Checks and Inspections
601 Repair
701 Assembly
801 Fits and Clearances
901 Special Tools
1001 Illustrated Parts List
A. Refer to the Table of Contents for the page location of applicable sections. An asterisked
flag note *( ) in place of the page number indicates that no special instructions are
provided since the function can be performed using standard industry practices.
B. The beginning of the REPAIR section includes a list of the separate repairs (if
appropriate).
25-61-00
Page INTRO-1
October 10, 2011
TD-03-008
Revision A
C. An explanation of the use of the Illustrated Parts List is provided in the introduction to
that section. All weights and measurements in the manual are in English units with metric
equivalents in parenthesis, unless otherwise noted.
This manual will be revised as necessary to reflect current information and customer input
through the use of Alert Service Bulletins (ASB’s), Service Bulletins (SB’s), Service
Information Letters (SIL’s), Technical Publication Deficiency Reports (TPDR’s), Engineering
Change Orders (ECO’s), etc.
A Technical Publication Deficiency Report (TPDR) is attached to the back of this manual for
customer use. All these amending documents are attached to the back of the manual and are
considered an approved change until incorporated as an official revision to the manual.
2. Proprietary Status and Liability
This Flight Line Operation and Maintenance Manual contains proprietary data, which is the
property of Breeze-Eastern Corporation. Neither this manual, nor any part thereof, shall be
duplicated, used or disclosed – in whole or in part – for any purpose other than those relating to
the operation and overhaul maintenance of the Rescue Hoist Assemblies by the owner / operator
/ maintenance facility.
Any activity involving the operation, maintenance, and testing of the Rescue Hoist
Assembly shall be performed in accordance with the procedures defined in this manual.
All maintenance requiring new components shall be performed utilizing only the parts
identified in this manual, which are readily available from Breeze-Eastern Corporation.
All actions taken by owners, operators, or maintenance facilities that deviate from the
procedures contained herein, or actions taken utilizing parts not identified in this manual, shall
not be the responsibility of Breeze-Eastern Corporation.
3. Verification
Manual Verification Date: TBD
4. Digital Pictures
It is recommended that the technician take digital pictures of each assembly and subassembly, to
be used as a visual reference for Section 701 Assembly, prior to disassembling the rescue hoist
system components.
25-61-00
Page INTRO-2
October 10, 2011
TD-03-008
Revision A
DESCRIPTION AND OPERATION
Figure 1. HS-20200-421 Series Rescue Hoist System.

1. Description
A. This publication explains the operation of, and provides flight line maintenance instructions for
the HS-20200-421 Series Rescue Hoist Systems. The instructions provided are used to maintain
the Systems, with select subassembly removals, in a serviceable condition while installed on the
helicopter (See Figure 1). Operators should be aware that maintenance training for
Breeze-Eastern products is available.
B. The Rescue Hoist System provides a means for lowering and raising personnel from an airborne
helicopter. The Rescue Hoist is operated from the Control Pendant Assembly.
C. Operators are encouraged to coordinate all scheduled maintenance / repair/ overhaul work with
Breeze-Eastern Corporation, or authorized Breeze-Eastern Corporation Service Centers,
Breeze-Eastern Corporation is a Federal Aviation Administration FAR Part 145 and EASA Part
145 approved Repair Station. Please contact Breeze-Eastern Customer Services below:
25-61-00
Page 1
October 10, 2011
TD-03-008
Revision A
Breeze-Eastern
35 Melanie Lane
Whippany, New Jersey 07981-1638 USA
Phone Number: 973-602-1001, Ext. 1083 or 1090, or 1-800-929-1919 (US and Canada only)
Fax Number: 973-739-9344
Fax Number: 908-688-6495
E-mail Address: [email protected]
Web Site Address: www.breeze-eastern.com
Revision Status of the Breeze-Eastern technical manuals is listed on the website referenced
above.
NOTE: PLEASE CONTACT BREEZE-EASTERN CUSTOMER SERVICES FOR THE
PRICE AND AVAILABILITY OF OPERATION AND MAINTENANCE TRAINING
WITH RESPECT TO THIS EMERGENCY RESCUE HOIST SYSTEM.
D. Rescue Hoist System
The Rescue Hoist Systems consist of the following components (See Table 1), which are
considered Line Replaceable Units (LRUs):
Rescue Hoist System Rescue Hoist Control Pendant Variable Hook Pressure
Assembly Pendant Cable Speed Assembly Cartridge Kit
Assembly Assembly Controller
HS-20200-421-01 BL-20200-421 CP-1500-5 EC-14170-1 EC-19000-23 HK-121-5 KT-198
HS-20200-421-02 BL-20200-421 CP-1500-7 EC-14170-1 EC-19000-23 HK-121-5 KT-198
Table 1. Rescue Hoist System Configuration Matrix
The main power requirement for the Rescue Hoist System is 28 VDC, 160 Amperes. The power
required for the controls in the Control Pendant, and the cable cutter for the Hoist, is 28 VDC, 5
Amperes. The power supplied by the helicopter is converted into the power required for the Rescue
Hoist System by the Variable Speed Controller. This Variable Speed Controller provides the
necessary power to the electric motor to drive the drum on the Hoist.
E. Rescue Hoist Assembly
The Hoist contains a rotating drum, which is driven by an electric motor through a gear train and
clutch assembly, raising and lowering a 245 ft. (74.7 m.) wire rope cable and swivel hook. The
Hoist operates at variable speeds, through a grease filled gearbox, from 0 to 215 fpm (1.09 mps)
with a 250 lb. (113 kg) load and 0 to 130 fpm (0.66 mps) with a 600 lb. (272 kg) load. A level wind
mechanism on the hoist assembly ensures even wrapping of the cable on the drum. Redundant limit
switches sense when the hook approaches the full in or full out limits. The Hoist stops
automatically when the hook reaches these two limits. The drum incorporates an improved means
of anchoring the cable to the drum flange by utilizing a slot into which the end of the cable is
inserted. The cable is held in the slot with a setscrew, and a second setscrew is installed to lock the
first setscrew in place.
An overload slip clutch is located in the inner diameter of the drum. The clutch operates if the cable
load exceeds 1200 to 1800 lb. (544 to 816 kg.), thereby preventing the wire rope cable from
25-61-00
Page 2
October 10, 2011
TD-03-008
Revision A
overload. However, this design improvement does not replace the cable inspections required for
proper operation.
The clutch design also offers improved hoist life and reliability by incorporating permanently
lubricated ball bearings, enhanced support stiffness, and provides four major functional capabilities:
(1) Protects the cable by absorbing homing load energy in the event of a malfunction of both the
intermediate speed and full in limit switches.
(2) Absorbs cable shock loads.
(3) Allows a means of protection for the hoist and aircraft structure in the event of system overload.
(4) Eliminates the need for a crushable bumper.
A skewed roller Weston brake is also incorporated into the inner diameter of the drum. When
power is removed, or operation is stopped, the brake is automatically applied to hold the load. The
brake consists of a skewed roller clutch disk pack assembly, and a jaw assembly.
The reduction gearing is of a planetary type, which drives a chain used to synchronize the drum
with the level wind shaft and cable guide. An idler also provides positive retention of the chain.
Together, these features mitigate the chances for tension loss due to slippage and resultant loss of
the drive chain.
An oil seal, between the drum and the outside of the ring gear, provides longer life by minimizing
the possibility of oil leakage between the faying surfaces. The Hoist also incorporates an oil sight
gage allowing for a visual reference for servicing of the drum.
A gear guard provides an extra measure of safety by protecting the cable from being cut, or
damaged, if a fouled cable got caught between the drum gear and overrunning clutch.
F. Wire Rope Cable
The load cable for the Hoist consists of a wire rope with a swaged stainless steel ball / shank fitting
per MS20664. The wire rope is a 0.1875 inch (4.76 mm.) diameter, corrosion resistant, preformed
spin resistant type conforming to MIL-W-83140. It is proof tested in accordance with BMC-283-53.
During its fabrication, an inert gas shielded electric arc process cuts off the drum end of the load
cable, such that the cable end is sealed, and made suitable for attachment at the drum anchor point.
G. Hook Assembly
The hook assembly rotates 360 degrees, attaches to the ball end of the cable using a terminal clamp,
nut and housing design, and incorporates a lockable keeper to prevent the load from inadvertently
releasing.
H. Tension Roller
The Rescue Hoist utilizes a tension roller system located between the cable guide and drum. The
tension roller is driven by the drum gear through an overrunning clutch, such that when reeling out,
the tangential speed of the tension roller is faster than the tangential speed of the drum, thereby
maintaining a “pull” force on the cable, even at no load. The tangential speed of the tension roller is
slower than the tangential speed of the drum when reeling in providing a drag force on the cable
ensuring tight cable wraps on the drum under all conditions.
25-61-00
Page 3
October 10, 2011
TD-03-008
Revision A
I. Cycle Counter
The hoist has a counter that records each revolution of the drum. A reed switch activated by a
magnet on the drum advances the counter. The number on the counter, divided by 334, provides the
total number of hoist cycles.
J. Limit Switches
WARNING: WHEN NOT IN USE, THE HOOK MUST BE HOMED COMPLETELY IN THE
“FULL IN” POSITION TO AVOID FATIGUE OF THE CABLE NEAR THE BALL
END DUE TO VIBRATION.
NOTE: IN THE OPERATION OF THE HOIST, THE CABLE RATE IS AUTOMATICALLY
SLOWED TO A SAFE SPEED WHENEVER THE HOIST IS OPERATED NEAR
THE EXTREMES OF THE CABLE TRAVEL (FULL IN AND FULL OUT) BY
REDUNDANT, INTERMEDIATE SPEED LIMIT SWITCHES.
Redundant limit switches control full in, full out, and intermediate speed cable travel with the
following purpose (see Figure 2):
Figure 2. Limit Switch Actuation Positions
25-61-00
Page 4
October 10, 2011
TD-03-008
Revision A
(1) The full in switch (S3) stops Rescue Hoist operation when the bumper assembly makes contact
with the cable guide.
(2) The up intermediate speed switch (S1) slows down the Rescue Hoist when reeling in, and
within a specified distance from full in switch actuation.
(3) The down intermediate speed switch (S1) slows down the Rescue Hoist when reeling out, and
within a specified distance from full out switch actuation.
(4) The full out switch (S2) stops Rescue Hoist operation at a specified number of dead wraps on
the cable drum.
The limit switches are directly coupled to the hoist drum to control full out and intermediate speed
cable positions (hook approach to aircraft and approach to full extension). The cable full in switch
is built into the cable guide to ensure proper homing of the hook. The limit switches are redundant
with two switches at each location.
K. Cable Cutter
WARNING: THE CARTRIDGE IS AN EXPLOSIVE DEVICE AND MUST BE SHIPPED,
STORED, AND HANDLED IN COMPLIANCE WITH ALL LOCAL STANDARDS
AND REGULATORY PRACTICES.
NOTE: MAXIMUM CARTRIDGE SERVICE LIFE IS 5 YEARS WHEN REMOVED FROM
PACKAGING, AND INSTALLED IN HOIST. MAXIMUM CARTRIDGE LIFE IS 13
YEARS (COMBINED SHELF AND SERVICE LIFE) FROM THE DATE OF
MANUFACTURE. THE DATE OF MANUFACTURE CAN BE FOUND IN THE
LOT NUMBER ON THE LABEL OF THE SEALED CONTAINER, IN WHICH THE
CARTRIDGE IS SHIPPED AND STORED, AND ON THE FLATS OF THE HEX
SHAPED PORTION OF THE CARTRIDGE. THE LOT NUMBER CAN BE
IDENTIFIED WITH THE FIRST THREE LETTERS “CAD.” IMMEDIATELY
FOLLOWING THESE LETTERS IS THE DATE OF MANUFACTURE,
REPRESENTED AS TWO DIGITS, WHICH IDENTIFY THE YEAR (EXAMPLE: 11
IS 2011), AND ONE LETTER, WHICH IDENTIFIES THE MONTH, AS DEFINED
BELOW:
A – JANUARY E – MAY J – SEPTEMBER
B – FEBRUARY F – JUNE K – OCTOBER
C – MARCH G – JULY L – NOVEMBER
D – APRIL H – AUGUST M – DECEMBER
NOTE: AFTER THE CABLE HAS BEEN CUT, THE ANVIL, CARTRIDGE, CUTTER, O-
RINGS, AND COTTER PIN MUST ALL BE REPLACED. REFERENCE CABLE
CUTTER REFIRE KIT KT-489.
The hoist is equipped with a cable cutter that is located in the cable guide, consisting of an
electrically fired pressure cartridge (squib), a guillotine, and anvil to sever the cable in an
emergency. At 28 VDC, the minimum all-fire current of the cartridge is 5.0 amperes per bridge
wire and the minimum no-fire current for the cartridge is 1.0 ampere, 1 Watt. The cartridge is
contained in a Pressure Cartridge Kit, which is supplied with the system. The Kit, KT-198,
25-61-00
Page 5
October 10, 2011
TD-03-008
Revision A
consists of one cartridge in a hermetically sealed container, three shims for clocking the
cartridge for correct cartridge harness orientation and one
O-ring, all to be used for the installation of the cartridge.
In the event the cartridge has been fired during a cable cut, Refire Kit, PN KT-489, can be
purchased from Breeze-Eastern, which includes anvil, cutter, O-Ring, cotter pin, and tie wire.
L. Cable Foul Assembly
WARNING: OPERATING THE HOIST WITH A FOULED CABLE CAN CAUSE THE CABLE
TO BREAK AND RESULT IN SEVERE INJURY OR DEATH. THE CAUSE OF
ANY CABLE FOUL FIRST MUST BE DETERMINED, AND THEN THE PROBLEM
CORRECTED, BEFORE THE HOIST IS RESTORED TO AN OPERATIONAL
CONDITION.
WARNING: DO NOT TRY TO CLEAR A FOULED CABLE IN FLIGHT. A FOULED CABLE
MAY BREAK, AND THIS MAY RESULT IN INJURY, OR DEATH.
The hoist incorporates a cable foul assembly, which is a switch actuated safety device, and is
mounted on the hoist flanges parallel to the drum axis. This cable foul assembly is designed to
interrupt the power to the hoist motor if a cable foul develops on the hoist drum; thereby preventing
possible cable breakage due to continued cable entanglement.
M. Variable Speed Controller
The Variable Speed Controller incorporates pulse-width-modulated speed control techniques. Hoist
speed control is accomplished by a speed command applied to the controller from either the
variable speed operator control, or the constant speed priority override at the pilot’s control switch,
if installed. The greater the deflection of the thumb wheel on the hoist operator’s pendant control
assembly, the greater average DC voltage applied to the motor, hence, faster hoisting speeds. Full
deflection of the thumb wheel applies maximum voltage to the DC motor, hence, maximum cable
speed.
The signal that controls the direction of cable motion also is sent to the controller and processed by
a circuitry located in its main board. The board is provided with a time delay relay that allows a
minimum lapse of inactive time, which is recommended for proper switching of hoist operation
between “cable up” to “cable down” directions.
The Variable Speed Controller assembly dissipates minimal power by design. The heat sink on the
side of the controller is used to remove heat from the controller and installation must be either
horizontal with heat sink facing up, or vertical.
The Variable Speed Controller (controller) incorporates the following safety features:
(1) Field loss detection circuit – The controller will inhibit hoist operation if a loss of motor field is
detected.
(2) Under voltage lockout – The controller will inhibit hoist operation if the input DC voltage is
<17 VDC.
25-61-00
Page 6
October 10, 2011
TD-03-008
Revision A
(3) Provides the hoist operator with a motor overheat indication by a continuously illuminated
motor warning light. This condition will result from operating the hoist system in prolonged
high temperature environments, which exceed the design limits of the system.
(4) Pulse by pulse current limit – The controller will detect excessive current requirements from the
DC power and limit the amount of power consumed from the helicopter power system.
N. Control Pendant Assembly
The control pendant assembly provides the crewmember with freedom of movement while utilizing
the following control features:
(1) Digital readout (green)
(2) Cable Direction / Speed control
(3) Inter-Communication System (ICS) control
(4) Indicator lights displaying motor hot (amber), slow speed (amber), and power on (green)
conditions
(5) Four-way toggle switch (CP-1500-5 configuration only)
The pendant is equipped with a digital cable pay out display that indicates the length in feet of cable
paid out from the Hoist, and an electrical connector for interfacing with the Variable Speed
Controller. A bracket is provided on the handgrip to facilitate stowing the pendant in the aircraft.
When power is initially applied to the rescue hoist system, “888” will be displayed for a moment,
and then the cable length displayed (“000” for full in).
The direction / speed control thumb wheel is centrally located on the shrouded upper portion of the
handgrip. The essence of the control pendant is the direction / speed control mechanism containing,
and actuating, two switches and a potentiometer. The two switches (one for either direction)
provide an on-off signal. The potentiometer, rotated by the thumb wheel, provides a speed
command signal to the controller.
Three indicator lights provide the hoist operator with a visual indication of the following
conditions: 1) motor hot (over temperature); 2) slow speed; and 3) power on. These indicators, as
well as the cable pay out digital display, are sunlight readable.
(1) Electrical power is applied to the Hoist System (green, labeled “PWR ON”).
(2) Hoist is operating in the slow speed modes (intermediate speed limit switch actuation, amber,
labeled “SLOW”).
(3) A motor over temperature condition has occurred (amber, labeled “MTR HOT”).
The ICS control is a snap action switch provided for connection to the aircraft intercom system. A
trigger on the back of the handgrip operates the switch. The switch conforms to MS24547-1 and is
rated for 2 amps inductive at 28 VDC.
For the CP-1500-5 configuration, a four-way toggle switch is provided to control an auxiliary
operation, such as hover trim control, which is not part of the System.
25-61-00
Page 7
October 10, 2011
TD-03-008
Revision A
Pendant Cable Assembly, Breeze Eastern Part Number EC-14170-1, electrically connects the
Control Pendant Assembly to the Variable Speed Controller.
O. Leading Particulars for Rescue Hoist System
Rescue Hoist Assembly
Cable:
Type 19 x 7 strand wraps
Length 245 feet (74.7 meters) usable length
Diameter 0.187 in. +0.006 / –0.001 in. (4.75 mm. +0.15 / –0.03 mm.)
Cable Drum Layers 4
Material Stainless Steel, flexible, preformed, spin resistant
Cable Speed (Hoisting):
600 pounds (272 kg.) 130 fpm (0.66 mps) with cable on top layer
250 pounds (113 kg.) 215 fpm (1.09 mps) with cable on top layer
Load:
Operating Load 600 lb. (272 kg.)
Overload Clutch Slips between 1200 lb. (544 kg.) and 1800 lb. (816 kg.)
Limit Load (Static) 2100 lb. (953 kg.), applied to structure
Ultimate Load (Static) 3150 lb. (1429 kg.), applied to structure
Fleet Angle:
Operational 15° to centerline (cone angle 30°)
Non-Operational 15° to centerline supporting 2100 lb. (953 kg.) static load
Temperature Range:
Operational -40° F to +125° F ( -40° C to +52° C)
Non-Operational -65° F to +257° F ( -54° C to +125° C)
Altitude Sea Level to 12,000 Feet (3658 m.)
Electric Motor:
Motor: Variable, 0 - 27.5 VDC at 155 Amps to motor series field and
armature circuits
Fixed, 28 VDC at 5 Amps to motor shunt field and shunt
brake circuits
Control Circuit 28 VDC, 5 Amps, maximum
Cable Foul Sensor Redundant switches IAW MS27216-5
Guillotine Ballistic type, electrically fired (5 Amps per bridgewire, min.)
Table 2. Leading Particulars for Rescue Hoist System
25-61-00
Page 8
October 10, 2011
TD-03-008
Revision A
Rescue Hoist Assembly (continued)
Gearbox - Main Gearbox 17.25 ounces (510 ml) of MIL-PRF-7808, Class 3 (NATO
Oil: Code No. O-148) Preferred – Alternate oil MIL-PRF-23699
for main gearbox. (Note: Do not intermingle / mix oils)
Side Gearbox Grease 1 – 1.5 ounces (30 – 44 ml) of Tribolube-9 (Replaces Amovis
8-X) grease.
Weight (maximum) 85 lb. (38.5 kg.) with hook, 81 lb. (36.7 kg.) without hook
Variable Speed Controller
Electrical Input 28 VDC, 160 Amps continuous, and 170 Amps for one (1)
second maximum, based on speed and load conditions
Electrical Output 0 - 27.5 VDC, 155 Amps to motor series field and armature,
fixed 28 VDC, 5 Amps to motor shunt field and shunt brake
Operating Channels Pilot hoist control, Pendant hoist control, ICS
Pilot-Crew Operation Pilot control has priority over crew control
Automatic Slow Speed Slowdown when approaching extremes of cable travel
Weight (maximum) 15.0 lb. (6.8 kg.)
Control Pendant Assembly
Voltage 28 VDC
Current 2 Amps
Speed Control Incremental potentiometer
Directional Control Thumb wheel actuated
Housing Totally enclosed
Speed-Control Knob Centering protected
Four-way Toggle Switch For control of auxiliary operation, such as hover trim control
(CP-1500-5 Control Pendant Assembly only)
Weight (maximum) 2.0 lb. (0.9 kg.)
Table 2. Leading Particulars for Rescue Hoist System (continued)
2. Operation
WARNING: SEARCH AND RESCUE OPERATIONS, AND ALL OTHER USES OF HOISTS FOR
HOISTING AND LOWERING PERSONNEL, CAN RESULT IN INJURY OR
DEATH. PROPERLY TRAINED PERSONNEL MUST UTILIZE APPROPRIATE
OPERATION, MAINTENANCE, AND INSPECTION PROCEDURES TO MINIMIZE
THE HAZARDS INHERENT IN THE USE OF ALL HOISTS.
WARNING: WORK GLOVES MUST BE WORN BY THE OPERATOR WHENEVER
HANDLING THE RESCUE HOIST CABLE TO PREVENT INJURY FROM
BROKEN STRANDS AND WIRES. EYE PROTECTION MUST BE WORN BY THE
OPERATOR WHENEVER OPERATING, OR MAINTAINING, THE RESCUE
25-61-00
Page 9
October 10, 2011
TD-03-008
Revision A
HOIST TO PREVENT INJURY FROM LUBRICANTS, SOLVENTS, AND OTHER
MATERIALS USED ON THE RESCUE HOIST, AS WELL AS METAL PARTS AND
OTHER DEBRIS.
WARNING: DO NOT TRY TO CLEAR A FOULED CABLE IN FLIGHT. A FOULED CABLE
MAY BREAK, AND THIS MAY RESULT IN INJURY OR DEATH.
CAUTION: THE TENSION ROLLER SYSTEM WORKS ON THE BASIS OF FRICTION, AND
THEREFORE, NO LUBRICANT SHOULD BE APPLIED TO THE CABLE.
CAUTION: WHEN REELING OUT, DO NOT IMPEDE THE CABLE IN ANY WAY (EITHER
WITH YOUR HANDS, OR OTHER OBSTRUCTION) AS THIS MAY IMPEDE
TENSION ROLLER OPERATION, AND CAUSE THE CABLE TO FOUL.
CAUTION: DO NOT ALLOW THE CABLE TO REEL IN TO THE FULL IN POSITION
WITHOUT HOLDING ONTO, AND GUIDING THE HOOK TO THIS POSITION.
ALLOWING THE HOOK TO SWING FREELY WHILE REELING IN TO THE
FULL IN POSITION MAY CAUSE DAMAGE TO THE HOOK, CABLE, HOIST,
AND HELICOPTER.
CAUTION: DO NOT LEAVE THE HOOK LOOSE UNDER THE HOIST AFTER THE HOIST
HAS BEEN USED. ALWAYS ENSURE THE HOOK HAS BEEN HOMED
SECURELY, AND THE BUMPER SPRING IS COMPRESSED SUFFICIENTLY TO
PREVENT THE HOOK FROM MOVING WHILE THE HELICOPTER IS IN
FLIGHT. A LOOSE HOOK MAY RESULT IN A DAMAGED CABLE.
CAUTION: DURING OPERATION OF THE RESCUE HOIST, DO NOT TOUCH THE MOTOR.
THE MOTOR TEMPERATURE MAY BE VERY HOT, AND MAY RESULT IN
SEVERE BURNS IF TOUCHED.
NOTE: A VISUAL MEANS OF FULL IN DETECTION ARE PROVIDED WITH THE
RESCUE HOIST. ONE IS ORANGE STAIN ON THE CABLE INDICATING
APPROXIMATELY 25 FT. (7.6 M.) OF CABLE REMAINS UNTIL REACHING
THIS LIMIT.
NOTE: A VISUAL MEANS OF FULL OUT DETECTION IS PROVIDED WITH THE
RESCUE HOIST. ORANGE COATING IS APPLIED ON THE CABLE INDICATING
APPROXIMATELY 14 FT. (4.3 M.) OF CABLE REMAINS UNTIL REACHING
THIS LIMIT.
NOTE: ALWAYS KEEP ONE HAND ON THE CABLE WHILE REELING IN. IF A
PROBLEM OCCURS WITH THE HOIST, YOU WILL FEEL IT IN THE CABLE.
NOTE: THE CABLE RATE IS AUTOMATICALLY SLOWED TO A SAFE SPEED
WHENEVER THE RESCUE HOIST IS OPERATED NEAR THE EXTREMES (FULL
IN AND FULL OUT) OF THE CABLE TRAVEL BY REDUNDANT,
INTERMEDIATE SPEED LIMIT SWITCHES.
NOTE: PRIOR TO TURNING POWER ON, THE RESCUE HOIST COMPONENTS MUST
BE VISUALLY INSPECTED FOR SOUND STRUCTURAL INTEGRITY AND
PROPER INTEGRATION.
25-61-00
Page 10
October 10, 2011
TD-03-008
Revision A
A. The HS-20200-421 Series Rescue Hoist System is operated by the Hoist Operator’s Control
Pendant. When power is initially applied to the system, “888” will be displayed for a moment,
and then the cable extension displayed (“000” for full in). Once the Variable Speed Controller
receives the reel in, or extension, command signal, an output signal is sent to the motor, either
to raise, or lower, the cable. The motor torque will drive the gear train, which will drive the
level wind, tension roller, and drum resulting in reeling the cable in, or out.
B. Once the down signal is received the cable will reel out, and speed should be faster as the
thumbwheel is moved farther from the center. Observe the amount of cable on the storage drum.
Manually reduce speed as the cable nears full extension. When the down intermediate speed
limit switch is actuated the hoist is slowed to 38 to 68 fpm (0.19 to 0.35 mps) until the full out
limit switch is reached and operation of the hoist is stopped with 3½ to 4½ wraps of cable
remaining on the drum.
Also, a visual means of full in and full out detection is provided by orange stain on the cable,
which indicates approximately 14 ft. (4.3 m.) of cable remains from the full out position and 25
ft. (7.6 m) from the full in position.
Figure 3. Approximate Dimensions of Orange Stain on Wire Rope Cable

