TD-04-006 Rev

TD-04-006
Original Release
FLIGHT LINE
OPERATION AND MAINTENANCE MANUAL
With
Illustrated Parts List
Rescue Hoist System
BREEZE-EASTERN PART NUMBER
HS-20200-511 SERIES
EXPORT CONTROLLED – WARNING

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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.
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January 11, 2005
FLIGHT LINE OPERATION AND MAINTENANCE MANUAL
HS-20200-511 SERIES RESCUE HOIST SYSTEM
RECORD OF REVISIONS
Retain this record in the front of the manual. On receipt of revisions, insert revised pages in the
manual, and enter revision number, date inserted, and initials.
REVISION REVISION DATE DATE REVISION REVISION DATE DATE

NUMBER FILLED BY NUMBER FILLED BY
Original January 11, 2005 - -
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January 11, 2005
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
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January 11, 2005
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 is incorporated
into the manual via a revision, Breeze-Eastern will enter the date terminated.
OPERATOR
DOCUMENT TYPE REVISION BREEZE-EASTERN
SUBJECT INCORPORATION
AND NUMBER AND DATE TERMINATION DATE
DATE
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January 11, 2005
LIST OF EFFECTIVE PAGES
*Indicates pages revised, added or deleted in latest revision.
Description Page Date
25-61-00, Title Page T-1 January 11, 2005
Record of Revisions RR-1 January 11, 2005
Record of Temporary Revisions RTR-1 January 11, 2005
Service Bulletin List SBL-1 January 11, 2005
List of Effective Pages LEP-1 January 11, 2005
LEP-2 January 11, 2005
Table of Contents T/C-1 January 11, 2005
T/C-2 January 11, 2005
Introduction INTRO-1 January 11, 2005
INTRO-2 January 11, 2005
Description and Operation 1 January 11, 2005
2 January 11, 2005
3 January 11, 2005
4 January 11, 2005
5 January 11, 2005
6 January 11, 2005
7 January 11, 2005
8 January 11, 2005
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10 January 11, 2005
11 January 11, 2005
12 January 11, 2005
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14 January 11, 2005
Testing and Troubleshooting 101 January 11, 2005
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103 January 11, 2005
104 January 11, 2005
105 January 11, 2005
106 January 11, 2005
107 January 11, 2005
108 January 11, 2005
109 January 11, 2005
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LIST OF EFFECTIVE PAGES (continued)
Testing and Troubleshooting (continued) 110 January 11, 2005
111 January 11, 2005
112 January 11, 2005
113 January 11, 2005
114 January 11, 2005
115 January 11, 2005
116 January 11, 2005
117 January 11, 2005
118 January 11, 2005
Schematics and Wiring Diagrams 201 January 11, 2005
202 January 11, 2005
203 January 11, 2005
204 January 11, 2005
Disassembly 301 January 11, 2005
302 January 11, 2005
303 January 11, 2005
304 January 11, 2005
305 January 11, 2005
306 January 11, 2005
307 January 11, 2005
308 January 11, 2005
309 January 11, 2005
310 January 11, 2005
311 January 11, 2005
312 January 11, 2005
313 January 11, 2005
314 January 11, 2005
315 January 11, 2005
316 January 11, 2005
317 January 11, 2005
318 January 11, 2005
Cleaning 401 January 11, 2005
402 January 11, 2005
403 January 11, 2005
404 January 11, 2005
Checks and Inspections 501 January 11, 2005
502 January 11, 2005
503 January 11, 2005
504 January 11, 2005
505 January 11, 2005
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Checks and Inspections (continued) 506 January 11, 2005
507 January 11, 2005
508 January 11, 2005
509 January 11, 2005
510 January 11, 2005
511 January 11, 2005
512 January 11, 2005
513 January 11, 2005
514 January 11, 2005
515 January 11, 2005
516 January 11, 2005
517 January 11, 2005
518 January 11, 2005
519 January 11, 2005
520 January 11, 2005
521 January 11, 2005
522 January 11, 2005
Repair 601 January 11, 2005
602 January 11, 2005
603 January 11, 2005
604 January 11, 2005
605 January 11, 2005
606 January 11, 2005
607 January 11, 2005
608 Blank
Assembly 701 January 11, 2005
702 January 11, 2005
703 January 11, 2005
704 January 11, 2005
705 January 11, 2005
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707 January 11, 2005
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710 January 11, 2005
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714 January 11, 2005
715 January 11, 2005
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Assembly (continued) 716 January 11, 2005
717 January 11, 2005
718 January 11, 2005
719 January 11, 2005
720 January 11, 2005
Fits and Clearances 801 January 11, 2005
802 January 11, 2005
803 January 11, 2005
804 January 11, 2005
805 January 11, 2005
806 Blank
Special Tools, Fixtures, and Equipment 901 January 11, 2005
902 January 11, 2005
Illustrated Parts List 1001 January 11, 2005
1002 January 11, 2005
1003 January 11, 2005
1004 January 11, 2005
1005 January 11, 2005
1006 January 11, 2005
1007 January 11, 2005
1008 January 11, 2005
1009 January 11, 2005
1010 January 11, 2005
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1016 January 11, 2005
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1021 January 11, 2005
1022 January 11, 2005
1023 January 11, 2005
1024 Blank
Technical Publication Deficiency Report
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TABLE OF CONTENTS
Section/Paragraph Title Page
25-61-00, Title Page ...................................................................... T-1
Record of Revisions ................................................................... RR-1
Record of Temporary Revisions ............................................. RTR-1
Service Bulletin List ................................................................ SBL-1
List of Effective Pages ............................................................. LEP-1
Table of Contents ...................................................................... T/C-1
Introduction Introduction.......................................................................... INTRO-1
Paragraph 1 General ................................................................................ INTRO-1
Paragraph 2 Proprietary Status and Liability .......................................... INTRO-1
Paragraph 3 Verification ......................................................................... INTRO-2
Section 1 Description and Operation ............................................................... 1
Paragraphs 1A through 1C Description ....................................................................................... 1
Paragraph 1D Rescue Hoist System ........................................................................ 2
Paragraph 1E Rescue Hoist Assembly ................................................................... 2
Paragraph 1F Wire Rope Cable .............................................................................. 4
Paragraph 1G Hook Assembly ................................................................................ 4
Paragraph 1H Tension Roller .................................................................................. 4
Paragraph 1I Cycle Counter .................................................................................. 4
Paragraph 1J Limit Switches ................................................................................. 4
Paragraph 1K Cable Cutter ..................................................................................... 6
Paragraph 1L Cable Foul Assembly ....................................................................... 7
Paragraph 1M Variable Speed Controller ................................................................ 7
Paragraph 1N Control Pendant Assembly ............................................................... 8
Paragraph 1O Leading Particulars for Rescue Hoist System .................................. 9
Paragraph 2 Operation ......................................................................................... 10
Section 101 Testing and Troubleshooting ........................................................ 101
Paragraph 1 Testing ........................................................................................... 101
Paragraph 2 Test Equipment and Materials ...................................................... 101
Paragraph 3 Test Conditions ............................................................................. 101
Paragraph 4 Test ................................................................................................ 101
Paragraph 4A Limit Switch Test .......................................................................... 102
Paragraph 4B Control Pendant Digital Readout Test .......................................... 108
Paragraph 4C Cable Foul Indicator Test .............................................................. 110
Paragraph 4D Hook Load Test ............................................................................. 111
Paragraph 4E Rated Load Test ............................................................................ 111
Paragraph 4F Bumper Assembly and Full In Limit Switch Test ........................ 112
Paragraph 5 Troubleshooting ............................................................................ 113
Paragraph 6 Rescue Hoist Assembly Electrical Continuity Check ................... 117
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TABLE OF CONTENTS (continued)
Section 201 Schematics and Wiring Diagrams ................................................. 201
Section 301 Disassembly .................................................................................. 301
Paragraphs 1 and 2 General .......................................................................................... 301
Paragraph 3 Removal of Hoist .......................................................................... 301
Paragraph 4 Removal of Variable Speed Controller ......................................... 302
Paragraph 5 Removal of Control Pendant and Pendant Cable Assembly.......... 303
Paragraph 6 Removal and Disassembly of HK-116 Series Hook Assemblies . 303
Paragraph 9 Removal and Disassembly of HK-112-1 Hook Assembly ........... 306
Paragraph 10 Removal and Disassembly of BL-5740-15 Hook Assembly ........ 307
Paragraph 12 Removal and Disassembly of BL-14584-10 Hook Assembly ...... 309
Paragraph 13 Removal and Disassembly of Bumper Assembly ......................... 310
Paragraph 14 Removal and Disassembly of Limit Switch Cover Assembly....... 311
Paragraph 15 Removal of Cable ......................................................................... 312
Paragraph 16 Removal of Cable Cutter .............................................................. 312
Paragraph 17 Removal of Cable Guide ............................................................... 314
Paragraph 18 Removal of Tension Roller ........................................................... 315
Paragraph 19 Removal of Overrunning Clutch ................................................... 315
Paragraph 20 Removal of Chain ......................................................................... 316
Paragraph 21 Removal of Motor ......................................................................... 316
Paragraph 22 Removal of Follower .................................................................... 317
Paragraph 23 Removal of Cable Pressure Roller Assemblies ............................ 317
Paragraph 24 Removal of Identification Plate and Labels .................................. 317
Paragraph 25 Removal of Electrical Components .............................................. 317
Paragraph 25A Removal of Full Out and Intermediate Limit Switches .................317
Paragraph 25B Removal of Potentiometer R1 ....................................................... 318
Paragraph 25C Removal of Full In Limit Switches ............................................... 318
Paragraph 25D Removal of Cable Foul Assembly Switches ................................. 318
Section 401 Cleaning ........................................................................................ 401
Paragraph 1 General .......................................................................................... 401
Paragraph 1A through 1J General .......................................................................................... 402
Paragraph 1K Cable (if exposed to lubricants) .................................................... 402
Paragraph 1L Hoist, Hook and/or Cable (if exposed to saltwater) ...................... 403
Paragraph 1M Forward and Aft Cowling Windows (if applicable) ......................404
Paragraph 1N Wiring Harness Assembly .............................................................404
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Section 501 Checks and Inspections ................................................................. 501
Paragraph 2 Inspections .................................................................................... 502
Paragraph 2A Overhaul of Rescue Hoist ............................................................. 502
Paragraph 2B General .......................................................................................... 502
Paragraph 2C Tension Roller ............................................................................... 504
Paragraph 2D Overrunning Clutch Assembly ..................................................... 506
Paragraph 2E Wire Rope Cable ........................................................................... 506
Paragraph 2F Hook Assemblies .......................................................................... 512
Paragraph 2G Cable Guide .................................................................................. 512
Paragraph 2H Chain ............................................................................................. 513
Paragraph 2I Cable Foul Indicator ..................................................................... 514
Paragraph 2J Pressure Roller Assemblies ........................................................... 517
Paragraph 2K Level Wind Shaft and Follower .................................................... 517
Paragraph 2L Pre-Flight Inspection ..................................................................... 517
Paragraph 2M Post-Flight Inspection ................................................................... 520
Paragraph 2N Cable Cutter .................................................................................. 521
Paragraph 2O Detailed Inspection of Rescue Hoist End Flanges ........................ 522
Paragraph 2P Inspection of Wiring ..................................................................... 522
Section 601 Repair ............................................................................................ 601
Paragraph 2 Refinish ......................................................................................... 603
Paragraph 3 Minor Surface Repair .................................................................... 604
Paragraph 4 Major Surface Repair .................................................................... 605
Paragraph 5 Application of Top Coat ............................................................... 605
Paragraph 6 Application of Coating on Cable .................................................. 605
Paragraph 7 Cable Foul Removal ..................................................................... 606
Paragraph 8 Cable Alignment Inspection / Adjustment .................................... 606
Section 701 Assembly ....................................................................................... 701
Paragraphs 1 and 2 General .......................................................................................... 701
Paragraph 3 Assembly of Rescue Hoist System ............................................... 701
Paragraph 4 Installation of Electrical Components ........................................... 702
Paragraph 4A Installation of Full In Limit Switch .............................................. 702
Paragraph 4B Installation of Full Out and Intermediate Limit Switches .............702
Paragraph 4C Installation of Potentiometer R1 ................................................... 702
Paragraph 4D Installation of Cable Foul Indicator Limit Switches ..................... 703
Paragraph 5 Installation of Motor ..................................................................... 703
Paragraph 6 Installation of Chain ...................................................................... 703
Paragraph 7 Installation of Overrunning Clutch Assembly ............................... 703
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Section 701 Assembly (continued)
Paragraph 8 Installation of Roller Assemblies and Follower ............................ 704
Paragraph 9 Installation of Tension Roller ....................................................... 704
Paragraph 10 Installation of Cable Guide ........................................................... 705
Paragraph 11 Installation of Limit Switch Cover Assembly .............................. 705
Paragraph 12 Installation of Cable Cutter and Cartridge .................................... 705
Paragraph 13 Installation of Cable ...................................................................... 706
Paragraph 14 Assembly and Installation of Bumper Assembly .......................... 706
Paragraph 15 Assembly and Installation of HK-116 Series Hook Assemblies .. 707
Paragraph 18 Assembly and Installation of HK-112-1 Hook Assembly ............ 712
Paragraph 19 Assembly and Installation of BL-5740-15 Hook Assembly ......... 713
Paragraph 21 Assembly and Installation of BL-14584-10 Hook Assembly ....... 717
Paragraph 22 Installation of Labels ..................................................................... 718
Paragraph 23 Installation of Control Pendant and Pendant Cable Assembly ..... 718
Paragraph 24 Installation of Variable Speed Controller ..................................... 719
Paragraph 25 Installation of Hoist ....................................................................... 719
Paragraph 26 Installation of Cable Cutter Cartridge ........................................... 719
Paragraph 27 Storage Instructions ...................................................................... 719
Section 801 Fits and Clearances ....................................................................... 801
Section 901 Special Tools, Fixtures, and Equipment ....................................... 901
Section 1001 Illustrated Parts List .................................................................... 1001
Paragraph 1 Introduction ................................................................................. 1001
Paragraph 1A Purpose ........................................................................................ 1001
Paragraph 1B Explanation and Usage of Section .............................................. 1001
Paragraph 1C Vendors ....................................................................................... 1002
Paragraph 2 Notes ........................................................................................... 1002
LIST OF TABLES
Table Title Page
1 Rescue Hoist System Configuration Matrix ................................................................ 2
2 Leading Particulars for Rescue Hoist System .............................................................. 9
101 Troubleshooting Procedures ..................................................................................... 113
102 Electrical Continuity Check ..................................................................................... 117
401 Materials Required for Cleaning .............................................................................. 401
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LIST OF TABLES (continued)
Table Title Page
501 Inspection Requirements........................................................................................... 501
601 Materials Required for Repair ................................................................................. 601
602 Allowable Material Removal ................................................................................... 602
701 Materials Required for Assembly ............................................................................ 701
801 Allowable Limit Values............................................................................................ 802
901 Special Tools, Fixtures, and Test Equipment List .................................................... 901
LIST OF FIGURES
Figure Title Page
1 HS-20200-511 Series Rescue Hoist System ................................................................ 1
2 Limit Switch Actuation Positions ................................................................................ 5
3 Approximate Dimensions of Orange Paint on Wire Rope Cable .............................. 12
101 Locations of Limit Switches, Screws, Potentiometers
on the Cyclocentric Assembly and Cable Guide ..................................................... 103
102 Limit Switch Actuation Positions ............................................................................ 104
103 Cable Guide Pin ....................................................................................................... 107
104 Cable Foul Assembly Inspection and Adjustment ................................................... 110
105 Deflection of Bumper Assembly with Hook at Full In Position .............................. 113
201 Typical Circuit Used to Drive the Cable Foul Indicator .......................................... 201
202 BL-20200-511 Rescue Hoist Assembly Wiring Diagram ....................................... 202
203 HS-20200-511-01 and -02 Rescue Hoist Systems
Interconnection Wiring Diagram ............................................................................. 203
204 EC-14170-1 Pendant Cable Assembly Wiring Diagram ......................................... 204
301 Cable Cutter Cartridge in Cable Guide Assembly ................................................... 302
302 Limit Switch Cover .................................................................................................. 311
303 Full Out Limit Switch (S2) and Potentiometer on Cyclocentric Assembly ............. 313
304 Cable Guide Assembly with Cable Guide ............................................................... 314
305 Chain, Sprocket, Follower and Attaching Hardware ............................................... 316
401 Example of Corrosion on Hook Assembly Parts ..................................................... 403
402 Example of Corrosion on Drum ............................................................................... 404
501 Examples of Unacceptable Damage to Gear ........................................................... 503
502 Tension Roller Gear and Overrunning Clutch Assembly ........................................ 504
503 Tension Roller Replacement Criteria ....................................................................... 505
504 Overrunning Clutch Assembly ................................................................................ 506
505 Example of Broken Strands in Wire Rope Cable .................................................... 507
506 Example of Abrasion of Wire Rope Cable .............................................................. 508
507 Example of Kink in Wire Rope Cable ..................................................................... 508
508 Example of Knot in Wire Rope Cable ..................................................................... 509
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LIST OF FIGURES (continued)
Figure Title Page
509 Example of Bird Caging in Wire Rope Cable ......................................................... 509
510 Hook Assembly Attachment to Wire Rope Cable ................................................... 510
511 Examples of Wire Rope Cable Looseness ............................................................... 510
512 Various Hooks and Assembly .................................................................................. 512
513 Required Terminal Clamp Orientation .................................................................... 513
514 Level Wind Chain Drive with Hoist Horizontal ...................................................... 513
515 Chain Tension Check with Hoist Horizontal ........................................................... 514
516 Chain Tension Check with Hoist Vertical ............................................................... 515
517 Cable Foul Sensor Dimensional Check ................................................................... 516
518 Cable Foul Sensor Test ............................................................................................ 516
519 Roller Replacement Criteria .................................................................................... 517
520 Dimensional Inspection of Level Wind Follower and Shaft ................................... 518
521 Oil Fill Location ....................................................................................................... 519
522 Deflection of Bumper Assembly with Hook at Full In Position .............................. 521
601 Wire Rope Cable Orange Paint Lengths .................................................................. 604
701 Tension Roller Shaft Assembly and Overrunning Clutch Assembly ...................... 704
702 Required Terminal Clamp Orientation .................................................................... 707
801 Rescue Hoist Assembly Illustration ......................................................................... 803
802 Variable Speed Controller Illustration ..................................................................... 804
803 Control Pendant Assembly Illustration .................................................................... 805
901 Retaining Ring Installation Tool, PN BLT-10300-V .............................................. 901
902 TE-120-1 Calibrated Weights .................................................................................. 902
903 TE-120-2 Calibrated Weights ................................................................................... 902
904 TE-120-3 Cart .......................................................................................................... 902
1001 Rescue Hoist Systems ............................................................................................ 1003
1002 Rescue Hoist Assembly ......................................................................................... 1005
1003 HK-116 Series Swivel Hook Assemblies .............................................................. 1010
1004 HK-118 Series Hook Assemblies .......................................................................... 1012
1006 HK-112-1 Hook Assembly .................................................................................... 1016
1007 BL-5740-15 Hook Assembly ................................................................................. 1018
1009 BL-14584-10 Hook Assembly ............................................................................... 1022
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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 Inspections

2. Record of Revision 8. Description and Operation 14. Repair
3. Record of Temporary Revisions 9. Testing and Troubleshooting 15. Assembly
4. Service Bulletin List 10. Schematics and Wiring Diagrams 16. Fits and Clearances
5. List of Effective Pages 11. Disassembly 17. Special Tools
6. Table of Contents 12. Cleaning 18. Illustrated Parts List
Refer to the Table of Contents for the page location of applicable sections. An asterisked
flagnote *( ) 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 the Technical Publication Deficiency Report (TPDR). Attached to the back of
this manual is a copy of a blank TPDR for use by the customer, plus copies of any TPDR’s
written against the manual for incorporation into the next revision.
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.
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January 11, 2005
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
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DESCRIPTION AND OPERATION
Figure 1. HS-20200-511 Series Rescue Hoist System.

1. Description
A. This publication explains the operation of, and provides flight line maintenance
instructions for the HS-20200-511 Series Rescue Hoist Systems. The instructions
provided are used to maintain the Systems, with select subassembly removals, in a
serviceable condition while installed on the helicopter (See Figure 1). Operators should
be aware that maintenance training for Breeze-Eastern products is available.
B. The Rescue Hoist System provides a means for lowering and raising personnel from an
airborne helicopter. The Rescue Hoist is operated from the Control Pendant, or from
optional pilot station / crew station equipment.
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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 all components of the Rescue Hoist System at
competitive prices and lead-times. Please contact Breeze-Eastern Customer Services as
listed below:
Breeze-Eastern
700 Liberty Avenue
Union, New Jersey 07083-8198 USA
Phone Number: 908-686-4000, or 1-800-929-1919 (US and Canada only)
Fax Number: 908-688-6495 E-mail Address: productsupport@breeze-eastern.com
Web Site Address: www.breeze-eastern.com
Revision Status of the Breeze-Eastern flight line technical manuals is available on the
website listed above.
D. Rescue Hoist System
The Rescue Hoist Systems consist of the following components (See Table 1), which are
considered Line Replaceable Units (LRUs):
Control Variable Pressure Pendant
Rescue Hoist Rescue Hoist Hook Bumper
Pendant Speed Cartridge Cable
System Assembly Assembly* Assembly*
Assembly Controller Kit Assembly*
HS-20200-511-01 BL-20200-511 CP-600-1 EC-14000-1 KT-198 EC-14170-1 Various BL-7720
HS-20200-511-02 BL-20200-511 CP-700-1 EC-14000-3 KT-198 EC-14170-1 Various BL-7720
The following Hook Assemblies PN’s are optional equipment:
HK-112-1, HK-115-1, HK-115-2, HK-116-1, HK-116-2, HK-118-1, HK-118-2, HK-121-1, HK-121-2
* Optional Equipment – Not part of configuration
Table 1. Rescue Hoist System Configuration Matrix
The main power requirement for the Rescue Hoist System is 28 VDC, 130 Amperes. The
power required for the controls in the Control Pendant, and the cable cutter for the Hoist,
is 28 VDC, 5 Amperes. The power supplied by the helicopter is converted into the power
required for the Rescue Hoist System by the Variable Speed Controller. The Variable
Speed Controller provides the necessary power to the electric motor to drive the drum on
the Hoist.
E. Rescue Hoist Assembly
The Hoist contains a rotating drum, which is driven by an electric motor through a gear
train and clutch assembly, raising and lowering a 245 ft. (74.7 m.) wire rope cable and
swivel hook. The Hoist operates at variable speeds, through an oil filled gearbox, from 0
to 200 fpm (1.0 mps) with a 250 lb. (113 kg) load and 0 to 100 fpm (0.5 mps) with a 600
lb. (272 kg) load. A level wind mechanism on the hoist assembly ensures even wrapping
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of the cable on the drum. Redundant limit switches sense when the hook approaches the
full in, or full out limits. The Hoist stops automatically when the hook reaches these two
limits. The drum incorporates an improved means of anchoring the cable to the drum
flange by utilizing a slot into which the end of the cable is inserted. The cable is held in
the slot with a setscrew, and a second setscrew is installed to lock the first setscrew in
place.
An overload slip clutch is located in the inner diameter of the drum. The clutch operates
if the cable load exceeds 1200 to 1800 lb. (544 to 816 kg.), thereby preventing the wire
rope cable and internal hoist components from overload. However, this design does not
replace the cable inspections required for proper operation.
This clutch design incorporates features such as, permanently lubricated ball bearings,
enhanced support stiffness, and provides four major functional capabilities:
(1) Protects the cable by absorbing homing load energy in the event of a malfunction of
both the intermediate speed and full in limit switches.
(2) Absorbs cable shock loads.
(3) Allows a means of protection for the hoist and helicopter structure in the event of
system overload.
(4) Eliminates the need for a crushable bumper.
A load control Weston brake is incorporated in the inner diameter of the drum. When
power is removed, or operation is stopped, the brake is automatically applied to hold the
load. The brake consists of a clutch disk pack assembly, and a jaw assembly.
The reduction gearing is of a planetary type, which drives a chain used to synchronize the
drum with the level wind shaft and cable guide. An idler also provides positive retention
of the chain. Together, these features mitigate the chances for tension loss due to slippage
and resultant loss of the drive chain.
NOTE: THE SIGHT GLASS CANNOT BE USED TO DETERMINE THE OIL LEVEL
OF THE TWO-SPEED MECHANISM, ONLY THE OIL LEVEL OF THE
DRUM ASSEMBLY. THE TWO-SPEED MECHANISM OIL LEVEL MUST
BE CHECKED AT ITS OIL FILL PLUG.
An oil seal, between the drum and the outside of the ring gear minimizes the possibility
of oil leakage between the faying surfaces. The Hoist also incorporates an oil sight gage
allowing for a visual reference for servicing of the drum.
A gear guard provides an extra measure of safety by protecting the cable from being cut,
or damaged, if a fouled cable got caught between the drum gear and overrunning clutch.
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F. Wire Rope Cable

The load cable for the Hoist consists of a wire rope with a swaged stainless steel ball /
shank fitting per MS20664. The wire rope is 0.1875 inch (4.76 mm.) diameter, corrosion
resistant, preformed spin resistant (19 x 7) construction conforming to MIL-W-83140.
During its fabrication, an inert gas shielded electric arc process cuts off the drum end of
the load cable, such that the cable end is sealed, and made suitable for attachment at the
drum anchor point.
G. Hook Assembly
The hook assembly rotates 360 degrees, attaches to the ball end of the cable using a
terminal clamp, nut and housing design, and incorporates a lockable keeper to prevent the
load from inadvertently releasing.
H. Tension Roller
The Rescue Hoist utilizes a tension roller system located between the cable guide and
drum. The tension roller is driven by the drum gear through an overrunning clutch and
tension roller gear such that when reeling out, the tangential speed of the tension roller is
faster than the tangential speed of the drum, thereby maintaining a “pull” force on the
cable, even at no load. The overrunning clutch allows the tension roller to freewheel
when reeling in providing no drag force on the cable.
I. Cycle Counter
The hoist has a counter that records each revolution of the drum. A reed switch activated
by a magnet on the drum advances the counter. The number on the counter, divided by
334, provides the total number of hoist cycles.
J. Limit Switches
WARNING: WHEN NOT IN USE, THE HOOK MUST BE HOMED COMPLETELY IN
THE FULL IN POSITION TO AVOID FATIGUE OF THE CABLE NEAR
THE BALL END DUE TO VIBRATION.
NOTE: IN THE OPERATION OF THE HOIST, THE CABLE RATE IS
AUTOMATICALLY SLOWED TO A SAFE SPEED WHENEVER THE
HOIST IS OPERATED NEAR THE EXTREMES OF THE CABLE
TRAVEL (FULL IN AND FULL OUT) BY REDUNDANT,
INTERMEDIATE SPEED LIMIT SWITCHES.
Redundant limit switches control full in, full out, and intermediate speed cable travel with
the following purpose (see Figure 2):
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Figure 2. Limit Switch Actuation Positions

(1) The full in switch (S3), located in the cable guide assembly, stops Rescue Hoist
operation when the bumper assembly makes contact with the cable guide.
(2) The up intermediate speed switch (S1), located on the cyclocentric assembly, slows
down the Rescue Hoist when reeling in, and within a specified distance from full in
switch actuation.
(3) The down intermediate speed switch (S1), located on the cyclocentric assembly,
slows down the Rescue Hoist when reeling out, and within a specified distance from
full out switch actuation.
(4) The full out switch (S2), located on the cyclocentric, assembly stops Rescue Hoist
operation at a specified number of dead wraps on the cable drum.
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The limit switches are directly geared to the hoist drum to control full out and
intermediate speed cable positions (hook approach to helicopter and approach to full
extension). The cable full in switch is built into the cable guide to ensure proper homing
of the hook.
K. Cable Cutter
WARNING: THE CARTRIDGE IS AN EXPLOSIVE DEVICE AND MUST BE SHIPPED,
STORED, AND HANDLED IN COMPLIANCE WITH ALL LOCAL
STANDARDS AND REGULATORY PRACTICES.
NOTE: MAXIMUM CARTRIDGE SERVICE LIFE IS 5 YEARS WHEN REMOVED
FROM PACKAGING, AND INSTALLED IN HOIST. MAXIMUM
CARTRIDGE LIFE IS 13 YEARS (COMBINED SHELF AND SERVICE LIFE)
FROM THE DATE OF MANUFACTURE. THE DATE OF MANUFACTURE
CAN BE FOUND IN THE LOT NUMBER ON THE LABEL OF THE SEALED
CONTAINER, IN WHICH THE CARTRIDGE IS SHIPPED AND STORED,
AND ON THE FLATS OF THE HEX SHAPED PORTION OF THE
CARTRIDGE. THE LOT NUMBER CAN BE IDENTIFIED WITH THE FIRST
THREE LETTERS “CAD.” IMMEDIATELY FOLLOWING THESE LETTERS
IS THE DATE OF MANUFACTURE, REPRESENTED AS TWO DIGITS,
WHICH IDENTIFY THE YEAR (EXAMPLE: 05 IS 2005), AND ONE
LETTER, WHICH IDENTIFIES THE MONTH, AS DEFINED BELOW:
A– JANUARY E– MAY J – SEPTEMBER
B– FEBRUARY F– JUNE K – OCTOBER
C– MARCH G– JULY L – NOVEMBER
D– APRIL H– AUGUST M – DECEMBER
NOTE: IF THE CABLE HAS BEEN CUT, THE ANVIL (BL-6329), CARTRIDGE (KT-
98), CUTTER (BL-6331), O-RING / PACKING (AN6227-10), AND COTTER
PIN (MS9245-10) SHALL BE REPLACED.
The hoist is equipped with a cable cutter that is located in the cable guide, consisting of
an electrically fired pressure cartridge (squib), a guillotine, and anvil to sever the cable in
an emergency. At 28 VDC, the minimum all-fire current of the cartridge is 5.0 amperes
per bridge wire and the minimum no-fire current for the cartridge is 1.0 ampere, 1 Watt.
The cartridge is contained in a Pressure Cartridge Kit, which is supplied with the system.
The Kit, KT-198, consists of one cartridge in a hermetically sealed container, three
shims, and one O-ring, all to be used for the installation of the cartridge.
In the event the cartridge has been fired during a cable cut, the cartridge (with shims,
packing, etc.) anvil, cutter, O-ring, cotter pin, shall be replaced.
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L. 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.
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. It
is mounted on the hoist 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.
M. Variable Speed Controller
The Variable Speed Controller incorporates pulse-width-modulated speed control
techniques. Hoist speed control is accomplished by a speed command applied to the
controller from either the variable speed control pendant, or the constant speed priority
override at the pilot’s control switch, if installed. The greater the deflection of the thumb
wheel on the hoist operator’s pendant control assembly, the greater average DC voltage
applied to the motor, hence, faster hoisting speeds. Full deflection of the thumb wheel
applies maximum voltage to the DC motor, hence, maximum cable speed.
The signal that controls the direction of cable motion is also sent to the controller and is
processed by circuitry located in its main circuit board. The board is provided with a time
delay relay that allows a minimum lapse of inactive time, which is recommended for
proper switching of hoist operation between “cable up” to “cable down” directions.
The Variable Speed Controller assembly dissipates minimal power by design. The heat
sink on the side of the controller is used to remove heat from the controller and
installation must be either horizontal with the heat sink facing up, or vertical.
The Variable Speed Controller (controller) incorporates the following safety features:
(1) Field loss detection circuit – The controller will inhibit hoist operation if a loss of
motor field is detected.
(2) Under voltage lockout – The controller will inhibit hoist operation if the input DC
voltage is <17 VDC.
(3) Provides the hoist operator with a motor overheat indication by a continuously
illuminated motor warning light. This condition will result from operating the hoist
system in prolonged high temperature environments, which exceed the design limits
of the system.
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January 11, 2005
(4) Pulse by pulse current limit – The controller will detect excessive current
requirements from the DC power and limit the amount of power consumed from the
helicopter power system.
N. Control Pendant Assembly
The control pendant assembly provides the crewmember with freedom of movement
while utilizing the following control features:
(1) Digital readout (if applicable)
(2) Cable Direction / Speed control
(3) Inter-Communication System (ICS) control
(4) Indicator light displaying motor over temperature (green - steady light), or high speed
mode overload (yellow - blinking light), as applicable.
The CP-700-1 pendant is equipped with a digital cable pay out display that indicates the
length in feet of cable paid out from the Hoist, and an electrical connector for interfacing
with the Variable Speed Controller. The pendant has a bracket incorporated on the
handgrip to facilitate stowing the pendant in the helicopter. When power is initially
applied to the rescue hoist system, “888” will be displayed for a moment, and then the
cable length displayed (“000” for full in).
The direction / speed control thumb wheel is centrally located on the shrouded upper
portion of the handgrip. The essence of the control pendant is the direction / speed control
mechanism containing, and actuating, two switches and a potentiometer. The two
switches (one for either direction) provide an on-off signal. The potentiometer, rotated by
the thumb wheel, provides a speed command signal to the controller.
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.
Pendant Cable Assembly is an optional piece of equipment, Breeze-Eastern Part Number
EC-14170-1, electrically connects the Control Pendant Assembly to the Variable Speed
Controller.
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O. Leading Particulars for Rescue Hoist System

