HS-29700 Series Rescue Hoist Systems PDF

TD-01-002
Rev. H
FLIGHT LINE OPERATION AND MAINTENANCE MANUAL
HS-29700 SERIES RESCUE HOIST SYSTEM
TO: HOLDERS OF BREEZE-EASTERN FLIGHT LINE OPERATION AND MAINTENANCE
MANUAL FOR HS-29700 SERIES RESCUE HOIST SYSTEMS, TD-01-002
REVISION H OF TD-01-002, DATED SEPTEMBER 19, 2008 IS RELEASED.
HIGHLIGHTS
Revision H, dated September 19, 2008, replaces Revision G, dated March 3, 2008 in its entirety. Please
replace Revision G with the new manual provided. Indicate on the Record of Revisions the date of this
action, as well as the initials of the individual performing this task.
SECTION, PAGE DESCRIPTION OF CHANGE
All Added standard format into manual, which include, but are not limited to the following:
All applicable sections, page dates change to September 19, 2008.
Reviewed all possible TPDR’s, ASB’s, SB’s, SIL’s and change orders for possible
applicability.
Revised List of Effective Pages and Table Of Contents to reflect changes as required.
Description and Operation Section - Added HS-29700-217 Rescue Hoist System
Configuration to the manual. Added the -217 Configuration to, Table 1, “System
Configuration Matrix,” Page 2.
Section 201, Added the HS-29700-217 reference to Paragraph 1 “General” statement.
Added Figure 209 Wiring Diagram for HS-29700-217, Rescue Hoist System and added
pages 209 and 210 (Blank).
Section 501, revised beginning paragraph to emphasize that Checks and Inspection are
applicable when the Rescue Hoist is installed on the helicopter e.g. not while being
stored, transported, processed, etc.
Table 501, Page 502, revised last row recommended inspection frequency to 6 months /
400 flight hours / 100 hoist cycles. Same Table 501, Page 502 second to last row changed
200 hoist cycles to 100 hoist cycles for levelwind and cable guide shaft to be consistent
with 100 hoist cycle standard.
Section 1001, Page 1005, Added reference to the HS-29700-217 Rescue Hoist System
Configuration (Added -18, Effectivity Code U) to the Illustrated Parts List.
HIGHLIGHTS
Page H-1
September 19, 2008
TD-01-002
Rev. H
FLIGHT LINE
OPERATION AND MAINTENANCE MANUAL
With
Illustrated Parts List
HS-29700 Series Rescue Hoist Systems
SAFETY WARNING
For your own safety and the safety of all others, read and understand all of the procedures and information in this operation and maintenance manual
before installing, operating, and / or maintaining any components of the rescue hoist systems covered herein.
EXPORT CONTROLLED – WARNING

This document 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.
NOTICE
This manual contains BREEZE-EASTERN CORPORATION, proprietary data that shall not be duplicated, used, or disclosed - in whole or in part - for
any purpose other than to evaluate this submittal by the recipient and is subject to return upon request. The recipient shall have the right to duplicate,
use or disclose the data to the extent provided in the contract. This restriction does not limit the recipient’s right to use information contained in this
data if it is properly obtained from another source without restriction.
25-61-00
Page T-1
September 19, 2008
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.
DATE DATE
REVISION REVISION DATE FILLED BY REVISION REVISION DATE FILLED BY
Original June 21, 2001 - -
A February 28, 2002 - -
B July 14, 2003 - -
C December 12, 2003 - -
D October 15, 2004 - -
E July 20, 2007 - -
F November 30, 2007 - -
G March 3, 2008 - -
H September 19, 2008
25-61-00
Page RR-1
September 19, 2008
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
September 19, 2008
SERVICE BULLETIN LIST
Retain this record in the front of the manual. On receipt 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., 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, letter, report,
change order is incorporated into this manual via a revision, Breeze-Eastern will enter the date
terminated and the above attachments on the back of the manuals will no longer be required.
SERVICE SUBJECT REVISION AND INCORPORATION

BULLETIN DATE DATE
NUMBER
CAB-100-57 One Time Inspection Procedure of the BL- A, July 14, 2003
29700 Rescue Hoists Operation to Return February 4, 1998
the Hoists to Active Service, Following the
Suspension Defined by Bollettino Tecnico
109K19 Issued by Agusta
SIL01 BL-4708 Awareness pertaining to the Hook Assembly Original, July 14, 2003
Clamp, Terminal (Bushing) Part Number September 27, 2000
BL-4708 Installation
SIL03 Maintenance Cable foul operator / installer information Original, July 14, 2003
by visual warning light illumination. August 12, 2002
SB BL-4712-1-25-1 Awareness of potential Needle Thrust Original, July 14, 2003
Bearing and Thrust Race corrosion in Hook August 19, 2002
Assemblies after the Hook Assembly is
immersed in water, or during operations in
high humidity environments. The potential
for corrosion can be alleviated through
proper maintenance techniques stated in the
appropriate Operation and Maintenance
Manual, or equivalent.
SB BL-4712-3-25-1 Awareness of potential Needle Thrust Original, July 14, 2003
Bearing and Thrust Race corrosion in Hook August 19, 2002
Assemblies after the Hook Assembly is
immersed in water, or during operations in
high humidity environments. The potential
for corrosion can be alleviated through
proper maintenance techniques stated in the
appropriate Operation and Maintenance
Manual, or equivalent.
25-61-00
Page SBL-1
September 19, 2008
SERVICE SUBJECT REVISION AND INCORPORATION

BULLETIN DATE DATE
NUMBER
ASB BL-29700-A25- Rescue Hoist Assembly, Part Number BL- A, July 14, 2003
01 29700-Series, concerning three requirements: June 27, 2003
1) The replacement of the existing cotter pin
retention method in the drag clutch, with a
spring pin safety wired to a modified
adjusting nut.
2) An inspection of the cable tensioner drag
clutch setting.
3) If the first two requirements were completed
in accordance with the original release of
this Alert Service Bulletin a one-time
inspection to ensure correct assembly
sequence of a flat washer and spring washer,
which was shown incorrectly in Figure 1 (of
the original release), but shown correctly in
Figure 2. After completion of the one-time
inspection, the second requirement, “cable
tensioner drag clutch setting inspection”
shall be repeated.
TPDR 071504002 In Table 1, change applicability from BL- December 12, October 15, 2004
29700-21 to BL-29700-23 for HS-29700- 2003
204. In Parts List for Figure 1001, change
EFF. CODE for Item 21 from DE to D and
for Item 23 from B to BE
SB BL-5448-25-01 Hook Assembly Nut Inspection Requirement Original, July 20, 2007
and August 31, 2005
SB BL-5448-1-25-01
SIL01 Maintenance Rescue Hoist and Cargo Winch Maintenance B, July 14, 2003
Concept (Note: No affect on hoist TBO, refer October 03, 2006
to Section 501)
SIL05 Maintenance Clarification on proper cleaning techniques Original, July 20, 2007
for Pilot and Crew Control Panels, Electronic May 15, 2007
Controllers, Pendants, etc.
SB Wire Rope Cables Changes Mandatory Replacement to Original, July 20, 2007
Recommended Replacement of Wire Rope June 2, 2006
Cable at 1,500 cycles
25-61-00
Page SBL-2
September 19, 2008
LIST OF EFFECTIVE PAGES

*Indicates pages revised, added or deleted in latest revision
Description Page Date
Highlights Page H-1 September 19, 2008
25-61-00, Title Page T-1 September 19, 2008
Record of Revisions RR-1 September 19, 2008
Record of Temporary Revisions RTR-1 September 19, 2008
Service Bulletin List SBL-1 September 19, 2008
SBL-2 September 19, 2008
List of Effective Pages LEP-1 September 19, 2008
LEP-2 September 19, 2008
Table of Contents T/C-1 September 19, 2008
T/C-2 September 19, 2008
Introduction INTRO-1 September 19, 2008
INTRO-2 September 19, 2008
Description and Operation 1 September 19, 2008
2 September 19, 2008
Testing and Troubleshooting 101 September 19, 2008
25-61-00
Page LEP-1
September 19, 2008

Testing and Troubleshooting (continued) 109 September 19, 2008
Schematics and Wiring Diagrams 201 September 19, 2008
210 Blank
Disassembly 301 September 19, 2008
Cleaning 401 September 19, 2008
406 Blank
Checks and Inspections 501 September 19, 2008
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Page LEP-2
September 19, 2008

Checks and Inspections (continued.) 506 September 19, 2008
526 Blank
Repair 601 September 19, 2008
608 Blank
Assembly 701 September 19, 2008
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Page LEP-3
September 19, 2008

Assembly (Continued) 716 September 19, 2008
Fits and Clearances 801 September 19, 2008
808 Blank
Special Tools, Fixtures, and Test Equipment 901 September 19, 2008
Illustrated Parts List 1001 September 19, 2008
1002 September 19, 2008
1003 September 19, 2008
1004 September 19, 2008
1005 September 19, 2008
1006 September 19, 2008
1007 September 19, 2008
1008 September 19, 2008
1009 September 19, 2008
1010 September 19, 2008
1011 September 19, 2008
1012 September 19, 2008
1013 September 19, 2008
1014 September 19, 2008
1015 September 19, 2008
1016 September 19, 2008
1017 September 19, 2008
1018 September 19, 2008
1019 September 19, 2008
1020 September 19, 2008
Technical Publication Discrepancy Report September 19, 2008
25-61-00
Page LEP-4
September 19, 2008
TABLE OF CONTENTS
Section / Paragraph Title Page
Highlights Highlights .................................................................................... H-1
Title Page 25-61-00, Title Page .....................................................................T-1
Record of Revisions Record of Revisions ..................................................................RR-1
Record of Temporary Revisions Record of Temporary Revisions ............................................. RTR-1
Service Bulletin List Service Bulletin List ................................................................SBL-1
List of Effective Pages List of Effective Pages ............................................................ LEP-1
Table of Contents Table of Contents ..................................................................... T/C-1
Introduction Introduction
Paragraph 1 General ............................................................................... INTRO-1
Paragraph 2 Proprietary Status and Liability .......................................... INTRO-1
Paragraph 3 Verification ......................................................................... INTRO-2
Section 1 Description and Operation
Paragraphs 1A through 1C Description .......................................................................................1
Paragraph 1D Rescue Hoist System ........................................................................2
Paragraph 1E Rescue Hoist Assembly ....................................................................3
Paragraph 1F Wire Rope Cable ..............................................................................4
Paragraph 1G Hook Assemblies ..............................................................................4
Paragraph 1H Tension Roller ..................................................................................4
Paragraph 1I Cycle Counter ...................................................................................4
Paragraph 1J Cable Foul Indicator .........................................................................4
Paragraph 1K Cable Cutter ......................................................................................5
Paragraph 1L Limit Switches ..................................................................................6
Paragraph 1M Pilot Control and Pendant Control ...................................................7
Paragraph 1N Variable Speed Controller ................................................................8
Paragraph 1O Leading Particulars for Rescue Hoist System ..................................8
Paragraph 2 Normal Operation .............................................................................9
Paragraph 3 Emergency In Flight Procedures for Hoist Operation ....................12
Paragraph 4 Flight Line / Ground Handling Hoist Operation Guidelines...........13
Section 101 Testing and Troubleshooting
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 and Adjustment ...............................................102
Paragraph 4B Adjustment of Payout Display .....................................................104
Paragraph 4C Cable Foul Indicator Test .............................................................105
Paragraph 4D Rescue Hoist Assembly Electrical Continuity Check ..................105
Paragraph 4E Control Pendant Electrical Continuity Check (CP-400-1, -2).......106
Paragraph 4F Control Pendant Electrical Continuity Check (CP-1600-1) ..........107
Paragraph 4G Control Pendant Cable Test...........................................................107
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Page T/C-1
September 19, 2008

Section 101 Testing and Troubleshooting (continued)
Paragraph 4H Variable Speed Controller Electrical Continuity Check ...............108
Paragraph 4I Hook Load Test .............................................................................108
Paragraph 4J Hoist Cycle Counter ......................................................................109
Paragraph 4K Rated Load Test.............................................................................109
Paragraph 4L Bumper Assembly .........................................................................110
Paragraph 5 Troubleshooting Procedures .........................................................110
Section 201 Schematics and Wiring Diagrams
Paragraph 1 General ..........................................................................................201
Section 301 Disassembly
Paragraphs 1 and 2 General .........................................................................................301
Paragraph 3 Rescue Hoist Assembly Removal ................................................301
Paragraph 4 Variable Speed Controller / Switch Junction Box Removal ........302
Paragraph 5 Pendant Control and Grip Assembly
and Pendant Cable Assembly Removal ........................................303
Paragraph 6 Pilot Display Removal ..................................................................303
Paragraph 7 BL-5740-14 Swivel Hook Assembly Removal and Disassembly 303
Paragraph 8 HK-111-1 Swivel Hook Assembly Removal and Disassembly....304
Paragraph 9 HK-116-7 Swivel Hook Assembly Removal and Disassembly....305
Paragraph 10 Limit Switch Cover Assembly Removal ......................................306
Paragraph 11 Wire Rope Cable Removal ...........................................................306
Paragraph 12 Cable Cutter Removal ..................................................................310
Paragraph 13 Fleet Angle Assembly Removal and Disassembly .......................310
Paragraph 14 Tension Roller Removal ...............................................................311
Paragraph 15 Motor Removal .............................................................................312
Paragraph 16 Limit, and Cable Foul Switches and
Harness Assembly Removal..........................................................313
Paragraph 17 Labels and Nameplate Removal ...................................................315
Paragraph 18 Rescue Hoist Assembly Mounting Brackets Removal .................315
Paragraph 19 Levelwind Follower Removal ......................................................316
Section 401 Cleaning
Paragraph 1 General .........................................................................................401
Paragraph 1A through 1J General .........................................................................................402
Paragraph 1K Cable (if exposed to lubricants) ....................................................402
Paragraph 1L Cowling, Hoist, Hook and/or Cable
(if exposed to saltwater) .............................................................. 403
Paragraph 1M Sight Glass Cleaning .....................................................................404
Paragraph 1N Wiring Harness Assembly Cleaning .............................................404
Section 501 Checks and Inspection
Paragraph 1 General ..........................................................................................501
Paragraph 2 Inspections.....................................................................................503
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Page T/C-2
September 19, 2008

Section 501 Checks and Inspections (continued)
Paragraph 2A General .........................................................................................503
Paragraph 2B Pressure Roller .............................................................................505
Paragraph 2C Tension Roller ..............................................................................505
Paragraph 2D Swivel Hook Assembly ................................................................507
Paragraph 2E Fleet Angle Assembly ..................................................................509
Paragraph 2F Wire Rope Cable ..........................................................................509
Paragraph 2G Cable Foul Indicator .....................................................................514
Paragraph 2H Pre-Flight Inspection ....................................................................514
Paragraph 2I In Flight Inspection ......................................................................518
Paragraph 2J Post Flight Inspection ...................................................................518
Paragraph 2K Cable Foul Removal .....................................................................520
Paragraph 2L Cable Alignment Inspection / Adjustment ...................................521
Paragraph 2M Detailed Inspection of Rescue Hoist End Flanges
and Mounting Brackets .................................................................522
Paragraph 2N Detailed Inspection / Overhaul of Rescue Hoist ..........................522
Paragraph 2O Lubrication of Cable Guide Shaft ................................................522
Paragraph 2P Inspection of Levelwind Follower ................................................522
Paragraph 2Q Inspection of Levelwind Shaft .....................................................523
Paragraph 2R Inspection of Geneva Wheel ........................................................524
Paragraph 2S Inspection of Wiring .....................................................................525
Section 601 Repair
Paragraph 1 General .........................................................................................601
Paragraph 2 Refinish ........................................................................................604
Paragraph 3 Minor Surface Repair ...................................................................604
Paragraph 4 Major Surface Repair ...................................................................605
Paragraph 5 Application of Top Coat ...............................................................605
Paragraph 6 Application of Coating on Cable ..................................................605
Paragraph 7 General Wiring harness Connector Pin Replacement ...................606
Section 701 Assembly
Paragraphs 1 and 2 General .........................................................................................701
Paragraph 3 Installation of Rescue Hoist System .............................................701
Paragraph 4 Installation of Limit Switches and Harness Assembly .................701
Paragraph 5 Installation of Motor .....................................................................704
Paragraph 6 Installation of Tension Roller .......................................................705
Paragraph 7 Assembly & Installation of Fleet Angle Assembly and Follower.707
Paragraph 8 Installation of Cable Cutter ..........................................................708
Paragraph 9 Installation of Rescue Hoist Assembly Mounting Brackets .........709
Paragraph 10 Installation of Cable .....................................................................710
Paragraph 11 Installation of Limit Switch Cover ...............................................711
Paragraph 12 Assembly & Installation of HK-111-1 Swivel Hook Assembly ...712
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Page T/C-3
September 19, 2008

Section 701 Assembly (Continued)
Paragraph 13 Assembly & Installation BL-5740-14 Swivel Hook Assembly ....714
Paragraph 14 Assembly & Installation of HK-116-7 Swivel Hook Assembly ...715
Paragraph 15 Installation of Nameplate and Labels ...........................................717
Paragraph 16 Installation of Rescue Hoist Assembly & Cowling Assemblies ...717
Paragraph 17 Installation of Variable Speed Controller / Priority
Switch Junction Box......................................................................718
Paragraph 18 Installation of Control Pendant and Grip Assembly
and Pendant Cable Assembly ........................................................718
Paragraph 19 Installation of Pilot Display ..........................................................719
Paragraph 20 Installation of Cartridge ................................................................719
Paragraph 21 Storage Instructions ......................................................................720
Section 801 Fits and Clearances
Paragraphs 1, 2, and 3 General .........................................................................................801
Section 901 Special Tools, Fixture, and Test Equipment .................................901
Section 1001 Illustrated Parts List
Paragraph 1 Introduction ................................................................................1001
Paragraph 2 Notes ...........................................................................................1002
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Page T/C-4
September 19, 2008
LIST OF TABLES
Table Title Page
1 System Configuration Matrix .............................................................................................2
2 Leading Particulars for Rescue Hoist System .....................................................................8
101 Full Out and Intermediate (slow) Limit Switches, and
Potentiometer Settings. ....................................................................................................103
102 Hoist Electrical Continuity Check ...................................................................................105
103 Control Pendant Continuity Check (CP-400-1, -2)..........................................................106
104 Control Pendant Continuity Check (CP-1600-1).............................................................107
105 Variable Speed Controller Electrical Continuity Check..................................................108
106 Troubleshooting Procedures ............................................................................................111
401 Equipment and Materials Required for Cleaning ...........................................................401
501 Inspection Requirements .................................................................................................501
601 Materials Required for Repair ........................................................................................601
602 Allowable Material Removal ..........................................................................................602
701 Materials Required for Assembly ...................................................................................701
801 Dimensional Limits for Rescue Hoist System ................................................................802
901 Special Tools, Fixtures, and Test Equipment List / Matrix .............................................901
LIST OF FIGURES
Figure Title Page
1 Rescue Hoist System ...........................................................................................................1
2 Rescue Hoist Assembly (Typical) .......................................................................................3
3 Limit Switch Locations .......................................................................................................6
101 Location of Full Out and Intermediate (Slow) Speed Limit Switches,
and Potentiometers...........................................................................................................103
102 Deflection of Bumper Assembly with Hook at Full In Position .....................................110
201 Typical Circuit Used to Drive The Cable Foul Indicator ................................................201
202 Rescue Hoist Assembly Wiring Diagram ........................................................................202
203 Wiring Diagram for HS-29700-200, -206, -207, -209, -211, and -213 Rescue Hoist
Systems ............................................................................................................................203
204 Wiring Diagram for HS-29700-201 Rescue Hoist System..............................................204
205 Wiring Diagram for HS-29700-202, -205, -208, -210, -212, and -214
Rescue Hoist Systems ......................................................................................................205
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Page T/C-5
September 19, 2008
LIST OF FIGURES (Continued)

Figure Title Page
207 Wiring Diagram for HS-29700-204, and -215 Rescue Hoist Systems ............................207
208 Wiring Diagram for HS-29700-216 Rescue Hoist System .............................................208
301 View of Cable Cutter and Cartridge in Cable Guide ......................................................302
302 View of Swivel Hook Assembly Resting on Flat Surface ..............................................303
303 Limit Switch Cover .........................................................................................................307
304 Location of Full In, Full Out, and Intermediate (Slow) Speed Limit Switches, and
Potentiometers .................................................................................................................308
305 View of Setscrew in Drum Flange ..................................................................................309
306 View of Slot in Drum Flange for Welded End of Cable .................................................309
307 View of Fleet Angle Assembly .......................................................................................310
308 View of Pressure Roller in Cable Guide Assembly ........................................................311
309 View of Drag Clutch .......................................................................................................312
310 View of Motor Assembly ................................................................................................313
311 View of Cable Foul Indicator Switches and Harness Assembly ....................................314
312 View of Full In Limit Switch ..........................................................................................315
313 Views of Mounting Brackets ..........................................................................................316
401 Example of Corrosion on Hook Assembly Parts ............................................................403
402 Example of Corrosion on Drum ......................................................................................404
501 Examples of Unacceptable Damage to Gear ..................................................................505
502 Roller Replacement Criteria ...........................................................................................505
503 Tension Roller Replacement Criteria ..............................................................................506
504 Various Hooks and Assemblies (typical).........................................................................507
505 Required Terminal Clamp Orientation (typical)..............................................................507
506 Example of Broken Strands in Wire Rope Cable ...........................................................510
507 Example of Abrasion of Wire Rope Cable .....................................................................510
508 Example of Bird Caging in Wire Rope Cable ................................................................510
509 Example of Kink in Wire Rope Cable ............................................................................511
510 Example of Knot in Wire Rope Cable (Typical) .............................................................511
511 Hook Assembly Attachment to Wire Rope Cable ..........................................................512
512 Examples of Wire Rope Cable Looseness ......................................................................513
513 Cable Foul Indicator Dimensional Check .......................................................................515
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Page T/C-6
September 19, 2008
LIST OF FIGURES (Continued)

Figure Title Page
514 Cable Foul Indicator Spring Test ....................................................................................515
515 Oil Fill and Oil Level Sight Glass Locations ..................................................................516
516 View of Setscrew Holding Wire Rope Cable in Drum Flange with Cowling Installed ..517
517 Deflection of Bumper Assembly with Hook at Full In Position .....................................519
518 Dimensions of Crushable Bumper ..................................................................................520
519 Cable Installation and Timing..........................................................................................521
520 Lubrication of Cable Guide Shaft and Location of Follower .........................................523
521 Dimensional Check of Follower .....................................................................................523
522 Levelwind Shaft ..............................................................................................................524
523 Geneva Wheel in Good Condition...................................................................................524
524 Damaged Geneva Wheel .................................................................................................525
601 Wire Rope Cable Orange Paint Lengths..........................................................................606
701 View of Full In Limit Switch...........................................................................................703
702 Views of Cable Foul Indicator Switches and Harness Assembly....................................704
703 Drag Clutch Assembly Sequence Views .........................................................................706
704 View of Fleet Angle Assembly Installation.....................................................................708
705 View of Cable Cutter and Cartridge in Cable Guide .......................................................709
706 Views of Mounting Brackets ...........................................................................................710
707 View of Setscrew Holding Wire Rope Cable in Drum Flange with Cowling Installed ..711
708 Limit Switch Cover..........................................................................................................711
709 Required Terminal Clamp Orientation (typical)..............................................................713
801 Rescue Hoist Assembly Installation ...............................................................................803
802 Rescue Hoist Assembly / Cowling Assembly Installation .............................................804
803 Variable Speed Controller Installation ............................................................................805
804 CP-1600-1 Pendant Control and Grip Assembly Installation .........................................806
805 CP-400-1 and -2 Pendant Control and Grip Assembly Installation ................................807
901 TE-120-1, Weights with TE-120-3 Cart ..........................................................................902
902 TE-132-1, Clevis Mount Maintenance Fixture................................................................902
1001 Rescue Hoist System .....................................................................................................1004
1002 Rescue Hoist Assembly (Sheet 1 of 5) .........................................................................1006
1003 Swivel Hook Assembly (for BL-29700-20, and 22 through 25 Rescue Hoists) ..........1015
1004 Swivel Hook Assembly (for BL-29700-21 Rescue Hoist) ...........................................1017
1005 Swivel Hook Assembly (for BL-29700-26 Rescue Hoist) ...........................................1019
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Page T/C-7
September 19, 2008
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 maintain the
Rescue Hoist System in a safe and serviceable condition.
The manual is divided into separate sections:
1. Title Page 7. Introduction 13. Checks and Inspection

2. Record of Revision 8. Description and Operation 14. Repair
3. Record of Temporary 9. Testing and Troubleshooting 15. Assembly
Revisions
4. Service Bulletin List 10. Wiring Diagrams 16. Fits and Clearances
5. List of Effective Pages 11. Disassembly 18. Special Tools, Fixtures
and Test Equipment
6. Table of Contents 12. Cleaning 17. Illustrated Parts List
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.
The beginning of the REPAIR section includes a list of the separate repairs (if appropriate).
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. This information is attached to the back of the manual as a formal modifying
document until the information is incorporated into this manual.
Attached to the back of this manual is a copy of a blank TPDR for use by the customer, plus
copies of any Breeze-Eastern modifying documents written against the manual for incorporation
into the next revision.
25-61-00
Page INTRO-1
September 19, 2008
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 flight line maintenance of the Rescue Hoist System by the owner / operator /
maintenance facility.
Any activity involving the operation, maintenance, and testing of the Rescue Hoist System shall
be performed in accordance with the procedures defined in this manual. Furthermore, all
maintenance requiring new components shall be performed utilizing only the parts identified in
this manual, which are all readily available from Breeze-Eastern. Any and all actions taken by
owners / operators / 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.
3. Verification:
Testing/Troubleshooting: TBD
Disassembly: TBD
Assembly: TBD
25-61-00
Page INTRO-2
September 19, 2008
DESCRIPTION AND OPERATION
Pilot Display
Pendant Cable Pendant Control and
Assembly Grip Assembly
Cowling Assembly Variable Speed

Rescue Hoist Assembly Priority Switch Controller
Junction Box
Typical
Figure 1. Rescue Hoist System
1. Description
A. This publication explains the operation of, and provides flight line maintenance instructions
for, the HS-29700 Series Rescue Hoist Systems. These instructions are used to maintain the
HS-29700 Series Rescue Hoist 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. These Rescue Hoist Systems provide a means for lowering, and raising personnel from an
airborne helicopter. The Rescue Hoist Assembly can be operated from the Pendant Control
and Grip Assembly, or pilot control (not supplied with Rescue Hoist System).
C. 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. BZ7R167O, 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 for any
of these services listed above as follows:
Breeze-Eastern
700 Liberty Avenue
Union, New Jersey 07083-8198 USA
Phone Number: Local Calls use: (908)-206-3901 or (908)-206-3891
In USA (except NJ) and Canada call toll free: (800)-929-1919
Fax Number: 908-688-6495
E-mail Address: customer.services@breeze-eastern.com
Web Site Address: www.breeze-eastern.com
Revision status of the Breeze-Eastern technical manuals is listed on the web site referenced
above.
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D. Rescue Hoist System
All of the HS-29700 Series Rescue Hoist Systems include a Rescue Hoist Assembly, a
Cowling Assembly, a Variable Speed Controller, a Pendant Control and Grip Assembly, a
Pendant Cable Assembly, and a Pressure Cartridge Kit. Equipment options included in specific
configurations of these systems include a Pilot Display Assembly, Mounting Screws (for the
Variable Speed Controller), and a Priority Switch Junction Box (see Table 1). All of these
assemblies are considered Line Replaceable Units (LRUs).
Rescue Hoist System Part Number Applicability
-200
-201
-202
-203
-204
-205
-206
-207
-208
-209
-210
-211
-212
-213
-214
-215
-216
-217
Component Description HS-29700
Rescue Hoist Assembly BL-29700-20 X -- -- -- -- -- X X -- X -- -- -- -- -- -- -- --

Rescue Hoist Assembly BL-29700-21 -- -- -- X -- -- -- -- -- -- -- -- -- -- -- -- -- --
Rescue Hoist Assembly BL-29700-22 -- -- X -- -- X -- -- X -- X -- -- -- -- -- -- --
Rescue Hoist Assembly BL-29700-23 -- X -- -- X -- -- -- -- -- -- -- -- -- -- X -- --
Rescue Hoist Assembly BL-29700-24 -- -- -- -- -- -- -- -- -- -- -- X -- X -- -- -- --
Rescue Hoist Assembly BL-29700-25 -- -- -- -- -- -- -- -- -- -- -- -- X -- X -- -- X
Rescue Hoist Assembly BL-29700-26 -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- X --
Cowling Assembly BL-14823-1 X X X X X X X X X X X X X X X X -- X
Variable Speed Controller EC-14000-2 -- X -- -- X -- X -- -- -- -- -- -- -- -- -- X --
Variable Speed Controller EC-14000-5 -- -- X X -- X -- -- -- -- -- -- -- -- -- -- -- --
Variable Speed Controller EC-14000-13 X -- -- -- -- -- -- X -- X -- X -- X -- X -- --
Variable Speed Controller EC-14000-14 -- -- -- -- -- -- -- -- X -- X -- X -- X -- -- X
Pendant Cable Assembly EC-14170-1 X -- X X -- X X X X X X X X X X -- -- X
Pendant Cable Assembly EC-14170-2 -- X -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- --
Pendant Cable Assembly EC-14190-1 -- -- -- -- X -- -- -- -- -- -- -- -- -- -- X X --
Pendant Control Assy. CP-400-1 X X X X -- -- -- -- -- X X -- -- X X -- -- --
Pendant Control Assy. CP-400-2 -- -- -- -- -- X X X X -- -- X X -- -- -- -- X
Pendant Control Assy. CP-1600-1 -- -- -- -- X -- -- -- -- -- -- -- -- -- -- X X --
Pilot Display Assembly EC-14070-1 X -- -- -- -- -- -- -- -- X -- -- -- X -- -- -- --
Pilot Display Assembly EC-14070-2 -- -- X X -- -- -- -- -- -- X -- -- -- X -- -- --
Pilot Display Assembly EC-14070-6 -- -- -- -- -- -- X X -- -- -- X -- -- -- -- -- --
Pilot Display Assembly EC-14070-7 -- -- -- -- -- X -- -- X -- -- -- X -- -- -- -- --
Pressure Cartridge Kit BL-11140-2 X X X X X X X X X X X X X X X X X X
Mounting Screws (Quantity 4) MS16995-51 -- X -- -- X -- -- -- -- -- -- -- -- -- -- X X X
Priority Switch Junction Box EC-14200-1 -- -- -- X -- -- -- -- -- -- -- -- -- -- -- -- -- --
Feet (F) or Meter (M) Display -- M -- F F -- F M M F M F M F M F -- -- --
Table 1. System Configuration Matrix
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The main power requirement for the Rescue Hoist System is 28 VDC, 96 Amperes. The
power required for the controls in the Pendant Control and Grip Assembly, and the cable
cutter for the Rescue Hoist Assembly, 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 Rescue Hoist Assembly.
E. Rescue Hoist Assembly
The hoist contains a rotating drum, which is driven by an electric motor through a gear train
and brake assembly, raising and lowering a 164 ft. (50.0 m) wire rope cable and swivel hook
(see Figure 2). The hoist operates at variable speeds from 0 to 210 fpm (1.07 mps). A level
wind mechanism on the hoist ensures even wrapping of the cable on the drum. Redundant
intermediate (slow) speed limit switches sense when the cable approaches the full in, or full out
position, and actuate to slow the speed of the hoist. When the cable reaches these positions,
redundant full in, or full out, limit switches actuate, and the hoist stops. The drum assembly
incorporates an improved means of anchoring the cable to the drum. The drum flange utilizes a
radial slot into which the formed end of the cable is inserted. The cable is held in the drum
flange by a setscrew.
Figure 2. Rescue Hoist Assembly (Typical)