C. Once the up signal is received by the Variable Speed Controller the hoist cable should reel in,
and speed should be faster as the thumbwheel is moved farther from the center. The motor
allows for a maximum cable speed of 215 fpm (1.09 mps) at 250 lb. (113 kg) load. Manually
reduce speed as the cable nears full retraction. When the up intermediate speed limit switch is
actuated the hoist is slowed to 38 to 68 fpm (0.19 to 0.35 mps) until the full in switch is reached
and operation of the hoist is stopped.
Also, a visual means of full in detection is provided by orange stain on the cable, which
indicates approximately 25 ft. (7.6 m.) of cable travel remains until reaching this limit (see
Figure 3).
WARNING: DO NOT TRY TO CLEAR CABLE FOUL IN FLIGHT. A FOULED CABLE MAY
BREAK, AND MAY RESULT IN INJURY OR DEATH.
When reeling in the cable, observe the cable wrapping on the drum. The cable layers should be
wrapping evenly with no gaps, or smiles, on the drum. If the cable incorrectly wraps on the
drum resulting in a cable foul, then as the cable exceeds the height of the top layer, the cable
foul indicator mechanically will actuate and command the hoist to stop. To clear the cable foul
on the ground, the cable foul indicator switches must be manually actuated and the cable paid
25-61-00
Page 11
October 10, 2011
TD-03-008
Revision A
out slowly under load. If this does not clear the foul, it must be removed from the drum by
cutting off sections of the fouled cable. In either case, the cause of the cable foul must be
determined, the problem must be corrected that caused the cable foul, and the cable must be
replaced before the hoist can be returned to a serviceable condition.
Always guide the hook by hand as the cable is reeled into the full in position at maximum slow
speed by deflecting the pendant assembly thumbwheel up fully. Homing the hook in this
manner ensures the spring bumper is compressed sufficiently to prevent the hook assembly
from moving / vibrating when the helicopter is in flight.
STORED AND HANDLED IN COMPLIANCE WITH ALL LOCAL STANDARDS
AND REGULATORY PRACTICES.
D. The Hoist is equipped with a cable cutter to sever the cable in an emergency. Actuation of the
cable cutter is under the control of the pilot using a switch located in the cockpit. A refire kit
KT-489 containing an anvil, cable cutter, cotter pin, O-ring, and cartridge with packing is
available and should be ordered in the event of actuation of the cable cutter.
CAUTION: OPERATION WITH THE MOTOR WARNING LIGHT ON CAN CONTINUE
DURING THIS TIME, BUT SERIOUS DAMAGE MAY RESULT REQUIRING
MOTOR REPLACEMENT, OR MORE SERIOUSLY, THE MOTOR MAY FAIL TO
WORK DURING OPERATIONS. THEREFORE, IT IS RECOMMENDED THAT
OPERATIONS CEASE AS SOON AS POSSIBLE IF THIS CONDITION OCCURS,
AND THE MOTOR BE ALLOWED TO COOL.
E. The Control Pendant is a hand held controller that allows the crewmember to raise, or lower, the
cable by using the directional thumb wheel. This thumb wheel also controls the speed of
operation proportional to the amount of deflection from the null position. The Control Pendant
displays indicate the amount of cable paid out, and indicator lights for a fully extended cable
(“FULL OUT”), a fully reeled in cable (“FULL IN”), and motor overheat (“MTR HOT”). The
motor overheat light will reset once the motor has cooled sufficiently, approximately 30
minutes, depending on ambient conditions, and the amount of time the light was illuminated
before operation was stopped. The Control Pendant for the
HS-20200-421-01 Configuration also has a four way top hat controller.
F. There have been instances where cable foul sensor equipped Systems automatically stops due to
detection of a cable foul, and the operator is unaware that a cable foul has occurred. In these
cases, operators may not be utilizing the electrical circuit provided to illuminate a warning light
to alert the operator of a cable foul.
Breeze-Eastern cable foul sensor equipped Hoists have connector pins for the operator to
receive an electrical signal, which can be used to provide a visual indication that a cable foul
has occurred. This circuit is provided to the aircraft interface. It is highly recommended the
operator utilize this interface to install the helicopter electrical, and display provisions for the
warning light.
25-61-00
Page 12
October 10, 2011
TD-03-008
Revision A
The Hoist provides 28 VDC out of the designated pin when a cable foul is detected. In this
instance, a typical circuit used to drive the indicator is shown in Figure 201 (Note: This circuit
is not supplied by Breeze-Eastern with the System, maximum current rating is 1 amp for the 28
VDC output on the Hoist).
3. Flight Line / Ground Handling Hoist Operation Guidelines
A. When operating the hoist during inspections, hoist speed shall be no greater then ¼ speed unless
the inspection is to verify hoist speed. Normal cable cleaning and hoist inspections do not
require high speed operation.
B. When operating the hoist never “pull” the cable from the hoist when lowering. Let the hoist do
the work of lowering. Pulling the cable can actually apply a force opposing the cable tensioning
system.
C. Always use a clean dry cloth when cleaning or checking the cable. Never use a cloth that
contains oil or any other lubricants. See Section 401, Cleaning, for complete cleaning
instructions of the hoist.
D. When cleaning the hoist and / or cable, the cable collection container should be as large in
diameter as possible. The larger diameter reduces the possibility of cable damage. A “kiddy”
pool is recommended. See Section 401, Cleaning, for complete cleaning instructions of the
hoist.
E. When cleaning or removing a cable, or inspecting the full-out switches, never use the limit
switch as a “jog” switch. When operating the hoist in this mode, depress and hold the limit
switch actuator and wait one second before deflecting the control pendant thumbwheel (if
applicable) – DO NOT have the control thumbwheel deflected and use the limit switch
(actuator) to move the hoist. Also, always wait one second before re-actuation of a limit switch.
F. When checking full in limit switch or stowing the hook, always operate the hoist at maximum
slow speed by deflecting the control thumbwheel to its maximum position. If the bumper is
stowed at a slower speed the cable load may be lower than required and can lead to cable
fatigue from excessive hook vibration.
G. If spinning occurs during hoisting operations, avoid using the top part of the hook as a brake.
The top part of the hook is mechanically connected to the cable, and if rotated will try to “spin,”
or “birdcage,” the cable. This will lead to premature cable replacement.
H. Salt water usage will require post flight cleaning of exposed components. During this post-flight
cleaning procedure it is also recommended to clean the cable drum, and this should be
accomplished as follows:
1) When cleaning the drum, make sure power to the hoist is removed.
2) Use a clean, damp rag to clean the drum.
3) Cleaning the drum will require multiple drum movements to clean the entire drum surface.
4) See Section 401, Cleaning, for complete cleaning instructions of the hoist.
25-61-00
Page 13
October 10, 2011
TD-03-008
Revision A
5) Do not use a pressure washer to clean the hoist or use high-pressure air to dry the hoist.
Excessive pressure could damage hoist components i.e. seals, switches, etc.
I. Do not “Water Soak” the electronics. Use isopropyl alcohol to clean panels or pendants.
J. Always wind, and unwind, the cable in a ‘race track’ fashion, never a ‘figure 8’ or a coil.
K. Always ‘season’ new cables in accordance with the Rated Load Test, as provided in Section
101, Testing and Troubleshooting.
L. Ice clearing. Remove any ice accumulation from the rescue hoist, especially visible ice from
the cable guide assembly / bellmouth and ensure that the hook assembly, bumper assembly /
grommet is not frozen to the cable guide assembly prior to hoist operations.
25-61-00
Page 14
October 10, 2011
TD-03-008
Revision A

TESTING AND TROUBLESHOOTING
1. Testing
This section covers testing, adjustment, fault isolation, and implementation of corrective actions
on the System utilizing troubleshooting procedures. The test procedures contained in this Section
are to be performed every twelve (12) months, as necessary for fault isolation, and as required by
actions accomplished in Checks and Inspections, Section 501, and Assembly, Section 701.
Electrical schematics and wiring diagrams are located in Section 201. Reference numbers in
parenthesis refer to Illustrated Parts List in Section 1001.
2. Test Equipment and Materials
The recommended method for testing the System at the flight line level is to perform the
procedures identified in this section with the equipment identified below, or suitable equivalent,
when the Hoist is mounted on the helicopter.
A. Electrical Power 28 VDC, 200 Amps, minimum.
B. Load Source The Hoist shall be loaded by use of calibrated weights of
300 lb. (136 kg.), and 600 lb. (272 kg.) on the Hoist hook.
C. Tape Measure To measure cable lengths (in feet or meters).
D. Tachometer Range: 0 – 2 m/s (0 – 410 fpm), 1% accuracy. If tachometer
(for measuring cable speed) is not available use stopwatch to measure the time it takes
the Hoist cable to travel over a known length.
E. Multimeter Range: 0.1 ohm to 100 mOhm, 1% accuracy
F. Voltmeter Range: 0 – 4 VDC, ½% F.S.
G. Spring Scale Range: 0 – 10 lb. (0 – 4.55 kg.), ± 2 % accuracy of reading
H. Indelible Felt Tip Marker For marking cable when setting limit switches
I. Potentiometer Sealant Glyptal Red
J. F-900 Torque Seal, Organic Products Company, Irving Texas, USA, CAGE CODE 01195
3. Test Conditions
The Rescue Hoist shall be mounted using the four mounting points (See Figure 801) in such a
manner that the cable is vertical (i.e. pay out is downward). The recommended method is to test
the rescue hoist when mounted on the helicopter in a hover with cowlings installed. All tests shall
be conducted at an ambient temperature between 60°F to 104°F (16°C to 40°C), barometric
pressure of 28-38 inches of mercury (0.95 to 1.29 BAR), and a relative humidity of 95 percent
maximum.
4. Test
WARNING: SEARCH AND RESCUE OPERATIONS, AND ALL OTHER USES OF HOISTS
FOR HOISTING AND LOWERING PERSONNEL, CAN RESULT IN INJURY OR
25-61-00
Page 101
October 10, 2011
TD-03-008
Revision A

OPERATION, MAINTENANCE, AND INSPECTION PROCEDURES TO
MINIMIZE THE HAZARDS INHERENT IN THE USE OF ALL RESCUE HOISTS.
WARNING: KEEP HANDS, BODY, AND CLOTHING AWAY FROM THE HOIST
SPECIFICALLY “PINCH POINTS” WHERE THE CABLE ENTERS THE CABLE
GUIDE AND CONTACTS THE DRUM.
WARNING: TAKE PROPER ELECTROSTATIC DISCHARGE (ESD) PRECAUTIONS TO
AVOID FIRING THE CARTRIDGE AND DAMAGING COMPONENTS DUE TO
ELECTRICAL SHOCK FROM ELECTROSTATIC DISCHARGE.
HANDLING THE HOIST CABLE TO PREVENT INJURY FROM BROKEN
CABLE STRANDS AND WIRES. EYE PROTECTION MUST BE WORN BY THE
OPERATOR WHENEVER OPERATING, OR MAINTAINING, THE HOIST TO
PREVENT INJURY FROM LUBRICANTS, SOLVENTS, AND OTHER
MATERIALS USED ON THE HOIST, AS WELL AS METAL PARTS AND
OTHER DEBRIS.
CAUTION: THE TENSION ROLLER SYSTEM WORKS ON THE BASIS OF FRICTION, AND
THEREFORE, NO LUBRICANT SHOULD BE APPLIED TO THE CABLE.
NOTE: PRIOR TO TURNING POWER ON, THE HOIST COMPONENTS MUST BE
VISUALLY INSPECTED FOR SOUND STRUCTURAL INTEGRITY AND
PROPER INTEGRATION.
NOTE: LIMIT SWITCHES MUST BE OPERATING AND SET PROPERLY PRIOR TO
PERFORMING LOAD TESTING.
NOTE: WHEN REELING IN THE CABLE WITH NO LOAD, APPLY TENSION WITH
GLOVED HANDS TO ENSURE SMOOTH AND EVEN WRAPPING.
APPROXIMATELY 20 LB. (9.1 KG.) TENSION IS RECOMMENDED.
A. Limit Switch Test (see Figures 101, 102, and 1003)
Check the limit switch settings for the required lengths defined in Figures 101 and 102.
(1) Full Out Limit Switch (S2) – Verification of Switch Setting From Cable Termination
Start with paragraph (a) below if checking full out limit switch setting of a Hoist with an
existing cable, or go to paragraph (b) below if checking full out limit switch setting of a
Hoist with a new cable.
(a) Apply power to the system, and with no load, reel out the cable at less than ½ of full
speed to verify the Hoist stops at the full out limit (4 ± ½ wraps of cable on drum from
cable termination). After verification of full out limit switch setting, go to paragraph
4 A (1) (c) below.
(b) If a new cable has been installed, apply power to the system, reel in the cable at less than
½ of full speed and stop the Hoist when 8 or more wraps of cable are on the drum, and
then reel out at less than ½ of full speed the cable to verify the Hoist stops at the full out
25-61-00
Page 102
October 10, 2011
TD-03-008
Revision A

limit (4 ± ½ wraps of cable on drum from cable termination). After verification of full
out limit switch setting, go to paragraph 4 A (1) (c) below.
(c) If the full out limit switch (S2) is set correctly, go to paragraph (2) below. If the full out
limit switch is inoperative, refer to Table 102 for Troubleshooting.
Symbol Function Requirements
S1 Intermediate speed 9.8 to 16.4 Ft. (3.0 to 5.0 m.) from full out
(same switch for both directions) 14.8 to 18.0 ft. (4.5 to 5.5 m.) from full in
S2 Full Out 4 ± ½ Wraps from cable termination
S3 Full In (not shown) Actuated when hook and bumper assy. contacts cable
guide
R1 Potentiometer Assembly For Cable Payout Display (full in adjustment)
R3 Trim Potentiometer For Cable Payout Display (full out adjustment)
Screws to be
loosened to S1
adjust R1
R1
R3
Adjustment
screw for R3 S2
Figure 101. Locations of Limit Switches and Potentiometers on the Cyclocentric Assembly
25-61-00
Page 103
October 10, 2011
TD-03-008
Revision A

Figure 102. Limit Switch Actuation Positions

If the setting for the full out limit switch is not correct, adjust limit switch cam to
obtain required setting as follows (see Figure 1003):
1) Remove tie wire, screws (30 and 40), washers (50), clamps (60 and 70), limit
switch cover (80), and gasket (90).
2) Remove screws (810) and move potentiometer bracket (820) out of the way
without damaging wiring to access limit switch cams.
3) Loosen screws (Figure 1003, View B, Item 1170), and rotate full out limit switch
cam (1180) as follows:
a) Rotate cam clockwise to allow full out limit switch to actuate with fewer wraps
of cable on the drum.
b) Rotate cam counterclockwise to allow full out limit switch to actuate with
more wraps of cable on the drum.
4) Tighten screws (1170) to hold adjusted position of cam by applying 3.0 to 4.0
in.-lb. (0.34 to 0.57 Nm.) torque to screws.
5) Recheck full out limit switch setting.
6) After successfully setting and checking the full out and intermediate speed limit
switches, install potentiometer bracket, limit switch cover, gasket, clamps,
washers, screws, and tie wire per MS33540 with MS20995NC32 or safety cable
per NASM33540 using AS3510-01.
25-61-00
Page 104
October 10, 2011
TD-03-008
Revision A

(2) Intermediate Speed Limit Switch (S1) – Verification of Switch Setting From Full Out
(a) Using an indelible felt tip marker, or equivalent, mark cable at the lengths specified
for intermediate speed limit switch (S1) 9.8 to 16.4 ft. (3.0 to 5.0 m.) from full out
limit and 14.8 to 18.0 ft. (4.5 to 5.5 m.) from full in limit (ball end of cable).
(b) Reel in the cable at less than ½ of full speed until both marks at 9.8 to 16.4 ft. (3.0 to
5.0 m.) from the full out limit have been reeled onto the drum (approximately 20
wraps on the drum total). Reverse the direction of the cable travel to reel out the cable
at less than ½ of full speed and verify the intermediate speed limit switch actuates
between 9.8 to 16.4 ft. (3.0 to 5.0 m.) from the full out limit.
(c) If the intermediate speed limit switch is set correctly from the full out position, go to
paragraph (3) below.
If the intermediate speed limit switch is inoperative, refer to Table 102 for
Troubleshooting.
If the setting for the intermediate speed limit switch is not correct, adjust limit switch
cam to obtain required setting as follows (see Figure 1003):
3) Loosen screws (Figure 1003, View B, Item 1190), and rotate intermediate speed
limit switch cam (1200) as follows:
a) Rotate cam clockwise to allow intermediate speed limit switch to actuate closer
to full out position.
b) Rotate cam counterclockwise to allow intermediate speed limit switch to
actuate further away from full out position.
5) Recheck intermediate speed limit switch setting.
washers, screws, and tie wire per MS33540 with MS20995NC32, or safety cable
per NASM33540 using AS3510-01.
(3) Intermediate Speed Limit Switch (S1) – Verification of Switch Setting From Full In
(a) Reel in the cable at less than ½ of full speed and verify the intermediate speed limit
switch actuates at 14.8 to 18.0 ft. (4.5 to 5.5 m.) from full in position.
(b) If the intermediate speed limit switch is set correctly from the full in position, go to
paragraph (4) below.
25-61-00
Page 105
October 10, 2011
TD-03-008
Revision A

If the intermediate speed limit switch is inoperative, refer to Table 102 for
Troubleshooting.
If the setting for the intermediate speed limit switch is not correct, adjust limit switch
cam to obtain required setting as follows (see Figure 1003):
3) Loosen screws (Figure 1003, View B, Item 1190), and rotate the intermediate
speed limit switch cam (1200) as follows:
a) Rotate cam clockwise to allow intermediate speed limit switch to actuate
further away from full in position.
b) Rotate cam counterclockwise to allow intermediate speed limit switch to
actuate closer to full in position.
NOTE: THE CAM AND LIMIT SWITCH FOR THE INTERMEDIATE SPEED LIMITS
FROM FULL OUT AND FULL IN ARE THE SAME. IF ADJUSTMENTS ARE
MADE FOR THE SETTING OF ONE OF THE LIMITS, THE OTHER LIMIT
MUST BE RECHECKED.
5) Re-verify intermediate speed limit switch setting from both full in and full out per
Paragraphs 4A(2) and 4A(3) above.
washers, screws, and tie wire per NASM33540 with MS20995NC32, or safety
cable per NASM33540 using AS3510-01.
(4) Full In Limit Switch (S3) – Verification of Switch Setting And Operation
NOTE: PERFORM THIS CHECK IF A PROBLEM WITH THE FULL IN LIMIT SWITCH
IS ENCOUNTERED, OR THE LIMIT SWITCHES ARE REPLACED.
(a) Preliminary Check
1) Reel in the cable at less than ½ of full speed. Using a spring scale, verify that when
a force of greater that 2 lb. (0.9 kg.) is applied to pin (Figure 1003, View A, Item
1010) located under the Cable Guide Assembly, the Hoist stops (see Figure 103).
25-61-00
Page 106
October 10, 2011
TD-03-008
Revision A

NOTE: Ensure Retaining Ring (1000), Ring
Retainer (1012), Spring (1020), and
Pin (1010) are properly installed, as
shown, when performing Full In
Limit Switch Check
Spring (1020) for Pin (1010)
Ring Retainer (1012) and Retaining Ring

(1000, under Ring Retainer) for Pin (1010)
Pin (1010) for Actuating Full In Limit Switch

(under the Cable Guide Assembly)
Figure 103. Cable Guide Pin (shown with cable guide cover [920] removed)
If a force of greater than 2 lb. (0.9 kg.) applied to the pin properly actuates the Full
In Limit Switch and the Hoist stops, the Full In Limit Switch Check has been
successfully completed.
If the force is less than 2 lb. (0.9 kg.) to stop the Hoist, the Hoist does not stop, or
does not operate, remove cable guide cover per paragraph 2) below, and check
installation of cable guide pin (1010), retaining ring (1000), ring retainer (1012)
and spring (1020). Refer to Figure 103 and Table 102 for Troubleshooting.
2) Remove screws (940), washers (950), cable guide cover (920) and gasket (930).
Retain gasket for future use, or replace if damaged.
3) Verify that Torque Seal compound, or equivalent, has been applied to the heads of
the switch mounting screws (970). If there is no evidence of Torque Seal, do not
loosen, but verify that screws are properly tightened, torque to 2.6 to 3.2 in.-lb.
(0.29 to 0.36 m-N).
(b) Check for switch activation prior to end of pin travel and full compression of bumper
assembly spring:
1) Reel out approximately 6 ft. (1.8 m.) of cable by operating hoist.
2) Slowly reel in cable. Manually depress pin (see Figure 103) and verify Hoist stops
prior to end of pin travel. Repeat procedure three times to confirm that the full in
limit switch is actuated and the Hoist stops consistently.
3) Reel in the cable to the full in position and verify the Hoist stops before full
compression of spring on bumper assembly. Repeat procedure three times to
confirm that the full in limit switch is actuated and the Hoist stops consistently. If
this check is completed successfully, go to step 4 A (4) (c).
4) If the full in limit switches do not actuate, or the Hoist does not stop, loosen
screws (970) and adjust position of switches. After position of switches has been
adjusted, torque screws (970) from 2.6 to 3.2 in.-lb. (0.29 to 0.36 m-N), and repeat
step 4 A (4) (b) above.
25-61-00
Page 107
October 10, 2011
TD-03-008
Revision A

(c) Check for switch release prior to end of pin travel and Hoist operation when reeling in:
1) Reel out approximately 6 ft. (1.8 m.) of cable by operating hoist.
2) Slowly reel in cable. If Hoist does not reel in, or stops before cable is in full in
position, loosen screws (970) and adjust position of switches. After position of
switches has been adjusted, torque screws (970) from 2.6 to 3.2 in.-lb. (0.29 to
0.36 m-N), and repeat step 4 A (4) (b) above.
(d) Post Full In Limit Switch Check Procedures
1) After successfully completing checks outlined in steps 4 A (4) (b) and 4 A (4) (c)
above, apply F-900 Torque Seal, or equivalent, to heads of screws (970) (if not
previously applied).
2) Install cable guide gasket (930), and cover (920), and secure with washers (950)
and screws (940). Torque screws to 2.6 to 3.2 in.-lb. (0.29 to 0.36 m-N).
(e) If the full in limit switch is inoperative, or cannot be adjusted, refer to Table 102 for
Troubleshooting Procedures.
B. Control Pendant Digital Readout Test
NOTE: CONTROL PENDANT DIGITAL READOUT IS FOR REFERENCE ONLY.
ACCURACY OF READOUT IS ± 3 FEET (0.91 METERS).
(1) Apply power to the system, and observe the readout on the Control Pendant. The numbers
“888” should be displayed for several seconds when power is initially applied, and then
the readout should display the position of the cable. If “888” remains displayed, either
when initially powering up the hoist, or when the Hoist is in operation, refer to Table 102
for Troubleshooting Procedures.
(2) With no load on the cable, reel out 3 feet (0.9 m.) of cable from the full in limit.
(3) Verify the readout on the Control Pendant displays 001 to 006 feet (00.1 to 01.82 m.).
(4) If the value is not met as specified above, adjust the large potentiometer R1 on the Hoist
as follows (see Figures 101 and 1003):
(a) Remove tie wire, screws (30 and 40), washers (50), clamps (60 and 70), limit switch
cover (80), and gasket (90).
(b) If applied, remove Torque Seal from the potentiometer mounting screws (1210).
Loosen screws on the potentiometer bracket (820) to unlock the position of the large
potentiometer R1 (1220). Slowly turn the potentiometer until the readout displays 001
to 006 feet (00.1 to 01.8 m.).
(c) Tighten screws (1210) to lock the potentiometer in position by applying 3.0 to 4.0
(d) Perform the test identified above in paragraphs B(2) and B(3) above to confirm the
potentiometer has been set correctly.
25-61-00
Page 108
October 10, 2011
TD-03-008
Revision A

(e) If the readout cannot be adjusted within 001 to 006 feet (00.1 to 01.8 meters) refer to
Table 102 for Troubleshooting Procedures.
(f) After successfully setting the cable readout potentiometers, apply torque seal to screws
for potentiometer R1.
(5) With no load on the cable, slowly reel out the cable until the Hoist stops at the full out
position (4 ± ½ wraps of cable on drum from cable termination).
(6) Verify the readout on the Control Pendant displays 242 to 248 feet (73.8 to 75.6 meters).
(7) If the value is not met as specified above, adjust the small potentiometer R3 on the Hoist
as follows (see Figures 101 and 1003):
(a) If not previously accomplished, remove tie wire, screws (30 and 40), washers (50),
clamps (60 and 70), limit switch cover (80), and gasket (90).
(b) Adjust the small potentiometer R3 (1230) by carefully removing any torque seal and
turning the adjustment screw until the value is 242 to 248 feet (73.8 to 75.6 meters).
(c) Perform the test identified above in paragraphs B(5) and B(6) above to confirm the
potentiometer has been set correctly.
(d) If the readout cannot be adjusted to 242 to 248 feet (73.8 to 75.6 meters) refer to Table
102 for Troubleshooting.
(e) After successfully setting the cable readout potentiometers, apply red Glyptal to
adjustment screw for potentiometer R3.
(8) If removed, install limit switch cover, gasket, clamps, washers, screws, and tie wire per
NASM33540 with MS20995NC32, or safety cable per NASM33540 using AS3510-01.
25-61-00
Page 109
October 10, 2011
TD-03-008
Revision A

C. Cable Foul Assembly Test (see Figures 104 and 1003)
CAUTION: DO NOT DISPLACE CABLE FOUL SENSOR GREATER THAN 0.188 IN.
(4.7 MM.) FROM ITS NORMAL “AT REST” POSITION.
(1) With cable at 20 ft (6.1 m.) from full in position, operate the hoist to reel out cable at
maximum speed. Actuate the cable foul sensor by lifting the flapper. Hoist operation shall
stop and resume when flapper is allowed to return to its “at rest” position.
(2) With no load attached, slowly reel in the cable 3.0 to 6.0 ft. (0.91 to 1.83 m.) of cable
length remaining from full in, position drum where the crossover point is aligned with the
cable foul sensor flapper. The clearance between the cable and the flapper shall be 0.06 in.
± 0.02 in. (1.5 mm. ± 0.5 mm.) per Figure 104.
(3) Adjust if necessary by turning cap screws in the cable foul assembly (see Figure 104).
Using a spring scale, measure and record the spring force on each side of the flapper
required to actuate switches in both reeling out and reeling in directions. The force shall
be 3.0 + 0.75 lb. (1.4 + 0.3 kg.).
Adjust Cap Screws

Through Holes in Cover
View B-B
Outer Layer
of Cable
0.060 ± 0.020 in.

(1.5 mm. ± 0.5 mm.)
View B-B
Figure 104. Cable Foul Assembly Inspection and Adjustment
25-61-00
Page 110
October 10, 2011
TD-03-008
Revision A

D. Electrical Continuity Test
Check continuity at MS3121F14-18PY connector as defined in Table 101.
Loss of continuity Damaged Wiring / Pins Pin check to diagnosis problem
With cable at Full In Pin A to Pin B > 10 Mohm
Pin A to all others except B > 10 Mohm
Pin C to Pin D < 1 ohm
Pin C to all others except D > 10 Mohm
Pin E to Pin G > 10 Mohm
Pin E to all others except G > 10 Mohm
With cable at least 10 m (33 ft) from Full In and Full Pin A to Pin B < 1 ohm
Out: Pin A to all others except B > 10 Mohm
Pin C to Pin D < 1 ohm
Pin E to Pin G < 1 ohm
Cable Foul Sensor actuated with cable at any position Pin A to Pin B > 10 Mohm
CAUTION: Do not displace switch actuator / cable Pin C to Pin D > 10 Mohm
foul sensor greater than 4.7 mm (0.188 Pin C to all others except D > 10 Mohm
in.) from its normal “at rest” position. Pin R to Pin S < 1 ohm
Pin R to all others except S > 10 Mohm
With cable at Full Out Pin A to Pin B < 1 ohm
Pin C to Pin D > 10 Mohm
Pin E to Pin G > 10 Mohm
With cable at any position All pins to hoist frame > 10 Mohm
Connector shell to hoist frame <1 ohm
Table 101. Electrical Continuity Check
E. Rated Load Test (Operational Flight Test to be performed with helicopter in hover and cowlings
installed).
CAUTION: DURING OPERATION OF THE RESCUE HOIST, DO NOT TOUCH THE

MOTOR. THE MOTOR TEMPERATURE MAY BE VERY HOT, AND MAY
RESULT IN SEVERE BURNS IF TOUCHED.
NOTE: LIMIT SWITCHES MUST BE SET AND OPERATING PRIOR TO LOAD
TESTING.
NOTE: THE RATED LOAD TEST REQUIRES TESTING OF THE HOIST ON THE
HELICOPTER IN A HOVER WITH COWLINGS INSTALLED.
NOTE: AT ANY TIME OBSERVE THE CYCLE COUNTER INCREASES BY 1 FOR
EACH REVOLUTION OF THE DRUM.
25-61-00
Page 111
October 10, 2011
TD-03-008
Revision A

(1) 600 lb. (272 kg.) Load Test
(a) Verify performance at the 600 lb. (272 kg.) mode by operating the hoist through its
full cable travel as follows:
1) Run hoist to slowly pay out cable until the hook can be connected to a weight of
600 lb. (272 kg.) that is resting on the ground.
2) Raise 600 lb. (272 kg.), and then rest 30 seconds.
3) Lower 600 lb. (272 kg.), and then rest 30 seconds.
4) Repeat steps 1) and 2) one more time.
When raising 600 lb. (272 kg.), with the cable on the top layer of the drum, the
minimum cable speed shall be 130 fpm (0.66 mps).
When lowering 600 lb. (272 kg.), with the cable on the top layer of the drum, the
maximum speed shall be 300 fpm (1.52 mps).
(b) Optional Procedures for Troubleshooting:
If the hoist does not meet the speed requirements specified above, the operator may
want to repeat this test while monitoring current and voltage to verify sufficient power
is being supplied by the helicopter. The current draw shall not exceed 155 amps for
the motor and 5 amps for the control circuit at the minimum supply voltage of 25
VDC measured at the controller connector when raising 600 lb. (272 kg.).
(2) 300 lb. (136 kg.) Load Test
(a) Verify performance in the 300 lb. (136 kg.) mode by operating the hoist through its
full cable travel as follows:
1) Raise 300 lb. (136 kg.), and then rest 30 seconds.
2) Lower 300 lb. (136 kg.), and then rest 30 seconds.
3) Repeat steps 1) and 2) one more time.
When raising 300 lb. (136 kg.), with the cable on the top layer of the drum, the
minimum cable speed shall be 210 fpm (1.07 mps).
When lowering 300 lb. (136 kg.), with the cable on the top layer of the drum, the
maximum speed shall be 300 fpm (1.52 mps).
(b) Optional Procedures for Troubleshooting:
If the hoist does not meet the speed requirements specified above, the operator may
want to repeat this test while monitoring current and voltage to verify sufficient power
is being supplied by the helicopter. The current draw shall not exceed 155 amps for
the motor and 5 amps for the control circuit at the minimum supply voltage of 25
VDC measured at the controller connector when raising 300 lb. (136 kg.). The
maximum lowering speed shall be 1.52 m/s (300 ft/min).
25-61-00
Page 112
October 10, 2011
TD-03-008
Revision A

If the helicopter power is correct, but the hoist does not meet the speed requirements
specified above, operator also might want to measure the temperature of the drum
flange at the end of the 300 lb. (136 kg.) load test. The temperature must be monitored
on the exposed surface of the large drum flange. The surface temperature shall not
exceed 200°F (94°C) after completion of testing.
F. Hook Load Test
NOTE: ENSURE THE CABLE HAS BEEN WRAPPED ON THE DRUM AT A TENSION OF
APPROXIMATELY 20 LB. (9.1 KG.) LOAD TO ENSURE SMOOTH, EVEN WRAPPING
BEFORE PERFORMING THE HOOK LOAD TEST. GAPS MAY OCCUR IN THE
LOWER LAYERS OF THE CABLE IF IT IS NOT TIGHT ON THE DRUM.
Check for proper installation of the hook by applying a rated load of 600 lb. (272 kg.) as
follows:
(1) Run hoist to reel out cable until the hook can be connected to a weight of 600 lb. (272 kg.)
that is resting on the ground directly below the hoist.
(2) Mount load on hook and slowly reel cable in until the weight is lifted off the ground.
Verify that the hook does not slip, or detach, from the cable for 2 minutes.
(3) Once weight is off the ground after 2 minutes, lower weight back to the ground.
(4) Remove weight and run hoist to the full in position to secure to hook and bumper
assembly on hoist.
G. Bumper Assembly and Full In Limit Switch Test
(1) Reel out 20 feet (6.0 m.) of cable.
(2) Reverse Hoist direction and reel in cable until full in limit switch actuates.
(3) Observe deflection of bumper assembly.
(4) Deflection should measure 1.00 to 1.39 inches (25.4 to 35.3 mm.) as measured from top of
bumper spring retaining plate to bottom of spring (see Figure 105).
1.00 to 1.39 in.