Rescue Hoist Assembly
Cable:
Type 19 x 7 strand wraps
Length 245 feet (74.7 meters) usable length
Diameter 0.187 in. +0.006 / –0.001 in. (4.75 mm. +0.15 / –0.03 mm.)
Cable Drum Layers 4
Material Stainless Steel, flexible, preformed, spin resistant
Cable Speed (Hoisting):
600 pounds (272 kg.) 100 fpm (0.5 mps) with cable on top layer
250 pounds (113 kg.) 200 fpm (1.0 mps) with cable on top layer
Load:
Operating Load 600 lb. (272 kg.)
Overload Clutch Slips between 1200 lb. (544 kg.) and 1800 lb. (816 kg.)
Fleet Angle:
Operational 15° to centerline (cone angle 30°)
Temperature Range:
Operational -40° F to +125° F ( -40° C to +52° C)
Non-Operational -65° F to +257° F ( -54° C to +125° C)
Altitude Sea Level to 12,000 Feet (3658 m.)
Electric Motor:
Motor: 125 Amps maximum
Control Circuit 28 VDC, 5 Amps, maximum
Cable Foul Sensor Redundant switches IAW MS27216-5
Guillotine Ballistic type, electrically fired (5 Amps per bridgewire,
min.)
Oil MIL-PRF-7808, Class 3 (NATO Code No. O-148)
Weight (maximum) 79 lb. (35.8 kg.) without hook
Table 2. Leading Particulars for Rescue Hoist System
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Variable Speed Controller

Electrical Input 28 VDC, 130 Amps continuous based on speed and load
conditions
Electrical Output 0 - 27.5 VDC, 125 Amps to motor series field and armature,
fixed 28 VDC, 5 Amps to motor shunt field and shunt brake
Operating Channels Pendant hoist control, ICS, & if applicable, pilot hoist
control
Pilot-Crew Operation If applicable, Pilot control has priority over crew control
Automatic Slow Speed Slowdown when approaching extremes of cable travel
Weight (maximum) 15.0 lb. (6.8 kg.)
Control Pendant Assembly
Voltage 28 VDC
Current 2 Amps
Speed Control Incremental potentiometer
Load Control 250 lb (113 kg.), or 600 lb (272 kg.) solenoid selected
Directional Control Thumb wheel actuated – centered null
Housing Totally enclosed
Speed-Control Knob Centering protected
Weight (maximum) 2.0 lb. (0.9 kg.)
Table 2. Leading Particulars for Rescue Hoist System (continued)
2. Operation
WARNING: SEARCH AND RESCUE OPERATIONS, AND ALL OTHER USES OF
HOISTS FOR HOISTING AND LOWERING PERSONNEL, CAN RESULT IN
INJURY OR DEATH. PROPERLY TRAINED PERSONNEL MUST UTILIZE
APPROPRIATE OPERATION, MAINTENANCE, AND INSPECTION
PROCEDURES TO MINIMIZE THE HAZARDS INHERENT IN THE USE OF
ALL HOISTS.
WARNING: WORK GLOVES MUST BE WORN BY THE OPERATOR WHENEVER
HANDLING THE RESCUE HOIST CABLE TO PREVENT INJURY FROM
BROKEN STRANDS AND WIRES. EYE PROTECTION MUST BE WORN
BY THE OPERATOR WHENEVER OPERATING, OR MAINTAINING, THE
RESCUE HOIST TO PREVENT INJURY FROM LUBRICANTS, SOLVENTS,
AND OTHER MATERIALS USED ON THE RESCUE HOIST, AS WELL AS
METAL PARTS AND 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 IMPEDE THE CABLE IN ANY WAY
(EITHER WITH YOUR HANDS, OR OTHER OBSTRUCTION) AS THIS
MAY IMPEDE TENSION ROLLER OPERATION, AND CAUSE THE CABLE
TO FOUL.
CAUTION: DO NOT ALLOW THE CABLE TO REEL IN TO THE FULL IN POSITION
WITHOUT HOLDING ONTO, AND GUIDING THE HOOK TO THIS
POSITION. ALLOWING THE HOOK TO SWING FREELY WHILE REELING
IN TO THE FULL IN POSITION MAY CAUSE DAMAGE TO THE HOOK,
CABLE, HOIST, AND HELICOPTER.
CAUTION: DO NOT LEAVE THE HOOK LOOSE UNDER THE HOIST AFTER THE
HOIST HAS BEEN USED. ALWAYS ENSURE THE HOOK HAS BEEN
HOMED SECURELY, AND THE BUMPER SPRING IS COMPRESSED
SUFFICIENTLY TO PREVENT THE HOOK FROM MOVING WHILE THE
HELICOPTER IS IN FLIGHT. A LOOSE HOOK MAY RESULT IN A
DAMAGED CABLE.
CAUTION: DURING OPERATION OF THE RESCUE HOIST, DO NOT TOUCH THE
MOTOR. THE MOTOR TEMPERATURE MAY BE VERY HOT, AND MAY
RESULT IN SEVERE BURNS IF TOUCHED.
NOTE: ORANGE PAINT PROVIDES A VISUAL MEANS OF IDENTIFYING CABLE
TRAVEL EXTREMES. FULL IN DETECTION IS PROVIDED BY ORANGE
PAINT ON THE CABLE INDICATING APPROXIMATELY 25 FT. (7.6 M.)
OF CABLE REMAINS UNTIL REACHING THE FULL IN LIMIT. FULL OUT
DETECTION IS PROVIDED BY ORANGE PAINT INDICATING
APPROXIMATELY 14 FT. (4.3 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 IS OPERATED NEAR THE EXTREMES
(FULL IN AND FULL OUT) OF THE CABLE TRAVEL BY REDUNDANT,
INTERMEDIATE SPEED LIMIT SWITCHES.
NOTE: PRIOR TO TURNING POWER ON, THE RESCUE HOIST COMPONENTS
MUST BE VISUALLY INSPECTED FOR SOUND STRUCTURAL
INTEGRITY AND PROPER INTEGRATION.
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A. The HS-20200-511 Series Rescue Hoist System is operated by the Hoist Operator’s
Control Pendant. When power is initially applied to the system, “888” will be displayed
for a moment on those pendants incorporating a digital display, and then the cable
extension displayed (“000” for full in). Once the Variable Speed Controller receives the
reel in, or extension, command signal, an output signal is sent to the motor, either to
raise, or lower, the cable. The motor torque will drive the gear train, which will drive the
level wind, tension roller, and drum resulting in reeling the cable in, or out.
B. Once the down signal is received the cable will reel out, and speed should be faster as the
thumbwheel is moved farther from the center. Observe the amount of cable on the storage
drum. Manually reduce speed as the cable nears full extension. When the down
intermediate speed limit switch is actuated the hoist speed is slowed to approximately 30
to 50 fpm (0.15 to 0.25 mps) until the full out limit switch is reached and operation of the
hoist is stopped with 3½ to 4½ wraps of cable remaining on the drum.
Also, a visual means of full out detection is provided by orange paint on the cable, which
indicates approximately 14 ft. (4.3 m.) of cable travel remains until reaching this limit
(see Figure 3).
Figure 3. Approximate Dimensions of Orange Paint on Wire Rope Cable

C. Once the up signal is received by the Variable Speed Controller the hoist cable should
reel in, and speed should be faster as the thumbwheel is moved farther from the center.
The motor allows for a maximum cable speed of 200 fpm (1.0 mps) at 250 lb. (113 kg)
load. Manually reduce speed as the cable nears full retraction. When the up intermediate
speed limit switch is actuated the hoist speed is slowed to approximately 30 to 50 fpm
(0.15 to 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 cable, which
indicates approximately 25 ft. (7.6 m.) of cable travel remains until reaching this limit
(see Figure 3).
WARNING: DO NOT TRY TO CLEAR CABLE FOUL IN FLIGHT. A FOULED CABLE
MAY BREAK, AND MAY RESULT IN INJURY OR DEATH.
When reeling in the cable, observe the cable wrapping on the drum. The cable layers
should be wrapping evenly with no gaps, or smiles, on the drum. If the cable incorrectly
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January 11, 2005
wraps on the drum resulting in a cable foul, then as the cable exceeds the height of the
top layer, the cable foul indicator mechanically will actuate and command the hoist to
stop. To clear the cable foul on the ground, the cable foul indicator switches must be
manually actuated and the cable paid 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 (refer to
Section 601, Repair). In either case, the cause of the cable foul must be determined, the
problem must be corrected that caused the cable foul, and the cable must be replaced
before the hoist can be returned to a serviceable condition.
Always guide the hook by hand as the cable is slowly reeled into 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 Hoist is equipped with a cable cutter to sever the cable in an emergency. Actuation
of the cable cutter is under the control of the pilot using a switch located in the cockpit. If
the cartridge is fired always replace the anvil, cable cutter, cotter pin, O-ring, and
cartridge with packing.
NOTE: WHEN CONDITIONS EXIST WHERE DAMAGE TO THE HOIST MAY
RESULT IN OVERHEATING, THE “MTR HOT” LIGHT WILL ILLUMINATE
ON THE CONTROL PENDANT. IT IS RECOMMENDED THAT
OPERATIONS CEASE AS SOON AS POSSIBLE IF THIS CONDITION
OCCURS, AND ALLOW THE MOTOR TO COOL TO AMBIENT
TEMPERATURE (TIME TO REACH AMBIENT IS APPROXIMATELY 30
MINUTES).
E. The Control Pendant is a hand held controller that allows the crewmember to raise, or
lower, the cable by using the directional thumb wheel. This thumb wheel also controls the
speed of operation proportional to the amount of deflection from the center off / null
position. Also incorporated is a 250 lb. (113 kg.) and 600 lb. (272 kg.) load selector
toggle switch.
The CP-700-1 Control Pendant display indicates the amount of cable paid out, and motor
overheat (“MTR WRN”). The motor overheat light (green) will reset once the motor has
cooled sufficiently, approximately 30 minutes, depending on ambient conditions and the
amount of time the light was illuminated before operation was stopped.
CP-600-1 has a yellow indictor light “O/L,” which illuminates when a hoist overload
condition is detected.
F. There have been instances where cable foul sensor equipped Systems automatically stops
due to detection of a cable foul, and the operator is unaware that a cable foul has
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January 11, 2005
occurred. In these cases, operators may not be utilizing the electrical circuit provided to
illuminate a warning light to alert the operator of a cable foul.
Breeze-Eastern cable foul sensor equipped Hoists have connector pins for the operator to
receive an electrical signal, which can be used to provide a visual indication that a cable
foul has occurred. This circuit is provided to the helicopter interface. It is highly
recommended the operator utilize this interface to install the helicopter electrical, and
display provisions for the warning light.
The Hoist provides 28 VDC out of the designated pin when a cable foul is detected. In
this instance, a typical circuit used to drive the indicator is shown in Figure 201 (Note:
This circuit is not supplied by Breeze-Eastern with the System, maximum current rating
is 1 amp for the 28 VDC output on the Hoist).
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TESTING AND TROUBLESHOOTING

1. Testing
This section covers testing, adjustment, fault isolation, and implementation of corrective actions
on the System utilizing troubleshooting procedures. The test procedures contained in this Section
are to be performed every twelve (12) months, as necessary for fault isolation, and as required by
actions accomplished in Checks and Inspections, Section 501, and Assembly, Section 701.
Electrical schematics and wiring diagrams are located in Section 201. Reference numbers in
parenthesis refer to Illustrated Parts List in Section 1001.
2. Test Equipment and Materials
The recommended method for testing the System at the flight line level is to perform the
procedures identified in this section with the equipment identified below, or suitable equivalent,
when the Hoist is mounted on the helicopter.
A. Electrical Power 28 VDC, 200 Amps, minimum.
B. Load Source The Hoist shall be loaded by use of calibrated weights
(TE-120-1, TE-120-2, or equivalent) of 250 lb. (113 kg.),
and 600 lb. (272 kg.) on the Hoist hook.
C. Tape Measure To measure cable lengths (in feet or meters).
D. Tachometer (for measuring If tachometer is not available, use stopwatch to measure the
cable speed) or Stopwatch: time it takes the Hoist cable to travel over a known length.
Range: 0-2 m/s (0-410 fpm, 1 % accuracy of reading.
E. Multimeter Range 0.1 ohm to 100 mohm, and 0-40 VDC, 0.5 – 1.0 %
accuracy of reading.
F. Spring Scale Range, 0 – 10 lb. (0 – 4.55 kg.), ± 2 % accuracy of reading.
G. Indelible Felt Tip Marker For marking cable when setting Limit Switch.
H. F-900 Torque Seal (Organic Products Company, Irving, Texas, USA, CAGE 01195)
3. Test Conditions
The hoist shall be mounted using the four mounting points (See Figure 801) in such a manner that
the cable reel out is downward. The recommended method is to test the hoist 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
WARNING: SEARCH AND RESCUE OPERATIONS, AND ALL OTHER USES OF HOISTS
FOR HOISTING AND LOWERING PERSONNEL, CAN RESULT IN INJURY OR
DEATH. PROPERLY TRAINED PERSONNEL MUST UTILIZE APPROPRIATE
OPERATION, MAINTENANCE, AND INSPECTION PROCEDURES TO
MINIMIZE THE HAZARDS INHERENT IN THE USE OF ALL RESCUE HOISTS.
WARNING: TAKE PROPER PRECAUTIONS TO AVOID FIRING THE CARTRIDGE AND
DAMAGING COMPONENTS DUE TO ELECTROSTATIC DISCHARGE (ESD).
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WARNING: KEEP HANDS, BODY, AND CLOTHING AWAY FROM THE HOIST
SPECIFICALLY “PINCH POINTS” WHERE THE CABLE ENTERS THE CABLE
GUIDE AND CONTACTS THE DRUM.
HANDLING THE HOIST CABLE TO PREVENT INJURY FROM BROKEN
CABLE STRANDS AND WIRES. EYE PROTECTION MUST BE WORN BY THE
OPERATOR WHENEVER OPERATING, OR MAINTAINING, THE HOIST TO
PREVENT INJURY FROM LUBRICANTS, SOLVENTS, AND OTHER
MATERIALS USED ON THE HOIST, AS WELL AS METAL PARTS AND
OTHER DEBRIS.
CAUTION: THE TENSION ROLLER SYSTEM WORKS ON THE BASIS OF FRICTION, AND
THEREFORE, NO LUBRICANT SHOULD BE APPLIED TO THE CABLE.
NOTE: PRIOR TO TURNING POWER ON, THE HOIST COMPONENTS MUST BE
VISUALLY INSPECTED FOR SOUND STRUCTURAL INTEGRITY AND
PROPER INTEGRATION.
NOTE: LIMIT SWITCHES MUST BE OPERATING AND SET PROPERLY PRIOR TO
PERFORMING LOAD TESTING.
NOTE: WHEN REELING IN THE CABLE WITH NO LOAD, APPLY TENSION WITH
GLOVED HANDS TO ENSURE SMOOTH AND EVEN WRAPPING.
APPROXIMATELY 20 LB. (9.1 KG.) TENSION IS RECOMMENDED.
A. Limit Switch Test (see Figures 101, 102, 103, and 1002)
Check the limit switch settings for the required lengths defined in Figures 101 and 102.
(1) Full Out Limit Switch (S2) – Verification of Switch Setting From Cable Termination
Start with paragraph (a) below if checking full out limit switch setting of a Hoist with an
existing cable, or go to paragraph (b) below if checking full out limit switch setting for a
Hoist with a new cable.
(a) Apply power to the system, and with no load, reel out the cable at less than ½ of full
speed to verify the Hoist stops at the full out limit (4 ± ½ wraps of cable on drum from
cable termination). After verification of the full out limit switch setting, go to
paragraph 4 A (1) (c) below.
(b) If a new cable has been installed, apply power to the system, reel in the cable at less
than ½ of full speed and stop the Hoist when 8 or more wraps of cable are on the
drum, and then reel out at less than ½ of full speed the cable to verify the Hoist stops
at the full out limit (4 ± ½ wraps of cable on drum from cable termination). After
verification of full out limit switch setting, go to paragraph 4 A (1) (c) below.
(c) If the full out limit switch (S2) is set correctly, go to paragraph (2) below.
If the full out limit switch is inoperative, refer to Table 101 for Troubleshooting.
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Symbol Function Requirements

Intermediate speed
S1 6 to 12 ft. (1.83 to 3.66 m.) from full in and full out
(same switch for both directions)
S2 Full Out 4 ± ½ Wraps from cable termination
S3 Full In Actuated when hook and bumper assembly contacts cable guide
R1 Potentiometer Assembly For Cable Payout Display (full in adjustment)
R3 Trim Potentiometer For Cable Payout Display (full out adjustment)
UP Limit Switch S3 Actuation

Cam Adjustment Screws (Figures 103 & 1002, View B, Item 110)
(Figure 1002, View C, Item 1060) Actuator (680)
Spring (730)
Retaining Ring (710)
Pin (720)
Cam Adjustment Screws

(Figure 1002, View C, Item 1080)
S1 (110)
Screws (820) to be loosened to
adjust R1 (840)
R1 (840)
R3 (1100)
Adjustment screw for R3
(Fig. 1002, View D, Item 1100) S2 (110)
Figure 101. Locations of Limit Switch, Screws, Potentiometers on Cyclocentric Assembly and Cable Guide
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Figure 102. Limit Switch Actuation Positions

If the setting for the full out limit switch is not correct, adjust limit switch cam to
obtain the required setting as follows (see Figure 1002):
1) Remove tie wire, screws (40 and 50), washers (60), clamp (70), terminal (80),
limit switch cover (90), and gasket (100).
2) Remove screws (530) and move potentiometer bracket (540) out of the way
without damaging wiring, or components, to access limit switch cams.
3) Loosen screws (Figure 1002, View C, Item 1060), and rotate full out limit switch
cam (1070) as follows:
a) Rotate cam clockwise to allow full out limit switch to actuate with fewer wraps
of cable on the drum.
b) Rotate cam counterclockwise to allow full out limit switch to actuate with
more wraps of cable on the drum.
4) Tighten screws (1060) to hold adjusted position of cam by applying 3.0 to 4.0
in.-lb. (0.34 to 0.57 Nm.) torque to screws.
5) Recheck full out limit switch setting.
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6) After successfully setting and checking the full out and intermediate speed Limit
Switch, install potentiometer bracket, limit switch cover, gasket, clamps, terminal,
washers, screws, and tie wire per MS33540 with MS20995NC32.
(2) Intermediate Speed Limit Switch (S1) – Verification of Switch Setting From Full Out
(a) Using an indelible felt tip marker, or equivalent, mark cable at the lengths specified
for intermediate speed limit switch (S1) 6 to 12 ft. (1.83 to 3.66 m.) from full out limit
and 6 to 12 ft. (1.83 to 3.66 m.) from full in limit (ball end of cable).
(b) Reel in the cable at less than ½ of full speed until both marks at 6 to 12 ft. (1.83 to
3.66 m.) from the full out limit have been reeled onto the drum. Reverse the direction
of the cable travel to reel out the cable at less than ½ of full speed and verify the
intermediate speed limit switch actuates between 6 to 12 ft. (1.83 to 3.66 m.) from the
full out limit.
(c) If the intermediate speed limit switch is set correctly from the full out position, go to
paragraph (3) below.
If the intermediate speed limit switch is inoperative, refer to Table 101 for
Troubleshooting.
If the setting for the intermediate speed limit switch is not correct, adjust limit switch
cam to obtain required setting as follows (see Figure 1002):
3) Loosen screws (Figure 1002, View C, Item 1080), and rotate intermediate speed
limit switch cam (1090) as follows:
a) Rotate cam clockwise to allow intermediate speed limit switch to actuate closer
to full out position.
b) Rotate cam counterclockwise to allow intermediate speed limit switch to
actuate further away from full out position.
NOTE: THE CAM AND LIMIT SWITCH FOR THE INTERMEDIATE SPEED LIMITS
FROM FULL OUT AND FULL IN ARE THE SAME. IF ADJUSTMENTS ARE
MADE FOR THE SETTING OF ONE OF THE LIMITS, THE OTHER LIMIT
MUST BE RECHECKED.
5) Re-verify intermediate speed limit switch setting from both full in and full out per
Paragraphs 4A(2) and 4A(3) in this section.
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(3) Intermediate Speed Limit Switch (S1) – Verification of Switch Setting From Full In
(a) Reel in the cable at less than ½ of full speed and verify the intermediate speed limit
switch actuates at 6 to 12 ft. (1.83 to 3.66 m.) from full in position.
(b) If the intermediate speed limit switch is set correctly from the full in position, go to
paragraph (4) below.
If the intermediate speed limit switch is inoperative, refer to Table 101 for
Troubleshooting.
If the setting for the intermediate speed limit switch is not correct, adjust limit switch
cam to obtain required setting as follows (see Figure 1002):
3) Loosen screws (Figure 1002, View C, Item 1080), and rotate the intermediate
speed limit switch cam (1090) as follows:
a) Rotate cam clockwise to allow intermediate speed limit switch to actuate
further away from full in position.
b) Rotate cam counterclockwise to allow intermediate speed limit switch to
actuate closer to full in position.
NOTE: THE CAM AND LIMIT SWITCH FOR THE INTERMEDIATE SPEED LIMITS
FROM FULL OUT AND FULL IN ARE THE SAME. IF ADJUSTMENTS ARE
MADE FOR THE SETTING OF ONE OF THE LIMITS, THE OTHER LIMIT
MUST BE RECHECKED.
5) Re-verify intermediate speed limit switch setting from both full in and full out per
Paragraphs 4A(2) and 4A(3) above.
(4) Full In Limit Switch (S3) – Verification of Switch Setting And Operation
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NOTE: PERFORM THIS CHECK IF A PROBLEM WITH THE FULL IN LIMIT SWITCH
IS ENCOUNTERED, OR THE LIMIT SWITCH IS REPLACED.
(a) Preliminary Check
1) Reel in the cable at less than ½ of full speed. Using a spring scale, verify that when
a force of greater that 2 lb. (0.9 kg.) is applied to pin (Figure 1002, View B, Item
720) located under the Cable Guide Assembly, the Hoist stops (see Figures 101
and 103).
NOTE: Ensure Retaining Ring (710), Pin

(720), and Spring (730) are properly
installed, as shown, when performing
Full In Limit Switch Check
Spring (730) for Pin (720)
Retaining Ring (710) for Pin (720)
Pin (720) for Actuating Full In Limit Switch

(under the Cable Guide Assembly)
Figure 103. Cable Guide Pin (shown with cable guide cover [640] removed)
If a force of greater than 2 lb. (0.9 kg.) is applied to the pin properly actuates the
Full In Limit Switch and the Hoist stops, the Full In Limit Switch Check has been
successfully completed.
If the force is less than 2 lb. (0.9 kg.) to stop the Hoist, the Hoist does not stop, or
does not operate, remove cable guide cover per paragraph 2) below, and check
installation of retaining ring (710), cable guide pin (720), and spring (730). Refer
to Figures 101, 103, and Table 101 for Troubleshooting.
2) Remove screws (660), washers (670), cable guide cover (640), and gasket (650).
Retain gasket for future use, or replace if damaged.
3) Verify that Torque Seal compound, or equivalent, has been applied to the heads of
the switch mounting screws (690). If there is no evidence of Torque Seal, do not
loosen, but verify that screws are properly tightened, torque to 2.6 to 3.2 in.-lb.
(0.29 to 0.36 m-N).
(b) Check for switch activation prior to end of pin travel and full compression of bumper
assembly spring:
1) Operate hoist and slowly reel out approximately 6 ft. (1.8 m.) of cable.
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2) Slowly reel in cable. Manually depress pin (720), [refer to Figure 103]) and verify
Hoist stops prior to end of pin travel. Repeat procedure three times to confirm that
the full in limit switch is actuated and the Hoist stops consistently.
3) Reel in the cable to the full in position and verify the Hoist stops before full
compression of spring on bumper assembly. Repeat procedure three times to
confirm that the full in limit switch is actuated and the Hoist stops consistently. If
this check is completed successfully, go to step 4 A (4) (c).
4) If the full in limit switch does not actuate, or the Hoist does not stop, loosen
screws (690) and adjust position of switches. After position of switches has been
adjusted, torque screws (690) from 2.6 to 3.2 in.-lb. (0.29 to 0.36 m-N), and repeat
step 4 A (4) (b) above.
(c) Check for switch release prior to end of pin travel and Hoist operation when reeling in:
1) Operate hoist and slowly reel out approximately 6 ft. (1.8 m.) of cable.
2) Slowly reel in cable. If Hoist does not reel in, or stops before cable is in full in
position, loosen screws (690) and adjust position of switches. After position of
switches has been adjusted, torque screws (690) from 2.6 to 3.2 in.-lb. (0.29 to
0.36 m-N), and repeat step 4 A (4) (b) above.
(d) Post Full In Limit Switch Check Procedures
1) After successfully completing checks outlined in steps 4 A (4) (b) and 4 A (4) (c)
above, apply F-900 Torque Seal, or equivalent, to heads of screws (690), if not
previously applied.
2) Install cable guide gasket (650), and cover (640), and secure with washers (670)
and screws (660). Torque screws to 2.6 to 3.2 in.-lb. (0.29 to 0.36 m-N).
(e) If the full in limit switch is inoperative, or cannot be adjusted, refer to Table 101 for
Troubleshooting Procedures.
B. Control Pendant Digital Readout Test (CP-700-1 Only)
NOTE: CONTROL PENDANT DIGITAL READOUT IS FOR REFERENCE ONLY.
ACCURACY OF READOUT IS ± 3 FEET (0.91 METERS).
(1) Apply power to the system, and observe the readout on the Control Pendant. The
numbers “888” should be displayed for several seconds when power is initially applied,
and then the readout should display the position of the cable. If “888” remains displayed,
either when initially powering up the hoist, or when the Hoist is in operation, refer to
Table 101 for Troubleshooting Procedures.
(2) With no load on the cable, slowly reel out 3 feet (0.9 m.) of cable from the full in limit.
(3) Verify the readout on the Control Pendant displays 001 to 006 feet (00.1 to 01.8 m.).
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(4) If the value is not met as specified above, adjust the large potentiometer R1 on the Hoist
cyclocentric as follows (see Figures 101 and 1002):
(a) Remove tie wire, screws (40 and 50), washers (60), clamp (70), terminal (80), limit
switch cover (90), and gasket (100).
(b) If applied, remove Torque Seal from the potentiometer mounting screws (820).
Loosen screws (820) on the potentiometer bracket (540) to unlock the position of the
large potentiometer R1 (840). Slowly turn the potentiometer until the readout displays
001 to 006 feet (00.1 to 01.8 m.).
(c) Tighten the screws (820) to lock the potentiometer in position by applying 3.0 to 4.0
(d) Perform the test identified above as steps B(1) through B(4) above to confirm the
potentiometer setting has not changed during tightening and is set correctly.
(e) If the readout cannot be adjusted within 001 to 006 feet (00.1 to 01.8 meters) refer to
Table 101 for Troubleshooting Procedures.
(f) After successfully setting the cable readout potentiometers, apply torque seal to screws
(820) for potentiometer R1 (840).
(5) With no load on the cable, reel out the cable until the Hoist stops at the full out position
(4 ± ½ wraps of cable on drum from cable termination).
(6) Verify the readout on the Control Pendant displays 242 to 248 feet (73.8 to 75.6 meters).
(7) If the value is not met as specified above, adjust the small potentiometer R3 on the Hoist
as follows (see Figures 101 and 1002):
(a) If not previously accomplished, remove tie wire, screws (40 and 50), washers (60),
clamp (70), terminal (80), limit switch cover (90), and gasket (100)
(b) Adjust the small potentiometer R3 (1100) by carefully removing any torque seal and
turning the adjustment screw until the value is 242 to 248 feet (73.8 to 75.6 meters).
(c) Perform the test identified above in paragraphs B(5) and B(6) above to confirm the
potentiometer has been set correctly.
(d) If the readout cannot be adjusted to 242 to 248 feet (73.8 to 75.6 meters) refer to Table
101 for Troubleshooting.
(e) After successfully setting the cable readout potentiometers, apply torque seal to
adjustment screw for potentiometer R3 (1100).
(8) If removed, install limit switch cover, gasket, clamps, washers, screws, terminal lug, and
tie wire per MS33540 with MS20995NC32.
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C. Cable Foul Indicator Test