The drum is driven by a DC motor, powered by the Variable Speed Controller, as commanded
from the pilot control (not supplied with Rescue Hoist System), or the Pendant Control and
Grip Assembly. The DC motor drives the drum through reduction gearing and a brake
assembly. The reduction gearing is of a planetary type, which directly drives the drum, and a
Geneva wheel to drive the level wind shaft and cable guide in synchronization. A Weston
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September 19, 2008
brake is also incorporated into the inner diameter of the drum. When power is removed, or
operation is stopped, the brake is applied to hold the load. The brake consists of clutch disk
pack assembly, and a sprag clutch assembly. The hoist also incorporates an oil sight gage
allowing for a visual reference for servicing of the drum assembly.
F. Wire Rope Cable
The load cable for the Rescue Hoist Assembly consists of a wire rope with a swaged stainless
steel ball / shank fitting per MS20664. The wire rope is a 0.156 inch (3.97 mm) diameter,
corrosion resistant, preformed spin resistant type. It is proof tested in accordance with
MIL-C-5688. 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 Assemblies
There are three hook assemblies associated with the HS-29700-200 Series Rescue Hoist
Systems. The HK-111-1 Hook Assembly is standard for the HS-29700-201 and -204 Rescue
Hoist Systems, the HK-116-7 Hook Assembly is standard for the HS-29700-216, and the
BL-5740-14 Hook Assembly is standard for all other HS-29700-200 Rescue Hoist Systems.
H. Tension Roller
To provide tension to the wire rope cable while reeling onto the drum, or reeling off of the
drum, the Rescue Hoist Assembly utilizes a tension roller located in the cable guide. The
tension roller is driven by a shaft, which passes through the tension roller and spans the end
flanges of the hoist. A gear and clutch assembly, which is driven by the drum gear, drives this
shaft, and is located in the motor end flange. The gear and clutch assembly allows the
tangential speed of the tension roller to be faster than the tangential speed of the drum when
reeling out, thereby maintaining a “pull” force on the cable, even at no load. A drag clutch,
consisting of a grooved nut, a flat washer, a spring washer, and a friction disc, is located on the
limit switch end of the shaft. The drag clutch allows the tangential speed of the tension roller to
be slower than the tangential speed of the drum when reeling in, thereby maintaining a “pull”
force on the cable, even at no load.
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 264,
provides the total number of hoist cycles.
A potentiometer in the Rescue Hoist Assembly provides cable payout information to the
Variable Speed Controller for distribution to digital displays on the pendant control assembly
and the pilot display.
J. Cable Foul Indicator
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.
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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 indicator, which is a switch actuated safety device, and is
mounted on the hoist’s flanges parallel to the drum axis. This cable foul indicator 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.
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.
WARNING: BEFORE INSTALLING THE CARTRIDGE IN THE HOIST, BE SURE THAT ALL
ELECTRICAL ACTUATING CIRCUITS ARE OPEN.
WARNING: DO NOT PERFORM RESISTANCE-CHECKS ON THE CARTRIDGE EITHER
PRIOR TO, OR AFTER, INSTALLATION IN THE HOIST.
WARNING: TAKE PROPER ESD PRECAUTIONS TO AVOID FIRING THE CARTRIDGE AND
DAMAGING COMPONENTS DUE TO ELECTRICAL SHOCK FROM
ELECTROSTATIC DISCHARGE.
NOTE: AFTER THE CABLE HAS BEEN CUT, THE ANVIL, CARTRIDGE, CUTTER,
O-RINGS, AND COTTER PIN MUST ALL BE REPLACED, WITH REFIRE KIT
PN KT-494.
NOTE: CARTRIDGE SERVICE LIFE IS 3 YEARS, STARTING WHEN REMOVED FROM
CONTAINER. CARTRIDGE LIFE (COMBINED SHELF AND SERVICE LIFE) IS
9 YEARS, STARTING FROM THE DATE OF MANUFACTURE, WHICH CAN BE
FOUND IN THE LOT NUMBER ON THE CONTAINER, AND ON THE
CARTRIDGE. THE LOT NUMBER STARTS WITH THE FIRST THREE LETTERS
“CDI,” FOLLOWED BY TWO DIGITS, IDENTIFYING THE YEAR OF
MANUFACTURE (EXAMPLE: 08 IS 2008), AND ONE LETTER, IDENTIFYING
THE MONTH OF MANUFACTURE, AS FOLLOWS:
A – JANUARY D - APRIL G – JULY K – OCTOBER
B – FEBRUARY E – MAY H – AUGUST L – NOVEMBER
C – MARCH F – JUNE J – SEPTEMBER M – DECEMBER
The cable cutter, contained in the cable guide assembly, is comprised of a pressure cartridge
(squib), guillotine, and anvil. The minimum all-fire current of the cartridge is 5.0 amperes per
bridge wire at 28 VDC. If the cartridge needs to be replaced due to expired service life, or shelf
life, the cartridge can be purchased in a Pressure Cartridge Kit, PN BL-11140-2, which consists
of one cartridge in a hermetically sealed container with packing, to be used with the installation
of the new cartridge. In the event the cartridge has been fired during a cable cut, a cable cutter
re-fire kit (PN KT-494) must be purchased; which includes a cable cutter (PN Y-1265-9-1),
and an impulse cartridge kit (PN BL-11140-2).
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L. 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 SLOWED
AUTOMATICALLY TO A SAFE SPEED WHENEVER THE HOIST IS OPERATED
NEAR THE EXTREMES OF THE CABLE TRAVEL (FULL IN AND FULL OUT)
BY REDUNDANT, INTERMEDIATE (SLOW) LIMIT SWITCHES.
Redundant limit switches control full in, full out, and slow speed cable positions with the
following purpose (see Figure 3):
(1) Stop at full in when the bumper assembly makes contact with fleet angle assembly located
in the cable guide.
(2) Intermediate (slow) speed when reeling in, and within a specified distance from full in
switch actuation.
(3) Intermediate (slow) speed when reeling out, and within a specified distance from full out
switch actuation.
(4) Stop at full out at a specified number of dead wraps on the cable drum.
Figure 3. Limit Switch Locations

The switches are directly coupled to the hoist drum by the cyclocentric assembly, which is a
gear train directly driven by the drum, to control full out and slow speed cable positions (hook
approach to helicopter and to full extension). The cable full in switch, actuated by the bumper
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September 19, 2008
assembly mounted on the cable above the hook assembly, is built into the cable guide to ensure
proper homing of the hook.
The bumper assembly consists of a spring and a crushable honeycomb constructed bumper,
which when crushed, provides a visual indication of a problem with either the full in limit
switches, or the intermediate (slow) up limit switches, or is the result of improper handling.
M. Pilot Control and Pendant Control
The pilot control (not supplied with Rescue Hoist System) and pendant control command
raising and lowering operations, with the pilot control having precedence over the pendant
control. The pilot control enables operation in either direction at a fixed cable speed, whereas
the pendant control enables operation at a variable speed.
The Pendant Control and Grip Assembly provides the crewmember with freedom of movement
while utilizing the following control features:
(1) Direction / speed control
(2) Inter-Communication System (ICS) control
(3) Digital readout indicating the amount of cable paid out from the Rescue Hoist Assembly
(contained in CP-400-1 and -2 Pendant Control and Grip Assembly Assemblies only)
(4) Indicator light displaying power on condition (contained in CP-1600-1 Pendant Control and
Grip Assembly only)
The direction / speed control thumb wheel is centrally located on the shrouded upper portion of
the handgrip. A bracket is provided on the handgrip to facilitate stowing the pendant in the
helicopter. The pendant is equipped with digital cable pay out display and an electrical
connector for interfacing with the Variable Speed Controller. Also, the digital cable payout
display momentarily shows “888” when power is initially turned on.
The function of the Pendant Control and Grip Assembly 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.
The indicator light provides the hoist operator with a visual indication of when the electrical
power is applied to the Hoist System (white, or yellow, labeled “ON”). The indicator, as well
as the cable pay out digital display, are night vision goggle (NVG) compatible / sunlight
readable.
The ICS control is a snap action switch provided for connection to the helicopter 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.
The Pendant Cable Assembly, Breeze-Eastern Part Numbers EC-14170-1, EC-14170-2, or
EC-14190-1, electrically connects the Pendant Control and Grip Assembly to the variable
speed electronic controller.
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N. Variable Speed Controller
A Variable Speed Controller is the central control unit and junction box for the Rescue Hoist
System. It contains electrical and electronic circuits, which convert pilot and crew / pendant
commands into control voltages for the DC motor driving the hoist assembly. A heat sink on
the side of the Variable Speed Controller provides cooling for electronic components. System
electrical cables attach to connectors at the front and rear of the Variable Speed Controller.
O. Leading Particulars for Rescue Hoist System (see Table 2)
Rescue Hoist Assembly
Cable:
Type Type 1, 19 (strands) x 7 (wires per strand) construction
Length 164 feet (50.0 meters) usable length
Diameter 0.156 +0.006 / -0.001 inch (3.97 +0.15/-0.03 mm)
Cable Drum Layers 4
Material Stainless Steel, preformed, spin resistant, per MIL-W-83140
Cable Speed (Hoisting):
Pendant Control (Hoisting) 140 fpm (0.71 mps) at 450 lb. (204 kg) opposing load
Pilot Control (Hoisting) 100 fpm (0.51 mps) at 450 lb. (204 kg) opposing load
Slow Speed (Hoisting) 50 fpm (0.25 mps) at 450 lb. (204 kg) opposing load
Pendant Control (Lowering) 210 fpm (1.07 mps) at 450 lb. (204 kg) aiding load
Load:
Operating Load 450 lb. (204 kg)
Limit Load (Static) 1350 lb. (612 kg), applied to structure
Ultimate Load (Static) 2400 lb. (1089 kg), applied to structure
Fleet Angle:
Operational 15° to centerline (cone angle 30°)
Temperature Range:
Operational -40° F to +122° F ( -40° C to +50° C)
Non-Operational -65° F to +160° F ( -54° C to +71° C)
Altitude Sea Level to 15,000 ft. (4572 m)
Electric Motor:
Motor: Variable, 0 - 27.5 VDC at 96 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 28 VDC, 5 Amps, Switches IAW MS27216-5
Cable Cutter Ballistic type, electrically fired (5 Amps per bridgewire, min.)
Weight (MAXIMUM) 48 lb (21.8 kg), for BL-29700-20, -22, -23, -25, -26.
55 lb. (25 kg.), for BL-29700-21, -24
Table 2. Leading particulars for Rescue Hoist System
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Gearbox Oil MIL-PRF-7808, Class 3 (NATO Code No. O-148), or
MIL-PRF-23699, Class STD (NATO Code No. O-156)
Quantity – 8 oz. (236 ml)
Variable Speed Controller
Electrical Input 28 VDC, 101 Amps continuous, and 110 Amps for one (1)
second maximum, based on speed and load conditions
Electrical Output 0 - 27.5 VDC, 96 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 14.0 lb. (6.0 kg), maximum
Pendant Control and Grip Assembly
Voltage 28 VDC
Current 2 Amps
Speed Control Incremental potentiometer
Directional Control Thumb wheel actuated
Housing Totally enclosed
Speed-Control Knob Centering protected
Displays Sunlight readable
Weight 1.2 lb. (0.5 kg), maximum
Table 2. Leading particulars for Rescue Hoist System (Continued)
2. Normal Operation
WARNING: KEEP HANDS, BODY, AND CLOTHING AWAY FROM RESCUE HOIST
ASSEMBLY, SPECIFICALLY “PINCH POINTS,” WHERE THE CABLE ENTERS
THE CABLE GUIDE AND CONTACTS THE DRUM.
WARNING: SEARCH AND RESCUE OPERATIONS, AND ALL OTHER USES OF RESCUE
HOIST ASSEMBLIES 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 HOIST ASSEMBLIES.
WARNING: WORK GLOVES MUST BE WORN BY THE OPERATOR WHENEVER
HANDLING THE RESCUE HOIST ASSEMBLY CABLE TO PREVENT INJURY
FROM BROKEN STRANDS AND WIRES. EYE PROTECTION MUST BE WORN
BY THE OPERATOR WHENEVER OPERATING, OR MAINTAINING, THE
RESCUE HOIST ASSEMBLY TO PREVENT INJURY FROM LUBRICANTS,
SOLVENTS, AND OTHER MATERIALS USED ON THE RESCUE HOIST
ASSEMBLY, 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.
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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 HINDER 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 ASSEMBLY, DO NOT TOUCH
THE MOTOR. THE MOTOR TEMPERATURE MAY BE VERY HOT, AND MAY
RESULT IN SEVERE BURNS IF TOUCHED.
NOTE: VISUAL MEANS OF FULL IN AND FULL OUT DETECTION IS PROVIDED
WITH THE RESCUE HOIST ASSEMBLY. ORANGE PAINT IS APPLIED TO THE
WIRE ROPE CABLE INDICATING APPROXIMATELY 30 FT. (9.1 M.) OF CABLE
REMAINS UNTIL REACHING THE FULL IN LIMIT, AND APPROXIMATELY 20
FEET (6.1 M.) OF CABLE REMAINS UNTIL REACHING THE FULL OUT 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 ASSEMBLY IS OPERATED NEAR THE
EXTREMES (FULL IN AND FULL OUT) OF THE CABLE TRAVEL BY
REDUNDANT, INTERMEDIATE (SLOW) LIMIT SWITCHES.
NOTE: PRIOR TO TURNING POWER ON, THE RESCUE HOIST ASSEMBLY
COMPONENTS MUST BE VISUALLY INSPECTED FOR SOUND STRUCTURAL
INTEGRITY AND PROPER INTEGRATION.
A. The HS-29700-200 Series Rescue Hoist Systems operate by the Pendant Control and Grip
Assembly, or the pilot control. Once the Variable Speed Controller receives the reel in, or out,
command signal, an output signal is sent to the electric motor, either to raise or lower the hoist
cable. The motor torque will drive the gear train, which will drive the level wind, tension roller
and drum, resulting in reeling in or out of the load cable.
B. Once the down signal is received the wire rope cable will reel out, and speed should be faster
as the control is moved farther from the center. Observe the amount of cable on the storage
drum. Reduce speed as cable nears full extension. When the intermediate (slow) limit switch is
reached, the hoist is slowed to 50 fpm (0.25 mps) until 3½ to 4 wraps of cable remain on the
drum, and the motor is stopped by activation of the down limit switch.
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Also, a visual means of full out detection is provided by orange paint on the wire rope cable,
which indicates approximately 20 ft. (6.1 m.) of cable remains until reaching this limit.
C. Once the up signal is received by the Variable Speed Controller, the wire rope cable should
reel in, and speed should be faster as the control is moved farther from the center. The motor
rate allows for a cable speed of 210 fpm (1.07 mps). When the intermediate (slow) limit switch
is reached the hoist is slowed to 50 fpm (0.25 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 paint on the wire rope cable,
which indicates approximately 30 ft. (9.1 m.) of cable remains until reaching this limit.
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 using a tongue
depressor, or equivalent, and the cable paid 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 that caused the cable foul
must be corrected, 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 in, at full pendant thumbwheel deflection,
to the full in position. Ensure the spring in the bumper is compressed sufficiently to prevent the
hook from moving when the helicopter is in flight.
D. The Rescue Hoist Assembly 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.
CAUTION: OPERATION WITH THE MOTOR HOT 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. During training, or when performing testing and troubleshooting procedures, if the
performance of the hoist degrades whereby the speed of the hoist slows, or the motor stalls
while trying to pick up rated loads, the most likely cause is an overheat condition of the motor.
If the motor overheats, allow the motor to cool sufficiently, approximately 30 minutes,
depending on ambient conditions, and the amount of time the hoist was operated with the
motor overheating.
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F. The Pendant Control and Grip Assembly is a handheld 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 Pendant Control and Grip Assembly display indicates the amount of cable paid out, and an
indicator light for power on (“ON”). Also, the cable payout display momentarily shows “888”
when power is initially turned on.
G. There have been instances where cable foul sensor equipped Rescue Hoist 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 Rescue Hoist Assemblies 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.
The Rescue Hoist Assembly 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 Rescue Hoist System, maximum
current rating is 1 amp for the 28 VDC output on the Rescue Hoist Assembly).
3. Emergency In Flight Procedures for Hoist Operation
To address the following emergency conditions, perform the procedures below:
A. Cable Fails to Extend or Retract
(1) Verify Hoist system power is on by checking the cable payout display on the pendant
control, or pilot display. If the cable payout display is not on, verify that all applicable
circuit breakers for Hoist operation are pushed in.
(2) If the cable payout display is still not on, abort the mission and troubleshoot the Hoist
system problem on the ground. If the cable payout display is on and the problem still exists,
proceed to step A.(3).
(3) If using pendant control, use pilot control to attempt to operate the Hoist. Similarly, if using
pilot control, use pendant control to attempt to operate the Hoist. If neither the pendant
control nor the pilot control operates the Hoist, proceed to step A.(4).
(4) Check the hoist to see if there is a cable foul. If a cable foul exists, DO NOT attempt to
clear the fouled cable, or to continue to operate the Hoist in flight. Perform troubleshooting
after helicopter has landed.
B. Uncontrolled or Uncommanded Hoist Up or Down
control nor pilot control operates the Hoist, proceed to step B.(2).
(2) Pull applicable circuit breakers to turn Hoist power off. Perform troubleshooting after the
helicopter has landed.
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C. Inadvertent Cable Cut
(1) DO NOT attempt to operate hoist. Pull applicable circuit breakers to turn Hoist power off,
and perform troubleshooting on ground after helicopter has landed.
D. Cable Cutter Fails to Cut Cable
(1) Use secondary cutting device to sever cable. DO NOT operate Hoist after failed attempt to
cut cable.
E. Hoist Fails to Make Speed
control nor pilot control operates the Hoist, proceed to step E.(2).
(2) Check the load on the hook to ensure it does not exceed 450 lb. (204 kg.). Try lifting less of
a load (one person instead of two).
F. Cable Fouls or Cable Wraps Loosely on Drum
(1) DO NOT attempt to clear the fouled cable, or use the hoist with a loosely wrapped cable on
the drum (which could result in a fouled cable). Discontinue operating hoist in flight, and
perform troubleshooting after the helicopter has landed.
G. Cable or Hook Snags on Object on Ground
(1) Cut cable, and discontinue use of hoist. Replace cable and hook assembly, and use refire kit
(PN KT-494) after the helicopter has landed per applicable sections of this manual.
H. Cable Subjected to Shock Load
(1) Discontinue use of hoist. Replace cable prior to further hoisting operations after the
helicopter has landed.
4. Flight Line / Ground Handling Hoist Operation Guidelines
A. When operating the hoist during inspections, hoist speed should be no greater than 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
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switch actuator and wait one second before deflecting the control pendant thumbwheel (if
applicable) – DO NOT have the thumbwheel deflected and use the limit switch (actuator) to
move the hoist. Also, always wait 1 second before re-actuation of a limit switch.
F. When checking the full in limit switch or stowing the hook, always operate the hoist at
maximum slow speed by deflecting the 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 tend to 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:
(a) When cleaning the drum, make sure power to the hoist is removed.
(b) Use a clean, damp rag to clean the drum.
(c) Cleaning the drum will require multiple drum movements to clean the entire drum surface.
(d) See Section 401, Cleaning, for complete cleaning instructions of the hoist.
I. 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.
J. Do not “Water Soak” the electronics. Use isopropyl alcohol to clean panels or pendants.
K. Always wind, and unwind, the cable in a ‘race track’ fashion, never a ‘Figure 8’ or a coil.
L. Always ‘season’ new cables, in accordance with the Rated Load Test, as given in Section 101,
Testing and Troubleshooting.
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TESTING AND TROUBLESHOOTING
1. Testing
This section covers testing, adjusting, 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.
Reference numbers in parenthesis refer to IPL in Section 1001.
2. Test Equipment and Materials
The recommended method for testing the Rescue Hoist 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 Rescue Hoist Assembly is mounted on the helicopter.
A. Electrical Power: 28 VDC, 101 amperes minimum.
B. Load Source
The force applied to the Rescue Hoist Assembly shall be by use of Breeze Eastern TE-120-1
calibrated weights (or equivalent), with Breeze Eastern TE-120-3 cart (or equivalent),
mounted on the Rescue Hoist Assembly hook, capable of loading the Rescue Hoist Assembly
to 450 lb. (204 kg.).
C. Tape Measure (in feet or meters).
D. Tachometer or Stopwatch (for measuring cable speed). If a tachometer is not available, use a
stopwatch and measure the time it takes the Rescue Hoist Assembly cable to travel over a
known length.
E. Multimeter; minimum range, 0 - 30 VDC, 0 - 40 ohms, 0 - 10 amps.
F. Tie Wire: MS20995NC32.
3. Test Conditions
The Rescue Hoist Assembly shall be mounted using the four mounting points (See Figure 801) in
such a manner that the cable pays out in a downward direction. The recommended method is to
test the Rescue Hoist Assembly when mounted on the helicopter. All tests shall be conducted at
ambient temperature of 60°F to 104°F (16°C to 40°C), and relative humidity of 95 percent
maximum.
4. Test
It is recommended that the test procedures identified below should be performed annually, or at
intervals more frequently, as recommended in this manual.
WARNING: KEEP HANDS, BODY, AND CLOTHING AWAY FROM THE RESCUE HOIST
ASSEMBLY, SPECIFICALLY “PINCH POINTS,” WHERE THE CABLE ENTERS
THE CABLE GUIDE AND CONTACTS THE DRUM.
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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 HOIST ASSEMBLIES.
FROM BROKEN STRANDS AND WIRES.
NOTE: BEFORE TURNING POWER ON, THE RESCUE HOIST ASSEMBLY
COMPONENTS MUST BE VISUALLY INSPECTED FOR SOUND
STRUCTURAL INTEGRITY AND 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.
A. Limit Switch Test and Adjustment
NOTE: TO ADJUST THE INTERMEDIATE (SLOW) SPEED AND FULL OUT LIMIT
SWITCH SETTINGS, UNLOCK DZUS FASTENERS AND OPEN COWLING (30,
FIGURE 1001), AND REMOVE TIE WIRE, SCREWS (50, FIGURE 1002, SHEET
3, VIEW B), WASHERS (60), TERMINAL LUG (70), LIMIT SWITCH COVER
(40), GASKET (80), SCREWS (480, FIGURE 1002, SHEET 5, VIEW E),
MOUNTING BRACKET (490), RETAINING RING (750), AND SPACER (760),
BEFORE ROTATING THE CAMS (770), AS REQUIRED.
(1) Full Out Limit Switch S2 Test and Adjustment (see Figure 101)
(a) Reel out the wire rope cable until the full out limit switch stops the Rescue Hoist
Assembly. When the Rescue Hoist Assembly stops at the full out position, 3 to 4
wraps of wire rope cable must be remaining on the drum.
(b) If the Rescue Hoist Assembly does not stop within the specified limits, adjust the cam
as follows:
1) Counterclockwise if the Rescue Hoist Assembly stopped with more than four
wraps on the drum.
2) Clockwise if the Rescue Hoist Assembly stopped with less than three wraps on the
drum.
(2) Intermediate (Slow) Speed Down Limit Switch S4 Test and Adjustment (see Figure 101)
(a) Mark the wire rope cable at 10 feet (3.0 meters) and at 13 feet (3.96 meters) from the
point where the wire rope cable enters the fleet angle assembly when the Rescue Hoist
Assembly is at the full out position (these marks are the limits for the intermediate
[slow] speed down limit switch S4 actuation point).
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(b) Reel in the wire rope cable onto the drum until both marks have passed the fleet angle
assembly. Reverse the direction of operation, and reel out the wire rope cable until the
intermediate (slow) speed down limit switch S4 actuates.
(c) If the Rescue Hoist Assembly does not slow down within the specified limits, adjust
the cam as follows:
1) Counterclockwise if the intermediate (slow) speed down limit switch actuates
more with than 13 feet (3.96 meters).
2) Clockwise if the intermediate (slow) speed down limit switch actuates with less
than 10 feet (3.0 meters).
Designation Name Setting Position
S1 Intermediate (Slow) Speed Up Switch 10 – 13 ft. (3.0 – 3.96 m.) from full in.
S2 Full Out Switch 3 to 4 wraps of cable on the drum.
S3 Full In Limit Switch (not shown below) None (actuated when bumper assembly
contacts cable guide at full in position).
S4 Intermediate (Slow) Speed Down Switch 10 – 13 ft. (3.0 – 3.96 m.) from full out.
R1 Potentiometer – for setting Full In Cable Payout 000 ft. (00.0 m.) at full in.
R3 Potentiometer – for setting Full Out Cable Payout 164 ft. (50.0 m.) at full out.
Table 101. Full Out and Intermediate (slow) Limit Switches, and Potentiometer
Settings.
Screws for setting

R1 potentiometer
S2
R1
R3
S4
S1
Figure 101. Location of Full Out and Intermediate (Slow) Speed Limit Switches, and Potentiometers
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(3) Intermediate (Slow) Speed Up Limit Switch S1 Test and Adjustment
(a) Mark the wire rope cable at 10 feet (3.0 meters) and at 13 feet (3.96 meters) from the
ball end of the cable (these marks are the limits for the intermediate [slow] speed up
limit switch S1 actuation point).
(b) Reel in the wire rope cable until the intermediate (slow) speed up limit switch S1
actuates.
(c) If the Rescue Hoist Assembly does not slow down within the specified limits, adjust
the cam as follows:
1) Clockwise if the intermediate (slow) speed up limit switch actuates more with than
13 feet (3.96 meters) from the ball end.
2) Counterclockwise if the intermediate (slow) speed down limit switch actuates with
less than 10 feet (3.0 meters) from the ball end.
NOTE: AFTER ADJUSTMENT OF CAMS (770, FIGURE 1002, SHEET 5, VIEW E) FOR
THE INTERMEDIATE (SLOW) SPEED AND FULL OUT LIMIT SWITCH
SETTINGS, INSTALL SPACERS (760), RETAINING RING (750), MOUNTING
BRACKET (490), SCREWS (480), GASKET (80, FIGURE 1002, SHEET 3, VIEW
B), LIMIT SWITCH COVER (40), TERMINAL LUG (70), WASHERS (60),
SCREWS (50), AND TIE WIRE PER MS33540 WITH MS20995NC32. CLOSE
COWLING (30, FIGURE 1001) AND LOCK DZUS FASTENERS.
(4) Full In Limit Switch S3 Test (no adjustment is possible)
Check operation of the full-up limit switch as follows:
(a) Reel out 20 feet (6.1 meters) of wire rope cable.
(b) While slowly reeling in the cable, press up by hand on the fleet angle assembly (130,
Figure 1002, Sheet 3, View A). Operation of the Rescue Hoist Assembly in the up
direction must stop when the full in limit switch is actuated by the movement of the
fleet angle assembly.
B. Adjustment Of Payout Display (see Figure 101)
If the cable payout display does not read correctly, perform the following cable payout
potentiometer adjustment as follows (for EC-14070-1, -2, and CP-400-1, -2 only):
(1) Run the cable to the full in position.
(2) Loosen the screws (Figure 101, and Item 720, Figure 1002, Sheet 5, View E) that secure
the mounting cleats of potentiometer R1 (730), and rotate the potentiometer, as necessary,
to obtain a 000 ft. (00.0 m.) reading on the cable payout display on the pendant control.
Hold the potentiometer in this position and tighten the mounting cleat screws. Torque
screws to 10 to 13 in.-lb. (115 to 150 mm.-kg.).
(3) Reel out cable until the full out limit switch stops operation. There must be 3 to 4 wraps
remaining on the drum at this point.
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(4) Adjust screw on potentiometer R3 (740) so that the reading on the pendant control cable
payout display is 164 ± 3 feet (50.0 ± 0.9 meters).
(5) Run the cable in to the full in position, and verify that the pendant control cable payout
display reads 000 + 3 / - 0 ft. (00.0 + 0.9 / - 0.0 m.). If the display is out of limits, repeat
steps (2) through (5) until display readouts are verified at both full in and full out.
(6) After steps (3) and (4) have been successfully completed, seal the screw on potentiometer
R3 (740) with red insulating paint, PN 1201; manufactured by Glyptal Specialty Coating,
Chelsea, MA 02150, or an equivalent sealant.
C. Cable Foul Indicator Test
NOTE: THE WIRE ROPE CABLE MUST BE REELED IN UNDER NO LOAD PRIOR TO
THE CABLE / SWITCH ACTUATOR GAP MEASUREMENT.
CAUTION: DO NOT DISPLACE CABLE FOUL SENSOR ACTUATOR GREATER THAN 0.188
IN. (4.7 MM) FROM ITS NORMAL “AT REST” POSITION.
(1) From the full in position, reel out approximately 30 feet (9.1 meters) of cable.
(2) Begin to reel in the cable from this point. While reeling in, pull up on the switch actuator
(see figure 513) of the cable foul indicator, and verify Rescue Hoist Assembly operation is
interrupted.
(3) While switch actuator is raised up, verify Rescue Hoist Assembly does not operate in
either reel in, or out, direction.
(4) Release the switch actuator and verify Rescue Hoist Assembly resumes normal operation
in both reel in and reel out modes.
(5) If Rescue Hoist Assembly fails to stop when actuator is pulled up, or if the Rescue Hoist
Assembly fails to resume normal operation when the actuator is released, refer to Table
106 for Troubleshooting Procedures.
D. Rescue Hoist Assembly Electrical Continuity Check
Using a digital multimeter, or equivalent, check electrical continuity at the MS3121F14-18PY
connector of the hoist harness assembly (Figure 1002, Item 900) as defined in Table 102
below.
Hoist Condition Measurement Required Result
Cable Full Out (Switch Unactuated) Pin C to Pin D Continuity
Pin C to all others except D Infinity
Pin R to Pin S (BL-29700 Open
20, -23, -24, -26 Only)
Cable Full Out (Switch Actuated) Pin C to Pin D Open
Pin C to all others except D Infinity
Table 102. Hoist Electrical Continuity Check
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Hoist Condition Measurement Required Result

Cable foul sensor actuated and with cable at Pin A to Pin B Open
any position. Pin A to all others except B Infinity
CAUTION: Do not displace switch Pin C to Pin D Open
actuator greater than 0.188
in. (4.7 mm) from its Pin C to all others except D Infinity
normal “at rest” position. Pin R to Pin S Continuity
Cable at least 15 feet (4.6 m) from Full In Pin E to Pin G Continuity
and Full Out (Switches Unactuated)
Pin E to all others except G Infinity
Cable at least 10 feet (3 m) from Full In Pin E to Pin G Open

and Full Out (Switches Actuated)
Pin E to all others except G Infinity
Cable Full In (Switch Unactuated) Pin A to Pin B Continuity