(25.4 to 35.3 mm.)
Figure 105. Deflection of Bumper Assembly with Hook at Full In Position
25-61-00
Page 113
October 10, 2011
TD-03-008
Revision A

H. If during testing above, the Hoist fails to operate, or the cable breaks, fouls, fails to wrap
properly on the drum, or snaps at turnaround points between layers on drum, refer to Table
102 for Troubleshooting.
5. Troubleshooting
Troubleshooting is the process of using a logical sequence to locate and eliminate an equipment
malfunction. The troubleshooting process relies heavily on the abilities of qualified technicians.
Refer to Table 102 below.
Trouble Probable Cause Remedy
Cable Fails to Electrical Circuit Check Full In Limit Switches (see Para. 4A, Section 101, for setting switches)
Retract due to Failure due to Full In Replace Cable Guide Pin (see Para. 19C, Section 301, for removal,
Electrical Failure Limit Switches (S3) and Para. 3A, Section 701, for installation)
Circuit Open Check Cable Foul Assembly for Cable Foul (see Para. 7, Section 601,
for cable foul removal)
Check Electrical Connectors and Wiring per Wiring Diagrams in Section 201
Replace Full In Limit Switches S3 (see Para. 19C, Section 301, for removal,
and Para. 3A, Section 701, for installation)
Replace Cable Foul Assembly Switches (see Para. 19D, Section 301,
for removal, and Para. 4D, Section 701, for installation)
Electrical Circuit Check Electrical Connectors and Wiring per Wiring Diagrams in Section 201
Failure due to Power, Check Helicopter Electrical Power, Connectors, and Wiring
or Logic Failure Replace Variable Speed Controller (see Para. 4, Section 301, for removal,
and Para. 17, Section 701, for installation)
Defective Motor Replace Motor (refer to Para. 17, Section 301, for removal,
Cable Fails to Electrical Circuit Check Full Out Limit Switches (see Para. 4A, Section 101, for setting switches)
Extend due to Failure due to Full Out Check Cable Foul Assembly for Cable Foul (see Para. 7, Section 601,
Electrical Failure Limit Switches (S2) for cable foul removal)
Circuit Open Check Electrical Connectors and Wiring per Wiring Diagrams in Section 201
Replace Full Out Limit Switches S2 (see Para. 19A, Section 301, for removal,
and Para. 3B, Section 701, for installation)
Failure due to Power, Check Helicopter Electrical Power, Connectors, and Wiring
or Logic Failure Replace Variable Speed Controller (see Para. 4, Section 301, for removal,
Defective hoist motor Replace Motor (refer to Para. 17, Section 301, for removal,
Table 102. Troubleshooting Procedures
25-61-00
Page 114
October 10, 2011
TD-03-008
Revision A


Cable Fails to Cable Fouled due to Replace Tension Roller Pin (see Para. 14, Section 301, for removal,
Extend, or Retract, Tension Roller Failure and Para. 7, Section 701, for installation)
due to Cable Foul Replace Roller Shaft Assembly (see Para. 14, Section 301, for removal,
Replace Tension Roller Clutch Assy. (see Para. 14, Section 301, for removal,
and Para7, Section 701, for installation)
Replace Overrunning Clutch Assy. (see Para. 15, Section 301, for removal,
Cable Foul due to Realign Cable Guide by adjusting Level Wind Shaft timing with Drum
Drum and Cable (see Para. 8, Section 601, for realignment)
Guide misalignment Torque Nut on Cyclocentric End of Level Wind Shaft to between
55 and 60 in.-lb. (6.2 and 6.8 Nm.)
Cable Fails to Cable Fouled due to Replace Chain (see Para. 16, Section 301, for removal,
Extend, or Retract, Level Wind Failure and Para. 5, Section 701, for installation)
due to Cable Foul Remove Hoist and send for repair (see Para. 3, Section 301, for removal,
(continued) and Para. 16, Section 701, for installation)
Cable Fouled due to Replace Spring (see Para. 14, Section 301, for removal,
Cable Guide Failure and Para. 7, Section 701, for installation)
Replace Plunger (see Para. 14, Section 301, for removal,
Remove Hoist and send for repair (see Para. 3, Section 301, for removal,
Cable Fails to Hoist Malfunction due Remove Hoist and send for repair (see Para. 3, Section 301, for removal,
Extend due to Hoist to Internal Mechanical and Para. 16, Section 701, for installation)
Failure Failure
Uncontrolled Hoist Thumbwheel switch Replace Control Pendant (see Para. 5, Section 301, for removal,
Up, or Down, due to inoperative, or Control and Para. 18, Section 701, for installation)
Control Pendant Pendant potentiometer
Failure defective
Uncontrolled Hoist Hoist Malfunction due Remove Hoist and send for repair (see Para. 3, Section 301, for removal,
Up, or Down, due to to Brake, Drive Train, and Para. 16, Section 701, for installation)
Failure to Support Cable, or Hook,
Load Failure
Uncontrolled Hoist Variable Speed Replace Variable Speed Controller (see Para. 4, Section 301, for removal,
Up, or Down, due to Controller Logic, or and Para. 17, Section 701, for installation)
Variable Speed Power, Failure
Controller Failure
Uncontrolled Hoist Intermediate Speed Check Limit Switches Setting (see Para. 4A, Section 101)
Up, or Down, due to Limit Switches (S1), Check Electrical Connectors and Wiring per Wiring Diagrams in Section 201
Intermediate speed or Circuit, Failure Check Helicopter Electrical Power, Connectors, and Wiring
Limit Switch Failure Replace Intermediate Speed Limit Switches S1 (see Para. 19A, Section 301,
for removal, and Para. 3B, Section 701, for installation)
Table 102. Troubleshooting Procedures (continued)
25-61-00
Page 115
October 10, 2011
TD-03-008
Revision A

Uncontrolled Hoist Full In Limit Switches Check Limit Switches Setting (see Para. 4A, Section 101, for setting switches)
Up due to Full In (S3), or Circuit, Ensure Pin is not sticking and returns. Replace Cable Guide Pin (see Para.
Limit Switch Failure Failure 19C, Section 301, for removal, and Para. 3A, Section 701, for installation)
Replace Full In Limit Switches S3 (see Para. 19C, Section 301, for removal,
and Para. 3A, Section 701, for installation)
Defective Bumper Replace Bumper Spring (see Para. 7, Section 301, for removal,
Spring and Para. 13, Section 701, for installation)
Uncommanded Hoist Malfunction due Remove Hoist and send for repair (see Para. 3, Section 301, for removal,
Hoist Down due to to Brake, Drive Train, and Para. 17, Section 701, for installation)
Failure to Support Cable, or Hook,
Load Failure
Uncommanded Variable Speed Replace Variable Speed Controller (see Para. 4, Section 301, for removal,
Hoist Down due to Controller Logic, or and Para. 17, Section 701, for installation)
Variable Speed Power, Failure
Controller Failure
Cable wraps loosely Drum and cable guide Realign Cable Guide by adjusting Level Wind Shaft timing with Drum
on drum, or does not are misaligned (see Para. 8, Section 601, for realignment)
reel out smoothly Defective, or missing, Replace Tension Roller Pin (see Para. 14, Section 301, for removal,
pin and Para. 7, Section 701, for installation)
Worn tension roller Replace Roller Shaft Assembly (see Para. 14, Section 301, for removal,
Defective tension Replace Tension Roller Clutch Assy. (see Para. 14, Section 301, for removal,
roller clutch assembly and Para. 7, Section 701, for installation)
Defective overrunning Replace Overrunning Clutch Assy. (see Para. 15, Section 301, for removal,
clutch assembly and Para. 6, Section 701, for installation)
Cable snaps at Drum and cable guide Realign Cable Guide by adjusting Level Wind Shaft timing with Drum
turnaround points are misaligned (see Para. 8, Section 601, for realignment)
Torque Nut on Cyclocentric End of Level Wind Shaft to between
55 and 60 in.-lb. (6.2 and 6.8 Nm.)
Inadvertent Cable Electrical Circuit Replace Cable (see Para. 9, Section 301, for removal,
Cut Failure and Para. 12, Section 701, for installation of cable)
Cartridge Failure Replace Cartridge (see Para. 3C, Section 301, for removal,
and Para. 19, Section 701, for installation of cartridge)
Failure to Cut Cable Cartridge Failure Replace Cartridge (see Para. 3C, Section 301, for removal,
on Demand and Para. 19, Section 701, for installation)
Failure Check Helicopter Electrical Power, Connectors, and Wiring
Cable Cutter Replace Cotter Pin (see Para. 10, Section 301, for removal,
Assembly Failure and Para. 11, Section 701, for installation)
Replace Cable Cutter (see Para. 10, Section 301, for removal,
Replace Anvil (see Para. 10, Section 301, for removal,
Replace Packing on Cartridge (see Para. 3C, Section 301, for removal,
Replace Cable Cutter O-Ring (see Para. 10, Section 301, for removal,

25-61-00
Page 116
October 10, 2011
TD-03-008
Revision A

Hoist fails to make Excess, or insufficient, Check oil level in hoist (refer to Section 501, Paragraph 2L(5),
speed amount of oil in hoist for servicing the hoist with oil)
Defective Variable Replace Variable Speed Controller (see Para. 4, Section 301, for removal,
Speed Controller and Para. 17, Section 701, for installation)
Defective motor Replace Motor (refer to Para. 17, Section 301, for removal,
Hoist is binding Remove Hoist and send for repair (see Para. 3, Section 301, for removal,
Control Pendant Potentiometers on Adjust potentiometers on hoist (refer to Paragraph 4B, Section 101)
readout not within hoist out of
acceptable limits adjustment, Remove Hoist and send for repair (see Para. 3, Section 301, for removal,
or damaged and Para. 16, Section 701, for installation)
Cable jams, or Defective, or broken, Replace Cable (see Para. 9, Section 301, for removal,
breaks Cable and Para. 12, Section 701, for installation of cable)
Defective Bumper Replace Bumper (refer to Para. 7, Section 301, for removal,
Assembly and Para. 13, Section 701, for installation)
Corroded, or binding, Perform Cleaning and Lubrication on Hook, and Hook Bearing
Hook Bearing (refer to Section 401, Paragraph 1L)
Worn Tension Roller Replace Tension Roller Pin (see Para. 14, Section 301, for removal,
Defective Tension Replace Tension Roller Clutch Assembly (refer to Para. 14, Section 301,
Roller Clutch for removal, and Para. 7, Section 701, for installation)
Assembly
Drum and cable guide Realign Cable Guide by adjusting Level Wind Shaft timing with Drum
are misaligned (refer to Para. 8, Section 601)
Defective Overrunning Replace Overrunning Clutch Assembly (refer to Para. 15, Section 301,
Clutch Assembly for removal, and Para. 6, Section 701, for installation)
Deflection of Defective Bumper Replace Bumper Spring (refer to Para. 7, Section 301, for removal,
Bumper Spring Spring and Para. 13, Section 701, for installation)
exceeds limits Full In Limit Switches Replace Full In Limit Switches S3 (refer to Para. 19C, Section 301,
(S3) inoperative for removal, and Para. 3A, Section 701, for installation)
Intermediate Speed Replace Intermediate Speed Limit Switches S1 (refer to Para. 19A,
Limit Switches (S1) Section 301 for removal, and Para. 3B, Section 701, for installation)
inoperative
Defective Overrunning Replace Overrunning Clutch Assembly (refer to Para. 15, Section 301,
Clutch Assembly for removal, and Para. 7, Section 701, for installation)

If defect cannot be corrected, contact Breeze-Eastern Customer Services at:
Breeze-Eastern Corporation
35 Melanie Lane
Phone Number: 973-602-1001, Ext.1083 or 1090, or 1-800-929-1919 (US and Canada Only)
Fax Number: 973-739-9344
25-61-00
Page 117
October 10, 2011
TD-03-008
Revision A

THIS PAGE INTENTIONALLY LEFT BLANK
25-61-00
Page 118
October 10, 2011
TD-03-008
Revision A
SCHEMATICS AND WIRING DIAGRAMS

1. General
Schematics and wiring diagrams for the HS-20200-421 Series Rescue Hoist Systems are
contained in this section. Figure 201 shows the typical circuit used to drive a helicopter supplied
cable foul indicator for the BL-20200-421 Rescue Hoist Assembly. Figure 202 shows the internal
wiring diagram of the BL-20200-421 Rescue Hoist Assembly. Figure 203 shows the wiring
diagram for the HS-20200-421-01 Rescue Hoist System. Figure 204 shows the wiring diagram
for the HS-20200-421-02 Rescue Hoist System. Figure 205 shows the wiring diagram for the
EC-14170-1 Control Pendant Cable Assembly. Figure 206 shows the wiring diagram for the
BL-16016-1 Cable Foul Sensor Assembly.
2. Contents of this Section
Figure # Description Page

Figure 201 Typical Circuit Used to Drive The Cable Foul Indicator 201
Figure 202 BL-20200-421 Rescue Hoist Assembly Wiring Diagram 202
Figure 203 HS-20200-421-01 Rescue Hoist System Wiring Diagram 203
Figure 204 HS-20200-421-02 Rescue Hoist System Wiring Diagram 204
Figure 205 EC-14170-1 Control Pendant Cable Assembly Wiring Diagram 205
Figure 206 BL-16016-1 Cable Foul Sensor Wiring Diagram 206
CABLE
FOUL
CABLE FOUL INDICATOR
SWITCH ON HOIST
HELICOPTER
SUPPLIED
INDICATOR
HELICOPTER
SUPPLIED
POWER
Figure 201. Typical Circuit Used to Drive The Cable Foul Indicator
25-61-00
Page 201
October 10, 2011
TD-03-008
Revision A
Figure 202. BL-20200-421 Rescue Hoist Assembly Wiring Diagram
25-61-00
Page 202
October 10, 2011
TD-03-008
Revision A
Figure 203. HS-20200-421-01 Rescue Hoist System Wiring Diagram

25-61-00
Page 203
October 10, 2011
TD-03-008
Revision A
Figure 204. HS-20200-421-02 Rescue Hoist System Wiring Diagram
25-61-00
Page 204
October 10, 2011
TD-03-008
Revision A
Figure 205. EC-14170-1 Control Pendant Cable Assembly Wiring Diagram
25-61-00
Page 205
October 10, 2011
TD-03-008
Revision A
Figure 206. BL-16016-1 Cable Foul Sensor Wiring Diagram
25-61-00
Page 206
October 10, 2011
TD-03-008
Revision A
DISASSEMBLY
1. General
Use the Testing and Troubleshooting procedures, in Section 101, to establish the condition of the
System, or most probable cause for its malfunction. These procedures must be followed to
determine the extent of disassembly required for repair and maintenance of the System, and to
limit the amount of maintenance required for returning it to a serviceable condition.
2. Disassemble the System in accordance with the following instructions. Reference numbers in
parenthesis refer to Illustrated Parts List (IPL) in Section 1001 (Figures 1001, 1002, and 1003).
Special Tools and general information are listed in Section 901. All mention of applying and
disconnecting power to hoist should be accomplished using helicopter circuit breakers, or
equivalent acceptable means.
WARNING: SEARCH AND RESCUE OPERATIONS, AND ALL OTHER USES OF HOISTS
FOR HOISTING AND LOWERING PERSONNEL, CAN RESULT IN INJURY OR
OPERATION, MAINTENANCE, AND INSPECTION PROCEDURES TO
MINIMIZE THE HAZARDS INHERENT IN THE USE OF ALL RESCUE HOISTS.
3. Remove the Hoist from helicopter as follows:
A. Disconnect power to the Hoist (Figure 1001, Item 10) by pulling applicable circuit breakers.
B. Disconnect electrical connectors to the motor, and to the harness assemblies, which connects
to the cable cutter cartridge, cable foul assembly, and limit switches.
C. Remove cable cutter cartridge (Figure 1003, View A, Item 10, and part of Figure 1001, Item
50) from hoist, as follows:
STORED, AND HANDLED IN COMPLIANCE WITH ALL LOCAL
STANDARDS, AND REGULATORY PRACTICES. TAKE PROPER
PRECAUTIONS TO AVOID SETTING OFF THE CARTRIDGE DURING
HANDLING DUE TO ELECTRICAL SHOCK FROM ELECTROSTATIC
DISCHARGE (ESD).
WARNING: THE CARTRIDGE MUST BE REMOVED BEFORE PERFORMING ANY
MAINTENANCE PROCEDURES INVOLVING THE HOIST AND MUST BE
INSTALLED AFTER ALL MAINTENANCE PROCEDURES ON THE HOIST
ASSEMBLY ARE COMPLETED.
(1) Disconnect electrical connector to cartridge in hoist.
(2) Short all pins of cartridge (Figure 1003, View A, Item 10) together with spring supplied
with cartridge (If spring is not available, short all pins with equivalent alternative). See
Figure 301.
(3) Place masking tape over cartridge to hold spring, or equivalent, in place.
25-61-00
Page 301
October 10, 2011
TD-03-008
Revision A
(4) Remove tie wire or safety cable and cartridge (Figure 1003, Detail A, Item 10) with
shims (15, A, if applicable), and packing (20) from cable guide housing.
Pins to be shorted Packing (20) and shims
together prior to (15, 15A, if applicable)
removal of cartridge are located under
cartridge hex. Shims are
only used with 90 degree
connector.
Cable Cutter Cartridge
Cable Guide Assembly
Figure 301. Cable Cutter Cartridge in Cable Guide Assembly

D. Remove cowling (not part of System, and not supplied by Breeze-Eastern) in accordance
with instructions provided by the helicopter manufacturer.
CAUTION: WHEN MOUNTED ON THE HELICOPTER THE HOIST WEIGHS
APPROXIMATELY 85 LB. (38.5 KG.) OR 81 LB. (36.7 KG.) WITHOUT THE
HOOK INSTALLED. TWO INDIVIDUALS SHOULD REMOVE THE HOIST
FROM THE HELICOPTER UNLESS SUITABLE SUPPORT IS PROVIDED TO
HOLD THE WEIGHT OF THE HOIST WHEN REMOVED.
CAUTION: AFTER REMOVAL FROM THE HELICOPTER, REST THE HOIST ONLY ON
THE FOUR MOUNTING POINTS. DO NOT REST THE HOIST ON ANY OTHER
COMPONENTS AS THIS MAY RESULT IN THE HOIST BEING DAMAGED.
E. Remove attaching hardware (not part of System and not supplied by Breeze-Eastern) from
four mounting points and remove the Hoist (Figure 1001, Item 10) from the helicopter and as
an option utilize the rescue hoist clevis maintenance fixture TE-132-1 for ease of
maintenance.
4. Remove Variable Speed Controller from helicopter as follows:
WARNING: TAKE PROPER PRECAUTIONS TO AVOID DAMAGING ELECTRONIC
COMPONENTS DURING HANDLING DUE TO ELECTRICAL SHOCK FROM
ELECTROSTATIC DISCHARGE (ESD).
25-61-00
Page 302
October 10, 2011
TD-03-008
Revision A
A. Disconnect power to Variable Speed Controller (Figure 1001, Item 20) by pulling applicable
circuit breakers.
B. Disconnect electrical connectors to Variable Speed Controller (20).
C. Remove four mounting screws (not part of System, and not supplied by Breeze-Eastern)
from Variable Speed Controller (20).
D. Remove Variable Speed Controller (20) from helicopter.
5. Remove Control Pendant and Cable Pendant Assembly from the helicopter as follows:
WARNING: TAKE PROPER PRECAUTIONS TO AVOID DAMAGING ELECTRONIC
COMPONENTS DURING HANDLING DUE TO ELECTRICAL SHOCK FROM
ELECTROSTATIC DISCHARGE (ESD).
A. Disconnect power to Control Pendant (Figure 1001, Items 30, or 40) by pulling applicable
circuit breakers.
B. Disconnect and remove Control Pendant (30, or 40) from electrical connector on pendant
cable assembly (70). Disconnect and remove cable pendant assembly (70) from controller.
6. Remove and disassemble hook assembly, part of Item 60 in Figure 1001, as follows (see Figure
1002 unless specified below):
A. Apply power to hoist (Figure 1001, Item 10).
B. Pay out approximately 6 feet (1.8 meters) of cable from hoist to allow the hook and bumper
assemblies to rest on a flat surface.
C. Disconnect power from hoist.
D. Pull up on bumper assembly (10), which consists of a bumper retainer (20), a compression
spring (30), and an over travel bumper (40), and slide it along cable (Figure 1003, View A,
Item 100) away from hook assembly (50) and toward the hoist to separate the bumper
assembly from the nut (60) in the hook assembly.
CAUTION: PARTS LOCATED INSIDE OF THE HOOK ASSEMBLY WILL FALL FREE
AFTER DISENGAGEMENT OF THE NUT FROM THE BODY. PLACE THE
HOOK ASSEMBLY ON A FIRM SURFACE BEFORE REMOVING THE NUT.
E. Remove cotter pins (70) and locking screws (80) from nut (60).
F. While holding hook housing (90) loosen, unthread and remove nut (60) and slide it up along
cable away from hook assembly.
NOTE: TERMINAL CLAMP (100) IS A TWO-PIECE MATCHED SET. KEEP BOTH
HALVES TOGETHER FOR FUTURE USE.
G. Remove ring (110) from terminal clamp (100), and then remove terminal clamp and nut (60)
from cable.
H. Remove spacer (120) and handwheel assembly (130) from hook assembly.
I. If necessary, press bearing (140) out of handwheel (150) in handwheel assembly (130).
25-61-00
Page 303
October 10, 2011
TD-03-008
Revision A
J. Line up hole in hook housing and, using a drift and a mallet, gently tap out orange colored
spring pin (160) to remove it from hook assembly.
K. Unthread, and remove castellated nut (170) from top of the hook assembly.
NOTE: SWIVEL HOOK (210) IS A PURCHASED ITEM, WHICH THIS MANUAL DOES
NOT COVER. PLEASE CONTACT THE VENDOR OF THIS HOOK FOR THEIR
RECOMMENDATIONS CONCERNING MAINTENANCE.
L. Remove thrust washer (180), bearing (190), housing (90), and washer (200) from hook (210).
7. Remove and disassemble bumper assembly, part of Item 60 in Figure 1001 (see Figure 1002
unless specified below):
A. Accomplish actions identified in Paragraph 6 (removal and disassembly of hook assembly)
above prior to performing the steps below; see Figure 1002 unless specified below:
B. Remove bumper assembly off the cable.
C. Using a screwdriver, or equivalent, pry compression spring (30) from four crimped areas of
the bumper retainer (20, IPL Figure 1002).
D. Remove overtravel bumper (40) by pressing out from bumper retainer (20).
8. Remove and disassemble limit switch cover assembly as follows (see Figures 302 and 1003):
A. Remove tie wire, or safety cable, screws (30 and 40), washers (50), clamps (60 and 70),
cover (80), and gasket (90). See Figure 302.
B. Remove gasket (90) from cover (80), if necessary.
25-61-00
Page 304
October 10, 2011
TD-03-008
Revision A
Clamps (60 and 70)
Screws (30) and Washers (50) Label (800)
Limit Switch Cover (80)

with Gasket (90)
Cycle Counter Label (790) Screws (40) with Tie Wire and
Washers (50) not shown,
Identification Plate (780) obscured by Limit Switch Cover
Figure 302. Limit Switch Cover
9. Remove cable from hoist as follows:

A. Accomplish actions identified in Paragraphs 3C, 6, 7, and 8 (removal and disassembly of
cable cutter cartridge, hook, bumper, and limit switch cover assemblies) above prior to
performing the steps below, see Figure 1003.
HANDLING THE HOIST CABLE TO PREVENT INJURY FROM BROKEN
CABLE STRANDS AND WIRES.
B. Apply power to hoist (Figure 1001, Item 10).
C. Pay out cable (Figure 1003, View A, Item 100) at less than half speed until hoist reaches full
out limit.
WARNING: PERSONNEL SHOULD USE TOOLS THAT DO NOT CONDUCT ELECTRICITY
TO ACTUATE THE LIMIT SWITCHES. PROPER GROUNDING IS REQUIRED.
25-61-00
Page 305
October 10, 2011
TD-03-008
Revision A
WARNING: THE HOIST MUST NOT BE OPERATED IN THE LOWERING DIRECTION
BEYOND THE POSITION WHERE THE OPENING IN THE DRUM FLANGE
FOR THE SETSCREWS IS VISIBLE. ROTATING THE DRUM IN THE
LOWERING DIRECTION BEYOND THIS POSITION WILL CAUSE THE
CABLE TO BACKWIND RESULTING IN SERIOUS DAMAGE TO THE HOIST.
D. Carefully override the full out limit switch, S2, (Figure 1003, View B, Item 110) by gently
pushing down on the actuators and manually closing the redundant switches with a small
screwdriver or equivalent tool. Slowly reel out cable until the opening in the drum flange for
setscrews (Figure 1003, Item 120) is visible and approximately 6 inches (0.15 meters) of
cable remains on the hoist (less than 1 wrap). See Figure 303.
Actuators
Full Out Limit Switch S2
Figure 303. Full Out Limit Switch (S2) on Cyclocentric Assembly
CAUTION: ONCE THE CABLE IS REMOVED, DO NOT ROTATE THE DRUM IN EITHER
DIRECTION. THE DRUM IS IN POSITION FOR INSTALLING THE NEW
CABLE. ROTATING THE DRUM WITHOUT THE CABLE ATTACHED WILL
CAUSE THE TIMING BETWEEN THE CABLE GUIDE AND THE DRUM TO BE
INCORRECT RESULTING IN DAMAGE TO THE DRUM AND THE CABLE.
E. Disconnect power from hoist.
F. Remove both setscrews (120) from drum flange to allow removal of cable.
G. Remove the end of cable from the slot in the drum flange. Pull cable out through cable guide.
10. Remove cable cutter as follows:
A. Accomplish actions identified in Paragraphs 3C, 6, 7, 8, and 9 (removal and disassembly of
cable cutter cartridge, hook, bumper, limit switch cover, and cable) above prior to
performing the steps below. See Figure 1003, View A.
25-61-00
Page 306
October 10, 2011
TD-03-008
Revision A
In the event the cartridge has been fired during a cable cut, Refire Kit, PN KT-489, which
includes the anvil, cutter, O-ring, cotter pin, and tie wire, and Cartridge Kit, KT-198, which
includes the cartridge in a hermetically sealed container, three shims, and one O-ring, can be
purchased from Breeze-Eastern Corporation.
STANDARDS, AND REGULATORY PRACTICES. TAKE PROPER
PRECAUTIONS TO AVOID FIRING THE CARTRIDGE DURING HANDLING
DUE TO ELECTRICAL SHOCK FROM ELECTROSTATIC DISCHARGE (ESD).
WARNING: THE CARTRIDGE MUST BE REMOVED BEFORE PERFORMING ANY
MAINTENANCE PROCEDURES INVOLVING THE HOIST AND MUST BE
INSTALLED AFTER ALL MAINTENANCE PROCEDURES ON THE HOIST
ASSEMBLY ARE COMPLETED.
NOTE: MAXIMUM CARTRIDGE SERVICE LIFE IS 5 YEARS WHEN REMOVED
FROM PACKAGING, AND INSTALLED IN HOIST. MAXIMUM CARTRIDGE
LIFE IS 13 YEARS (COMBINED SHELF AND SERVICE LIFE) FROM THE
DATE OF MANUFACTURE. THE DATE OF MANUFACTURE CAN BE FOUND
IN THE LOT NUMBER ON THE LABEL OF THE SEALED CONTAINER, IN
WHICH THE CARTRIDGE IS SHIPPED AND STORED, AND ON THE FLATS
OF THE HEX SHAPED PORTION OF THE CARTRIDGE. THE LOT NUMBER
CAN BE IDENTIFIED WITH THE FIRST THREE LETTERS “CAD.”
IMMEDIATELY FOLLOWING THESE LETTERS IS THE DATE OF
MANUFACTURE, REPRESENTED AS TWO DIGITS, WHICH IDENTIFY THE
YEAR (EXAMPLE: 11 IS 2011), AND ONE LETTER, WHICH IDENTIFIES THE
MONTH, AS DEFINED BELOW:
B. If not accomplished previously, remove electrical connector (not shown in IPL) and cartridge
(10) with packing (20), and shims (15, 15A, if applicable) per paragraph 3C above.
C. Remove tie wire or safety cable and unthread anvil (130).
D. Remove cotter pin (140), cutter (150), and O-ring (160).
11. Remove cable guide as follows (see Figures 304 and 1003):
performing the steps below, see Figure 1003, View A.
B. Remove and discard cotter pin (170) from end of stop (180). See Figure 304.
25-61-00
Page 307
October 10, 2011
TD-03-008
Revision A
Self-Locking
Nut (190)
Stop (180)
Cotter Pin (170)