CAUTION: DO NOT DISPLACE THE ACTUATOR OF THE CABLE FOUL SENSOR MORE
THAN 0.188 IN. (4.7 MM.) FROM ITS NORMAL, REST POSITION.
NOTE: FOR THIS TEST, THE CABLE MUST BE REELED OUT AND REELED BACK
IN UNDER NO LOAD BEFORE MAKING ANY OBSERVATIONS,
MEASUREMENTS, OR ADJUSTMENTS.
(1) From the full in position, reel out approximately 30 feet (9.1 meters) of cable from the full
in position.
(2) Reel in the cable and actuate the cable foul sensor by lifting up on the actuator (Figure
1002, item 740). Confirm hoist operation stops.
(3) While switch actuator (740) is raised up, verify hoist does not operate in either reel in, or
out, direction.
(4) Release the switch actuator to its “at rest” position, and verify hoist resumes normal
operation in both the reel in and out directions.
(5) With no load attached, slowly reel in the cable 3.0 to 6.0 ft. (0.91 to 1.83 m.) of cable
length remaining from full in, position drum where the crossover point is aligned with the
cable foul sensor flapper. The clearance between the cable and the flapper shall be 0.06 in.
± 0.02 in. (1.5 mm. ± 0.5 mm.), refer to Figure 104.
(6) If clearance is not within limits, adjust setscrews (780) evenly to obtain correct dimension.
After inspection / adjustment is completed, slowly reel in cable until the hook is at the
full-in position and disconnect power to the Hoist.
(780)
(740)
Setscrew (120) showing location of crossover
point for cable on drum (setscrew must be aligned
with switch actuator to properly check gap)
Figure 104. Cable Foul Assembly Inspection and Adjustment
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D. Hook Load Test (Required when only the hook assembly alone has been removed and
replaced)
NOTE: ENSURE THE CABLE HAS BEEN WRAPPED ON THE DRUM AT A TENSION
OF APPROXIMATELY 20 LB. (9.1 KG.) LOAD TO ENSURE SMOOTH, EVEN
WRAPPING BEFORE PERFORMING THE HOOK LOAD TEST. GAPS MAY
OCCUR IN THE LOWER LAYERS OF THE CABLE IF IT IS NOT TIGHT ON
THE DRUM.
Check for proper installation of the hook by applying a rated load of 600 lb. (272 kg.) as
follows:
(1) Run hoist to reel out cable until the hook can be connected to a weight of 600 lb. (272 kg.)
that is resting on the ground directly below the hoist.
(2) Mount load on hook and slowly reel cable in until the weight is lifted off the ground.
Verify that the hook does not slip, or detach, from the cable for 2 minutes.
(3) Once weight is off the ground after 2 minutes, lower weight back to the ground.
(4) Remove weight and run hoist to the full in position to secure to hook and bumper
assembly on hoist.
E. Rated Load Test (Operational Flight Test to be performed with helicopter in hover).
CAUTION: DURING OPERATION OF THE HOIST, DO NOT TOUCH THE MOTOR. THE
MOTOR TEMPERATURE MAY BE VERY HOT, AND MAY RESULT IN
SEVERE BURNS IF TOUCHED.
NOTE: THE RATED LOAD TEST REQUIRES TESTING OF THE HOIST EITHER ON
THE HELICOPTER IN LOW HOVER OR ON A TEST STAND THAT
SIMULATES THE HOIST MOUNTED ON THE HELICOPTER.
(1) 600 lb. (272 kg.) Load Test
(a) Verify performance at the 600 lb. (272 kg.) mode using TE-120-1, TE-120-2, or
equivalent, by operating the hoist through its full cable travel as follows:
1) Raise 600 lb. (272 kg.), and then rest 30 seconds.
2) Lower 600 lb. (272 kg.), and then rest 30 seconds.
3) Repeat steps 1) and 2) one more time.
When raising 600 lb. (272 kg.) in the low speed mode, the minimum cable speed shall
be 100 fpm (0.5 mps).
(b) Optional Procedures for Troubleshooting:
If the hoist does not meet the speed requirements specified above, the operator may
want to repeat this test while monitoring current and voltage to verify sufficient power
is being supplied by the helicopter. The current draw shall not exceed 125 amps for
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the motor and 5 amps for the control circuit at the minimum supply voltage of 25
VDC measured at the controller connector when raising 600 lb. (272 kg.).
If the helicopter power is correct, but the hoist does not meet the speed requirements
specified above, the operator may want to measure the temperature of the gearbox
housing upon the completion of the second cycle of the 600 lb. (272 kg.) load test. The
temperature monitored on the exposed surface of the gearbox housing shall not exceed
200°F (94°C) after completion of testing.
NOTE: ALLOW THE HOIST TO COOL TO AMBIENT TEMPERATURE PRIOR TO
PERFORMING THE 250 LB. (113 KG.) LOAD TEST.
(2) 250 lb. (113 kg.) Load Test
(a) Verify performance in the 250 lb. (113 kg.) mode using TE-120-1, TE-120-2, or
equivalent, by operating the hoist through its full cable travel as follows:
1) Raise 250 lb. (113 kg.), and then rest 30 seconds.
2) Lower 250 lb. (113 kg.), and then rest 30 seconds.
3) Repeat steps 1) and 2) two more times.
When raising 250 lb. (113 kg.) in the high speed mode, with the cable on the top layer
of the drum, the minimum cable speed shall be 200 fpm (1.0 mps).
(b) Optional Procedures for Troubleshooting:
If the hoist does not meet the speed requirements specified above, the operator may
want to repeat this test while monitoring current and voltage to verify sufficient power
is being supplied by the helicopter. The current draw shall not exceed 125 amps for
the motor and 5 amps for the control circuit at the minimum supply voltage of 25
VDC measured at the controller connector when raising 250 lb. (113 kg.).
If the helicopter power is correct, but the hoist does not meet the speed requirements
specified above, the operator may want to measure the temperature of the gearbox
housing upon the completion of the fourth cycle of the 250 lb. (113 kg.) load test. The
temperature monitored on the exposed surface of the gearbox housing shall not exceed
200°F (94°C) after completion of testing.
F. Bumper Assembly and Full In Limit Switch Test
(1) Reel out 20 feet (6.0 m.) of cable.
(2) Reverse hoist direction and reel in cable until full in limit switch actuates.
(3) Observe deflection of bumper assembly.
(4) Deflection should measure 1.00 to 1.39 inches (25.4 to 35.3 mm.) as measured from top of
bumper spring retaining plate to bottom of spring (see Figure 105).
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1.00 to 1.39 in.

(25.4 to 35.3 mm.)
Figure 105. Deflection of Bumper Assembly with Hook at Full In Position

G. If during testing above, the Hoist fails to operate, or the cable breaks, fouls, fails to wrap
properly on the drum, or snaps at turnaround points between layers on drum, refer to Table
101 for Troubleshooting.
5. Troubleshooting
Troubleshooting is the process of using a logical sequence to locate and eliminate an equipment
malfunction. The troubleshooting process relies heavily on the abilities of qualified technicians.
Refer to Table 101 for troubleshooting procedures.
Trouble Probable Cause Remedy

Cable Fails to Electrical Circuit Check Full In Limit Switch (see Para. 4A, Section 101, for setting switches)
Retract due to Failure due to Full In Replace Cable Guide Pin (see Para. 25C, Section 301, for removal,
Electrical Failure Limit Switch (S3) and Para. 4A, Section 701, for installation)
Circuit Open Check Cable Foul Assembly for Cable Foul (see Para. 7, Section 601,
for cable foul removal)
Check Electrical Connectors and Wiring per Wiring Diagrams in Section 201
Replace Full In Limit Switch S3 (see Para. 25C, Section 301, for removal,
and Para. 4A, Section 701, for installation)
Replace Cable Foul Assembly Switches (see Para. 25D, Section 301,
for removal, and Para. 4D, Section 701, for installation)
Electrical Circuit Check Electrical Connectors and Wiring per Wiring Diagrams in Section 201
Failure due to Power, Check Helicopter Electrical Power, Connectors, and Wiring
or Logic Failure Replace Variable Speed Controller (see Para. 4, Section 301, for removal,
and Para. 24, Section 701, for installation)
Defective Motor Replace Motor (refer to Para. 21, Section 301, for removal, and Para. 5,
Section 701, for installation)
Table 101. Troubleshooting Procedures
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Cable Fails to Electrical Circuit Check Full Out Limit Switch (see Para. 4A, Section 101, for setting switches)
Extend due to Failure due to Full Out Check Cable Foul Assembly for Cable Foul (see Para. 7, Section 601,
Electrical Failure Limit Switch (S2) for cable foul removal)
Circuit Open Check Electrical Connectors and Wiring per Wiring Diagrams in Section 201
Replace Full Out Limit Switch S2 (see Para. 25A, Section 301, for removal,
and Para. 4B, Section 701, for installation)
Failure due to Power, Check Helicopter Electrical Power, Connectors, and Wiring
or Logic Failure Replace Variable Speed Controller (see Para. 4, Section 301, for removal,
Defective hoist motor Replace Motor (refer to Para. 21, Section 301, for removal, and Para. 5,
Cable Fails to Cable Fouled due to Replace Tension Roller Pin (see Para. 18, Section 301, for removal,
Extend, or Retract, Tension Roller Failure and Para. 9, Section 701, for installation)
due to Cable Foul Replace Roller Shaft Assembly (see Para. 18, Section 301, for removal,
Replace Tension Roller Gear (see Para. 18, Section 301, for removal,
Replace Overrunning Clutch Assy. (see Para. 19, Section 301, for removal,
Cable Foul due to Realign Cable Guide by adjusting Level Wind Shaft timing with Drum
Drum and Cable (see Para. 8, Section 601, for realignment)
Guide misalignment Torque Nut on Cyclocentric End of Level Wind Shaft to between
55 and 60 in.-lb. (6.2 and 6.8 Nm.)
Cable Fouled due to Replace Chain (see Para. 20, Section 301, for removal, and Para. 6,
Level Wind Failure Section 701, for installation)
Remove Hoist and send for repair (see Para. 3, Section 301, for removal,
Cable Fouled due to Replace Spring (see Para. 18, Section 301, for removal, and Para. 9,
Cable Guide Failure Section 701, for installation)
Replace Plunger (see Para. 18, Section 301, for removal, and Para. 9,
Remove Hoist and send for repair (see Para. 3, Section 301, for removal,
Cable Fails to Hoist Malfunction due Remove Hoist and send for repair (see Para. 3, Section 301, for removal,
Extend due to Hoist to Internal Mechanical and Para. 25, Section 701, for installation)
Failure Failure
Uncontrolled Hoist Thumbwheel switch Replace Control Pendant (see Para. 5, Section 301, for removal, and Para. 23,
Up, or Down, due to inoperative, or Control Section 701, for installation)
Control Pendant Pendant potentiometer
Failure defective
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Uncontrolled Hoist Hoist Malfunction due Remove Hoist and send for repair (see Para. 3, Section 301, for removal,
Up, or Down, due to to Brake Slippage, and Para. 25, Section 701, for installation)
Failure to Support Drive Train, Cable, or
Load Hook Failure
Uncontrolled Hoist Variable Speed Replace Variable Speed Controller (see Para. 4, Section 301, for removal,
Up, or Down, due to Controller Logic, or and Para. 24, Section 701, for installation)
Variable Speed Power, Failure
Controller Failure
Uncontrolled Hoist Intermediate Speed Check Limit Switch Setting (see Para. 4A, Section 101)
Up, or Down, due to Limit Switch (S1), or Check Electrical Connectors and Wiring per Wiring Diagrams in Section 201
Intermediate speed Circuit, Failure Check Helicopter Electrical Power, Connectors, and Wiring
Limit Switch Failure Replace Intermediate Speed Limit Switch S1 (see Para. 25A, Section 301,
for removal, and Para. 4B, Section 701, for installation)
Uncontrolled Hoist Full In Limit Switch Check Limit Switch Setting (see Para. 4A, Section 101, for setting switches)
Up due to Full In (S3), or Circuit, Replace Cable Guide Pin (see Para. 25C, Section 301, for removal,
Limit Switch Failure Failure and Para. 4A, Section 701, for installation)
Replace Full In Limit Switch S3 (see Para. 25C, Section 301, for removal,
and Para. 4A, Section 701, for installation)
Defective Bumper Replace Bumper Spring (see Para. 13, Section 301, for removal, and Para. 14,
Spring Section 701, for installation)
Uncommanded Hoist Malfunction due Remove Hoist and send for repair (see Para. 3, Section 301, for removal,
Hoist Down due to to Brake, Drive Train, and Para. 25, Section 701, for installation)
Failure to Support Cable, or Hook,
Load Failure
Uncommanded Variable Speed Replace Variable Speed Controller (see Para. 4, Section 301, for removal,
Hoist Down due to Controller Logic, or and Para. 24, Section 701, for installation)
Variable Speed Power, Failure
Controller Failure
Cable wraps loosely Drum and cable guide Realign Cable Guide by adjusting Level Wind Shaft timing with Drum
on drum, or does not misaligned (timing) (see Para. 8, Section 601, for realignment)
reel out smoothly Defective, or missing, Replace Tension Roller Pin (see Para. 18, Section 301, for removal,
pin and Para. 9, Section 701, for installation)
Worn tension roller Replace Roller Shaft Assembly (see Para. 18, Section 301, for removal,
Defective tension Replace Tension Roller Gear (see Para. 18, Section 301, for removal,
roller gear and Para. 9, Section 701, for installation)
Defective overrunning Replace Overrunning Clutch Assy. (see Para. 19, Section 301, for removal,
clutch assembly and Para. 7, Section 701, for installation)
Cable snaps at Drum and cable guide Realign Cable Guide by adjusting Level Wind Shaft timing with Drum
turnaround points misaligned (timing) (see Para. 8, Section 601, for realignment)
Torque Nut on Cyclocentric End of Level Wind Shaft to between
55 and 60 in.-lb. (6.2 and 6.8 Nm.)
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Inadvertent Cable Electrical Circuit Replace Cable (see Para. 15, Section 301, for removal, and Para. 13,
Cut Failure Section 701, for installation of cable)
Cartridge Failure Replace Cartridge (see Para. 3C, Section 301, for removal, and Para. 26,
Section 701, for installation of cartridge)
Failure to Cut Cable Cartridge Failure Replace Cartridge (see Para. 3C, Section 301, for removal, and Para. 26,
on Demand Section 701, for installation)
Failure Check Helicopter Electrical Power, Connectors, and Wiring
Cable Cutter Replace Cotter Pin (see Para. 16, Section 301, for removal, and Para. 12,
Assembly Failure Section 701, for installation)
Replace Cable Cutter (see Para. 16, Section 301, for removal, and Para. 12,
Replace Anvil (see Para. 16, Section 301, for removal, and Para. 12,
Replace Packing on Cartridge (see Para. 3C, Section 301, for removal,
Replace Cable Cutter O-Ring (see Para. 16, Section 301, for removal,
Hoist fails to make Excess, or insufficient, Check oil level in hoist (refer to Section 501, Paragraph 2L(5), for servicing
speed amount of oil in hoist the hoist with oil)
Defective Variable Replace Variable Speed Controller (see Para. 4, Section 301, for removal,
Speed Controller and Para. 24, Section 701, for installation)
Defective motor Replace Motor (see Para. 21, Section 301, for removal, and Para. 5,
Hoist is binding Remove Hoist and send for repair (see Para. 3, Section 301, for removal,
Control Pendant Potentiometers on hoist Adjust potentiometers on hoist (refer to Paragraph 4B, Section 101)
readout not within out of adjustment,
acceptable limits or damaged Remove Hoist and send for repair (see Para. 3, Section 301, for removal,
Cable jams, or Defective, or broken, Replace Cable (see Para. 15, Section 301, for removal, and Para. 13,
breaks Cable Section 701, for installation of cable)
Defective Bumper Replace Bumper (refer to Para. 13, Section 301, for removal, and Para. 14,
Assembly Section 701, for installation)
Corroded, or binding, Perform Cleaning and Lubrication on Hook, and Hook Bearing (refer to
Hook Bearing Section 401, Paragraph 1L)
Worn Tension Roller Replace Tension Roller (refer to Para. 18, Section 301, for removal, and
Para. 9, Section 701, for installation)
Defective Tension Replace Tension Roller Gear (refer to Para. 18, Section 301, for removal,
Roller Gear and Para. 9, Section 701, for installation)
Drum and cable guide Realign Cable Guide by adjusting Level Wind Shaft timing with Drum
misaligned (timing) (refer to Para. 8, Section 601)
Defective Overrunning Replace Overrunning Clutch Assembly (refer to Para. 19, Section 301,
Clutch Assembly for removal, and Para. 7, Section 701, for installation)
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Deflection of Defective Bumper Replace Bumper Spring (refer to Para. 13, Section 301, for removal,
Bumper Spring Spring and Para. 14, Section 701, for installation)
exceeds limits Full In Limit Switch Replace Full In Limit Switch S3 (refer to Para. 25C, Section 301,
(continued) (S3) inoperative for removal, and Para. 4A, Section 701, for installation)
Intermediate Speed Replace Intermediate Speed Limit Switch S1 (refer to Para. 25A,
Limit Switch (S1) Section 301, for removal, and Para. 4B, Section 701, for installation)
inoperative
Defective Overrunning Replace Overrunning Clutch Assembly (refer to Para. 19, Section 301,
Clutch Assembly for removal, and Para. 7, Section 701, for installation)
6. Rescue Hoist Assembly Electrical Continuity Check.

Check continuity at MS3121F14-18PY connector as defined in Table 102.
Loss of continuity Damaged Wiring / Pins Pin check to diagnosis problem
With cable at Full In Pin A to Pin B > 10 Mohm
Pin A to all others except B > 10 Mohm
Pin C to Pin D < 1 ohm
Pin C to all others except D > 10 Mohm
Pin E to Pin G > 10 Mohm
Pin E to all others except G > 10 Mohm
With cable at least 20 ft (6 m) from Full In and Full Out: Pin A to Pin B < 1 ohm
Pin C to Pin D < 1 ohm
Pin E to Pin G < 1 ohm
Cable Foul Sensor actuated with cable at any position Pin A to Pin B > 10 Mohm
CAUTION: Do not displace switch actuator Pin C to Pin D > 10 Mohm
greater than 4.7 mm (0.188 in.) Pin C to all others except D > 10 Mohm
from its normal “at rest” position. Pin R to Pin S < 1 ohm
Pin R to all others except S > 10 Mohm
With cable at Full Out Pin A to Pin B < 1 ohm
Pin C to Pin D > 10 Mohm
Pin E to Pin G > 10 Mohm
With cable at any position All pins to hoist frame > 10 Mohm
Connector shell to hoist frame <1 ohm
Table 102. Electrical Continuity Check
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If defect cannot be corrected, contact Breeze-Eastern Customer Services at the following:

Breeze-Eastern
700 Liberty Avenue
Phone Number: 908-686-4000 or 1-800-929-1919 (US and Canada only)
Fax Number: 908-688-6495
E-mail Address: productsupport@breeze-eastern.com
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SCHEMATICS AND WIRING DIAGRAMS
Schematics and wiring diagrams for the HS-20200-511-01 and -02 Rescue Hoist Systems are
contained in this section. Figure 201 shows the typical circuit used to drive a helicopter supplied
cable foul indicator for the BL-20200-511 Rescue Hoist Assembly. Figure 202 shows the internal
wiring diagram of the BL-20200-511 Rescue Hoist Assembly. Figure 203 shows the wiring diagram
for the HS-20200-511-01 and -02 Rescue Hoist Systems. Figure 204 shows the wiring diagram for
the EC-14170-1 Control Pendant Cable Assembly.
HELICOPTER
SUPPLIED
INDICATOR
CABLE FOUL
SWITCH ON HOIST
HELICOPTER
SUPPLIED
POWER
Figure 201. Typical Circuit Used to Drive the Cable Foul Indicator
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Figure 204. EC-14170-1 Pendant Cable Assembly Wiring Diagram
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DISASSEMBLY
1. General
Use the Testing and Troubleshooting procedures, in Section 101, to establish the condition of the
System, or most probable cause for its malfunction. These procedures must be followed to
determine the extent of disassembly required for repair and maintenance of the System, and to
limit the amount of maintenance required for returning it to a serviceable condition.
2. Disassemble the System in accordance with the following instructions. Reference numbers in
parenthesis refer to Illustrated Parts List (IPL) in Section 1001 (Figures 1001 through 1009).
Special Tools and general information are listed in Section 901. All mention of applying and
disconnecting power to the Rescue Hoist should be accomplished using helicopter circuit
breakers, or equivalent acceptable means.
WARNING: SEARCH AND RESCUE OPERATIONS, AND ALL OTHER USES OF HOISTS
FOR HOISTING AND LOWERING PERSONNEL, CAN RESULT IN INJURY OR
DEATH. PROPERLY TRAINED PERSONNEL MUST UTILIZE APPROPRIATE
OPERATION, MAINTENANCE, AND INSPECTION PROCEDURES TO
MINIMIZE THE HAZARDS INHERENT IN THE USE OF ALL RESCUE HOISTS.
3. Remove the Hoist from helicopter as follows:
A. Disconnect power to the Hoist (Figure 1001, Item 10) by pulling applicable circuit breakers.
B. Disconnect electrical connectors to the motor, and to the harness assemblies, which connects
to the cable cutter cartridge, cable foul assembly, and limit switches.
C. Remove cable cutter cartridge (Figure 1002, View B, Item 10, and part of Figure 1001, Item
60) from hoist, as follows:
STANDARDS, AND REGULATORY PRACTICES.
WARNING: TAKE PROPER PRECAUTIONS TO AVOID SETTING OFF THE CARTRIDGE
DURING HANDLING DUE TO ELECTRICAL SHOCK FROM
ELECTROSTATIC DISCHARGE (ESD).
WARNING: THE CARTRIDGE MUST BE REMOVED BEFORE PERFORMING ANY
MAINTENANCE PROCEDURES INVOLVING THE HOIST AND MUST BE
INSTALLED AFTER ALL MAINTENANCE PROCEDURES ON THE HOIST
ASSEMBLY ARE COMPLETED.
(1) Disconnect electrical connector to cartridge in hoist.
(2) Short all pins of cartridge (Figure 1002, View B, Item 10) together with spring shunt
supplied with cartridge (If spring shunt is not available, short all pins with equivalent
alternative). See Figure 301.
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Pins to be shorted
together prior to
removal of cartridge
Cable Cutter Cartridge
Cable Guide Assembly
Figure 301. Cable Cutter Cartridge in Cable Guide Assembly
(3) Place masking tape over cartridge to hold spring shunt, or equivalent, in place.
(4) Remove tie wire and cartridge with packing (20) from cable guide housing.
D. Remove cowling (not part of System, and not supplied by Breeze-Eastern) in accordance
with instructions provided by the helicopter manufacturer.
CAUTION: WHEN MOUNTED ON THE HELICOPTER THE HOIST WEIGHS
APPROXIMATELY 79 LB. (35.2 KG.) OR 83 LB. (37.6 KG.) WITH THE HOOK
INSTALLED. TWO INDIVIDUALS SHOULD REMOVE THE HOIST FROM
THE HELICOPTER UNLESS SUITABLE SUPPORT IS PROVIDED TO HOLD
THE WEIGHT OF THE HOIST WHEN REMOVED.
CAUTION: AFTER REMOVAL FROM THE HELICOPTER, REST THE HOIST ONLY ON
THE FOUR MOUNTING POINTS. DO NOT REST THE HOIST ON ANY OTHER
COMPONENTS AS THIS MAY RESULT IN THE HOIST BEING DAMAGED.
E. Remove attaching hardware (not part of System and not supplied by Breeze-Eastern) from
four mounting points and remove the Hoist (Figure 1001, Item 10) from the helicopter.
4. Remove Variable Speed Controller from helicopter as follows:
WARNING: TAKE PROPER PRECAUTIONS TO AVOID DAMAGING ELECTRONIC
COMPONENTS DURING HANDLING DUE TO ELECTRICAL SHOCK FROM
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A. Disconnect power to Variable Speed Controller (Figure 1001, Item 20, or 30) by pulling
applicable circuit breakers.
B. Disconnect electrical connectors to Variable Speed Controller (20, or 30).
C. Remove four mounting screws (not part of System and not supplied by Breeze-Eastern) from
Variable Speed Controller (20, or 30).
D. Remove Variable Speed Controller (20, or 30) from the helicopter.
5. Remove Control Pendant and Cable Pendant Assembly from the helicopter as follows:
WARNING: TAKE PROPER PRECAUTIONS TO AVOID DAMAGING ELECTRONIC
COMPONENTS DURING HANDLING DUE TO ELECTRICAL SHOCK FROM
A. Disconnect power to Control Pendant (Figure 1001, Items 40, or 50) by pulling applicable
circuit breakers.
B. Disconnect and remove Control Pendant (40, or 50) from electrical connector on pendant
cable assembly (70). Disconnect and remove cable pendant assembly (70) from controller.
6. Remove and disassemble HK-116 Series Hook Assemblies (Figure 1001, Items 130 and 140,
and Figure 1003, Items 1 and 2) as follows:
A. Apply power to the rescue hoist (Figure 1001, Item 10).
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.
C. Disconnect power from the rescue hoist.
D. To separate bumper assembly (Figure 1003, Item 10) from hook assembly (50, or 50A), pull
up on bumper assembly while holding hook assembly to force the bottom of the compression
spring (20) off the nut (60) of the hook assembly. Slide bumper assembly along wire rope
cable (Figure 1002, View B, Item 30) 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 1003, ITEM 60) FROM THE
HOUSING (90). PLACE THE HOOK ASSEMBLY ON A FIRM SURFACE
BEFORE REMOVING THE NUT.
E. Remove cotter pins (Figure 1003, Item 70) and locking screws (80) from the nut (60).
F. While holding the hook housing (90), loosen, unthread and remove nut and slide it along
wire rope cable away from hook assembly.
NOTE: TERMINAL CLAMP (100) IS A TWO-PIECE MATCHED SET. KEEP BOTH
HALVES TOGETHER FOR FUTURE USE.
G. Remove ring (110) from terminal clamp (100), and then remove terminal clamp and nut from
the ball end of the wire rope cable.
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H. Remove rubber bumper (120) 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 (130) to remove it from hook
assembly.
J. Remove castellated nut (140) from top of the hook assembly.
NOTE: SWIVEL HOOKS (180 AND 190) ARE PURCHASED ITEMS, WHICH THIS
MANUAL DOES NOT COVER. PLEASE CONTACT THE VENDOR OF THESE
HOOKS FOR THEIR RECOMMENDATIONS CONCERNING MAINTENANCE.
K. Remove housing (90) and flat washer (150) from hook.
L. Remove thrust washer (160) and bearing (170) from housing.
D. To separate bumper assembly (Figure 1004, Item 10) from hook assembly (1, or 2), pull up
on bumper assembly while holding hook assembly to force the bottom of the compression
ball end of the wire rope cable.
H. For hook assembly with a handwheel, proceed as follows:
(1) Remove spacer (110) and handwheel assembly (120) from hook assembly.
(2) Press bearing (130) out of handwheel (140) in handwheel assembly.
I. For hook assembly without a handwheel, remove rubber bumper (150) from hook assembly.
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J. Align hole in housing with hole on stem of hook, and using BLT-10300-J, or equivalent, and
mallet, gently tap out orange colored pin (160) to remove it from hook assembly.
K. Remove castellated nut (170) from top of the hook assembly.
L. Remove housing (80) and flat washer (180) from swivel hook (210).
M. Remove thrust washer (190) and bearing (200) from housing (80).
N. Pull quick release pin (220) out of keeper (310), and remove it from lanyard assembly (260).
O. Remove rivet (230) holding the lanyard assembly on the hook by machining, or chiseling, off
rivet head and tapping out with a drift and a mallet.
P. Remove bushing (240), washers (250), and lanyard assembly (260) from hook (290).
Q. If necessary, cut lanyard (270) to remove crimps (280).
WARNING: TO AVOID INJURY, EXTREME CAUTION MUST BE USED WHEN
REMOVING RIVET (300), KEEPER (310), AND SPRING (320). THE SPRING IS
UNDER COMPRESSION WHEN INSTALLED AND CAN FLY OFF HOOK (340)
WHEN REMOVING TUBE AND KEEPER.
R. Remove rivet (300) holding the keeper on the hook (340) by machining, or chiseling, off
rivet head, and tapping it out with a drift and a mallet. Remove keeper (310), spring (320),
and bushing (330) from hook.
D. To separate bumper assembly (Figure 1005, Item 10) from hook assembly (50, or 50A), pull
up on bumper assembly while holding hook assembly to force the bottom of the compression
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H. For hook assembly with a handwheel, proceed as follows:
(1) Remove spacer (120) and handwheel assembly (130) from hook assembly.
(2) Press bearing (140) out of handwheel (150) in handwheel assembly.
I. For hook assembly without a handwheel, remove rubber bumper (160) from hook assembly.
a mallet, gently tap out orange colored pin (170) to remove it from hook assembly.
NOTE: HOOK (220) IS A PURCHASED ITEM, WHICH THIS MANUAL DOES NOT
COVER. PLEASE CONTACT THE VENDOR OF THIS HOOK FOR THEIR
RECOMMENDATIONS CONCERNING MAINTENANCE.
L. Remove housing (90) and flat washer (190) from hook (220).
M. Remove thrust washer (200) and bearing (210) from housing.
9. Remove and disassemble HK-112-1 Hook Assembly (Figure 1001, Item 100, and Figure 1006,
Item 2) as follows:
D. To separate bumper assembly (Figure 1006, Item 1) from hook assembly (2), pull up on
bumper assembly while holding hook assembly to force the bottom of the compression
spring (10) off the sleeve (40) of the hook assembly. Slide bumper assembly along wire rope
AFTER DISENGAGEMENT OF THE NUT FROM THE BODY. PLACE THE
HOOK ASSEMBLY ON A FIRM SURFACE BEFORE REMOVING THE NUT.
F. While holding the body (80), loosen, unthread and remove nut and slide sleeve and nut along
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H. Remove handwheel assembly (110) from hook assembly.
I. Press bearing (120) out of handwheel (130) in handwheel assembly.
L. Remove body (80), bearing (220), and spacer (210) from hook (230).
M. Remove bearing retainer (160) with packing (170 or 170A), thrust bearing races (180 and
200), and needle bearing (190) from body.
N. Remove packing (170 or 170A) from bearing retainer.
O. To unlock keeper, remove quick release pin (240) from swivel hook (230).
P. If necessary, cut ball end of cable assembly (250) attaching quick release pin (240) to swivel
hook, and remove cable assembly and quick release pin.
Q. If necessary, separate quick release pin (240) from cable assembly (250) by cutting cable
assembly and removing sleeve (260).
REMOVING TUBE (270), KEEPER (280), AND SPRING (290). THE SPRING IS
R. Remove tube (270) in the swivel hook by machining, or chiseling, off flared end of tube,
tapping it out with a drift and a mallet, and separating keeper (280) and spring (290) from
hook (300).
10. Remove and disassemble BL-5740-15 Hook Assembly (Figure 1001, Item 90, and Figure 1007,
Item 2) as follows:
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BODY (80). PLACE THE HOOK ASSEMBLY ON A FIRM SURFACE BEFORE
REMOVING THE NUT.
I. If necessary, remove cable size label (120) from rubber bumper.
L. Remove body (80), bearing (210), and spacer (200) from swivel hook (220).
REMOVING TUBE (230), KEEPER (240), AND SPRING (250). THE SPRING IS
O. Remove tube (230) in the swivel hook by machining, or chiseling, off flared end of tube,
tapping it out with a drift and a mallet, and separating keeper (240) and spring (250) from
hook (260).
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D. To separate bumper assembly (Figure 1008, Item 1) from hook assembly (2 or 3), pull up on
BODY (80). PLACE THE HOOK ASSEMBLY ON A FIRM SURFACE BEFORE
REMOVING THE NUT.
I. If necessary, remove cable size label (120) from rubber bumper.
L. Remove body (80), bearing (210), and spacer (200) from swivel hook (220 or 230).
NOTE: SWIVEL HOOKS (220 AND 230) ARE PURCHASED ITEMS, WHICH THIS
MANUAL DOES NOT COVER. PLEASE CONTACT THE VENDOR OF THESE
HOOKS FOR THEIR RECOMMENDATIONS CONCERNING MAINTENANCE.
12. Remove and disassemble BL-14584-10 Series Hook Assembly (Figure 1001, Item 80, and
Figure 1009, Item 2) as follows:
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the ball end of the wire rope cable.
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 (120) from stem of hook assembly (160).
K. Remove housing (70) and flat washer (130) from stem of hook assembly.
L. Remove thrust washer (140) and bearing (150) from housing.
M. To unlock hook assembly (160), remove quick release pin (170) from keeper.
REMOVING RIVET (180) FROM HOOK (200) TO REMOVE CABLE
ASSEMBLY (190). THE KEEPER SPRING IS UNDER COMPRESSION WHEN
INSTALLED AND CAN FLY OFF HOOK WHEN REMOVING RIVET.
N. Remove rivet (180) holding the cable assembly (190) on the hook (200) by machining, or
chiseling, off rivet head and tapping out with a drift and a mallet, and remove cable
assembly.
O. Separate cable assembly (190) from quick release pin (170).
13. Remove and disassemble bumper assembly (Figure 1001, Item 190, Figures 1003, 1004, and
1005, Item 10, and Figures 1006, 1007, 1008, and 1009, Item 1) as follows:
A. Accomplish actions identified in Paragraphs 3C, and 6 through 12 (removal and disassembly
of cable cutter cartridge, and hook assembly) above prior to performing the steps below.
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B. Slide bumper assembly down and over the ball end of the wire rope cable (Figure 1002,
View B, Item 30) to remove it from the cable.
C. Bend the four crimped areas of the bumper retainer (Figures 1003, 1004, and 1005, Item 30,
and Figures 1006, 1007, 1008, and 1009, Item 20) out of the way to allow removal of the
compression spring (Figures 1003, 1004, and 1005, Item 20, and Figures 1006, 1007, 1008,
and 1009, Item 10) and remove from spring.
D. Remove overtravel bumper (Figures 1003, 1004, and 1005, Item 40, and Figures 1006, 1007,
1008, and 1009, Item 30) from bumper retainer.
14. Remove and disassemble limit switch cover assembly as follows (see Figure 302):
A. Remove tie wire, screws (Figure 1002, 40 and 50), washers (60), clamp (70), terminal (80),
cover (90) with gasket (100). See Figure 302.
B. Remove gasket (100) from cover (90), if necessary.
Clamp (70)
Screws (40) and Washers (60)
Limit Switch Cover (90)

with Gasket (100)
Cycle Counter Label (1030)
Identification Plate (1020)