Pin A to all others except B Infinity
Pin R to Pin S (BL-29700 Open
20, -23, -24, -26 Only)
Cable Full In (Switch Actuated) Pin A to Pin B Open
Pin A to all others except B Infinity
Cable at any position All pins to Hoist Frame Infinity
Connector shell to Hoist Continuity
Frame
Table 102. Hoist Electrical Continuity Check (continued)
E. Control Pendant Electrical continuity Check (CP-400-1 and CP-400-2)
Using a digital multimeter (or equivalent), and a 5-28 VDC, 3A power supply (set to 10±0.2
VDC), check the continuity at the connector of the Control Pendant (Figure 1001, Items 110
and 120) as defined in table 103.
Control Pendant Condition Measurement Required Result
Thumbwheel control at the center (OFF) position Pin E(neg) to Pin D(pos) 10±0.1VDC
Pin C(neg) to Pin E(pos) <0.2VDC
Pin A(neg) to Pin D(pos) <0.2VDC
Pin B(neg) to Pin D(pos) <0.2VDC
Move Thumbwheel control slightly off center to UP Pin A(neg) to Pin E(pos) <0.2VDC
Pin B(neg) to Pin E(pos) <0.2VDC
Move Thumbwheel control gradually to Full UP Pin A(neg) to Pin E(pos) 9.8±0.2VDC
Pin B(neg) to Pin E(pos) <0.2VDC
Move Thumbwheel control slightly off center to Pin A (neg) to Pin E(pos) <0.2VDC
DOWN Pin B(neg) to Pin E(pos) <0.2VDC
Table 103 Control Pendant Continuity Check (CP-400-1, -2)
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Move Thumbwheel control gradually to Full Pin A(neg) to Pin E(pos) <0.2VDC
DOWN Pin B(neg) to Pin E(pos) 9.8±0.2VDC
ICS switch (Not Actuated) Pin N to Pin P Open Circuit
ICS switch (Actuated) Pin N to Pin P Closed Circuit
Frame Ground Pin G to Connector housing Closed Circuit
Table 103 Control Pendant Continuity Check (CP-400-1, -2) (Continued)
F. Control Pendant Electrical Continuity Check (CP-1600-1)
Using a digital multimeter (or equivalent), and a 5-28VDC, 3A power supply (set to
10±0.2VDC), check the continuity at the connector Control Pendant (Figure 1001, Item 130)
as defined in table 104.
Thumbwheel control at the center (OFF) position Pin 5(neg) to Pin 4(pos) 10±0.2VDC
Pin 3(neg) to Pin 5(pos) <0.2VDC
Move Thumbwheel control slightly off center to Pin 1(neg) to Pin 5(pos) <0.2VDC
UP Pin 2(neg) to Pin 5(pos) <0.2VDC
Move Thumbwheel gradually to Full UP Pin 1(neg) to Pin 5(pos) 9.8±0.2VDC
Move Thumbwheel control slightly off center to Pin 1(neg) to Pin 5(pos) <0.2VDC
DOWN Pin 2(neg) to Pin 5(pos) <0.2VDC
Move Thumbwheel gradually to Full DOWN Pin 1(neg) to Pin 5(pos) <0.2VDC
Pin 2(neg) to Pin 5(pos) 9.8±02VDC
ICS switch (Not Actuated) Pin 13 to Pin 14 Open Circuit
ICS switch (Actuated) Pin 13 to Pin 14 Closed Circuit
Frame Ground Pin 7 to Connector housing Closed Circuit
Table 104. Control Pendant Continuity check (CP-1600-1)
G. Control Pendant Cable Test
Test the Control Pendant Cable (Figure 1001, Items 140, 150, and 160) as follows:
(1) Remove Pendant Control Cable from Variable Speed Controller (Figure 1001, Items 50,
60, 70, and 80) and Control Pendant (Figure 1001, Items 110, 120, and 130).
(2) Using a digital multimeter (or equivalent), verify continuity readings (less than 1 ohm)
between designated pins at each connector (A to A, B to B, etc.).
(3) Verify continuity between connector shells
(4) Verify open circuit reading (more than 1 megaohm) between each pin of either connector
and all pins of the same connector.
(5) Verify open circuit reading between all connector pins and connector shell.
(6) If readings are not as specified, refer to table 106 for Troubleshooting.
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H. Variable Speed Controller Electrical Continuity Check
Using a digital multimeter (or equivalent), check the electrical continuity at the connectors of
the Variable Speed Controller (Figure 1001, Items 50, 60, 70, and 80) as defined in Table 105.
Contact To Contact Result
J1-W J1-X >5 MΩ
J1-W Case >100 MΩ
J1-X Case >100 MΩ
J1-O J1-N >100 MΩ
J1-O J13-P <1 Ω
J1-O Case >100 MΩ
J1-N J13-N <1 Ω
J1-N Case >100 MΩ
J1-D J13-F <1 Ω
J2-A J2-D >100 MΩ
J2-A Case >100 MΩ
J2-D Case >100 MΩ
J2-E J2-F >100 MΩ
J2-E Case >100 MΩ
J2-F Case >100 MΩ
J2-B J2-C >100 MΩ
J2-B Case >100 MΩ
J2-C Case >100 MΩ
J2-G J1-X >1 MΩ
J2-H J2-J Approx. 10 KΩ
J2-H Case >100 MΩ
J2-J Case >100 MΩ
J3-A, B, C, D, G Case >100 MΩ
J13-A, B, C, D, E, N, P Case >100 MΩ
J3-M J3-A 20±2Ω
J3-L J13-C <1 Ω
Table 105. Variable Speed Controller Electrical Continuity Check
I. Hook Load Test
Check for proper assembly and installation of the hook by applying a rated load of 450 lb.
(204 kg.), using Breeze Eastern TE-120-1 (or equivalent) as follows:
(1) Run Rescue Hoist Assembly to pay out cable until the hook can be connected to a weight
of 450 lb. (204 kg.) that is resting on the ground.
(2) Mount load on hook and slowly reel cable in until the weight is lifted off the ground.
(3) Once weight is off the ground, lower weight back to the ground.
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(4) Remove weight and run Rescue Hoist Assembly to the full in position to secure the hook
and bumper assembly on Rescue Hoist Assembly.
J. Hoist Cycle Counter
Check for proper operation of hoist cycle counter. The counter shall count up by one for each
revolution of the hoist drum. Observe the revolution counter to verify that for each revolution
of the hoist drum the counter increments by one.
K. Rated Load Test
NOTE: LIMIT SWITCHES MUST BE OPERATING, AND SET PROPERLY, BEFORE
PERFORMING LOAD TESTING.
NOTE: THE RATED LOAD TEST REQUIRES TESTING OF THE RESCUE HOIST
ASSEMBLY EITHER ON A HELICOPTER IN HOVER WITH THE COWLING
INSTALLED, OR ON A TEST STAND THAT IS CAPABLE OF SUBJECTING
THE RESCUE HOIST ASSEMBLY TO A 450 LB. (204 KG.) LOAD.
(1) Attach a load of 450 lb. (204 kg) to the hook, using Breeze Eastern TE-120-1 (or
equivalent), and verify 28 VDC power input is available to the Rescue Hoist Assembly.
(2) Reel out the wire rope cable to the full out position.
(a) After the Rescue Hoist Assembly operates at full speed, measure and record the speed
as the cable is reeling off the top layer on the drum. Use a tachometer to measure the
actual speed of the cable, or a stopwatch, to measure the time it takes for the cable to
travel over a known length. Cable speed must not exceed 210 ft/min. (1.1 meters/sec).
(b) Verify the cable speed slows during the first and last 10 to 13 feet (3.0 to 3.96 meters)
of cable travel, and the Rescue Hoist Assembly stops with a minimum of three wraps
on the drum.
(3) Wait 30 seconds.
(4) Reel in the cable onto the drum.
(a) After the Rescue Hoist Assembly is no longer operating at Intermediate (slow) speed,
measure and record the speed as the cable is reeling onto the innermost layer on the
drum. Cable speed must be at least 140 ft/min (0.71 meters/sec).
(b) Before the Rescue Hoist Assembly is operating at Intermediate (slow) speed, measure
and record the speed as the cable is reeling onto the top layer on the drum. Cable
speed must not exceed 210 ft./min. (1.1 meters/sec).
(5) Wait one minute.
(6) Repeat steps (2) through (5) three more times. On all of the three cycles, observe cable
wrapping on the drum, and verify the following:
(a) The cable wraps evenly on the drum during all cycles.
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(b) The limit switches operate properly, and that speed reduction occurs at the proper set
points.
(c) The cable payout displays in the pendant control and pilot display provide a repeatable
and consistent reading of cable payout (CP-1600-1 not included).
L. Bumper Assembly
Pay out 20 feet (6.1 meters) of cable.
(1) Reverse Rescue Hoist Assembly direction, and reel in cable until the full in limit switch
actuates.
(2) Observe deflection of conical bumper spring. Deflection should measure 1.3 to 1.7 inches
(33 to 43.2 mm.) as measured from top of spring retaining plate to bottom of spring (see
Figure 102).
Figure 102. Deflection of Bumper Assembly with Hook at Full In Position

M. If the System fails to meet any of the test parameters identified in Paragraphs 4A through 4L
above, or if the cable breaks, fouls, or fails to wrap properly on the drum, refer to Table 106
for Troubleshooting Procedures.
5. Troubleshooting Procedures
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 106 for Troubleshooting Procedures.
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Trouble Probable Cause Remedy

Cable Fails to Electrical Circuit Failure due to Replace Actuating Rod, Spring, Retaining Ring, or Switch
Retract due to Full In Limit Switch Circuit Actuator (see Para. 16C, Section 301, for removal, and Para.
Electrical Open 4B, Section 701, for installation)
Failure Check for Cable Foul (see Para. 2K, Section 501, for cable
foul removal)
Check Electrical Connectors per Figures 202 through 208
Check Wiring per Figures 202 through 208
Replace Full In Limit Switch (see Para. 16C, Section 301, for
removal, and Para. 4B, Section 701, for installation)
Replace Cable Foul Sensor Switch (see Para. 16A, Section
301, for removal, and Para. 4D, Section 701, for installation)
Electrical Circuit Failure due to Check Electrical Connectors per Figures 202 through 208
Power or Logic Failure Check Wiring per Figures 202 through 208
Check Helicopter Power
Replace Variable Speed Controller (see Para. 4, Section 301,
for removal, and Para. 17, Section 701, for installation)
Motor Fails Check Electrical Connectors per Figures 202 through 208
Replace Motor (see Para. 15, Section 301, for removal, and
Para. 5, Section 701, for installation)
Cable Fails to Cable Fouled due to Tension Replace Tension Roller (see Para. 14, Section 301, for
Extend or Roller Failure removal, and Para. 6, Section 701, for installation)
Retract due to Adjust/Replace Clutch for Tension Roller (see Para. 14,
Cable Foul Section 301, for removal, and/or Para. 6, Section 701, for
adjustment/installation)
Cable Foul due to Incorrect Realign Cable Guide by adjusting Level Wind Shaft timing
Timing Between Cable Guide with Drum (see Para. 2L, Section 501, for realignment)
and Drum
Cable Fouled due to Level Wind, Remove Rescue Hoist and send for repair (see Para. 3, Section
or Indexing Wheel, Failure 301, for removal, and Para. 16, Section 701, for installation)
Cable Fails to Rescue Hoist Assembly Failure Remove Rescue Hoist and send for repair (see Para. 3, Section
Extend due to due to Internal Mechanical 301, for removal, and Para. 16, Section 701, for installation)
Rescue Hoist Failure
Assembly
Failure
Cable Fails to Electrical Circuit Failure due to Check Limit Switch Setting (see Para. 4A, Section 101)
Extend due to Full Out Limit Switch Circuit Check for Fouled Cable (see Para. 2K, Section 501, for cable
Electrical Open foul removal)
Failure Check Electrical Connectors per Figures 202 through 208
Table 106. Troubleshooting Procedures
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Cable Fails to Electrical Circuit Failure due to Check Wiring per Figures 202 through 208
Extend due to Full Out Limit Switch Circuit Replace Full Out Limit Switch (see Para. 16B, Section 301,
Electrical Open (continued) for removal, and Para. 4C, Section 701, for installation)
Failure Replace Cable Foul Sensor Switch (see Para. 16A, Section
(continued) 301, for removal, and Para. 4D, Section 701, for installation)
Electrical Circuit Failure due to Check Electrical Connectors per Figures 202 through 208
Power or Logic Failure Check Wiring per Figures 202 through 208
Replace Variable Speed Controller (see Para. 4, Section 301,
for removal, and Para. 17, Section 701, for installation)
Defective Pendant Control and Replace Pendant Control and Grip Assembly (see Para. 5,
Grip Assembly Section 301, for removal, and Para. 18, Section 701, for
installation)
Rescue Hoist Defective Variable Speed Replace Variable Speed Controller (see Para. 4, Section 301,
Assembly fails Controller for removal, and Para. 17, Section 701, for installation)
to make speed Defective motor Replace Motor (see Para. 15, Section 301, for removal, and
Defective Pendant Control and Replace Pendant Control and Grip Assembly (see Para. 5,
Grip Assembly Section 301, for removal, and Para. 18, Section 701, for
installation)
Rescue Hoist Assembly is Remove Rescue Hoist and send for repair (see Para. 3, Section
binding 301, for removal, and Para. 16, Section 701, for installation)
Uncontrolled Rescue Hoist Assembly Failure Replace Rescue Hoist and send for repair (see Para. 3, Section
Rescue Hoist due to Brake, Drive Train, 301, for removal, and Para. 16, Section 701, for installation)
Assembly Up or Cable, or Hook Failure
Down due to
Failure to
Support Load
Uncontrolled Variable Speed Controller Logic Replace Variable Speed Controller (see Para. 4, Section 301,
Rescue Hoist or Power Failure for removal, and Para. 17, Section 701, for installation)
Assembly Up or Defective Pendant Control and Replace Pendant Control and Grip Assembly (see Para. 5,
Down due to Grip Assembly Section 301, for removal, and Para. 18, Section 701, for
Variable Speed installation)
Controller or
Pendant Failure
Uncontrolled Intermediate (Slow) Speed Limit Check Limit Switch Setting (see Para. 4A, Section 101)
Rescue Hoist Switch or Circuit Failure Check Electrical Connectors per Figures 202 through 208
Assembly Up or Check Wiring per Figures 202 through 208
Down due to Check Helicopter Power
Intermediate Replace Intermediate (Slow) Speed Limit Switch (see Para.
(slow) speed 16B, Section 301, for removal, and Para. 4C, Section 701, for
Limit Switch installation)
Failure
Table 106. Troubleshooting Procedures (continued)
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Uncontrolled Full In Limit Switch or Circuit Replace Actuating Rod, Spring, Retaining Ring, or Switch
Rescue Hoist Failure Actuator (see Para. 16C, Section 301, for removal, and Para.
Assembly Up 4B, Section 701, for installation)
due to Full In Replace Full In Limit Switch (see Para. 16C, Section 301, for
Limit Switch removal, and Para. 4B, Section 701, for installation)
Failure Bumper Spring Failure Replace Bumper (see Para. 7, 8 or 9, Section 301, for removal,
and Para. 12, 13, or 14 Section 701, for installation)
Uncommanded Rescue Hoist Assembly Failure Remove Rescue Hoist and send for repair (see Para. 3, Section
Rescue Hoist due to Brake, Drive Train, 301, for removal, and Para. 16, Section 701, for installation)
Assembly Down Cable, or Hook Failure
due to Failure to
Support Load
Uncommanded Variable Speed Controller Logic Replace Variable Speed Controller (see Para. 4, Section 301,
Rescue Hoist or Power Failure for removal, and Para. 17, Section 701, for installation)
Assembly Down Defective Pendant Control and Replace Pendant Control and Grip Assembly (see Para. 5,
due to Variable Grip Assembly Section 301, for removal, and Para. 18, Section 701, for
Speed installation)
Controller or
Pendant Failure
Inadvertent Variable Speed Controller Replace Variable Speed Controller, Cartridge, Cable Cutter,
Cable Cut Failure and Cable (see Para. 4, Section 301, for removal, and Para. 17,
Section 701, for installation of Variable Speed Controller;
Para. 3C, Section 301, for removal, and Para. 20, Section 701,
for installation of cartridge; see Para. 12, Section 301, for
removal, and Para. 8, Section 701, for installation of cable
cutter; and see Para. 11, Section 301, for removal, and Para.
10, Section 701, for installation of cable)
Cartridge Failure Replace Cartridge, Cable Cutter, and Cable (see Para. 3C,
Section 301, for removal, and Para. 20, Section 701, for
installation of cartridge; see Para. 12, Section 301, for
removal, and Para. 8, Section 701, for installation of cable
cutter; and see Para. 11, Section 301, for removal, and Para.
10, Section 701, for installation of cable)
Failure to Cut Variable Speed Controller Replace Variable Speed Controller (see Para. 4, Section 301,
Cable on Failure for removal, and Para. 17, Section 701, for installation)
Demand Cartridge Failure Replace Cartridge (see Para. 3C, Section 301, for removal, and
Electrical Circuit Failure Check Electrical Connectors per Figures 202 through 208
Cable Cutter Assembly Failure Replace Cable Cutter (see Para. 12, Section 301, for removal,
and Para. 8, Section 701, for installation)
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Pendant Control Potentiometer on Rescue Hoist Adjust potentiometer on Rescue Hoist Assembly (refer to
and Grip Assembly out of adjustment Section 101, Paragraph 4B)
Assembly Degradation of digital readout Replace Pendant Control and Grip Assembly (see Para. 5,
and/or pilot due to corrosion, or other Section 301, for removal, and Para. 18, Section 701, for
display digital malfunction installation), or pilot display (see Para. 6, Section 301, for
readout not removal, and Para. 19, Section 701, for installation)
within
acceptable limits
Cable wraps Timing between cable guide and Realign Cable Guide by adjusting Level Wind Shaft timing
loosely on drum, drum is incorrect with Drum (see Para. 2L, Section 501, for realignment)
does not pay out Worn tension roller Replace Tension Roller (see Para. 14, Section 301, for
smoothly, or removal, and Para. 6, Section 701, for installation)
feels rough Defective drag clutch assembly Adjust/Replace Clutch for Tension Roller (see Para. 14,
when reeling in, Section 301, for removal, and/or Para. 6, Section 701, for
or out adjustment/installation)
Brackets cracked, or damaged Replace Bracket(s) (see Para. 18, Section 301, for removal,
and Para. 9, Section 701, for installation)
Cable snaps at Timing between cable guide and Realign Cable Guide by adjusting Level Wind Shaft timing
turnaround drum is incorrect with Drum (see Para. 2L, Section 501, for realignment)
points
If defect cannot be corrected, contact Breeze-Eastern Customer Services at:
Breeze-Eastern
700 Liberty Avenue
Fax Number: 908-688-6495
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SCHEMATICS AND WIRING DIAGRAMS
1. General
This section provides all schematic diagrams, wiring, and interconnecting diagrams for the
HS-29700 series rescue hoists. These schematics and diagrams are provided for use during
disassembly, assembly, installation, and troubleshooting of the rescue hoists.
Figure 201 shows a typical circuit used to drive the cable foul indicator. Figure 202 shows
the rescue hoist assembly wiring diagram, while Figure 203 shows the wiring diagram for
HS-29700-200, -206, -207, -209, -211, and -213 rescue hoist systems. Figure 204 shows the
wiring diagram for HS-29700-201 rescue hoist system. Figure 205 shows the wiring diagram
for HS-29700-202, -205, -208, -210, -212, and -214 rescue hoist systems. Figure 206 shows
the wiring diagram for HS-29700-203 rescue hoist system, and Figure 207 shows the wiring
diagram for HS-29700-204, and -215 rescue hoist systems. Figures 208 and 209 show the
HS-29700-216, and HS-29700-217 rescue hoist systems, respectively.
CABLE
FOUL
INDICATOR
CABLE FOUL
SWITCH ON HOIST
AIRCRAFT
SUPPLIED
POWER
Figure 201. Typical Circuit Used to Drive the Cable Foul Indicator
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Figure 202. Rescue Hoist Assembly Wiring Diagram
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Figure 203. Wiring Diagram for HS-29700-200, -206, -207, -209, -211, and -213 Rescue Hoist Systems
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September 19, 2008
Figure 204. Wiring Diagram for HS-29700-201 Rescue Hoist System
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September 19, 2008
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September 19, 2008
Figure 207. Wiring Diagram for HS-29700-204, and -215, Rescue Hoist Systems
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September 19, 2008
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Figure 208. Wiring Diagram for HS-29700-216, Rescue Hoist System September 19, 2008
Inside Outside
Aircraft Aircraft
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Figure 209. Wiring Diagram for HS-29700-217, Rescue Hoist System
Page Intentionally Blank
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HS-29700 SERIES RESCUE HOIST ASSEMBLY SYSTEM
DISASSEMBLY
1. General
Use the Testing and Troubleshooting procedures, in Section 101, to establish the condition of the
Rescue Hoist System, or most probable cause, for its malfunction. These procedures are to be
followed to determine the extent of disassembly required for repair of the Rescue Hoist System,
and to limit the amount of maintenance required for returning it to a serviceable condition.
2. Disassemble the Rescue Hoist System in accordance with the following instructions. Reference
numbers in parenthesis refer to IPL in Section 1001. All mention of applying and disconnecting
power to the Rescue Hoist System should be accomplished using helicopter circuit breakers, or
equivalent acceptable means.
RESULT IN INJURY, OR DEATH. PROPERLY TRAINED PERSONNEL MUST
3. Remove Rescue Hoist Assembly (20, 21, 22, 23, 24, 25, or 26, Figure 1001), or Breeze-Eastern
supplied Cowling Assembly (30, if applicable), from helicopter as follows:
A. Disconnect power to Rescue Hoist Assembly (20, 21, 22, 23, 24, 25, or 26) by pulling
applicable circuit breakers.
B. Disconnect electrical connectors to cartridge, cable foul sensor, limit switches, and motor.
STORED, AND HANDLED IN COMPLIANCE WITH ALL LOCAL
STANDARDS, AND REGULATORY PRACTICES.
WARNING: THE CARTRIDGE MUST BE REMOVED BEFORE PERFORMING ANY
REMOVAL, OR MAINTENANCE PROCEDURES, INVOLVING THE RESCUE
HOIST ASSEMBLY, AND INSTALLED LAST AFTER THE RESCUE HOIST
ASSEMBLY IS ASSEMBLED, AND INSTALLED ON THE HELICOPTER.
C. To remove cartridge (40) from Rescue Hoist Assembly (20, 21, 22, 23, 24, 25, or 26), proceed
as follows:
(1) Short all pins of the cartridge (40) together with spring supplied with cartridge (if spring is
not available, short all pins with equivalent alternative), and place masking tape over pins
to hold spring in place.
(2) Remove tie wire and unthread cartridge (40) with packing (45) from cable cutter in cable
guide in Rescue Hoist Assembly (see Figure 301).
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Setscrew Holding Cable Cutter in Cable Guide

Cable Cutter
Cable Guide
Cartridge
Setscrews Holding
Fleet Angle Assy. in
Fleet Angle Assembly Cable Guide
Figure 301. View of Cable Cutter and Cartridge in Cable Guide (with tie wire removed)
D. Unlock four Dzus fasteners, and open Cowling Assembly (30, if applicable)
CAUTION: THE RESCUE HOIST ASSEMBLY WEIGHS APPROXIMATELY 48 LB (21.8 KG)

FOR BL-29700-20, -22, -23, -25, AND -26, AND 55 LB. (25 KG.) FOR
BL-29700-21, -24 WHEN MOUNTED ON THE HELICOPTER. TWO
INDIVIDUALS MUST BE AVAILABLE TO REMOVE THE RESCUE HOIST
ASSEMBLY FROM THE HELICOPTER UNLESS SUITABLE SUPPORT IS
PROVIDED TO HOLD THE WEIGHT OF THE RESCUE HOIST ASSEMBLY
WHEN REMOVED.
CAUTION: AFTER REMOVAL FROM THE HELICOPTER, REST THE RESCUE HOIST
ASSEMBLY ON THE TWO MOUNTING BRACKETS. DO NOT REST THE
RESCUE HOIST ASSEMBLY ON ANY OTHER COMPONENTS AS THIS MAY
DAMAGE THE RESCUE HOIST ASSEMBLY.
E. Remove attaching hardware (not shown in IPL, or supplied by Breeze-Eastern) from the two
mounting brackets and remove Rescue Hoist Assembly (20, 21, 22, 23, 24, 25, or 26, Figure
1001) and Cowling Assembly (30, if applicable) from helicopter. Install on clevis mount
maintenance fixture TE-132-1, or equivalent refer to section 901.
4. Remove Variable Speed Controller (50, 60, 70, or 80, Figure 1001), or Priority Switch Junction
Box (90), from helicopter as follows:
A. Disconnect power to Variable Speed Controller (50, 60, 70, or 80), or Priority Switch
Junction Box (90), by pulling applicable circuit breakers.
B. Disconnect electrical connectors, and remove four mounting screws (100, if applicable) from
Variable Speed Controller (50, 60, 70, or 80), or Switch Junction Box (90).
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C. Remove Variable Speed Controller (50, 60, 70, or 80), or Switch Junction Box (90), from
helicopter.
5. Remove Pendant Control and Grip Assembly (110, 120, or 130, Figure 1001) and Pendant Cable
Assembly (140, 150, or 160) from helicopter as follows:
A. Disconnect power to Pendant Control and Grip Assembly (110, 120, or 130) and Pendant
Cable Assembly (140, 150, or 160) by pulling applicable circuit breakers.
B. Disconnect electrical connector from the Pendant Cable Assembly (140, 150, or 160) to
Pendant Control and Grip Assembly (110, 120, or 130).
C. Remove Pendant Control and Grip Assembly (110, 120, or 130) from helicopter.
D. Disconnect the electrical connector from the Pendant Cable Assembly (140, 150, or 160) to
connector on the variable speed controller (50, 60, 70, or 80).
E. Remove Pendant Cable Assembly (140, 150, or 160) from helicopter.
6. Remove Pilot Display Assembly (170, 180, 190, or 200, Figure 1001) from helicopter as follows:
A. Disconnect power to Pilot Display Assembly (170, 180, 190, or 200) by pulling applicable
circuit breakers.
B. Remove four mounting screws (not shown in IPL, or supplied by Breeze-Eastern), and
disconnect electrical connector to Pilot Display Assembly (170, 180, 190, or 200).
C. Remove Pilot Display Assembly (170, 180, 190, or 200) from helicopter.
7. Remove and disassemble BL-5740-14 Swivel Hook Assembly (10, Figure 1002, Sheet 1, and
Figure 1003) as follows:
A. With the Rescue Hoist System installed on the helicopter, apply power to the system by
pushing in applicable circuit breakers.
B. Pay out approximately 6 feet (1.8 meters) of wire rope cable to allow the Swivel Hook
Assembly (10) to rest on flat surface (see Figure 302).
Swivel Hook Assembly (10) Bumper Assembly (30)
Figure 302. View of Swivel Hook Assembly Resting on Flat Surface
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C. Disconnect power to Rescue Hoist Assembly (20, 21, 22, 23, 24, 25, or 26, Figure 1001) by
pulling applicable circuit breakers.
D. To separate the bumper assembly from the Swivel Hook Assembly, pull up on bumper
assembly (30, Figure 1002, Sheet 1), and slide it up wire rope cable toward the Rescue Hoist
Assembly.
E. Remove cotter pins (10, Figure 1003) and locking screws (20) from Swivel Hook Assembly.
CAUTION: PARTS LOCATED INSIDE OF SWIVEL HOOK ASSEMBLY WILL FALL FREE
AFTER DISENGAGEMENT OF NUT FROM HOUSING. PLACE SWIVEL HOOK
ASSEMBLY ON A FIRM SURFACE BEFORE REMOVING NUT.
F. While holding the body (30, Figure 1003), unthread nut (40), and remove bottom half of
Swivel Hook Assembly.
G. Slide nut (40) and sleeve (50) up cable away from the ball end to expose terminal clamp (60).
NOTE: TERMINAL CLAMP (60) IS A TWO-PIECE MATCHED SET. KEEP BOTH
HALVES TOGETHER FOR FUTURE USE.
H. Remove retaining ring (70) from terminal clamp (60), and remove terminal clamp, sleeve
(50), nut (40), and bumper assembly (30, Figure 1002, Sheet 1) from wire rope cable.
I. Remove rubber bumper (80, Figure 1003) with label (90) from Swivel Hook Assembly.
J. If required remove label (90) from rubber bumper (80).
K. Align the holes in the body (30) to allow access to the spring pin (100) in the Swivel Hook
Assembly, and drive out the spring pin using a drift and a mallet.
L. Remove castellated nut (110) from Swivel Hook Assembly.
M. Remove body (30) from Swivel Hook Assembly.
N. Remove bearing retainer (120) with preformed packing (130 and 130A), thrust washer (141)
thrust bearing race (140), thrust bearing (150), from body (30).
O. Remove preformed packing (130 and 130A) from bearing retainer (120).
P. Remove spacer (170), and ball bearing (160), from hook assembly (180).
Q. Remove tube (190, Figure 1003) in the swivel hook by machining, or chiseling off flared end
of tube and tapping out with a drift and a mallet.
R. Remove keeper (200) and spring (210) in the hook (220).
8. Remove and disassemble HK-111-1 Swivel Hook Assembly (20, Figure 1002, Sheet 1, and
B. Pay out approximately 6 feet (1.8 meters) of wire rope cable to allow the Swivel Hook
Assembly (20) to rest on flat surface (see Figure 302).
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C. Disconnect power to Rescue Hoist Assembly (20, 21, 22, 23, 24, 25, or 26, Figure 1001) by
pulling applicable circuit breakers.
D. To separate bumper assembly from the Swivel Hook Assembly, pull up on bumper assembly
(30, Figure 1002, Sheet 1), and slide it up wire rope cable toward the Rescue Hoist Assembly.
E. Remove cotter pins (10, Figure 1004) and locking screws (20) from Swivel Hook Assembly.
CAUTION: PARTS LOCATED INSIDE OF SWIVEL HOOK ASSEMBLY WILL FALL FREE
AFTER DISENGAGEMENT OF NUT FROM HOUSING. PLACE SWIVEL HOOK
ASSEMBLY ON A FIRM SURFACE BEFORE REMOVING NUT.
F. While holding the housing (30), unthread nut (40), and remove bottom half of Swivel Hook
Assembly.
G. Slide nut (40) up wire rope cable away from the ball end to expose terminal clamp (50).
H. Remove retaining ring (60) from terminal clamp (50), and remove terminal clamp, nut (40),
and bumper assembly (30, Figure 1002, Sheet 1) from wire rope cable.
I. Remove hand ring (70, Figure 1004), key (80), and spacer (90) from bottom half of Swivel
Hook Assembly.
J. Align the holes in the housing (30) to allow access to the spring pin (100) in the Swivel Hook
Assembly, and drive out the spring pin using a drift and a mallet.
K. Remove castellated nut (110) from Swivel Hook Assembly.
L. Remove housing (30) from Swivel Hook Assembly.
M. Remove thrust washer (120) and bearing (130) from housing (30).
N. Remove flat washer (140) from hook assembly (150).
O. If quick-release pin (160, Figure 1004), or cable assembly (170), are damaged, remove the
rivet (180) in the hook (190) using chisel and mallet, and discard the damaged part(s).
9. Remove and disassemble HK-116-7 Swivel Hook Assemblies (Figure 1002, Sheet 1, Item 15, and
A. With the rescue hoist system installed on the helicopter, apply power to the rescue hoist by
B. Pay out approximately 6 feet (1.8 meters) of wire rope cable from the rescue hoist to allow the
hook and bumper assembly to rest on a flat surface (See figure 302).
C. Disconnect power from the rescue hoist (20, 21, 22, 23, 24, 25, or 26, Figure 1001) by pulling
applicable circuit breakers.
D. To separate bumper assembly (Figure 1002, Sheet 1, Item 30) from hook assembly (Figure
1005), pull up on bumper assembly while holding hook assembly to force the bottom of the
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September 19, 2008
compression spring off the nut (30) of the hook assembly. Slide bumper assembly along wire
rope cable (Figure 1002, Sheet 2, Item 90) away from hook assembly and toward the hoist.
CAUTION: PARTS LOCATED INSIDE OF THE HOOK ASSEMBLY WILL FALL FREE
AFTER DISENGAGEMENT OF THE NUT (FIGURE 1005, ITEM 30) FROM THE
HOUSING (100). PLACE THE HOOK ASSEMBLY ON A FIRM SURFACE
BEFORE REMOVING THE NUT.
E. Remove cotter pins (Figure 1005, Item 10) and locking screws (20) from the nut (30).
F. While holding the hook housing (100), loosen, unthread and remove nut and slide it along
wire rope cable away from hook assembly.
G. Remove ring (50) from terminal clamp (40), and then remove terminal clamp and nut from
the ball end of the wire rope cable.
H. Remove rubber bumper (60) from hook assembly.
I. Align hole in hook housing, or body, with hole on stem of hook, and using BLT-10300-J, or
equivalent, and a mallet, gently tap out orange colored pin (110) to remove it from hook
assembly.
J. Remove castellated nut (70) from top of the hook assembly.
NOTE: SWIVEL HOOKS (130) ARE PURCHASED ITEMS, WHICH THIS MANUAL
DOES NOT COVER. PLEASE CONTACT THE VENDOR OF THESE HOOKS
FOR THEIR RECOMMENDATIONS CONCERNING MAINTENANCE.
K. Remove housing (100) and flat washer (120) from hook.
L. Remove thrust washer (80) and bearing (90) from housing.
10. Remove and disassemble limit switch cover assembly (40, Figure 1002, Sheet 3, View B) as
follows (accomplish actions identified in Paragraphs 3C, and 3D for removal of cartridge and
opening of cowling prior to performing the steps below):
A. Remove screws (50), washers (60), lug terminal (70), cover (40) with gasket (80).
B. If necessary, remove and discard gasket (80) from cover (see Figure 303).
11. Remove wire rope cable (90, Figure 1002, Sheet 2) as follows (accomplish actions identified in
Paragraphs 3C, 3D, 7, 8, 9, and 10 for removal of cartridge, opening of cowling, and removal of
hook and limit switch cover assemblies, respectively, prior to performing the steps below):
FROM BROKEN CABLE STRANDS AND WIRES.
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Screw (50) and Lug Terminal (70)