Cable Guide
(200)
Figure 304. Cable Guide Assembly with Cable Guide (200)
C. Unthread self-locking nut (190) until nut is at the end of the stop (180).
D. Position stop to permit removal of cable guide, and remove cable guide (200).
E. Lightly tap unthreaded end of stop (180) out to clear the cable guide assembly.
12. Remove follower as follows (see Figure 1003, View A):
A. Thread an 8-32 x 0.375 inch screw (PN MS16995-25, not provided by Breeze-Eastern, see
Table 901) into the follower (240), press down on screw to remove pressure against retaining
ring (220) from spring washer (230) and back up washer (210), and remove retaining ring.
B. Pull back on screw and remove back up spacer (210), spring washer (230), and follower
(240). Remove screw from follower (240).
13. Remove cable pressure roller assemblies as follows (see Figure 1003, View A):
A. Remove tie wire or safety cable from roller shafts (250).
B. Remove roller shafts (250), support (260), spacers (270), and roller assemblies (280 and
310).
C. If required, disassemble roller assemblies (280 and 310) by using a suitable press, and press
out staked bearings (290 and 320) from cable pressure rollers (300 and 330).
14. Remove tension roller as follows, see Figure 1003:
performing the steps below.
B. Apply power to hoist (Figure 1001, Item 10).
C. Position cable guide approximately at center of hoist, equidistant from end flanges.
25-61-00
Page 308
October 10, 2011
TD-03-008
Revision A
D. Disconnect power from hoist.
E. Insert a soft wooden wedge, or equivalent, between the spacer plate (Figure 1003, Item 340)
and the cable (Figure 1003, View A, Item 100) on the drum to prevent the cable from
loosening on the drum.
F. Remove cap screws (Figure 1003, 350) and guide bar (360).
G. Remove pressure roller plunger (Figure 1003, View A, Item 370) and spring (380).
H. Remove gear guard (Figure 1003, Item 390) by removing screws (400 and 410) and washers
(420 and 430).
I. Remove spring pin (440) from tension roller assembly using Tension Roller Removal and
Installation Tool, Part Number BLT-10300-J, or equivalent. Refer to Figure 901.
CAUTION: SHIMS, WASHERS, AND ROLLER WILL FALL FREE AFTER REMOVAL OF
THE SHAFT FROM THE HOIST. PLACE A SUITABLE CONTAINER UNDER
HOIST TO CATCH THESE PARTS WHILE REMOVING SHAFT.
J. Remove inner roller shaft (450) from tension roller assembly by applying pressure at motor
end of shaft and driving shaft through roller until shaft can be accessed and removed from
switch end of hoist.
K. Remove shims (460 through 460C) and thrust washers (470) from both ends of shaft. Record
thickness and location of shims.
L. Remove tension roller (480) and clutch assembly (490).
M. Remove clutch assembly from end of tension roller.
15. Remove overrunning clutch as follows:
A. Remove gear guard (Figure 1003, Item 390) by removing screws (400 and 410) and washers
(420 and 430).
B. Remove screws (500 and 510), washers (520), and clutch guard (530).
C. Remove bolt (540), spacer (550), and overrunning clutch assembly (560).
16. Remove chain as follows, see Figures 305 and 1003:
WARNING: CYCLOCENTRIC ASSEMBLY AND PRINTED CIRCUIT BOARD ASSEMBLY
ARE CONNECTED TO THE HOIST WIRING. DO NOT PULL WIRING AND
SOLDER JOINTS ON ELECTRICAL COMPONENTS WHEN REMOVING
THESE ASSEMBLIES.
A. Accomplish actions identified in Paragraph 8 (removal of limit switch cover assembly) above
prior to performing the steps below.
B. To gain access to the chain, remove screws (570), washers (580) and cyclocentric assembly
(590). See Figure 305.
25-61-00
Page 309
October 10, 2011
TD-03-008
Revision A
Drum Sprocket (630)
not shown, underneath
Cyclocentric Assembly
Lock nut (610) not

Shown
Chain (620)
Hex Head Level Wind

Screw Shaft Sprocket
(640)
Screws (570) and Washers (580)
Cam Follower (600)
Cyclocentric Assembly (590)
Figure 305. Chain, Sprocket, Follower, and Attaching Hardware
C. Loosen cam follower assembly (600) using a 0.125 in. (3.175 mm.) Allen wrench and
backing out hex head screw holding cam follower assembly while holding lock nut (610)
between end flange and drum. Slide idler away to relax tension on chain (620). See Figure
305.
D. Remove chain from the drum drive sprocket (630) and the level wind shaft sprocket (640).
17. Remove motor as follows (see Figures 306, 1003, and View C):
A. Disconnect electrical connector from motor.
B. Remove screws (650), washers (660), motor strap clamp (670), and motor strap (680) from
motor support (690). See Figure 306.
NOTE: REMOVE MOTOR SUPPORT AND SHIMS ONLY IF MOTOR IS TO BE
REPLACED
C. If necessary, remove motor support (690) and shims (700 through 700C) by removing screws
(710) and washers (720), and remove motor pad (730) from motor support.
D. Remove screws (740) and washers (750) and remove motor (760) from Hoist.
E. Remove O-ring (770) from motor.
25-61-00
Page 310
October 10, 2011
TD-03-008
Revision A
Figure 306. Motor Support with Attaching Hardware

18. If necessary, remove identification plate (780) and labels (790 and 800) as follows (see Figures
302 and 1003) as follows:
A. All typed-in information on identification plate (780) should be recorded prior to removal,
and will be required for new plate when installed. If illegible, or missing, contact
Breeze-Eastern with all known information concerning rescue hoist for original, or new, data
for plate.
B. Remove plate (780), labels (790 and 800), and any residual adhesive from the parts the labels
are applied with by using a sharp knife, razor blade, isopropyl alcohol, or equivalent.
19. Removal of Electrical Components (refer to Figures 202, 203, and 204 for Wiring Diagrams):
A. Remove full out limit switches, S2, and intermediate speed limit switches, S1, as follows:
(1) If not previously accomplished, remove tie wire or safety cable, screws (Figure 1003, 30
and 40), washers (50), clamps (60 and 70), cover (80), and gasket (90).
(2) Remove screws (810) and remove potentiometer bracket (820).
(3) Remove switch mounting brackets (Figure 1003, View B, 830 and 840) by removing
screws (850) and washers (860).
(4) Remove switches (110) and actuators (870) from brackets by removing screws (880 and
890), flat washers (900), and nuts (910). Refer to Section 101, Figure 101.
(5) Remove sealant and unsolder wire connections of full out and intermediate speed limit
switches.
25-61-00
Page 311
October 10, 2011
TD-03-008
Revision A
B. Remove potentiometer R1 (Figure 1003, Item 1220, and View D) as follows (See Figures
101 and 303):
(1) Loosen screws (Figure 1003, Item 1210 and View D), rotate cleats (1212), and remove
potentiometer R1 (1222) from mounting bracket.
(2) Remove O-Rings (1224) from shaft of potentiometer R1.
(3) Carefully remove any sealant from wire connections and unsolder wire connections to the
potentiometer circuit board positioned on top of the potentiometer, which includes R3
(1230).
C. Remove full in limit switches, S3, as follows: (Refer to Figures 202, 203, & 204 for
applicable wiring diagrams).
(1) Remove cable guide limit switch cover (Figure 1003, View A, 920) with gasket (930) by
removing screws (940) and washers (950).
(2) Remove full in limit switches, S3, (110) and actuator (960) from cable guide assembly by
removing screws (970), flat washers (980), and tooth lock washers (990).
(3) Remove ring retainer (1012), retaining ring (1000), cable guide pin (1010), and spring
(1020) from cable guide assembly. Discard retaining ring. Refer to Section 101, Figure
103.
(4) Remove sealant and unsolder wire connections of full in limit switches.
D. Remove cable foul assembly switches as follows (see Figures 307, 308, and 1003):
(1) Unthread screws (1040), washers (1060), and loop clamps (1080) securing wiring
harnesses to cable foul assembly. Refer to Figure 307.
(2) Disconnect both electrical connector / harnesses (1240 and 1250) on top of cable foul
sensor.
(3) Through center hole of cable foul sensor (on the inside) remove wiring harness retention
screw (1050), washer (1070), harness (1250), and loop clamp (1090).
(4) Cut and remove safety wire (NASM20995NC20) or safety cable and remove cable foul
sensor retention screws (1040), with washers (1060), and terminal clamp from harness.
(5) If necessary, position cable foul sensor to gain access to the limit switches (1110).
Remove limit switch attach screws (1120), with washers (1130), and nuts (1110).
Carefully remove sealant and unsolder wires from limit switch terminals. Refer to Figure
308.
25-61-00
Page 312
October 10, 2011
TD-03-008
Revision A
Screws (1040) and Washers (1060)
Screw, Washer, Clamp

(1040, 1060, 1080)
Electrical Connector Electrical Connector

(1240) (1250)
Access Screw (1050), Washer (1070), and Clamp (1090)

through hole in Cable Foul Assembly
Figure 307. Cable Foul Assembly
Loop Clamp.
Wiring Harness, (1080)
(1250)
CFS Limit switch attach
screws,(1120) nuts, (1110)
Safety wire or safety and washers (1130) both
cable on both attach sides.
screws (1040) and
washers (1060). Limit Switches
(1100) (3 per side).
Harness ground terminal
Figure 308. Cable Foul Assembly(Left Side View)
25-61-00
Page 313
October 10, 2011
TD-03-008
Revision A
25-61-00
Page 314
October 10, 2011
TD-03-008
Revision A

CLEANING
1. General
Cleaning instructions for the components of the Rescue Hoist System are provided in this
section. To ensure satisfactory results, each cleaning procedure should be performed as described
with the equipment and materials listed in Table 401. All dust, dirt, soot, corrosion, rust, and
moisture must be removed, as these destructive agents will eventually cause operational failure.
Materials Required for Cleaning (Equivalent substitutes may be used for listed items).
Equipment / Material * Name
ASTM-D3699 Kerosene
ASTM D770 or TT-I-735 Isopropyl Alcohol
Anti-Static Plastic and Glass Cleaner Plasti-Glass
Brush Soft Bristle Brush
Vacuum Cleaner Vacuum Cleaner
DC (Medium), if applicable Grease for Hook Assembly – Thrust Bearing
MIL-G-81322, if applicable Grease for Hook Assembly used in sealed ball bearing
*Equivalent substitutes may be used.
Table 401. Materials Required for Cleaning
WARNING: SEARCH AND RESCUE OPERATIONS, AND ALL OTHER USES OF RESCUE
HOISTS FOR HOISTING AND LOWERING PERSONNEL, CAN RESULT IN
INJURY OR DEATH. PROPERLY TRAINED PERSONNEL MUST UTILIZE
APPROPRIATE OPERATION, MAINTENANCE, AND INSPECTION
PROCEDURES TO MINIMIZE THE HAZARDS INHERENT IN THE USE OF
ALL RESCUE HOISTS.
BROKEN STRANDS AND WIRES. EYE PROTECTION MUST BE WORN BY
THE OPERATOR WHENEVER OPERATING, OR MAINTAINING, THE
RESCUE HOIST TO PREVENT INJURY FROM LUBRICANTS, SOLVENTS,
AND OTHER MATERIALS USED ON THE RESCUE HOIST, AS WELL AS
METAL PARTS AND OTHER DEBRIS.
WARNING: KEROSENE AND ISOPROPYL ALCOHOL ARE COMBUSTIBLE. DO NOT USE
NEAR OPEN FLAMES, NEAR WELDING AREAS, OR ON HOT SURFACES.
PROLONGED CONTACT OF VAPOR WITH SKIN CAN IRRITATE NOSE AND
THROAT AND CAN CAUSE DIZZINESS. IF ANY LIQUID CONTACTS SKIN
OR EYES, IMMEDIATELY FLUSH AFFECTED AREA THOROUGHLY WITH
WATER. REMOVE SATURATED CLOTHING. IF VAPORS CAUSE DIZZINESS,
GO TO FRESH AIR.
25-61-00
Page 401
October 10, 2011
TD-03-008
Revision A

WARNING: KEEP HANDS, BODY, AND CLOTHING AWAY FROM RESCUE HOIST
ASSEMBLY, SPECIFICALLY “PINCH POINTS,” WHERE CABLE ENTERS THE
CABLE GUIDE AND CONTACTS THE DRUM
CAUTION: THE TENSION ROLLER SYSTEM WORKS ON THE BASIS OF FRICTION;
THEREFORE, NO LUBRICANT SHOULD BE APPLIED TO THE CABLE. IF
OIL, OR GREASE, GETS ON THE CABLE, CLEAN THE CABLE WITH A
CLOTH AND ISOPROPYL ALCOHOL. SOLVENTS MAY BE DETRIMENTAL
TO THE TENSION ROLLERS; THEREFORE, A CABLE CLEANED IN THIS
MANNER MUST BE DRY BEFORE BEING REELED IN.
CAUTION: DO NOT LET KEROSENE, ISOPROPYL ALCOHOL, HYDRAULIC FLUIDS,
LUBRICANTS, SOLVENTS, DETERGENTS, OR FUELS COME INTO
CONTACT WITH HOIST TENSION ROLLER.
A. Clean all metal parts with kerosene, isopropyl alcohol, or equivalent. Remove caked-on dirt /
soot with a stiff-bristle, non-metallic brush and solvent.
WARNING: COMPRESSED AIR USED FOR CLEANING CREATES AIRBORNE
PARTICLES THAT MAY ENTER THE EYES. PRESSURE SHALL NOT
EXCEED 15 PSIG (1.0 BAR). EYE PROTECTION IS REQUIRED.
B. Thoroughly dry parts with a lint-free cleaning cloth. Blow off extra cleaning materials from
hard-to-reach areas with moisture-free compressed air.
C. Wipe parts using a clean, lint-free cloth to prevent contamination of parts.
D. Place cleaned parts on a clean dust-free surface.
WARNING: DO NOT HOSE WATER SOAK THE ELECTRONICS; SUCH AS PILOT
CONTROLS, CREW CONTROLS, PENDANTS, WIRING HARNESSES, ETC.,
OR ELECTRICAL SHORTS MAY OCCUR.
E. Wipe electronics i.e. pilot and crew control panels, pendants, switches, electrical receptacles,
and connectors with a clean cloth and isopropyl alcohol, or equivalent non-flammable, non-
corrosive volatile solution suitable for electrical cleaning applications.
F. Do not attempt to clean painted parts in a vapor degreaser, as stain will be removed.
G. For cleaning of bearings, thoroughly clean all bearings with soft-bristle brush and kerosene
or isopropyl alcohol. Dry the bearing with clean, dry compressed air at a maximum pressure
of 15 psig (1.0 bar), or with a clean, lint-free cloth. Do not allow bearings to spin when
drying with compressed air.
H. Prior to installation of label, clean surface with isopropyl alcohol to remove any residual
adhesive, dirt, dust, or grease prior to assembly. Dry surface with clean, dry compressed air
at a maximum pressure of 15 psig (1.0 bar), or with a clean, lint-free cloth.
I. For all faying or mating surfaces, specifically where gaskets, O-Rings, packings, and seals
are to be installed, clean with isopropyl alcohol to remove any dirt, dust, soot, or grease, prior
25-61-00
Page 402
October 10, 2011
TD-03-008
Revision A

to assembly. Dry surface with clean, dry compressed air at a maximum pressure of 15 psig
(1.0 bar), or with a clean lint-free cloth.
J. After servicing with oil, wipe off, and clean up any excess oil that spilled on, or under the
Hoist using a clean, lint-free cloth.
K. If cable has been exposed to lubricants, proceed as follows:
(1) Slowly reel out cable to exposed affected area.
(2) Wipe affected area with a clean cloth saturated with isopropyl alcohol to remove
contaminants and clean surface of cable.
(3) Pass the cable through a clean cloth when reeling in to thoroughly dry the cable and
remove any excess isopropyl alcohol.
L. Hoist, Hook and / or Cable (if exposed to saltwater)
This procedure shall be accomplished at the next available helicopter maintenance action,
and shall be performed monthly thereafter, unless the hook assembly has been immersed in
water, operated in high humidity environments (including rain, snow, etc.), then it shall be
accomplished after completion of each such mission. If any corrosion is visible, remove
corrosion, and re-treat affected area. Wash drum, hook, and cable with clean fresh water as
specified below:
NOTE: IF THE HOOK ASSEMBLY IS IMMERSED IN WATER (FRESH OR SALT
WATER), OR OPERATED IN A HIGH HUMIDITY ENVIRONMENT,
CORROSION MAY OCCUR (SEE FIGURE 401). DISASSEMBLE HOOK
ASSEMBLY, RINSE WITH FRESH WATER, CLEAN, DRY, AND
RELUBRICATE DURING POST FLIGHT INSPECTION AFTER EVERY
RESCUE / TRAINING MISSION.
(1) Remove and disassemble hook assembly per procedures in Section 301, Disassembly.
(2) Rinse off hook and bumper assembly components so that all contamination has been
thoroughly washed off with fresh water, and ensure parts have been cleaned, and
thoroughly dried. Remove any surface corrosion per Section 601, Repair. Inspect and
replace, as necessary, per Section 501, Checks and Inspection. Relubricate, and assemble
components per Section 701, Assembly. Do not install hook and bumper assembly onto
cable at this time.
NOTE: ALWAYS WIND, AND UNWIND, THE CABLE IN A “RACE TRACK”
FASHION, NEVER A “FIGURE 8” OR A COIL
(3) Fill a container with fresh water and slowly reel out cable into container until hoist
reaches the full out position
25-61-00
Page 403
October 10, 2011
TD-03-008
Revision A

Figure 401. Example of Corrosion on Hook Assembly Parts (Typical)

NOTE: DO NOT RINSE OFF HOIST WITH FRESH WATER UNDER HIGH
PRESSURE. HIGH PRESSURE WATER MAY DAMAGE SEALS IN HOIST.
USE LOW PRESSURE FRESH WATER TO RINSE OFF HOIST
(RECOMMENDED PRESSURE TO BE THAT OF WATER SUPPLY, NO
GREATER THAN 5 PSI [0.34 BAR]).
(4) While cable is immersed in fresh water, rinse off hoist drum and cable guide assembly
with fresh water. Failure to thoroughly rinse saltwater contamination off drum will result
in corrosion (Figure 402).
Figure 402. Example of Corrosion on Drum (Typical)

(5) Pass cable through clean, dry cloth as cable is slowly being reeled in onto hoist.
(6) After reeling in cable, assemble and install hook and bumper assembly components per
Assembly, Section 701.
(7) Perform hook load test as directed in Section 101, Testing and Troubleshooting.
25-61-00
Page 404
October 10, 2011
TD-03-008
Revision A

M. If applicable, clean oil gauge sight glass window, or applicable cowling windows, on motor
end of hoist with non-abrasive, plastic window cleaner (i.e., Plasti-Glass), or equivalent.
Wipe windows clean with clean cloth.
N. Wiring Harness Assembly Cleaning
(1) Remove any loose contamination by hand.
(2) Using a vacuum cleaner, remove dust, dirt, soot, and grime accumulations on the harness
assembly.
(3) Use a non-metallic soft bristle brush to loosen accumulations of dust, dirt, soot, and
grime that remain, and vacuum the area again.
(4) Remove any remaining dust, dirt, and grime by wiping with isopropyl alcohol and a clean
cloth.
25-61-00
Page 405
October 10, 2011
TD-03-008
Revision A

25-61-00
Page 406
October 10, 2011
TD-03-008
Revision A
CHECKS AND INSPECTIONS
1. General
The items listed in Table 501 shall be inspected while installed on the helicopter, in accordance
with the procedures contained in this section at the recommended frequency. More frequent
inspections can be made, but inspections cannot be made less frequently. In addition, a
maintenance log shall be maintained for each Rescue Hoist System in order to keep track of hoist
cycles, maintenance actions, and inspections.
Part Name
Recommended Frequency of Inspections Figure and Inspection Required
(Para. Ref. in Section 501,
(whichever occurs first)* Item Number
unless otherwise noted)
At the beginning of the day Oil Level (Para. 2L[5]) Figure 520 Pre-Flight Inspection
At the beginning (pre-flight), Hook Assembly Figures 509, 512, 513, 520 and Pre-Flight and Post-Flight
(Para. 2L and 2M) 1002 Inspections
or
Cable Cutter Cotter Pin Figure 1003, View A, Item 140 Pre-Flight and Post-Flight
at the end (post-flight), of the day
(Para. 2N) Inspections
Wire Rope Cable Figures 505 through 512, and Post-Flight Inspection
At the end of the day
(Para. 2E) 1003, View A, Item 100
Perform every month, Hook Assembly Figures 509, 513, 514, and Inspect for defects and
(Para. 2F) 1002 binding when installed
100 flight hours,
Wire Rope Cable Figures 505 through 511, and Inspect for defects
or 25 hoist cycles
(Para. 2E) 1003, View A, Item 100
Perform every 3 months, Level Wind Shaft Figures 519 and 1003, Item 1140 Inspect for wear
(Para. 2K)
200 flight hours,
Follower (Para. 2K) Figures 519 and 1003, View A, Inspect for wear
or 50 hoist cycles
Item 240
Tension Roller (Para. 2C) Figures 502, 503, and Inspect for wear, and
1003, Item 480 defects
Cable Foul Assembly Figure 1003, Item 1030 Inspect for proper setting,
(Para. 2I) and damage
Overrunning and Tension Figure 1003, Items 490 and 560 Inspect for proper
Roller Clutches (Para. 2D) operation, and damage
Perform every 6 months, Cable Guide (Para. 2G) Figure 1003, View A, Item 200 Inspect for wear
400 flight hours,
Roller Assembly (Para. 2J) Figures 518 and 1003, View A, Inspect for wear
or 100 hoist cycles
Items 280 & 310
Chain (Para. 2H) Figure 1003, Item 620 Inspect for proper tension
when installed
Oil Level (Para. 2L[5]) Figure 520 Inspect oil level
Wiring Harness Assemblies - Inspect wiring and
(Para. 2P) connectors
Perform every 12 months, Hoist Assy. (Section 101, Figure 1001, Item 10 Test
1000 flight hours, or 400 hoist cycles Para 4E)
Wire Rope Cable (Para. 2E) Figure 1003, View A, Item 100 Recommended
Perform every 1500 hoist cycles**
Replacement
Perform every 10 years, Hoist Assy. (Para. 2A) Figure 1001, Items 10 Overhaul
Or 2000 hoist cycles End Flanges (Para. 2O) - Detailed Inspection
Table 501. Inspection Requirements
25-61-00
Page 501
October 10, 2011
TD-03-008
Revision A
Recommended Frequency of Inspections Part Name (Para. Ref. in Figure and Inspection Required
(whichever occurs first)* Section 501) Item Number
Every 5 years Oil Change (Para. 2L, 5(b) ) Figure 520 Oil Change
Limit Switch Integrity Figures 101, 102, 307, 308, 522 Check integrity of
Check (Para. 2Q) individual limit switches
Perform every 5 years from date of Cable Cutter Cartridge Figure 1003, View A, Item 10 Mandatory Replacement
installation, and every 13 years from (Para. 2N)
date of manufacture
General (Para. 2B) - Inspection for wear,
As applicable for all visual inspections
damage, or corrosion
Hook Assembly Figures 509, 513, 514, and Inspect for defects and
(Para. 2F) 1002 binding when installed
As required
Cable Alignment - Required if cable is
(Para. 8, Section 601) leading, or lagging
Cycle Counter Reading 334 3340 8340 16680 25020 33400 668000
Equivalent Hoist Cycles 1 10 25 50 75 100 2000
* One hoist cycle is equal to reeling out the cable from full in to full out, and then reeling in the cable back to full in.
** Recommended 1500 hoist cycle replacement criteria is under ideal laboratory conditions, which may not be representative
of actual operating conditions.
Table 501. Inspection Requirements (continued)
2. Inspections
A. Overhaul of Rescue Hoist
The Rescue Hoist must be overhauled every 10 years, or 2000 hoist cycles, whichever occurs
first. This overhaul is required to properly maintain the assembly, and is recommended for
this Rescue Hoist manufactured by Breeze-Eastern. Note: System electronics such as
pendants, pilot and crew control panels, etc. are considered “On Condition” maintenance.
Operators are encouraged to coordinate all repair / overhaul work with Breeze-Eastern, or
their authorized Service Centers. Breeze-Eastern is a Federal Aviation Administration (FAA)
and a European Aviation Safety Agency (EASA) FAR / EASA Part 145 approved Repair
Station (FAA Repair Station No. BZ7R1670, EASA-145 Acceptance Certificate Reference
No. EASA.5454). and can repair / overhaul all components of the Rescue Hoist System at
competitive prices and lead-times. Please contact Breeze-Eastern Customer Services listed
below:
35 Melanie Lane
Phone Number: 908-686-4000, or 1-800-929-1919 (Toll-Free US and Canada only)
Fax Number: 908-688-6495 E-mail Address: [email protected]
25-61-00
Page 502
October 10, 2011
TD-03-008
Revision A
B. General
ALL RESCUE HOISTS.
WARNING: KEEP HANDS, BODY, AND CLOTHING AWAY FROM RESCUE HOIST,
SPECIFICALLY “PINCH POINTS,” WHERE THE CABLE ENTERS THE CABLE
THE OPERATOR WHENEVER OPERATING, OR MAINTAINING THE RESCUE
MATERIALS USED ON THE RESCUE HOIST, AS WELL AS METAL PARTS
AND OTHER DEBRIS.
THEREFORE, NO LUBRICANT SHOULD BE APPLIED TO THE CABLE. IF OIL
OR GREASE GETS ON THE CABLE, CLEAN THE CABLE WITH A CLOTH
AND ISOPROPYL ALCOHOL. SOLVENTS MAY BE DETRIMENTAL TO THE
TENSION ROLLERS; THEREFORE, A CABLE CLEANED IN THIS MANNER
MUST BE DRY BEFORE BEING REELED IN.
PROPER INTEGRATION.
Use this procedure for visually inspecting any and all parts, as necessary, for obvious wear,
damage, or corrosion as specified below:
(1) Check all parts for nicks, cracks, scratches, and corrosion.
(2) All gear splines and shafts shall be free of nicks, burrs, sharp edges, and wear (see Figure
501).
(3) Check the four mounting holes for the hoist interface with the helicopter for cracks,
scoring and elongation (see Figure 801).
25-61-00
Page 503
October 10, 2011
TD-03-008
Revision A
Figure 501. Examples of Unacceptable Damage to Gear

(4) Examine threads for stripping, distortion, nicks, and cross threading.
(5) All bearings shall be inspected to approved industry standard bearing inspection methods
and procedures. General Guidelines to be used, but not limited to, are as follows:
(a) Visually inspect ball bearings for radial wear, binding, sticking, loss of lubrication,
contamination, corrosion, scoring, cracks, bent, dented, warped, seized, brinelling,
spalling, scuffing, excessive heat, excessive play, shield placement (if applicable), or
any physical or chemical decomposition.
(b) Hold the inner race with one hand while rotating the outer race. Note the sound and
vibration of the bearings during rotation. This inspection helps detect defects large
enough to be visible but hidden from sight. Reject bearings that bind or that is
exceptionally noisy.
(c) Inspect prepackaged bearings for binding, excessive looseness (possibly indicating
loss of lubricant), or noise. Reject prepackaged bearings having any of these
indications.
(d) Inspect bearings for corrosion which will be evidenced by reddish coloring in
advanced stages of staining. Clean and polish external surfaces that exhibit corrosion.
If possible, check for corrosion on the race paths. Deep pits will serve as stress raisers
causing fatigue and flaking. Reject bearings having pits on the ball paths.
(6) Inspect all mating and faying surfaces for possible damage.
(7) Check retaining ring and seal grooves for obstructions, or damage, which might prevent
assembly.
C. Tension Roller (see Figures 502, 503, 1003)
(1) Visually inspect tension roller (Figure 1003, Item 480) for any abnormal wear, or obvious
defects, of rubber material (i.e., cracks, tears, abrasion, and degradation). Replace tension
roller if any abnormal wear or any of these defects are found (see Figures 502 and 503).
25-61-00
Page 504
October 10, 2011
TD-03-008
Revision A
Figure 502. Tension Roller and Overrunning Clutch Assemblies