Screws (50) with Tie Wire and
Washers (60) not shown,
obscured by Limit Switch Cover
Figure 302. Limit Switch Cover
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15. Remove cable from hoist as follows:

of cable cutter cartridge, hook, bumper, and limit switch cover assemblies) above prior to
performing the steps below.
HANDLING THE HOIST CABLE TO PREVENT INJURY FROM BROKEN
CABLE STRANDS AND WIRES.
B. Apply power to hoist (Figure 1001, Item 10).
C. Pay out cable (Figure 1003, View B, Item 30) at less than half speed until hoist reaches full
out limit.
WARNING: PERSONNEL SHOULD USE TOOLS THAT DO NOT CONDUCT ELECTRICITY
TO ACTUATE THE LIMIT SWITCHES. PROPER GROUNDING IS REQUIRED.
WARNING: THE HOIST MUST NOT BE OPERATED IN THE LOWERING DIRECTION
BEYOND THE POSITION WHERE THE OPENING IN THE DRUM FLANGE
FOR THE SETSCREWS IS VISIBLE. ROTATING THE DRUM IN THE
LOWERING DIRECTION BEYOND THIS POSITION WILL CAUSE THE
CABLE TO BACKWIND RESULTING IN SERIOUS DAMAGE TO THE HOIST.
D. Carefully override the full out limit switch, S2, (Figure 1002, View C, Item 110) by gently
pushing down on the actuators (590) and manually closing the redundant limit switches with
a small screwdriver, or equivalent tool. Slowly reel out the cable until the opening in the
drum flange for setscrews (Figure 1002, Item 120) is visible and approximately 6 inches
(0.15 meters) of cable remains on the hoist (less than 1 wrap). See Figure 303.
CAUTION: ONCE THE CABLE IS REMOVED, DO NOT ROTATE THE DRUM IN EITHER
DIRECTION. THE DRUM IS IN POSITION FOR INSTALLING THE NEW
CABLE. ROTATING THE DRUM WITHOUT THE CABLE ATTACHED WILL
CAUSE THE TIMING BETWEEN THE CABLE GUIDE AND THE DRUM TO BE
INCORRECT RESULTING IN DAMAGE TO THE DRUM AND THE CABLE.
E. Disconnect power from hoist.
F. Remove both setscrews (120) with a 0.0625 (1/16) in. Allen wrench from drum flange to
allow removal of cable.
G. Remove the end of cable from the slot in the drum flange. Pull cable out through cable guide.
16. Remove cable cutter as follows:
of cable cutter cartridge, hook, bumper, limit switch cover, and cable assembly) above prior
to performing the steps below.
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STANDARDS, AND REGULATORY PRACTICES.
Potentiometer (840)
(R1, under circuit board)
Mount Cleats (830) and

Screws (820)
Actuators (590)
Full Out Limit Switch S2 (110)
Figure 303. Full Out Limit Switch (S2) and Potentiometer on Cyclocentric Assembly
WARNING: THE CARTRIDGE MUST BE REMOVED BEFORE PERFORMING ANY
MAINTENANCE PROCEDURES INVOLVING THE HOIST AND MUST BE
INSTALLED AFTER ALL MAINTENANCE PROCEDURES ON THE HOIST
ASSEMBLY ARE COMPLETED.
WARNING: TAKE PROPER PRECAUTIONS TO AVOID FIRING THE CARTRIDGE
DURING HANDLING DUE TO ELECTRICAL SHOCK FROM
FROM PACKAGING, AND INSTALLED IN HOIST. MAXIMUM CARTRIDGE
LIFE IS 13 YEARS (COMBINED SHELF AND SERVICE LIFE) FROM THE
DATE OF MANUFACTURE. THE DATE OF MANUFACTURE CAN BE FOUND
IN THE LOT NUMBER ON THE LABEL OF THE SEALED CONTAINER, IN
WHICH THE CARTRIDGE IS SHIPPED AND STORED, AND ON THE FLATS
OF THE HEX SHAPED PORTION OF THE CARTRIDGE. THE LOT NUMBER
CAN BE IDENTIFIED WITH THE FIRST THREE LETTERS “CAD.”
IMMEDIATELY FOLLOWING THESE LETTERS IS THE DATE OF
MANUFACTURE, REPRESENTED AS TWO DIGITS, WHICH IDENTIFY THE
YEAR (EXAMPLE: 05 IS 2005), AND ONE LETTER, WHICH IDENTIFIES THE
MONTH, AS DEFINED BELOW:
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A– JANUARY E– MAY J – SEPTEMBER

B– FEBRUARY F– JUNE K – OCTOBER
C– MARCH G– JULY L – NOVEMBER
D– APRIL H– AUGUST M – DECEMBER
In the event the cartridge is fired resulting in a cable cut, the anvil (Figure 1002, View B,
Item 130), cotter pin (140), cutter (150), O-ring (160), MS20995NC32 tie wire, and
Cartridge Kit KT-198 (Figure 1001, Item 60), which includes the cartridge (Figure 1002,
Item 10) in a hermetically sealed container, three shims, and one O-ring (20), must be
replaced. These items can be purchased from Breeze-Eastern.
B. If not accomplished previously, remove electrical connector (not shown in IPL) and cartridge
(Figure 1002, View B, Item 10) with packing (20) per paragraph 3C.
C. Remove tie wire and anvil (130).
D. Remove cotter pin (140), cutter (150), and O-ring (160).
17. Remove cable guide as follows (see Figure 304):
of cable cutter cartridge, hook, bumper, limit switch cover, and cable assemblies) above prior
B. Remove and discard cotter pin (Figure 1002, View B, Item 165) from end of stop (180).
C. Unthread self-locking nut (170) until nut is at the end of the stop (180).
D. Rotate and position stop to permit removal of cable guide, and remove cable guide (190).
E. If necessary, fully unthread self-locking nut (170) and lightly tap unthreaded end of stop
(180) out to clear the cable guide assembly.
Self-Locking
Nut (170)
Stop (180)
Cotter Pin (165)

Cable Guide
(190)
Figure 304. Cable Guide Assembly with Cable Guide (190)

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18. Remove tension roller shaft assembly as follows:

of cable cutter cartridge, hook, bumper, limit switch cover, and cable assemblies) above prior
B. Apply power to hoist (Figure 1001, Item 10).
C. Position cable guide approximately at center of hoist, equidistant from end flanges.
D. Disconnect power to hoist.
E. Remove cap screws (Figure 1002, 200) and guide bar (210).
F. Remove plunger (Figure 1002, View B, Item 220) and spring (230).
G. Remove gear guard clamp (Figure 1002, View A, Item 240) by removing screws (250) and
washers (260).
H. Remove retaining ring (Figure 1002, Item 270) from groove in roller gear (330) and move it
away from gear towards tension roller shaft assembly (320).
I. Remove spring pin (280) from roller gear (330) using Pin Removal and Installation Tool,
Part Number BLT-10300-J, or equivalent.
CAUTION: SHIMS, WASHERS, AND ROLLER WILL FALL FREE AFTER REMOVAL OF
THE SHAFT FROM THE HOIST. PLACE A SUITABLE CONTAINER UNDER
HOIST TO CATCH THESE PARTS WHILE REMOVING SHAFT.
J. Remove inner roller shaft (290) from tension roller assembly by applying pressure at motor
end of shaft and driving shaft through roller until shaft can be accessed and removed from
cyclocentric end of hoist.
K. Remove thrust washers (300 and 310) and shims (315 through 315A) from both ends of
tension roller shaft assembly (320). Record thickness and location of shims.
L. Remove retaining ring (270), tension roller shaft assembly (320), and roller gear (330).
19. Remove overrunning clutch as follows:
A. Accomplish actions identified in Paragraphs 3C, 6 through 15 (removal and disassembly of
cable cutter cartridge, hook, bumper, limit switch cover, and cable assemblies), and 18
(removal and disassembly of tension roller shaft assembly) above prior to performing the
steps below.
B. Remove gear guard (Figure 1002, View A, Item 390) by removing setscrew (350) from block
(360), screws (340 and 370), washers (260 and 380), and block (360).
C. Remove bolt (Figure 1002, 400), spacer (410), and overrunning clutch assembly (420).
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20. Remove chain as follows (see Figure 305):

WARNING: CYCLOCENTRIC ASSEMBLY AND PRINTED CIRCUIT BOARD ASSEMBLY
ARE CONNECTED TO THE HOIST WIRING. DO NOT PULL WIRING AND
SOLDER JOINTS ON ELECTRICAL COMPONENTS WHEN REMOVING
THESE ASSEMBLIES.
A. Accomplish actions identified in Paragraph 14 (removal of limit switch cover assembly)
above prior to performing the steps below.
B. To gain access to the chain, remove screws (430), washers (440) and cyclocentric assembly
(450). See Figure 305.
C. Loosen cam follower (460) using a 0.125 in. (3.175 mm.) Allen wrench and backing out hex
head screw holding cam follower assembly while holding lock nut (470) between end flange
and drum. Slide idler away to relax tension on chain (480). See Figure 305.
D. Remove chain from level wind shaft sprocket (1050) and drive sprocket (1110).
21. Remove motor as follows:
A. Disconnect electrical connector from motor.
B. Remove screws (490) and washers (500), and remove motor (510) from Hoist.
C. Remove O-ring (520) from motor.
Drive Sprocket (1110)
not shown, underneath
Cyclocentric Assembly
Chain (480)
Hex Head
Screw Level Wind Shaft Sprocket
(1050)
Screws (430) and Washers (440)
Cam Follower (460)
Cyclocentric Assembly (450)
Figure 305. Chain, Sprocket, Follower, and Attaching Hardware
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22. Remove follower as follows:

A. Thread an 8-32 x 0.375 inch screw (PN MS16995-25, not provided by Breeze-Eastern, see
Table 901) into the follower (Figure 1002, View B, Item 980), press down on screw to
remove pressure against retaining ring (950) from spring washer (970) and back up spacer
(960), and remove retaining ring.
B. Pull back on screw and remove back up spacer (960), spring washer (970), and follower
(980). Remove screw from follower.
23. Remove cable pressure roller assemblies as follows:
A. Accomplish actions identified in Paragraphs 3C, 6 through 15 (removal and disassembly of
cable cutter cartridge, hook, bumper, limit switch cover, and cable assemblies), and 18
(removal and disassembly of tension roller shaft assembly) above prior to performing the
steps below.
B. Remove tie wire from roller shafts (860).
C. Remove roller shafts (860), support (870), spacers (880), and roller assemblies (890 and
920).
D. If required, disassemble roller assemblies (890 and 920) by using a suitable press, and press
out the bearings (900 and 930) from cable pressure rollers (910 and 940).
24. If necessary, remove identification plate (1020) and labels (990, 1000, 1010, and 1030) as
follows (see Figure 302):
A. All typed-in information on identification plate (1020) should be recorded prior to removal,
and will be required for new plate when installed. If illegible, or missing, contact Breeze-
Eastern with all known information concerning Hoist for original, or new, data for plate.
B. Remove plate (1020), labels (990, 1000, 1010, and 1030), and any residual adhesive from the
parts the labels are applied with by using a sharp knife, razor blade, isopropyl alcohol, or
equivalent.
25. Removal of Electrical Components (refer to Figures 101 and 303, and Figures 202, 203, and 204
for Wiring Diagrams):
A. Remove full out limit switches, S2, and intermediate speed limit switches, S1, as follows:
(1) If not previously accomplished, remove tie wire, screws (Figure 1002, 40 and 50),
washers (60), clamps (70), terminals (80), and cover (90) with gasket (100).
(2) Remove screws (530) and remove potentiometer bracket (540).
(3) Remove switch mounting brackets (Figure 1003, View C, 550 and 560) by removing
screws (570) and washers (580).
(4) Remove switches (110) and actuators (590) from brackets by removing screws (600 and
610), flat washers (620), and nuts (630). See Figure 101.
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(5) Remove sealant and unsolder wire connections of full out and intermediate speed limit
switches.
B. Remove potentiometer R1 as follows (See Figures 101 and 303):
(1) Loosen screws (Figure 1002, View D, Item 820), rotate cleats (830), and remove
potentiometer R1 (840).
(2) Remove O-rings (850) from shaft of potentiometer R1.
(3) Carefully remove any sealant from wire connections, and unsolder wire connections to
potentiometer R1.
C. Remove full in limit switches, S3, as follows (Refer to Figures 202, 203, & 204 for
applicable wiring diagrams):
(1) Remove limit switch cover (Figure 1003, View B, 640) with gasket (650) by removing
(2) Remove full in limit switches, S3, (110) and actuator (680) from cable guide assembly by
removing screws (690), and tooth lock washers (700).
(3) Remove retaining ring (710), cable guide pin (720), and spring (730) from cable guide
assembly. Discard retaining ring. See Figure 103.
(4) Remove sealant and unsolder wire connections of full in limit switches.
D. Remove cable foul switches as follows:
(1) Pull up on switch actuator (740) of cable foul indicator and insert a soft wooden wedge,
or equivalent, between the indicator and the cable drum to allow access to cable foul
switches (750).
(2) Remove cable foul switches by removing screws (760) and nuts (770).
(3) Remove any sealant from switch connections, and unsolder wire connections of switches
(750).
(4) If necessary, remove setscrews (780) and springs (790) from switch actuator (740).
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CLEANING
1. General
Cleaning instructions for the components of the Rescue Hoist System are provided in this
section. To ensure satisfactory results, each cleaning procedure should be performed as
described. All soot, dust, dirt, corrosion / rust, and moisture must be removed, as these
destructive agents will eventually cause operational failure.
Materials Required for Cleaning (Equivalent substitutes may be used for Listed items)
Equipment / Material Name
ASTM-D3699 Kerosene
TT-I-735 Isopropyl Alcohol
Plasti-Glass Anti-Static Plastic and Glass Cleaner (commercially available)
- Soft Bristle Brush (commercially available)
- Vacuum Cleaner (commercially available)
Table 401. Materials Required for Cleaning
WARNING: KEEP HANDS, BODY, AND CLOTHING AWAY FROM RESCUE HOIST
ASSEMBLY, SPECIFICALLY “PINCH POINTS,” WHERE CABLE ENTERS THE
CABLE GUIDE AND CONTACTS THE DRUM.
WARNING: SEARCH AND RESCUE OPERATIONS, AND ALL OTHER USES OF RESCUE
ALL RESCUE HOISTS.
BROKEN STRANDS AND WIRES. EYE PROTECTION MUST BE WORN BY
THE OPERATOR WHENEVER OPERATING, OR MAINTAINING, THE
METAL PARTS AND 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: THE TENSION ROLLER SYSTEM WORKS ON THE BASIS OF FRICTION;
THEREFORE, NO LUBRICANT SHOULD BE APPLIED TO THE CABLE. IF
OIL, OR GREASE, GETS ON THE CABLE, CLEAN THE CABLE WITH A
CLOTH AND ISOPROPYL ALCOHOL. SOLVENTS MAY BE DETRIMENTAL
TO THE TENSION ROLLERS; THEREFORE, A CABLE CLEANED IN THIS
MANNER MUST BE DRY BEFORE BEING REELED IN.
CAUTION: DO NOT LET KEROSENE, ISOPROPYL ALCOHOL, HYDRAULIC FLUIDS,
LUBRICANTS, SOLVENTS, DETERGENTS, OR FUELS COME INTO
CONTACT WITH HOIST TENSION ROLLER.
A. Clean all metal parts with kerosene, isopropyl alcohol, or equivalent. Remove caked-on dirt
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.
E. Wipe switches, receptacles, and connectors with a clean cloth, and 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, clean surface with isopropyl alcohol to remove any residual
adhesive, dirt, dust, or grease prior to assembly. Dry surface with clean, dry compressed air
at a maximum pressure of 15 psig (1.0 bar), or with a clean, lint-free cloth.
I. For all faying or mating surfaces, specifically where gaskets are to be installed, clean with
alcohol to remove any dirt, dust, or grease prior to assembly. Dry surface with clean, dry
compressed air at a maximum pressure of 15 psig (1.0 bar), or with a clean, lint-free cloth.
J. After servicing with oil, wipe off, and clean up any excess oil that spilled on, or under the
Hoist using a clean, lint-free cloth.
K. If cable has been exposed to lubricants, proceed as follows:
(1) Slowly reel out cable to exposed affected area.
(2) Wipe affected area with a clean cloth saturated with isopropyl alcohol to remove
contaminants and clean surface of cable.
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(3) Pass the cable through a clean cloth when reeling in to thoroughly dry the cable and
remove any excess isopropyl alcohol.
L. Hoist, Hook and / or Cable (if exposed to saltwater)
This procedure shall be accomplished at the next available helicopter maintenance action,
and shall be performed monthly thereafter, unless the hook assembly has been immersed in
water, operated in high humidity environments (including rain, snow, etc.), then it shall be
accomplished after completion of each such mission. If any corrosion is visible, remove
corrosion, and re-treat affected area. Wash drum, hook, and cable with clean fresh water as
specified below:
NOTE: IF THE HOOK ASSEMBLY IS IMMERSED IN WATER (FRESH OR SALT
WATER), OR OPERATED IN A HIGH HUMIDITY ENVIRONMENT,
CORROSION MAY OCCUR (SEE FIGURE 401). DISASSEMBLE HOOK
ASSEMBLY, RINSE WITH FRESH WATER, CLEAN, DRY, AND
RELUBRICATE DURING POST FLIGHT INSPECTION AFTER EVERY
RESCUE / TRAINING MISSION.
(1) Remove and disassemble hook assembly per procedures in Section 301, Disassembly.
(2) Rinse off hook and bumper assembly components so that all contamination has been
thoroughly washed off with fresh water, and ensure parts have been cleaned, and
thoroughly dried. Remove any surface corrosion per Section 601, Repair. Inspect and
replace, as necessary, per Section 501, Checks and Inspection. Relubricate, and assemble
components per Section 701, Assembly. Do not install hook and bumper assembly onto
cable at this time.
Figure 401. Example of Corrosion on Hook Assembly Parts (Typical)

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

(5) Pass cable through clean, dry cloth as cable is slowly being reeled in onto hoist.
(6) After reeling in cable, assemble and install hook and bumper assembly components per
Assembly (Section 701).
M. Clean windows in forward and aft cowling assemblies (if applicable) with non-abrasive,
plastic window cleaner (i.e., Plasti-Glass), or equivalent. Wipe windows with clean cloth.
N. Wiring Harness Assembly Cleaning
(1) Remove any loose contamination by hand.
(2) Using a vacuum cleaner, remove dust, dirt, soot, and grime accumulations on the harness
assembly.
(3) Use a non-metallic soft bristle brush to loosen accumulations of dust, dirt, soot, and
grime that remain, and vacuum the area again.
(4) Remove any remaining dust, dirt, and grime by wiping with isopropyl alcohol and a clean
cloth.
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CHECKS AND INSPECTIONS
1. General
The items listed in Table 501 shall be inspected in accordance with the procedures contained in
this section at the recommended frequency. More frequent inspections can be made, but
inspections cannot be made less frequently. In addition, a maintenance log shall be maintained
for each Rescue Hoist System in order to keep track of hoist cycles, maintenance actions, and
inspections.
Part Name
Recommended Frequency of Inspections Figure and Inspection Required
(Para. Ref. in Section 501,
(whichever occurs first)* Item Number
unless otherwise noted)
At the beginning of the day Oil Level (Para. 2L[5]) Figure 521 Pre-Flight Inspection
At the beginning (pre-flight), Hook Assembly Figures 510, 512, 513, 527 and Pre-Flight and Post-
(Para. 2F, 2L, and 2M) Figures 1003 – 1009, as applicable Flight Inspections
or
at the end (post-flight), of the day Cable Cutter Cotter Pin Figure 1002, View B, Item 140 Pre-Flight and Post-
(Para. 2N) Flight Inspections
Wire Rope Cable Figures 505 through 511, and Post-Flight Inspection
At the end of the day
(Para. 2E) 1002, View B, Item 30
Perform every month, Hook Assembly Figures 510, 512, 513, 522, and Inspect for defects and
100 flight hours, (Para. 2F) Figures 1003 – 1009, as applicable binding when installed
Wire Rope Cable Figures 505 through 511, and Inspect for defects
or 25 hoist cycles
(Para. 2E) 1002, View B, Item 30
Perform every 3 months, Level Wind Shaft Figures 520, 1002, Item 1040 Inspect for wear
200 flight hours, (Para. 2K)
Follower (Para. 2K) Figures 520 and 1002, View B, Inspect for wear
or 50 hoist cycles
Item 980
Tension Roller (Para. 2C) Figures 502, 503, and Inspect for wear, and
1002, Item 320 defects
Cable Foul Assembly Figure 1002, Item 740 Inspect for proper
(Para. 2I) setting, and damage
Overrunning Clutch and Tension Figures 501, 504, 1002, Items 330 Inspect for proper
Roller Gear (Para. 2D) and 420 operation, and damage
Perform every 6 months, Cable Guide (Para. 2G) Figures 1002, View B, Item 190 Inspect for wear
330 flight hours,
or 100 hoist cycles Roller Assemblies (Para. 2J) Figures 519 and 1002, View B, Inspect for wear
Items 890 & 920
Chain (Para. 2H) Figure 1002, Item 480 Inspect for proper tension
when installed
Oil Level (Para. 2L[5]) Figure 521 Inspect oil level
Wiring Harness Assemblies - Inspect wiring and
(Para. 2P) connectors
Perform every 12 months, Hoist Assy. (Section 101, Para Figure 1001, Item 10 Test
1000 flight hours, or 330 hoist cycles 4E)
Perform every 1500 hoist cycles** Wire Rope Cable (Para. 2E) Figure 1002, View B, Item 30 Mandatory Replacement
Perform every 5 years, Hoist Assy. (Para. 2A) Figure 1001, Items 10 Overhaul
Or 2000 hoist cycles End Flanges (Para. 2O) - Detailed Inspection
Table 501. Inspection Requirements
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January 11, 2005
Recommended Frequency of Inspections Part Name (Para. Ref. in Figure and Inspection Required
(whichever occurs first)* Section 501) Item Number
Perform every 5 years from date of Cable Cutter Cartridge Part of Figure 1001, Item 60, and Mandatory Replacement
installation, and every 13 years from (Para. 2N) Figure 1002, View B, Item 10
date of manufacture
General (Para. 2B) - Inspection for wear,
As applicable for all visual inspections
damage, or corrosion
Hook Assembly Figures 510, 512, 513, 522 and Inspect for defects and
As required (Para. 2F) Figures 1003 – 1009, as applicable binding when installed
Cable Alignment - Required if cable is
(Para. 8, Section 601) leading, or lagging
Cycle Counter Reading 334 3340 8350 16700 25050 33400 668000
Equivalent Hoist Cycles 1 10 25 50 75 100 2000
* One hoist cycle is equal to reeling out the cable from full-in to full out, and then reeling in the cable back to full-in.
** 1500 hoist cycle replacement criteria is under ideal laboratory conditions, which may not be representative of actual
operating conditions.
Table 501. Inspection Requirements (continued)
2. Inspections
A. Overhaul of Rescue Hoist
The Rescue Hoist must be overhauled every 5 years, or 2000 hoist cycles, whichever occurs
first. This overhaul is required to properly maintain the assembly, and is recommended for all
Rescue Hoists manufactured by Breeze-Eastern.
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 listed below:
Breeze-Eastern
700 Liberty Avenue
Phone Number: 908-686-4000, or 1-800-929-1919 (Toll-Free US and Canada only)
Fax Number: 908-688-6495 E-mail Address: productsupport@breeze-eastern.com
B. General
ALL RESCUE HOISTS.
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January 11, 2005
WARNING: KEEP HANDS, BODY, AND CLOTHING AWAY FROM RESCUE HOIST,
SPECIFICALLY “PINCH POINTS,” WHERE THE CABLE ENTERS THE CABLE
THE OPERATOR WHENEVER OPERATING, OR MAINTAINING THE RESCUE
HOIST TO PREVENT INJURY FROM LUBRICANTS, SOLVENTS, AND
OTHER MATERIALS USED ON THE RESCUE HOIST, AS WELL AS METAL
PARTS AND DEBRIS.
THEREFORE, NO LUBRICANT SHOULD BE APPLIED TO THE CABLE. IF OIL
OR GREASE GETS ON THE CABLE, CLEAN THE CABLE WITH A CLOTH
AND ISOPROPYL ALCOHOL. SOLVENTS MAY BE DETRIMENTAL TO THE
TENSION ROLLERS; THEREFORE, A CABLE CLEANED IN THIS MANNER
MUST BE DRY BEFORE BEING REELED IN.
MUST BE VISUALLY INSPECTED FOR SOUND STRUCTURAL INTEGRITY
AND PROPER INTEGRATION.
Use this procedure for visually inspecting any, and all parts, as necessary, for obvious wear,
damage, or corrosion as specified below:
(1) Check all parts for nicks, cracks, scratches, and corrosion.
(2) All gear splines and shafts shall be free of nicks, burrs, sharp edges, and wear (see Figure
501).
Figure 501. Examples of Unacceptable Damage to Gear

(3) Check the four mounting holes for the hoist interface with the helicopter for cracks,
scoring and elongation (see Figure 801).
(4) Examine threads for stripping, distortion, nicks, and cross threading.
(5) All bearings shall be inspected to standard industry 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,
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January 11, 2005
spalling, scuffing, excessive heat, excessive play, shield placement (if applicable), or
any physical or chemical decomposition.
(b) Hold the inner race with one hand while rotating the outer race. Note the sound and
vibration of the bearings during rotation. This inspection helps detect defects large
enough to be visible but hidden from sight. Reject bearings that bind or that is
exceptionally noisy.
(c) Inspect prepackaged bearings for binding, excessive looseness (possibly indicating
loss of lubricant), or noise. Reject prepackaged bearings having any of these
indications.
(d) Inspect bearings for corrosion which will be evidenced by reddish coloring in
advanced stages of staining. Clean and polish external surfaces that exhibit corrosion.
If possible, check for corrosion on the race paths. Deep pits will serve as stress raisers
causing fatigue and flaking. Reject bearings having pits on the ball paths.
(6) Inspect all mating and faying surfaces for possible damage.
(7) Check retaining ring and seal grooves for obstructions, or damage, which might prevent
assembly.
C. Tension Roller (see Figures 502 and 503)
(1) Check endplay of tension roller (Figure 1002, Item 320) and center to center alignment of
roller gear (330) and large gear of the overrunning clutch assembly (420) when installed
using a feeler gage (see Figure 502). Endplay should be between 0.002 to 0.010 in.
(0.051 to 0.254 mm), and the gears should be aligned center to center ± 0.015 in.
(0.381 mm). If either of these dimensions exceeds these limits re-shim as required at the
both ends of the tension roller between thrust washers (310) and end flanges by removing
per Section 301 and installing per Section 701 the spring pin (280) and inner roller shaft
(290). When checking these dimensions, partially install spring pin halfway until
shimming has been completed and successfully checked to the limits above, then install
spring pin completely.
Figure 502. Tension Roller Gear and Overrunning Clutch Assembly

(Cyclocentric End is on left and Motor End is on right)
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January 11, 2005
(2) Visually inspect tension roller (Figure 1002, Item 320) for any abnormal wear, or obvious
defects, of rubber material (i.e., cracks, tears, abrasion, and degradation). Replace tension
roller if any abnormal wear or any of these defects are found (see Figures 502 and 503).
(3) Measure outside diameter of roller at most seriously worn areas. Replace tension roller if
diameter is below 0.801 inches (20.35 mm.) at any worn area (see Figure 503).
Figure 503. Tension Roller Replacement Criteria
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January 11, 2005
D. Overrunning Clutch Assembly (Figures 502 and 504)
(1) Remove overrunning clutch assembly per Section 301, Disassembly.
(2) Inspect overrunning clutch assembly (420) for broken, cracked, corroded, or damaged
gear teeth (see Figures 501 and 504). Replace if any defects are found.
(3) Inspect overrunning clutch assembly (420) to ensure the large gear rotates freely in
counterclockwise direction, and does not freely rotate in clockwise direction when
viewed from the small gear (as installed on the cyclocentric end flange, see Figure 504).
Replace if gear binds in counterclockwise direction, or slips, in the clockwise direction.
OverrunningClutch
Overrunning Clutch Assembly
Assembly
(420)
Figure 504. Overrunning Clutch Assembly (Typical)

(4) Check overrunning clutch assembly for wear. If lateral movement measured between
gears measures 0.050 in. (1.27 mm.), or more, replace the overrunning clutch assembly.
(5) Install overrunning clutch assembly per Section 701, Assembly.
E. Wire Rope Cable (see Figure 1002, View B, for ball end of cable [30] and Figure 1002 for
drum attachment screws {120} for cable).
ALL RESCUE HOISTS.
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.
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January 11, 2005
WARNING: KEEP HANDS, BODY, AND CLOTHING AWAY FROM RESCUE HOIST,
SPECIFICALLY “PINCH POINTS,” WHERE THE CABLE ENTERS THE CABLE
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.
NOTE: CABLE IS TO BE INSPECTED IN ITS NATURAL STATE. DO NOT TWIST,
BEND, LOAD, ETC. IN ANY MANNER THAT WOULD DAMAGE THE CABLE.
Inspect cable for corrosion, kinking, fraying, necking down, and distortion of swaged ball
end of cable. Check for broken wires; replace as soon as breaks in any strand are found.
Check for splicing; no splicing of the cable is allowed. Follow the guidelines for cable
inspection as defined below.
In order to be effective, cable inspection must be performed on a regularly scheduled basis.
Wire rope cables used for personnel lifting should be inspected carefully and frequently. Use
the following acceptance and rejection standard:
(1) Broken wires
Continued use of a cable with broken wires can result in the damaged area of the cable
being caught in the cable guide assembly upon paying out (see Figure 505). This will
result in the cable fouling or some other problem that may lead to a more severe situation.
It is for this reason that no broken wires are allowed for the hoist cable. If broken
wires are detected, the cable shall be removed and replaced immediately.
Figure 505. Example of Broken Strands in Wire Rope Cable