Gasket (80)
Cover (40)
Screws (50) and Washers (60)

Figure 303. Limit Switch Cover
B. Pay out cable (90) at reduced speed until Rescue Hoist Assembly reaches full out limit.
WARNING: PERSONNEL SHOULD USE TOOLS THAT DO NOT CONDUCT ELECTRICITY
TO ACTUATE THE LIMIT SWITCHES. PROPER GROUNDING IS REQUIRED.
WARNING: THE RESCUE HOIST ASSEMBLY MUST NOT BE OPERATED IN THE
LOWERING DIRECTION BEYOND THE POSITION WHERE THE OPENING IN
THE DRUM FLANGE FOR THE SETSCREW (FIGURE 1002, SHEET 2, ITEM
101) IS VISIBLE. ROTATING THE DRUM IN THE LOWERING DIRECTION
BEYOND THIS POSITION WILL CAUSE THE CABLE TO BACKWIND
RESULTING IN SERIOUS DAMAGE TO RESCUE HOIST ASSEMBLY.
WARNING: DO NOT JOG THE LIMT SWITCHES – DAMAGE MAY OCCUR. PRESS,
HOLD, AND RELEASE SWITCH TO GAIN DESIRED CABLE POSITION.
C. Carefully override the full out limit switch (S2, Figure 304) by manually closing switch with a
small screwdriver, or equivalent tool, until the opening in the drum flange for setscrew (101,
Figure 1002, Sheet 2) is visible and approximately 6 inches (0.15 meters) of cable remains on
the Rescue Hoist Assembly (less than 1 wrap).
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Designation Name Setting Position
S1 Intermediate (Slow) Speed Up Switch 10 – 13 ft. (3.0 – 3.96 m.) from full in.
S2 Full Out Switch 3 to 4 wraps of cable on the drum.
S3 Full In Switch (located in cable guide assembly, None (switch actuates when hook assy.
no adjustment required) contacts fleet angle assy. as wire rope
cable is reeled in to full in position).
S4 Intermediate (Slow) Speed Down Switch 10 – 13 ft. (3.0 – 3.96 m.) from full out.
R1 Potentiometer for setting Full In Cable Payout 000 ft. (00.0 m.) at full in.
R3 Potentiometer for setting Full Out Cable Payout 164 ft. (50.0 m.) at full out.
Screws for setting

R1 potentiometer
S2
R1
R3 View of Cyclocentric End
with Limit Switch Cover
(40, Figure 1002, Sheet 3,
S4 View B) Removed
S1
View of Cable Guide with Full In Limit

Switch Cover (600, Figure 1002, Sheet 5,
View D) Removed
S3 S3
Figure 304. Location of Full In, Full Out, and Intermediate (Slow) Speed Limit Switches, and Potentiometers
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CAUTION: ONCE THE CABLE IS REMOVED, DO NOT ROTATE DRUM IN EITHER
DIRECTION. THE DRUM IS IN THE CORRECT POSITION FOR
INSTALLATION OF A NEW CABLE. ROTATING THE DRUM WITHOUT THE
CABLE ATTACHED WILL CAUSE THE TIMING BETWEEN THE CABLE
GUIDE AND THE DRUM TO BE INCORRECT, POSSIBLY RESULTING IN
DAMAGE TO THE DRUM AND THE CABLE. IF OTHER MAINTENANCE IS
REQUIRED, WHERE THE CABLE GUIDE AND THE DRUM HAVE TO BE
MOVED (I.E., TENSION ROLLER REPLACEMENT), USE THE CABLE
ALIGNMENT PROCEDURE, IN PARAGRAPH 2L, OF CHECKS AND
INSPECTIONS, SECTION 501.
D. Disconnect power to Rescue Hoist Assembly (20, 21, 22, 23, 24, 25, or 26, Figure 1001).
E. Remove setscrew (101, Figure 1002, Sheet 2) from drum flange to allow removal of wire rope
cable (see Figure 305).
F. Remove the welded end of wire rope cable (90) from slot in the drum flange (see Figure 306).
Continue to remove the cable by feeding the cable forward from the drum through cable guide
and out the fleet angle assembly (130, Figure 1002, Sheet 3, View A).
Setscrew (101)
Figure 305. View of Setscrew in Drum Flange
Hole in Drum Flange for Setscrew
Slot in Drum Flange for

Welded End of Cable
Figure 306. View of Slot in Drum Flange for Welded End of Cable
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12. Remove cable cutter assembly (110, Figure 1002, Sheet 2) as follows (accomplish actions
identified in Paragraphs 3C, 3D, 7, 8, 9, 10, and 11 for removal of cartridge, opening of cowling,
and removal of hook and limit switch cover assemblies, and wire rope cable, respectively, prior to
performing the steps below):
A. If not accomplished previously, remove electrical connector (not shown in IPL, not supplied
by Breeze-Eastern), tie wire, and cartridge (40, Figure 1001) with packing (45) per paragraph
3C above.
B. Remove setscrew (120, Figure 1002, Sheet 2) holding cable cutter in cable guide (see Figure
301).
C. Remove cable cutter (110) from Rescue Hoist Assembly.
13. Remove and disassemble fleet angle assembly (130, Figure 1002, Sheet 3, View A) as follows
(accomplish actions identified in Paragraphs 3C, 3D, 7, 8, 9, 10 and 11 for removal of cartridge,
opening of cowling, removal of hook and limit switch cover assemblies, and wire rope cable,
respectively, prior to performing the steps below):
A. Position cable guide near center of the Rescue Hoist Assembly so three setscrews (100, Figure
1002, Sheet 3, View A) are accessible.
B. Remove setscrews (100) holding fleet angle assembly in cable guide (see Figures 301 and
307).
C. Remove fleet angle assembly (130, Figure 1002, Sheet 3, View A) from Rescue Hoist
Assembly.
D. Remove shoulder screws (131, Figure 1002, Sheet 4, View F) from fleet angle assembly (see
Figure 307).
Roller Cover (132) Setscrews (100)
Shoulder Screw (131)
Figure 307. View of Fleet Angle Assembly
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E. Separate roller cover (132) from roller housing (133), and remove springs (134) and shaft
retainers (135).
F. Remove roller shafts (136) and roller assemblies (137).
G. Disassemble roller assemblies (137) by removing bearings (138) from rollers (139).
H. Remove retaining ring (141) from roller housing (133).
I. Remove bearing retainer (142) with bearings (143) from roller housing (133).
J. Remove bearings (143) from bearing retainer (142).
K. Remove screws (144) and guide plate (145) from roller cover (132).
14. Remove tension roller (140, Figure 1002, Sheet 3, View A) as follows (accomplish actions
identified in Paragraphs 3C, 3D, 10, and 11 for removal of cartridge and opening of cowling,
removal of limit switch cover assembly, and wire rope cable, respectively, prior to performing the
steps below):
A. Apply power to Rescue Hoist Assembly (20, 21, 22, 23, 24, 25, or 26, Figure 1001).
B. Position cable guide approximately at center of Rescue Hoist Assembly, equidistant from end
flanges.
C. Disconnect power to Rescue Hoist Assembly.
D. At point where wire rope cable comes off drum and enters cable guide, insert a soft wooden
wedge, or suitable alternative, between wire rope cable on drum and flange spacer to prevent
the wire rope cable from loosening on the drum.
E. Remove cotter pins (150, Figure 1002, Sheet 3, View A), spring retainers (160), springs
(170), pressure roller assembly (180), and washers (190) from cable guide assembly (see
Figure 308).
Pressure Roller (180)
Spring (170)
Spring
Retainers
(160)
Cotter Pins (150)
Figure 308. View of Pressure Roller in Cable Guide Assembly
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F. Remove tie wire, screws (200, Figure 1002, Sheet 3, View A), and washers (210) to remove
cover (220) to allow access of the motor end of the tension roller shaft (230).
G. Remove cotter pin (240A, prior to implementation of ASB BL-29700-A25-01), or tie wire
and spring pin (240B, after implementation of ASB BL-29700-A25-01), to unlock the
adjusting nut (250A, prior to implementation of ASB BL-29700-A25-01), or grooved
adjusting nut (250B, after implementation of ASB BL-29700-A25-01). See Figure 309.
Friction Disc (300) Grooved Adjusting

Nut (250B)
Tension Roller
Shaft (230)
Flat Washer (320)

Spring Washer (310)
Figure 309. View of Drag Clutch (shown without tie wire and cotter / spring pin)
CAUTION: SPACER (260), BEARING (270), WASHER (280), AND GEAR AND CLUTCH
ASSEMBLY (290) WILL FALL FREE WHEN REMOVING THE SHAFT (230).
H. With a rubber mallet, remove tension roller shaft (230), spacer (260), bearing (270), flat
washer (280), and gear and clutch assembly (290) out of end flange to access tension roller
(140).
I. Remove the friction disc (300), spring washer (310), and flat washer (320). Unscrew the
adjusting nut (250A), or grooved adjusting nut (250B). See Figure 309.
J. Slide the shaft (230) out until the tension roller (140) can be removed.
15. Remove motor (330, or 340, Figure 1002, Sheet 2) as follows (accomplish actions identified in
Paragraphs 3A through 3D for removal of cartridge and opening of cowling prior to performing
the steps below):
A. Disconnect electrical connector from motor (330, or 340).
B. Remove cap screws (350), flat washers (360), and motor (330, or 340).
C. Remove preformed packing (370) from motor.
D. Secure key (380) onto motor shaft with masking tape, or suitable equivalent.
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Cap Screws (350) and

Flat Washers (360)
Motor Assembly (330, or 340)
Figure 310. View of Motor Assembly

16. Removal of Limit, and Cable Foul Switches and Harness Assembly (refer to Figure 301 and
Figure 1002, Sheets 4 and 5):
A. Remove the cable foul indicator switches (390, Figure 1002, Sheet 4, View C) as follows
(accomplish actions identified in Paragraphs 3A through 3D for removal of cartridge and
opening of cowling prior to performing the steps below):
(1) Insert a soft wooden wedge, or suitable alternative, between wire rope cable on drum and
cable foul switch actuator (400) to allow access to the switches.
(2) Remove sealant from terminals, and unsolder the wires to the cable foul sensor switches
(390).
(3) Remove the self-locking nuts (410), screws (420), washers (430), switch retainer plates
(440), switch actuators (450), insulators (460), and cable foul switches (390). See Figure
311.
B. Remove the full out and intermediate (slow) speed (up and down) limit switches (470, Figure
1002, Sheet 5, View E) as follows (accomplish actions identified in Paragraphs 3A through
3D, and 10 for removal of cartridge and opening of cowling, and removal of limit switch
cover assemblies, respectively, prior to performing the steps below):
(1) Remove screws (480) and potentiometer and cycle counter mounting bracket (490).
(2) Unsolder the wires to the limit switches (470, Figure 1002, Sheet 5, View E).
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Cable Foul Sensor Wiring Harness Cable Foul Sensor Wiring Harness
Cable Foul Indicator Switches (390)

Cable Foul Indicator Switches (390)
Figure 311. View of Cable Foul Indicator Switches and Harness Assembly
(3) Remove screws (500) and washers (510) holding the limit switch mounting brackets (520,
530, or 540) in place.
(4) Remove self-locking nuts (550), screws (560), switch actuators (570), insulators (460),
and limit switches (470) from mounting brackets (520, 530, or 540).
C. Remove the full in limit switches (Figure 312, and Item 470, Figure 1002, Sheet 5, View D)
as follows (accomplish actions identified in Paragraphs 3C, 3D, and 13 for removal of
cartridge, opening of cowling, and removal of the fleet angle assembly, respectively, prior to
performing the steps below):
(1) Position cable guide near the motor end of the Rescue Hoist Assembly so the full in limit
switch cover (600) is accessible.
(2) Remove screws (580), washers (590), full in limit switch cover (600) with gasket (610),
and remove and discard gasket, if necessary.
(3) Unsolder the wires to the limit switches (470).
(4) Remove retaining ring (620), actuating rod (630), and spring (640).
(5) Remove screws (560), actuator guide (650), insulators (460), switch actuator (660), and
limit switches (470).
D. Remove harness assemblies (670 and 900, Figure 1002, Sheet 2) as follows:
(1) Disconnect electrical connector from harness assembly (670) to helicopter.
(2) Disconnect electrical connectors from harness assembly (670) to harness assembly (900)
on the Rescue Hoist Assembly and remove harness assembly (670).
(3) Unsolder all limit switch wiring connections identified in Paragraphs 16A, 16B, and 16C
above, and remove harness assembly (900).
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Switch Actuator (660)
Spring
(640)
Retaining
Ring (620)
Actuator Actuating
Guide (650) Rod (630)
Screws (560)
Full In Limit Switches

(S3, and 470)
Figure 312. View of Full In Limit Switch
17. If necessary, remove labels and nameplate (680 through 710, Figure 1002, Sheet 2) as follows:
A. All typed-in information on nameplates should be recorded prior to removal. This information
will be required when the new nameplate is installed during assembly. If nameplate is
illegible or missing, contact Breeze-Eastern with all known information concerning Rescue
Hoist Assembly for original or new data.
B. Remove label / nameplate by using a sharp knife, razor blade or equivalent.
C. Remove any residual adhesive from the parts the label / nameplate was applied to by using
similar means as removing the label, and cleaning off the parts with a lint-free cloth saturated
with isopropyl alcohol, or equivalent.
18. Remove Rescue Hoist Assembly mounting brackets (850, 851, 860, and 861, Figure 1002, Sheet
2) as follows:
NOTE: DO NOT REMOVE BOTH RESCUE HOIST ASSEMBLY MOUNTING
BRACKETS AT THE SAME TIME. REMOVE, AND REPLACE ONE BRACKET
BEFORE REMOVING, AND REPLACING, THE OTHER RESCUE HOIST
ASSEMBLY MOUNTING BRACKET.
A. Remove tie wire, nuts (820), washers (830), and right-hand (RH) mounting bracket (850, or
851) from below motor on end of Rescue Hoist Assembly. See Figure 313.
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Left-Hand (LH) Right-Hand (RH)
Mounting Mounting
Bracket (860, or 861) Bracket (850, or 851)
Nuts (820), Washer (830),

and Loop Clamp (840) Nuts (820) and Washers (830)
Figure 313. Views of Mounting Brackets

B. Remove tie wire, nuts (820), washer (830), loop clamp (840), and left-hand (LH) mounting
bracket (860, or 861) from below limit switch cover on end of Rescue Hoist Assembly.
C. If brackets removed are old configuration (850, and / or 860) discard brackets, replace with
new configuration (851, and / or 861), and note in hoist / helicopter maintenance log.
19. Remove levelwind follower (890, Figure 1002, Sheet 2) as follows:
A. Thread a 4-40 (.112-40 NC-2B) screw into follower and press in to allow access to retaining
ring (870).
B. Remove retaining ring (870), and flat washers (880) that secures follower (890) in cable guide
assembly.
C. Remove follower (890) from cable guide assembly.
D. Unthread screw from follower.
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CLEANING
1. General
Cleaning instructions for the components of the Rescue Hoist Systems 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, corrosion, rust and moisture
must be removed, as these destructive agents will eventually cause operational failure.
Equipment/Material Name
ASTM-D3699 Kerosene
TT-I-735 Isopropyl Alcohol
Anti-Static Plastic and Glass Cleaner Plasti-Glass
Brush Soft Bristle Brush
Vacuum Cleaner Vacuum Cleaner
MIL-G-81322, A-A-59173 Grease, or Lubricant for Hook Bearing
DC-33 (Dow Corning Corp.)
Table 401. Equipment and Materials Required for Cleaning (suitable equivalents
acceptable)
WARNING: KEEP HANDS, BODY, AND CLOTHING AWAY FROM RESCUE HOIST
ASSEMBLY, SPECIFICALLY “PINCH POINTS,” WHERE CABLE ENTERS THE
CABLE GUIDE AND CONTACTS THE DRUM.
INJURY OR DEATH. PROPERLY TRAINED PERSONNEL MUST UTILIZE
ALL RESCUE HOISTS.
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
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.
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CAUTION: DO NOT LET KEROSENE, ISOPROPYL ALCOHOL, HYDRAULIC FLUIDS,
LUBRICANTS, SOLVENTS, DETERGENTS, OR FUELS COME INTO CONTACT
WITH HOIST TENSION ROLLER.
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.
A. Clean all metal parts with kerosene, isopropyl alcohol, or equivalent. Remove caked-on dirt
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 paint 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 or nameplate, clean surface with isopropyl alcohol to remove any
dirt, dust, soot, 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 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.
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September 19, 2008
(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. Cowling, 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 cowling, hoist drum, hook, and cable with clean
fresh water as specified below:
NOTE: NEEDLE THRUST BEARING, AND THRUST RACE IN THE HOOK
ASSEMBLY ARE MANUFACTURED FROM 52100 STEEL. IF THE HOOK
ASSEMBLY IS IMMERSED IN WATER (FRESH OR SALT WATER), OR
OPERATED IN GEOGRAPHICAL, HIGH HUMIDITY ENVIRONMENTS,
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 with
MIL-G-81322, A-A-59173, or equivalent, and assemble components per Section 701,
Assembly. Do not install hook and bumper assembly onto cable at this time.
NOTE: HOOK ASSEMBLIES THAT HAVE NEEDLE BEARINGS (AS DEPICTED IN

FIGURE 401) MUST BE LUBRICATED AFTER CLEANING. REFER TO
ASSEMBLY PROCEDURES.
Figure 401. Example of Corrosion on Hook Assembly Parts
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(3) Remove and disassemble hook and bumper assembly as specified in Disassembly (Section
301).
(4) Rinse off hook and bumper assembly components so that all saltwater contamination has
been thoroughly washed off. Set hook components aside to allow them to thoroughly dry.
(5) Fill a container, like a kiddy pool or equivalent, with fresh water and reel out cable into
container until hoist reaches the full out position.
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 [0.3 BAR]).
(6) While cable is immersed in fresh water, rinse off cowling (if applicable), hoist drum and
cable guide assembly with fresh water. Failure to thoroughly rinse saltwater
contamination off drum will result in corrosion (Figure 402).
(7) Pass cable through clean, dry cloth as cable is being reeled in onto hoist.
(8) After reeling in cable, assemble and install hook and bumper assembly components per
Assembly (Section 701).
Figure 402. Example of Corrosion on Drum

M. Sight Glass Cleaning
Clean sight glass 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.
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September 19, 2008
(3) Use a 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, soot, and grime by wiping with isopropyl alcohol and a
clean cloth.
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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. Furthermore, a maintenance log must be maintained
for each Rescue Hoist System in order to keep track of hoist cycles, maintenance actions and inspections.
Details of Vital Point Inspections identified in this table below are contained in Section 701, Assembly.
Recommended Part Name, Section, Paragraph Figure and Item Number Inspection Required
Frequency of
Inspections (whichever
occurs first)*
Fleet Angle Assy., Sec. 501, Para. 2E Fig. 1002, Sh. 3, View A, Item 130 Vital Point Inspection for Fleet Angle
Assembly Installation
Setscrew, Sec. 701, Para. 8B Fig. 1002, Sh. 2, Item 120 Vital Point Inspection for Cable Cutter
Installation
Setscrew, Sec. 701, Para. 10D Fig. 1002, Sh. 2, Item 101 Vital Point Inspection for Wire Rope
Cable Installation
Wire Rope Cable, Sec. 701, Para. 10H Fig. 1002, Sh. 2, Item 90 Vital Point Inspection for Wire Rope
Cable Installation
Terminal Clamp and Retaining Ring, Sec. Fig. 1003, Items 60 & 70 Vital Point Inspection for Terminal
701, Para. 12C, 12D, 13C, 13D, 14C & Fig. 1004, Items 50 & 60 Clamp Installation
14D Fig. 1005, Items 40 & 50
Rivet, and Tube, Sec. 701, 12F, & 13E Fig. 1003, Item 190 & Fig. 1004, Vital Point Inspection for Keeper
Item 180, Installation
Spring Pin, Sec. 701, Para. 12K, 12L, Fig. 1003 & 1004, Item 100 Vital Point Inspection for Spring Pin
As Required 13L, 13M, 14I & 14J Fig. 1005, Item 110 Installation
After Assembly Locking Screws and Cotter Pins, Sec. 701, Fig. 1003, 1004 & 1005, Items 10 & Vital Point Inspection for Locking
Para. 12P, 13R, & 14M 20 Screws and Cotter Pins Installation
Swivel Hook Assy., Sec. 701, Para. 12T, Fig. 1003, 1004, & 1005 Item 1 Vital Point Inspection for Swivel Hook
13U, & 14Q Assembly Installation
Limit Switches, Sec. 101, Para. 4A Fig. 1002, Sh. 5, View E, Item 470 Functional Test of Switches and Check
of Switch Settings
Potentiometers, Sec. 101, Para. 4B Fig. 1002, Sh. 5, View E, Items 730 Functional Test of Cable Payout
& 740 Displays
Cable Foul Switches, Sec. 101, Para. 4C Fig. 1002, Sh. 4, View C, Item 390 Functional Test and Check of Settings
for Cable Foul Sensor
Hook Load Test, Sec. 101, Para. 4I Fig. 1002, Sh. 1, Items 10, 15 & 20 Check for Proper Assembly and
Installation of Swivel Hook Assembly
Rescue Hoist System, Sec. 101, Para. 4K Fig. 1001, Items -1 thru -17 Rated Load Test
Bumper Assembly, Sec. 101, Para. 4L Fig. 1002, Sh. 1, Item 30 Check Condition
* One hoist cycle is equal to reeling out cable from full in to full out, and then reeling in cable back to full in.
** 1500 hoist cycle recommended replacement criteria is under ideal laboratory conditions, may not be representative of
actual operating conditions, or usage.
Table 501. Inspection Requirements
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Frequency of
occurs first)*
Preflight Cable Foul Sensor, Sec. 501, Para. 2G Fig. 1002, Sh. 4, View C, Item 400 Functionally check
Swivel Hook Assy., Sec. 501, Para. 2D Fig. 1002, Sh. 1, Items 10, 15, & 20 Inspect for binding when installed
Preflight / Post Wire Rope Cable, Sec. 501, Para. 2F Fig. 1002, Sh. 2, Item 90 Inspect for defects
Flight Rescue Hoist, Sec. 501, Para. 2H thru 2N Fig. 1001, Items 20 thru 26 Preflight, In Flight, Post Flight
Inspections as specified
Perform post Swivel Hook Assy., Sec. 501, Para. 2D, Fig. 1002, Sh. 1, Items 10, 15, & 20 Disassemble/ Clean / Inspect all
and Sec. 401, Para. 1L subassemblies for defects.
flight if hook is
Relubricate bearing(s), as required
found binding, or
hook / cable was Wire Rope Cable, Sec. 501, Para. 2F, and Fig. 1002, Sh. 2, Item 90 Clean / Inspect for defects
immersed in Sec. 401, Para. 1L
water Rescue Hoist, Sec. 401, Para. 1L Fig. 1001, Items 20 thru 26 Clean (specifically the drum after cable
has been reeled out)
After last use of Rescue Hoist, Sec. 501, Para. 2H thru 2N Fig. 1001, Items 20 thru 26 Operational check of intermediate
(slow) speed up/down and full in/full
the day, and if out switches, and cable foul circuit
not used for last 7 Cable Guide Shaft, Sec. 501, Para. 2O Figure 520 Clean, inspect, and lubricate shaft, as
days, prior to the required
first use of the Wire Rope Cable, Sec. 501, Para. 2F Fig. 1002, Sh. 2, Item 90 Inspect full length for defects, and wear
day
Levelwind Follower, Sec. 501, Para. 2P Fig. 521 Clean / Inspect
Every 3 months / Fig. 1002, Sh. 2, Item 890
100 hoist cycles Levelwind Shaft, Sec. 501, Para. 2Q Figure 522 Clean / Inspect
Cable Guide Shaft, Sec. 501, Para. 2O Figure 520 Clean / Inspect / Lubricate Shaft
Geneva Wheel, Sec. 501, Para. 2R Figures 523, and 524 Inspect
Pressure Roller, Sec. 501, Para. 2B Fig. 1002, Sh. 3, View A, Item 180 Inspect
6 months / 400 Tension Roller, Sec. 501, Para. 2C Fig. 1002, Sh. 3, View A, Item 140 Inspect
flight hours / 100 Swivel Hook Assy., Sec. 501, Para. 2D Fig. 1002, Sh. 1, Items 10, 15, & 20 Disassemble and Inspect
hoist cycles Fleet Angle Assy., Sec. 501, Para. 2E Fig. 1002, Sh. 3, View A, Item 130 Clean / Inspect
Cable Foul Sensor, Sec. 501, Para. 2G Fig. 1002, Sh. 4, View C, Item 400 Clean / Inspect
Wiring Harness, Sec. 501, Para. 2S Fig. 1002, Sh. 2, Items 670 and 900 Clean / Inspect
Table 501. Inspection Requirements (continued)
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Frequency of
occurs first)*
Limit Switches, Sec. 101, Para. 4A Fig. 1002, Sh. 5, View E, Item 470 Functional Test of Switches and Check
of Switch Settings
Potentiometers, Sec. 101, Para. 4B Fig. 1002, Sh. 5, View E, Items 730 Functional Test of Cable Payout
& 740 Displays
Cable Foul Switches, Sec. 101, Para. 4C Fig. 1002, Sh. 4, View C, Item 390 Functional Test and Check of Settings
for Cable Foul Sensor
Annually Hook Load Test, Sec. 101, Para. 4I Fig. 1002, Sh. 1, Items 10, 15, & 20 Check for Proper Assembly and
Installation of Swivel Hook Assembly
Rescue Hoist System, Sec. 101, Para. 4K Fig. 1001, Items -1 thru -17 Rated Load Test
Bumper Assembly, Sec. 101, Para. 4L Fig. 1002, Sh. 1, Item 30 Check Condition
Wire Rope Cable, Sec. 501, Para. 2F Fig. 1002, Sh. 2, Item 90 Inspect swaged ball end of cable for
integrity of attachment
Every 1500 hoist Wire Rope Cable, Sec. 501, Para. 2F Fig. 1002, Sh. 2, Item 90 Recommended Replacement
cycles**
Every 5 years / Detailed Inspection of End Flanges and
Mounting Brackets
2000 hoist cycles,
and prior to
installation of Rescue Hoist, Sec. 501, Para. 2H thru 2N Fig. 1001, Items 20 thru 26
hoist onto
helicopter
Every 5 years / Detailed Inspection/Overhaul
2000 hoist cycles
Cycle Counter Reading 264 2640 6600 13200 26400 105600
Equivalent Hoist Cycles 1 10 25 50 100 400
Table 501. Inspection Requirements (continued)
2. Inspections
A. General
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.
WARNING: KEEP HANDS, BODY, AND CLOTHING AWAY FROM RESCUE HOIST,
SPECIFICALLY “PINCH POINTS,” WHERE THE CABLE ENTERS THE CABLE
GUIDE AND CONTACTS THE DRUM.
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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 HOIST TO
PREVENT INJURY FROM LUBRICANTS, SOLVENTS, AND OTHER MATERIALS
USED ON THE RESCUE HOIST, AS WELL AS METAL PARTS AND OTHER
DEBRIS.
CAUTION: THE TENSION ROLLER AND PRESSURE ROLLER WORK 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.
NOTE: BEFORE TURNING POWER ON, THE RESCUE HOIST COMPONENTS MUST BE
VISUALLY INSPECTED FOR SOUND STRUCTURAL INTEGRITY AND PROPER
INTEGRATION.
Visually inspect for obvious wear, damage, or corrosion, as specified below:
(1) Check all parts for nicks, cracks, scratches and corrosion.
(2) All gears and shafts shall be free of nicks, burrs, sharp edges, and wear (see Figure 501).
(3) Check the two mounting brackets for the hoist interface with the helicopter for cracks,
scoring, and elongation of holes (see Figure 801).
(4) Examine threads for stripping, distortion, nicks, and cross threading.
(5) All bearings shall be inspected to standard aerospace 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 are
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.
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September 19, 2008
Figure 501. Examples of Unacceptable Damage to Gear

(6) Inspect all mating and faying surfaces for possible damage.
(7) Check all retaining rings and grooves for obstructions, or damage that might prevent
assembly.
B. Pressure Roller (see Figure 502, and Figure 1002, Sheet 3, View A)
(1) Check diameter of groove in pressure roller (180, Figure 1002, Sheet 3, View A) when
installed on Hoist using vernier calipers. If diameter is less than 0.916 in. (23.27 mm.),
replace pressure roller (see Figure 502).
(2) Check condition of groove in pressure roller. If groove shows signs of any abnormalities (i.e.,
cable marks), replace pressure roller (see Figure 502).
Normal Wear. Abnormal Wear
(note impression of
cable in groove).
Replace roller if diameter of Replace roller.
groove is less than
0.916 inches (23.27 mm.).
Figure 502. Roller Replacement Criteria (examples of rollers shown, actual rollers look different)
C. Tension Roller (see Figure 503, and Figure 1002, Sheet 3, View A)
(1) Remove cable per Disassembly, Section 301, and check depth of groove on tension roller
(140, Figure 1002, Sheet 3, View A) when installed on Hoist using depth gage (see Figure
503). Measure depth from the top of the unworn ends of the roller to the deepest part of the
groove. If this depth exceeds 0.050 in. (1.3 mm.), replace the tension roller.
(2) Visually inspect tension roller for any abnormal wear, or obvious defects of material (i.e.,
cracks, abrasion, degradation). Replace tension roller if any abnormal wear or any of these
defects are found (see Figure 503), and install cable per Assembly, Section 701.
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Figure 503. Tension Roller Replacement Criteria
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September 19, 2008
D. Swivel Hook Assembly (see Figure 1002, Sheet 1, and Figures 1003, 1004, and 1005)
(1) Inspect hook assembly (10, 15, or 20, Figure 1002, Sheet 1) for cracks, corrosion, damaged
threads, and gouges (reference section 401, Cleaning). See Figure 504.
(2) Disassemble hook per Section 301, clean per Section 401, 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.
(3) Check that 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 505).
Bumper
Threads Assembly Locking
Rivet - Grommet Screws &
- Spring Cotter Pins
Keeper - Retainer (Qty. 2)
Lock
Plungers Hook and