(Cyclocentric End is on left and Motor End is on right)
(2) Measure outside diameter of roller at most seriously worn areas. Replace tension roller if
diameter is below 0.801 inches (20.35 mm.) at any worn area (see Figure 503).
25-61-00
Page 505
October 10, 2011
TD-03-008
Revision A
Figure 503. Tension Roller Replacement Criteria
25-61-00
Page 506
October 10, 2011
TD-03-008
Revision A
D. Overrunning Clutch Assembly and Tension Roller Clutch Assembly (Figures 504 and 1003)
(1) Inspect tension roller and overrunning clutch assemblies (490 and 560) for broken, cracked, or
damaged gear teeth (see Figures 501 and 504). Replace if any defects are found.
Figure 504. Overrunning Clutch Assembly (Typical)

(2) Remove overrunning clutch as follows:
(a) Remove gear guard (Figure 1003, Item 390) by removing screws (Figure 1003, Items 400
and 410) and washers (420 and 430).
(b) Remove screws (500 and 510), washers (520), and clutch guard (530).
(c) Remove bolt (540), spacer (550), and overrunning clutch assembly (560).
(d) Inspect tension roller clutch assembly (490) to ensure it rotates freely in counterclockwise
direction, and drives clutch in clockwise direction when viewed from the small gear side
(as installed on the tension roller). Replace if clutch binds in counterclockwise direction,
or slips, in the clockwise direction.
(e) Inspect overrunning clutch assembly (560) to ensure it rotates freely in counterclockwise
direction, and drives the clutch in clockwise direction when viewed from the small gear
side (as installed on the cyclocentric end flange). Replace if clutch binds in
counterclockwise direction, or slips, in the clockwise direction.
(3) Check overrunning clutch assembly for wear. If lateral movement measured at face of large
gear at outside diameter measures 0.050 inch (1.27 mm.), or more, replace the overrunning
clutch assembly.
(4) Install the overrunning clutch assembly (560), spacer (550), and bolt (540). Check for visible
gap between large gears on both clutch assemblies. If binding occurs, remove spring pin (440)
and inner roller shaft (450) to re-shim, as required, at cyclocentric end of tension roller shaft
assembly (480) between thrust washer (470) and tension roller clutch assembly (490). Install
shaft (450) and install spring pin (440) halfway, to check for a minimum of 0.030 in. (0.762
mm.) gap between the gears (490 and 560). Completely install spring pin (440) after check is
complete.
25-61-00
Page 507
October 10, 2011
TD-03-008
Revision A
E. Wire Rope Cable (see Figure 1003, View A, for ball end of cable [100] and Figure 1003 for drum
attachment screws [120] for cable).
ALL RESCUE HOISTS.
WARNING: KEEP HANDS, BODY, AND CLOTHING AWAY FROM RESCUE HOIST,
SPECIFICALLY “PINCH POINTS,” WHERE THE CABLE ENTERS THE CABLE
THE OPERATOR WHENEVER OPERATING, OR MAINTAINING THE RESCUE
MATERIALS USED ON THE RESCUE HOIST, AS WELL AS METAL PARTS
AND OTHER DEBRIS.
PROPER INTEGRATION.
NOTE: WHEN REELING IN THE CABLE WITH NO LOAD, APPLY TENSION WITH
GLOVED HANDS TO ENSURE SMOOTH AND EVEN WRAPPING.
APPROXIMATELY 20 LB. (9.1 KG.) TENSION IS RECOMMENDED.
NOTE: CABLE IS TO BE INSPECTED IN ITS NATURAL STATE. DO NOT TWIST,
BEND, LOAD, ETC. IN ANY MANNER THAT WOULD DAMAGE THE CABLE.
Inspect cable for corrosion, kinking, fraying, necking down, and distortion of swaged ball end
of cable. Check for broken wires; replace as soon as breaks in any strand are found. Check for
splicing; no splicing of the cable is allowed. Follow the guidelines for cable inspection as
defined below.
In order to be effective, cable inspection must be performed on a regularly scheduled basis.
Wire rope cables used for personnel lifting should be inspected carefully and frequently. Use
the following acceptance and rejection standard:
25-61-00
Page 508
October 10, 2011
TD-03-008
Revision A
Broken wires
(1) Continued use of a cable with broken wires can result in the damaged area of the cable
being caught in the cable guide assembly upon paying out (see Figure 505). This will
result in the cable fouling or some other problem that may lead to a more severe situation.
It is for this reason that no broken wires are allowed for the hoist cable. If broken
wires are detected, the cable shall be removed and replaced immediately.
Figure 505. Example of Broken Strands in Wire Rope Cable

(2) Evidence of dragging over obstacles or worn cable guides
Cable abrasion is caused by contact with other cable sections, or any material that may
contact the cable, such as helicopter structural members, auxiliary equipment, or almost
any abrasive surface (see Figure 506). Abrasion removes metal from the external wires in
the outer strands and thus weakens the cable. Nicking, scarring, and scrubbing are also
referred to as abrasion. Severe abrasion, resulting from dragging a cable across helicopter
structure, can result in a catastrophic cable failure, and possibly loss of life. Severe
abrasion as evidenced by a worn, or damaged, cable resulting in multiple broken wires in
an outer strand in any section requires immediate cable replacement.
Figure 506. Example of Abrasion of Wire Rope Cable

(3) Kinking (permanent bend) in cable
Kinks are man-made defects caused by a loop being pulled up tight, resulting in a sharp,
permanent bend in the cable (see Figure 507). Kinks are identified as "open," or "closed."
Pulling a cable loop tight causes an “open” kink, creating a sharp, permanent bend that
tends to open the layering of strands in the cable. A "closed" kink is caused in a similar
manner, but creates a sharp, permanent bend that tends to tighten the lay of the cable.
Continued use of a kinked cable will result in the kink being caught in the cable guide
assembly upon paying out, and will result in cable fouling. A kinked cable should not be
run back onto a hoist for any reason.
25-61-00
Page 509
October 10, 2011
TD-03-008
Revision A
Figure 507. Example of Kink in Wire Rope Cable

(4) Bird caging (permanent deformation or “opening up” of cable strands)
Bird caging is the permanent deformation, or “opening up” of the strands and wires of the
wire rope itself. This condition results from a torsion imbalance that occurs due to
mistreatments such as sudden stops, the wire rope being worked through tight sheaves, or
a hook bearing that is binding (see Figure 508). Any evidence of bird caging requires
immediate replacement of the load cable.
Figure 508. Example of Bird Caging in Wire Rope Cable

(5) Improperly attached or defective fittings
Carefully inspect the cable in the area of the hook ball end attachment (see Figure 509).
Do not bend the cable in the process of the inspection. The ball end of the cable must not
evidence any broken wires at the swaged ball fitting. Any necking down, broken wires,
loose wires in the immediate vicinity of the ball end is a cause for cable replacement. This
condition may have resulted from the cable not being snugged up against the cable guide
bell mouth properly, or a full in limit switch that is activating too fast. The continual
vibration of a helicopter and a loosely "homed" hook can result in a fatigue failure of the
cable immediately above the ball end fitting. This inspection should be performed prior to
every flight. If a loose hook is noted, the necessary adjustment to the full in limit switch
shall be performed after the cable inspection.
25-61-00
Page 510
October 10, 2011
TD-03-008
Revision A
Wire Rope Cable
Top of Swaged (Ball) End of Cable

Top of Terminal Clamp
Top of Hook Assembly

(with Bumper Assembly Removed)
Figure 509. Hook Assembly Attachment to Wire Rope Cable

(6) Knots in Cable
Knots are formed in the cable by passing one free cable section, or end, through a loop
and drawing it tight, or by a tangle drawn tight (See Figure 510). Cable knots are
generally caused by improper ground maintenance handling, or if cable inadvertently
loops / tangles while operating the rescue hoist. A knotted cable should not be run back
onto hoist for any reason and requires immediate cable replacement.
Figure 510. Example of Knot in Wire Rope Cable (Typical)

(7) Cable Looseness
NOTE: REPEATED OPERATION OF A WIRE ROPE CABLE EXHIBITING A
LOCALIZED LOOSE CONDITION MAY RESULT IN PERMANENT
DEFORMATION OF THE STRANDS NECESSITATING REMOVAL OF THE
CABLE FROM SERVICE.
25-61-00
Page 511
October 10, 2011
TD-03-008
Revision A
When a wire rope cable is cycled predominantly over a small range (less than 50 feet
[15.2 meters] from the hook end) of its overall length, cable strands may loosen. The
strands will appear visibly loose, or will feel rough (see Examples A and B in Figure 511),
typically near the hook end, over a short length of cable (not the entire length of cable). If
the cable is no longer taut, it may appear damaged.
Early Indications of Advanced Indications

Cable Looseness of Cable Looseness
A B
Figure 511. Examples of Wire Rope Cable Looseness
NOTE: MILD LOOSENESS IN THE CABLE MAY BE ELIMINATED BY REMOVAL
AND STORAGE OF THE CABLE FOR SEVERAL DAYS.
To remove the looseness in the cable, apply a weight equal to the rated load of the hoist,
and cycle the cable five (5) times from full in to full out positions.
After cycling the cable under load, slowly reel out approximately 5 feet (1.5 meters) of
cable, and inspect for looseness. If visible looseness was successfully removed, no further
action is required. If early indications of cable looseness are still visible (as shown in
Example A of Figure 511), repeat the rated load cycling as stated above. If this does not
remove the looseness, remove the cable from service, and store for several days. If
looseness is still evident after several days of storage, discard cable.
Repeat the full-length, rated load cycling whenever inspection indicates looseness in the
cable.
(8) Improperly adjusted or defective cable guide
Cables showing damage, such as broken wires at the turnaround, or at cable crossovers,
are an indication that the hoist needs to have the level wind readjusted, or replaced (see
Figure 512). Smiles (gaps between adjacent turns of cable) are the result of the cable not
being tightly, and evenly, wrapped, and / or the level wind leading the cable too much. If
the level wind is adjusted to lag the cable too much, excessive abrasion of the cable as it
wraps on the drum occurs, particularly at the crossovers. All of the above inspections are
subjective, and require an experienced technician to make the inspection, and
readjustment, if required. If the condition is corrected before excessive damage occurs, the
cable can continue in service if no wire breaks are discovered.
25-61-00
Page 512
October 10, 2011
TD-03-008
Revision A
Figure 512. Example of a Raised Strand in a Wire Rope Cable

(9) Severe overload and shock loading
A cable that has been severely overloaded, or shock loaded, may, or may not, show the
immediate results of the overload. Broken strands and wires are the most obvious defects.
However, broken inner wires may also result from overload. "Necking-down" of any
section of the cable is an indication of broken inner wires. A cable that has been suspected
of being overloaded, or knowingly overloaded, should be replaced immediately even if no
obvious physical damage is detected. Any obvious reduction in cable diameter is cause for
immediate cable replacement.
(10) Internal wear caused by grit or dirt penetration
Internal wear caused by grit, dirt, sand, etc. embedded between the strands of the cable is
extremely difficult to detect. Preventive maintenance, in the form of carefully wiping off
the cable to remove gritty material as it is reeled in during inspection is recommended.
Prolonged use of a cable loaded with gritty material will result in broken wires.
(11) Recommended Replacement of Wire Rope Cables
NOTE: RECOMMENDED 1500 HOIST CYCLE CABLE REPLACEMENT
REQUIREMENT IS BASED ON THE FATIGUE LIFE OF WIRE ROPE DURING
HOIST OPERATIONS IN LABORATORY CONDITIONS. ACTUAL
CONDITIONS WITH THE HOIST ON THE HELICOPTER WILL VARY FROM
THESE IDEAL CONDITIONS. THEREFORE, INSPECTION OF THE CABLE IS
NOT TO BE ELIMINATED DUE TO THIS RECOMMENDED REPLACEMENT
INTERVAL.
In addition to the inspection identified above, every 1500 cycles the cable (Figure 1003, View
A, 100) must be replaced on the hoist. See procedures in Disassembly, Section 301, for
removal of the cable, and in Assembly, Section 701, for installation of the cable.
F. Hook Assembly (see Figures 509, 513, 514, and 1002)
(1) Inspect hook parts for cracks, corrosion, damaged threads, and gouges (reference Section
401, Cleaning). Ensure dowel pins, springs, and rivets are not missing, or damaged, and
check lock moves freely over plungers and stops at dowel pins. See Figure 513.
25-61-00
Page 513
October 10, 2011
TD-03-008
Revision A
Bumper Locking
Threads Assembly Screws &
Springs - Grommet Cotter Pins
Rivets - Spring (Qty. 2)
- Retainer
Keeper
Lock
Plungers
(Qty. 2) Hook and
Dowel Handwheel Keeper
Pins bearings
(Qty. 2) (not shown) Lock Pin and
Lanyard
Utility bag attach only – not for primary load attachment
Figure 513. Hook Assembly

(2) Check that the keeper in the hook operates without binding, locks properly, and the rivet
holding the keeper is properly fastened.
(3) Check the terminal clamp and ring are properly installed in the hook, and properly
oriented with the cone end pointing toward the top of the hook to secure it to the ball end
of the cable. See Figure 514.
Cable
Terminal Clamp
Retaining Ring
Sleeve / Nut
Figure 514. Required Terminal Clamp Orientation (typical)

(4) Check to see that locking screws are properly seated in the body and locked in place with
the cotter pins.
(5) Check that the hook freely swivels / rotates in a smooth and non-binding manner. If
binding occurs, disassemble hook per Section 301, and inspect the bearings for corrosion,
galling, imperfections, or signs of roughness during rotation. If bearing is found to be
unacceptable, discard. Replace with new bearing, and assemble hook per Section 701.
(6) After assembly, check that the hook swivels freely without binding.
25-61-00
Page 514
October 10, 2011
TD-03-008
Revision A
G. Cable Guide (when installed on hoist, see Figure 1003, View A)
Check cable guide (200) for cracks, gouges, and wear. Using 0.125 inch (3.17 mm.) diameter
rod with no sharp edges, probe rod between cable and sides of cable guide. If worn area
accepts rod, turn the cable guide 90° and continue to use. If cable guide has been turned
previously due to wear, replace cable guide in accordance with Section 301, Assembly, and
701, Disassembly.
H. Chain (see Figure 515, 516, 517, and 1003)
(1) Chain Tension Check In Horizontal Position (hoist off helicopter, sitting on mounting
points, with limit switch cover removed).
NOTE: INSIDE SURFACES OF CHAIN MUST NOT TOUCH.
(a) Using a torque wrench with a range of 0 to 30 in.-lb. (3.39 Nm.) and a 0.687 in.
(17.46 mm.) adapter, apply counterclockwise torque of 12 in.-lb. (1.36 Nm.) to the nut
that retains drive sprocket (See Figures 515 and 516).
(b) If inside surfaces of the chain touch, adjust idler, and recheck chain tension per Step
(a) above.
(c) If idler cannot be adjusted any further to achieve this chain tension requirement, use a
micrometer, vernier caliper, or equivalent, and check idler for wear (minimum
acceptable O.D. for idler is 0.75 in. [19.0 mm.]). If idler O.D. is unacceptable, replace
idler. If idler O.D. is acceptable, replace chain.
CHAIN
NUT
IDLER DRIVEN
SPROCKET
Figure 515. Level Wind Chain Drive with Hoist Horizontal (Shown with limit switch cover removed)
25-61-00
Page 515
October 10, 2011
TD-03-008
Revision A
TORQUE WRENCH
GAP (RANGE: 0 – 30 IN.-LB.
(INSIDE SURFACES (0 – 3.39 Nm.)
OF CHAIN MUST
NOT TOUCH)
11/16 IN. ADAPTER
Figure 516. Chain Tension Check with Hoist Horizontal (Shown with limit switch cover removed)
(2) Chain Tension Check In Vertical Position (hoist mounted on helicopter by mounting
points with limit switch cover removed). See Figure 517.
NOTE: INSIDE SURFACES OF CHAIN MUST NOT TOUCH.
(a) Using a force gauge with a range of 0 to 10 lb. (0 to 4.5 kg.), and a linear scale, or
ruler, deflect the chain 3/32, or 0.094 in. (2.38 mm.), as shown in Figure 517. Verify
spring scale reads between 2 to 3 lb. (0.91 to 1.36 kg.).
(b) If force gauge does not read between 2 to 3 lb. (0.91 to 1.36 kg.), adjust idler. If idler
cannot be adjusted any further to achieve this chain tension requirement, use a
micrometer, vernier caliper, or equivalent, and check idler for wear (minimum
acceptable O.D. for idler is 0.75 in. [19.0 mm.]). If idler O.D. is unacceptable, replace
idler. If idler O.D. is acceptable, replace chain. When idler adjustment is complete,
tighten idler adjustment self-locking nut between the end flanges, using a thinned
down 7/16 inch open wrench (.4375 in. [11.113 mm]).
25-61-00
Page 516
October 10, 2011
TD-03-008
Revision A
DEFLECT CHAIN
0.094 IN. (2.38 MM.)
AND VERIFY
FORCE GAUGE READING
IS 2 TO 3 LB. (0.9 TO 1.36 KG.)
Figure 517. Chain Tension Check with Hoist Vertical (Shown with limit switch cover removed)
I. Cable Foul Assembly (Figure 104 and Figure 1003, Item 1030)
CAUTION: DO NOT DISPLACE CABLE FOUL SENSOR GREATER THAN 0.188 IN.
(4.7 MM.) FROM ITS NORMAL “AT REST” POSITION.
(1) From the full in position, slowly reel out approximately 30 feet (9.1 meters) of cable.
(2) Begin to slowly reel in the cable from this point. While reeling in, pull up on the cable
foul assembly and verify hoist operation is interrupted.
(3) While cable foul assembly is raised up verify hoist does not operate in either reel in, or
out, direction.
25-61-00
Page 517
October 10, 2011
TD-03-008
Revision A
(4) Release the cable foul assembly and verify hoist resumes normal operation in both reel in
and reel out modes.
(5) Inspect the condition of the cable foul assembly. Inspect all fasteners (i.e., screws, nuts)
are properly installed, tie wired or safety cabled (if applicable), and not missing. Ensure
cable foul assembly shows no signs of damage.
J. Pressure Roller Assemblies
Check roller assemblies (Figure 1003, View A, Items 280 and 310) for corrosion, excessive,
or abnormal wear (See Figure 518).
Normal Wear
Wearing / Worn
Replace roller if diameter of groove is
(Note: Deep impression of
less than 0.628 inches (15.95 mm.).
cable in groove). Replace
roller.
Thick flange of pressure roller
assembly should be oriented to the
right side when installed looking at the
rescue hoist.
Figure 518. Roller Replacement Criteria
K. Level Wind Shaft and Follower
CAUTION: USE CAUTION WHEN HANDLING THE LEVELWIND SHAFT. THE POINTS
ARE VERY SHARP AT THE INTERSECTION OF THE HELICAL GROOVES.
(a) Visually inspect level wind shaft (Figure 1003, Item 1140) for corrosion, wear, and
damage. If any of these conditions exists, remove hoist and send for repair.
(b) Measure, at a minimum of six places, the groove width on the level wind shaft (Figure
1003, Item 1140) per Figure 519.
(c) The maximum allowable dimension is 0.160 in. (4.06 mm.). If dimension measured is out
of specification, remove hoist and send for repair.
(d) Remove the follower (Figure 1003, View A, Item 240) per the procedures in Section 301,
Disassembly.
(e) Measure the follower for width of follower per Figure 519. The minimum allowable
dimension is 0.148 in. (3.76 mm.).
(f) Replace the follower if measurement is out of tolerance.
(g) Install the follower per the procedure in Section 701.
25-61-00
Page 518
October 10, 2011
TD-03-008
Revision A
0.160 in. (4.06 mm.) = Maximum Gap
Levelwind Shaft (1140)
0.148 in. (3.76 mm.) = Minimum Width
Levelwind Follower (240)
Figure 519. Dimensional Inspection of Level Wind Follower and Shaft

L. Pre-Flight Inspection
The following procedures are to be performed before each day in which the hoist may be used
for airborne rescue operations (including training).
(1) Visually check the hoist structure for cracks, missing mounting and retaining hardware
(bolts, lock nuts, cotter pins, locking screws, etc.), hardware slippage marks (if applied),
or material surface imperfections.
(2) Check swivel hook assembly for smooth and non-binding operation, corrosion, and
freeness of latch. Check to see locking screws (Figure 1002, Item 80) are properly seated
in the body, and locked in place with the cotter pins (70). Check the rivet holding the
keeper on the hook assembly is secure. Check that the ball end of the cable has no signs of
damage (See Figure 509). Ensure the bumper does not bind / adhere to the cable guide
(Bellmouth) and will allow the hook assembly to reel in and out freely. Ensure plungers
and dowel pins in the hook are not missing, or damaged, and check lock moves freely
over plungers and stops at dowel pins. See Figure 513.
(3) Check all covers, plugs, and guards for proper attachment and tie wire or safety cable
installation.
(4) Visually inspect hoist for any oil leakage.
25-61-00
Page 519
October 10, 2011
TD-03-008
Revision A
NOTE: TO PROPERLY CHECK THE OIL LEVEL OF THE HOIST WHILE INSTALLED
ON THE HELICOPTER, THE HELICOPTER MUST BE ON A LEVEL SURFACE
AND THE HOIST SIGHT GLASS MUST BE PERPENDICULAR TO THIS
SURFACE AS MUCH AS POSSIBLE.
(5) Check oil level and perform oil changes (per Table 501) as follows (See Figures 520 and 1003).
a) Check hoist to verify the oil level is between the lines on the sight glass (see Figures
520 and 1003). If hoist oil level is below the bottom line of the sight glass, remove tie
wire or safety cable, bolt (Item 1150, IPL Figure 1003) with seal (1160) above the
sight glass and slowly add oil MIL-PRF-7808, Class 3 or MIL-PRF-23699 (Do not
intermingle / mix oils), until oil level is between the lines on the sight glass. When the
oil level is between the lines on the sight glass, install bolt with seal and tie wire per
NASM33540 with NASM20995NC32 or safety cable per NASM33540 using
AS3510-01.
Figure 520. Oil Fill Location (Helicopter Mounted Position)

b) It is recommended to change the oil every 5 years as follows: (See Figure 520.)
NOTE: FIVE YEAR OIL CHANGE INTERVAL (EVERY SECOND OIL CHANGE) IS
SATISFIED AT THE 10 YEAR OVERHAUL PERIOD, BECAUSE THE OIL IS
CHANGED AT OVERHAUL.
1) When mounted on the helicopter, place an oil drain pan under the drain port (bottom
most bolt on right side when looking directly at sight gauge). Cut and discard safety
wire or safety cable and remove top bolt (1150) on top of the sight gauge, and seal
washer (1160) and bottom bolts (1150) and seal washer (1160). Let oil drain out for a
minimum of 30 minutes.
2) If on a bench in the horizontal position, place an oil drain pan under the drain port
(bottom most bolt on bottom side when looking directly at the sight gauge in the
25-61-00
Page 520
October 10, 2011
TD-03-008
Revision A
horizontal position). Cut and discard safety wire or safety cable and remove top bolt
(1150) (when horizontal) and seal washer (1160) and bottom bolt (1150) and seal
washer (1160). Let oil drain for a minimum of 30 minutes.
3) After the oil is drained out, install drain bolt (1150) and seal washer (1160).
CAUTION: THE RESCUE HOIST OIL FILL INTERNAL PASSAGEWAYS ARE SMALL IN
DIAMETER. THEREFORE, OIL MUST BE ADDED IN SMALL VOLUME AND
POURED SLOWLY (NURSED) OR OVERFLOW WILL OCCUR.
NOTE: USE SIGHT GLASS FOR VOLUME REFERENCE.
4) Using a funnel with a small diameter leader, or equivalent, slowly add 17.25 ounces
(510 ml) of MIL-PRF-7808, Class 3 (NATO Code No. 0-148) or MIL-PRF-23699 oil
(Do not intermingle / mix oils), or until filled as referenced by the sight gauge.
5) Install fill bolt (1150) and seal washer (1160). Visually check sight gauge to ensure oil
level is between the fill lines. Tie wire all fill and drain port bolts per NASM33540
with NASM20995C20 or safety cable per NASM33540 using AS3510-01.
(6) Check that electrical connectors are properly installed and secure. Also, check for any
indications of chaffing or conductor separation from the connectors.
(7) Perform the following operational check of the Rescue Hoist System:
(a) Apply power to Rescue Hoist System by pushing in applicable circuit breakers.
(b) Using the control pendant, slowly reel out cable from full in position and ensure
bumper assembly (Figure 1002, Item 10) moves freely from cable guide assembly.
(c) Stop the hoist with approximately 20 feet (6.1 meters) of cable paid out from the hoist.
Check the readout on the control pendant and verify its reading is within ± 3 feet
(± 0.9 meters) equivalent to the amount of cable paid out.
(d) Continue to reel out cable at less than half speed until the hoist slows down
automatically. Verify the hoist slowed down at 9.8 to 16.4 feet (3.0 to 5.0 meters)
from full out (mark the cable and check the distance after the cable is reeled out to the
full out position).
(e) Continue to reel out cable at less than half speed until full out limit switch actuates and
stops the hoist. Verify the hoist stopped with 3½ to 4½ wraps remaining on the drum.
(f) Reel in the cable at half speed using the control pendant, while looking for cable
defects in accordance with Section 501, Paragraph 2E.
(g) Reel in cable at less than half speed until the hoist slows down automatically. Verify
the hoist slowed down at 14.8 to 18.0 feet (4.5 to 5.5 meters) from full in.
(h) Continue to reel in the cable to full in, and verify full in switch operates normally,
stopping the hoist.
25-61-00
Page 521
October 10, 2011
TD-03-008
Revision A
M. Post-Flight Inspection
The following procedures should be observed and / or executed at the end of each day of any
airborne hoist operations (including training).
(1) Visually check the hoist structure for cracks, missing mounting hardware, hardware
slippage marks (if applied), or material surface imperfection.
(2) Check all covers, plugs, and guards for proper attachment and tie wire installation.
(3) Visually inspect hoist for any oil leakage.
(4) Inspect the entire usable length of wire rope cable for defects. Slowly reel out the cable
until the full out limit switch stops the hoist. Then, slowly reel in the cable looking for
defects per Section 501, Paragraph 2E. Home hook at full pendant thumbwheel deflection.
(5) Check height of bumper assembly when hook is at full in position (see Figure 521).
Measure height from top of bumper retainer to bottom of spring. If height is not 1.00 to
1.39 inches (25.4 to 35.3 mm.), check full in limit switch operation using procedure in
Testing and Troubleshooting (Section 101, Paragraph 4.B.).
(6) Check that electrical connectors are properly installed and secure. Also, check for any
indications of chaffing or conductor separation from the connectors.
1.00 to 1.39 in.