(2) Evidence of dragging over obstacles or worn cable guides
Cable abrasion is caused by contact with other cable sections, or any material that may
contact the cable, such as helicopter structural members, auxiliary equipment, or almost
any abrasive surface (see Figure 506). Abrasion removes metal from the external wires
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January 11, 2005
leaving a shinny cable surface 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 the helicopter structure, can result in a catastrophic cable failure
and possible loss of life. Severe abrasion as evidenced by a worn, or damaged, cable
resulting in multiple broken wires in an outer strand in any section requires immediate
cable replacement.
Figure 506. Example of Abrasion of Wire Rope Cable

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

(4) Knots in cable
A knot is 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 in the cable (see Figure 508). 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.
(5) Bird caging (permanent deformation or “opening up” of cable strands)
Bird caging is the permanent deformation, or “opening up” of the strands and wires of the
wire rope itself. This condition results from a torsion imbalance that occurs due to
mistreatments such as sudden stops, the wire rope being worked through tight sheaves, or
a hook bearing that is binding (see Figure 509). Any evidence of bird caging requires
immediate cable replacement.
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January 11, 2005
Figure 508. Example of Knot in Wire Rope Cable (Typical)
Figure 509. Example of Bird Caging in Wire Rope Cable

(6) Improperly attached or defective fittings
Carefully inspect the cable in the area of the hook ball end attachment (see Figure 510).
Do not bend the cable in the process of the inspection. The ball end of the cable must not
evidence any broken wires at the swaged ball fitting. Any necking down, broken wires,
loose wires in the immediate vicinity of the ball end is a cause for cable replacement.
This condition may have resulted from the cable not being snugged up against the cable
guide bell mouth properly, or a full-in limit switch that is activating too fast. The
continual vibration of a helicopter and a loosely "homed" hook can result in a fatigue
failure of the cable immediately above the ball end fitting. This inspection should be
performed prior to every flight. If a loose hook is noted, the necessary adjustment to the
full-in limit switch shall be performed after the cable inspection.
(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.
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January 11, 2005
Wire Rope Cable
Top of Swaged (Ball) End of Cable
Top of Terminal Clamp
Top of Hook Assembly

(with Bumper Assembly Removed)
Figure 510. Hook Assembly Attachment to Wire Rope Cable

When a wire rope cable is cycled predominantly over a small range (less than 50 feet
[15.2 meters] from the hook end) of its overall length, cable strands may loosen. The
strands will appear visibly loose, or will feel pliable / soft (see Examples A and B in
Figure 511), typically near the hook end, over a short length of cable (not the entire
length of cable). If the cable is no longer taut, it may appear damaged.
Mild Cable Severe Cable

Looseness Looseness
A B
Figure 511. Examples of Wire Rope Cable Looseness
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 511), repeat the rated load cycling as stated above. If this does not
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January 11, 2005
remove the looseness, remove the cable from service, and store for several days. If
looseness is still evident after several days of storage, discard cable.
Repeat the full-length, rated load cycling whenever inspection indicates looseness in the
cable.
(8) Improperly adjusted or defective cable guide
Cables showing damage, such as broken wires at the turnaround, or at cable crossovers,
are an indication that the hoist needs to have the level wind readjusted, or replaced.
Smiles (gaps between adjacent turns of cable) are the result of the cable not being tightly,
and evenly, wrapped, and / or the level wind leading the cable too much. If the level wind
is adjusted to lag the cable too much, excessive abrasion of the cable as it wraps on the
drum occurs, particularly at the crossovers. All of the above inspections are subjective,
and require an experienced technician to make the inspection, and readjustment, if
required. If the condition is corrected before excessive damage occurs, the cable can
continue in service if no wire breaks are discovered.
(9) Severe overload and shock loading
A cable that has been severely overloaded, or shock loaded, may, or may not, show the
immediate results of the overload. Broken strands and wires are the most obvious defects.
However, broken inner wires may also result from overload. "Necking-down" of any
section of the cable is an indication of broken inner wires. A cable that has been
knowingly overloaded should be replaced immediately, even if no obvious physical
damage is detected. Any obvious reduction in diameter is cause for immediate cable
replacement.
(10) Internal wear caused by grit or dirt penetration
Internal wear caused by grit, dirt, sand, soot, etc. embedded between the strands of the
cable is extremely difficult to detect. Preventive maintenance, in the form of carefully
cleaning and wiping off the cable to remove gritty material as it is reeled in during
inspection is recommended. Prolonged use of a cable loaded with gritty material will
result in broken wires.
(11) Mandatory Replacement of Wire Rope Cables
NOTE: MANDATORY 1500 HOIST CYCLE CABLE REPLACEMENT REQUIREMENT
IS BASED ON THE FATIGUE LIFE OF WIRE ROPE DURING HOIST
OPERATIONS IN LABORATORY CONDITIONS. ACTUAL CONDITIONS
WITH THE HOIST ON THE HELICOPTER WILL VARY FROM THESE IDEAL
CONDITIONS. THEREFORE, INSPECTION OF THE CABLE IS NOT TO BE
ELIMINATED DUE TO THIS MANDATORY REPLACEMENT INTERVAL.
In addition to the inspections identified above, every 1500 cycles the cable (Figure 1002,
View B, 30) must be replaced on the hoist. See procedures in Disassembly, Section 301, for
removal of the cable, and in Assembly, Section 701, for installation of the cable.
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F. Hook Assemblies (see Figures 510, 512, 513, and 1003 – 1009, as applicable)
(1) Inspect hook parts for cracks, corrosion, damaged threads, and gouges (reference Section
401, Cleaning). See Figure 512.
Bumper
Assembly Locking
Threads Screws &
- Grommet
Rivet - Spring Cotter Pins
- Retainer (Qty. 2)
Keeper
Lock
Plungers
(Qty. 2) Hook and
Springs Handwheel
Dowel bearings Keeper
Pins (not shown)
(Qty. 2) Lock Pin and
Lanyard
Figure 512. Various Hooks and Assembly (Typical)
(2) Check that the keeper in the hook operates without binding, locks properly, and the rivet
holding the keeper is properly fastened. Ensure locking pin and its attaching lanyard are
secure and undamaged. Check to see that the springs in the D-Lock actuate properly.
Ensure Slide Lock plungers, dowel pins, locks, pins etc. are in place and undamaged.
Check that the lock moves freely over plungers and stops at dowel pins.
(3) Check the terminal clamp and ring are properly installed in the hook, and properly
oriented with the cone end pointing toward the top of the hook to secure it to the ball end
of the cable. See Figure 513.
(4) Check to see that dual locking screws are properly seated through the nut and in the body
and locked in place with the dual cotter pins.
(5) Check that the hook freely swivels / rotates on its bearing in a smooth, non-binding
manner. If binding occurs, disassemble hook per Section 301, and inspect the bearings for
corrosion, galling, imperfections, or signs of roughness during rotation. If bearing is
found to be unacceptable, discard. Replace with new bearing, and assemble hook per
Section 701.
(6) After assembly, check that the hook swivels freely without binding.
G. Cable Guide (when installed on hoist, see Figure 1002, View B, Item 190)
Check cable guide (190) for cracks, gouges, and wear. Using 0.125 inch (3.17 mm.) diameter
rod with no sharp edges, probe rod between cable and sides of cable guide. If worn area
accepts rod, remove cotter pin (165), nut (170) and rotate stop (180) to allow the cable guide
to turn / rotate 90° for continued use. If cable guide has been turned previously due to wear,
replace cable guide. After cable guide rotation, position stop (180) properly, and snug nut
(170) against cable guide housing. Secure with new cotter pin (165).
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Cable
Terminal Clamp
Retaining Ring
Nut / Sleeve
Figure 513. Required Terminal Clamp Orientation (typical)

H. Chain (see Figure 514, 515, 516, and 1002, Item 480)
(1) Chain (480) Tension Check In Horizontal Position (hoist off helicopter, sitting on
mounting points)
NOTE: INSIDE SURFACES OF CHAIN MUST NOT TOUCH.
(a) Using a torque wrench with a range of 0 to 30 in.-lb. (3.39 Nm.) and a 0.687 in.
(17.46 mm.) adapter, apply counterclockwise torque of 12 in.-lb. (1.36 Nm.) to the
nut (part of 1050) that retains drive sprocket (See Figures 514 and 515).
(b) If inside surfaces of the chain touch, adjust idler (460), and recheck chain tension per
Step (a) above.
(c) If idler cannot be adjusted any further to achieve this chain tension requirement, use a
micrometer, vernier caliper, or equivalent, and check idler (460) for wear (minimum
acceptable O.D. for idler is 0.75 in. [19.0 mm.]). If idler O.D. is unacceptable, replace
idler (460). If idler O.D. is acceptable, replace chain (480).
CHAIN
NUT
IDLER DRIVEN
SPROCKET
Figure 514. Level Wind Chain Drive with Hoist Horizontal (Shown with limit switch cover removed)
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TORQUE WRENCH
GAP (RANGE: 0 – 30 IN.-LB.
(INSIDE SURFACES (0 – 3.39 Nm.)
OF CHAIN MUST
NOT TOUCH)
11/16 IN. ADAPTER
Figure 515. Chain Tension Check with Hoist Horizontal (Shown with limit switch cover removed)
(2) Chain Tension Check In Vertical Position (hoist mounted on helicopter by mounting
points)
NOTE: INSIDE SURFACES OF CHAIN MUST NOT TOUCH.
(a) Using a force gauge with a range of 0 to 10 lb. (0 to 4.5 kg.), and a linear scale, or
ruler, deflect the chain 3/32, or 0.094 in. (2.38 mm.), as shown in Figure 516. Verify
spring scale reads between 2 to 3 lb. (0.91 to 1.36 kg.).
(b) If force gauge does not read between 2 to 3 lb. (0.91 to 1.36 kg.), adjust idler. If idler
cannot be adjusted any further to achieve this chain tension requirement, use a
micrometer, vernier caliper, or equivalent, and check idler for wear (minimum
acceptable O.D. for idler is 0.75 in. [19.0 mm.]). If idler O.D. is unacceptable, replace
idler (460). If idler O.D. is acceptable, replace chain (480).
I. Cable Foul Indicator (Figure 517 and Figure 1002, Item 740)
CAUTION: DO NOT DISPLACE THE ACTUATOR OF THE CABLE FOUL SENSOR MORE
THAN 0.188 IN. (4.7 MM.) FROM ITS NORMAL, REST POSITION.
NOTE: FOR THIS TEST, THE CABLE MUST BE REELED OUT AND REELED BACK
IN UNDER NO LOAD BEFORE MAKING ANY OBSERVATIONS,
MEASUREMENTS, OR ADJUSTMENTS.
(1) Apply power to the Hoist, slowly reel out cable to full-out position. Slowly reel in the
cable under no load condition to the full-in position.
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January 11, 2005
DEFLECT CHAIN
0.094 IN. (2.38 MM.)
AND VERIFY
FORCE GAUGE READING
IS 2 TO 3 LB. (0.9 TO 1.36 KG.)
Figure 516. Chain Tension Check with Hoist Vertical (Shown with limit switch cover removed)
(2) Slowly reel out the cable until the setscrews (120) in the drum flange is aligned with the
bottom of the switch actuator (740). Use a vernier caliper, or equivalent, and check the
clearance 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 517). The clearance should be 0.060 ± 0.020 inches (1.5 ± 0.5 mm.). If clearance
is not within limits, adjust setscrews (780) evenly to correct dimension. After inspection /
adjustment is completed, slowly reel in cable until the hook is at the full-in position and
disconnect power to the Hoist.
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(780)
(740)
Setscrew (120) showing location of
crossover point for cable on drum
(setscrew must be aligned with switch
actuator to properly check gap)
Figure 517. Cable Foul Sensor Dimensional Check

(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 (740) just inside the switches (see Figure 518) to stop the
hoist while reeling the cable out. The force required shall be 2.25 to 3.75 lb. (1.02 to 1.7
kg.).
Lift here Lift here
Figure 518. Cable Foul Sensor Test (Typical)

(4) Check condition of the cable foul sensor. Ensure springs (790, Figure 1002,) are not
broken, damaged, deformed (no large gaps between coils), or yielded. Check that all
fasteners (i.e., rivets, screws, nuts) are installed and properly secured. Ensure cable foul
actuator (740) has no signs of damage i.e. bent, cracked, etc.
(5) After inspection has been successfully completed, install cowlings / cover as necessary.
J. Pressure Roller Assemblies (Figure 519 and Figure 1002, View B, Items 890 and 920)
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January 11, 2005
Check roller assemblies (Items 890 and 920) for corrosion or wear (See Figure 519).
Normal Wear
Replace roller if diameter Abnormal Wear
of groove is less than (Note impression
of cable in groove).
0.628 inches (15.95 mm.). Replace roller.
Figure 519. Roller Replacement Criteria

K. Level Wind Shaft and Follower
CAUTION: USE CAUTION WHEN HANDLING THE LEVELWIND SHAFT. THE POINTS
ARE VERY SHARP AT THE INTERSECTION OF THE HELICAL GROOVES.
(1) Visually inspect level wind shaft (Figure 1002, Item 1040) for corrosion, wear, and
damage. If any of these conditions exists, remove hoist and send for repair.
(2) Measure, at a minimum of six places, the groove width on the level wind shaft (Figure
1002, Item 1040) per Figure 520.
(3) The maximum allowable dimension is 0.160 in. (4.06 mm.). If dimension measured is out
of specification, remove hoist and send for repair.
(4) Remove the follower (Figure 1002, View B, Item 980) per the procedures in Section 301,
Disassembly.
(5) Measure the width of the follower per Figure 520. The minimum allowable dimension is
0.148 in. (3.76 mm.).
(6) Replace the follower if measurement is out of tolerance.
(7) Install the follower per the assembly procedure in Section 701.
L. Pre-Flight Inspection
The following procedures are to be performed before each day in which the hoist may be
used for airborne rescue operations (including training).
(1) Visually check the hoist structure for cracks, missing mounting and retaining hardware
(bolts, lock nuts, cotter pins, locking screws, etc.), hardware slippage marks (if applied),
or material surface imperfections.
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January 11, 2005
0.160 in. (4.06 mm.) = Maximum Gap
Levelwind Shaft (1040)
0.148 in. (3.76 mm.) = Minimum Width
Levelwind Follower (980)
Figure 520. Dimensional Inspection of Level Wind Follower and Shaft

(2) Check swivel hook assembly for smooth and non-binding operation, corrosion, and
freeness of latch. Check to see the dual locking screws (Figures 1003 - 1009, Items 60,
70, 80, as applicable) are properly seated in the nut / body, and are locked in place with
dual cotter pins (Figures 1003 - 1009, Items 50, 60, 70, as applicable). Check the rivet
holding the keeper on the hook assembly is in place and secure. Check that the ball end of
the cable has no signs of damage (See Figures 510 and 513). Ensure the bumper (Figures
1003 - 1009, Items 1, or 10, as applicable) does not bind / adhere to the cable guide
(Bellmouth) and will allow the hook assembly to reel in and out freely. Ensure Slide
Lock plungers, dowel pins, are in the hook are not missing, or damaged. Check to see that
the lock moves freely over plungers and stops at the dowel pins. Ensure that the D-Lock /
springs secure the keeper. See Figure 512.
(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.
(5) Check hoist to verify oil level is in the middle of the sight glass and to verify the oil level
in two-speed mechanism is at the level of the fill port (see Figure 521 and Figure 1002).
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January 11, 2005
Figure 521. Oil Fill Locations (Helicopter Mounted Position)

(a) If hoist oil level is below the middle of the sight glass, remove tie wire, plug / bolt
(800) with seal (810) next to the sight glass and add oil, MIL-PRF-7808, until level
rises to center of sight glass. When the oil level is at the center of the sight glass,
install bolt with seal and tie wire per MS33540 with MS20995NC32.
(b) If oil level is above center of sight glass, put a container under the hoist to catch
excess oil, remove tie wire, and slightly back off plug / bolt (800) at sight glass to
allow excess oil to slowly leak out of hoist. When the oil level is at the center of sight
glass, tighten bolt and tie wire per MS33540 with MS20995NC32.
(c) To check the level of oil in the two-speed mechanism, put a container under the hoist
to catch excess oil, remove tie wire, and slightly back off plug / bolt (800) located at
fill port for two-speed mechanism, approximately 4 inches (102 mm.) from the sight
glass. If hoist oil level is above the level of the bottom of the fill port, allow excess oil
to drain from the fill port. If no oil drains from the fill port after loosening plug / bolt,
remove bolt (800) with seal (810) and check to verify oil level is at the bottom of the
fill port. If oil level is below the fill port, add oil, MIL-PRF-7808, to fill port until it
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January 11, 2005
overflows. When the oil level is at the bottom of the fill port, install bolt with seal and
tie wire per MS33540 with MS20995NC32.
(6) Check that electrical connectors are properly installed and secure. Also, check for any
indications of chaffing or conductor separation from the connectors.
(7) Perform the following operational check of the Rescue Hoist System:
(a) Apply power to Rescue Hoist System by pushing in applicable circuit breakers.
(b) Using the control pendant, slowly reel out cable from full-in position and ensure
bumper assembly (Figures 1003 - 1009, Items 1 or 10, as applicable) moves freely
from cable guide assembly.
(c) Stop the hoist with approximately 20 feet (6.1 meters) of cable paid out from the
hoist. Check the readout on the control pendant and verify its reading is within ± 3
feet (± 0.9 meters) equivalent to the amount of cable paid out.
(d) Continue to reel out cable at half speed until the hoist slows down automatically.
Verify the hoist slowed down at 6 to 12 ft. (1.83 to 3.66 m.) from full out (mark the
cable, and check the distance after the cable is reeled out to the full out position).
(e) Continue to reel out cable at half speed until full out limit switch actuates and stops
the hoist. Verify the hoist stopped with 3½ to 4½ wraps remaining on the drum.
(f) Reel in the cable at half speed using the control pendant.
(g) Reel in cable at half speed until the hoist slows down automatically. Verify the hoist
slowed down at 6 to 12 ft. (1.83 to 3.66 m.) from full-in.
(h) Continue to reel in the cable to full-in, and verify full-in switch operates normally,
stopping the hoist.
M. Post-Flight Inspection
The following procedures should be observed and / or executed at the end of each day of any
airborne hoist operations (including training).
(1) Visually check the hoist structure for cracks, missing mounting hardware, hardware
slippage marks (if applied), or material surface imperfection.
(2) Check all covers, plugs, and guards for proper attachment and tie wire installation.
(3) Visually inspect hoist for any oil leakage.
(4) Inspect the entire usable length of wire rope cable for defects. Slowly reel out the cable
until the full out limit switch stops the hoist. Then, slowly reel in the cable while cleaning
with a cloth and looking for defects per Section 501, Paragraph 2E.
(5) Check height of bumper assembly when hook is at full-in position (see Figure 522).
Measure height from top of bumper retainer to bottom of spring. If height is not 1.00 to
1.39 inches (25.4 to 35.3 mm.), check full-in limit switch operation using procedure in
Testing and Troubleshooting (Section 101).
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January 11, 2005
1.00 to 1.39 in.

(25.4 to 35.3 mm.)
Figure 522. Deflection of Bumper Assembly with Hook at Full-in Position

(6) Check that electrical connectors are properly installed and secure. Also, check for any
indications of chaffing or conductor separation from the connectors.
N. Cable Cutter
STORED AND HANDLED IN COMPLIANCE WITH ALL LOCAL
NOTE: IF THE CABLE HAS BEEN CUT, THE ANVIL (BL-6329), O-RING /
PACKING (AN6227-10), CUTTER (BL-6331), CARTRIDGE (KT-198), AND
COTTER PIN (MS9245-10) SHALL BE REPLACED.
FROM PACKAGING, AND INSTALLED IN HOIST. MAXIMUM
CARTRIDGE LIFE IS 13 YEARS (COMBINED SHELF AND SERVICE LIFE)
FROM THE DATE OF MANUFACTURE. THE DATE OF MANUFACTURE
CAN BE FOUND IN THE LOT NUMBER ON THE LABEL OF THE SEALED
CONTAINER, IN WHICH THE CARTRIDGE IS SHIPPED AND STORED,
AND ON THE FLATS OF THE HEX SHAPED PORTION OF THE
CARTRIDGE. THE LOT NUMBER CAN BE IDENTIFIED WITH THE FIRST
THREE LETTERS “CAD.” IMMEDIATELY FOLLOWING THESE LETTERS
IS THE DATE OF MANUFACTURE, REPRESENTED AS TWO DIGITS,
WHICH IDENTIFY THE YEAR (EXAMPLE: 05 IS 2005), AND ONE
LETTER, WHICH IDENTIFIES THE MONTH, AS DEFINED BELOW:
A – JANUARY E – MAY J – SEPTEMBER
B – FEBRUARY F – JUNE K – OCTOBER
C – MARCH G – JULY L – NOVEMBER
D – APRIL H – AUGUST M – DECEMBER
Visually inspect the date on the cable cutter cartridge (Figure 1002, View B, Item 10) should
be less than 13 years from the current date, and less than 5 years from the date of installation
on the hoist. If the date has expired, remove and replace cartridge.
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January 11, 2005
Visually inspect the cotter pin (Figure 1002, View B, Item 140) in the cable guide for
condition and proper installation. If missing, or damaged, remove and replace pin per
procedures in Disassembly, Section 301, and Assembly, Section 701.
O. Detailed Inspection of Rescue Hoist End Flanges
Visually inspect end flanges for cracks, missing mounting and retaining hardware, hardware
slippage marks (if applied), or material surface imperfections. Check mounting hole locations
for the Rescue Hoist dimensionally, as identified in Fits and Clearances, Section 801.
P. Inspection of Wiring
Visually inspect wiring for degradation due to wear, vibration, moisture, contamination, and
excessive heat. Check electrical wiring for the following defects:
(1) Wiring that has been subjected to chafing, fraying, or is brittle.
(2) Insulation that is abraded, cracked, over-stressed, or suspected of being penetrated.
(3) Conductors or shields that are broken or exposed.
(4) Clamps or brackets that are loose or missing.
(5) Wiring that is not correctly attached to terminals or connectors.
(6) Backshells that are loose or separated.
(7) Connector pin damage.
(8) Grommets that are loose or cracked.
Replace any wiring found with defects.
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REPAIR
1. General
ALL RESCUE HOISTS.
Material Name Supplier
-- 240 grit, or finer, aluminum oxide abrasive cloth Commercially Available
-- 320 grit, or finer, abrasive paper Commercially Available
MIL-P-7962 Primer Coating Commercially Available
MIL-C-46168 Lacquer, Top Coat Commercially Available
-- Wire Rope Paint / Orange Staining Color ITW Dykem / Dymon
(PN 81448 = 8 oz. Bottle, PN 81748 = 1 gal. Bottle, 805 E. Old 56 Hwy.
PN 81848 = 5 Gal. Can.) Olathe, KS 66061
Iridite Solution #14-2 Commercially Available
MIL-R-25134 Solvent Type Paint and Lacquer Remover Commercially Available
TT-I-735 Isopropyl Alcohol Commercially Available
Table 601. Materials Required for Repair
(Equivalent substitutes may be used for listed items)
A. Causes of surface corrosion are as follows:
(1) Nicks, dents, scratches, and wear that remove paint, and / or plating, are the principal
causes of surface corrosion.
(2) Salt water exposure can cause surface corrosion, as well as joint corrosion, due to
moisture between dissimilar metals through electrolytic action. When paint, coating,
and / or plating are removed, corrosion may occur due to the interaction of aluminum and
steel parts used in the manufacturing process.
B. Removal of corrosion on aluminum parts (see Table 601 for list of materials required for
repair).
(1) Remove surface scratches, nicks, pitting, or corrosion as specified by using 240 grit, or
finer, aluminum oxide cloth (Scotch Brite). Limits and dimensions are provided in Fits
and Clearances, Section 801.
(2) Superficial damage to primed surfaces may be touched up locally using primer
procedures listed in the refinishing section below.
(3) Blend repaired areas. See Table 602 for allowable material removal.
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January 11, 2005
NOMENCLATURE DAMAGE REPAIR LIMITS

Figure 1001
Exterior Control Box Assembly Surface Corrosion, Clean with Scotch Brite, and protect surface with
Surfaces of Variable Speed Nicks, Blemishes conductive corrosion preventive compound, as
Controller (20, 30) required
Moderate to Heavy Replace Controller and Motor, or return hoist to a
FAA / JAA Repair Station, or Depot Facility, for
repair
Electrical Connectors of Variable Surface Corrosion, Clean exterior surface with Scotch Brite, and protect
Speed Controller (20, 30), Control Nicks, Blemishes on exterior surface with conductive corrosion preventive
Pendant Assembly (40 and 50), exterior surfaces compound, as required
and Control Pendant Cable Moderate to Heavy on Damage greater than 0.002 in. (0.05 mm.), replace
Assembly (70) exterior surfaces
Any corrosion to internal Replace
surfaces, or components
Figure 1002
Hardware (Nuts, Bolts, Screws, None Allowed Replace
Washers, etc.)
Electrical Connectors Surface Corrosion, Clean exterior surface with Scotch Brite, and protect
Nicks, Blemishes on exterior surface with conductive corrosion preventive
exterior surfaces compound, as required
Moderate to Heavy on Damage greater than 0.002 in. (0.05 mm.), replace
exterior surfaces
Any corrosion to internal Replace
surfaces, or components
Electrical Switches None Allowed Replace
Potentiometer Bracket (540) None Allowed Replace
Cyclocentric Housing (450) None Allowed Replace
(Level Wind Shaft) Sprocket Surface Corrosion Clean with Scotch Brite, and protect surface with
(1050) conductive corrosion preventive compound, as
required
Moderate to Heavy Replace
Motor Assembly (510) Surface Corrosion, Clean with Scotch Brite, and protect surface with
Nicks, Blemishes conductive corrosion preventive compound, or paint,
as required
Moderate to Heavy Replace Controller and Motor, or return hoist to a
FAA/JAA Repair Station, or Depot Facility, for
repair
Springs (230 and 790) None Allowed Replace
Retaining Ring (710) None Allowed Replace
Cable Guide Pin (720) None Allowed Replace
Table 602. Allowable Material Removal
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NOMENCLATURE DAMAGE REPAIR LIMITS

Figure 1002 (Continued)
Cable Cutter (150) None Allowed Replace
Cutter Anvil Cap (130) None Allowed Replace
Switch Actuator (740) Surface Corrosion, Clean with Scotch Brite, and protect surface with
Nicks, Blemishes corrosion preventive compound, or paint, as required
Moderate to Heavy Damage greater than 0.002 in. (0.05 mm.), replace
Figures 1003 – 1009, As Applicable
Hook (180, 190, 200, 220, 230, Surface Corrosion, Clean with Scotch Brite, and protect surface with
260, 290, 300, 340, as applicable) Nicks, Blemishes corrosion preventive compound, or paint, as required
Moderate to Heavy Damage greater than 0.002 in. (0.05 mm.), replace
Spring (10, 20, as applicable) None Allowed Replace
Bearings (120, 130, 140, 150, None Allowed Replace

160, 170, 180, 190, 200, 210,
220, as applicable)
Hardware (Nuts, Bolts, Screws, None Allowed Replace
Washers, etc.)
Hand Ring (130, 140, 150, as Surface Corrosion, Clean with Scotch Brite, and protect surface with
applicable) Nicks, Blemishes corrosion preventive compound, or paint, as required
Moderate to Heavy Pits exceeding 0.002 in. (0.05 mm.) can be blended
Corrosion using rubber wheel and compound. Blend shall not
exceed 0.009 in. (0.23 mm.). Pits that exceed 0.010
in. (0.25 mm.) depth, replace component
Hook Housing (70, 80, 90, as None Allowed Replace
applicable)
Table 602. Allowable Material Removal (continued)

C. Removal of corrosion on steel parts (see Table 601 for list of materials required for repair)
(1) Remove surface scratches, nicks, pitting, or corrosion as specified by using 240 grit, or
finer, aluminum oxide cloth (Scotch Brite). Limits and dimensions are provided in Fits
and Clearances, Section 801.
(2) Remove moderate to heavy corrosion with a fine file, or a non-woven abrasive wheel.
(3) Blend repaired areas. See Table 602 for allowable material removal.
D. Superficial damage to primed surfaces may be touched up locally using primer procedures
listed in the refinishing section below.
2. Refinish (see Table 601 for list of materials required for repair)
A. If primed surfaces of the hoist are worn, or bared, due to repair sanding, refinish using the
following materials:
Primer: MIL-P-7962, or equivalent
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January 11, 2005
Top Coat: MIL-C-46168, Color #34031 (aircraft green) per FED-STD-595, or equivalent
(2 coats recommended)
B. If cable requires additional orange paint on the ends, refinish using the following material
(see Figure 601):
Coating: Orange Staining Color (ITW Dykem/Dymon, Olathe, KS )
12 + 0 / – 6 in.
(305 + 0 / – 152 mm)
1.00 ± .25 in. 25 ± .5 ft. 14 ± .5 ft.
(25.4 ± 6 mm) (7.6 ± .15 m) (4.3 ± .15 m)
Figure 601. Wire Rope Cable Orange Paint Lengths

3. Minor Surface Repair (Damage of Surface Area with no exposed metal, see Table 601 for list of
materials required for repair)
A. Remove contamination from damaged area using clean cloths moistened with isopropyl
alcohol, or equivalent.
B. Wipe surface area until free of oil, grease, or other contamination.
C. Lightly sand damaged area with 320 grit, or finer abrasive paper.
CAUTION: AVOID OVER SANDING SURFACE AREA. REMOVE SANDING RESIDUE
WITH CLEAN CLOTH MOISTENED WITH ISOPROPYL ALCOHOL.
D. Mask, or protectively cover, all areas not being treated or primed.
E. Aluminum will not require a surface treatment if primer is applied immediately. If a delay of
more than two hours occurs, use Iridite #14-2 solution (4 ounces per gallon [32 ml. per
liter]). Apply by brush or swab at room temperature. A contact time of 15 to 30 seconds will
usually produce a golden yellow color. Rinse thoroughly and dry.
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.
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January 11, 2005
4. Major Surface Repair (Damage of Surface Area with exposed metal, see Table 601 for list of
materials required for repair)
A. To strip primer, and coating, from damaged area use approved strippers per MIL-R-25134, or
equivalent. The viscosity of this primer is high enough so that it can be applied by brush, or
swab, to the specific area to be stripped without running. It is to be used in the as received
condition at temperatures above 50° F (10° C).
B. Follow procedures A through H listed in Minor Surface Repair above.
5. Application of Top Coat
A. Top coat application should be accomplished under the following atmospheric conditions:
Temperature: 50° F (10° C) minimum
Relative Humidity: 85% maximum
B. Using a quality natural-bristled 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
THE OPERATOR WHENEVER OPERATING, OR MAINTAINING, THE
METAL PARTS AND OTHER DEBRIS.
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:
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January 11, 2005
Temperature: 50° F (10° C) minimum Relative Humidity: 85% maximum