(Qty. 2) Handwheel
Springs bearings
Dowel
Pins (not shown)
(Qty. 2) Lock
Pin and
Lanyard
Figure 504. Various Hooks and Assembly (Typical)
Figure 505. Required Terminal Clamp Orientation (typical)
(4) After assembly, check that the hook swivels freely without binding.
(5) Check that the keeper in the hook operates without binding, and locks properly, and the rivet
holding the keeper is properly fastened.
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(6) Check to see that locking screws are properly seated in the body and locked in place with the
cotter pins.
(7) Service Bulletin BL-5448-25-01 and Service Bulletin BL-5448-1-25-01, titled “Breeze-Eastern
Hook Assembly Nut Part Numbers BL-5448 and BL-5448-1 Inspection Requirement” addresses
the Breeze-Eastern Hook Assembly Nut (on BL-5740-14 Hook Assembly ONLY, Figure 1003,
item 40).
(a) Nut part numbers BL-5448 and BL-5448-1 sustained cracks through the drilled holes.
Analysis determined that the cracks developed as a result of stress corrosion. The Nut is
used in the Hook Assembly and is made from AMS 5643 (17-4PH), which is a
precipitation hardened stainless steel. Industry practice recommends that this material
be aged at temperatures above 1000°F (538°C) if the parts are to be used in an
environment where stress corrosion may occur.
The nuts were aged below this temperature. A nut aged at these lower temperatures and
exposed to an electrolyte, such as salt water, and subjected to a prolonged period of
constant stress is potentially subject to a stress corrosion fracture. It is unclear, from an
analysis of this part, how stresses were developed in a direction indicated by the
fracture plane nevertheless stress corrosion is indicated as the failure mode.
It should be noted that the nut is constrained in the hook assembly by a mating part in
such a manner that even a complete fracture, does not reduce the full-load carrying
capacity of the hook assembly. Although the cracks have no effect on the function of
the hook, the presence of these cracks is considered unacceptable. Therefore, an
immediate 10x visual inspection shall be accomplished on the nut as a precautionary
measure.
The nut has external threads and screws into the corresponding hook body / housing.
Perform a 10x visual inspection on the BL-5448 and BL-5448-1 to determine whether
cracks exist. If cracks are found a new nut will have to be purchased.
This Service Bulletin shall be accomplished immediately. In addition, a recurring 10x
visual inspection shall be accomplished every six months thereafter. The requirement of
this recurring 10x visual inspection may be combined and satisfied with any
maintenance action requiring hook assembly removal and replacement i.e. cable change
out, hook assembly cleaning, etc.
If cracks are found a new nut will have to be purchased. New replacement nuts are
identified with “H1025” marked on the top surface of the nut. When the replacement
nut is installed in the hook assembly this Service Bulletin is terminated.
The preferred hook assembly nut replacement is part number BL-5448-1
(interchangeable with BL-5448), in lieu of BL-5448, because of its dual locking
features. The BL-5448-1 requires two locking screws and cotter pins for reassembly.
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E. Fleet Angle Assembly (when installed on hoist, see Item 130, Figure 1002, Sheet 3, View A)
Remove and disassemble per Section 301, and check fleet angle assembly components for corrosion,
contamination i.e. dirt, sand, seaweed, cracks, gouges, and wear. Check all four internal rollers to
ensure they are free of defects and binding. Replace any fleet angle assembly components if these
defects are found. Assemble and install per Section 701.
F. Wire Rope Cable (see Figure 1002, Sheet 2, for ball end of cable [90] and for drum attachment
screws {101} for cable)
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.
WARNING: KEEP HANDS, BODY, AND CLOTHING AWAY FROM RESCUE HOIST, SPECIFICALLY
“PINCH POINTS,” WHERE THE CABLE ENTERS THE CABLE GUIDE AND CONTACTS
THE DRUM.
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 HOIST TO PREVENT INJURY FROM LUBRICANTS,
SOLVENTS, AND OTHER MATERIALS USED ON THE RESCUE HOIST, AS WELL AS
METAL PARTS AND OTHER DEBRIS.
CAUTION: THE TENSION ROLLER AND PRESSURE ROLLER WORK ON THE BASIS OF
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.
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: PRIOR TO TURNING POWER ON, THE HOIST COMPONENTS MUST BE
VISUALLY INSPECTED FOR SOUND STRUCTURAL INTEGRITY AND PROPER
INTEGRATION.
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, looseness, and distortion of swaged
ball end of cable. Check for broken wires; replace as soon as breaks in any strand are found.
Clean the cable per Section 401, if necessary, and follow the guidelines for cable inspection as
defined below.
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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, and check for the defects identified:
(1) Broken wires
The number of broken wires on the outside of a wire rope is an indication of its general condition
(see Figure 506). However, continued use of a cable with broken wires can result in the damage
area of the cable being caught in the cable guide assembly upon paying out, and will result in
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 506. 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 507). 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
catastrophic cable failure, and possibly loss of life. Severe abrasion as evidenced by a worn shiny
surface, or damaged, cable resulting in multiple broken wires in an outer strand in any section
requires immediate cable replacement.
Figure 507. Example of Abrasion of Wire Rope Cable

(3) 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 torsion imbalance that occurs, because of 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
wire rope cable.
Figure 508. Example of Bird Caging in Wire Rope Cable
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September 19, 2008
(4) Kinking (permanent bend) in cable
Kinks are man made defects in cables; caused by a loop in a cable being pulled up tight, resulting
in a sharp, permanent bend in the cable (see Figure 509). 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 the same manner,
but creates a sharp permanent bend that tends to close the lay of the cable. Continued use of a
kinked cable can result in the kink being caught in the cable guide assembly upon paying out,
and can result in cable fouling. A kinked cable should not be run back onto a hoist for any
reason.
Figure 509. Example of Kink in Wire Rope Cable

(5) 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 the cable inadvertently loops / tangles while
operating the rescue hoist. A knotted cable should not be run back onto a hoist for any reason
and requires immediate cable replacement.
Figure 510. Example of Knot in Wire Rope Cable (Typical)

(6) Improperly attached or defective fittings
Carefully inspect the cable in the area of the hook ball end attachment (see Figure 511). Do not
bend the cable in the process of the inspection. The ball end of the cable must not evidence any
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September 19, 2008
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 and fleet angle assembly
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.
Wire Rope Cable
Top of Swaged (Ball) End of Cable
Top of Terminal Clamp
Top of Hook Assembly

(with Bumper Assembly Removed)
Figure 511. Hook Assembly Attachment to Wire Rope Cable

(7) Cable Looseness
NOTE: 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.
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 at no load, cable strands may loosen. The
strands will appear visibly loose, or will feel pliable / soft (see Examples A and B in Figure
512), 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.
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.
NOTE: MILD LOOSENESS IN THE CABLE MAY BE ELIMINATED BY REMOVING AND
STORING THE CABLE FOR SEVERAL DAYS, OR BY LOAD CYCLING AS
DIRECTED.
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 512), 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
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September 19, 2008
looseness is still evident after several days of storage, repeat the full-length, rated load
cycling until inspection indicates no looseness is evident in the wire rope cable. If looseness
remains evident after repeating full-length, rated load cycling, replace cable.
Early Indications of Advanced Indications

Cable Looseness of Cable Looseness
A B
Figure 512. Examples of Wire Rope Cable Looseness
(8) Internal wear caused by grit or dirt penetration
Internal wear caused by grit, dirt, sand, etc. embedded between cable strands is extremely
difficult to detect. Preventive maintenance is the best procedure. The cable should be
carefully wiped to remove gritty material as it is reeled in during post flight inspection.
Prolonged use of a cable loaded with gritty material will result in broken wires.
(9) Severe overload and shock loading
Severe overloading can result if the load being hoisted is greater than 450 lb. (204 kg.), or if
the hoist hook becomes snagged on an object on the ground, or the mast of a ship at sea.
Shock loading can result if the load on the hoist hook freefalls when the cable is slack. In
either case, the result is a cable that has been severely overloaded, which may, or may not,
show immediate results of the overload. Broken strands are the most obvious defects.
However, broken core wires, which are not visible, may also result from overload. “Necking-
down” of a section of cable is an indication of broken core wires. A cable that has been
knowingly overloaded should be replaced immediately even if no obvious physical damage is
detected. Any obvious reduction in diameter that is noted is cause for immediate cable
replacement.
(10) Improperly adjusted, or defective cable guide
Cables evidencing 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 repaired. 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 inspector to make the inspection, and readjustment, if required. If the condition
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September 19, 2008
is corrected prior to excessive damage occurring, the cable can be continued in service if no
wire breaks are evident.
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 CABLE IS NOT TO BE
ELIMINATED DUE TO THIS RECOMMENDED REPLACEMENT INTERVAL.
In addition to the inspection identified above, every 1500 cycles, the cable (90) is recommended
to be replaced on the hoist. See the procedures in Disassembly, Section 301, for removal of the
cable, and in Assembly, Section 701, for installation of the cable.
G. Cable Foul Indicator (when installed, see Figure 513 and Figure 1002, Sheet 4, View C)
NOTE: THE WIRE ROPE CABLE MUST BE REELED IN UNDER NO LOAD PRIOR TO
THE CABLE / SWITCH ACTUATOR GAP MEASUREMENT.
CAUTION: DO NOT DISPLACE CABLE FOUL SENSOR ACTUATOR GREATER THAN 0.188
IN. (4.7 MM) FROM ITS NORMAL “AT REST” POSITION.
(1) Apply power to the Hoist, and slowly reel out cable until the cable attach setscrew (101)
is aligned with the bottom of the switch actuator (400). Use a vernier caliper, or
equivalent, and check the gap between the switch actuator and the highest point on the
top layer of the cable at the cross over point on the drum (located on the drum adjacent to
the setscrew, see Figure 513). The gap should be 0.060 ± 0.020 inches (1.5 ± 0.5 mm.). If
gap is not within limits, adjust setscrews (780) to correct dimension. After inspection /
adjustment is completed, slowly reel in cable until the hook is at full in, and disconnect
power to the Hoist.
(2) Check condition of springs (810) on cable foul indicator. Ensure springs are not broken,
damaged, or deformed (no large gaps between coils).
(3) Apply power to the hoist, and using a spring scale, check the force required to pull up on
each side of the switch actuator just inside the switches (see Figure 514) to stop the hoist
while reeling the cable in, and out. The force shall be 0.75 to 2.25 lb. (0.34 to 1.02 kg.).
H. Pre-Flight Inspection
The following procedures are to be performed before each day when 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 imperfection.
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September 19, 2008
Figure 513. Cable Foul Indicator Dimensional Check
Lift here Lift here
Figure 514. Cable Foul Indicator Spring Test

(2) Check hook assembly (10, 15, or 20, Figure 1002, Sheet 1) bearing(s) for smooth and
non-binding swivel operation. Check keeper spring for retention in closed position, and
overall condition. Check bumper for damage and shock-absorbing capacity. Check that ball
end of cable has no signs of damage. Check to see that locking screws are properly installed
and locked in place with cotter pins.
(3) Check all covers, plugs, and guards for proper attachment and tie wire installation.
(4) Visually inspect hoist for any oil leakage.
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.
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September 19, 2008
(5) Check sight glass to verify oil level is in the middle of the glass. If hoist oil level is not in the
middle of the glass, perform the following (see Figure 515, and Figure 1002, Sheet 2):
CAUTION: DO NOT ALLOW OIL TO SPILL ONTO MOTOR WHILE FILLING HOIST. PLACE
A CLOTH AROUND AND UNDER OIL FILL PORT, AND OVER MOTOR WHEN
FILLING HOIST.
Oil Fill Port
Oil Level
Sight Glass
Location
Figure 515. Oil Fill and Oil Level Sight Glass Locations
(Motor End of Rescue Hoist in Helicopter Mounted Position)
(a) If hoist oil level is below the middle of the glass, remove tie wire and plug (790) with
seal (800) above motor, and slowly add oil to hoist. Stop adding oil when oil level rises to
the line. When finished, install plug with seal and tie wire per MS33540 with
MS20995NC32.
(b) If oil level is above the middle of the glass (excessive fill), remove hoist from helicopter
per Disassembly, Section 301. Put container under hoist to catch excess oil, remove tie
wire, and remove plug (790). Turn hoist over and allow excess oil to drain out of hoist.
When oil level is at white line, tighten bolt, tie wire per MS33540 with MS20995NC32,
and install hoist onto helicopter per Assembly, Section 701.
(6) Check that electrical connectors are properly installed and secured. Also check for any
indications of back shell damage, chaffing, or conductor separation from the connectors.
(7) Check that the setscrew (101) holding the wire rope cable in drum flange is visible, and is
installed properly i.e., flush with the drum flange (see Figure 516).
(8) Perform the following operational check for the Rescue Hoist System if not used for the last
seven (7) days:
WARNING: DO NOT TOUCH, OR HOLD CABLE NEAR HOIST DURING PAYOUT UNDER
NO LOAD. GUIDING OF CABLE DURING PAYOUT COULD
INADVERTENTLY REDUCE THE TENSION APPLIED BY THE TENSION
ROLLER AND INDUCE CABLE FOULING.
(a) Apply power to Rescue Hoist System by pushing in applicable circuit breakers.
(b) Using the Pendant Control and Grip Assembly, reel out the wire rope cable from the full
in position under no load.
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September 19, 2008
Drum Flange
Drum Flange
Setscrew (101) Setscrew (101)
Figure 516. View of Setscrew Holding Wire Rope Cable in Drum Flange with Cowling Installed
(c) After the hoist reels out approximately 30 feet (9.1 m.) of cable, actuate the pilot control
switch to reel out the cable, and verify the cable speed slows down indicating the pilot
control (when applicable) has overridden the Pendant Control and Grip Assembly.
(d) Return the thumbwheel on the Pendant Control and Grip Assembly to the null, or center,
position, and then stop the hoist by returning the pilot control to the stop position.
(e) Continue reeling out the cable using the Pendant Control and Grip Assembly until the
hoist stops at full out. Verify the hoist stops with 3 to 4 cable wraps on the drum.
(f) Mark the cable at 10 feet (3.0 m.) and at 13 feet (3.96 m.) from full out, and mark the
cable at 10 feet (3.0 m.) and at 13 feet (3.96 m.) from full in, or from the top of the hook
and bumper assembly. Check condition and visibility of the orange paint on the ends of
the cable at full out and full in positions. Reapply paint, as required, per Section 601,
Repair.
(g) Reel in the wire rope cable approximately 40 feet (12.2 m.) using the Pendant Control
and Grip Assembly, and stop the hoist.
(h) Reel out the cable, and verify the intermediate (slow) speed down switch actuates
slowing the speed of the hoist between 10 feet (3.0 m.) and 13 feet (3.96 m.).
(i) After verifying the setting of the intermediate (slow) down switch, reel in the wire rope
cable. With approximately 60 feet (18.3 m.) of cable from full in, actuate the pilot control
switch and verify the cable speed slows down indicating the pilot control has overridden
the Pendant Control and Grip Assembly.
(j) Return the thumbwheel on the control pendant to the null, or center, position, and then
stop the hoist by returning the pilot control to the stop position.
(k) Continue reeling in the cable, and verify the intermediate (slow) speed up switch actuates
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September 19, 2008
(l) Reel in the cable to full in, and verify that the full in limit switch operates normally
stopping the hoist.
I. In Flight Inspection
The following procedures should be observed and / or executed during any airborne hoist
operations (including training).
WARNING: DO NOT OPERATE HOIST, OR TRY TO CLEAR CABLE FOUL, IN FLIGHT. A
FOULED CABLE MAY BREAK, AND THIS MAY RESULT IN CAUSING
INJURY OR DEATH.
WARNING: DO NOT TOUCH, OR HOLD THE CABLE NEAR HOIST DURING PAYOUT
UNDER NO LOAD. GUIDING OF CABLE DURING PAYOUT COULD
(1) Observe the pay out of the cable (90, Figure 1002, Sheet 2) during operation of the hoist to
ensure the cable is not impeded, and is unwinding from the cable drum properly.
(2) Observe that the cable wraps evenly and tightly on the drum during hoisting. If smiles (gaps
between cable on drum) exist while reeling in cable, reel out gap beyond point where defect
exists, and reel in cable again. If problems persist, stop hoist operation, and perform cable
alignment procedure defined in Paragraph L below, when on the ground.
J. Post Flight Inspection
The following procedures should be observed and / or executed at the end of each day after
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) Check hook assembly (10, 15, or 20, Figure 1002, Sheet 1) bearing(s) for smooth and non-
binding swivel operation. Check keeper spring for retention in closed position, and overall
condition. Check bumper for damage and shock-absorbing capacity. Check that ball end of
cable has no signs of damage. Check to see that locking screws are properly installed and
locked in place with cotter pins.
(5) Check height of spring in bumper assembly (30), when hook is at full in position (see Figure
517). Measure height from top of bumper retainer to bottom of spring. If height is not 1.3 to
1.7 inches (33 to 43.2 mm.), check full in limit switch operation using test procedure in
Paragraph 4A (4) of Testing and Troubleshooting (Section 101).
(6) Check height of crushable bumper in bumper assembly (30) when hook is at full in position
(see Figure 517). Measure height from top of crushable bumper to bottom of spring retainer.
If height is not 2.25 inches (57.2 mm.), check full in limit switch operation using test
procedure in Paragraph 4A (4) of Testing and Troubleshooting (Section 101).
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Figure 517. Deflection of Bumper Assembly with Hook at Full In Position

(7) Check concavity of crushable bumper in bumper assembly (30) when hook is at full in
position (See Figure 518). Measure depth of bumper at its deepest point. If depth exceeds
0.375 in. (9.5 mm.), replace bumper assembly, and check full in limit switch operation using
test procedure in Paragraph 4A(4) of Testing and Troubleshooting (Section 101).
(8) Check that electrical connectors are properly installed and secured. Also check for any
indications of back shell damage, chaffing, or conductor separation from the connectors.
(9) Perform the following operational check for the Rescue Hoist System after the last use of the
day:
WARNING: DO NOT TOUCH, OR HOLD THE CABLE NEAR HOIST DURING PAYOUT
UNDER NO LOAD. GUIDING OF CABLE DURING PAYOUT COULD
(a) Apply power to Rescue Hoist System by pushing in applicable circuit breakers.
(b) Using the Pendant Control and Grip Assembly, reel out the wire rope cable from the full
in position under no load.
(c) After the hoist reels out approximately 30 feet (9.1 m.) of cable, actuate the pilot control
switch (when applicable) to reel out the cable, and verify the cable speed slows down
indicating the pilot control has overridden the Pendant Control and Grip Assembly.
(d) Return the thumbwheel on the Pendant Control and Grip Assembly to the null, or center,
position, and then stop the hoist by returning the pilot control to the stop position.
(e) Continue reeling out the cable using the Pendant Control and Grip Assembly until the
hoist stops at full out. Verify the hoist stops with 3 to 4 cable wraps on the drum.
(f) Mark the cable at 10 feet (3.0 m.) and at 13 feet (3.96 m.) from full out, and mark the
cable at 10 feet (3.0 m.) and at 13 feet (3.96 m.) from full in, or from the top of the hook
and bumper assembly. Check condition and visibility of the orange paint on the ends of
the cable at full out and full in positions. Reapply paint, as required, per Section 601,
Repair.
(g) Reel in the wire rope cable approximately 40 feet (12.2 m.) using the Pendant Control
and Grip Assembly, and stop the hoist.
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(h) Reel out the cable, and verify the intermediate (slow) speed down switch actuates
(i) After verifying the setting of the intermediate (slow) down switch, reel in the wire rope
cable. With approximately 60 feet (18.3 m.) of cable from full in, actuate the pilot control
switch and verify the cable speed slows down indicating the pilot control has overridden
the Pendant Control and Grip Assembly.
(j) Return the thumbwheel on the control pendant to the null, or center, position, and then
stop the hoist by returning the pilot control to the stop position.
Figure 518. Dimensions of Crushable Bumper

(k) Continue reeling in the cable, and verify the intermediate (slow) speed up switch actuates
(l) Reel in the cable to full in, and verify that the full in limit switch operates normally
stopping the hoist.
K. Cable Foul Removal
WARNING: DO NOT TRY TO CLEAR CABLE FOUL IN FLIGHT. A FOULED CABLE MAY
BREAK, AND THIS MAY RESULT IN CAUSING INJURY, OR DEATH.
(1) To clear a cable foul, gently push down on switches on both sides of cable foul indicator
using a non-conducting tool, or flat piece of wood, and carefully pull on the cable (90, Figure
1002, Sheet 2) as it is being paid out.
(2) If cable starts to backwind, or fouled cable cannot be paid out, use a manual cable cutter and
cut off sections of cable until foul is removed.
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September 19, 2008
NOTE: CABLE EXTREMES ARE PAINTED ORANGE IN COLOR. DO NOT CONFUSE
THIS COLOR FOR RED INDICATING A SCRAPPED CABLE AND DO NOT
USE ORANGE TO INDICATE A SCRAPPED CABLE.
(3) 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).
(4) Perform test procedures listed in Testing and Troubleshooting, Section 101, Paragraphs 4A
(1), 4A (2), 4A (3), 4B, and 4K after clearing cable foul and installation of new cable.
L. Cable Alignment Inspection / Adjustment
(1) Remove cable per Disassembly, Section 301.
(2) Position cable guide against motor end flange, with hole in drum for setscrew (101, Figure
1002, Sheet 2) in position to install cable.
(a). Locate drum in approximate position as shown in Figure 519.
(b). Locate the levelwind shaft as shown below in Figure 519.
(c). Locate cable guide so that it aligns with the first groove on drum.
(d). Install index wheel in position as shown in Figure 519.
Figure 519. Cable Installation and Timing

(3) Install cable per Assembly, Section 701.
(4) Perform test procedures in Paragraphs 4A(1), 4A(2), 4A(3), and 4B of Testing and
Troubleshooting (Section 101).
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September 19, 2008
M. Detailed Inspection of Rescue Hoist End Flanges and Mounting Brackets
Visually inspect end flanges and mounting brackets for cracks, elongation, missing mounting and
retaining hardware, hardware slippage marks (if applied), or material surface imperfection.
Check mounting locations for the Rescue Hoist dimensionally, as identified in Fits and
Clearances, Section 801.
N. Detailed Inspection / Overhaul of Rescue Hoist
The Rescue Hoist is to be subjected to a detailed inspection, as part of overhaul every 5 years, or
2000 hoist cycles from the date of manufacture, whichever occurs first. This detailed inspection
and overhaul is required to properly maintain this assembly. Operators should be aware that
maintenance training for Breeze-Eastern products is available.
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. BZ7R167O, 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 for any of these services listed
above as follows:
Breeze-Eastern
700 Liberty Avenue
Fax Number: 908-688-6495
above.
O. Lubrication of Cable Guide Shaft
After last use of the day, and if not used for last 7 days, prior to the first use of the day, and every
3 months, or 100 hoist cycles, wipe off contamination, and apply a light coating of
MIL-PRF-23827 grease, or equivalent, to the cable guide shaft only (see Figure 520).
P. Inspection of Levelwind Follower
Every 3 months, or 100 hoist cycles, remove the follower per the procedure in Section 301,
Disassembly, and inspect for signs of excessive wear by measuring the thick section and the tips
(see Figures 520 and 521). If the thick section is less than 0.140 in. (3.56 mm), or the tips are less
than 0.030 in. (0.76 mm.), replace the follower. After inspection of the follower, install the
follower per the procedure in Section 701, Assembly.
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September 19, 2008
Lubricate Cable Guide Shaft Only.

Do Not Lubricate Levelwind Shaft
and / or Tension Roller Shaft.
Figure 520. Lubrication of Cable Guide Shaft and Location of Follower
Figure 521. Dimensional Check of Follower

Q. Inspection of Levelwind Shaft
CAUTION: USE CAUTION WHEN HANDLING THE LEVELWIND SHAFT. THE POINTS ARE
VERY SHARP AT THE INTERSECTION OF THE HELICAL GROOVES.
Every 3 months, or 100 hoist cycles, the levelwind shaft must be inspected to ensure that it is
free of grease, debris, corrosion, or any other foreign material (see Figure 522, Figure 1002,
Sheet 2, Item 895). After cleaning the levelwind shaft, inspect the points at the intersection of
the helical grooves. Also, if the follower is worn the levelwind shaft may also be damaged and
must be inspected. If the points are bent, or broken, on the levelwind shaft the Rescue Hoist must
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September 19, 2008
be removed from the helicopter and sent to Breeze-Eastern, or a certified repair facility for
repair.
Grooves 0.160 in
(4.1 mm.)
(895)
Figure 522. Levelwind Shaft (895)

R. Inspection of Geneva Wheel
The first of 6 months, 400 flight hours, or 100 hoist cycles, remove screws (200, Figure 1002,
Sheet 3) washers (210) and cover (220). Inspect the Geneva wheel to ensure there are no signs of
excessive wear, corrosion, cracks, or damage, such as broken nylon (see Figures 523 and 524).
The Geneva wheel is made of an aluminum hub with a molded nylon material covering the hub’s
perimeter. The Geneva wheel should only be replaced if the nylon material is broken off, or if
extreme wear (exceeding 0.390 in. [0.99 mm.]), or corrosion is found. If replacement of the
Geneva wheel is necessary, remove the Rescue Hoist from the helicopter and send to Breeze-
Eastern, or a certified repair facility for repair.
Figure 523. Geneva Wheel in Good Condition
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September 19, 2008
Figure 524. Damaged Geneva Wheel (notice molded nylon material damaged and missing from hub)
S. Inspection of Wiring
Visually inspect wiring for degradation due to wear, vibration, moisture, contamination,
excessive heat, and damage. 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.
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THIS PAGE
INTENTIONALLY
LEFT BLANK
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REPAIR
1. General
INJURY OR DEATH. PROPERLY TRAINED PERSONNEL MUST UTILIZE
ALL RESCUE HOISTS.
Material Name Supplier
-- 240 grit, or finer, abrasive cloth Commercially Available
-- 320 grit, or finer, aluminum oxide abrasive cloth Commercially Available
MIL-P-7962 and TT-P-1757 Primer Coating Commercially Available
TT-E-527 Lusterless Enamel, Top Coat Commercially Available
-- Wire Rope Paint / Orange Staining Color ITW Dykem / Dymon
PN 81448 = 8 oz. Bottle 805 E. Old 56 Hwy.
PN 81748 = 1 gal. Bottle Olathe, KS 66061
PN 81848 = 5 Gal. Can
Iridite Solution #14-2, #5025, or NCP Commercially Available
MIL-R-25134 Solvent Type Paint and Lacquer Remover Commercially Available
ASTM D770, TT-I-735 Isopropyl Alcohol Commercially Available
Table 601. Materials Required for Repair (equivalent substitutes can be used)
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 and / or coating / plating
are removed as described above. This type of corrosion exists due to the use of aluminum
and steel parts in the manufacturing of the rescue hoists.
B. Removal of corrosion on aluminum parts.
NOTE: DO NOT INTERCHANGE ALUMINUM OXIDE CLOTH (SCOTCH BRITE) PADS
WHEN CLEANING ALUMINUM AND STEEL PARTS.
(1) Remove mild surface corrosion with 320 grit aluminum oxide abrasive cloth, abrasive mat
(Scotch Brite), or equivalent.
(2) Remove moderate to heavy corrosion with Vacu-blast, or equivalent, with glass beads
only.
(3) Blend repaired areas. See Table 602 for allowable material removal.
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September 19, 2008
NOMENCLATURE DAMAGE REPAIR LIMITS
Figure 1001
Cowling Assembly (30), Surface Corrosion, Clean with Scotch Brite, and protect surface with conductive
Priority Switch Junction Nicks, Blemishes corrosion preventive compound, or paint, as required
Box (90), and Pilot Moderate to Heavy Damage greater than 0.002 in. (0.05 mm.), replace
Display Assembly (170,
180, 190, and 200)
Electronic Controller, Surface Corrosion, Clean with Scotch Brite, and protect surface with conductive
except for heat sink (50, Nicks, Blemishes corrosion preventive compound, or paint, as required
60, 70, and 80) Moderate to Heavy Damage greater than 0.002 in. (0.05 mm.), replace
Figure 1002
Hardware (Nuts, Bolts, None Allowed Replace
Screws, Washers, Etc.)
Electrical Connectors Surface Corrosion, Clean with Scotch Brite, and protect surface with conductive
Nicks, Blemishes corrosion preventive compound, as required
Moderate to Heavy Damage greater than 0.002 in. (0.05 mm.), replace
Electrical Switches None Allowed Replace
Covers (40, 220, and Surface Corrosion, Clean with Scotch Brite, and protect surface with corrosion
600), Switch Actuator Nicks, Blemishes preventive compound, or paint, as required
(400), and Switch Moderate to Heavy Damage greater than 0.002 in. (0.05 mm.), replace
Retainer Plate (440) Corrosion
Wire Rope Cable (90) None Allowed Replace

Cable Cutter Assy. (110) None Allowed Replace
Fleet Angle Assy. (130) Surface Corrosion, Clean with Scotch Brite, and protect surface with corrosion
Nicks, Blemishes preventive compound, or paint, as required
Corrosion
Roller Assemblies (140 None Allowed Replace
and 180)
Springs (170, 640, and None Allowed Replace
810)
Tension Roller Shaft None Allowed Replace
(230)
Bearing (270) None Allowed Replace
Gear and Clutch Assy., Surface Corrosion, Clean with Scotch Brite, and protect surface with conductive
except on teeth of gear Nicks, Blemishes corrosion preventive compound, as required
(290) Moderate to Heavy Replace
Corrosion
Friction Disc (300) None Allowed Replace
Table 602. Allowable Material Removal
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September 19, 2008
NOMENCLATURE DAMAGE REPAIR LIMITS
Figure 1002 (continued)
Motor Assemblies (330 Surface Corrosion, Clean with Scotch Brite, and protect surface with conductive
and 340) Nicks, Blemishes corrosion preventive compound, or paint, as required
Corrosion
Switch Actuators (450, None Allowed Replace
570, and 660)
Mounting Brackets (490, None Allowed Replace
520, 530, 540, 850, 851,
860, 861)
Actuating Rod (630) None Allowed Replace
Actuator Guide (650) None Allowed Replace
Potentiometers (730 and None Allowed Replace
740)
Limit Switch Cam (770) None Allowed Replace
Figures 1003, 1004, and 1005
Hooks (220, Figure 1003, Surface Corrosion, Clean with Scotch Brite, and protect surface with corrosion
190, Figure 1004, and 130 Nicks, Blemishes preventive compound, or paint, as required
Figure 1005), and Keeper Moderate to Heavy Damage greater than 0.002 in. (0.05 mm.), replace
(200, Figure 1003)
Quick Release Pin (160, None Allowed Replace
Figure 1004)
Springs (210, Figure 1003) None Allowed Replace
Bearings (150 and 160, None Allowed Replace
Figure 1003; 130, Figure
1004, and 90 figure 1005)
Hardware (Nuts, Bolts, None Allowed Replace
Screws, Washers, etc.)
Spacers (170, Figure 1003 None Allowed Replace
and 90, Figure 1004)
Hand Ring (70, Figure Surface Corrosion, Clean with Scotch Brite, and protect surface with corrosion
1004) Nicks, Blemishes preventive compound, or paint, as required
Moderate to Heavy Damage greater than 0.002 in. (0.05 mm.) can be blended using
Corrosion rubber wheel and compound. Blend shall not exceed 0.009 in.
(0.23mm). Pits that exceed 0.010 in. (0.23 mm ) depth, replace
component
Sleeve (50, Figure 1003), None Allowed Replace
Hook Housing, and Body
(30, Figure 1003 and 1004;
100 figure 1005) and Hook
Nut (40, Figures 1003 and
1004; 30 figure 1005)
Table 602. Allowable Material Removal (continued)
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September 19, 2008
C. Removal of corrosion on steel parts.