(25.4 to 35.3 mm.)
Figure 521. Deflection of Bumper Assembly with Hook at Full In Position

N. Cable Cutter
STORED AND HANDLED IN COMPLIANCE WITH ALL LOCAL
STANDARDS AND REGULATORY PRACTICES.
NOTE: AFTER THE CABLE HAS BEEN CUT, THE ANVIL, CARTRIDGE, CUTTER,
O-RINGS, AND COTTER PIN MUST ALL BE REPLACED PER REFIRE KIT
KT-489 AND KT-198.
NOTE: MAXIMUM CARTRIDGE SERVICE LIFE IS 5 YEARS WHEN REMOVED
FROM PACKAGING, AND INSTALLED IN HOIST. MAXIMUM
25-61-00
Page 522
October 10, 2011
TD-03-008
Revision A
CARTRIDGE LIFE IS 13 YEARS (COMBINED SHELF AND SERVICE LIFE)
FROM THE DATE OF MANUFACTURE. THE DATE OF MANUFACTURE
CAN BE FOUND IN THE LOT NUMBER ON THE LABEL OF THE SEALED
CONTAINER, IN WHICH THE CARTRIDGE IS SHIPPED AND STORED,
AND ON THE FLATS OF THE HEX SHAPED PORTION OF THE
CARTRIDGE. THE LOT NUMBER CAN BE IDENTIFIED WITH THE FIRST
THREE LETTERS “CAD.” IMMEDIATELY FOLLOWING THESE LETTERS
IS THE DATE OF MANUFACTURE, REPRESENTED AS TWO DIGITS,
WHICH IDENTIFY THE YEAR (EXAMPLE: 11 IS 2011), AND ONE LETTER,
WHICH IDENTIFIES THE MONTH, AS DEFINED BELOW:
Visually inspect the date on the cable cutter cartridge (Figure 1003, View A, Item 10) should
be less than 13 years from the current date, and less than 5 years from the date of installation
on the hoist. If the date has expired, remove and replace cartridge.
Visually inspect the cotter pin (Figure 1003, View A, Item 140) in the cable guide for
condition and proper installation. If missing, or damaged, remove and replace pin per
procedures in Disassembly, Section 301, and Assembly, Section 701.
O. Detailed Inspection of Rescue Hoist End Flanges
Visually inspect end flanges for cracks, missing mounting and retaining hardware, hardware
slippage marks (if applied), or material surface imperfections. Check mounting locations for
the Rescue Hoist dimensionally, as identified in Fits and Clearances, Section 801, Figure 801.
Ensure integrity of the mounting points.
P. Inspection of Wiring
Visually inspect wiring for degradation due to wear, vibration, moisture, contamination, and
excessive heat. Check electrical wiring for the following defects:
(1) Wiring that has been subjected to chafing, fraying, or is brittle.
(2) Insulation that is abraded, cracked, over-stressed, or suspected of being penetrated.
(3) Conductors or shields that are broken or exposed.
(4) Clamps or brackets that are loose or missing.
(5) Wiring that is not correctly attached to terminals or connectors.
(6) Backshells that are loose or separated.
(7) Connector pin damage.
(8) Grommets that are loose or cracked.
Replace any wiring found with defects.
25-61-00
Page 523
October 10, 2011
TD-03-008
Revision A
Q. Inspect Integrity of Individual Limit Switches (Every 5 year period ONLY)
NOTE: FIVE YEAR LIMIT SWITCH INSPECTION INTERVALS CAN BE COORDINATED
WITH THE 10 YEAR OVERHAUL PERIOD. THE LIMIT SWITCHES ARE
CHECKED AT OVERHAUL. ALSO, THIS INSPECTION CAN BE COORDINATED
WITH OTHER CHECKS AND INSPECTIONS WHENEVER CONVENIENT TO THE
OPERATOR AS LONG AS THE INSPECTION IS CONDUCTED EVERY FIVE
YEARS. THIS INSPECTION ONLY PERTAINS TO RESCUE HOISTS INSTALLED
ON THE HELICOPTER I.E. NOT IN STORAGE.
The rescue hoist incorporates redundant limit switches, for the full-in (located in the cable
guide assembly), full-out (located on cyclocentric cams), intermediate slow (located on
cyclocentric cams), and cable foul (located in the cable foul assy.) functions. An operator may
not know if one of the redundant limit switches has malfunctioned, depending on how the
switch fails. Therefore; to ensure the redundant limit switches are both operating properly, a 5
year inspection has been incorporated. The check essentially checks each individual switch as
defined below: (Ref. Section 201 for electrical wiring schematics)
NOTE: THE LIMIT SWITCH INSPECTIONS SHOULD BE CONDUCTED AT NO LOAD.
(1) Full-In (S3) Limit Switch Inspection (Figure 1003)
(a) Apply power and using the control pendant reel-out 10 to 15 ft (3 - 4.5m) of cable.
(b) Remove power to rescue hoist and remove the cable guide limit switch cover (920)
by removing screws (940), washers (950) and gasket (930) in accordance with
Section 301, Disassembly to gain access to the full-in switches.
(c) Apply power and use the control pendant to slowly reel-in the cable while
depressing one limit switch plunger with a small non-conductive flat screwdriver
surface, or equivalent, ensure the rescue hoist stops operation.
(d) Repeat process for the remaining limit switch plunger. If both limit switch plungers
individually stop the hoist the full-in limit switch check is complete. If an individual
limit switch does not stop hoist operation replace switch.
(e) Using the control pendant reel-cable back to the Full-In position and verify the cable
stops automatically, remove power, and install gasket (930), cover (920), and secure
with washers (950) and attach screws (940) in accordance with Section 701,
Assembly.
(2) Full-Out (S2) and Intermediate Slow (S1) Limit Switch Inspection (Figure 1003)
(a) Apply power and using the control pendant slowly reel-out cable to the Full-Out
position and verify the cable stops automatically.
(b) Remove power to rescue hoist and (Figure 1003), remove tie wire or safety cable,
screws (30 and 40), washers (50), clamps (60 and 70), limit switch cover (80), and
gasket (90) to obtain access to the cyclocentric full out and intermediate slow limit
switches.
25-61-00
Page 524
October 10, 2011
TD-03-008
Revision A
(c) To test the individual full-out limit switch apply power and depress one (S2) limit
switch plunger with a small non-conductive flat screwdriver surface, or equivalent.
Use the control pendant to slowly reel-out the rescue hoist cable. The rescue hoist
should not operate. This ensures the other full-out limit switch, whose plunger is not
depressed, is working properly.
(d) Repeat process for the remaining full-out limit switch plunger. If both limit switch
plungers individually do not allow the rescue hoist to operate in the reel-out mode
the full-out limit switch check is complete. If an individual limit switch allows hoist
operation replace the opposite limit switch than the one used with the depressed
plunger, due to the design of the circuit.
(e) Check the intermediate slow (S1) limit switches while at the full-out position by
depressing an individual slow (S1) limit switch plunger and use the control pendant
to slowly reel-in the cable. The cable shall reel-in at slow speed. This ensures switch
integrity for both slow speed positions for full-in and full-out limit switches.
(f) Repeat process for the remaining slow limit switch plunger. If both limit switch
plungers individually reel-in at slow speed in the slow speed range setting the slow
speed limit switch check for full in and full-out is complete i.e. same switches for
both functions. If an individual limit switch allows full speed hoist operation replace
the opposite limit switch than the one used with the depressed plunger due to the
design of the circuit.
(g) Using the control pendant reel-in cable to the Full-In position, remove power, and
install gasket (90), limit switch cover (80), clamps (60 and 70) and attach with
washers (50), and screws (30) and (40) in accordance with Section 701, Assembly.
(3) Cable Foul Sensor Limit Switch Inspection (S1 – S4 Full-In) and (S2 – S5 Full-Out), and
Cockpit EDU signal (S3 and S6) (Refer to Figures 307, 308, and Figure 1003)
NOTE: THE CABLE FOUL LIMIT SWITCH LOCATIONS IN FIGURE 522.
.
Figure 522. Cable Foul Limit Switch Locations
(a) Apply power and using the control pendant reel-out 10 to 15 ft (3 - 4.5m) of cable.
(b) Using the control pendant slowly reel-in the cable and simultaneously lift up on one
side of the cable foul actuator plate. The hoist should stop operation. This means the
cable foul limit switch circuit is working properly in the up direction. Return the
actuator plate to its normal position and slowly reel-out the cable and lift up on the
25-61-00
Page 525
October 10, 2011
TD-03-008
Revision A
same side of the cable foul actuator plate. The hoist should stop operation. This
means the cable foul limit switch circuit is working properly in the down direction.
(c) Repeat the above inspection for the opposite side in both the reel-in and reel-out
direction. The hoist should stop operation in both directions. If both limit switch
plungers individually do not allow the rescue hoist to operate in the reel-in and reel-
out mode the cable foul switch check is complete.
(d) If an individual limit switch allows hoist operation in either direction replace the
limit switch (on same side of test where the plate was lifted).
(e) Check the cockpit EDU limit switches (S3 – S6) by positioning a technician in the
control cabin to view the EDU cable foul signal illumination. With power supplied,
lift up one side of the cable foul actuator plate, and confirm illumination of the EDU
cable foul caution. Repeat for other side, if the EDU cable foul caution illuminates
the EDU cable foul signal integrity is confirmed and the test is complete.
(f) If the EDU cable foul signal does not illuminate, the technician shall trouble shoot
the helicopter, and cable foul sensor limit switch circuit i.e. check circuit breaker,
power source, etc. If the cable foul limit switch is at fault, replace the individual
limit switch on same side of test where the plate was lifted.
25-61-00
Page 526
October 10, 2011
TD-03-008
Revision A
REPAIR
1. General
ALL RESCUE HOISTS.
Material Name Supplier
-- 240 grit, or finer, aluminum oxide abrasive cloth Commercially Available
-- 320 grit, or finer, abrasive paper Commercially Available
MIL-P-7962 Primer Coating Commercially Available
MIL-C-46168 Lacquer, Top Coat Commercially Available
Cable Stain – Cable Orange Stain (replaces paint / lacquer) ITW Dykem/Dymon
Visual (PN 81413 = 8 oz. bottle, PN 81713 = 1 gallon bottle.) 805 E. Old 56 Hwy.
Reference Cable White Stain for drum end flange attach point Olathe, KS 66061
(PN 81427 = 8 oz. bottle, PN 81727 = 1 gallon bottle)
Iridite Solution #14-2, or # 5025, or NCP acceptable Commercially Available
MIL-R-25134 Solvent Type Paint and Lacquer Remover Commercially Available
TT-I-735 Isopropyl Alcohol Commercially Available
Table 601. Materials Required for Repair

(Equivalent substitutes may be used for listed items)
A. Causes of surface corrosion are as follows:
(1) Nicks, dents, scratches, and wear that remove paint, and / or plating, are the principal
causes of surface corrosion.
(2) Salt water exposure can cause surface corrosion, as well as joint corrosion, due to
moisture between dissimilar metals through electrolytic action. When paint, coating,
and / or plating are removed, corrosion may occur due to the interaction of aluminum and
steel parts used in the manufacturing process.
B. Removal of corrosion on aluminum parts (see Table 601 for list of materials required for
repair).
(1) Remove surface scratches, nicks, pitting, or corrosion as specified by using 240 grit, or
finer, aluminum oxide cloth (Scotch Brite). Limits and dimensions are provided in Fits
and Clearances, Section 801.
(2) Superficial damage to primed surfaces may be touched up locally using primer
procedures listed in the refinishing section below.
(3) Blend repaired areas. See Table 602 for allowable material removal.
25-61-00
Page 601
October 10, 2011
TD-03-008
Revision A
NOMENCLATURE DAMAGE REPAIR LIMITS

Figure 1001
Exterior Control Box Assembly Surface Corrosion, Clean with Scotch Brite, and protect surface with
Surfaces of Variable Speed Nicks, Blemishes conductive corrosion preventive compound, as
Controller (20) required
Moderate to Heavy Replace Controller and Motor, or return hoist to a
FAA / JAA Repair Station, or Depot Facility, for
repair
Electrical Connectors of Variable Surface Corrosion, Clean exterior surface with Scotch Brite, and protect
Speed Controller (20), Control Nicks, Blemishes on exterior surface with conductive corrosion preventive
Pendant Assembly (30 and 40), exterior surfaces compound, as required
and Control Pendant Cable Moderate to Heavy on Damage greater than 0.002 in. (0.05 mm.), replace
Assembly (70) exterior surfaces
Any corrosion to internal Replace
surfaces, or components
Figures 1002
Hook (210) Surface Corrosion, Clean with Scotch Brite, and protect surface with
Nicks, Blemishes corrosion preventive compound, or paint, as required
Moderate to Heavy Damage greater than 0.002 in. (0.05 mm.), replace
Spring (30) None Allowed Replace
Bearings (140 and 190) None Allowed Replace
Hardware (Nuts, Bolts, Screws, None Allowed Replace

Washers, etc.)
Hand Ring (150) Surface Corrosion, Clean with Scotch Brite, and protect surface with
Moderate to Heavy Pits exceeding 0.002 in. (0.05 mm.) can be blended
Corrosion using rubber wheel and compound. Blend shall not
exceed 0.009 in. (0.23 mm.). Pits that exceed 0.010
in. (0.25 mm.) depth, replace component
Hook Housing (90) None Allowed Replace
Figure 1003
Hardware (Nuts, Bolts, Screws, None Allowed Replace
Washers, etc.)
Electrical Connectors Surface Corrosion, Clean exterior surface with Scotch Brite, and protect
Nicks, Blemishes on exterior surface with conductive corrosion preventive
exterior surfaces compound, as required
Moderate to Heavy on Damage greater than 0.002 in. (0.05 mm.), replace
exterior surfaces
Any corrosion to internal Replace
surfaces, or components
Table 602. Allowable Material Removal
25-61-00
Page 602
October 10, 2011
TD-03-008
Revision A
NOMENCLATURE DAMAGE REPAIR LIMITS

Figure 1003 (continued)
Electrical Switches None Allowed Replace
Potentiometer Bracket (820) None Allowed Replace
Cyclocentric Housing (590) None Allowed Replace
(Level Wind Shaft) Sprocket Surface Corrosion Clean with Scotch Brite, and protect surface with
(640) conductive corrosion preventive compound, as
required
Moderate to Heavy Replace
Motor Assembly (760) Surface Corrosion, Clean with Scotch Brite, and protect surface with
Nicks, Blemishes conductive corrosion preventive compound, or paint,
as required
Moderate to Heavy Replace Controller and Motor, or return hoist to a
FAA/JAA Repair Station, or Depot Facility, for
repair
Springs (380 and 1020) None Allowed Replace
Retaining Ring (1000) None Allowed Replace
Cable Guide Pin (1010) None Allowed Replace
Cable Cutter (150) None Allowed Replace
Cutter Anvil Cap (130) None Allowed Replace
Switch Actuator (870) Surface Corrosion, Clean with Scotch Brite, and protect surface with
Moderate to Heavy Damage greater than 0.002 in. (0.05 mm.), replace
Table 602. Allowable Material Removal (continued)

C. Removal of corrosion on steel parts (see Table 601 for list of materials required for repair)
(1) Remove surface scratches, nicks, pitting, or corrosion as specified by using 240 grit, or
finer, aluminum oxide cloth (Scotch Brite). Limits and dimensions are provided in Fits
and Clearances, Section 801.
(2) Remove moderate to heavy corrosion with a fine file, or a non-woven abrasive wheel.
(3) Blend repaired areas. See Table 602 for allowable material removal.
D. Superficial damage to primed surfaces may be touched up locally using primer procedures
listed in the refinishing section below.
NOTE: DO NOT INTERCHANGE ALUMINUM AND STEEL SCOTCH BRITE PADS / CLOTHS.
2. Refinish (see Table 601 for list of materials required for repair)
A. If primed surfaces of the hoist are worn, or bared, due to repair sanding, refinish using the
following materials:
Primer: MIL-P-7962, or equivalent
Top Coat: Paint touchup permissible on exterior surfaces using acrylic gloss lacquer in
accordance with MIL-PRF-81532, Color Gloss Aluminum #17178.
25-61-00
Page 603
October 10, 2011
TD-03-008
Revision A
B. Cable Dykem Opaque Orange Stain has replaced orange paint / lacquer DXX-323. The stain has
enhanced durability, whereby the paint / lacquer tends to flake off. Also, White Dykem Stain is
added on the last .47 - .53 inch (11.94 – 13.46 mm) of the cable drum flange attachment to
provide a visual reference for proper cable attachment. If the wire rope cable requires additional
orange or white stain on the ends, refinish using the instruction in Paragraph 6 and the following
material:
Coating: Orange or White Staining Color (ITW Dykem / Dymon, Olathe, KS, per Table 601 and
Figure 601)
Figure 601. Wire Rope Cable Orange Stain Lengths

3. Minor Surface Repair (Damage of Surface Area with no exposed metal, see Table 601 for list of
materials required for repair)
A. Remove contamination from damaged area using clean cloths moistened with isopropyl
alcohol, or equivalent.
B. Wipe surface area until free of oil, grease, or other contamination.
C. Lightly sand damaged area with 320 grit, or finer abrasive paper.
CAUTION: AVOID OVER SANDING SURFACE AREA. REMOVE SANDING RESIDUE
WITH CLEAN CLOTH MOISTENED WITH ISOPROPYL ALCOHOL.
D. Mask, or protectively cover, all areas not being treated or primed.
E. Aluminum will not require a surface treatment if primer is applied immediately. If a delay of
more than two hours occurs, use Iridite #14-2 solution (4 ounces per gallon [32 ml. per
liter]). Apply by brush or swab at room temperature. A contact time of 15 to 30 seconds will
usually produce a golden yellow color. Rinse thoroughly and dry. (Iridite # 5025 or NCP
Acceptable – follow manufacturer’s instructions.)
F. Primer application should be accomplished under the following conditions:
Temperature: 50° F (10° C) minimum
Relative Humidity: 85% maximum
G. Using a cotton swab or brush, apply Primer to the affected area and allow to dry. The
minimum drying time prior to service use is 48 hours when cured under 75° F (24° C) and 24
hours when cured above 75° F (24° C).
25-61-00
Page 604
October 10, 2011
TD-03-008
Revision A
H. Apply topcoat as specified in paragraph 5 below.

4. Major Surface Repair (Damage of Surface Area with exposed metal, see Table 601 for list of
materials required for repair)
A. To strip primer, and coating, from damaged area use approved strippers per MIL-R-25134, or
equivalent. The viscosity of this primer is high enough so that it can be applied by brush, or
swab, to the specific area to be stripped without running. It is to be used in the as received
condition at temperatures above 50° F (10° C).
B. Follow procedures A through H listed in Minor Surface Repair above.
5. Application of Top Coat
A. Top coat application should be accomplished under the following atmospheric conditions:
Temperature: 50° F (10° C) minimum
Relative Humidity: 85% maximum
B. Using a quality natural-bristled paint brush, apply coating in one direction as much as
practical. Brush the surface to form an even continuous coat. Avoid repeated brushing out of
wet coating that causes pick-up, air bubbles, and voids, which require later touch-up. The
minimum drying time prior to use is 48 hours when cured at a temperature under 75° F
(24° C) and 24 hours when cured above 75° F (24° C).
6. Application of Coating on Cable
THE OPERATOR WHENEVER OPERATING, OR MAINTAINING, THE
RESCUE HOIST TO PREVENT INJURY FROM LUBRICANTS, SOLVENTS,
AND OTHER MATERIALS USED ON THE RESCUE HOIST, AS WELL AS
METAL PARTS AND OTHER DEBRIS.
NOTE: CABLE DYKEM OPAQUE ORANGE STAIN HAS REPLACED ORANGE PAINT
/ LACQUER DXX-323. THE STAIN HAS ENHANCED DURABILITY,
WHEREBY THE PAINT / LACQUER TENDS TO FLAKE OFF. ALSO, WHITE
DYKEM STAIN IS ADDED ON THE LAST .47 - .53 INCH (11.94 – 13.46 MM)
OF THE CABLE DRUM FLANGE ATTACHMENT TO PROVIDE A VISUAL
REFERENCE FOR PROPER CABLE ATTACHMENT.
25-61-00
Page 605
October 10, 2011
TD-03-008
Revision A
A. Remove contamination from area of cable where stain has been damaged using a clean cloth
moistened with isopropyl alcohol, or equivalent.
B. Wipe surface area until free of oil, grease, or other contamination.
C. Top coat application should be accomplished under the following atmospheric conditions:
Temperature: 50° F (10° C) minimum Relative Humidity: 85% maximum
D. Using a quality natural-bristled brush, or equivalent, apply up to three coats of orange, or
white Dykem Opaque Stain, as applicable, to the cable designated areas in accordance with
Figure 601 and Table 601. Stain thickness can be measured with a micrometer and should not
exceed 0.001 inches (0.25 mm) on the cable diameter.
E. Allow cable to dry for 30 minutes between coats, and prior to installing cable on hoist.
7. Cable Foul Removal (see Figures 602 and 1003)
WARNING: DO NOT TRY TO CLEAR CABLE FOUL IN FLIGHT. A FOULED CABLE MAY
BREAK, AND THIS MAY RESULT IN CAUSING INJURY OR DEATH.
Figure 602. Cable Fouls on Rescue Hoists (Typical)

A. To clear cable foul the cable foul sensor assembly has to be removed enough to relieve
pressure on the limit switches. Remove in accordance with Section 301. Disassembly, and tilt
cable foul sensor assembly out of the way.
B. Using the control pendant, slowly reel out cable.
C. If cable starts to backwind, or fouled cable cannot be reeled out, use a bolt cutter, or
equivalent, and cut off small sections of the cable until the cable foul is removed.
NOTE: CABLE EXTREMES ARE PAINTED WITH ORANGE STAIN. DO NOT CONFUSE
THIS COLOR FOR RED INDICATING A SCRAPPED CABLE AND DO NOT USE
ORANGE TO INDICATE A SCRAPPED CABLE.
25-61-00
Page 606
October 10, 2011
TD-03-008
Revision A
D. Remove cable that was involved in cable foul incident per Disassembly (Section 301),
identify cable as scrap (recommend painting ends of cable red and / or tagging cable with red
tag labeled “SCRAP”), and install new cable per Assembly (Section 701).
E. Install hook assembly onto cable per Section 701, Assembly, and perform test procedures in
Paragraphs 4A, 4B and 4E of Section 101, Testing and Troubleshooting, to ensure the cable
is properly installed and to condition the cable for proper wrapping on drum.
8. Cable Alignment Inspection / Adjustment (see Figure 1003):
A. Slowly reel out cable (IPL Figure 1003, Detail A, Item 100) to full out hoist position.
B. Slowly reel in the cable three (3) to five (5) wraps. Position the centerline of the cable
crossover point (the center of the flat area) of the drum 180° (opposite) from the tangent
point where the cable is beginning to wrap on the drum (where the cable begins to touch the
drum after being fed through the cable guide and past the tension roller).
C. Check cable alignment. Cable shall be in the center of the groove and seated in the bottom of
the groove with no sign of leading (overtravel), or lagging, as it transitions from the drum
over the tension roller shaft assembly (480) and through the cable guide.
NOTE: ADVANCE LEVEL WIND SHAFT SPROCKET (640) SLOWLY (ONE TOOTH AT A
TIME) IN ORDER TO PROPERLY ADJUST CABLE GUIDE POSITION TO
CORRECTLY ALIGN CABLE.
D. If alignment has to be adjusted, follow the chain removal procedure in Section 301
(Disassembly), and move the level wind sprocket accordingly as defined below:
Cable lagging: Rotate sprocket clockwise to correct for lag.
Cable leading: Rotate sprocket counterclockwise to correct for overtravel.
E. After alignment of cable is completed, follow the chain installation procedure in Section 701
(Assembly).
F. Torque nut on cyclocentric end of level wind shaft to between 55 and 60 in.-lb. (6.2 and 6.8
Nm).
G. After installing chain, perform steps A. through D. above.
9. General Wiring Harness Connector Pin Replacement Procedures – for bent or otherwise
damaged connector pin contacts (Refer to Section 201, Figures 201 – 206, and to SAE
AS95049/Series Specification, or equivalent. Requires crimp, insertion, and extraction tools,
which are commercially available):
A. Extract connector pin (contact) as instructed below:
(1) Remove hardware from connector plug, or receptacle, and slide hardware back along
wire bundle.
25-61-00
Page 607
October 10, 2011
TD-03-008
Revision A
(2) Using a proper plastic, or metal, extraction tool with proper color code corresponding to
contact size, place wire in tool.
(3) Insert tool into contact cavity until the tool tip bottoms against the contact shoulder,
expanding clip retaining tines.
(4) Hold wire firmly in tool and extract wired contact and tool. Repeat operation for all
contacts to be extracted.
(5) Fill any empty wire cavities with wire sealing plugs.
(6) Reassemble connector plug or receptacle.
B. Crimp (new) contact as instructed below:
(1) Strip insulation from end of wire to be crimped. Do not cut or damage wire strands.
(2) Insert stripped wire into contact crimp pot. Wire must be visible through inspection hole.
(3) Using correct crimp tool and locator, cycle the tool once to be sure the indentors are
open. Insert contact and wire into locator. Squeeze tool handles firmly and completely
to insure a proper crimp. The tool will not release unless the crimp indentors in the tool
head have been fully actuated.
(4) Release crimped contact and wire from tool. Ensure the wire is visible through
inspection hole in contact.
C. Insert (new) contact as instructed below:
(1) Remove hardware from connector plug, or receptacle, and slip over wire bundle in proper
order for reassembly.
(2) Using a proper plastic, or metal, insertion tool for corresponding contact, position wire in
tip of the tool so that the tool tip butts up against the contact shoulder.
(3) Press tool against contact shoulder and, with firm and even pressure, insert wire contact
and tool tip into center contact cavity. A slight click may be heard as metal retaining ring
tines snap into place behind contact shoulder.
(4) Remove tool and pull back lightly on wire to make sure contact is properly seated.
Repeat operation with remainder of contacts to be inserted, beginning with the center
cavity and working outward in alternating rows.
(5) After all contacts are inserted, fill any empty cavities with wire sealing plugs.
Reassemble connector plug or receptacle hardware.
25-61-00
Page 608
October 10, 2011
TD-03-008
Revision A
ASSEMBLY
1. General
Assemble the Rescue Hoist System in accordance with the following instructions. Reference
numbers in parenthesis refer to IPL in Section 1001. Special tools and general information are listed
in Section 901. Electrical schematics and wiring diagrams are located in Section 201. All mention of
applying and disconnecting power to the system components should be accomplished using
helicopter circuit breakers, or equivalent acceptable means. Materials Required for Assembly
(suitable equivalents acceptable) are identified in Table 701 below:
Material Name, Application, & Description

MIL-PRF-7808 Lubricating Oil for Rescue Hoist Assembly, MIL-PRF-
7808, Class 3 (NATO Code No. O-148) Preferred.
See description for further details. Alternate oil MIL-PRF-23699 for main gearbox only.
(Not for side gearbox, which uses grease) (Note: Do
not intermingle / mix oils)
MIL-S-8660 Anti-Seize Compound for cartridge packing and cutter
O-Ring
MS20995C32 / AS3510-02 (UNS S32100) Tie Wire / Safety Cable
MIL-A-46146, or 3145 RTV Adhesive / Sealant
(Dow Corning Corp)
MIL-S-22473, Grade A Thread Locking Compound
MIL-PRF-83483, or Anti-Seize Compound
Loctite 767
SAE AMS-M-7866 Lubricant for tension roller shaft
A-A-59173 (MIL-G-46886) or DC-33 (Dow Lubricant for hook assembly thrust bearing, hoist
Corning Corp.) assembly chain, tension roller clutch assembly, and
overrunning clutch assembly
DC-55 (Dow Corning Corp.) Motor O-Ring Lubricant
SN60-63WRMAP2/3, or Solder
SN60-63WRP2/P3
TT-L-58E, Type I, Class I Clear Gloss Lacquer for protective coating on labels
MIL-A-46106, Group 1, Type 1, or RTV Sealant for limit switch harness assembly
RTV 102 (GE Silicones)
Glyptal 1201, or MIL-E-22118 Red Enamel Sealant for solder connection insulation
Pliobond #35 (Note: #35 replaces #30, which Contact Adhesive
is being phased out due to MEK. Pliobond #30
can be used up, Ashland Chemical Corp)
Vibra-Tite Formula 3 (ND Industries) Thread Locking Compound
Table 701. Materials Required for Assembly (suitable equivalents acceptable)
25-61-00
Page 701
October 10, 2011
TD-03-008
Revision A
All procedures identified with the note VITAL INSPECTION POINT and parts with their item
numbers identified with the note VP require an individual, other than the technician who performed
the operation, to inspect the work completed due to the criticality of the operation. This inspection
shall be documented in both the helicopter and rescue hoist maintenance logs.
2. Assemble the Rescue Hoist System in accordance with the following instructions and Figures
1001 through 1003.
ALL RESCUE HOISTS.
3. Installation of Electrical Components (refer to Figure 202 – 206 for Wiring Diagrams of Rescue
Hoist Assembly, and Figures 101 - 104, 303, 307, and 1003, Views A and B)
WARNING: ALL ELECTRICAL WORK SHALL BE ACCOMPLISHED WITH POWER
DISCONNECTED TO HOIST AND TOOLS THAT DO NOT CONDUCT
ELECTRICITY. PROPER GROUNDING IS REQUIRED.
WARNING: TAKE PROPER ELECTROSTATIC DISCHARGE (ESD) PRECAUTIONS TO
AVOID DAMAGING COMPONENTS DURING HANDLING DUE TO
ELECTRICAL SHOCK FROM ELECTROSTATIC DISCHARGE.
NOTE: ALL WORK INVOLVING ELECTRICAL WIRING, SPECIFICALLY WORK
INVOLVING SOLDERING, MUST BE PERFORMED BY QUALIFIED
TECHNICIANS.
A. Install full in limit switch (S3) (Figure 1003, View A, Item 110) as follows:
(1) Using SN60-63WRMAP2/3 or SN60-63WRP2/P3 Solder, attach wire connections to full
in limit switch (S3) per wiring diagram on Figure 202.
(2) Apply Dow Corning 3145 Sealant to switch terminals after soldering.
(3) VITAL INSPECTION POINT. Install spring (1020), and pin (1010). Install
retaining ring (VP 1000) into the retaining ring installation tool, Breeze-Eastern part
number BLT-10300-V, or equivalent, with the sharp edge of the retaining ring orientated
towards the bottom of the cable guide housing, and the rounded edge positioned up
towards the spring. Use a screwdriver to compress spring (1020) and install retaining ring
(VP 1000). Ensure the retaining ring is undamaged after installation. It shall remain
stationary and not rotate on the pin. If bending, damage, or rotation is evident, remove
and discard retaining ring (VP 1000) and install a new retaining ring (VP 1000) per
these instructions. After successful installation of retaining ring, secure with ring retainer
(1012). See Figure 103.
25-61-00
Page 702
October 10, 2011
TD-03-008
Revision A
(4) Install full in limit switch (110) and actuator (960) into cable guide. Apply thread locking
compound IAW MIL-S-22473, Grade A to screw threads prior to installation.
(5) Install flat washers (990), tooth lock washers (980), and screws (970). Torque screws to
9.0 ± 0.5 in.-lb. (1.02 ± 0.06 Nm.), and apply torque seal to heads of screws.
(6) Install gasket (930) and cover (920). Secure using screws (940) and washers (950).
(7) After installing switches above, perform test procedures in Section 101, Paragraph
4.A.(4), after hoist is installed on the helicopter.
B. Install full out limit switch S2 (Figure 1003, View B, Item 110) and intermediate limit switch
S1 (Figure 1003, View B, Item 110) as follows:
(1) Using SN60-63WRMAP2/3 or SN60-63WRP2/P3 Solder, attach wire connections to full
out limit switch S2 and intermediate limit switch S1 per wiring diagram on Figure 202.
(2) Apply Glyptal 1201 Red Enamel, or equivalent, to switch terminals after soldering.
(3) Install full out limit switch S2 (110), intermediate limit switch S1 (110), and actuators
(870). Secure with screws (880 and 890), flat washers (900), and nuts (910) onto brackets
(830 and 840). Torque screws to 9.0 ± 0.5 in.-lb. (1.02 ± 0.06 Nm.). See Figures 101 and
303.
(4) Install brackets (Figure 1003, View B, Items 830 and 840) onto cyclocentric assembly
(Figure 1003, Item 590) with screws (Figure 1003, View B, Item 850) and washers (860).
See Figures 101 and 303.
(5) After installing switches above, perform test procedures in Section 101, Testing and
Troubleshooting, Paragraphs 4.A.(1), 4.A.(2), and 4.A.(3), after hoist is installed on the
helicopter.
C. Installation of Potentiometer R1
(1) Using SN60-63WRMAP2/3 or SN60-63WRP2/P3 Solder, attach wire connections to
potentiometer R1 per wiring diagram on Figures 202 to 204, as applicable.
(2) Install new O-Rings (1224) onto shaft of potentiometer (1222).
(3) Install potentiometer onto bracket (Figure 1003, 820), and secure with screws (1210) and
mounting cleats (1212).
(4) If removed, install bracket (820) onto cyclocentric assembly (590), and secure with
screws (810).
D. Install cable foul assembly limit switches as follows (Figure 1003, Item 1100):
(1) Using SN60-63WRMAP2/3 or SN60-63WRP2/P3 Solder, attach wire connections to
switches (1100) per wiring diagram on Figure 202.
(2) Apply Dow Corning 3145 Sealant to switch terminals after soldering.
(3) Install screws (1120), flat washers (1130), and nuts (1110) holding switches in place.
Torque screws to 1.2 to 1.5 in.-lb. (0.14 to 0.17 Nm.). See Figure 104.
25-61-00
Page 703
October 10, 2011
TD-03-008
Revision A
(4) Install cable foul assembly (1030) and secure with clamps (1080 and 1090), washers
(1060 and 1070), and screws (1040 and 1050). Refer to Figure 307.
(5) After installing switches above, perform test procedures in Section 101, Paragraph 4.C.
after hoist is installed on the helicopter.
4. Install motor as follows (see Figures 306, 1003, and View C):
NOTE: ALL MATING AND FAYING SURFACES, ESPECIALLY THOSE SURFACES
IN CONTACT WITH GASKETS, SHALL BE CLEANED PRIOR TO ASSEMBLY.
A. Disconnect all electrical power to hoist.
B. If necessary, install new pad (730) onto motor support (690). If motor has been replaced,
install support with shims (700 through 700C) and secure with washers (720) and cap screws
(710). Refer to Figure 306.
C. Apply DC-55 to new O-ring (770) prior to installation.
D. Install O-ring in groove on motor mounting flange.
E. Position motor so that electrical connector is facing outward from hoist
F. While supporting motor carefully engage shaft spline of motor (760) with internal spline of
gear on hoist.
G. Apply a light coat of MIL-PRF-83483 anti-seize compound to cap screw (740) threads.
Using a ¼ inch Allen wrench secure using washers (750) and cap screws (740). Torque cap
screws (740) to 125 – 145 lb.-in. (14.12 – 16.28 Nm).
H. Install strap (680) around motor (760) and secure strap with clamps (670), washers (660),
and cap screws (650). Refer to Figure 306.
I. Install wiring harness (not shown in IPL, not supplied by Breeze-Eastern) to electrical
connector on motor.
5. Install chain as follows (see Figures 305 and IPL Figure 1003):
A. Apply a light coat of lubricant A-A-59173, DC-33, or equivalent, to chain (620) and
sprockets from the level wind shaft and the drum pinion.
B. Install chain (620) over sprockets (630 and 640) on the level wind shaft and the drum. See
Figure 305.
C. Slide cam follower assembly (600) over to provide proper tension on the chain and tighten
nut (610) between flange and drum to secure cam follower.
D. Check gap between inside surfaces of chain using procedure in Checks and Inspections
(Section 501), paragraph 2.H.
E. Apply a light coat of A-A-59173 or DC-33 lubricant to cyclocentric drive gear. Install
cyclocentric assembly (590) secure with screws (570) and washers (580). See Figure 305.
6. Install overrunning clutch assembly as follows (see Figures 504, 701 and 1003):
A. Coat gear teeth of overrunning clutch assembly (560) with lubricant A-A-59173, DC-33, or
equivalent.
25-61-00
Page 704
October 10, 2011
TD-03-008
Revision A
B. Install overrunning clutch assembly, on the inside of flange, using bolt (540) and spacer
(550).
C. Install clutch guard (530) secure with screws (500 and 510), and washers (520).
7. Install tension roller as follows (see Figures 701 and 1003, and Figure 1003, View A):
A. Apply A-A-59173 lubricant to external surfaces of clutch assembly (490) before installation.
B. Install clutch assembly (490) onto tension roller (480).
C. Coat both mating surfaces of inner roller shaft (450) ends and inside surface of both bushings
in flanges with SAE AMS-M-7866 lubricant, or equivalent.
D. Slide inner roller shaft (450) through bushing on motor end flange from the outside of hoist.
As shaft is pushed through motor end flange, install thrust washer (470) with Teflon side
towards bushing. Install first set of shims (460 through 460C), if required, between Teflon
washer and tension roller using thickness previously recorded during disassembly (Section
301).
E. Install tension roller (480) and clutch assembly (490) on inner roller shaft.
F. Install second set of shims (460 through 460C), if required, using thickness previously
recorded during disassembly. Install thrust washer (470) keeping Teflon side of washer
towards bushing in cyclocentric end flange.
G. Slide inner roller shaft (450) into bushing in cyclocentric end flange. Partially install new pin
(440) halfway using tool BLT-10300-J, or equivalent, to allow removal if re-shimming is
required.
H. Check gap between large gears on both overrunning clutch and tension roller clutch
assemblies using feeler gage (see Figure 701). Measure gap between gears of clutch
assemblies. Gap should be 0.030 inches (0.762 mm.) minimum. If gap is less than this limit,
remove spring pin and shaft to re-shim as required at cyclocentric end of tension roller
assembly between thrust washer and tension roller clutch assembly. Install shaft and partially
install spring pin halfway when checking gap, and when tension roller clutch assembly
shimming is complete.
I. Check for tension roller endplay using feeler gage (see Figure 701). Measure gap between
tension roller shaft assembly and shims at the motor end flange. Endplay should be between
0.002 to 0.010 inches (0.051 to 0.254 mm.). If endplay exceeds these limits, remove spring
pin and shaft and re-shim as required at motor end of tension roller assembly between thrust
washer and tension roller. Install shaft and partially install spring pin halfway when checking
endplay. When shimming is complete, use BLT-10300-J, or equivalent, to completely install
spring pin (440).
J. Install gear guard (390) using screws (400 and 410) and washers (420 and 430).
K. Install spring (Figure 1003, View A, 380) and plunger (370) into cable guide assembly.
25-61-00
Page 705
October 10, 2011
TD-03-008
Revision A
Figure 701. Tension Roller and Overrunning Clutch Assemblies

(Cyclocentric End is on left and Motor End is on right)
L. Install guide bar (Figure 1003, 360) using cap screws (350).
M. If previously installed remove soft wooden wedge, or equivalent, from between the spacer
plate (Item 340, IPL Figure 1003) and the cable (Item 100, Detail A) on the drum.
8. Install roller assemblies and follower as follows (see Figures 702 and 1003, View A):
A. If necessary, press bearings (290 and 320) into rollers (300 and 330) from the open / staked
bearing side. Secure bearings (290 and 320) in rollers (300 and 330) by ring staking the open
side of the roller flange in six equidistant positions, take care not to reuse the existing stake
positions.
B. Install roller assemblies (280 and 310) with spacers (270, one spacer on each side) with the
thick side of the roller flange on the right side in-between support (260) ears / flanges. Refer
to Figure 702.
C. Secure roller assemblies (280 and 310), with spacers (270) on either side, in support (260)
using the cable guide using shafts (250). Tie wire shafts together with MS20995C32 per
NASM33540 after installation or safety cable using AS3510-02 (UNS32100). Refer to
Figure 702.
D. Install follower (240) in cable guide with spring washer (230), back up spacer (210). Thread
a #8-32 screw (MS16995-25) into follower, press in and secure with retaining ring (220) in
groove. Unthread and remove screw.
25-61-00
Page 706
October 10, 2011
TD-03-008
Revision A
Figure 702. Safety Tie Wire Installation and Roller Placement

9. To install cable guide proceed as follows (see Figure 304 and Figure 1003, View A):
A. If removed, install cable guide stop (180). Rotate cable guide stop (180) in cable guide
housing to permit insertion of cable guide bushing (200) in the radius / scarf of the stop.
B. Insert cable guide bushing fully, rotate and seat stop (180) in locking groove of bushing.
C. VITAL INSPECTION POINT. Start nut (190 VP) on cable guide stop (180) and
tighten to obtain drag on cable guide bushing when rotating bushing (200) by hand. Tighten
nut (190) one additional, complete turn to lock nut.
D. VITAL INSPECTION POINT. Install cotter pin (170 VP) through hole in stop (180).
10. Install limit switch cover assembly as follows (see Figures 302 and 1003):
NOTE: ALL MATING AND FAYING SURFACES, ESPECIALLY THOSE SURFACES IN
CONTACT WITH O-RINGS, PACKINGS, AND GASKETS, SHALL BE CLEANED
PRIOR TO ASSEMBLY PER SECTION 401.
A. If removed, install new gasket (90) on limit switch cover (80) by removing paper backing
from adhesive side of gasket. Install gasket with adhesive side towards cover.
B. Attach cover (80) with gasket (90) to end flange, using screws (30 and 40), washers (50), and
clamps (60 and 70). Install tie wire in screws (40) per NASM33540 with MS20995C32 or
safety cable using AS3510-02 (UNS32100). See Figure 302.
C. Seal limit switch harness assembly opening between cover (80) and end flange with sealant,
RTV 102, or equivalent.
11. Install cable cutter follows (see Figure 1003, View A):
A. Grease O-ring (160) with “O”-Ring lubricant Dow Corning DC-55, and using a scribe or
equivalent, insert into groove in cable guide assembly.
B. Insert cable cutter (150) into cable guide with blade facing toward the opening for the cutter
anvil cap (130). Using a needle nose pliers or equivalent, install and position cable cutter
25-61-00
Page 707
October 10, 2011
TD-03-008
Revision A
(150) into cable guide cutter bore with blade facing toward the opening for the cutter anvil
(130). Press in until seated in O-ring (160) and until it bottoms out in bore. Move cutter in
and out axially for alignment as required, and align the cutter so the cotter pin holes in cutter
blade align with the holes on the outside of the cable guide assembly, refer to Figure 703.
C. VITAL INSPECTION POINT. Position cable cutter and align hole in cable cutter with
hole in cable guide. Insert cotter pin (140 VP). Bend tabs to secure cotter pin.
D. Thread anvil cap (130) into annulus of cable guide assembly until bottomed.
E. Tie wire anvil cap head to tab on cable guide assembly per NASM33540 with MS20995C32,
or safety cable using AS3510-02 (UNS32100).
Figure 703. Cutaway of Correct Cable Cutter Orientation (Typical)

12. Install cable as follows (see Figure 1003 and Figure 1003, View A):
WARNING: OPERATOR SHALL WEAR WORK GLOVES WHEN HANDLING WIRE ROPE
CABLES. EXERCISE EXTREME CAUTION TO PREVENT GETTING HANDS
OR CLOTHING CAUGHT ON DAMAGED AREAS OF CABLE THAT WILL
RESULT IN INJURY.
NOTE: CABLE EXTREMES ARE STAINED ORANGE IN COLOR. DO NOT CONFUSE
THIS COLOR FOR RED, INDICATING A SCRAPPED CABLE, AND DO NOT
USE ORANGE TO INDICATE A SCRAPPED CABLE.
NOTE: AN OPTIONAL STEP TO EASE CABLE INSTALLATION IS TO REMOVE THE
GUIDE BAR (360) SECURED BY TWO CAP SCREWS (350). REINSTALL
AFTER CABLE INSTALLATION.
A. Ensure the cable guide assembly / pressure roller is mostly aligned with the first groove in
the drum on the cable attach end flange side. This confirms the cable guide assembly was not
moved since cable removal.
B. Feed welded end of cable (100) through cable guide bushing (200) and route cable around
back of drum. Ensure cable is captured in rollers of cable guide assembly and between
pressure roller and tension roller.
25-61-00
Page 708
October 10, 2011
TD-03-008
Revision A
NOTE: THE CABLE MUST BE FULLY INSERTED INTO THE DRUM FLANGE TO
ENSURE THAT THE ATTACHMENT SCREW ENGAGES THE CABLE
SUFFICIENTLY TO ASSURE A FIRM ATTACHMENT. CONFIRM THAT THE
CABLE IS FULLY INSERTED INTO THE DRUM FLANGE BY VISUALLY
OBSERVING THAT THE WHITE MAKING IS BARELY VISIBLE PRIOR TO
SECURING THE CABLE WITH THE ATTACHMENT SCREW. REFER TO
FIGURE 704.
C. Route the cable around the back of the drum and insert white stained end of cable in the hole
of drum. Check for proper installation of the cable by looking through the screw hole in the
top of the drum flange. Ensure the white stained end of the cable is visible through the screw
hole, and is barely visible outside the flange. This ensures the cable is properly inserted far
enough and the cable attach screw will contact the cable strands and not the welded end,
Refer to Figure 704.
Figure 704. Correct and Incorrect Wire Rope Cable Attachment Drum
D. VITAL INSPECTION POINT. Tighten first setscrew (120 VP) to a torque of 5.0 ± 0.5
in.-lb. (0.57 ± 0.06 Nm.).
E. VITAL INSPECTION POINT. Remove slack from cable by putting tension on cable.
Check holding force of installed setscrew (120 VP) by giving a tug on the cable. Cable shall
remain tight, with no movement.
F. VITAL INSPECTION POINT. Install second setscrew (120 VP) above installed
setscrew to lock first setscrew in place. Torque to 5.0 ± 0.5 in.-lb. (0.57 ± 0.06 Nm.).
G. Apply power to hoist.
NOTE: ALWAYS REEL-IN TO CHECK CABLE ALIGNMENT. NEVER PAY OUT CABLE
TO CHECK ALIGNMENT (SEE CHECKS AND INSPECTIONS SECTION 601 FOR
CABLE ALIGNMENT PROCEDURE).
H. Check cable alignment by operating hoist (less than half speed) to reel in cable for about five
(5) turns, keeping tension of approximately 20 lb. (9.1 kg.) on cable by hand. Position drum
with centerline of flat on drum 180° from tangent point of cable on drum first wrap. Check
25-61-00
Page 709
October 10, 2011
TD-03-008
Revision A
the alignment - cable should be in center of groove, and seated on bottom of groove. Reel in
cable at half speed until approximately 6 feet (1.8 m.) of cable remain, keeping tension of
approximately 20 lb. (9.1 kg.) on cable. Check that cable is wrapping on hoist properly with
no leading, or lagging, and with no snapping at turnaround on drum.
I. Install hook assembly onto cable per paragraphs 14, and 15 below, and perform test
procedures in Paragraphs 4A, 4B, and 4E of Testing and Troubleshooting, Section 101 to
ensure the cable is properly installed, and to condition (season) the cable for proper wrapping
on drum.
J. Disconnect power from hoist.
13. Assemble and install bumper assembly (Figures 1001, Item (60) and 1002, Item 10) as follows:
A. Press over travel bumper (40) into bottom of bumper retainer (20).
B. Place compression spring (30) in bumper retainer and using a screwdriver, or equivalent,
slide / pry in spring coil in four places equally spaced on circumference of bumper retainer.
C. Lightly grease ball end of cable (Figure 1003, View A, Item 100) with A-A-59173 lubricant,
or equivalent, to ease installation of bumper assembly onto cable. Do not allow any
lubrication on the wire rope cable itself, only the ball end.
D. Install bumper assembly (10) onto cable by pressing ball end of cable through rubber
bumper.
14. Assemble and install hook assembly (Figures 1001, Item 60 and 1002, Item 50) as follows:
A. Accomplish actions identified in Paragraph 13 (assembly and installation of bumper
assembly) above prior to performing the steps below; see Figure 1002 unless specified
below.
WARNING: THE TERMINAL CLAMP IS A TWO-PIECE, MATCHED SET. IT IS
MACHINED AS AN ASSEMBLY AND MUST BE INSTALLED AS A SET.
WARNING: ORIENTATION OF TERMINAL CLAMP DURING INSTALLATION IS
CRITICAL FOR PROPER LOAD CARRYING CAPABILITY OF THE HOIST
HOOK. THE RETAINING RING MUST BE ON THE END OF THE TERMINAL
CLAMP LOCATED CLOSEST TO THE HOOK WITH THE CHAMFERED OR
CONE SHAPED END OF THE TERMINAL CLAMP FACING TOWARD THE
HOIST.
B. VITAL INSPECTION POINT. Reference Figure 1002: Slide nut (60) up cable towards
hoist. Attach terminal clamp (100 VP) onto ball end of cable. Secure terminal clamp with
ring (110 VP).
C. VITAL INSPECTION POINT. Reference Figure 1002: Slide bumper assembly (10) down
until terminal clamp (100 VP) seats in nut (60).
25-61-00
Page 710
October 10, 2011
TD-03-008
Revision A
Cable
Terminal Clamp
Retaining Ring
Nut/Sleeve
Sleeve / Nut
Figure 705. Required Terminal Clamp Orientation (Typical)

D. Install bearing (190) and thrust washer (180) into housing (90).
E. Install flat washer (200) and housing (90) onto stem of hook (210).
F. With an applicator brush, spread Vibra-Tite on the male threads of the hook. Completely
cover threads in the area where the nut will be engaged when assembled. Allow Vibra-Tite to
dry.
CAUTION: ONLY TIGHTEN CASTELLATED NUT (170) HAND TIGHT (IF HAND
THREADING IS DIFFICULT A WRENCH CAN BE USED TO ASSIST), THEN
BACK-OFF. NEVER TIGHTEN THE NUT TO REACH THE NEXT AVAILABLE
CASTELLATION.
G. Install castellated nut (170) onto stem of hook and tighten until bearing is fully seated in
housing.
H. VITAL INSPECTION POINT. Back castellated nut (170) off slightly to allow
installation of new orange colored spring pin. Using a drift and mallet, install spring pin
(160 VP) through stem of hook and castellated nut, with access through housing (90).
I. VITAL POINT INSPECTION. Rotate hook while holding housing to check for
binding of bearing (190). If binding exists, remove spring pin (160), and back off castellated
nut one additional gap. Install new pin, and rotate hook while holding housing to check for
binding of bearing again. Repeat binding check, and repositioning of nut as necessary until
binding is eliminated. If binding continues to occur, replace bearing (190).
J. If necessary, press bearing (140) into handwheel (150).
K. Install handwheel assembly (130) and nut spacer (120) onto housing (90).
L. Install housing and assembled hook parts onto nut (60) by threading, or screwing them
together until bottomed.
M. VITAL INSPECTION POINT. Install locking screws (80 VP) into nut (60). Try to
ensure attach screws are properly seated in the castellated cut outs of the hook housing / body
to lock nut and housing together. Lock setscrews in place with new cotter pins (70 VP).
Refer to Figure 706.
25-61-00
Page 711
October 10, 2011
TD-03-008
Revision A
Figure 1002:
Setscrew
properly
engaged locking
Nut (60) and
Housing / Body
(160) together.
Setscrew not
engaged, the
Nut (60) &
Housing / Body
(160) can
unthread and
drop the load.
Figure 706. Hook Assembly Setscrew Correct vs. Incorrect Assembly

N. Push down on bumper assembly (10) to snap the bumper assembly onto nut (60).
O. Apply power to hoist.
P. Run hoist to the full in position to secure to hook and bumper assembly on hoist.
Q. VITAL INSPECTION POINT. Perform Hook Load Test identified in Testing and
Troubleshooting (Section 101, Paragraph 4.F.), to ensure hook (50 VP) has been properly
installed. Verify hook bearing rotates with a smooth, non-binding rotation.
R. Disconnect power to hoist.
15. Install labels (Figure 1003, Items 780 through 800) onto limit switch cover as follows:
NOTE: ALL SURFACES SHALL BE CLEANED PRIOR TO INSTALLATION OF
NAMEPLATES OR LABELS (SEE SECTION 401 FOR CLEANING
INSTRUCTIONS).
A. All typed information should be added on identification label (780) from previously recorded
data obtained during disassembly. If information on label was illegible when removed,
contact Breeze-Eastern with all known information concerning hoist (part number and serial
number, if known) for original, or new, data.
B. Remove backing of labels to expose adhesive, or apply isopropyl alcohol on back to activate
adhesive and install labels (780, 790, and 800). Allow adhesive to dry for 30 minutes. See
Section 301, Figure 302.
C. Coat labels with TT-L-58E, Type I, Class I, Clear Gloss Lacquer, or equivalent.
16. Install Hoist onto helicopter as follows (see Figures 202, 203, 204, 801, and Figure 1001):
CAUTION: THE HOIST WEIGHS APPROXIMATELY 85 LB. (38.5 KG) WITH THE HOOK
INSTALLED AND 81 LB. (36.7 kg.) WITHOUT THE HOOK INSTALLED. TWO
INDIVIDUALS SHOULD INSTALL THE HOIST ONTO THE HELICOPTER
UNLESS SUITABLE SUPPORT IS PROVIDED TO HOLD THE WEIGHT OF
THE HOIST WHEN INSTALLED.
25-61-00
Page 712
October 10, 2011
TD-03-008
Revision A
A. Install Hoist (10) onto mount using attaching hardware (not part of System and not supplied
by Breeze-Eastern) for four mounting points.
B. Route electrical cables, install restraints, and connect electrical connectors to hoist motor,
cable cutter cartridge, cable foul indicator, and limit switch connectors.
C. Check oil level and service the hoist with MIL-PRF-7808 per Checks and Inspections
(Section 501).
D. Apply power to hoist by pushing in applicable circuit breakers.
E. Perform test procedures in Paragraph 4E of Testing and Troubleshooting, Section 101.
17. Install variable speed controller as follows (see Figures 202 - 205, 802, and Figure 1001):
A. Disconnect all electrical power to hoist.
B. Install the variable speed controller (20) using four mounting screws (not supplied by
Breeze-Eastern).
C. Connect electrical connectors of pendant cable (70) and other helicopter wiring harnesses
(not supplied by Breeze-Eastern) to the variable speed controller.
D. Apply power to variable speed controller by pushing in applicable circuit breakers.
E. Perform test procedures in Paragraph 2.L.(7) of Checks and Inspections, Section 501.
18. Install control pendant and pendant cable assembly as follows (see Figures 202 - 205, 803, and
Figure 1001):
A. Disconnect all electrical power to hoist and variable speed controller.
B. Connect electrical connector of pendant cable (70) to control pendant (30 or 40).
C. Apply power to control pendant, hoist, and variable speed controller by pushing in applicable
circuit breakers.
D. Perform test procedures in Paragraph 2.L.(7) of Checks and Inspections, Section 501.
19. Install cartridge as follows (see Figures 301, 1001, Item 50, and 1003, Item 10):
CAUTION: IF THE CARTRIDGE HAS A CARTRIDGE WIRING HARNESS WITH A 90
DEGREE CONNECTOR BACKSHELL YOU SHALL USE THE INSTRUCTIONS
AND CLOCKING SHIMS PROVIDED WITH THE CARTRIDGE IN KT-198, OR
KT 489, OR DAMAGE TO THE HARNESS WILL RESULT. REFER TO
FIGURES 707 AND FIGURE 1003, VIEW A)
Remove any grounding wires installed on cartridge pins (replacement supplied in pressure
cartridge kit [Figure 1001, Item 50]) and install cartridge (Figure 1003, View A, Item 10) as
follows:
A. Apply O-Ring lubricant MIL-S-8660, or DC 55, to O-Ring (20) prior to installation.
25-61-00
Page 713
October 10, 2011
TD-03-008
Revision A
B. If the cartridge has a cartridge wiring harness with a 90° connector backshell you shall use
the clocking shims and instructions provided in Kit KT-198 or KT 489, or damage could
result. If a straight connector is used shims are not required; skip to Paragraph C below.
Refer to Figure 707. Install shims (15, 15A) prior to installing packing (20) on cartridge.
Figure 707. Improper Clocking Results and Proper Clocking Installation Instructions Of The
Cartridge / Wiring Harness (For Reference).
C. Install cartridge (10), clocking shims (15, A, B, if required for 45° & 90° cable cut harness
connector), with packing (20).
D. Torque cartridge to 65 – 75 lb-in. (7.34 – 8.47 Nm).
E. Tie wire cartridge hex to cable guide tab in accordance with NASM33540 with
MS20995NC32, or safety cable using AS3510-02 (UNS32100).
F. Install electrical connector to cartridge.
G. Apply power to hoist by pushing in applicable circuit breakers.
20. Storage Instructions
NOTE: WHEN THE RESCUE HOIST IS STORED THE PERIODIC INSPECTIONS LISTED
IN SECTION 501, “CHECKS AND INSPECTIONS” DO NOT HAVE TO BE
PERFORMED. SECTION 501, “CHECKS AND INSPECTIONS” APPLIES WHEN
THE RESCUE HOIST IS INSTALLED ON THE HELICOPTER.
If the Rescue Hoist System, or any part of the system, is removed from the Helicopter for more
than twenty-four (24) hours, it is recommended that the component(s) be prepared for storage
with packaging and preservation as follows:
A. Cap or plug all electrical connectors using suitable plastic caps, or plugs, as required.
25-61-00
Page 714
October 10, 2011
TD-03-008
Revision A
NOTE: LUBRICATING OIL, MIL-PRF-7808, IS IN THE RESCUE HOIST ASSEMBLY
WHEN SHIPPED FROM BREEZE-EASTERN (AS SPECIFIED BY THE
CUSTOMER). IT IS RECOMMENDED TO STORE THE RESCUE HOIST
ASSEMBLY IN THIS SAME CONDITION PRIOR TO INSTALLATION ON THE
HELICOPTER.
B. The component(s) shall be stored in a clean, dry, climate controlled environment where the
relative humidity does not exceed 85 percent, and the temperature does not exceed a low
temperature of 50° F (10° C), and a high temperature of 86° F (30° C).
C. If the component(s) cannot be stored in a controlled climate as stated above, they shall be
packaged with sufficient desiccant in a suitable container that meets the best commercial
practices to withstand normal handling and storage, and to withstand a low temperature of
-40° F (-40° C) and a high temperature of 160° F (71° C).
D. The Rescue Hoist Assembly shall be stored with packaging and preservation so that the
orientation of the four mounting points are underneath, and supporting the weight of the
hoist. All packaging for the hoist shall be identified showing the proper orientation for
storage so that the hoist is on its four mounting points.
E. If the Rescue Hoist Assembly is kept in storage as described above for more than one year,
then a rated load test must be performed per Section 101, Testing and Troubleshooting after
being installed on the helicopter, and before being placed in service. If the storage time
exceeds 10 years, the Rescue Hoist must be returned to Breeze-Eastern, or one of its certified
repair facilities for overhaul.
F. Store the Pressure Cartridge Assembly (Reference: U.N Number UN0276, U.N
Classification Code 1.4C) in approved magazines only. Storage and handling must conform
to appropriate quantity / distance requirements, barricading, grounding and personnel
material limits. Keep the cartridge shunted until installed with protective caps. Avoid high
temperature, store in a cool and dry place.
G. Effective shielding is recommended for personnel when handling these devices. Humidity
control (i.e. higher relative humidity > 60%) reduces or prevents static electricity build-up.
Explosion –proof equipment is required when operating with exposed explosive materials.
21. Shipping Instructions
From Breeze-Eastern Manufacturing Facility:
When Breeze-Eastern ships the Rescue Hoist Assembly (Item 10, Figure 1001) from the
manufacturing facility the cartridge (Item 40) is shipped separately. It is done this way, because
the Pressure Cartridge Kit (Item 40) contains an explosive and must be shipped separately in
accordance with local and government regulatory authority requirements. Once the items are
received by the operator, they can be reassembled.
25-61-00
Page 715
October 10, 2011
TD-03-008
Revision A
To Breeze-Eastern from the Operators / Field
When shipping the Rescue Hoist Assembly back to Breeze-Eastern the Pressure Cartridge / Kit
(Figure 1001, Item 40) shall be removed and properly stored, or disposed of, by the operator in
accordance with your local regulatory authority laws and regulations. If the shipment to Breeze-
Eastern contains an explosive and the packaging does not meet US Department of Transportation
/ International Air Transport Association regulations and standards, Breeze-Eastern is required to
report the situation. Additionally, you will be charged a minimum fee of $500 USD for the
proper disposal of the explosive.
25-61-00
Page 716
October 10, 2011
TD-03-008
Revision A
FITS AND CLEARANCES
1. Table 801 and Figures 801 through 803 show the allowable limits for close tolerance parts and
installation dimensions for the Rescue Hoist System. These limits are to be applied when any
doubt exists concerning the serviceability of a part as a result of visual inspection for wear or
from an improper fit during assembly and installation. When this condition exists the affected
part(s) shall be dimensionally inspected in accordance with Section 501 (Checks and
Inspections). Parts that do not meet the limits, and for which rework is not applicable, are to be
replaced.
2. The values given in the “Dimension Limits” column in Table 801 are the applicable minimum,
or maximum, permitted to ensure proper functioning of the hoist. If parts fail to meet these
requirements, the applicable parts must be replaced, unless rework of the part is applicable. The
dimensional limits should be used as a guide to assemble and install reworked parts.
3. The values shown in Table 801 are applicable to the HS-20200-421 Series Rescue Hoist System.
All dimensions shown in Figures 801 through 803 are in inches, with dimensions in millimeters
in parentheses. See the following figures contained in this section and Figures in Section 1001
for items referenced in Table 801:
A. Figure 801 Rescue Hoist Assembly Illustration
B. Figure 802 Variable Speed Controller Illustration
C. Figure 803 Control Pendant Assembly Illustration
Dimension Limits in Inches