NOTE: DO NOT INTERCHANGE ALUMINUM OXIDE CLOTH (SCOTCH BRITE) PADS
WHEN CLEANING ALUMINUM AND STEEL PARTS.
(1) Remove mild surface corrosion with a steel wire brush, 240 grit abrasive paper, or
equivalent.
(2) Remove moderate to heavy corrosion with fine file, or non-woven abrasive wheel.
(3) Blend repaired areas. See Table 602 for allowable material removal.
(4) Clean thoroughly with TT-I-735 isopropyl alcohol after blending is completed.
D. Superficial damage to primed surfaces may be touched up locally using primer procedures
listed in the refinishing section below.
2. Refinish (refer to table 601)
A. If primed surfaces of the Hoist are worn, or bared, due to repair sanding, refinish using the
following materials:
Primer: MIL-P-7962 Primer
Top Coat: TT-E-527 Lusterless Enamel (FED-STD-595 Color #36231, Gray), or
equivalent (2 coats recommended)
B. If the cable requires additional orange paint on the extreme ends, refinish using the following
material:
Coating: Wire Rope Paint / Orange Staining Color (Dykem Company, St. Louis, MO)
C. If primed surfaces of the electronic controller are worn, or bared, due to repair sanding,
refinish using the following materials:
Primer: TT-P-1757, Type I, Color Y
Top Coat: TT-E-527, Color No. 37038 (Black) per FED-STD-595
3. Minor Surface Repair (Damage of Surface Area with no exposed metal)
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.
NOTE: IRIDITE #5025, OR NCP ALSO ACCEPTABLE, FOLLOW MANUFACTURERS
INSTRUCTIONS WHEN USING.
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September 19, 2008
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.
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).
H. Apply topcoat as specified in paragraph 5 below.
4. Major Surface Repair (Damage of Surface Area with exposed metal)
A. To strip primer, and coating, from damaged area using 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 paragraph 3, Minor Surface Repair.
5. Application of Top Coat
A. Top coat application should be accomplished under the following atmospheric conditions:
B. Using a quality natural-bristled paintbrush, 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
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
HOIST TO PREVENT INJURY FROM LUBRICANTS, SOLVENTS, AND OTHER
MATERIALS USED ON THE RESCUE HOIST, AS WELL AS METAL PARTS
AND OTHER DEBRIS.
CAUTION: THE TENSION ROLLER AND PRESSURE ROLLER WORKS ON THE BASIS OF
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September 19, 2008
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.
A. Remove contamination from area of cable where paint 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:
D. Using a quality natural-bristled paintbrush, apply two (2) coats of ITW Dykem / Dymon orange
staining color Lacquer (thickness not to exceed 0.005 inches [0.13 mm] on cable diameter) to
30 feet (9.14meters) of the end of the cable that attaches to the drum of the hoist, and 21 feet
(6.4 meters) of the end of the cable that attaches to the hook assembly, see figure 601.
Figure 601. Wire Rope Cable Orange Paint Lengths

E. Allow cable to air dry for 30 minutes between coats and prior to coiling, or installing, cable
on hoist.
7. General Wiring Harness Connector Pin Replacement Procedures – for bent or otherwise damaged
connector pin contacts (Refer to Section 201, Figures 202 – 207, 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.
(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.
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September 19, 2008
(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.
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September 19, 2008
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September 19, 2008
ASSEMBLY
1. General
Assemble the Rescue Hoist System in accordance with the following instructions. Reference
numbers in parenthesis refer to IPL in Section 1001. Applicable special tools, fixtures, or
equipment necessary for the tasks identified below are listed in section 901. All mention of
applying and disconnecting power to the system components should be accomplished using
helicopter circuit breakers, or equivalent. Materials Required for Assembly (suitable equivalents
acceptable) are identified in Table 701 below:
Material Name and Application
MIL-PRF-7808, Grade 3, or MIL-PRF-23699, Lubricating Oil for Rescue Hoist Assembly (drain hoist
Class STD completely before switching from one type of oil to another
type of oil)
MIL-S-8660, or DC-4 (Dow Corning Corp.) Anti-Seize Compound for Cartridge Packing
MS20995NC32 Tie Wire
A-A-59173, MIL-G-81322, or DC-33 (Dow Lubricant for Hook Assembly Thrust Bearing, and Packings
Corning Corp.)
MIL-G-23827 Lubricant for Gear and Clutch Assembly Gear Teeth
MIL-PRF-83483 Anti-Seize Compound for Indexing Wheel Cover Screws
MIL-L-46146, or 3145 (Dow Corning Corp.) Sealant for Cable Foul and Limit Switch Terminals
SN60-63WRMAP2/3, or SN60-63WRP2/P3 Solder for Cable Foul and Limit Switch Terminals
MIL-T-5544 Anti-Seize Compound for Full In Limit Switch Screws
TT-L-58E, Type I, Class I Clear Gloss Lacquer for Protective Coating on Labels
Table 701. Materials Required for Assembly (suitable equivalents acceptable)
2. All procedures identified with the note VITAL INSPECTION POINT and parts with their
item numbers identified with the note VP requires a qualified technician, other than the
maintenance technician who performed the operation, to inspect the work completed due to the
criticality of the operation. This inspection must be documented in both the helicopter and Rescue
Hoist Assembly maintenance log.
3. Assemble and install the Rescue Hoist System in accordance with the following instructions and
Figures 1001 through 1005.
4. Installation of Limit Switches and Harness Assembly (refer to Figure 202, and Figure 1002,
Sheets 2, 3, 4, and 5).
RESULT IN INJURY, OR DEATH. PROPERLY TRAINED PERSONNEL MUST
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September 19, 2008
WARNING: ALL ELECTRICAL WORK SHALL BE ACCOMPLISHED WITH POWER
DISCONNECTED TO RESCUE HOIST ASSEMBLY, AND TOOLS THAT DO
NOT CONDUCT ELECTRICITY. PROPER GROUNDING IS REQUIRED.
NOTE: ALL WORK INVOLVING ELECTRICAL WIRING, SPECIFICALLY WORK
INVOLVING SOLDERING, MUST BE PERFORMED BY QUALIFIED
PERSONNEL.
A. Install harness assembly (670 and 900, Figure 1002, Sheet 2) as follows:
(1) Install harness assembly (900) and connect all wiring to limit switches per Paragraphs 4B,
4C, and 4D below.
(2) Connect electrical connectors (670, Figure 1002, Sheet 2) of harness (900) to Rescue
Hoist Assembly (20, 21, 22, 23, 24, 25, and 26 Figure 1001).
(3) Connect electrical connector of harness assembly (670, Figure 1002, Sheet 2) to connector
from helicopter.
B. Install full in limit switch (470, Figure 1002, Sheet 5, View D) as follows:
(1) Ensure cable guide is positioned near the motor end flange of the Rescue Hoist Assembly
so the limit switch cover (600) is accessible.
(2) VITAL INSPECTION POINT. Install switch actuator (660), spring (640), and
actuating rod (630), and secure with retaining ring (620 VP). See Figure 701.
(3) Apply MIL-T-5544 anti-seize compound to threads of screws (560), and install limit
switches (470), insulators (460), actuator guide (650). Secure with screws (560), and
torque screws to 8 to 10 in.-lb. (0.90 to 1.13 Nm).
(4) Using SN60-63WRMAP2/3, or SN60-63WRP2/P3, solder attach wire connections to
limit switches per wiring diagram on Figure 202.
(5) Apply 3145 Sealant to switch terminals after soldering.
(6) If required, peel out paper backing and install new gasket (610) onto full in limit switch
cover (600).
(7) Install full in limit switch cover (600) with gasket (610), and washers (590). Secure with
screws (580).
(8) Perform procedure identified in Paragraphs 4A(4) of Testing and Troubleshooting
(Section 101) after Rescue Hoist Assembly is mounted onto helicopter per Paragraph 16
in Section 701.
C. Install full out and intermediate (slow) speed (up and down) limit switches (470, Figure 1002,
Sheet 5, View E) as follows:
(1) Install limit switches (470), insulators (460), switch actuators (570), screws (560), and
self-locking nuts (550) onto mounting brackets (520, 530, or 540). Torque screws to 8 to
10 in.-lb. (0.90 to 1.13 Nm).
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Switch Actuator
(660)
Spring
(640)
Retaining
Ring (620)
Actuator Actuating
Guide (650)
Rod (630)
Screws (560)
Full In Limit Switches (S3,

and 470) and Insulators (460)
Figure 701. View of Full In Limit Switch
(2) Install screws (500), washers (510), and limit switch mounting brackets (520, 530, or 540)
onto Rescue Hoist Assembly. Torque screws to 15 to 20 in.-lb. (1.69 to 2.26 Nm).
limit switches per wiring diagram on Figure 202.
(5) Install potentiometer and cycle counter mounting bracket (490) and secure to Rescue
Hoist Assembly with screws (480).
(6) Depending on which of these switches were installed, perform procedure identified in
Paragraphs 4A(1), 4A(2), and 4A(3) of Testing and Troubleshooting (Section 101)
applicable to the full out limit switch, or intermediate (slow) speed limit switches, after
Rescue Hoist Assembly is mounted onto helicopter per Paragraph 16 below.
D. Install cable foul indicator switches (390, Figure 1002, Sheet 4, View C) as follows:
(1) Pull up on switch actuator of cable foul switch actuator (400) and insert a soft wooden
wedge, or suitable alternative, between actuator and cable on drum to allow access for
installation of switches (390).
(2) Install switches (390), insulators (460), switch actuator (450), switch retainer plate (440),
flat washers (430), screws (420), and miniature nuts (410). Torque screws to 8 to 10 in.-lb.
(0.90 to 1.13 Nm). See Figure 702.
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Cable Foul Sensor Wiring Harness Cable Foul Sensor Wiring Harness
Cable Foul Sensor Switches Cable Foul Sensor Switches
Figure 702. Views of Cable Foul Indicator Switches and Harness Assembly
switches (390) per wiring diagram on Figure 202.
(5) Remove soft wooden wedge, or suitable alternative, between actuator and cable on drum.
(6) Perform procedure identified in Paragraph 4C of Testing and Troubleshooting (Section
101) after Rescue Hoist Assembly is mounted onto helicopter per Paragraph 16 below.
5. Install motor (330, or 340, Figure 1002, Sheet 2) proceed as follows:
NOTE: ALL MATING AND FAYING SURFACES, ESPECIALLY THOSE SURFACES IN
CONTACT WITH GASKETS, SHALL BE CLEANED PRIOR TO ASSEMBLY.
A. Remove masking tape, or equivalent, from shaft of motor (330, or 340) and check key (380) is
properly installed.
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September 19, 2008
B. Apply light coat of A-A-59173 lubricant to packing and install preformed packing (370) onto
motor.
C. Align key (380) with slot in rescue hoist assembly and engage shaft of motor with Rescue
Hoist Assembly orienting connector on motor in the down direction.
D. Install flat washers (360) and cap screws (350) securing motor to Rescue Hoist Assembly.
Torque screws to 35 to 40 in.-lb. (3.95 to 4.52 Nm).
E. Attach connector to motor, close B-E supplied cowling, and secure with Dzus fasteners.
F. Perform procedure identified in Paragraph 4K of Testing and Troubleshooting (Section 101)
after Rescue Hoist Assembly is mounted onto helicopter per Paragraph 16 in Section 701.
6. Install tension roller (140, Figure 1002, Sheet 3, View A) as follows:
A. Ensure cable guide is positioned approximately at center of Rescue Hoist Assembly equidistant
from end flanges.
B. Apply a light coat of MIL-G-23827 grease to the teeth of the gear and clutch assembly (290).
C. Install new tension roller (140) into cable guide and slide the shaft (230) through to retain it.
D. Screw the grooved adjusting nut (250B) onto the shaft and assemble friction disc (300), spring
washer (310), and flat washer (320). See Figure 703.
E. Install the gear and clutch assembly (290), flat washer (280), bearing (270), and spacer (260)
onto the tension roller shaft (230) in the motor end flange. Lubricate Cable Guide Shaft (230)
in accordance with Section 501.
F. Apply MIL-T-83483 anti-seize compound to the threads of the screws (200).
G. Install cover (220) with washers (210) and secure with screws (200). Torque screws to 15 to
20 in.-lb. (1.69 to 2.26 Nm).
H. Set the pre-adjustment position and secure the grooved adjusting nut (250B) temporarily with
spring pin (240B) as follows:
(1) Start with gap between tension roller (140), and grooved adjusting nut (250B) preset to
.020 +/- .005 in. (.508 +/- .127 mm). Allow cable to slack approximately 8 to 12 in. (203.2
to 304.8 mm.) on last wrap. Hold preceding wraps tight in place to avoid cable fouling.
CAUTION: USE CARE NOT TO KINK, NICK, OR DAMAGE THE CABLE IN ANY WAY,
WHEN ATTACHING THE VICE GRIP.
(2) Attach padded vice grip, or soft jaw clamp, to cable.
(3) Hook spring scale onto vice grip, or clamp, and hold Rescue Hoist Assembly secure.
(4) Slowly pull spring scale, and observe the force attained when cable begins to slip. This
value must be 5 to 7 lb. (2.27 to 3.18 kg.) of force, and after any adjustment, there must
still be a gap between the friction disc (300, Figure 1002, Sheet 3, View A), and grooved
adjusting nut (250B).
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CAUTION: OBSERVE ROLLER SHAFT (230) TO MAKE SURE SHAFT ROTATES WHEN
CABLE SLIPS. IF IT DOES NOT ROTATE, READJUST TO REDUCE DRAG.
(5) If adjustment is required to satisfy paragraph (4) above, remove the spring pin (240B) and
while holding the shaft (230) with the .312 inch (7.9 mm.) wrench, rotate the grooved
Side View Top View
Safety wire shall be placed
in groove half way around
adjusting nut.
Spring Adjusting Nut (250B)
Washer Install new
(310) spring pin here,
and insert safety
wire as shown.
Note: Safety wire is through
Friction
spring pin and around
Disc
half of adjusting nut.
(300)
Safety wire shall not protrude
past this nut face.
Flat Washer Note: Spring washer (310) is between friction disc (300)
(320) and flat washer (320).
Actual View
Friction Disc (300) Flat Washer (320)
Safety Wire
Groove
Adjusting
Spring Washer (310) Nut (250B)
Figure 703. Drag Clutch Assembly Sequence Views
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September 19, 2008
adjusting nut (250B) with the .5 inch (12.7 mm.) wrench to tighten, or relieve tension on
friction disc (300).
(6) Replace the temporary cotter / spring pin or equivalent and repeat steps H(2) through
H(4).
(7) If 5 to 7 pounds (2.27 to 3.18 kg.) force cannot be obtained, replace the tension roller.
NOTE: WHEN THE RESCUE HOIST ASSEMBLY IS DRIVEN IN THE REELING-IN
DIRECTION, THE FRICTION DISC WILL ROTATE. HOWEVER, THE SPEED
WILL BE SLOWER DUE TO THE DRAG CLUTCH. IT IS ALLOWABLE FOR
THE FRICTION DISC TO PAUSE FOR SHORT TIME PERIODS WHILE
REELING-IN UNDER LOAD. THE FRICTION DISC MAY STOP COMPLETELY
ON ANY LAYER OF CABLE WITH A LOAD ON THE CABLE. THE ROLLER
SHOULD ALWAYS HAVE SOME ROTATION WITH NO LOAD ON THE
CABLE. THIS IS BECAUSE WITH A LOAD ON THE CABLE, THE CABLE
LIFTS OFF THE ROLLER.
I. Install washers (190) and pressure roller assembly (180).
J. Position one spring (170) and spring retainer (160) in place. While depressing the spring
retainer down, insert and bend cotter pin (150) to secure the spring and retainer in place.
Repeat the procedure for the other spring and retainer.
CAUTION: THE FOLLOWING PROCEDURES REQUIRE THAT ALL THE ELECTRICAL
HARNESSES BE RECONNECTED TO THE RESCUE HOIST ASSEMBLY.
BEFORE WRAPPING THE CABLE ONTO THE RESCUE HOIST ASSEMBLY
DRUM, THE TENSION ROLLER SYSTEM MUST BE SET PROPERLY.
K. Connect wiring harness to motor, cable cutter cartridge, cable foul indicator, and limit
switches. Connect power to Rescue Hoist Assembly by pushing in applicable circuit breakers.
L. Install the cable per paragraph 10 below.
M. Slowly reel the cable in until 3 to 4 feet (0.9 to 1.2 meters) of cable remains. Check for proper
wrapping and tensioning of cable.
N. After setting the drag clutch, tie wire spring pin (240B, Figure 1002, Sheet 3, View A) per
MS33540 with MS20995NC32, keeping the grooved adjusting nut (250B) in the set position.
O. Upon successful completion of tension roller system setting and testing, tie wire the screws
(200) with MS20995NC32 in accordance with MS33540.
P. Close B-E supplied cowling (30 if applicable, Figure 1001) and lock Dzus fasteners.
Q. Perform procedure identified in Paragraph 4K of Testing and Troubleshooting (Section 101)
after Rescue Hoist Assembly is mounted onto helicopter per Paragraph 16 in Section 701.
7. Install fleet angle assembly (130, Figure 1002, Sheet 3, View A) and follower (890, Figure 1002,
Sheet 2) as follows (see Figure 704):
A. Install guide plate (145, Figure 1002, Sheet 4, View F) with screws (144) onto bottom of
roller cover (132).
B. Install bearings (143) in both ends of the bearing retainer (142).
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C. Install bearing retainer (142) onto roller housing (133) and secure with retaining ring (141).
D. Install bearings (138) into rollers (139) so that the outer races of the bearings are flush with
the sides of the rollers.
E. Install roller assemblies (137) and shafts (136) into roller housing (133).
F. Install shaft retainers (135) and springs (134) into roller housing (133).
G. Install roller cover (132) onto roller housing (133) and secure with shoulder screws (131).
H. Install fleet angle assembly (130, Figure 1002, Sheet 3, View A) fully into cable guide.
I. VITAL INSPECTION POINT. Apply anti-seize compound per MIL-PRF-83483 to set
screws (100). Install three new setscrews (100 VP) into cable guide to hold fleet angle
assembly in place. Torque setscrews to 5.0 to 7.0 in.-lb. (0.56 to 0.79 Nm).
J. VITAL INSPECTION POINT. If necessary thread a 4-40 (.112 -40NC -2B) screw into
follower and press in to allow access to retaining ring groove. Install follower (890) into cable
guide and secure with washers (880), and retaining ring (870 VP).
8. Install cable cutter (110, Figure 1002, Sheet 2) as follows:
A. Insert cable cutter (110) into opening in cable guide.
B. VITAL INSPECTION POINT. Align hole in cable cutter with hole in the cable guide
assembly for setscrew and install setscrew (120 VP). See Figure 705.
Setscrews (100)
Roller Cover (132)
Shoulder Screw (131)
Figure 704. View of Fleet Angle Assembly Installation
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September 19, 2008
Setscrew Holding Cable Cutter in Cable Guide
Cable Cutter
Cartridge
Cable Guide
Setscrews Holding
Fleet Angle Assy. in
Cable Guide
Fleet Angle Assembly
Figure 705. View of Cable Cutter and Cartridge in Cable Guide (with tie wire removed)
9. Install Rescue Hoist Assembly mounting brackets (850, 851, 860, and 861 Figure 1002, Sheet 2)
as follows:
NOTE: DO NOT REMOVE BOTH RESCUE HOIST ASSEMBLY MOUNTING
BRACKETS AT THE SAME TIME. REMOVE AND REPLACE ONE BRACKET
BEFORE REMOVING AND REPLACING THE OTHER RESCUE HOIST
ASSEMBLY MOUNTING BRACKET.
NOTE: DO NOT INSTALL OLD BRACKETS (850 AND 860). REPLACE WITH NEW
BRACKETS (851 AND 861).
A. Install right-hand (RH) mounting bracket (851) below motor on end of Rescue Hoist
Assembly and secure with washers (830), and nuts (820). Torque nuts between 60 and 85
in.-lb. (6.78 to 9.60 Nm).
B. Install left-hand (LH) mounting bracket (861) below limit switch cover on end of Rescue
Hoist Assembly, and secure with loop clamp (840), washer (830), and nuts (820). Torque nuts
between 60 and 85 in.-lb. (6.78 to 9.60 Nm). See Figure 706.
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September 19, 2008
Left-Hand (LH) Right-Hand (RH)
Mounting Mounting
Bracket (861) Bracket (851)
Nut (820), Washer (830),

and Loop Clamp (840) Nut (820) and Washer (830)
Figure 706. Views of Mounting Brackets

10. Install cable (90, Figure 1002, Sheet 2) as follows:
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.
A. Partially install setscrew (101) into drum flange.
B. Feed welded end of cable (90, Figure 1002, Sheet 2) through cable guide. Ensure cable is
captured in rollers of fleet angle assembly, between pressure roller and tension roller, and
routed over drum in front of Rescue Hoist Assembly.
C. Insert welded end of cable in slot of drum with hole in cable aligned with screw hole.
D. VITAL INSPECTION POINT. Tighten setscrew (101 VP) until setscrew is flush with
the drum flange. See Figure 707. Torque setscrew between 9 to 11 in.-lb. (1.02 to 1.24 Nm).
E. VITAL INSPECTION POINT. Remove slack by putting tension on cable. Check
holding force of screw by applying approximately 20 lb. (9.1 kg.) by hand on the cable. Cable
shall remain tight with no movement from under setscrew.
F. After Rescue Hoist Assembly is installed onto helicopter per Paragraph 16 in Section 701,
apply power to Rescue Hoist Assembly.
G. Operate Rescue Hoist Assembly to reel-in cable until approximately 6 feet (1.8 m.) of cable
remains out of the Rescue Hoist Assembly. Keep tension of approximately 20 lb. (9.1 kg.) by
hand on the cable. Check cable is wrapping on Rescue Hoist Assembly properly with no
leading, or lagging, and with no snapping at extremes of layers on drum. If cable alignment
requires adjustment, use procedure in Paragraph 2L of Checks and Inspections (Section 501).
H. VITAL INSPECTION POINT. After installation of respective swivel hook assembly,
perform rated load test identified in Paragraph 4K of Testing and Troubleshooting (Section
101), to ensure cable (90 VP) has been properly installed.
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September 19, 2008
I. Disconnect power from Rescue Hoist Assembly.
Drum Flange
Drum Flange
Setscrew (101) Setscrew (101)
Figure 707. View of Setscrew Holding Wire Rope Cable in Drum Flange with Cowling Installed
11. Install limit switch cover (40, Figure 1002, Sheet 3, View B) as follows:
NOTE: ALL MATING AND FAYING SURFACES ESPECIALLY THOSE SURFACES IN
CONTACT WITH GASKETS, SEALS, O-RINGS, PACKINGS, ETC. SHALL BE
CLEANED PRIOR TO ASSEMBLY PER SECTION 401.
A. Remove paper backing from gasket (80) and install adhesive side of gasket on limit switch
cover (40).
B. Install limit switch cover (40) to cyclocentric end flange using lug terminal (70), washers
(60), and secure with screws (50). See Figure 708.
Screw (50) and Lug Terminal (70)
Gasket (80)
Cover (40)
Screws (50) and Washers (60)
Figure 708. Limit Switch Cover
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September 19, 2008
12. Assemble and install HK-111-1 Swivel Hook Assembly as follows (20, Figure 1002, Sheet 1, and
1, Figure 1004):
A. Lightly grease ball end of cable (90, Figure 1002, Sheet 1) with A-A-59173, or MIL-G-81322
(or equivalent), lubricant to ease installation of bumper assembly onto cable. Do not allow
any lubrication on wire rope cable itself, only the ball end.
B. Install bumper assembly (30) onto cable by pressing ball end of cable through bumper.
WARNING: THE TERMINAL CLAMP IS A TWO-PIECE MATCHED SET, MACHINED AS
AN ASSEMBLY, AND MUST BE USED TOGETHER.
WARNING: ORIENTATION OF TERMINAL CLAMP DURING INSTALLATION IS
CRITICAL FOR PROPER LOAD CARRYING CAPABILITY OF THE 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 RESCUE
HOIST ASSEMBLY.
C. VITAL INSPECTION POINT. Install nut (40, Figure 1004) and terminal clamp (50
VP) onto ball end of wire rope cable and secure with ring (60 VP). See Figure 709.
D. VITAL INSPECTION POINT. Slide nut (40) down until terminal clamp (50 VP,
Figure 1004) seats in nut securely.
E. If removed, install cable assembly (170), quick-release pin (160), and rivet (180) onto hook
(190).
F. VITAL INSPECTION POINT. Using a mallet and punch, or equivalent, round off, or
upset, the other end of rivet (180 VP) to secure keeper, spring, and cable assembly on hook.
G. Install flat washer (140) on hook assembly (150).
H. Install ball bearing (130) and thrust washer (120) into housing (30).
I. Install housing (30) onto hook assembly (150).
CAUTION: ONLY TIGHTEN CASTELLATED NUT (110) 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 AVAILABE
CASTELLATION.
J. Install castellated nut (110) onto hook assembly (150) and tighten castellated nut until housing
is fully seated onto hook assembly. Do not apply torque to castellated nut (110), install finger
tight only.
NOTE: USE ONLY SPRING PINS (100) SUPPLIED BY BREEZE-EASTERN. THESE
SPRING PINS, PAINTED ORANGE FOR EASY VISUAL IDENTIFICATION,
ARE SPECIALLY PROCESSED FOR USE IN SWIVEL HOOK ASSEMBLIES.
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September 19, 2008
Figure 709. Required Terminal Clamp Orientation (typical)