Fig. No. IPL Fig. No. Description of Location for Dimensional (Millimeters)
(in Sec. 801) and Item No. Check
Minimum Maximum
Fig. 1001,
Fig. 801 Diameter of 2 Large Hoist Mounting Holes 0.375 (9.52) 0.377 (9.58)
Item 10
Fig. 1001,
Fig. 801 Diameter of 2 Small Hoist Mounting Holes 0.250 (6.35) 0.252 (6.40)
Item 10
Fig. 1001, Location of Hoist Mounting Holes

Fig. 801 6.092 (154.74) 6.094 (154.79)
Item 10 Horizontally
Fig. 1001,
Fig. 801 Location of Hoist Mounting Holes Vertically 1.654 (42.01) 1.657 (42.09)
Item 10
Fig. 1001,
Fig. 801 Gap in End Flanges at Hoist Mounting Holes 0.482 (12.24) 0.488 (12.40)
Item 10
Fig. 1003, Diameter of Tension Roller (greater than

- 0.801 (20.34) -
Item 480 minimum is acceptable)
Table 801. Allowable Limit Values
25-61-00
Page 801
October 10, 2011
TD-03-008
Revision A
Dimension Limits in Inches
Fig. No. IPL Fig. No. Description of Location for Dimensional (Millimeters)
(in Sec. 801) and Item No. Check
Minimum Maximum
Fig. 1003,
- Tension Roller Endplay 0.002 (0.051) 0.010 (0.254)
Item 480
Fig. 1003, Overrunning Clutch / Tension Roller Clutch

- Items 490, Clearance (greater than minimum is 0.030 (0.76) -
and 560 acceptable)
Fig. 1002, Height of Bumper Assembly at full in

- 1.00 (25.4) 1.39 (35.3)
Item 10 position
Fig. 1003, Gap from Cable Foul Assembly to top layer

- 0.040 (1.02) 0.080 (2.03)
Item 1030 of cable
Fig. 1003,
- Level Wind Shaft groove dimension - 0.160 (4.06)
Item 1140
Fig. 1003,
- View A, Level Wind Follower dimension 0.148 (3.76) -
Item 240
Fig. 1001, Location of Variable Speed Controller

Fig. 802 7.73 (196.3) 7.77 (197.4)
Item 20 Mounting Holes Horizontally
Fig. 1001, Location of Variable Speed Controller

Fig. 802 6.73 (170.9) 6.77 (172.0)
Item 20 Mounting Holes Vertically
Fig. 1001,
Fig. 803 Items 30 Diameter of Pendant Mounting Hole 0.36 (9.14) 0.40 (10.16)
and 40
Table 801. Allowable Limit Values (continued)
25-61-00
Page 802
October 10, 2011
TD-03-008 TD-03-008
Revision A Revision A
Figure 801. Rescue Hoist Assembly Illustration.

Dimensions shown in inches (with millimeters in parentheses)
25-61-00
Page 803 / 804 Blank
October 10, 2011
TD-03-008
Revision A
NOTES:
1. INPUT POWER: MAXIMUM POWER
SHALL NOT EXCEED 160 AMPS
CONTINUOUS AND 170 AMPS FOR ONE
SECOND MAX. WITH 28 VDC APPLIED.
2. OUTPUT POWER: VARIABLE 0 - 27.5V AT
155 AMPS TO MOTOR SERIES FIELD AND
ARMATURE CIRCUITS. FIXED 28VDC AT
5 AMPS TO MOTOR SHUNT FIELD AND
SHUNT BRAKE CIRCUITS.
3. FEATRUES: A) PILOT & CREW
OPERATION, WITH PILOT HAVING
PRIORITY OVER CREW OPERATION, B)
CURRENT LIMITING ON OVERLAOD, C)
SLOWDOWN CONTROL WHEN
APPROACHING EXTREMES OF CABLE
TRAVEL.
4. WEIGHT: APPROX 14.5 LBS (6.6 KG.)
Figure 802. Variable Speed Controller Illustration

25-61-00
Page 805
October 10, 2011
TD-03-008
Revision A
Figure 803. Control Pendant Assembly Illustration

(CP-1500-5 Installation is shown; CP-1500-7 Installation is identical)
25-61-00
Page 806
October 10, 2011
TD-03-008
Revision A
SPECIAL TOOLS, FIXTURES, AND TEST EQUIPMENT

Note: Equivalent substitutes may be used for listed items.
Tool /
Testing and
Equipment Nomenclature Use and Application Disassembly Repair Assembly
Troubleshooting
Number
Screw (Level Wind)
Cable Alignment - - -
BLT-10300-E Shaft Locking
Adjustment X
Wrench
Roller Pin Removal Removal and
and Installation installation of pin into
BLT-10300-J Tool (0.094 in. roller gear and pin in
- X - X
[2.39 mm] diameter hook assembly
punch) housing / body.
Installation of
Retaining (E-Ring)
retaining ring to
Ring Installation
BLT-10300-V secure cable guide pin
Tool (see Figure - - - X
that actuates Full In
901)
Limit Switch
Clevis Mount Maintenance Fixture
TE-132-1 Maintenance Fixture for Clevis Mount - X X X
(see Figure 903) Rescue Hoists
Calibrated Weights
Rescue Hoist 250 lb.
(capable of
(113 kg) and 600 lb.
TE-120-1 additional weight X - - -
(272 kg) Rated Load
increments, see
Tests
Figure 902)
Rescue Hoist 250 lb.
Cart (for carrying
(113 kg) and 600 lb.
TE-120-3 weights, see Figure X - - -
(272 kg) Rated Load
902)
Tests
Remove Follower
MS16995-25 8-32 x 0.375 Screw (610) from Cable - X - -
Guide Assy.
Table 901. Special Tools, Fixtures, and Test Equipment List / Matrix
Figure 901. Retaining Ring Installation Tool
25-61-00
Page 901
October 10, 2011
TD-03-008
Revision A
Figure 902. TE-120-1, Weights with TE-120-3 Cart
Figure 903. TE-132-1, Clevis Mount Maintenance Fixture

(Allows Rescue Hoist to Rotate 360 Degrees – Adjustable – Incorporates Oil Change Tray)
Note: For information on the acquisition of special tools and test equipment contact:
35 Melanie Lane
Phone Number: 973-602-1001, Ext.1083 or 1090, or 1-800-929-1919 (US and Canada only)
Fax Number: 973-739-9344
25-61-00
Page 902
October 10, 2011
TD-03-008
Revision A
ILLUSTRATED PARTS LIST
1. Introduction
A. Purpose
This section provides illustrations and parts breakdown of all parts of the assemblies shown
that can be disassembled, repaired, or replaced and reassembled.
B. Explanation and Usage of Section
(1) Assembly Order Indenture System
This indenture system used in the parts list shows the relationship of one part to another.
For a given item, the number of indentures depicts the relationship of the item to the
associated next higher assembly as follows:
1 2 3 4
Assembly
• Detail Parts for Assembly
• • Subassembly
• • • Detail Parts for Subassembly
(2) Part Numbering System
The part numbering system consists of each part number identifier by which a part may
be ordered or procured.
(3) Effectivity Code
Reference letters (A through Z except I and O) are assigned to the EFF. CODE column to
each top assembly in each IPL figure. The reference letter is also shown in EFF. CODE
column for each part used on the corresponding top assembly, or left blank, if used on all
top assemblies.
(4) Parts Replacement Data
The interchangeability between parts is identified in the NOMENCLATURE column of
the parts list. A list of terms used to show interchangeability and their definition is as
follows:
Term Abbreviation Definition
Optional OPT This part is optional to, and interchangeable with, other parts
in the same number variant group or other item number as
designated.
Alternate ALT Alternate designates a definitive sequence of parts. The part is
optional to, and interchangeable with, other parts in the same
number variant group or other item number as designated.
Preferred PREF When an alternate part is listed, the preferred part will be
identified in the same item number variant group, or other
item number, as designated.
(5) Items Not Illustrated
Items not illustrated are indicated by a dash (-) ahead of the item number in the FIG. &
ITEM NO. Column.
25-61-00
Page 1001
October 10, 2011
TD-03-008
Revision A
(6) Units per Assembly
The UNITS PER ASSY. column shows the quantity required per assembly, per
subassembly, and per sub-subassembly, as applicable. For bulk items, the letters AR
indicate, “As Required.” The letters RF indicate the item is listed for reference purposes.
(7) Alpha Variant Item Numbers
(a) Alpha variants (A through Z except I and O) are assigned to existing item numbers
when necessary to show:
1) Added items.
2) Service bulletin modifications.
3) Configuration differences.
4) Optional or alternate parts.
5) Product improvement parts (non-service bulletin).
(b) Alpha variant item numbers are not shown on the exploded views when the
appearance and location of these items are the same as the basic items.
C. Vendors
V70133 Aerial Machine and Tool Corporation
4298 Jeb Stuart Highway, P.O. Box 222, Vesta. VA 24177-0222
Phone No.: (276) 952-2006 Fax No. (276) 952-2231
Website: www.aerialmachineandtool.com
E-mail: [email protected]
2. Notes:
A. Terminal Clamp (Figure 1002, Item 100) consists of a two-piece, matched set clamp
machined as an assembly and secured by a ring (Figure 1002, Item 110). Each half of the
clamp cannot be purchased separately and must be purchased together. The ring must be
replaced if the clamp is in need of replacement, which can be ordered separately.
STANDARDS AND REGULATORY PRACTICES.
NOTE: WHEN SHIPPING THE RESCUE HOIST ASSEMLBY TO BREEZE-EASTERN
THE PRESSURE CARTRIDGE / KIT (FIGURE 1001, ITEM 90) SHALL BE
REMOVED AND PROPERLY STORED, OR DISPOSED OF, BY THE
OPERATOR IN ACCORDANCE WITH YOUR LOCAL REGULATORY
AUTHORITY LAWS AND REGULATIONS. IF THE SHIPMENT TO
BREEZE-EASTERN CONTAINS AN EXPLOSIVE AND THE PACKAGING
DOES NOT MEET US DEPARTMENT OF TRANSPORTATION /
INTERNATIONAL AIR TRANSPORT ASSOCIATION REGULATIONS AND
STANDARDS, BREEZE-EASTERN IS REQUIRED TO REPORT THE
25-61-00
Page 1002
October 10, 2011
TD-03-008
Revision A
SITUATION. ADDITIONALLY, YOU WILL BE CHARGED A MINIMUM FEE
OF $500 USD FOR THE PROPER DISPOSAL OF THE EXPLOSIVE.
B. Pressure Cartridge Kit (Figure 1001, Item 50) consists of the pressure cartridge (Figure 1003,
View A, Item 10), contained in hermetically sealed container, and packing (20). The
cartridge only can be purchased as part of the kit due to the longer shelf life it has in the
container. The packing must be replaced when a new cartridge is installed. However, if
packing needs to be replaced due to damage, or wear, it can be ordered separately.
C. Refire Kit PN KT-489 includes the Anvil, (Item 130, IPL Figure 1003, Detail A), cable cutter
(150), O-Ring (160), and cotter pin (140), which must be replaced whenever the cable cutter
has been actuated. Also, shims are included for 45° and 90° angle cable cutter harness
connector positioning when applicable.
D. Cable guide pressure roller (Figure 1003, View A, Items 280 and 310) and guide rollers are
generally replaced as an assembly due to the difficulty replacing staked bearings (290 and
310), but piece parts can be replaced if necessary
25-61-00
Page 1003
October 10, 2011
TD-03-008
Revision A
10
30 40
20
60
50
70
Figure 1001. Rescue Hoist System
25-61-00
Page 1004
October 10, 2011
TD-03-008
Revision A
NUMERICAL PARTS LIST INDEX

FIG. AND NOMENCLATURE USABLE UNITS PER
ITEM NO. PART NUMBER 1234 ON CODE ASSY.
1001-
-1 HS-20200-421-01 HOIST SYSTEM, RESCUE A RF
-2 HS-20200-421-02 HOIST SYSTEM, RESCUE B RF
10 BL-20200-421 • Hoist Assembly, Rescue 1
20 EC-19000-23 • Variable Speed Controller 1
30 CP-1500-5 • Control Pendant Assembly A 1
40 CP-1500-7 • Control Pendant Assembly B 1
50 KT-198* • Kit, Pressure Cartridge 1
60 HK-121-5 • Hook Assembly 1
70 EC-14170-1 • Control Pendant Cable Assembly 1
* KT-198 - Pressure Cartridge Kit includes the container, cartridge, O-Ring, tags, tab, tie wire, and
includes shims for 90° cable cutter harness connector positioning (if applicable), and includes the
O-Ring PN MS28778-5. Shims are not required for straight connectors.
KT-489 - Refire Kit is used if cable cutter / cartridge is activated / fired. It includes Pressure
Cartridge Kit KT-198, anvil, cable cutter, shims for 90° angle cable cutter harness connector
positioning (if applicable), O-ring, cotter pin, tie wire, etc. See Note 2.C.
25-61-00
Page 1005
October 10, 2011
TD-03-008
Revision A
Figure 1002. Hook Assembly
25-61-00
Page 1006
October 10, 2011
TD-03-008
Revision A
FIG. AND NOMENCLATURE USABLE UNITS
ITEM NO. PART NUMBER 1234 ON CODE PER ASSY.
1002-
1 HK-121-5 SWIVEL HOOK ASSEMBLY RF
10 BL-7720-4* • Bumper Assembly (Replaces 1
BL-7720)
20 BL-7676 • • Retainer, Bumper 1
30 BL-7675-1 • • Spring, Compression 1
40 BL-7674-2 • • Bumper, Over Travel 1
50 HK-121-1 • Hook Assembly 1
60 BL-11685-1 • • Nut 1
70 MS24665-88 • • Pin, Cotter 2
80 BL-9920 • • Screw, Locking 2
90 BL-11686-1 • • Housing, Hook 1
100 BL-11682-1 • • Clamp, Terminal 1
(See Note A, pg. 1002)
110 BL-4718 • • • Ring (See Note A, pg. 1002) 1
120 BL-14827-1 • • Spacer, Nut 1
130 BL-13677-1 • • Handwheel Assembly 1
140 AJ-9800-23-46 • • • Bearing, Ball 1
150 BL-13676-1 • • • Handwheel 1
160 BL-14792-2 • • Pin, Spring 1
170 BL-8089 • • Nut, Castellated 1
180 BL-11684-2 • • Washer, Thrust 1
190 AJ-9800-95-8 • • Bearing, Ball 1
200 AN960C816 • • Washer, Flat 1
210 BL-15704-2 • • Hook, Slide Lock 1
- Item not Illustrated
* BL-7720-4 replaces and is interchangeable with BL-7720 Bumper Assembly.
25-61-00
Page 1007
October 10, 2011
TD-03-008
Revision A

Figure 1003. Rescue Hoist Assembly

25-61-00
Page 1008 / 1009 Blank
October 10, 2011
TD-03-008
Revision A
1003-
-1 BL-20200-421 RESCUE HOIST ASSEMBLY RF
10 KT-198 • Cartridge Kit 1
(See Applicable Notes B& C)
15 BL-2095-R481 • • Shim (.010 in. thick [.254 mm]) 2
15A BL-2095-R482 • • Shim (.031 in. thick [.787 mm]) 1
20 MS28778-5 • • Packing, Preformed 1
30 MS51957-44 • Screw 4
40 MS35265-44 • Screw 2
50 AL-1256-C62 • Washer, Flat 6
60 MS21919WDG3 • Clamp 1
70 MS21919WCH3 • Clamp 1
80 BL-12930-1 • Cover, Limit Switch 1
90 BL-4648-2 • Gasket, Limit Switch Cover 1
100 BL-6260 • Cable Assembly 1
110 MS24547-1 • Switch, S1, S2, and S3 (2 each) 6
120 AN565DC4H3 • Setscrew, Cable Attach 2
130 BL-6329 • Cap, Anvil (See Note C) 1
140 MS9245-10 • Cotter Pin 1
150 BL-6331 • Cutter, Cable 1
160 MS28775-112 • O-Ring 1
170 MS24665-86 • Pin, Cotter 1
180 BL-6909-1 • Stop, Cable Guide 1
190 MS21083C3 • Nut, Self Locking 1
200 BL-6910 • Guide, Cable 1
210 BL-3948 • Spacer, Back Up 1
220 Y-1176-1-68S • Ring, Retaining 1
230 Y-1047-1-6 • Washer, Spring 1
240 BL-3953 • Follower 1
250 BL-6753 • Shaft, Roller 4
260 BL-6757 • Support 1
270 BL-6752 • Spacer 6
280 BL-6759 • Roller Assembly 1
290 AJ-9800-31-3 • • Bearing, Ball 2
25-61-00
Page 1010
October 10, 2011
TD-03-008
Revision A
NUMERICAL PARTS LIST INDEX (continued)

1003-
300 BL-6758 • • Roller 1
310 BL-6760 • Roller Assembly 2
320 AJ-9800-31-3 • • Bearing, Ball 2
330 BL-6761 • • Roller 1
340 BL-15977-1 • Plate, Spacer 1
350 MS16995-36 • Screw, Cap 2
360 BL-3950-2 • Bar, Guide 1
370 BL-6742 • Plunger, Cable Pressure Roller 1
380 BL-6741 • Spring, Compression 1
390 BL-15989-1 • Guard, Gear 1
400 MS16995-25 • Screw, Cap 1
410 MS51958-63 • Screw, Pan Head 3
420 AN960C8L • Washer 1
440 MS171496 • Pin, Spring 1
450 BL-10699 • Shaft, Inner Roller 1
460 BL-2095-R225 • Shim (0.002 in. [0.051 mm.] thickness) AR
460A BL-2095-R226 • Shim (0.003 in. [0.076 mm.] thickness) AR
460B BL-2095-R227 • Shim (0.005 in. [0.127 mm.] thickness) AR
460C BL-2095-R228 • Shim (0.010 in. [0.254 mm.] thickness) AR
470 Y-1076-5-2 • Thrust Washer 2
480 BL-16203-1 • Shaft Assembly, Tension Roller 1
490 BL-10695 • Clutch Assembly, Tension Roller 1
500 MS16995-28 • Screw 1
510 MS16995-26 • Screw 1
530 BL-15987-1 • Guard, Clutch 1
540 NAS1224C16L • Bolt 1
550 BL-8033 • Spacer 1
560 BL-6825 • Clutch Assembly, Overrunning 1
580 AN960C8 • Washer 3
25-61-00
Page 1011
October 10, 2011
TD-03-008
Revision A

1003-
590 BL-12918-4 • Cyclocentric Assembly 1
600 BL-9146 • Cam Follower Assembly 1
610 MS21083C4 • Nut, Self-Locking 1
620 Y-1021-4-1512 • Chain 1
630 BL-4626 • Pinion Sprocket 1
640 BL-6235 • Sprocket 1
650 MS16996-24 • Screw, Cap 2
660 AN960C416 • Washer 2
670 BL-15986-1 • Clamp, Motor Strap 1
680 BL-15982-1 • Strap, Motor 1
690 BL-15979-1 • Support, Motor 1
700 BL-15980-1 • Shim (0.002 in. [0.051 mm.] thickness) AR
700A BL-15980-2 • Shim (0.005 in. [0.127 mm.] thickness) AR
700B BL-15980-3 • Shim (0.010 in. [0.254 mm.] thickness) AR
700C BL-15980-4 • Shim (0.025 in. [0.635 mm.] thickness) AR
710 MS16996-12 • Screw, Cap 4
720 AN960C10 • Washer, Flat 4
730 BL-16027-1 • Pad, Motor 1
740 MS16996-33 • Screw, Cap 4
760 Y-1242-41-5 • Motor Assembly 1
770 M83248/1-032 • O-Ring 1
780 BL-15312-1 • Plate, Identification 1
790 BL-13686-1 • Label, Cycle Counter 1
800 BL-2294 • Label 1
820 BL-12915-1 • Bracket, Potentiometer 1
830 BL-12927-1 • Bracket, Mounting, Switch (S1) 1
840 BL-12914-1 • Bracket, Mounting, Switch (S2) 1
870 Y-1184-7-1 • Actuator, Roller Leaf 4
880 MS51959-8 • Screw, Flat Countersink Head 2
25-61-00
Page 1012
October 10, 2011
TD-03-008
Revision A
1003-
910 WA-138-33 • Nut, Self-Locking 4
920 BL-6911 • Cover 1
930 BL-6912 • Gasket, Cover 1
950 MS15795-803 • Washer 3
960 BL-6074 • Actuator, Roller Leaf 1
980 MS35333-69 • Washer, Tooth Lock 2
990 AL-1256-C85 • Washer 2
1000 MS16633-4018 • Ring, Retaining 1
1010 BL-6914 • Pin, Cable Guide 1
1012 BL-15976-1 • Retainer, Ring 1
1020 Y-1182-55-1 • Spring, Compression 1
1030 BL-16016-1 • Cable Foul Assembly 1
1060 AN960C6L • Washer, Flat 4
1070 AN960C8L • Washer, Flat 1
1080 MS21919WCH3 • Clamp 3
1090 MS25281-F3 • Clamp, Loop 1
1100 Y-1382-2-1 • Switch, Limit (S1 - S6) 6
1110 MS21042-02 • Nut, Self-Locking 4
1120 Y-1391-4-1 • Screw, Cap, Socket Head 4
1130 AL-1256-C85 • Washer 1
1140 BL-3880 • Shaft, Screw, Levelwind 1
1150 AN107506 • Bolt 2
1160 Y-1125-1-7 • Washer, Seal 2
1170 MS51957-18 • Screw 2
1180 BL-12912-1 • Cam, Full Out Limit Switch 1
1190 MS51957-15 • Screw 3
1200 BL-15328-1 • Cam, Intermediate Limit Switch 1
1210 MS51957-13 • Screw 3
1212 Y-1249-1-1 • Cleat, Potentiometer Mount 3
25-61-00
Page 1013
October 10, 2011
TD-03-008
Revision A
1003-
1220 BL-12668-2 • Potentiometer Assembly 1
1222 BL-12613-1 • • Potentiometer (R1) 1
1224 M83248/1-003 • • O-Rings 2
1230 RJR26FW103P • • Potentiometer, Trim (R3) 1
1240 MS3471W10-6P • Connector, Electrical/Harness 1
1250 MS3476W10-6S • Connector, Electrical/Harness 1
- Item not Illustrated
25-61-00
Page 1014
October 10, 2011
TECHNICAL PUBLICATION DEFICIENCY REPORT
Page 1 of 1
B-E Tracking Number:
Customer: Date:
Type: O&M Type: CMM Manual Type:
Manual: Type:
Manual: Revision: O&M
Number: Number: CMM
Number: Number:
Section: Page: Section:
Figure: Table: Figure:
Discrepancy (Provide as much detail as possible):
Initiator: Title:
Submit to: B-E Customer Services.
via email [email protected] or FAX (973)-739-9344
Breeze Eastern Use Only

Engineering Services Disposition:
Engineering Services: Date:

Customer Services: Date:
35 Melanie Lane
Phone: Local calls use 973-602-1001, Ext. 1083 or 1090.
In the USA (except New Jersey) and Canada call toll free 1-800-929-1919.
Fax: 973-739-9344
Web Site: www.breeze-eastern.com
QC1334

Aw139 Hoist Td-03-008 Rev A

Uploaded by

Copyright:

Available Formats

Aw139 Hoist Td-03-008 Rev A

Uploaded by

Document Information

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

Aw139 Hoist Td-03-008 Rev A

Uploaded by

Copyright:

Available Formats

TD-03-008

TO: HOLDERS OF BREEZE-EASTERN FLIGHT LINE OPERATION

THIS IS TO INFORM YOU OF THE RELEASE OF

PARAGRAPH DESCRIPTION OF CHANGE

All General Manual Revision and Logo Change.

NOTE: BREEZE-EASTERN CORPORATION HAS MOVED ITS CORPORATE AND

REVISION REVISION DATE DATE REVISION REVISION DATE DATE

REV. ISSUE DATE REMOVAL INCORPORATOR’S REMOVER’S

DOCUMENT TYPE SUBJECT REVISION OPERATOR BREEZE-EASTERN

Technical Publication Deficiency Report

LIST OF TABLES (continued)

701 Materials Required for Assembly ............................................................................ 701

505 Example of Broken Strands in Wire Rope Cable .................................................... 509

The manual is divided into separate sections:

Figure 1. HS-20200-421 Series Rescue Hoist System.

Figure 2. Limit Switch Actuation Positions

Figure 3. Approximate Dimensions of Orange Stain on Wire Rope Cable

FLIGHT LINE OPERATION AND MAINTENANCE MANUAL

FLIGHT LINE OPERATION AND MAINTENANCE MANUAL

FLIGHT LINE OPERATION AND MAINTENANCE MANUAL

FLIGHT LINE OPERATION AND MAINTENANCE MANUAL

Figure 102. Limit Switch Actuation Positions

FLIGHT LINE OPERATION AND MAINTENANCE MANUAL

FLIGHT LINE OPERATION AND MAINTENANCE MANUAL

FLIGHT LINE OPERATION AND MAINTENANCE MANUAL

Spring (1020) for Pin (1010)

Ring Retainer (1012) and Retaining Ring

Pin (1010) for Actuating Full In Limit Switch

FLIGHT LINE OPERATION AND MAINTENANCE MANUAL

FLIGHT LINE OPERATION AND MAINTENANCE MANUAL

FLIGHT LINE OPERATION AND MAINTENANCE MANUAL

Adjust Cap Screws

0.060 ± 0.020 in.

Figure 104. Cable Foul Assembly Inspection and Adjustment

FLIGHT LINE OPERATION AND MAINTENANCE MANUAL

CAUTION: DURING OPERATION OF THE RESCUE HOIST, DO NOT TOUCH THE

FLIGHT LINE OPERATION AND MAINTENANCE MANUAL

FLIGHT LINE OPERATION AND MAINTENANCE MANUAL

1.00 to 1.39 in.

Figure 105. Deflection of Bumper Assembly with Hook at Full In Position

FLIGHT LINE OPERATION AND MAINTENANCE MANUAL

Table 102. Troubleshooting Procedures

FLIGHT LINE OPERATION AND MAINTENANCE MANUAL

Trouble Probable Cause Remedy

Table 102. Troubleshooting Procedures (continued)

FLIGHT LINE OPERATION AND MAINTENANCE MANUAL

Table 102. Troubleshooting Procedures (continued)

FLIGHT LINE OPERATION AND MAINTENANCE MANUAL

Table 102. Troubleshooting Procedures (continued)

FLIGHT LINE OPERATION AND MAINTENANCE MANUAL

THIS PAGE INTENTIONALLY LEFT BLANK

SCHEMATICS AND WIRING DIAGRAMS

2. Contents of this Section

Figure # Description Page

Figure 202. BL-20200-421 Rescue Hoist Assembly Wiring Diagram

Figure 203. HS-20200-421-01 Rescue Hoist System Wiring Diagram

Figure 204. HS-20200-421-02 Rescue Hoist System Wiring Diagram

Figure 205. EC-14170-1 Control Pendant Cable Assembly Wiring Diagram

Figure 206. BL-16016-1 Cable Foul Sensor Wiring Diagram

Cable Cutter Cartridge