K. VITAL INSPECTION POINT. Back castellated nut (110) off slightly to allow
installation of new orange spring pin (100 VP) through hole in stem of hook and castellated
nut, with access through housing (30).
L. VITAL INSPECTION POINT. Rotate hook while holding housing to check for binding
of bearing (130). If binding exists, remove spring pin (100) with a drift and mallet, and back
off castellated nut one additional gap. Install spring 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 (130).
M. Install spacer (90), key (80), and hand ring (70) onto housing (30).
N. Install assembled hook parts onto nut (40) by threading housing (30) and nut together until
fully seated. Do not apply torque to nut (40), install finger tight only.
O. Back off nut (40) slightly until first set of grooves in housing (30) is aligned with holes in nut.
P. VITAL INSPECTION POINT. Install locking screws (20 VP), and cotter pins (10 VP)
into nut (40) to lock nut and housing (30) in place.
Q. VITAL INSPECTION POINT. Slide bumper assembly (30, Figure 1002, Sheet 1) down
until terminal clamp (50 VP, Figure 1004) seats in nut securely.
R. After Rescue Hoist Assembly is installed onto helicopter per Paragraph 16 in Section 701,
S. Run Rescue Hoist Assembly to the full in position to secure to hook and bumper assembly.
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September 19, 2008
T. VITAL INSPECTION POINT. Perform test identified in Paragraphs 4I of Testing and
Troubleshooting (Section 101) to ensure hook assembly (10, 15, or 20, Figure 1002, Sheet 1
VP) has been properly installed.
U. Disconnect power to Rescue Hoist Assembly.
13. Assemble and install BL-5740-14 Swivel Hook Assembly as follows (10, Figure 1002, Sheet 1,
and 1, Figure 1003):
A. Lightly grease ball end of cable with A-A-59173, or MIL-G-81322 (or equivalent), lubricant
to ease installation of bumper assembly onto cable. Do not allow any lubrication on wire rope
cable itself, only the ball end.
WARNING: THE TERMINAL CLAMP IS A TWO-PIECE, MATCHED SET MACHINED AS
AN ASSEMBLY AND MUST BE USED TOGETHER.
CRITICAL FOR PROPER LOAD CARRYING CAPABILITY OF THE 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 RESCUE
HOIST ASSEMBLY.
C. VITAL INSPECTION POINT. Install nut (40, Figure 1003), sleeve (50), and terminal
clamp (60 VP) onto ball end of cable and secure terminal clamp with ring (70 VP). See
Figure 709.
D. VITAL INSPECTION POINT. Slide nut (40) and sleeve (50) down until terminal
clamp (60 VP) seats in sleeve (50) securely.
E. VITAL INSPECTION POINT Install spring (210), keeper (200), and secure onto hook
(220) with tube (190, VP) by flaring out each end using a mallet and punch, or equivalent.
F. Install spacer (170) and bearing (160) onto hook assembly (180).
G. Apply light coat of A-A-59173, or MIL-G-81322 (or equivalent), lubricant onto preformed
packing (130 and 130A) and install preformed packing onto bearing retainer (120).
H. Lightly coat needle thrust bearing (150) and needle thrust bearing races with A-A-59173, or
MIL-G-81322 (or equivalent) lubricant.
I. Install thrust bearing race (140), thrust bearing (150), thrust washer (141), and bearing
retainer (120) with preformed packing (130 and 130A) into body (30).
J. Install body (30) onto hook assembly (180), over bearing (160) and spacer (170).
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September 19, 2008
BACK OFF. NEVER TIGHTEN THE NUT TO REACH THE NEXT AVAILABE
CASTELLATION.
K. Install castellated nut (110) onto hook assembly (180), and tighten castellated nut until body is
fully seated onto hook assembly. Do not apply torque to castellated nut (110), install finger
tight only.
NOTE: USE ONLY SPRING PINS (100) SUPPLIED BY BREEZE-EASTERN. THESE
SPRING PINS, PAINTED ORANGE FOR EASY VISUAL IDENTIFICATION,
ARE SPECIALLY PROCESSED FOR USE IN SWIVEL HOOK ASSEMBLIES.
L. VITAL INSPECTION POINT. Back castellated nut (110) off slightly to allow
installation of new orange spring pin (100 VP) through stem of hook and castellated nut.
Install new orange spring pin (100 VP) using mallet and drift, through body (30).
M. VITAL INSPECTION POINT. Rotate hook while holding housing to check for binding
of bearings (150 and 160). If binding exists, remove spring pin (100) using drift and mallet
and back off castellated nut one additional gap. Install 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, replace bearings (150, and 160).
N. If removed, peel off backing of label (90), activate adhesive with alcohol and install label onto
rubber bumper (80).
O. Install rubber bumper (80) with label (90) onto body (30).
P. Install assembled hook parts onto nut (40) by threading body (30) and nut together until fully
seated.
Q. Back off nut (40) slightly until first set of grooves in body (30) are aligned with holes in nut.
R. VITAL INSPECTION POINT. Install locking screws (20 VP), and cotter pins (10 VP)
into nut (40) to lock nut and body (30) in place.
S. After Rescue Hoist Assembly is installed onto helicopter per Paragraph 16 in Section 701, and
T. Run Rescue Hoist Assembly to the full in position to secure to hook and bumper assembly.
U. VITAL INSPECTION POINT. Perform test identified in Paragraphs 4I of Testing and
Troubleshooting (Section 101), to ensure hook assembly (10, 15, or 10, Figure 1002, Sheet 1
VP) has been properly installed.
V. Disconnect power to Rescue Hoist Assembly.
14 Assemble and install HK-116-7 Series Hook Assemblies (15, Figure 1002, Sheet 1, and Figure
1005, Item -1) as follows:
A. Lightly grease ball end of cable (90, Figure 1002, Sheet 1) with A-A-59173, or MIL-G-81322
(or equivalent), lubricant to ease installation of bumper assembly onto cable. Do not allow
any lubrication on wire rope cable itself, only the ball end.
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September 19, 2008
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.
WARNING: THE TERMINAL CLAMP IS A TWO-PIECE, MATCHED SET. IT IS MACHINED
AS AN ASSEMBLY AND MUST BE INSTALLED AS A SET.
C. VITAL INSPECTION POINT. Install nut (Figure 1005, Item 30) over ball end and
slide nut up cable towards hoist. Attach terminal clamp (40 VP) onto ball end of cable.
Secure terminal clamp with ring (50 VP) and slide nut over terminal clamp. See Figure 709.
D. VITAL INSPECTION POINT. Slide nut (30) down cable, and ensure terminal clamp (40
VP) is properly seated in nut (30).
E. Install bearing (90) and thrust washer (80) into housing (100).
F. Install flat washer (120) and housing (100) onto stem of hook (130).
G. With an applicator brush, spread Vibra-Tite around the stem threads of the hook. Completely
cover threads in the area where the nut will be engaged when assembled. Allow Vibra-Tite to
dry.
BACK-OFF. NEVER TIGHTEN THE NUT TO REACH THE NEXT AVAILABLE
CASTELLATION.
H. Install castellated nut (70) onto stem of hook and tighten castellated nut until bearing is fully
seated in housing. Do not apply torque to castellated nut (70), install finger tight only.
I. VITAL INSPECTION POINT. Back castellated nut (70) off slightly to allow
installation of new orange colored spring pin (110 VP) through stem of hook and castellated
nut, with access through housing (100).
J. VITAL POINT INSPECTION. Rotate hook while holding housing to check for binding
of bearing (90). If binding exists, remove spring pin (110) 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 (90).
K. Install rubber bumper (60) onto housing (100).
L. Install housing and assembled hook parts onto nut (30) by threading, or screwing, together
until bottomed.
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September 19, 2008
M. VITAL INSPECTION POINT. Install locking screws (20 VP) into nut (30) to lock
housing, and then lock setscrews in place with new cotter pins (10 VP).
N. Push down on bumper assembly (Fig. 1002, Sheet 1, Item 30) to snap the bumper assembly
onto nut (30).
O. After Rescue Hoist Assembly is installed onto helicopter per Paragraph 16 Section 701 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 4I.) to ensure hook assembly (Fig. 1005) has been
properly installed. Verify hook bearing rotates with a smooth, non-binding rotation.
R. Disconnect power to hoist.
15. Install nameplate and labels (680 through 710, Figure 1002, Sheet 2) 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 nameplate from previously recorded data obtained
during disassembly. If information on nameplate was illegible when removed, contact
Breeze-Eastern with all known information concerning Rescue Hoist Assembly (part number
and serial number, if known) for original or new data.
B. Remove backing of nameplate / label to expose adhesive.
C. Apply alcohol on back to activate adhesive and install nameplate / labels.
D. Coat nameplate / labels with TT-L-58E, Type I, Class I, Clear Gloss Lacquer.
16. Install Rescue Hoist Assembly and Breeze-Eastern supplied cowling assemblies onto helicopter
as follows (see Figures 203 through 207, 801, 802, and 1001):
CAUTION: THE RESCUE HOIST ASSEMBLY WEIGHS APPROXIMATELY 48 LB (21.8 KG)
FOR BL-29700-20, -22, -23, -25, AND -26, AND 55 LB. (25 KG.) FOR
BL-29700-21, AND -24 WHEN MOUNTED ON THE HELICOPTER. TWO
INDIVIDUALS MUST BE AVAILABLE TO REMOVE THE RESCUE HOIST
ASSEMBLY FROM THE HELICOPTER UNLESS SUITABLE SUPPORT IS
PROVIDED TO HOLD THE WEIGHT OF THE RESCUE HOIST ASSEMBLY
WHEN REMOVED.
NOTE: LUBRICATING OIL, MIL-PRF-7808, IS IN THE RESCUE HOIST ASSEMBLY
WHEN SHIPPED FROM BREEZE-EASTERN. IT IS RECOMMENDED TO
STORE THE RESCUE HOIST ASSEMBLY IN THIS SAME CONDITION PRIOR
TO INSTALLATION ON THE HELICOPTER.
A. Inspect Rescue Hoist Assembly and helicopter mounting structure to verify all dimensional
tolerances identified in Fits and Clearances (Figure 801 and 802) applicable to the mounting
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September 19, 2008
of the Rescue Hoist Assembly and the cowling assemblies on the helicopter are within
acceptable limits.
B. Install cowling assembly (30) and Rescue Hoist Assembly (20, 21, 22, 23, 24, 25 and 26,
Figure 1001) onto helicopter using attaching hardware (not shown in Figure 1001, not part of
System, and not supplied by Breeze-Eastern) for two mounting brackets. Secure as required.
C. Connect electrical connectors to Rescue Hoist Assembly motor, cable foul indicator, and limit
switch connectors.
D. After installation of Rescue Hoist Assembly onto helicopter, check oil level of drum assembly
and service the Rescue Hoist Assembly, if necessary, with MIL-PRF-7808, or
MIL-PRF-23699 oil per Checks and Inspections (Section 501).
E. Apply power to Rescue Hoist Assembly by pushing in applicable helicopter circuit breakers.
F. Perform procedure identified in Paragraphs 4A through 4K of Testing and Troubleshooting
(Section 101).
17. Install Variable Speed Controller (50, 60, 70, or 80, Figure 1001) and Priority Switch Junction
Box (90) as follows (refer to Figures 203 through 207 for wiring diagrams of Rescue Hoist
Systems):
A. Inspect Variable Speed Controller and helicopter mounting structure to verify all dimensional
tolerances, identified in Fits and Clearances (Figure 803) applicable to the mounting of the
Variable Speed Controller on the helicopter, are within acceptable limits.
B. Install Variable Speed Controller (50, 60, 70, or 80), and Priority Switch Junction Box (90)
using four mounting screws (100, for Item 50 only, when installed as part of -2 Rescue Hoist
System; for all other systems, not shown in IPL, not part of system).
C. Connect electrical connectors to Variable Speed Controller and Priority Switch Junction Box.
D. Apply power to Variable Speed Controller by pushing in applicable helicopter circuit
breakers.
E. Perform procedure identified in Paragraphs 4K of Testing and Troubleshooting (Section 101).
18. Install Control Pendant and Grip Assembly (110, 120, or 130, Figure 1001) and Pendant Cable
Assembly (140, 150, or 160) as follows (refer to Figures 203 through 207 for wiring diagrams of
Rescue Hoist Systems):
A. Connect mating electrical connector of Pendant Cable Assembly (140, 150, or 160) to
connectors on the variable speed controller (50, 60, 70, or 80).
B. Connect mating connector of the Pendant Cable Assembly to Control Pendant and Grip
Assembly (110, 120, or 130).
C. Apply power to Control Pendant and Grip Assembly by pushing in applicable helicopter
circuit breakers.
D. Perform operational check defined in Paragraph 2H of Checks and Inspections (Section 501).
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19. Install Pilot Display (170, 180, 190, or 200, Figure 1001) as follows (refer to Figures 203 through
207 for wiring diagrams of Rescue Hoist Systems):
A. Connect electrical connector to pilot display (170, 180, 190, or 200).
B. Install pilot display (170, 180, 190, or 200, Figure 1001) with mounting hardware (not shown
in IPL, not part of Breeze Eastern system).
C. Apply power to Pilot Display by pushing in applicable circuit breakers.
D. Perform procedure identified in Paragraphs 4B of Testing and Troubleshooting (Section 101).
20. Remove any grounding wires installed on cartridge pins (replacement supplied in pressure
cartridge kit), and install cartridge (40, Figure 1001) as follows:
WARNING: THE CARTRIDGE MUST BE REMOVED BEFORE PERFORMING ANY
REMOVAL OR MAINTENANCE PROCEDURES INVOLVING THE RESCUE
HOIST ASSEMBLY, AND INSTALLED LAST AFTER ALL MAINTENANCE
AND INSTALLATION PROCEDURES ARE ACCOMPLISHED.
WARNING: BEFORE INSTALLING THE CARTRIDGE IN THE RESCUE HOIST
ASSEMBLY, BE SURE THAT ALL ACTUATING CIRCUITS ARE OPEN.
WARNING: DO NOT PERFORM RESISTANCE-CHECKS ON THE CARTRIDGE EITHER
PRIOR TO OR AFTER INSTALLATION IN THE RESCUE HOIST ASSEMBLY.
O-RINGS, AND COTTER PIN MUST ALL BE REPLACED, WITH REFIRE KIT
PN KT-494.
NOTE: CARTRIDGE SERVICE LIFE IS 3 YEARS, STARTING WHEN REMOVED
FROM CONTAINER. CARTRIDGE LIFE (COMBINED SHELF AND SERVICE
LIFE) IS 9 YEARS, STARTING FROM THE DATE OF MANUFACTURE, WHICH
CAN BE FOUND IN THE LOT NUMBER ON THE CONTAINER, AND ON THE
CARTRIDGE. THE LOT NUMBER STARTS WITH THE FIRST THREE
LETTERS “CDI,” FOLLOWED BY TWO DIGITS, IDENTIFYING THE YEAR OF
MANUFACTURE (EXAMPLE: 08 IS 2008), AND ONE LETTER, IDENTIFYING
THE MONTH OF MANUFACTURE, AS FOLLOWS:
A) JANUARY B) MARCH 3, 2008 C) MARCH D) APRIL
E) MAY F) JUNE G) JULY H) AUGUST
J) SEPTEMBER K) OCTOBER L) NOVEMBER M) DECEMBER
NOTE: INSURE THAT PACKING IS ON CARTRIDGE PRIOR TO INSTALLATION,
AND THE PACKING IS COATED WITH A THIN FILM OF ANTI-SEIZE
COMPOUND, MIL-S-8660, OR EQUIVALENT.
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A. Apply anti-seize compound, MIL-S-8660, to packing (45) prior to installation.
B. Install cartridge (40) with packing (45) into cable cutter (110, Figure 1002, Sheet 2), and tie
wire to cable cutter per MS33540 with MS20995NC32.
21. 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.
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
Rescue Hoist Assembly. All packaging for the Rescue Hoist Assembly shall be identified
showing the proper orientation for storage so that the Rescue Hoist Assembly is on its four
mounting points.
E. If the Rescue Hoist System is kept in storage as described above for more than one (1) 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 5 years, the Rescue Hoist must be returned to Breeze-Eastern, or one of its certified
repair facilities, for overhaul.
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FITS AND CLEARANCES

1. Table 801 identifies the allowable limits for close tolerance parts 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 of
the system components. When this condition exists the affected part(s) shall be dimensionally
inspected in accordance with Figures 801 through 805. Replace parts that do not meet the limits,
and for which rework is not applicable.
2. The values given in the “Dimension Limits” column in Table 801 are the applicable minimum, or
maximum, permitted to ensure proper functioning for the components of the system. If parts fail
to meet these requirements one or more of the parts must be replaced, unless rework of the part is
applicable. The dimensional limits should be used as a guide for assembling and installing
reworked parts.
3. The values shown in Table 801 are applicable to the components of the Rescue Hoist System. See
Figures 801, 802, 803, 804, 805, and 1002 for items referenced. Figures 801, 802, and 803 show
the components for the HS-29700 Series Rescue Hoist System, but the dimensions, which are
identified in inches and apply to all configurations.
A. Figure 801. Rescue Hoist Assembly Installation (Part Numbers
BL-29700-20, -21,
-22, -23, -24, -25,
-26)
B. Figure 802. Rescue Hoist Assembly / Cowling Assembly Installation (Part Numbers
BL-29700-20, -21,
-22, -23, -24, -25)
C. Figure 803. Variable Speed Controller Installation (Part Numbers
EC-14000-2, -5,
-13, -14)
D. Figure 804. Pendant Control and Grip Assembly Installation (Part Number
CP-1600-1)
E. Figure 805. Pendant Control and Grip Assembly Installation (Part Numbers
CP-400-1, -2)
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Fig. No. (and Description of Location for Dimensional Check Dimension Limits in Inches
Item No., if (Millimeters)
applicable) Minimum Maximum
Fig. 801 Diameter of 4 Hoist/Cowling Mounting Holes 0.265 (6.73) 0.272 (6.91)
Fig. 802 Vertical Dimension of Hoist/Cowling Mounting Holes 3.470 (88.14) 3.530 (89.66)
Fig. 802 Horizontal Dimension of Hoist/Cowling Mounting Holes 8.720 (221.49) 8.780 (223.01)
Fig. 517and Height of Bumper Assembly at full in position in Hoist 1.3 (33.0) 1.7 (43.2)
Fig. 1002, Sheet 1,
Item 30
Fig. 518and Crushable Bumper Dimensions – Height (minimum only) 2.25 (57.2) -
Fig. 1002, Sheet 1,
Item 30 – Concavity (max. only) - 0.375 (4.8)
Fig. 503 and Depth of Wear in Tension Roller (maximum only) - 0.05 (1.3)
Fig. 1002, Sheet 3,
View A, Item 140
Fig. 502 and Diameter of Groove in Pressure Roller (minimum only) 0.916 (23.27) -
Fig. 1002, Sheet 3,
View A, Item 180
Figure 521 Thickness of Follower – At thick section (minimum only) 0.140(3.56) -
Fig. 1002, Sh. 2,
Item 890
Figure 523 Dimension of Grooves in Geneva Wheel (maximum only) - 0.390 (0.99)
Fig. 803 Vertical Dimension of Mounting Holes in base of Variable 7.73 (196.3) 7.77 (197.4)
Speed Controller
Fig. 803 Horizontal Dimension of Mounting Holes in base of 6.73 (170.9) 6.77 (172.0)
Fig. 803 Horizontal Dimension of Mounting Holes in base of 6.73 (170.9) 6.77 (172.0)
Fig. 804 Width of CP-1600-1 Pendant Control Bracket (top) 1.62 (41.1) 1.64 (41.7)
Fig. 804 Width of CP-1600-1 Control Pendant Bracket (back) 3.24 (82.3) 3.26 (82.9)
Fig. 804 Length of CP-1600-1 Control Pendant Bracket 5.69 (144.5) 5.71 (145.1)
Fig. 804 Thickness of CP-1600-1 Control Pendant Bracket 0.120 (3.04) 0.130 (3.30)
Fig. 804 Depth of CP-1600-1 Control Pendant (maximum only) - 4.91 (124.7)
Fig. 805 Diameter of CP-400 Control Pendant Bracket Mounting - .40 (10.16)
Hole (maximum only)
Table 801. Dimensional Limits for Rescue Hoist System
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September 19, 2008
Note: Hook Assembly shown

is for reference only for one
type configuration. Other
configurations may have a
different hook assembly with
a slightly different overall
length.
Note: The two Hook Assemblies shown are for reference only for two types of configurations. Other
configurations may have a different hook assembly with a slightly different overall length.
Installation Drawing for BL-29700-20, -22, -24, -25, and -26 Rescue Hoists Installation Drawing for BL-29700-21, and -23 Rescue Hoists
Figure 801. Rescue Hoist Assembly Installation (Dimensions in Inches [Millimeters])
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Installation Drawing for BL-29700-20, -22, -24, 25, and -26 Rescue Hoists Installation Drawing for BL-29700-21, and -23 Rescue Hoists
Figure 802. Rescue Hoist Assembly / Cowling Assembly Installation (Dimensions in Inches [Millimeters])
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Figure 803. Variable Speed Controller Installation (Dimensions in Inches [Millimeters]) EC-14000-2, -5, -13, -14.
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Figure 804. CP-1600-1 Pendant Control and Grip Assembly Installation (Dimensions in Inches [Millimeters])
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September 19, 2008
0.75 REF
(18.3)
1.02 REF
(25.9)
0.44 REF 3.33 REF 3.30 REF

(11.2) (84.6) (83.8)
2.38 REF
(60.5)
0.38 THRU REF 7.00 REF

(9.7) (177.8)
Figure 805. CP-400-1 and -2 Pendant Control and Grip Assembly Installation (Dimensions in Inches [Millimeters])
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September 19, 2008
SPECIAL TOOLS, FIXTURES, AND TEST EQUIPMENT
Note: Equivalent substitutes may be used for listed items.

Tool /
Use and Testing and
Equipment Nomenclature Disassembly Repair Assembly
Application Troubleshooting
Number
Calibrated
Weights (capable Rescue Hoist
of additional 450 lb. (204 kg)
TE-120-1 X - - -
weight Rated Load
increments, see Tests
Figure 901)
Rescue Hoist
Cart (for carrying
450 lb. (204 kg)
TE-120-3 weights, see X - - -
Rated Load
Figure 901)
Tests
Clevis Mount Maintenance
Maintenance Fixture for
TE-132-1 - X X X
Fixture (Figure Clevis Mount
902) Rescue Hoists
Assembly and
4-40 (.112-40 Disassembly
- - X X X
NC-2B) Screw of Levelwind
Follower
Table 901. Special Tools, Fixtures, and Test Equipment List / Matrix
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Figure 901. TE-120-1, Weights with TE-120-3 Cart
Figure 902. 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:
Breeze-Eastern
700 Liberty Avenue
Fax Number: 908-688-6495
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September 19, 2008
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 of the applicable top assembly is
also shown in EFF CODE column for each detail part and subassembly used on all top
assemblies. If only one assembly is shown in the IPL figure, then no reference letters will be
entered in the corresponding EFF CODE column.
(4) Units per Assembly
The UNITS PER ASSY. column shows the total number of parts required per assembly, and
per subassembly as applicable. For bulk items, the letters AR indicate “as required.” The
letters RF indicate the item is listed for reference purposes.
(5) Parts Replacement Data
The interchangeability between parts is identified in the NOMENCLATURE column of the
parts list. The list of terms below shows the interchangeability and their definition:
Term Abbreviation Definition
Alternate ALT Alternate designates a definitive sequence of parts. The part is optional to,
and interchangeable with, other parts in the same item 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.
Superseded by SUPSD BY When one part is superseded by another, the superseded part will be
identified, as designated.
Supersedes SUPSDS When one part supersedes another, the part superseding another will be
identified, as designated.
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September 19, 2008
(6) Items Not Illustrated
Items not illustrated are indicated by a dash (-) ahead of the item number in the FIG. & ITEM
NO. Column.
(7) Alpha Variant Item Numbers
(a) Alpha variants A through Z (except I and O) are assigned to the existing item number
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.
2. Notes:
CAUTION: THE CABLE CUTTER CARTRIDGE IS AN EXPLOSIVE DEVICE AND MUST BE
SHIPPED, STORED, AND HANDLED IN COMPLIANCE WITH ALL LOCAL
STANDARDS, AND REGULATORY PRACTICES.
O-RINGS, AND COTTER PIN MUST ALL BE REPLACED WITH REFIRE KIT
PN KT-494.
A. The pressure cartridge kit (PN BL-11140-2) consists of a cartridge (40, Figure 1001) contained
in a hermetically sealed container with preformed packing (45). The cartridge can be purchased
only as part of this kit due to the longer shelf life it has while in the sealed container. The
preformed packing must be replaced when a new cartridge is installed. If preformed packing
only needs to be replaced it can be ordered separately.
In the event the cartridge has been fired during a cable cut, a cable cutter re-fire kit (PN
KT-494) must be purchased; which includes a cable cutter (PN Y-1265-9-1) and an impulse
cartridge kit (PN BL-11140-2).
B. The terminal clamp consists of a two-piece, matched set (60, Figure 1003, 50, Figure 1004, and
40, Figure 1005) machined as an assembly and held together by a retaining ring (70, Figure
1003, 60, Figure 1004, and 50, Figure 1005). Each half of the clamp cannot be purchased
separately and must be purchased together as a set. The retaining ring must be replaced if the
terminal clamp is in need of replacement and can be purchased separately.
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September 19, 2008
C. 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. BZ7R167O, 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 for any
of these services listed above as follows:
Breeze-Eastern
700 Liberty Avenue
Fax Number: 908-688-6495
above.
Operators should be aware that maintenance training for Breeze-Eastern products is available.
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September 19, 2008
Figure 1001. Rescue Hoist System
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September 19, 2008
NUMERICAL PARTS LIST INDEX FOR FIGURE 1001
FIG. AND ITEM NO. PART No. NOMENCLATURE 1 2 3 4 EFF. CODE UNITS PER
1001- ASSY.
-1 HS-29700-200 RESCUE HOIST SYSTEM A RF
-2 HS-29700-201 RESCUE HOIST SYSTEM B RF
-3 HS-29700-202 RESCUE HOIST SYSTEM C RF
-4 HS-29700-203 RESCUE HOIST SYSTEM D RF
-5 HS-29700-204 RESCUE HOIST SYSTEM E RF
-6 HS-29700-205 RESCUE HOIST SYSTEM F RF
-7 HS-29700-206 RESCUE HOIST SYSTEM G RF
-8 HS-29700-207 RESCUE HOIST SYSTEM H RF
-9 HS-29700-208 RESCUE HOIST SYSTEM J RF
-10 HS-29700-209 RESCUE HOIST SYSTEM K RF
-11 HS-29700-210 RESCUE HOIST SYSTEM L RF
-12 HS-29700-211 RESCUE HOIST SYSTEM M RF
-13 HS-29700-212 RESCUE HOIST SYSTEM N RF
-14 HS-29700-213 RESCUE HOIST SYSTEM P RF
-15 HS-29700-214 RESCUE HOIST SYSTEM R RF
-16 HS-29700-215 RESCUE HOIST SYSTEM S RF
-17 HS-29700-216 RESCUE HOIST SYSTEM T RF
-18 HS-29700-217 RESCUE HOIST SYSTEM U RF
20 BL-29700-20 • Hoist Assembly, Rescue AGHK 1
21 BL-29700-21 • Hoist Assembly, Rescue D 1
22 BL-29700-22 • Hoist Assembly, Rescue CFJL 1
23 BL-29700-23 • Hoist Assembly, Rescue BE 1
24 BL-29700-24 • Hoist Assembly, Rescue MP 1
25 BL-29700-25 • Hoist Assembly, Rescue NRU 1
26 BL-29700-26 • Hoist Assembly, Rescue T 1
30 BL-14823-1 • Cowling Assembly ABCDEFGHJKLMNPRSU 1
40 BL-11140-2 • PC Kit (See Page 1002, Note 2A) 1
45 MS28778-4 • Packing (See Page 1002, Note 2A) 1
50 EC-14000-2 • Variable Speed Controller BEGT 1
60 EC-14000-5 • Variable Speed Controller CDF 1
70 EC-14000-13 • Variable Speed Controller AHKMPS 1
80 EC-14000-14 • Variable Speed Controller JLNRU 1
90 EC-14200-1 • Priority Switch Junction Box D 1
100 MS16995-51 • Screw, Mounting, Controller BESTU 4
110 CP-400-1 • Pendant Control and Grip Assembly ABCDKLPR 1
120 CP-400-2 • Pendant Control and Grip Assembly FGHJMNU 1
130 CP-1600-1 • Pendant Control and Grip Assembly EST 1
140 EC-14170-1 • Cable, Control Pendant ACDFGHJKLMNPRU 1
150 EC-14170-2 • Cable, Control Pendant B 1
160 EC-14190-1 • Cable, Control Pendant EST 1
170 EC-14070-1 • Pilot Display Assembly AKP 1
180 EC-14070-2 • Pilot Display Assembly CDLR 1
190 EC-14070-6 • Pilot Display Assembly GHM 1
200 EC-14070-7 • Pilot Display Assembly FJN 1
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September 19, 2008
Figure 1002 (Sheet 1 of 5). Rescue Hoist Assembly
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September 19, 2008
895
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September 19, 2008
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September 19, 2008
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September 19, 2008
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September 19, 2008
FIG. AND PART NUMBER NOMENCLATURE EFF. UNITS PER
ITEM NO. 1234 CODE ASSY.
1002
-1 BL-29700-20 HOIST ASSEMBLY, Rescue A RF
-2 BL-29700-21 HOIST ASSEMBLY, Rescue B RF
-3 BL-29700-22 HOIST ASSEMBLY, Rescue C RF
-4 BL-29700-23 HOIST ASSEMBLY, Rescue D RF
-5 BL-29700-24 HOIST ASSEMBLY, Rescue E RF
-6 BL-29700-25 HOIST ASSEMBLY, Rescue F RF
-7 BL-29700-26 HOIST ASSEMBLY, Rescue G RF
10 BL-5740-14 • Hook Assembly, Swivel (SB BL-5448-1-25-01) see sec. 501 ACDEF 1
15 HK-116-7 • Hook Assembly, Swivel G 1
20 HK-111-1 • Hook Assembly, Swivel B 1
30 BL-12816-1 • Bumper Assembly 1
40 BL-12684-1 • Cover, Limit Switch 1
50 MS51957-28 • Screw 4
60 AL-1256-C4 • Washer, Flat 4
70 MS25036-102 • Terminal, Lug 1
80 BL-12646-1 • Gasket, Limit Switch Cover 1
90 BL-12606-1 • Cable Assembly, Wire Rope 1
100 AN565BC6H6 • Setscrew, Cone Point 3
101 BL-9182-3 • Setscrew 1
110 Y-1265-9-1 • Cable Cutter Assembly 1
120 AN565DC6H6 • Setscrew, Cup Point 1
130 BL-12670-1 • Fleet Angle Assembly 1
131 BL-14096-1 • • Screw, Shoulder 2
132 BL-12677-1 • • Cover, Roller 1
133 BL-12678-1 • • Housing, Roller 1
134 Y-1182-6-43 • • Spring, Compression 4
135 BL-12665-1 • • Retainer, Shaft 4
136 BL-12674-1 • • Shaft, Roller 4
137 BL-12683-1 • • Roller Assembly 4
138 MS27641-36 • • • Bearing, Ball 4
139 BL-12676-1 • • • Roller, Fleet Angle 4
140 BL-12804-1 • Roller Assembly, Tension 1
141 MS16624-4062 • • Ring, Retaining 1
142 BL-12673-1 • • Retainer, Bearing 1
143 MS27646-38G • • Bearing, Ball 2
144 MS51959-13 • • Screw, Flat Head 4
145 BL-12671-1 • • Plate, Guide 1
150 MS24665-153 • Pin, Cotter 2
160 BL-7454-1 • Retainer, Spring 2
NUMERICAL PARTS LIST INDEX FOR FIGURE 1002 (continued)
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FIG. AND PART NOMENCLATURE EFF. UNITS
ITEM NO. NUMBER 1234 CODE PER ASSY.
1002
170 Y-1182-6-44 • Spring 2
180 BL-14470-1 • Roller Assembly, Pressure 1
190 AL-1256-C185 • Washer, Flat 2
200 MS24674-11 • Screw, Cap 5
220 BL-12666-1 • Cover, Wheel 1
230 BL-14488-1 • Shaft, Tension Roller 1
240A MS24665-153 • Pin, Cotter (Pre-ASB BL-29700-A25-01) 1
240B MS16562-6 • Pin, Spring (Post ASB BL-29700-A25-01) 1
250A BL-14487-1 • Nut, Adjusting (Pre-ASB BL-29700-A25-01) 1
250B BL-14487-2 • Nut, Grooved Adj. (Post ASB BL-29700-A25-01) 1
260 BL-12629-1 • Spacer 1
270 MS27646-39G • Bearing, Ball 1
280 AL-1256-C180 • Washer, Flat 1
290 BL-7359 • Gear and Clutch Assembly 1
300 BL-14486-1 • Disc, Friction 1
310 Y-1131-2-5 • Washer, Belleville (Spring) 1
330 BL-12820-1 • Motor Assembly (Note: Connector faces down) ACEFG 1
340 BL-12820-2 • Motor Assembly (Note: Connector faces to the side) BD 1
350 MS16996-24 • Screw, Cap 4
360 AL-1256-C86 • Washer 4
370 M83248/1-132 • Packing, Preformed 1
380 No Number • Key (Part of Motor Assembly, Items 330 and 340) 1
390 MS27216-5 • Switch 6
400 BL-14745-1 • Actuator, Cable Foul Switch 1
410 MS21042-02 • Nut, Self-Locking 4
420 MS35206-321 • Screw, Pan Head 4
440 BL-14788-1 • Plate, Switch Retainer 4
450 BL-14787-1 • Actuator, Switch 2
460 Y-1357-1-1 • Insulator 20
470 MS24547-1 • Switch, Limit 6
480 MS51957-3 • Screws, Pan Head 4
490 BL-12865-1 • Bracket, Potentiometer and Cycle Counter Mounting 1
510 AN960C4L • Washer, Flat 6
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1002
520 BL-12696-1 • Bracket, Switch Mounting 1
550 WA-138-33 • Nut, Self-Locking 6
570 BL-6074 • Actuator, Switch 3
590 AN960C4 • Washer, Flat 3
600 BL-12667-1 • Cover, Full In Limit Switch 1
610 BL-12669-1 • Gasket, Cover 1
620 MS16633-4018 • Ring, Retaining 1
630 BL-12679-1 • Rod, Actuating 1
640 Y-1182-6-23 • Spring 1
650 BL-12689-1 • Guide, Actuator 1
660 BL-12688-1 • Actuator, Switch 1
670 BL-14777-1 • Harness Assembly 1
680 BL-12706-1 • Plate, Motor Identification 1
690 BL-12890-1 • Nameplate, Rescue Hoist System ACEF 1
700 11694-1 • Plate, PMA ACEF 1
710 BL-12601-1 • Nameplate, Rescue Hoist Assembly 1
720 BL-14913-1 • Screw, Pan Head 3
730 BL-12613-1 • Potentiometer (R1) 1
740 RJR26FW103P • Potentiometer (R3) 1
750 Y-1176-2-118 • Ring, Retaining 1
760 BL-11954-4 • Spacer 2
770 BL-12694-1 • Cam, Limit Switch 3
780 AN565AC6H6 • Setscrew, Hex 2
790 BL-12872-1 • Plug 1
800 Y-1125-1-7 • Seal 1
810 Y-1182-49-1 • Spring, Extension 2
820 MS9882-11 • Nut 4
830 AN960C516L • Washer 3
840 MS21333-109 • Clamp, Loop 1
850 BL-12649-1 • Bracket, Mounting, Hoist, RH (SUPSD BY Item 851) ABCD 1
851 BL-15933-1 • Bracket, Mounting, Hoist, RH (SUPSDS Item 850) EFG 1
860 BL-12649-2 • Bracket, Mounting, Hoist, LH (SUPSD BY Item 861) ABCD 1
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September 19, 2008
1002
861 BL-15933-2 • Bracket, Mounting, Hoist, LH (SUPSDS Item 860) EFG 1
870 Y-1176-1-50S • Ring, Retaining 1
880 AL-1256-C113 • Washer, Flat 2
890 BL-7182 • Follower 1
895 BL-14589-1 • Levelwind Shaft 1
900 BL-14776-1 • Wiring Harness 1
25-61-00
Page 1014
September 19, 2008
141
140
Figure 1003. Swivel Hook Assembly BL-5740-14 (for BL-29700-20, 22, 23, 24, and 25 Rescue Hoist
Assemblies)
25-61-00
Page 1015
September 19, 2008
ITEM NO. NUMBERS 1234 CODE PER
1003 ASSY.
-1 BL-5740-14 HOOK ASSEMBLY, Swivel 1
10 MS24665-88 • Pin, Cotter 2
20 BL-9920 • Screw, Locking 2
30 BL-4706 • Body 1
40 BL-5448-1 • Nut, Adapter (Replaces BL-5448 Nut Adapter, Reference SB BL-5448- 1
25-01 and SB- BL-5448-1-25-01 for SB termination requirements)
50 BL-5449 • Sleeve 1
60 BL-4708-5 • Clamp, Terminal 1
70 BL-4718 • • Ring, Retaining 1
80 BL-4719 • Bumper, Rubber 1
90 BL-10192-1 • Label, Cable Size 1
100 BL-14792-1 • Pin, Spring 1
110 AN310C7 • Nut, Castellated 1
120 BL-4707 • Retainer, Bearing 1
130 MS9021-022 • • Packing, Preformed 1
130A AN3578-022 • • Packing, Preformed 1
140 BL-4712-3 • Race, Needle Thrust Bearing 1
141 BL-4712-2 • Washer, Thrust 1
150 BL-4712-1 • Bearing, Needle Thrust 1
160 BL-4720 • Bearing, Ball 1
170 BL-3915-11 • Spacer 1
180 BL-4810-6 • Hook Assembly 1
190 BL-5497 • Tube 1
200 BL-14047-1 • Keeper 1
210 BL-4809 • Spring, Keeper 1
220 BL-4807 • Hook 1
25-61-00
Page 1016
September 19, 2008
Figure 1004. Swivel Hook Assembly HK-111-1 (for BL-29700-21 Rescue Hoist Assembly)
25-61-00
Page 1017
September 19, 2008
FIG. AND NOMENCLATURE EFF. UNITS
ITEM NO. PART NUMBER 1234 CODE PER
ASSY.
1004
-1 HK-111-1 HOOK ASSEMBLY, Swivel 1
10 MS24665-88 • Pin, Cotter 2
30 BL-9197 • Housing 1
40 BL-10892 • Nut 1
50 BL-4708-5 • Clamp, Terminal 1
60 BL-4718 • • Ring, Retaining 1
70 BL-10522 • Ring, Hand 1
80 BL-10521 • Key 1
90 BL-10213-1 • Spacer 1
100 BL-14792-2 • Pin, Spring 1
110 BL-8089 • Nut, Castellated 1
130 MS27641-8 • Bearing, Ball 1
150 HK-201-1 • Hook Assembly 1
160 Y-1223-1-1 • Pin, Quick-Release 1
170 Y-1096-11-2 • Cable Assembly 1
180 MS20613-4C16 • Rivet 1
190 HK-201-10 • Hook 1
25-61-00
Page 1018
September 19, 2008
Figure 1005. Swivel Hook Assembly HK-116-7 (for BL-29700-26 Rescue Hoist Assembly)
25-61-00
Page 1019
September 19, 2008
FIG. AND NOMENCLATURE EFF. UNITS
ITEM NO. PART NUMBER 1234 CODE PER
ASSY.
1005
-1 HK-116-7 HOOK ASSEMBLY, Swivel 1
10 MS24665-88 • Pin, Cotter 2
30 BL-11685-1 • Nut, Bushing 1
40 BL-4708-5 • Clamp, Terminal (See Note B, pg. 1002) 1
50 BL-4718 • • Ring, Retaining (See Note B, pg. 1002) 1
60 BL-4719 • Bumper, Rubber 1
70 BL-8089 • Nut, Castellated 1
90 AJ-9800-95-8 • Bearing, Ball 1
100 BL-11686-1 • Housing, Hook 1
110 BL-14792-1 • Pin, Spring 1
130 410-F • Hook, Swivel (V64249), B-E PN Y-1231-9-1 1
25-61-00
Page 1020
September 19, 2008
BREEZE EASTERN TECHNICAL PUBLICATION DEFICIENCY REPORT
Address: Date: Manual:
Manual Revision: Revision Date:

Section Page Para
Phone:
Figure Table Item
Part Number Affected:
E Mail:
Discrepancy (Provide as much detail as possible):
Initiator: Title:
Breeze Eastern Use Only
Date Received: Received By: Tracking Number:

Forwarded To: Date: Customer Receipt:
BE Research Result:
Response to Customer:
Engineering Services: Date: Customer Services: Date:
Mail To: Breeze Eastern Or fax to: (908)-686-6911

700 Liberty Avenue Attn: Engineering Services
Union, New Jersey USA 07083-8198
Attn: Engineering Services
TECHNICAL PUBLICATION DEFICIENCY REPORT
Page 1 of 1
BE-Tracking #
Customer: P. Husband, CMC IRL, SAR Unit, Shannon Airport, Cty Clare, IRE Date: 16/3/2012
Type: O&M Type: CMM Manual
Manual: H Revision Date:
Number: TD-01-002 Number: Revision: 9/19/08
Section: 501 Page: 516 Para: 5
Figure: 515 Table: Part Number:
(See attached customer input) retyped here for clarity.
Over time, the oil level sight glass becomes stained & difficult to see oil level.
Can you produce a procedure for cleaning/removing the sight glass.
Please provide email contact address.
Initiator: P. Husband Title: Continuing Airworthiness Manager

Submit to: B-E Customer Services.
via email Customerservices@breeze-eastern.com or FAX 973-739-9344

Engineering Services Disposition:
Section 501, Figure 515, page 516 covers the sight glass for the HS-29700 system. The cleaning procedure for the
sight glass is given in Section 401, Cleaning. Section 401, subsection 1. M. recommends cleaning the glass with
Antistatic Plastic and Glass Cleaner (name Plasti-Glass) using a clean cloth.
Removal of the sight glass is not a flight line activity.
There are no changes required in the manual. Therefore, no tracking number will be created.
Customer was provided with contact information by Gary Olson concerning another TPDR. It was also explained in
correspondence that the contact information being used was old, since Breeze-Eastern had moved its main location.
Engineering Services: Rich Preston Date: 6/5/12

Customer Services: Chuck Duncan, Robert Gaffin, Mike Koons, Date: 6/5/12
Zoltan Varsanyi
QC1334 Rev. B 04/12/12

CAGE CODE 08484
SIL01 BL-11140-Series
35 Melanie Lane
Whippany NJ, 07981 USA Original Release 04/27/10
SERVICE INFORMATION LETTER Page 1 of 2
BL-11140 PRESSURE CARTRIDGE KIT - INCREASE IN CARTRIDGE LIFE

AND PROPER INSTALLATION OF THE IMPULSE CARTRIDGE
SUBJECT: Breeze-Eastern Rescue Hoists utilizing Pressure Cartridge Kit PN BL-11140-Series, which
incorporate the Breeze-Eastern impulse cartridges PN’s Y-1265-10-1 and BL-9280 have an
increase in cartridge life from 3 years to 5 years as directed by the manufacturer. In addition, the
military equivalent cartridge kit PN’s Mark 44 Mod O and NAVAIR No. 2240772 are shipped
from the manufacturer with a collar and packing that must be removed prior to installation in
the rescue hoist.
I. INFORMATION.
A. Reason.
1. The manufacturer of the cartridge has extended the pressure cartridge life from 30 – 36 months
to 5 years. The cartridge life definition should now be as follows:
a) Packaged in hermetically sealed containers, 9 years beginning from date of manufacture of

which not more than 5 years shall have elapsed after opening the container.
b) Packaged in other than hermetically sealed containers, 5 years from the date of manufacture.
Essentially there is an increase in cartridge life of approximately 2 years, which enhances the
cartridge life cycle costs.
2. The military equivalent cartridge kit PN’s Mark 44 Mod O, and NAVAIR No. 2240772 (Not
Supplied by Breeze-Eastern), are shipped from the manufacturer with a collar and packing that
must be removed prior to installation in Breeze-Eastern rescue hoists.
Incorrect installation of the cartridge has been made in the field with the collar, and incorrect
packing / O-Ring installed, refer to Figures 1 and 2. This may affect the proper operation /
function of the cable cut system.
PROPRIETARY RIGHTS NOTICE: This Service Information Letter 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
EXPORT CONTROLLED – WARNING This Service Information Letter 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.
CAGE CODE 08484
SIL01 BL-11140-Series
35 Melanie Lane
Whippany NJ, 07981 USA Original Release, 04/27/10
SERVICE INFORMATION LETTER Page 2 of 2
BL-11140 PRESSURE CARTRIDGE KIT - INCREASE IN CARTRIDGE LIFE

AND PROPER INSTALLATION OF THE IMPULSE CARTRIDGE
Collar - Discard
Packing / O-Ring –
Discard (MS29513-13 or
different MS part number
[Not supplied by B-E]).
Cartridge incorrectly
installed with collar,
which damaged the
packing (O-ring).
For proper installation, 1) Remove Mark 44 Mod O packing /
O-Ring and discard, 2) Remove and discard collar, and 3) re-
install packing / O-Ring (MS28778-5) supplied with B-E
Pressure Cartridge Kit PN BL-11140-Series.
Figure 1. Impulse Cartridge Incorrectly Installed. Figure 2. Remove Collar and Shields
B. Effectivity.
This Service Information Letter (SIL) pertains to Pressure Cartridge Kit PN BL-11140-Series,
incorporating the Breeze-Eastern impulse cartridges PN Y-1265-10-1 and BL-9280. The cartridge is
equivalent to the militaries cartridge in PN MARK 44 MOD O and NAVAIR No. 2240772.
C. Contacts / Further Information.
Any questions concerning this Service Information Letter should be directed to Breeze-Eastern
Customer Services listed below:
Breeze-Eastern Corporation
35 Melanie Lane
Whippany, New Jersey 07981-1638 USA
Phone Number: (973) 602-1083, or (973) 602-1090
In the USA (except New Jersey) and Canada call toll free 1-800-929-1919.
Fax Number: (973) 739-9344
E-Mail: customerservices@breeze-eastern.com
Web Site: www.breeze-eastern.com
Service Information Letter 01 BL-11140-Series, Original Release ATA 100 Format

Use or disclosure of data contained on this sheet is subject to the restriction on the title page of this report.
CAGE CODE 08484
35 Melanie Lane SIL01 Maintenance

Whippany, NJ 07981 USA
Revision C, 04/30/10, Highlights

SERVICE INFORMATION LETTER
Breeze-Eastern Rescue Hoist and Cargo Winch Maintenance Concept
(Includes Time Between Overhaul Definition)
TO: HOLDERS OF BREEZE-EASTERN SERVICE INFORMATION LETTER
(SIL) 01 BREEZE-EASTERN RESUE HOIST AND CARGO WINCH
MAINTENANCE CONCEPT, REVISION B.
THIS IS TO INFORM YOU OF THE RELEASE OF

SIL01 MAINTENANCE REVISION C, DATED APRIL 30, 2010
HIGHLIGHTS
Revision C replaces in its entirety Revision B of SIL01 Maintenance, dated October 03, 2006. Please
discard revision B and replace it with Revision C. Record the revision change in your records.
PAGE / PARAGRAPH DESCRIPTION OF CHANGE
Added / Deleted / Addressed

Highlights Added
Page 1, Subject Added Overhaul Clarification Note
Page 4 Revised Table 1. “Breeze-Eastern’s Hoist / Winch Time Between
Overhaul (TBO) Period,” with added configurations.
Revised Note (2)
Page 5 Revised Breeze-Eastern Maintenance Contacts.
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.
PROPRIETARY RIGHTS NOTICE: This Service Information Letter 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
EXPORT CONTROLLED – WARNING This Service Information Letter 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.
CAGE CODE 08484

Revision C, 04/30/10, Page 1 of 5
SUBJECT: Breeze-Eastern has modified its maintenance concept for Rescue Hoists and Cargo Winches to
reflect revised government aviation authority requirements, as well as current industry and
military standards. C
Notes: This SIL pertains to Breeze-Eastern Rescue Hoists and Cargo Winches. System
Electronics such as Pendants, Pilot and Crew Control Panels are considered “On
Condition” Maintenance.
This Service Information Letter replaces CAB-100-45, “Recommended Intervals For

Planned Maintenance of Breeze-Eastern Hoists And Winches” in its entirety.
INFORMATION.
A. Reason.
Revisions made to the Federal Aviation Regulations (FAR), specifically FAR 27, “Airworthiness
Standards: Normal Category Rotorcraft,” and FAR 29, “Airworthiness Standards: Transport
Category Rotorcraft,” as well as the corresponding European Aviation Safety Agency (EASA)
Certification Specifications (CS), CS-27, “Small Rotorcraft,” CS-29, “Large Rotorcraft,” mandate
a stringent set of design requirements on the handling of external loads, both human and
non-human.
To meet the FAR / EASA requirements for helicopter type certification the commercial helicopter
manufacturers require an additional in depth level of detail in analyses, test, inspection, and
maintenance.
Although the military is not bound by the commercial FAR’s and EASA CS’s, their design
requirements on the handling of external loads, both human and non-human are as stringent, if not
more stringent, than the civil aviation authorities.
Therefore, Breeze-Eastern is adopting and implementing a maintenance concept that will meet the
changing / evolving requirements for safe Rescue Hoist and Cargo Winch design, operation, and
maintenance.
B. Effectivity.
This Service Information Letter pertains to all Rescue Hoist and Cargo Winch Systems
manufactured by Breeze-Eastern.
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
EXPORT CONTROLLED – WARNING This Service Information Letter 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.
CAGE CODE 08484

C. Maintenance Concept Description.
Breeze-Eastern has revised its maintenance concept to three (3) levels of established
maintenance. They encompass both commercial and military definitions as defined below.
NOTE: All maintenance actions for Breeze-Eastern Rescue Hoists or Cargo Winches shall be
accomplished in accordance with applicable Breeze-Eastern manuals and technical
documentation. Furthermore, it is required that all maintenance requiring new
components be accomplished utilizing Breeze-Eastern Federal Aviation Administration
(FAA) / European Aviation Safety Agency (EASA) approved parts. Any and all actions
taken by the owners / operators / maintenance facilities that deviate from Breeze-Eastern
recommended procedures contained herein, or actions taken utilizing parts, or
procedures not prescribed by Breeze-Eastern, shall not be the responsibility of
Breeze-Eastern.
Definitions.
1. Organizational / Flight Line Level:
Maintenance at this level consists of preventative maintenance, visual inspection, and
scheduled maintenance of the system, corrective maintenance for fault isolation, removal and
replacement of the hardware that can be performed at the organization or flight line “within
the shadow of the aircraft.”
2. Intermediate / Hangar Level:
Maintenance actions that cannot be accomplished at the Organizational / Flight Line Level of
maintenance will require removal of the system, or component, to a hangar workshop /
bench.
Examples where removal is required are access restrictions due to cowling, or helicopter,
interface, and alternate power or testing needs not available on the flight line etc.
(Note: For certain export controlled items (ITAR), intermediate, or depot-level repair, and
maintenance information may be exported to a location outside the United States only under
a Technical Assistance Agreement approved specifically for that purpose).
3. Depot Level / FAA - EASA Certified Repair Station:
Maintenance at the Depot Level consists of Line Replaceable Unit (LRU) / Weapons
Replaceable Assembly (WRA) repair, or overhaul, to return the unit to a fully operational
condition.
At this level, the units may be tested prior to disassembly, disassembled, inspected, repaired /
overhauled, and reassembled. After completion of assembly, the unit is acceptance tested.
At the Depot Level a functional test rig, as well as some special fixtures may be required.
Service Information Letter01 Maintenance, Revision C

CAGE CODE 08484

(Note: For certain export controlled items (ITAR), intermediate, or depot-level repair, and
maintenance information may be exported to a location outside the United States only
under a Technical Assistance Agreement approved specifically for that purpose).
D. Breeze-Eastern Maintenance Services.
Breeze-Eastern has revised its available maintenance services as defined in the following
information.
1. Scheduled Maintenance:
Breeze-Eastern’s maintenance action at this level is to perform scheduled maintenance on a

Hoist or Winch System, returned by operators who do not have the capability, or who do not
want to attempt, to accomplish these maintenance actions on their own.
2. Repair / Unscheduled Maintenance:
Breeze-Eastern’s maintenance action at this level is to go to the repair level necessary to

return the Hoist or Winch System to service. It will include functional testing, as well as any
Breeze-Eastern mandated improvements that are known to enhance the performance and / or
safety of the assembly.
3. Overhaul:
Breeze-Eastern’s maintenance action at this level is to bring the Hoist or Winch System to a
zero time / zero cycles condition regarding its overhaul status (see Table 1). The unit is
completely disassembled and the torque path / load critical parts are inspected to engineering
design criteria. Consumable, wear parts, and mandated parts are replaced, or reworked, in
accordance with customer instructions / contract. The unit is reassembled, and acceptance
tested, prior to being returned to service.
Overhaul Interval:
NOTE: If operators consistently sortie at excessive utilization rates, operate in adverse

environmental conditions, etc. it is the operator’s responsibility to increase the
scope, and frequency of all Hoist, or Winch, maintenance actions to ensure safe
operation of the equipment.
More frequent inspections can be made, but inspections cannot be accomplished

less frequently.

CAGE CODE 08484

Breeze-Eastern’s Hoist / Winch Time Between Overhaul (TBO) period is either five (5) years
or two thousand (2,000) cycles from date of manufacture, whichever comes first, or ten (10)
years or two thousand (2,000) cycles from date of manufacture, whichever comes first. Refer
to Table 1 for the applicable Hoist / Winch Time Between Overhaul (TBO) period.
NOTE: A Hoist, or Winch, cycle is defined as reeling out the cable from full-in to full-out,
and then reeling back to full-in.
Table 1. Breeze-Eastern’s Hoist / Winch Time Between Overhaul (TBO) Period.
Hoist / Winch PN Cycles Years Note(s)

All Cargo Winches 2000 10 (1)
All BL-29900’s 2000 10 (2)
BL-10300-16X Series 2000 10 (2) and (3) C
BL-10300-59-4, -63-1 2000 10 (2) and (3)

BL-20200-400-2 2000 10 (2)
BL-20200-41X Series and higher within the 2000 10 (2) and (3)
41X, 42X, 43X, etc. Series of Rescue Hoists
only.
BL-20200-516, 517 2000 10 (2) and (3)
BL-27100 Series 2000 10 (2) and (3)
All others 2000 5 (3)
If incorporated, a Hoist or Winch cycle is defined by the cycle counter. If a Hoist, or Winch,
does not have a cycle counter, then tracking of the number of cycles is dependent on the
operator’s records / usage logs.
Note(s):
(1) With the exception of those cargo winches used in hoisting operations (5 year TBO). C
(2) With a 10 year overhaul period, an oil change and limit switch integrity check is
recommended every 5 years.
(3) If the part number is not listed in Table 1 then the TBO is 5 years or 2000 cycles.

CAGE CODE 08484

E. Breeze-Eastern Maintenance Contacts. C
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
Joint Aviation Authorities (JAA) FAR / JAR-145 approved Repair Station (FAA Repair Station
No. BZ7R167O, JAR-145 Acceptance Certificate Reference No. JAA.5454), and can repair /
overhaul the system at competitive prices and lead-times. Please contact Breeze-Eastern
Customer Services as follows:
Breeze-Eastern Corporation
35 Melanie Lane
Whippany, New Jersey 07981-1638 USA
Phone Number: 973-602-1001, Ext.1175 or 1102, or 1-800-929-1919 (US and Canada only)
Fax Number: 973-739-9344
E-mail Address: customerservices@breeze-eastern.com

CAGE CODE 08484
SIL07 Maintenance
Original Release, 04/21/11
Page 1 of 4
Improved Wire Rope Cable Marking

SUBJECT: Wire Rope (cable) extremes will now be identified using a marking
process that will provide a more durable marking of the Wire Rope.
I. PLANNING INFORMATION.
A. Reason.
1. Provide a more durable marking of wire rope cable assemblies that require a visual
indication of travel extremes, i.e. Full Out, Full In, or both by replacing a painting
process with a metal staining process. (See Table 1.)
2. Provide a visual indication that the end of the wire rope cable that attaches to the
cable storage drum is positioned correctly prior to securing with the attachment
screw. (See Table 2.)
B. Effectivity.
This Service Information Letter (SIL) pertains to cable assemblies in Tables 1 and 2.
Wire Rope Cable Assemblies

BL-1572 BL-6542 BL-12524
BL-5283 BL-7505 BL-12552
BL-5485 BL-8439 BL-12606
BL-5583 BL-8827 BL-15677
BL-5866 BL-9149 BL-16204
BL-6260 BL-10653 BL-18222
Table 1. Wire Rope Cable Assemblies Affected

PROPRIETARY RIGHTS NOTICE: This Service Information Letter 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
EXPORT CONTROLLED – WARNING This Service Information Letter 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.
CAGE CODE 08484
SIL07 Maintenance
Page 2 of 4
L
Part Number L (Length of white mark.)

BL-6542 0.97 ± 0.03 in 24.6 ± 0.7 mm
BL-8439
BL-8827
BL-9149
0.50 ± 0.03 in 12.7 ± 0.7 mm
BL-10653
BL-12606
BL-18222
Table 2. Wire Rope Cables with White Marking.
C. Maintaining Marking on Wire Rope Cables.
The following materials are required for maintenance of marking on wire rope cables:
Material Description Supplier

Dykem Part Number 81713 Opaque Staining Color (Orange) Commercially Available
(Ref. 1 gallon bottle)
Dykem Part Number 81727 Opaque Staining Color (White) Commercially Available
(Ref. 1 gallon bottle)
TT-I-735A Isopropyl Alcohol Commercially Available

HANDLING THE WIRE ROPE CABLE TO PREVENT INJURY FROM
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 DEBRIS.
Service Information Letter - Maintenance ATA 100 Format

Use or disclosure of data contained on this sheet is subject to the restriction on the title page of this Service Information Letter.
CAGE CODE 08484
SIL07 Maintenance
Page 3 of 4
1. If the marking on the wire rope cable becomes worn, reapply using the following
procedure:
a) Remove any surface contamination from the area to be marked by using
isopropyl alcohol (Federal Spec TT-I-735A) applied with a clean, lint-free
cloth.
b) Apply stain to the area using a soft, clean cloth, or a brush.
c) Allow the stain to dry for at least 30 minutes. (Drying time is dependent upon
environmental conditions.)
d) Apply a second coat per step b.
e) Allow the stain to dry per step c.
f) If required, apply a third coat per step b.
g) Allow the stain to dry per step c.
h) With the use of a micrometer, confirm that the final diameter of the marked area
is no more than 0.001 inch (0.025 mm) greater than the uncolored wire rope
cable diameter.
D. Using the White Marking for Wire Rope Cable Installation. (For wire rope cables
with white marking at the attachment point. See Figure 1.)
Figure 1. White Marking at The Wire Rope Cable Attachment Point.
Add the following note to the wire rope cable installation instructions in the Operation
and Maintenance Manual, Section 701.
NOTE: CONFIRM THAT THE WIRE ROPE CABLE IS INSERTED FULLY

INTO THE DRUM FLANGE AND THAT THE WHITE MARKING IS
BARELY VISIBLE PRIOR TO SECURING WITH THE WIRE ROPE
CABLE ATTACHMENT SCREW. (SEE FIGURES 2 AND 3 BELOW.)

CAGE CODE 08484
SIL07 Maintenance
Page 4 of 4
Figure 2. Acceptable Wire Rope Cable Attachment.
Figure 3. Unacceptable Wire Rope Cable Attachment.
Please consult your applicable Operation and Maintenance Manual for specific wire rope
installation procedure.
E. Contacts / Further Information.

Breeze-Eastern Corporation Phone Number: (973) 602-1001, Ext. 1083, or 1090.
35 Melanie Lane 1-800-929-1919 (Toll-Free US and Canada only)
Whippany, New Jersey Fax Number: (973) 739-9344
07981-1638 USA E-Mail: customerservices@breeze-eastern.com
Web Site: www.breeze-eastern.com

CAGE CODE 08484
SIL08 Maintenance
Page 1 of 2
Information about Greases, Oils, Coatings, and Sealants
SUBJECT: Information on current grease, oils, coatings, and sealants for

B-E products.
I. PLANNING INFORMATION.
A. Reason.
To provide the operators of Breeze-Eastern products with updated information on

consumables due to component obsolescence, compatibility, compliance, and / or product
improvement.
B. Summary.
The following table lists alternate consumables for B-E products.
Consumable Replaced by / Alternate Remarks

Amovis 8-X Tribolube-9 grease Note 1
MIL-G-46886 A-A-59173 grease Note 2
DC-33 grease A-A-59173 grease Note 2
MIL-PRF-7808 oil MIL-PRF-23699 oil Note 3
MIL-PRF-7870 oil MIL-PRF-7808 oil Note 4
Iridite #14-2 Iridite NCP, Iridite #525 Note 5
Pliobond 30 Pliobond 35 Note 6
Table 1. Alternate Consumables.
C. Notes.
1. Tribolube-9 grease, made by Aerospace Lubricants Inc., replaces the discontinued

Amoco Amovis No. 8-X grease.
NOTE: DO NOT MIX TRIBOLUBE-9 AND AMOVIS 8-X GREASE. CLEAN

COMPONENTS BEFORE APPLYING TRIBOLUBE-9.
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
EXPORT CONTROLLED – WARNING This Service Information Letter 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.
CAGE CODE 08484
SIL08 Maintenance
Page 2 of 2
Information about Greases, Oils, Coatings, and Sealants
2. A-A-59173 silicone grease replaces MIL-G-46886. Any A-A-59173 spec compliant

grease is interchangeable with DC-33 grease.
3. MIL-PRF-23699 oil is an acceptable alternate for MIL-PRF-7808 Grade 3 oil

EXCEPT for the side gearbox of two-speed BL-20200 series hoists.
NOTE: DRAIN HOIST COMPLETELY BEFORE REFILLING WITH NEW OIL.
Recommended Oil Minimum Operating Temperature.

MIL-PRF-7808 Below -40° F (-40° C)
MIL-PRF-23699 Over -40° F (-40° C)
Table 2. Recommended Oil for Minimum Operating Temperatures
4. MIL-PRF-7808 oil is an acceptable alternate for MIL-PRF-7870 oil.
NOTE: DRAIN HOIST COMPLETELY BEFORE REFILLING WITH NEW OIL.
5. Iridite NCP, Iridite #525, or any MIL-DTL-5541 Class 1A compliant coating is

interchangeable with Iridite #14-2.
6. Pliobond 35 sealant replaces Pliobond 30. Pliobond 35 is a Volatile Organic

Compound (VOC) regulation compliant adhesive.
D. Effectivity.
Wherever mentioned in B-E documentation, Table 1. Alternate Consumables applies.

Page 1 of 2
BE-Tracking #TD01002TPDR060115009
Customer: AIRBUS HELICOPTERS Date: March 26, 2015
Type: O&M Type: CMM Manual Revision
Manual: H Sept. 19,2008
Number: TD-01-006 Number: TD-01-002 Revision: Date:
Schematics and
Section: wiring diagrams
Page: 202 to 209 Para:
Figure: 202 to 209 Table: Part Number:
CMM 25‐61‐10 Rescue Hoist Systems. Pages 202 to 209, fig 202 and 209.
Schematics and wiring diagrams are impossible to read. Please insert readable diagrams and update CMM.
Initiator: Marc FRANCESKIN Title: CMM’S manager AIRBUS HELICOPTERS
via email Customerservices@breeze-eastern.com or FAX (908) 688 6495
To be clear, the information given on the TPDR form is conflicting. Neither of the manuals noted on the form are
actually CMMs. CMM terminology refers to a depot overhaul manual (Component Maintenance Manual). Conversely,
O&M manuals are Flight Line Operation and Maintenance manuals (FLMM). Given the other information on the form
about the publication pages and figures stated, date and manual revision, and inquiries made of B-E Customer Care,
the assumption is made that the user is referring to pages within the FLMM, TD-01-002 HS-29700 Series Hoist
Systems.
As for readable schematics within the manual: the schematic details of most systems are excerpted from B-E engineering
schematics. As such, capturing those details in a page size that will fit into the standard technical manual, has always
been a challenge. It has been the practice of B-E, according to the specification invoked for technical manuals, to
accommodate the schematics to the allowable page sizes for a manual. Since many of the original B-E schematics are
prepared in a much larger drawing page format for engineering use, the illustrations need to be enlarged by the user when
reviewing the pdf file of the schematic page in order to see the details in a readable size.
In order to maximize the readability of the schematics, the attached pdf file of Section 201 or Revision H of the manual will
replace the existing Section 201. The attachment has enhanced resolution images of the schematics which can be read
upon magnification.
Engineering Services: Datalis Solutions Corporation Documenter Date: 6/2/15

Customer Services: Mike Koons, Jim Fett, Anthony Clarke, Patrick Date: 6/2/15
Doyle, Chuck Duncan
QC1334 Rev.-
Page 2 of 2
0201 ELEC DWGS See Attached file

SEC201 RevH.pdf
QC1334 Rev.-
1. General
CABLE
FOUL
INDICATOR
CABLE FOUL
SWITCH ON HOIST
AIRCRAFT
SUPPLIED
POWER
25-60-00
Page 201
September 19, 2008
25-60-00
Page 202
September 19, 2008
25-60-00
Page 203
September 19, 2008
25-60-00
Page 204
September 19, 2008
25-60-00
Page 205
September 19, 2008
25-60-00
Page 206
September 19, 2008
25-60-00
Page 207
September 19, 2008
25-60-00
Page 208
Inside Outside
Aircraft Aircraft
25-60-00
Page 209
September 19, 2008
25-60-00
Page 210
September 19, 2008
Page 1 of 2
Customer: AIRBUS HELICOPTERS Date: March 26, 2015
Type: O&M Type: CMM Manual Revision
Manual: H Sept. 19,2008
Number: TD-01-006 Number: TD-01-002 Revision: Date:
Schematics and
Section: wiring diagrams
Page: 202 to 209 Para:
Figure: 202 to 209 Table: Part Number:
CMM 25‐61‐10 Rescue Hoist Systems. Pages 202 to 209, fig 202 and 209.
Schematics and wiring diagrams are impossible to read. Please insert readable diagrams and update CMM.
Initiator: Marc FRANCESKIN Title: CMM’S manager AIRBUS HELICOPTERS
via email Customerservices@breeze-eastern.com or FAX (908) 688 6495
To be clear, the information given on the TPDR form is conflicting. Neither of the manuals noted on the form are
actually CMMs. CMM terminology refers to a depot overhaul manual (Component Maintenance Manual). Conversely,
O&M manuals are Flight Line Operation and Maintenance manuals (FLMM). Given the other information on the form
about the publication pages and figures stated, date and manual revision, and inquiries made of B-E Customer Care,
the assumption is made that the user is referring to pages within the FLMM, TD-01-002 HS-29700 Series Hoist
Systems.
As for readable schematics within the manual: the schematic details of most systems are excerpted from B-E engineering
schematics. As such, capturing those details in a page size that will fit into the standard technical manual, has always
been a challenge. It has been the practice of B-E, according to the specification invoked for technical manuals, to
accommodate the schematics to the allowable page sizes for a manual. Since many of the original B-E schematics are
prepared in a much larger drawing page format for engineering use, the illustrations need to be enlarged by the user when
reviewing the pdf file of the schematic page in order to see the details in a readable size.
In order to maximize the readability of the schematics, the attached pdf file of Section 201 or Revision H of the manual will
replace the existing Section 201. The attachment has enhanced resolution images of the schematics which can be read
upon magnification.
Engineering Services: Datalis Solutions Corporation Documenter Date: 6/2/15

Customer Services: Mike Koons, Jim Fett, Anthony Clarke, Patrick Date: 6/2/15
Doyle, Chuck Duncan
QC1334 Rev.-
Page 2 of 2
0201 ELEC DWGS See Attached file

SEC201 RevH.pdf
QC1334 Rev.-
1. General
CABLE
FOUL
INDICATOR
CABLE FOUL
SWITCH ON HOIST
AIRCRAFT
SUPPLIED
POWER
25-60-00
Page 201
September 19, 2008
25-60-00
Page 202
September 19, 2008
25-60-00
Page 203
September 19, 2008
25-60-00
Page 204
September 19, 2008
25-60-00
Page 205
September 19, 2008
25-60-00
Page 206
September 19, 2008
25-60-00
Page 207
September 19, 2008
25-60-00
Page 208
Inside Outside
Aircraft Aircraft
25-60-00
Page 209
September 19, 2008
25-60-00
Page 210
September 19, 2008

HS-29700 Series Rescue Hoist Systems PDF

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TD-01-002

HS-29700 Series Rescue Hoist Systems

EXPORT CONTROLLED – WARNING

RECORD OF TEMPORARY REVISIONS

REV. ISSUE DATE REMOVAL INCORPORATOR’S REMOVER’S

SERVICE SUBJECT REVISION AND INCORPORATION

SERVICE SUBJECT REVISION AND INCORPORATION

LIST OF EFFECTIVE PAGES

Description Page Date

Description Page Date

Description Page Date

Section / Paragraph Title Page

Section / Paragraph Title Page

Section / Paragraph Title Page

LIST OF FIGURES (Continued)

LIST OF FIGURES (Continued)

The manual is divided into separate sections:

1. Title Page 7. Introduction 13. Checks and Inspection

2. Proprietary Status and Liability

Cowling Assembly Variable Speed

Rescue Hoist Assembly BL-29700-20 X -- -- -- -- -- X X -- X -- -- -- -- -- -- -- --

Table 1. System Configuration Matrix

Figure 2. Rescue Hoist Assembly (Typical)

Figure 3. Limit Switch Locations

Screws for setting

Hoist Condition Measurement Required Result

Cable at least 10 feet (3 m) from Full In Pin E to Pin G Open

Cable Full In (Switch Unactuated) Pin A to Pin B Continuity

Control Pendant Condition Measurement Required Result

Figure 102. Deflection of Bumper Assembly with Hook at Full In Position

Trouble Probable Cause Remedy

Trouble Probable Cause Remedy

Trouble Probable Cause Remedy

SCHEMATICS AND WIRING DIAGRAMS

Figure 202. Rescue Hoist Assembly Wiring Diagram

Figure 204. Wiring Diagram for HS-29700-201 Rescue Hoist System

Figure 206. Wiring Diagram for HS-29700-203 Rescue Hoist System

Page Intentionally Blank

Setscrew Holding Cable Cutter in Cable Guide

CAUTION: THE RESCUE HOIST ASSEMBLY WEIGHS APPROXIMATELY 48 LB (21.8 KG)

Swivel Hook Assembly (10) Bumper Assembly (30)

Figure 302. View of Swivel Hook Assembly Resting on Flat Surface

Screw (50) and Lug Terminal (70)

Screws (50) and Washers (60)

Screws for setting

View of Cable Guide with Full In Limit

Figure 305. View of Setscrew in Drum Flange

Hole in Drum Flange for Setscrew

Slot in Drum Flange for

Roller Cover (132) Setscrews (100)

Shoulder Screw (131)

Figure 307. View of Fleet Angle Assembly

Friction Disc (300) Grooved Adjusting

Flat Washer (320)

Cap Screws (350) and

Motor Assembly (330, or 340)

Figure 310. View of Motor Assembly

Cable Foul Indicator Switches (390)

Switch Actuator (660)

Full In Limit Switches

Nuts (820), Washer (830),

Figure 313. Views of Mounting Brackets

NOTE: HOOK ASSEMBLIES THAT HAVE NEEDLE BEARINGS (AS DEPICTED IN