D. Using a quality natural-bristled paintbrush, apply two (2) coats of orange Dykem Lacquer
(thickness not to exceed 0.005 inches [0.13 mm] on cable diameter).
E. Allow cable to dry for 30 minutes between coats, and prior to installing cable on hoist.
7. Cable Foul Removal (see Figure 1002)
WARNING: DO NOT TRY TO CLEAR CABLE FOUL IN FLIGHT. A FOULED CABLE
MAY BREAK, AND THIS MAY RESULT IN CAUSING INJURY OR
DEATH.
A. To clear cable foul, gently push down on switches (750) using wooden tongue depressors, or
equivalent, on both sides of cable foul indicator, and carefully pull on the cable as it is being
slowly reeled out. Using the control pendant, slowly reel out cable.
B. If cable starts to backwind, or fouled cable cannot be reeled out, use a bolt cutter, or
equivalent, and cut off small sections of the cable until the cable foul is removed.
NOTE: CABLE EXTREMES ARE PAINTED ORANGE IN COLOR. DO NOT
CONFUSE THIS COLOR FOR RED INDICATING A SCRAPPED CABLE
AND DO NOT USE ORANGE TO INDICATE A SCRAPPED CABLE.
C. 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).
D. Perform all test procedures in Testing and Troubleshooting (Section 101) after installation of
new cable.
8. Cable Alignment Inspection / Adjustment (see Figure 1002):
A. Slowly reel out cable (Figure 1002, View B, Item 30) to full out hoist position.
B. Slowly reel in the cable three (3) to five (5) wraps. Position the centerline of the cable
crossover point (the center of the flat area) of the drum 180° (opposite) from the tangent
point where the cable is beginning to wrap on the drum (where the cable begins to touch the
drum after being fed through the cable guide and past the tension roller).
C. Check cable alignment. Cable shall be in the center of the groove and seated in the bottom of
the groove with no sign of leading (overtravel), or lagging, as it transitions from the drum
over the tension roller shaft assembly (320) and through the cable guide.
NOTE: ADVANCE LEVEL WIND SHAFT SPROCKET (1050) SLOWLY (ONE
TOOTH AT A TIME) IN ORDER TO PROPERLY ADJUST CABLE GUIDE
POSITION TO CORRECTLY ALIGN CABLE.
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D. If alignment has to be adjusted, follow the chain removal procedure in Section 301
(Disassembly), and move the level wind sprocket accordingly as defined below:
Cable lagging: Rotate sprocket clockwise to correct for lag.
Cable leading: Rotate sprocket counterclockwise to correct for overtravel.
E. After alignment of cable is completed, follow the chain installation procedure in Section 701
(Assembly).
F. After installing chain, perform steps A. through D. above.
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ASSEMBLY
1. General
Assemble the Rescue Hoist System in accordance with the following instructions. Reference
numbers in parenthesis refer to IPL in Section 1001. Special tools and general information are
listed in Section 901. All mention of applying and disconnecting power to the system components
should be accomplished using helicopter circuit breakers or equivalent acceptable means.
Material Name and Application
MIL-PRF-7808 Oil for Rescue Hoist Assembly
MIL-S-8660 Anti-Seize Compound for cartridge packing and knife O-ring
MS20995NC32 Tie Wire
Amovis No. 8X (Amoco Oil Co.) Lubricant for overrunning clutch assembly and drum gear
MIL-G-6886 Lubricant for tension roller clutch assembly
MIL-M-7866 Lubricant for tension roller shaft
MIL-G-46886 or Lubricant for hook assembly thrust bearing and hoist
DC-33 (Dow Corning Corp.) assembly chain
SN60-63WRMAP2/3 or
Solder
SN60-63WRP2/P3
3145 Clear (Dow Corning Corp.) Sealant for switch terminals
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 require an individual
other than the technician who performed the operation to inspect the work completed due to the
criticality of the operation. This inspection must be documented in either the helicopter or hoist
maintenance log.
3. Assemble the Rescue Hoist System in accordance with the following instructions and the IPL
Figures 1001 through 1009.
ALL RESCUE HOISTS.
4. Installation of Electrical Components (refer to Figure 202 for Wiring Diagram of Rescue Hoist
Assembly).
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NOTE: ALL WORK INVOLVING ELECTRICAL WIRING, SPECIFICALLY WORK

INVOLVING SOLDERING, MUST BE PERFORMED BY QUALIFIED
PERSONNEL.
WARNING: ALL ELECTRICAL WORK SHALL BE ACCOMPLISHED WITH POWER
DISCONNECTED TO HOIST AND TOOLS THAT DO NOT CONDUCT
ELECTRICITY. PROPER GROUNDING IS REQUIRED.
A. Install full in limit switch S3 (Figure 1002, View B, Item 110) as follows:
(1) Using SN60-63WRMAP2/3 or SN60-63WRP2/P3 Solder, attach wire connections to full
in limit switch S3 per wiring diagram on Figure 202.
(2) Apply 3145 Sealant to switch terminals after soldering.
(3) VITAL POINT INSPECTION Install spring (730), and cable guide pin (720). Place
retaining ring (710) in the installation tool BLT-10300-V, or equivalent, with the sharp
edges orientated down against the bottom of the cable guide housing and the rounded
edges positioned up against the spring. Use a screw driver, or equivalent, to lift up on
spring (730) and install the retaining ring (VP 710). Ensure the retaining ring is
undamaged after installation. It shall remain stationary and not rotate on the pin. If
damage or rotation is evident, remove and discard old retaining ring and install a new
retaining ring per these instructions.
(4) Install full in limit switch (110) and actuator (680) into cable guide with screws (690) and
washers (700).
(5) Install cover (640) and gasket (650) with screws (660) and washers (670).
B. Install full out limit switch S2 (Figure 1002, View C, Item 110) and intermediate limit switch
S1 (110) as follows:
(1) Using SN60-63WRMAP2/3 or SN60-63WRP2/P3 Solder, attach wire connections to full
out limit switch S1 and intermediate limit switch S2 per wiring diagram on Figure 202.
(3) Install full out limit switch (110), intermediate limit switch (110), and actuators (590) with
screws (600 and 610), washers (620), and nuts (630) onto brackets (550 and 560).
(4) Install brackets onto cyclocentric assembly (450) with screws (570) and washers (580).
C. Install potentiometer R1 (Figure 1002, View D, Item 840) as follows:
(1) Using SN60-63WRMAP2/3 or SN60-63WRP2/P3 Solder, attach wire connections to
potentiometer R1 per wiring diagram on Figure 202.
(2) Install O-rings (850) onto shaft of potentiometer (840).
(3) Install potentiometer onto bracket (Figure 1002, 540), and secure with screws (820) and
mount cleats (830).
(4) Install bracket onto cyclocentric assembly (450), and secure with screws (530).
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D. Install cable foul indicator limit switches (Figure 1002, Item 750) as follows:
(1) Pull up on switch actuator (740) and insert a soft wooden wedge, or suitable alternate,
between the actuator and drum to allow access for installation of switches (750).
(2) Using SN60-63WRMAP2/3 or SN60-63WRP2/P3 Solder, attach wire connections to
switches (750) per wiring diagram in Figure 202.
(4) Install screws (760) and nuts (770) holding switches in place.
(5) Remove soft wooden wedge, or suitable alternate, between the actuator and drum.
5. Install motor (Figure 1002, Item 510) proceed as follows:
NOTE: ALL MATING AND FAYING SURFACES, ESPECIALLY THOSE SURFACES IN
CONTACT WITH GASKETS, SHALL BE CLEANED PRIOR TO ASSEMBLY.
A. Apply DC-33 lubricant to O-ring (520) prior to installation.
B. Install new O-ring in groove in mounting surface of motor (510).
C. Engage shaft spline of motor with internal spine of gear on hoist.
D. Position motor so that electrical connector is facing outward from hoist and secure with
E. Install electrical connector (not shown in IPL).
6. Install chain as follows:
A. Apply a light coat of MIL-G-46886, or DC-33 LUBRICANT, lubricant to chain (480), drive
sprocket (1110), and the level wind shaft sprocket (1050).
B. Install chain over sprockets, and slide the cam follower assembly (460) over to provide proper
tension on the chain.
C. Check gap between inside surfaces of chain using procedure in Checks and Inspections
(Section 501). Tighten nut (470) between flange and drum after using procedure to check gap.
D. Install cyclocentic assembly (450) using screws (430) and washers (440).
7. Install overrunning clutch assembly as follows:
A. Before installation, coat gear teeth of overrunning clutch assembly (420) with MIL-G-6886
lubricant, or equivalent.
B. Install overrunning clutch assembly, on the inside of the flange, using bolt (400) and spacer
(410).
C. Install gear guard (Figure 1002, View A, Item 390) using screws (340 and 370), washers (260
and 380), block (360), and setscrew (350).
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8. Install roller assemblies and follower as follows:

A. Assemble roller assemblies (Figure 1002, View B, 890 and 920) by pressing ball bearings
(900 and 930) into rollers (910 and 940) flush with each side.
B. Coat roller shafts (860) lightly with grease MIL-G-46886. Install roller assemblies (890 and
920) in support (870) and cable guide with a spacer (880) on either side. Secure with shafts
(860) and tie wire shafts together with MS20995NC32 per MS33540 after installation.
C. Install follower (980) in cable guide with spring washer (970), back up spacer (960), and
secure with retaining ring (950).
9. Assemble and install tension roller shaft assembly as follows (see Figure 701):
A. Before installation, coat gear teeth of roller gear (330) with MIL-G-6886 lubricant, or
equivalent.
B. Coat both inner roller shaft (290) ends and inside surface of both bushings with MIL-M-7866
lubricant.
C. Slide inner roller shaft through bearing on motor end flange from the outside of hoist. As shaft
is pushed through bearing, install thrust washers (300 and 310) with Teflon side towards
bearings in end flanges, tension roller shaft assembly (320), roller gear (330), and shims (315
through 315C) using thickness previously recorded during disassembly. See Figure 701.
Figure 701. Tension Roller Shaft Assembly and Overrunning Clutch Assembly
(Cyclocentric End Flange is on left and Motor End Flange is on right)
D. Slide inner roller shaft (290) into end flange bushing. Partially install new pin (280) halfway
through roller gear using tool BLT-10300-J, or suitable alternate, to allow removal if re-
shimming is required.
E. Check for tension roller endplay using feeler gage (see Figure 701). Measure gap between
tension roller shaft assembly and shims at the cyclocentric end flange. Endplay should be
between 0.002 to 0.010 inches (0.051 to 0.254 mm.). If endplay exceeds these limits, remove
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spring pin and shaft and re-shim as required at cyclocentric end of inner roller shaft assembly
between thrust washer and tension roller shaft assembly. Install shaft and partially install
spring pin halfway when checking endplay. When shimming is complete, install spring pin
completely and insert retaining ring (270) into groove in roller gear.
F. Install clamp (Figure 1002, View A, Item 240) using screws (250) and washers (260).
G. Install spring (Figure 1002, View B, Item 230) and plunger (220).
H. Install guide bar (Figure 1002, Item 210) using screws (200).
10. Install cable guide, proceed as follows:
A. Rotate cable guide stop (Figure 1002, View B, Item 180) in cable guide assembly to permit
insertion of cable guide (190).
B. Insert cable guide fully and seat cable guide stop in locking groove of bushing.
C. Install nut (170) on cable guide stop and snug up cable guide stop against bushing. Tighten
nut one additional, complete turn, and secure with cotter pin (165).
11. Install limit switch cover assembly as follows:
NOTE: ALL MATING AND FAYING SURFACES, ESPECIALLY THOSE SURFACES IN
CONTACT WITH GASKETS, SHALL BE CLEANED PRIOR TO ASSEMBLY
PER SECTION 401.
A. Remove backing from gasket (Figure 1002, Item 100) and install adhesive side of gasket on
limit switch cover (90).
B. Attach cover to end flange, using screws (40 and 50), terminal lug (80), clamp (70), and
washers (60). Install tie wire in screws (50) per MS33540 with MS20995NC32.
12. Install cable cutter and cartridge as follows:
WARNING: THE CARTRIDGE IS AN EXPLOSIVE AND MUST BE SHIPPED, STORED, AND
HANDLED IN COMPLIANCE WITH ALL LOCAL STANDARDS, AND
REGULATORY PRACTICES. IT ALSO MUST BE REMOVED BEFORE
PERFORMING ANY MAINTENANCE PROCEDURES INVOLVING THE CABLE
CUTTER, AND IT MUST BE INSTALLED LAST AFTER CABLE CUTTER IS
ASSEMBLED.
A. Lubricate O-ring (Figure 1002, View B, Item 160) with anti-seize compound, MIL-S-8660,
and insert into cable guide assembly.
B. Insert cutter (150) into cable guide with blade facing anvil (130).
C. VITAL INSPECTION POINT. Align hole in cutter with hole in cable guide assembly,
and insert cotter pin (140). Bend tabs to secure cotter pin.
D. Install anvil (130) and tie wire per MS33540 with MS20995NC32.
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13. Install wire rope cable as follows:

WARNING: OPERATOR SHALL WEAR APPROVED 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. Feed welded end of cable (30) through cable guide (190). Ensure cable is captured in rollers
of the cable guide assembly and between the pressure roller and the tension roller.
B. Insert welded end of cable in slot of drum flange until strands of the wire rope cable (not just
the welded end) are visible through the drum flange hole for the setscrew.
C. VITAL INSPECTION POINT. Install first setscrew (120) in drum flange hole and
secure cable by applying a torque of 4 to 5 in.-lb. (46 to 58 mm.-kg.) with a torque wrench
and a 0.0625 (1/16) in. Allen wrench drive.
D. VITAL INSPECTION POINT. Starting at setscrew remove slack from cable by putting
tension on cable. Check holding force of setscrew by giving a tug on the cable. Cable shall
remain tight with no movement and lay in first groove after exiting slot in drum flange.
E. VITAL INSPECTION POINT. Install second setscrew (120) on top of first setscrew
and secure first setscrew by applying a torque of 4 to 5 in.-lb. (46 to 58 mm.-kg.) with a
torque wrench and a 0.0625 (1/16) in. Allen wrench drive.
F. Apply power to hoist.
NOTE: ALWAYS REEL IN TO CHECK CABLE ALIGNMENT. NEVER PAY OUT CABLE
TO CHECK ALIGNMENT (SEE CHECKS AND INSPECTIONS SECTION 501 FOR
CABLE ALIGNMENT PROCEDURE).
G. Operate hoist to reel-in cable until approximately six feet of cable remain. Keep tension of
approximately 20 lb. (9.1 kg.). on cable by hand. Check cable is wrapping on hoist properly
with no severe leading or lagging, and with no snapping at extremes of layers on drum.
H. Disconnect power to hoist.
I. VITAL INSPECTION POINT. After installing hook and bumper assembly, perform
Rated Load Test identified in Testing and Troubleshooting (Section 101, Paragraph 4.E.) to
ensure cable and hook have been properly installed.
J. Disconnect power to hoist.
14. Assemble and install bumper assembly (Figure 1001, Item 190, Figures 1003, 1004, and 1005,
Item 10, and Figures 1006, 1007, 1008, and 1009, Item 1) as follows:
A. Press over travel bumper (Figures 1003, 1004, and 1005, Item 40, and Figures 1006, 1007,
1008, and 1009, Item 30) into bumper retainer (Figures 1003, 1004, and 1005, Item 30, and
Figures 1006, 1007, 1008, and 1009, Item 20).
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B. Place spring (Figures 1003, 1004, and 1005, Item 20, and Figures 1006, 1007, 1008, and
1009, Item 10) in bumper retainer and crimp in four places equally spaced on circumference
of bumper retainer.
C. Lightly grease ball end of wire rope cable (Figure 1002, View B, Item 30) with MIL-G-6886
lubricant to ease installation of bumper assembly onto cable. Do not allow any lubrication on
the wire rope cable itself, only the ball end.
D. Install bumper assembly onto cable by pressing ball end of cable through bumper.
15. Assemble and install HK-116 Series Hook Assemblies (Figure 1001, Items 130 and 140, and
Figure 1003, Items 1 and 2) as follows:
WARNING: ORIENTATION OF TERMINAL CLAMP DURING INSTALLATION IS
CRITICAL FOR PROPER LOAD CARRYING CAPABILITY OF THE HOIST
HOOK. THE RETAINING RING MUST BE ON THE END OF THE TERMINAL
CLAMP LOCATED CLOSEST TO THE HOOK WITH THE CHAMFERED, OR
CONE SHAPED, END OF THE TERMINAL CLAMP FACING TOWARD THE
HOIST.
WARNING: THE TERMINAL CLAMP IS A TWO-PIECE, MATCHED SET. IT IS MACHINED
AS AN ASSEMBLY AND MUST BE INSTALLED AS A SET.
A. VITAL INSPECTION POINT. Install nut (Figure 1003, Item 60) over ball end and
slide nut up cable towards hoist. Attach terminal clamp (100 VP) onto ball end of cable.
Secure terminal clamp with ring (110 VP), and slide nut over terminal clamp. See Figure 702.
B. VITAL INSPECTION POINT. Slide bumper assembly (10) down cable, and ensure terminal
clamp (100 VP) is properly seated in nut (60).
Cable
Terminal Clamp
Nut / Sleeve
Retaining Ring
Figure 702. Required Terminal Clamp Orientation (typical)
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C. Install bearing (170) and thrust washer (160) into housing (90).
D. Install flat washer (150) and housing (90) onto stem of hook (180 or 190).
E. 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.
CAUTION: ONLY TIGHTEN CASTELLATED NUT (140) HAND TIGHT (IF HAND
THREADING IS DIFFICULT A WRENCH CAN BE USED TO ASSIST), THEN
BACK-OFF. NEVER TIGHTEN THE NUT TO REACH THE NEXT AVAILABLE
CASTELLATION.
F. Install castellated nut (140) onto stem of hook and tighten until bearing is fully seated in
housing.
G. VITAL INSPECTION POINT. Back castellated nut (140) off slightly to allow
installation of new orange colored spring pin (130 VP) through stem of hook and castellated
nut, with access through housing (90).
H. VITAL POINT INSPECTION. Rotate hook while holding housing to check for binding
of bearing (170). If binding exists, remove spring pin (130), 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 (170).
I. Install rubber bumper (120) onto housing (90).
J. Install housing and assembled hook parts onto nut (60) by threading, or screwing, them
together until bottomed.
K. VITAL INSPECTION POINT. Install locking screws (80 VP) into nut (60) to lock
housing, and then lock setscrews in place with new cotter pins (70 VP).
L. Push down on bumper assembly (10) to snap the bumper assembly onto nut (60).
M. Apply power to hoist.
N. Run hoist to the full in position to secure to hook and bumper assembly on hoist.
O. VITAL INSPECTION POINT. Perform Hook Load Test identified in Testing and
Troubleshooting (Section 101, Paragraph 4.D.), to ensure hook (50, or 50A VP) has been
properly installed. Verify hook bearing rotates with a smooth, non-binding rotation.
P. Disconnect power to hoist.
A. If required, assemble swivel hook (Figure 1004, Item 210) as follows:
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INSTALLING RIVET (300), KEEPER (310), AND SPRING (320). THE SPRING IS
WHEN INSTALLING BUSHING AND RIVET.
(1) Install spring (320) and keeper (310) onto hook (340), and secure with new bushing (330)
and new rivet (300).
(2) VITAL INSPECTION POINT. Using a mallet and punch, or equivalent, round off
or upset the other end of rivet (300 VP) to hold keeper, spring, and bushing on hook.
(3) Assemble crimps (280) onto lanyard (270), and install lanyard assembly (260), washers
(250), and bushing (240) onto hook. Secure with new rivet (230).
or upset the other end of rivet (230 VP) to hold lanyard assembly, washers, and bushing
on hook.
(5) Secure quick release pin (220) with lanyard assembly (260), and lock hook by installing
quick release pin into keeper.
CLAMP LOCATED CLOSEST TO THE HOOK WITH THE CHAMFERED OR
CONE SHAPED END OF THE TERMINAL CLAMP FACING TOWARD THE
HOIST.
B. VITAL INSPECTION POINT. Install nut (50) over ball end of cable and slide nut up
cable towards hoist. Attach terminal clamp (90 VP) onto ball end of cable. Secure terminal
clamp with ring (100 VP), and slide nut over terminal clamp. See Figure 702.
C. VITAL INSPECTION POINT. Slide bumper assembly (10) down cable, and ensure terminal
D. Install bearing (200) and thrust washer (190) into housing (80).
E. Install flat washer (180) and housing (80) onto stem of hook (210).
F. With an applicator brush, spread Vibra-Tite around the stem threads of the hook. Completely
dry.
CASTELLATION.
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G. Install castellated nut (170) onto stem of hook and tighten until bearing is fully seated in
housing.
H. VITAL INSPECTION POINT. Back castellated nut (170) off slightly to allow
I. VITAL POINT INSPECTION. Rotate hook while holding housing to check for binding
J. If applicable, install rubber bumper (150) onto housing (80).
K. If applicable, press bearing (130) into handwheel (140).
L. If applicable, install handwheel assembly (120) and nut spacer (110) onto housing (80).
M. Install housing and assembled hook parts onto nut (50) by threading, or screwing, them
N. VITAL INSPECTION POINT. Install locking screws (70 VP) into nut (50) to lock
O. Push down on bumper assembly (10) to snap the bumper assembly onto nut (50).
P. Apply power to hoist.
Q. Run hoist to the full in position to secure to hook and bumper assembly on hoist.
R. VITAL INSPECTION POINT. Perform Hook Load Test identified in Testing and
Troubleshooting (Section 101, Paragraph 4.D.), to ensure hook (1 or 2 VP) has been properly
installed. Verify hook bearing rotates with a smooth, non-binding rotation.
S. Disconnect power to hoist.
HOIST.
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A. VITAL INSPECTION POINT. Install nut (Figure 1005, Item 60) over ball end of cable
and slide nut up cable towards hoist. Attach terminal clamp (100 VP) onto ball end of cable.
C. Install bearing (210) and thrust washer (200) into housing (90).
D. Install flat washer (190) and housing (90) onto stem of hook (220).
E. With an applicator brush, spread Vibra-Tite around the stem threads of the hook. Completely
dry.
BACK OFF. NEVER TIGHTEN THE NUT TO REACH THE NEXT AVAILABLE
CASTELLATION.
F. Install castellated nut (180) onto stem of hook and tighten until bearing is fully seated in
housing.
G. VITAL INSPECTION POINT. Back castellated nut (180) off slightly to allow
H. VITAL POINT INSPECTION. Rotate hook while holding housing to check for binding
I. If applicable, install rubber bumper (160) onto housing (90).
J. If applicable, press bearing (140) into handwheel (150).
K. If applicable, install handwheel assembly (130) and nut spacer (120) onto housing (90).
L. Install housing and assembled hook parts onto nut (60) by threading, or screwing, them
M. VITAL INSPECTION POINT. Install locking screws (80 VP) into nut (60) to lock
N. Push down on bumper assembly (10) to snap the bumper assembly onto nut (60) in swivel
hook assembly (50 or 50A).
O. Apply power to hoist.
P. Run hoist to the full in position to secure to hook and bumper assembly on hoist.
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Q. VITAL INSPECTION POINT. Perform Hook Load Test identified in Testing and
Troubleshooting (Section 101, Paragraph 4.D.), to ensure hook assembly (1 or 2 VP) has
been properly installed. Verify hook bearing rotates with a smooth, non-binding rotation.
R. Disconnect power to hoist.
18. Assemble and install HK-112-1 Hook Assembly (Figure 1001, Item 100, and Figure 1006,
Item 2) as follows:
INSTALLING TUBE (270), KEEPER (280), AND SPRING (290). THE SPRING IS
WHEN INSTALLING TUBE.
(1) Install spring (290) and keeper (280) onto hook (300), and secure with tube (270).
both ends of tube (270 VP) to hold keeper and spring on hook.
(3) Install cable assembly (250) through tube (270) and around ring on quick release pin
(240). Secure quick release pin to cable with sleeve (260).
(4) Lock hook by installing quick release pin into keeper.
HOIST.
B. VITAL INSPECTION POINT. Install nut (70) and sleeve (40) over ball end of cable
and slide them up cable towards hoist. Attach terminal clamp (90 VP) onto ball end of cable.
clamp (90 VP) is properly seated in sleeve (40).
D. Apply DC-33 lubricant to needle thrust bearing (190) and races (180 and 200), and install into
body (80).
E. Apply DC-33 lubricant to packing (170 and 170A), and install into groove in bearing retainer
(160).
F. Install bearing retainer (160) into body (80).
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G. Install spacer (210), ball bearing (220), and body (80) onto stem of hook (220).
H. With an applicator brush, spread Vibra-Tite around the stem threads of the hook. Completely
dry.
CASTELLATION.
I. Install castellated nut (150) onto stem of hook (230) and tighten until bearing is fully seated in
housing.
J. VITAL INSPECTION POINT. Back castellated nut (150) off slightly to allow
nut, with access through body (80).
K. VITAL POINT INSPECTION. Rotate hook while holding body to check for binding of
bearings (190 and 220). If binding exists, remove spring pin (130), 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 bearings (190 and 220).
L. Press bearing (120) into handwheel (130).
M. Install handwheel assembly (110) onto body (80).
N. Install body and assembled hook parts onto nut (70) by threading, or screwing, them together
until bottomed.
O. VITAL INSPECTION POINT. Install locking screws (60 VP) into nut (70) to lock
P. Push down on bumper assembly (1) to snap the bumper assembly onto sleeve (40).
Q. Apply power to hoist.
R. Run hoist to the full in position to secure to hook and bumper assembly on hoist.
S. VITAL INSPECTION POINT. Perform Hook Load Test identified in Testing and
Troubleshooting (Section 101, Paragraph 4.D.), to ensure hook (2 VP) has been properly
T. Disconnect power to hoist.
19. Assemble and install BL-5740-15 Hook Assembly (Figure 1001, Item 90, and Figure 1007,
Item 2) as follows:
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INSTALLING TUBE (230), KEEPER (240), AND SPRING (250). THE SPRING IS
WHEN INSTALLING TUBE.
(1) Install spring (250) and keeper (240) onto hook (260), and secure with tube (230).
both ends of tube (230 VP) to hold keeper and spring on hook.
HOIST.
B. VITAL INSPECTION POINT. Install nut (70) and sleeve (40) over ball end and slide
nut up cable towards hoist. Attach terminal clamp (90 VP) onto ball end of cable. Secure
terminal clamp with ring (100 VP), and slide sleeve over terminal clamp. See Figure 702.
D. Apply DC-33 lubricant to needle thrust bearing (180) and races (170 and 190), and install into
body (80).
E. Apply DC-33 lubricant to packing (160 and 160A), and install into groove in bearing retainer
(150).
F. Install bearing retainer (150) into body (80).
G. Install spacer (200), ball bearing (210), and body (80) onto stem of hook (220).
H. With an applicator brush, spread Vibra-Tite around the stem threads of the hook. Completely
dry.
CASTELLATION.
I. Install castellated nut (140) onto stem of hook (220) and tighten until bearing is fully seated in
housing.
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January 11, 2005
J. VITAL INSPECTION POINT. Back castellated nut (140) off slightly to allow
K. VITAL POINT INSPECTION. Rotate hook while holding housing to check for binding
of bearings (180 and 210). If binding exists, remove spring pin (130), and back off castellated
binding of bearings again. Repeat binding check and repositioning of nut as necessary until
L. Remove backing of cable size label (120) to expose adhesive, apply alcohol on back to
activate adhesive, and install label onto rubber bumper (110).
M. Install rubber bumper (110) onto housing (90).
N. VITAL INSPECTION POINT. Install locking screws (60 VP) into nut (70) to lock
O. Push down on bumper assembly (10) to snap the bumper assembly onto nut (70).
P. Apply power to hoist.
Q. Run hoist to the full in position to secure to hook and bumper assembly on hoist.
R. VITAL INSPECTION POINT. Perform Hook Load Test identified in Testing and
S. Disconnect power to hoist.
HOIST.
A. VITAL INSPECTION POINT. Install nut (Figure 1008, Item 70) and sleeve (40) over
ball end of cable and slide nut up cable towards hoist. Attach terminal clamp (90 VP) onto
ball end of cable. Secure terminal clamp with ring (100 VP), and slide nut over terminal
clamp. See Figure 702.
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January 11, 2005
C. Apply DC-33 lubricant to needle thrust bearing (180) and races (170 and 190), and install into
body (80).
D. Apply DC-33 lubricant to packing (160 and 160A), and install onto bearing retainer (150).
E. Install bearing retainer (150) into body (80).
F. Install spacer (200), bearing (210), and body (80) onto stem of hook (220 and 230).
G. With an applicator brush, spread Vibra-Tite around the stem threads of the hook. Completely
dry.
CASTELLATION.
H. Install castellated nut (140) onto stem of hook and tighten until bearing is fully seated in body.
I. VITAL INSPECTION POINT. Back castellated nut (140) off slightly to allow
J. VITAL POINT INSPECTION. Rotate hook while holding housing to check for binding
of bearings (180 and 210). If binding exists, remove spring pin (130), and back off castellated
binding of bearings again. Repeat binding check and repositioning of nut as necessary until
K. Remove backing of cable size label (120) to expose adhesive, apply alcohol on back to
activate adhesive, and install label onto rubber bumper (110).
L. Install rubber bumper (110) onto body (80).
M. VITAL INSPECTION POINT. Install locking screws (60 VP) into nut (70) to lock
N. Push down on bumper assembly (1) to snap the bumper assembly onto sleeve (40).
O. Apply power to hoist.
P. Run hoist to the full in position to secure to hook and bumper assembly on hoist.
Q. VITAL INSPECTION POINT. Perform Hook Load Test identified in Testing and
Troubleshooting (Section 101, Paragraph 4.D.), to ensure hook (2 or 3 VP) has been properly
R. Disconnect power to hoist.
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21. Assemble and install BL-14584-10 Hook Assembly (Figure 1001, Item 80, and Figure 1009,
Item 2) as follows:
INSTALLING RIVET (180), KEEPER (210), AND SPRING (220). THE SPRING IS
WHEN INSTALLING RIVET.
(1) Install spring (220), keeper (210), and cable assembly (190) onto hook (230), and secure
with rivet (180).
or upset end of rivet (180 VP) to hold cable assembly (190), keeper (210), and spring
(220) on hook (200).
HOIST.
B. VITAL INSPECTION POINT. Install nut (40) over ball end and slide nut up cable
towards hoist. Attach terminal clamp (80 VP) onto ball end of cable. Secure terminal clamp
with ring (90 VP), and slide nut over terminal clamp. See Figure 702.
D. Install bearing (150) and thrust washer (140) into housing (70).
E. Install flat washer (130) and housing (70) onto stem of hook (160).
F. With an applicator brush, spread Vibra-Tite around the stem threads of the hook. Completely
dry.
BACK OFF. NEVER TIGHTEN THE NUT TO REACH THE NEXT AVAILABLE
CASTELLATION.
G. Install castellated nut (120) onto stem of hook and tighten until bearing is fully seated in
housing.
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H. VITAL INSPECTION POINT. Back castellated nut (120) off slightly to allow
I. VITAL POINT INSPECTION. Rotate hook while holding housing to check for binding
J. Install rubber bumper (100) onto housing (70).
K. VITAL INSPECTION POINT. Install locking screws (60 VP) into nut (40) to lock
L. Push down on bumper assembly (1) to snap the bumper assembly onto nut (40).
M. Apply power to hoist.
O. VITAL INSPECTION POINT. Perform Hook Load Test identified in Testing and
P. Disconnect power to hoist.
22. Install labels (Figure 1002, Items 990 through 1030) as follows:
NOTE: ALL SURFACES SHALL BE CLEANED PRIOR TO INSTALLATION OF
LABELS (SEE SECTION 401 FOR CLEANING INSTRUCTIONS).
A. All typed information should be added on identification label (1020) from previously
recorded data obtained during disassembly. If information on nameplate was illegible when
removed, contact Breeze-Eastern with all known information concerning hoist (part number
and serial number, if known) for original or new data.
B. Remove backing of label to expose adhesive.
C. Apply alcohol on back to activate adhesive and install labels.
D. Coat labels with TT-L-58E, Type I, Class I Clear Gloss Lacquer.
23. Install control pendant and control pendant cable as follows:
A. Connect pendant cable (Figure 1001, Item 70) to control pendant (40 and 50).
B. Connect pendant cable (70) to controller (20 and 30).
C. Apply power to control pendant by pushing in applicable circuit breakers.
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24. Install controller as follows:

A. Install controller (20 and 30) and secure with four mounting screws (not part of System, and
not supplied by Breeze-Eastern).
B. Connect electrical connectors to controller.
C. Apply power to controller by pushing in applicable circuit breakers.
25. Install hoist onto helicopter as follows:
CAUTION: WHEN MOUNTED ON THE HELICOPTER THE HOIST WEIGHS
APPROXIMATELY 79 LB. (35.2 KG.) OR 83 LB. (37.6 KG.) WITH THE HOOK
INSTALLED. TWO INDIVIDUALS SHOULD REMOVE THE HOIST FROM THE
HELICOPTER UNLESS SUITABLE SUPPORT IS PROVIDED TO HOLD THE
WEIGHT OF THE HOIST WHEN REMOVED.
A. Install hoist (10) onto helicopter using attaching hardware (not part of System, and not
supplied by Breeze-Eastern) for four mounting points.
B. Connect electrical connectors to hoist motor, cable foul indicator and limit switch connectors.
C. Check oil level of drum assembly and two-speed mechanism and service the hoist with oil per
Checks and Inspections (Section 501).
D. Apply power to hoist by pushing in applicable circuit breakers.
26. Installation of Cable Cutter Cartridge
A. Remove spring shunt installed on pins of cartridge [replacement supplied in pressure cartridge
kit (Figure 1001, Item 60)].
B. Apply anti-seize compound, MIL-S-8660, to packing (Figure 1002, View B, Item 20) prior to
installation.
C. Install cartridge (Figure 1002, Item 10) with packing (20) and tie wire per MS33540 with
MS20995NC32.
27. Storage Instructions
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.
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
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January 11, 2005
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 hoist (Figure 1001, 10) shall be stored with packaging and preservation so that the
orientation of the four mounting points are underneath, and supporting the weight of the hoist.
All packaging for the hoist shall be identified showing the proper orientation for storage so
that the hoist is on its four mounting points.
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FITS AND CLEARANCES
1. Table 801 and Figures 801 through 803 show the allowable limits for close tolerance parts and
installation dimensions for the Rescue Hoist System. These limits are to be applied when any
doubt exists concerning the serviceability of a part as a result of visual inspection for wear or
from an improper fit during assembly and installation. When this condition exists the affected
part(s) shall be dimensionally inspected in accordance with Section 501, Checks and Inspections
and Section 601, Repair. Parts that do not meet the limits, and for which rework is not applicable,
are to be replaced.
2. The values given in the “Dimension Limits” column in Table 801 are the applicable minimum, or
maximum, permitted to ensure proper functioning of the hoist. If parts fail to meet these
requirements, the applicable parts must be replaced, unless rework of the part is applicable. The
dimensional limits should be used as a guide to assemble and install reworked parts.
3. The values shown in Table 801 are applicable to the HS-20200-511 Series Rescue Hoist System.
All dimensions shown in Figures 801 through 803 are in inches, with dimensions in millimeters
in parentheses. See the following figures contained in this section and Figures in Section 1001 for
items referenced in Table 801:
A. Figure 801 Rescue Hoist Assembly
B. Figure 802 Variable Speed Controller
C. Figure 803 Control Pendant Assembly
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Dimension Limits in Inches
Fig. No. and IPL Fig. No. Description of Location for
(Millimeters)
(in Sec. 801) and Item No. Dimensional Check
Minimum Maximum
Fig. 801 Fig. 1001, Diameter of 2 Large Hoist Mounting -- 0.377 (9.58)
Item 10 Holes (Lug “X”)
Fig. 801 Fig. 1001, Diameter of 2 Small Hoist Mounting -- 0.252 (6.40)
Item 10 Holes (Lug “Y”)
Fig. 801 Fig. 1001, Location of Hoist Mounting Holes 6.083 (154.51) 6.103 (155.02)
Item 10 Horizontally
Fig. 801 Fig. 1001, Location of Hoist Mounting Holes 1.646 (41.81) 1.666 (42.32)
Item 10 Vertically
Fig. 801 Fig. 1001, Gap in End Flanges at Hoist 0.482 (12.24) 0.488 (12.40)
Item 10 Mounting Holes
- Fig. 1002, Diameter of Tension Roller (greater 0.801 (20.34) -
Item 320 than minimum is acceptable)
- Fig. 1003, Tension Roller Endplay 0.002 (0.051) 0.010 (0.254)
Item 320
- Fig. 1002, Overrunning Clutch/ Tension Roller 0.030 (0.762) -
Items 330 Gear Clearance (greater than
and 420 minimum is acceptable)
- Fig. 1002, Gap from Switch Actuator on Cable 0.040 (1.02) 0.080 (2.03)
Item 740 Foul Indicator to top layer of cable
- Fig. 1002, Levelwind Shaft groove dimension 0.154 (3.91) 0.160 (4.06)
Item 1040
- Fig. 1002, Levelwind Follower dimension 0.148 (3.76) 0.153 (3.89)
Item 980
Fig. 802 Fig. 1001, Location of Variable Speed Controller 7.73 (196.3) 7.77 (197.4)
Item 20, 30 Mounting Holes Horizontally
Fig. 802 Fig. 1001, Location of Variable Speed Controller 6.73 (170.9) 6.77 (172.0)
Item 20, 30 Mounting Holes Vertically
Fig. 803 Fig. 1001, Diameter of Pendant Mounting Hole 0.36 (9.1) 0.40 (10.2)
Items 40, 50
- Fig. 1001, Height of Bumper Assembly at full 1.00 (25.4) 1.39 (35.3)
Item 190 in position
Table 801. Allowable Limit Values
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Figure 801. Rescue Hoist Assembly Illustration [dimensions shown in inches (with millimeters in parentheses)]
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Figure 802. Variable Speed Controller Illustration [dimensions shown in inches (with millimeters in parentheses)]
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Figure 803. Control Pendant Assembly Illustration [Dimensions shown in inches (with millimeters in parentheses)]
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SPECIAL TOOLS, FIXTURES, AND EQUIPMENT

Note: Equivalent substitutes may be used for listed items.
Tool /
Testing and
Equipment Nomenclature Use and Application Disassembly Assembly
Troubleshooting
Number
Roller Pin Removal Removal and installation of
and Installation Tool pin into roller gear and pin
BLT-10300-J
[0.094 in. (2.39 mm) in hook assembly housing / - X X
diameter punch] body.
Installation of retaining ring
Retaining (E-Ring)
to secure cable guide pin
BLT-10300-V Ring Installation Tool
that actuates Full In Limit - - X
(see Figure 901)
Switch
Remove follower in Cable
MS16995-25 8-32 x 0.375 Screw - X -
Guide Assembly.
Calibrated Weights
Rescue Hoist 250 lb. (113 kg)
(capable of additional
TE-120-1 and 600 lb. (272 kg) Rated X - -
weight increments, see
Load Tests
Figure 902)
Calibrated Weights
Rescue Hoist 250 lb. (113 kg)
(capable of three weight
TE-120-2 and 600 lb. (272 kg) Rated X - -
increments, see Figure
Load Tests
903)
Cart (for carrying Rescue Hoist 250 lb. (113 kg)
TE-120-3 weights, see Figure and 600 lb. (272 kg) Rated X - -
904) Load Tests
Table 901. Special Tools, Fixtures, and Test Equipment List
Figure 901. Retaining Ring Installation Tool
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Figure 902. TE-120-1 Calibrated Weights Figure 903. TE-120-2 Calibrated Weights
Figure 904. TE-120-3 Cart (shown with TE-120-2 Calibrated Weights)
Note: For information on the acquisition of special tools and test equipment contact:
Breeze-Eastern
700 Liberty Avenue
Union, New Jersey 07083-8107
Attention: Customer Services
Phone: (908) 686-4000 or (Toll-Free in US and Canada): 1-800-929-1919
Fax: (908) 688-6495
E-mail: productsupport@breeze-eastern.com
Web site: www.breeze-eastern.com
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ILLUSTRATED PARTS LIST
1. Introduction
A. Purpose
This section provides illustrations and parts breakdown of all parts of the assemblies shown that
can be disassembled, repaired, or replaced and reassembled.
B. Explanation and Usage of Section
(1) Assembly Order Indenture System
This indenture system used in the parts list shows the relationship of one part to another.
For a given item, the number of indentures depicts the relationship of the item to the
associated next higher assembly as follows:
1 2 3 4
Assembly
• Detail Parts for Assembly
• • Subassembly
• • • Detail Parts for Subassembly
(2) Part Numbering System
The part numbering system consists of each part number identifier by which a part may be
ordered or procured.
(3) Effectivity Code
Reference letters (A through Z except I and O) are assigned to the EFF. CODE column to
each top assembly in each IPL figure. The reference letter is also shown in EFF. CODE
column for each part used on the corresponding top assembly, or left blank, if used on all
top assemblies.
(4) Parts Replacement Data
The interchangeability between parts is identified in the NOMENCLATURE column of the
parts list. A list of terms used to show interchangeability and their definition is as follows:
Term Abbreviation Definition
Optional OPT Optional to and interchangeable with other parts in the same
number variant group or other item number as designated.
Alternate ALT Alternate designates a definitive sequence of parts. The part is
optional to and interchangeable with other parts in the same
number variant group or other item number as designated.
Preferred PREF When an alternate part is listed, the preferred part will be
identified in the same item number variant group or other item
number as designated.
(5) Items Not Illustrated
Items not illustrated are indicated by a dash (-) ahead of the item number in the FIG. &
ITEM NO. Column.
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January 11, 2005
(6) Units per Assembly
The UNITS PER ASSY. column shows the quantity 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.
(7) Alpha Variant Item Numbers
(a) Alpha variants (A through Z except I and O) are assigned to existing item numbers
when necessary to show:
1. Added items.
2. Service bulletin modifications.
3. Configuration differences.
4. Optional or alternate parts.
5. Product improvement parts (non-service bulletin).
(b) Alpha variant item numbers are not shown on the exploded views when the appearance
and location of these items are the same as the basic items.
C. Vendors
V64249 Lifesaving Systems Corporation
220 Elsberry Road, Apollo Beach, Florida 33572-2289
Phone No.: (813) 645-2748 Fax No. (813) 645-2768
Website: www.lifesavingsystems.com E-mail: lsc@combase.com
2. Notes:
A. Terminal Clamp (Figures 1003 and 1005, Item 100, Figures 1004, 1006, 1007 and 1008, Item
90, and Figure 1009, Item 80) consists of a two-piece, matched set clamp machined as an
assembly and secured by a ring (Figures 1003 and 1005, Item 110, Figures 1004, 1006, 1007
and 1008, Item 100, and Figure 1009, Item 90). Each half of the clamp cannot be purchased
separately and must be purchased together. The ring can be ordered separately, but must be
replaced if the clamp is in need of replacement.
STORED, AND HANDLED IN COMPLIANCE WITH ALL LOCAL STANDARDS
AND REGULATORY PRACTICES.
B. Pressure Cartridge Kit (Figure 1001, Item 60 and Figure 1002, View B, Item 10) consists of the
pressure cartridge, contained in a hermetically sealed container, and packing (Figure 1002,
View B, Item 20). The cartridge only can be purchased as part of the kit due to the longer shelf
life it has in the container. The packing must be replaced when a new cartridge is installed.
However, if packing needs to be replaced due to damage, or wear, it can be ordered separately.
C. Anvil (Figure 1002, View B, Item 130), cotter pin (140), cable cutter (150), and O-Ring (160)
must be replaced whenever the cable cutter cartridge has been fired. These items can be
purchased separately.
D. Gear Guard (Figure 1002, View A, Item 390) is a two piece, matched set machined as an
assembly. Each half of the gear guard cannot be purchased separately and must be purchased
together.
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January 11, 2005
← 10
20
30
↓
40 → 50 → 60 →
70 →
Figure 1001. Rescue Hoist Systems

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January 11, 2005
NUMERICAL PARTS LIST INDEX
FIG. AND NOMENCLATURE EFF. UNITS
ITEM NO. PART NUMBER 1234 CODE PER ASSY.
1001-
-1 HS-20200-511-01 HOIST SYSTEM, RESCUE A RF
-2 HS-20200-511-02 HOIST SYSTEM, RESCUE B RF
10 BL-20200-511 • Hoist Assembly, Rescue 1
20 EC-14000-1 • Variable Speed Controller A 1
30 EC-14000-3 • Variable Speed Controller B 1
40 CP-600-1 • Control Pendant Assembly A 1
50 CP-700-1 • Control Pendant Assembly B 1
60 KT-198 • Kit, Pressure Cartridge 1
70 EC-14170-1 • Cable Assembly, Pendant (OPT)
-80 BL-14584-10 • Hook Assembly (OPT)
-90 BL-5740-15 • Hook Assembly (OPT)
-100 HK-112-1 • Hook Assembly (OPT)
-190 BL-7720 • Bumper Assembly (OPT)
- (not illustrated)
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January 11, 2005
FIG. AND NOMENCLATURE UNITS
ITEM NO. PART NUMBER 1234 PER ASSY.
1002-
-1 BL-20200-511 RESCUE HOIST ASSEMBLY RF
10 KT-198 • Cartridge (See Note B, pg. 1002) 1
20 MS28778-5 • • Packing (See Note B, pg. 1002) 1
30 BL-6260 • Cable Assembly 1
40 MS51957-44 • Screw 4
50 MS35265-44 • Screw 2
60 AL-1256-C62 • Washer 6
70 MS21919WCH4 • Clamp 1
80 MS25036-103 • Terminal, Lug 1
90 BL-6255 • Cover, Limit Switch 1
100 BL-4648-2 • Gasket 1
110 MS24547-1 • Switch 6
120 AN565DC4H3 • Setscrew 2
130 BL-6329 • Anvil (See Note C, pg. 1002) 1
140 MS9245-10 • Pin, Cotter 1
150 BL-6331 • Cutter, Cable 1
160 AN6227-10 • O-Ring 1
165 MS24665-86 • Pin, Cotter 1
170 MS21083C4 • Nut, Self Locking 1
180 BL-6909 • Stop, Cable Guide 1
190 BL-6910-2 • Bushing, Cable Guide 1
200 MS16995-36 • Screw 2
210 BL-3950-2 • Guide Bar 1
220 BL-6742 • Plunger, Cable Pressure Roller 1
230 BL-6741 • Spring, Compression 1
240 BL-10778-2 • Clamp, Gear Guard 1
250 MS16995-17 • Screw 2
260 AL-1256-C59 • Washer 4
270 Y-1176-2-68S • Ring, Retaining 1
280 MS171528 • Pin, Spring 1
290 BL-6468 • Shaft, Inner Roller 1
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NUMERICAL PARTS LIST INDEX (continued)
1002-
300 Y-1076-5-2 • Thrust Washer 1
310 Y-1076-5-4 • Thrust Washer 1
315 BL-2095-R225 • Shim [0.002 in. (0.051 mm.) thickness] AR
315A BL-2095-R226 • Shim [0.003 in. (0.076 mm.) thickness] AR
315B BL-2095-R227 • Shim [0.005 in. (0.127 mm.) thickness] AR
315C BL-2095-R228 • Shim [0.010 in. (0.254 mm.) thickness] AR
320 BL-6739 • Shaft Assembly, Tension Roller 1
330 BL-6468 • Gear, Roller 1
340 MS16997-23 • Screw 2
350 AN565B8H5 • Setscrew 1
360 BL-10698-2 • Block 1
370 MS16995-28 • Screw 1
380 AN960C8L • Washer 1
390 BL-10684-2 • Gear Guard (See Note D, pg. 1002) 1
400 NAS1224C16L • Bolt 1
410 BL-8033 • Spacer 1
420 BL-6825 • Clutch Assembly, Overrunning 1
430 MS51957-27 • Screw 3
450 BL-12918-1 • Cyclocentric Assembly 1
460 BL-9146 • Cam Follower Assembly 1
470 MS21083C4 • Nut, Self-Locking 1
480 Y-1021-4-1512 • Chain 1
490 MS16996-24 • Screw 4
500 AL-1256-C86 • Washer 4
510 BL-8053-1 • Motor Assembly 1
520 Y-1126-132 • O-Ring 1
530 MS51957-3 • Screw 3
540 BL-12915-1 • Bracket, Potentiometer 1
550 BL-12927-1 • Bracket, Mounting, Switch 1
560 BL-12914-1 • Bracket, Mounting, Switch 1
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1002-
570 MS51957-15 • Screw, Pan Head 4
590 Y-1184-7-1 • Actuator, Roller Leaf 4
600 MS51959-8 • Screw, Flat Countersink Head 2
620 AL-1256-C85 • Washer, Flat 8
630 WA-138-33 • Nut, Self-Locking 4
640 BL-6911 • Cover 1
650 BL-6912 • Gasket, Cover 1
670 MS15795-803 • Washer 3
680 BL-6074 • Actuator, Roller Leaf 1
700 AN936A2 • Washer, Tooth Lock 2
710 MS16633-4018 • Ring, Retaining 1
720 BL-6914 • Pin 1
730 BL-5805 • Spring 1
740 BL-14790-1 • Actuator, Cable Foul Switch 1
750 MS27216-5 • Switch 6
770 MS21042-02 • Nut, Miniature 4
780 AN565AC6H6 • Setscrew 2
790 Y-1182-49-1 • Spring, Extension 2
800 AN107506 • Plug 2
810 Y-1125-1-7 • Seal 2
820 MS51957-13 • Screw 3
830 Y-1249-1-1 • Cleat, Potentiometer Mount 3
840 BL-12668-3 • Potentiometer Assembly (R1) 1
850 M83248/1-003 • O-Ring 2
860 BL-6753 • Shaft, Roller 4
870 BL-6757 • Support 1
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January 11, 2005
1002-
880 BL-6752 • Spacer 6
890 BL-6759 • Roller Assembly 1
900 AJ-9800-31-2 • • Bearing, Ball 2
910 BL-6758 • • Roller 1
920 BL-6760 • Roller Assembly 2
930 AJ-9800-31-3 • • Bearing, Ball 4
940 BL-6761 • • Roller 2
950 Y-1176-1-68S • Retaining Ring 1
960 BL-3953 • Spacer, Back-Up 1
970 Y-1047-1-6 • Washer, Spring 1
980 BL-3953 • Follower 1
990 BL-9880 • Label, Oil 1
1000 BL-8966 • Label, Oil 1
1010 BL-2294 • Label 1
1020 BL-12994-1 • Label, Identification 1
1030 BL-13686-1 • Label, Cycle Counter 1
1040 BL-3880 • Level Wind Shaft 1
1050 BL-6235 • Sprocket, Level Wind Shaft 1
1060 MS51957-18 • Screw 2
1070 BL-12912-1 • Cam, Full Out Limit Switch 1
1080 MS51957-15 • Screw 3
1090 BL-12911-1 • Cam, Intermediate Limit Switch 1
1100 RJR26FW103P • Potentiometer, Trim (R3) 1
1110 BL-4626 • Sprocket, Drive 1
- (not illustrated)
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Figure 1003. HK-116 Series Swivel Hook Assemblies
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1003-
1 HK-116-5 SWIVEL HOOK ASSEMBLY A RF
2 HK-116-6 SWIVEL HOOK ASSEMBLY B RF
10 BL-7720 • Bumper Assembly 1
20 BL-7675-1 • • Spring, Compression 1
30 BL-14390-1 • • Retainer, Bumper 1
40 BL-12789-1 • • Bumper, Over Travel 1
50 HK-116-1 • Hook Assembly, Swivel A 1
50A HK-116-2 • Hook Assembly, Swivel B 1
60 BL-11685-1 • • Nut 1
70 MS24665-88 • • Pin, Cotter 2
80 BL-9920 • • Screw, Locking 2
90 BL-11686-1 • • Housing, Hook 1
100 BL-11682-1 • • Clamp, Terminal (See Note A, pg. 1002) 1
110 BL-4718 • • • Ring (See Note A, pg. 1002) 1
120 BL-4719 • • Bumper 1
130 BL-14792-1 • • Pin, Spring 1
140 BL-8089 • • Nut, Castellated 1
150 AN960C816 • • Washer, Flat 1
160 BL-11684-2 • • Washer, Thrust 1
170 AJ-9800-95-8 • • Bearing, Ball 1
180 410-F • • Hook, Swivel (V64249), B-E PN Y-1231-9-1 A 1
190 411-F • • Hook, Swivel (V64249), B-E PN Y-1231-10-1 B 1
- (not illustrated)
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Figure 1004. HK-118 Series Hook Assemblies
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January 11, 2005
1004-
1 HK-118-1 HOOK ASSEMBLY A RF
2 HK-118-2 HOOK ASSEMBLY B RF
50 BL-10892 • Nut 1
60 MS24665-88 • Pin, Cotter 2
70 BL-9920 • Screw, Locking 2
80 BL-9197 • Housing, Hook 1
90 BL-15585-1 • Clamp, Terminal (See Note A, pg. 1002) 1
100 BL-4718 • • Ring (See Note A, pg. 1002) 1
110 BL-14827-1 • Spacer, Nut A 1
120 BL-13677-1 • Handwheel Assembly A 1
130 AJ-9800-23-46 • • Bearing A 1
140 BL-13676-1 • • Handwheel A 1
150 BL-4719 • Bumper B 1
160 BL-14792-2 • Pin, Spring 1
170 BL-8089 • Nut, Castellated 1
180 AN960C816 • Washer, Flat 1
190 BL-7016-4 • Washer, Thrust 1
200 AJ-9800-95-8 • Bearing, Ball 1
210 BL-10524 • Hook, Swivel 1
220 MS17985C407 • • Pin, Quick Release 1
230 MS20613-3C7 • • Rivet 1
240 MS-18027-12 • • Bushing 1
250 AL-1256-143 • • Washer, Flat 2
260 BL-10524-10 • • Lanyard Assembly 1
270 Y-1096-7-1 • • • Lanyard 1
280 Y-1174-1-1 • • • Crimp 2
-290 BL-10523 • • Hook, Rescue Hoist 1
300 MS20613-4C16 • • • Rivet 1
310 MS18027-4 • • • Latch (Keeper) 1
320 MS18027-7 • • • Spring 1
330 MS18027-11 • • • Bushing 1
340 No Number • • • Hook 1
- (not illustrated)
25-61-00
Page 1013
January 11, 2005
25-61-00
Page 1014
January 11, 2005
1005-
1 HK-121-5 SWIVEL HOOK ASSEMBLY A RF
2 HK-121-6 SWIVEL HOOK ASSEMBLY B RF
50 HK-121-1 • Hook Assembly, Swivel A 1
50A HK-121-2 • Hook Assembly, Swivel B 1
60 BL-11685-1 • • Nut 1
70 MS24665-88 • • Pin, Cotter 2
80 BL-9920 • • Screw, Locking 2
90 BL-11686-1 • • Housing, Hook 1
100 BL-11682-1 • • Clamp, Terminal (See Note A, pg. 1002) 1
110 BL-4718 • • • Ring (See Note A, pg. 1002) 1
120 BL-14827-1 • • Spacer, Nut A 1
130 BL-13677-1 • • Handwheel Assembly A 1
140 AJ-9800-23-46 • • • Bearing A 1
150 BL-13676-1 • • • Handwheel A 1
160 BL-4719 • • Bumper B 1
170 BL-14792-1 • • Pin, Spring 1
180 BL-8089 • • Nut, Castellated 1
190 AN960C816 • • Washer, Flat 1
200 BL-11684-2 • • Washer, Thrust 1
210 AJ-9800-95-8 • • Bearing, Ball 1
220 BL-15704-2 • • Hook 1
- (not illustrated)
25-61-00
Page 1015
January 11, 2005
Figure 1006. HK-112-1 Hook Assembly
25-61-00
Page 1016
January 11, 2005
1006-
1 BL-7720 BUMPER ASSEMBLY A RF
10 BL-7675-1 • • Spring, Compression A 1
20 BL-14390-1 • • Retainer, Bumper A 1
30 BL-12789-1 • • Bumper, Over Travel A 1
40 BL-5449 • Sleeve B 1
50 MS24665-88 • Pin, Cotter B 2
60 BL-9920 • Screw, Locking B 2
70 BL-5448-1 • Nut B 1
80 BL-4706 • Body B 1
90 BL-4708-1 • Clamp, Terminal (See Note A, pg. 1002) B 1
100 BL-4718 • • Ring (See Note A, pg. 1002) B 1
110 BL-13677-1 • Handwheel Assembly B 1
120 AJ-9800-23-46 • • Bearing, Ball B 1
130 BL-13676-1 • • Hand Ring B 1
140 BL-14792-1 • Pin, Spring B 1
150 AN310C7 • Nut, Castellated B 1
160 BL-4707 • Retainer, Bearing B 1
170 MS9021-022 • Packing, Preformed (PREF) B 1
170A AS3578-022 • Packing, Preformed (ALT) B 1
180 BL-4712-3 • Upper Race, Needle Thrust Bearing B 1
190 BL-4712-1 • Bearing, Needle Thrust B 1
200 BL-4712-2 • Lower Race, Needle Thrust Bearing B 1
210 BL-3915-11 • Spacer B 1
220 BL-4720 • Bearing, Ball B 1
230 BL-4810-4 • Hook, Swivel B 1
240 Y-1223-1-1 • • Pin, Quick Release B 1
250 BL-8062 • • Cable Assembly B 1
260 Y-1174-1-1 • • Sleeve B 1
270 BL-5497 • • Tube B 1
280 BL-4808-2 • • Keeper B 1
290 BL-4809 • • Spring, Keeper B 1
300 BL-4807 • • Hook B 1
- (not illustrated)
25-61-00
Page 1017
January 11, 2005
Figure 1007. BL-5740-15 Hook Assembly
25-61-00
Page 1018
January 11, 2005
1007-
2 BL-5740-15 HOOK ASSEMBLY B RF
10 BL-7675-1 • Spring, Compression A 1
20 BL-14390-1 • Retainer, Bumper A 1
30 BL-12789-1 • Bumper, Over Travel A 1
40 BL-5449 • Sleeve B 1
50 MS24665-88 • Pin, Cotter B 2
70 BL-5448-1 • Nut B 1
80 BL-4706 • Body B 1
110 BL-4719 • Bumper B 1
120 BL-10192-1 • Label, Cable Size B 1
130 BL-14792-1 • Pin, Spring B 1
140 AN310C7 • Nut, Castellated B 1
150 BL-4707 • Retainer, Bearing B 1
160 MS9021-022 • Packing, Preformed (PREF) B 1
160A AS3578-022 • Packing, Preformed (ALT) B 1
170 BL-4712-3 • Race, Needle Thrust Bearing B 1
180 BL-4712-1 • Bearing, Needle Thrust B 1
190 BL-4712-2 • Race, Needle Thrust Bearing B 1
200 BL-3915-11 • Spacer B 1
210 BL-4720 • Bearing, Ball B 1
220 BL-4810-6 • Hook, Swivel B 1
230 BL-5497 • • Tube B 1
240 BL-14047-1 • • Keeper, Swivel Hook B 1
250 BL-4809 • • Spring, Keeper B 1
260 BL-4807 • • Hook B 1
- (not illustrated)
25-61-00
Page 1019
January 11, 2005
25-61-00
Page 1020
January 11, 2005
1008-
3 HK-115-2 HOOK ASSEMBLY C
40 BL-5449 • Sleeve BC 1
50 MS24665-88 • Pin, Cotter BC 2
60 BL-9920 • Screw, Locking BC 2
70 BL-5448-1 • Nut BC 1
80 BL-4706 • Body BC 1
90 BL-4708-1 • Clamp, Terminal (See Note A, pg. 1002) BC 1
100 BL-4718 • • Ring (See Note A, pg. 1002) BC 1
110 BL-4719 • Bumper BC 1
120 BL-10192-1 • Label, Cable Size BC 1
130 BL-14792-1 • Pin, Spring BC 1
140 AN310C7 • Nut, Castellated BC 1
150 BL-4707 • Retainer, Bearing BC 1
160 MS9021-022 • Packing, Preformed (PREF) BC 1
160A AS3578-022 • Packing, Preformed (ALT) BC 1
170 BL-4712-3 • Race, Needle Thrust Bearing BC 1
180 BL-4712-1 • Bearing, Needle Thrust BC 1
190 BL-4712-2 • Race, Needle Thrust Bearing BC 1
200 BL-3915-11 • Spacer BC 1
210 BL-4720 • Bearing, Ball BC 1
220 410-F • Hook, Swivel (V64249), B-E PN Y-1231-9-1 B 1
230 411-F • Hook, Swivel (V64249), B-E PN Y-1231-10-1 C 1
- (not illustrated)
25-61-00
Page 1021
January 11, 2005
25-61-00
Page 1022
January 11, 2005
1009-
2 BL-14584-10 HOOK ASSEMBLY B RF
40 BL-11685-1 • Nut B 1
50 MS24665-88 • Pin, Cotter B 2
70 BL-11686-1 • Housing, Hook B 1
100 BL-4719 • Bumper B 1
110 BL-14792-1 • Pin, Spring B 1
120 BL-8089 • Nut, Castellated B 1
130 AN960C816 • Washer, Flat B 1
140 BL-11684-2 • Washer, Thrust B 1
150 AJ-9800-95-8 • Bearing, Ball B 1
160 HK-201-1 • Hook Assembly B 1
170 Y-1223-1-1 • • Pin, Quick Release B 1
180 MS20613-4C16 • • Rivet B 1
190 Y-1096-11-2 • • Cable Assembly B 1
-200 HK-201-10 • • Hook B 1
210 MS18027-4 • • • Keeper B 1
220 MS18027-7 • • • Spring B 1
230 No Number • • • Hook B 1
- (not illustrated)
25-61-00
Page 1023
January 11, 2005
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:
Initiator: Title:
Breeze Eastern Use Only
Date Received: Received By: Tracking Number:

Forwarded To: Date: Customer Receipt Message:
BE Research Result:
Response to Customer:
Engineering Support: Date: Product Support: 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 Service
Address: Robert Mabli - Trace Worldwide Corp. Date: 02/27/07 Manual: TD-04-006
Trace-Goko LLC
116 Avenue I Manual Revision: Original Revision Date: Jan. 11, 2005
Redondo Beach, CA 90277 Section 501 Page 517 Para. K
Phone: 310-791-5500
Figure 1002, page Table 1002 Item 1040, pages
Fax: 310-791-5510
1005 1005/1009
E Mail: RMabli@traceww.com
Part Number Affected: Rescue Hoist Sys. HS-20200-511
Series Rescue Hoist, BL-20200-511, and Levelwind BL-3880.
Discrepancy (Provide as much detail as possible):
Excessive wear is occurring on the levelwind shaft and follower due to the attitude of the helicopter hoist mount. Request grease be
applied to reduce wear?
Initiator: Gary Olson Title: Senior VP Marketing

Date Received: Feb. 26, 07 Received By: Tom McLoughlin – Tracking Number: TD04006TPDR022707001
Senior VP Engineering
Forwarded To: Robert Kajor Date: 02/26/07 Customer Receipt:
BE Research Result:
B-E agrees to the application of MIL-G-21164 grease (NATO Code # G-353) to the levelwind shaft and follower to reduce wear.
Response to Customer: This TPDR will be attached to the manual and this change will be incorporated at the next revision.
Add to Section 501, “Checks and Inspections,” page 517, Paragraph K .
CAUTION: Do not over grease / lubricate the levelwind shaft, which may capture excessive contamination i.e. dirt, sand, dust, soot, etc.
The levelwind shaft should be clean of contaminants. Inspect on pre-flight to ensure any grease contaminants / particles do
not impede the operation of the Rescue Hoist. If contaminants are found clean and regrease the levelwind shaft.
Using a brush, or equivalent, apply a light film of MIL-G-21164 grease (NATO Code # G-353) grease to the level wind shaft (BL-3880).
Reapply as necessary.
Add to Section 501, “Checks and Inspections,” page 517, Paragraph L.
If applicable, check for grease contamination on the levelwind shaft. If contaminants are found clean and regrease the levelwind shaft.
Engineering Services: Robert Kajor Date: 02/27/07 Customer Services: G. Olson, Z. Date: 02/27/07
Varsanyi. C. Duncan, P. Lehrer

Address: Robert Mabli - Trace Worldwide Corp. Date: 02/27/07 Manual: TD-04-006
Trace-Goko LLC
116 Avenue I Manual Revision: Original Revision Date: Jan. 11, 2005
Redondo Beach, CA 90277 Section 501 Page 517 Para. K
Phone: 310-791-5500
Figure 1002, page Table 1002 Item 1040, pages
Fax: 310-791-5510
1005 1005/1009
E Mail: RMabli@traceww.com
Part Number Affected: Rescue Hoist Sys. HS-20200-511
Series Rescue Hoist, BL-20200-511, and Levelwind BL-3880.
Excessive wear is occurring on the levelwind shaft and follower due to the attitude of the helicopter hoist mount. Request grease be
applied to reduce wear?
Initiator: Gary Olson Title: Senior VP Marketing

Date Received: Feb. 26, 07 Received By: Tom McLoughlin – Tracking Number: TD04006TPDR022707001
Senior VP Engineering
BE Research Result:
B-E agrees to the application of MIL-G-21164 grease (NATO Code # G-353) to the levelwind shaft and follower to reduce wear.
Response to Customer: This TPDR will be attached to the manual and this change will be incorporated at the next revision.
Add to Section 501, “Checks and Inspections,” page 517, Paragraph K .
CAUTION: Do not over grease / lubricate the levelwind shaft, which may capture excessive contamination i.e. dirt, sand, dust, soot, etc.
The levelwind shaft should be clean of contaminants. Inspect on pre-flight to ensure any grease contaminants / particles do
not impede the operation of the Rescue Hoist. If contaminants are found clean and regrease the levelwind shaft.
Using a brush, or equivalent, apply a light film of MIL-G-21164 grease (NATO Code # G-353) grease to the level wind shaft (BL-3880).
Reapply as necessary.
Add to Section 501, “Checks and Inspections,” page 517, Paragraph L.
If applicable, check for grease contamination on the levelwind shaft. If contaminants are found clean and regrease the levelwind shaft.
Engineering Services: Robert Kajor Date: 02/27/07 Customer Services: G. Olson, Z. Date: 02/27/07
Varsanyi. C. Duncan, P. Lehrer

CAGE CODE 08484
700 Liberty Avenue SIL05 Maintenance
Union, NJ 07083
05/15/07, Original Release
SERVICE INFORMATION LETTER Page 1 of 2
PILOT AND CREW CONTROL PANELS AND ELECTRONICS CLEANING

ADVISORY
SUBJECT: Breeze-Eastern is providing clarification on the proper cleaning techniques for Pilot and
Crew Control Panels, Electronic Controllers, Pendants, etc.
I. INFORMATION.
A. Reason.
It is recommended that when the aircraft is being washed / cleaned, internally or externally, that
the Pilot and Crew Control Panels, Electronic Controllers, Pendants, etc. be adequately protected /
covered from over spray, to assure that the electronic components do not get wet, or water soaked.
Although some category of “controllers” are environmentally sealed against these environments if
the electronic components take on contaminants internally by directly spraying water, cleaning
solvents, soaps, minerals, etc., it may create a conductive path between the various internal
circuits creating erroneous commands and unwanted effects.
B. Effectivity.
This Service Information Letter (SIL) pertains to all Pilot and Crew Control Panels, Electronic
Controllers, Pendants, etc.
C. Precautions.
The following precautions are recommended:
1. Adequately protect / cover the electronics during aircraft, internal or external, cleaning
operations.
2. Do not immerse the Pilot and Crew Control Panels, Electronic Controllers, Pendants, etc. in any
type of fluid.
3. Do not use a high pressure spray on any surface of the Pilot and Crew Control Panels,
Electronic Controllers, Pendants, etc.
NOTICE: This Service Information Letter 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 ensure compliance with this submittal by the
recipient, and all other end users, 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.
CAGE CODE 08484
700 Liberty Avenue SIL05 Maintenance
Union, NJ 07083
05/15/07, Original Release
SERVICE INFORMATION LETTER Page 2 of 2
PILOT AND CREW CONTROL PANELS AND ELECTRONICS CLEANING

ADVISORY
4. Clean the Pilot and Crew Control Panels, Electronic Controllers, Pendants, etc. by wiping with a
clean cloth and isopropyl alcohol, or an equivalent, non-flammable, non-corrosive, solution
suitable for electrical cleaning applications.
D. Contacts / Further Information.
Any questions concerning this Service Information Letter should be directed to Breeze-Eastern
Customer Services listed below:
Breeze-Eastern Corporation
Attention: Customer Services
700 Liberty Avenue
Union, NJ 07083-8198 USA
Phone: Local calls use 908-206-3901, or 908-206-3891.
In the USA (except New Jersey) and Canada call toll free 1-800-929-1919.
Fax: 908-688-6495
E-Mail Address: customer.services@breeze-eastern.com
Web Site: www.breeze-eastern.com.
Service Information Letter 05 Maintenance

Use or disclosure of data contained on this sheet is subject to the restriction on the title page of this report.
Breeze-EasternA DIVISION OF
CAGE CODE 08484
TransTechnology Corporation 700 Liberty Avenue SB BL-4712-1,-2,-3 -25-01
SERVICE BULLETIN Union NJ, 07083 USA Rev. B. 04/22/05
HIGHLIGHTS SHEET
Part Number BL-4712-1 Bearing, Needle Thrust - Hook Assembly, and

Part Numbers BL-4712-2 and BL-4712-3 Race, Thrust - Hook Assembly
TO: HOLDERS OF SERVICE BULLETIN BL-4712-1,-2,-3 -25-01, Revision A, Dated 03/01/04.
THIS IS TO INFORM YOU OF THE RELEASE OF SERVICE BULLETIN

BL-4712-1, -2, -3 -25-01, Revision B, Dated 04/22/05.
HIGHLIGHTS SHEET
Pages that have been revised are outlined below together with the highlights of the revision.
Please delete the original issue and enter Revision B, dated April 22, 2005 into your records.
PAGE/ PARAGRAPH DESCRIPTION OF CHANGE

Page 6, Table 2. Maintenance Publication HK-112-1 Hoist (BL) and System (HS) column
Matrix changed to N/A, and moved to HK-115-1. Combined
HK-115-2 with HK-115-1. Changed HK-115-2 to
HK-117-1. Removed extra row. Updated table to
include additional HS-29700 configurations.
Page 3, Paragraph F, Material. Change Product Support to Customer Services to
reflect name change.
All Repaginated as necessary
NOTICE: This Service Bulletin contains Breeze-Eastern, a Division of TransTechnology 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.
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.
Breeze-EasternA DIVISION OF
CAGE CODE 08484
TransTechnology Corporation 700 Liberty Avenue SB BL-4712-1,-2,-3 -25-01
SERVICE BULLETIN Union NJ, 07083 USA Rev. B. 04/22/05, Page 1 of 46

SUBJECT: Hoist operators should be aware of the potential Needle Thrust Bearing and Thrust Race corrosion
in Hook 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.
I. PLANNING INFORMATION.
A. Effectivity.
This Service Bulletin (SB) pertains to Needle Thrust Bearing PN BL-4712-1, and its associated Thrust
Races PN’s BL-4712-2 and BL-4712-3, utilized in the following Hook Assemblies, Hoist, and Winch
Systems. See Table 1, “Effectivity Matrix.”
Table 1. Effectivity Matrix
BL-4740-1 BL-5740-8 BL-5740-16 BL-7480-4 BL-14831-1 BL-5100-12 HS-5100-300
BL-4740-2 BL-5740-11 BL-5750-2 BL-7480-5 HK-112-1 BL-5100-14 HS-5100-301
BL-4740-3 BL-5740-12 BL-7480 BL-12877-1 HK-115-1 BL-5100-15 HS-5100-370
BL-5740-1 BL-5740-14 BL-7480-2 BL-12900-1 HK-115-2 BL-5100-16
BL-5740-7 BL-5740-15 BL-7480-3 BL-12900-2 HK-117-1 BL-5100-17
B. Reason.
After exposure to moisture (immersion in water, or high humidity environments) there have been
isolated cases of corrosion, which may result in the binding of the bearing in Hook Assemblies utilizing
the Needle Thrust Bearings, PN BL-4712-1, and associated Thrust Races, PN’s BL-4712-2 and
BL-4712-3, when not properly maintained. See Figure 1. It is imperative for the proper operation of the
Hook Assembly that the bearings rotate freely and smoothly, without binding.
Figure 1. Example of Corrosion on Hook Assembly Parts.
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.
Breeze-Eastern A DIVISION OF
CAGE CODE 08484
TransTechnology Corporation 700 Liberty Avenue SB BL-4712-1,-2,-3, -25-01

C. Description.
Needle Thrust Bearing PN BL-4712-1, and Thrust Races PN’s BL-4712-2 and BL-4712-3 are
manufactured from 52100 steel. If the Hook Assembly and Thrust Race parts are immersed in water, or
operated in a high humidity environment, and not disassembled, rinsed with fresh water, cleaned, dried,
relubricated, and reassembled after every rescue / training / cargo loading mission, per the Operation
and Maintenance instructions, or equivalent supporting documentation, corrosion may occur. If
inspection reveals a corroded bearing, the bearing must be replaced.
Instructions, or maintenance manual references, are provided to disassemble, inspect, relubricate (if
necessary), and reassemble the affected hook assemblies.
D. Compliance Recommendation.
This Service Bulletin shall be accomplished at the next available aircraft maintenance action, but no
more than twenty-five (25) helicopter flight hours, or three months whichever comes first. The
inspection shall be performed every three (3) months thereafter, unless the hook assembly has been
immersed in water, then it shall be accomplished after completion of each such mission.
E. Manpower.
The hook assembly inspection is estimated to take one (1) maintenance technician approximately twenty
(20) minutes to disassemble, inspect, relubricate (if necessary), reassemble, and test the hook assembly.
F. Material – Cost and Availability.
Hardware materials are not required. This SB is an inspection directive.
NOTE: The recommended lubrication, unless otherwise specified, for the Hook Assembly parts, i.e.
Needle Thrust Bearing PN BL-4712-1, Thrust Races PN’s BL-4712-2 and BL-4712-3, etc., is
Molykote 33 Grease, or equivalent, to specifications A-A-59173, or MIL-G-46886. Molykote 33
Grease is available from the Dow Corning Corporation at the contacts listed below:
Dow Corning Corporation

Customer Service Department
Midland, Michigan 48686-0994 U.S.A.
Phone Number: (517) 496-6000
Web Site: www.dowcorning.com
Service Bulletin BL-4712-1, BL-4712-2, & BL-4712-3 ATA 100 Format

CAGE CODE 08484

Any questions pertaining to this SB should be directed to Breeze-Eastern’s Customer Services contacts
listed below
Breeze-Eastern Phone Number: (908) 686-4000, Ext. 3897, or 3891.
700 Liberty Avenue 1-800-929-1919 (Toll-Free US and Canada only)
Union, New Jersey 07083-8198 USA Fax Number: (908) 688-6495
E-Mail: productsupport@breeze-eastern.com
Web Site: www.breeze-eastern.com
G. Tooling - Price and Availability.
Not applicable.
H. Weight and Balance.
Not applicable.
I. Electrical Load Data.
Not affected.
J. Software Accomplishment Summary.
Not applicable.
K. References.
Please refer your Hook Assembly, Hoist, and Winch System part numbers to Table 2, Maintenance
Publication Matrix. Applicable Operation and Maintenance Manuals are listed, which provide the
necessary maintenance instructions. If there is no publication listed for your component, specific
instructions are provided in Appendix A.

CAGE CODE 08484

Table 2. Maintenance Publication Matrix.

Other Next Operation and Appendix A
Higher Hoist/Winch System Maintenance Manual Page & Figure
Hook PN Hoist/Winch PN Assembly PN PN Number Reference No.
BL-12877-1 BL-30700-1 N/A HS-30700-1 TD-93-008
WE-5650-3 N/A WE-5651-3 No Manual Page 8, Figure 2
BL-12900-1 N/A N/A N/A No Manual Page 12, Figure 3
BL-14831-1 BL-10300-66-1 N/A N/A TD-00-001

BL-10300-66-2 N/A N/A TD-01-015
BL-10300-66-3 N/A N/A TD-00-001
No Number BL-5100-15 BL-5100-14 HS-5100-370 TD-99-008

BL-5100-17 BL-5100-12 HS-5100-300 TD-99-029
BL-5100-18 BL-5100-16 HS-5100-301 TD-98-009
BL-5750-2 BL-5100-8 N/A HS-5100-100 TD-87-001
BL-7480 BL-17400-2 N/A N/A NAVAIR 03-90B-3/ -4

BL-29800-1 N/A N/A TD-94-006
BL-29800-2 N/A N/A TD-94-006
BL-7480-2 BL-17400-50 N/A N/A T.O. 13C1-34-2/ -3/ -4

CAGE CODE 08484

BL-5740-1 BL-10300 N/A N/A T.O. 13C1-22-3/ -4

BL-10300-50 N/A N/A T.O. 13C1-22-3/ -4
BL-10300-50A N/A N/A T.O. 13C1-22-3/ -4
BL-10300-50B N/A N/A T.O. 13C1-22-3/ -4
BL-10300-54 N/A N/A No Manual Page 22, Figure 7
BL-10300-55 N/A N/A No Manual Page 22, Figure 7
BL-10300-55TBO N/A N/A TD-83-003
BL-20200-1 BL-22000-60 N/A No Manual Page 22, Figure 7
BL-20200-1 N/A HS-20200-104 No Manual Page 22, Figure 7
BL-20200-1 N/A HS-20200-105 TD-94-008
BL-20200-2 N/A HS-20200-116 TD-96-014
BL-20200-2T N/A N/A No Manual Page 22, Figure 7
BL-20200-70-1 N/A N/A No Manual Page 22, Figure 7
N/A N/A HS-20200-503-01 No Manual Page 22, Figure 7
N/A KT-209-1 N/A No Manual Page 22, Figure 7
BL-5740-7 N/A KT-209-2 N/A No Manual Page 22, Figure 8
BL-5740-8 BL-20200-135 N/A HS-20200-120 No Manual Page 22, Figure 9

BL-20200-75 N/A HS-20200-115 TD-96-002

CAGE CODE 08484

BL-5740-14 BL-29700-20 N/A HS-29700-200 TD-01-002 Page 22, Figure 12
BL-29700-20 N/A HS-29700-206 TD-01-002
B
BL-29700-20 N/A HS-29700-207 TD-01-002
BL-29700-20 N/A HS-29700-209 TD-01-002
BL-29700-22 N/A HS-29700-202 TD-01-002
BL-29700-22 N/A HS-29700-205 TD-01-002
BL-29700-22 N/A HS-29700-208 TD-01-002
BL-29700-22 N/A HS-29700-210 TD-01-002
BL-29700-23 N/A HS-29700-201 TD-01-002
BL-29700-23 N/A HS-29700-204 TD-01-002
BL-29700-23 N/A HS-29700-215 TD-01-002
BL-5740-15 BL-20200-80 N/A HS-20200-108 TD-96-006

N/A N/A HS-20200-503-02 No Manual Page 22, Figure 13
N/A KT-209-4 N/A No Manual Page 22, Figure 13
B
HK-112-1 N/A N/A N/A No Manual Page 38, Figure 17
HK-115-1 BL-20200-130 N/A HS-20200-122 No Manual Page 41, Figure 18

HK-115-2 BL-27100-85-1 N/A N/A No Manual Page 41, Figure 18
HK-117-1 BL-20200-110 N/A HS-20200-118 TD-98-005 Page 44, Figure 19

BL-20200-110 N/A HS-20200-124 No Manual
BL-20200-120 N/A HS-20200-119 TD-98-005 Page 45, Figure 19
BL-20200-120 N/A HS-20200-123 No Manual

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L. Other Publications Affected.
Not applicable.
M. Family Tree Charts of Modification Relationships.
Not applicable.
II. ACCOMPLISHMENT INSTRUCTIONS.
Please follow the procedures provided in the applicable maintenance manual. A listing of the applicable
maintenance manual is provided in Table 1, “Maintenance Publication Matrix.” If a maintenance manual is
not available, please follow the specific instructions provided in Appendix A.
NOTE: If inspection reveals a corroded bearing, the bearing must be replaced.
A. Hook Load Test.
After the inspection is completed, and the hook has been reassembled on the Hoist, or Winch System. A
hook load test shall be accomplished to ensure proper operation.
The testing procedure to check for proper installation of the hook by applying the rated load of the hoist,
or winch, is as follows:
(1) Run hoist/winch to pay out cable until the hook can be connected to a weight rated for the
hoist/winch that is resting on the ground.
(2) Mount load on hook and slowly reel cable in until the weight is lifted off the ground, or in the case
of a winch the load begins to move.
(3) Once weight is off the ground, or movement is observed, lower weight back to the ground, or stop
operation.
(4) Remove weight and run hoist/winch to the full in position to secure the hook and bumper
assembly.

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APPENDIX A
Hook Assembly Part Number(s) Page Number Figure(s) Number
BL-12877-1 9 2
BL-12900-1 & -2 12 3
BL-4740-1, -2, & -3 16 4, 5, & 6
BL-5740-1, -7, -8, -11, -12, -14, & -15 22 7, 8, 9, 10, 11, 12, & 13
BL-7480-3, -4, & -5 32 14, -15, & -16
HK-112-1 38 17
HK-115-1, & -2 41 18
HK-117-1 44 19

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PN BL-12877-1 (Ref. Figure 2)

Disassembly, Inspection, and Assembly Procedures.
Disassembly
1. Remove setscrew (Item 14, Qty 1) from bushing guide nut (Item 13, Qty. 1).
2. While holding hook body, unthread bushing guide nut (Item 13, Qty. 1), from body (Item 4, Qty. 1).
NOTE: Terminal clamp (Item 11, Qty. 1) is a two piece matched set. Keep both halves together for future use.
3. Slide bushing guide nut (Item 13, Qty. 1) up along the cable to expose terminal clamp (Item 11).
4. Remove ring (Item 12, Qty. 1) securing terminal clamp (Item 11, Qty. 1). Remove and retain the two
terminal clamp pieces in matched sets using retaining ring (Item 12).
5. Remove bushing guide nut (Item 13, Qty. 1) from cable.
6. Line up hole in hook body, and using a drift and mallet, gently tap out spring pin (Item 10, Qty. 1).
Remove and discard spring pin from the hook assembly.
7. Remove castellated nut (Item 9, Qty. 1) from threaded stem of hook assembly (Item 1, Qty. 1), and
remove hook assembly, with ball bearing (Item 3, Qty. 1), and spacer (Item 2, Qty. 1).
8. Remove retainer (Item 7, Qty. 1) from body (Item 4, Qty. 1), and discard o-ring (Item 8, Qty. 1).
9. Remove thrust washers (Items 5, Qty. 1, and 16, Qty. 1) and needle thrust bearing (Item 6, Qty.1) from
body.

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VP
VP
VP Independent Assembly /
Process Verification Required

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Cleaning / Inspection
1. Clean all metal parts with isopropyl alcohol, or equivalent. Remove caked on dirt with a stiff bristle,
non-metallic brush and alcohol.
2. Inspect all parts for corrosion. If corrosion exists, replace affected parts. If warranted, Magnetic Particle
Inspect in accordance with ASTM-E1444. Liquid Penetrant Inspect in accordance with ASTM-E1417.
Criterion for acceptance/rejection shall be in accordance with MIL-STD-1907.
Assembly
NOTE: All procedures with the note VITAL INSPECTION POINT and parts with item numbers that are
identified with the note VP require 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 either the helicopter or Hoist maintenance log.
1. Install bushing guide nut (Item 13, Qty.1) and two-piece terminal clamp (Item 11, Qty. 1) onto the cable
with the cone portion of the clamp facing up toward the hoist/winch, and the ring groove orientated
toward the hook. Secure terminal clamp with ring (Item 12, Qty. 1).
2. Lubricate, and pack needle thrust bearing and thrust races with Dow Corning 33 Bearing Grease, or
equivalent. Install one thrust washer (Item 5, Qty. 1) in body (Item 4, Qty. 1). Install needle thrust
bearing (Item 6, Qty. 1) on top of thrust washer, then install remaining thrust washer (Item 16, Qty. 1)
on top of thrust bearing.
3. Lubricate new o-ring (Item 8, Qty.1) with Dow Corning 33 Bearing Grease, or equivalent. Install o-ring
in retainer (Item 7, Qty. 1) groove.
4. Install retainer (Item 7, Qty. 1) in body (Item 4, Qty. 1) over the installed thrust washer and bearing.
5. Install spacer (Item 2, Qty.1), and ball bearing (Item 3, Qty. 1) on hook assembly (Item 1, Qty. 1).
6. Install hook assembly threaded shaft with spacer and thrust bearing, through the body, and through the
assembled thrust bearing, and retainer.
7. VITAL INSPECTION POINT Thread the castellated nut (Item 9, Qty. 1) onto the hook assembly until
snug. Once snug, back off slightly to allow installation of spring pin (Item 10, Qty. 1VP) in body
through stem of hook and castellated nut, with access through the hook housing. Install the spring pin.
8. Check for binding while holding hook body (Item 4, Qty. 1), and rotating hook assembly (Item 1, Qty.
1). If binding is found, remove pin, and back castellated nut off one slot to allow installation of spring
pin in body through stem of hook assembly. Continue this check until binding is eliminated and the
hook rotates smoothly.
9. Thread body (Item 4, Qty. 1), and assembled hook parts onto bushing guide nut (Item 13, Qty. 1).
10. VITAL INSPECTION POINT Install locking setscrew (Item 14, Qty. 1VP) into bushing guide nut
(Item 13, Qty. 1) to lock body (Item 4, Qty. 1) into place.
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PN BL-12900-1, -2 (Ref. Figure 3)

Disassembly
1. Remove cotter pin (Item 17, Qty 1) securing locking screw (Item 16, Qty. 1).
2. Remove locking screw (Item 16, Qty. 1) from nut (Item 15, Qty. 1).
3. While holding hook body (Item 3, Qty. 1), unthread nut (Item 15, Qty. 1), from body (Item 3, Qty.
1), and remove shims (Item 11, as required).
4. Slide nut (Item 15, Qty. 1) and sleeve (Item 14, Qty. 1) up along the cable to expose terminal clamp
(Item 12, or 18, Qty. 1).
NOTE: Terminal clamp (Item 12, or 18, Qty. 1) is a two piece matched set. Keep both halves together for
future use.
5. Remove ring (Item 13, Qty. 1) securing terminal clamp (Item 12, or 18, Qty. 1). Remove and retain
the two pieces in matched sets using retaining ring (Item 13).
6. Slide nut (Item 15, Qty. 1) and sleeve (Item 14, Qty. 1) down off the cable.
7. Remove hand ring (Item 10, Qty. 1).
9. Remove nut (Item 8, Qty. 1) from threaded stem of hook assembly (Item 1, Qty. 1), and remove
hook assembly (Item 1, Qty 1).
10. Remove bearing retainer (Item 7, Qty. 1) with preformed packing (Item 6, Qty. 1), thrust races
(Items 4, Qty. 1, and 20, Qty. 1), with needle thrust bearing (Item 5, Qty. 1), ball bearing (Item 2,
Qty. 1), and seal spacer (Item 19, Qty. 1) from body (Item 3, Qty. 1).

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VP
VP
Independent Assembly /
VP Process Verification Required
Figure 3. BL-12900-1 and -2 Hook Assemblies

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2. Inspect all parts for corrosion. If corrosion exists, replace affected parts. If warranted, Magnetic Particle
Assembly
1. Install nut (Item 15, Qty.1), sleeve (Item 14, Qty. 1), two-piece terminal clamp (Item 12 or 18, Qty. 1),
onto the cable with the cone portion of the clamp facing up toward the hoist/winch, and the ring groove
orientated toward the hook. Secure terminal clamp with ring (Item 13, Qty. 1).
2. Lubricate thrust races, and pack needle thrust bearing, with Dow Corning 33 Bearing Grease, or
equivalent. Install one thrust race (Item 4, Qty. 1) in body (Item 3, Qty. 1). Install needle thrust bearing
(Item 5, Qty. 1) on top of thrust washer, then install remaining thrust washer (Item 20, Qty. 1) on top of
needle thrust bearing.
3. Install preformed packing (Item 6, Qty. 1) in groove on bearing retainer (Item 7, Qty. 1). Lubricate
preformed packing and bearing retainer with Dow Corning 33, and install in body (Item 3, Qty.1).
4. Install seal spacer (Item 19, Qty. 1), and bearing (Item 2, Qty. 1) on hook assembly (Item 1, Qty 1).
5. Align and install assembled body (Item 3, Qty. 1) on hook assembly (Item 1, Qty. 1).
6. Install nut (Item 8, Qty. 1) onto the hook assembly threaded shaft (Item 1, Qty. 1). Tighten nut snug,
then back off to line up hole with spring pin hole in body (Item 3, Qty. 1).
7. VITAL INSPECTION POINT Install spring pin (Item 9, Qty. 1VP) through body, nut and hook.
8. Install hand ring (Item 10, Qty. 1) on body (Item 3, Qty. 1).
9. Thread and tighten nut (Item 8, Qty.1) and body (Item 3, Qty.1) together until bottomed. Back off just
enough to allow alignment and installation of locking screw (Item 16, Qty. 1).

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11. VITAL INSPECTION POINT Insert cotter pin (Item 17, Qty. 1VP) through slot in locking screw
(Item 16, Qty. 1) to secure retention.

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PN’s BL-4740-1, -2, -3 (Ref. Figures 4, 5, & 6)
Disassembly, Inspection, and Assembly Procedures
Disassembly
1. Pay out approximately 6 feet (1.8 meters) of wire rope cable to allow the swivel hook assembly to rest on
flat surface.
2. Remove power to Hoist Assembly.
3. Separate the bumper assembly from the swivel hook assembly. Pull bumper assembly from top of sleeve
(Item 13) then slide it up wire rope cable toward the Hoist Assembly.
4. Remove locking screw (Item 15) from swivel hook assembly.
CAUTION: PARTS LOCATED INSIDE OF SWIVEL HOOK ASSEMBLY WILL FALL FREE AFTER
DISENGAGEMENT OF NUT FROM HOUSING. PLACE THE SWIVEL HOOK ASSEMBLY
ON A FIRM SURFACE BEFORE REMOVING NUT.
5. While holding the body (Item 3), unthread nut (Item 14), and remove bottom half of swivel hook
assembly.
6. Slide nut (Item 14) and sleeve (Item 13) up wire rope cable away from the ball end to expose terminal
clamp (Item 11).
NOTE: TERMINAL CLAMP (Item 11) IS A TWO-PIECE MATCHED SET. KEEP BOTH HALVES
TOGETHER FOR FUTURE USE.
7. Remove retaining ring (Item 16) from terminal clamp (Item 11) to allow removal of terminal clamp,
sleeve (Item 13), nut (Item 14), and bumper assembly from wire rope cable. Remove and retain the two
8. Remove rubber bumper (Item 10) with label from bottom half of swivel hook assembly.
9. Remove label from rubber bumper (Item 10), if required.
10. Align the holes in the body (Item 3) to allow access to the spring pin (Item 9) in the swivel hook
assembly. Gently tap out the spring pin using a punch and a mallet. Discard spring pin.
11. Remove castellated nut (Item 8) from swivel hook assembly.
12. Remove body (Item 3) from swivel hook.
13. Remove bearing retainer (Item 7) with preformed packing (Item 6), thrust bearing races (Item 4 and 18),
needle thrust bearing (Item 5), ball bearing (Item 2), from body (Item 3).
14. Remove and discard preformed packing (Item 6) from bearing retainer (Item 7).

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15. Remove spacer (Item 17) from stem of hook (Item 1).
2. Inspect all parts for corrosion. If corrosion exists replace affected parts. If warranted for Ferromagnetic
components, Magnetic Particle Inspect in accordance with ASTM-E1444. Criterion for acceptance /
rejection shall be in accordance with Breeze-Eastern specification BQC-290-1000. If warranted for
Aluminum Alloy components, Liquid Penetrant Inspect in accordance with ASTM-E1417. Criterion for
acceptance/rejection shall be in accordance with Breeze-Eastern specification BQC-290-7.
Assembly
1. Slide bumper assembly, nut (Item 14) then sleeve (Item 13) up wire rope cable toward rescue hoist
assembly. Install terminal clamp (Item 11) over ball end of cable and secure clamp with ring (Item 16)
over ball.
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 HOIST.
2. Slide sleeve (Item 13) and nut (Item 14) down cable until sleeve captures terminal clamp (Item 11).
3. Slide bumper assembly down to top surface of nut (Item 14). Bumper must sit flush with top of nut.
4. Apply light coat of Dow Corning 33 Bearing Grease, or equivalent, onto preformed packing (Item 6),
and install preformed packing into groove of bearing retainer (Item 7).
5. Completely coat needle thrust bearing (Item 5), and both needle thrust bearing races (Items 4 and 18)
with Dow Corning 33 Bearing Grease, or equivalent, prior to installation.
6. Install ball bearing (Item 2), needle thrust bearing race (Item 4), needle thrust bearing (Item 5), needle
thrust bearing race (Item 18), and bearing retainer (Item 7) with preformed packing (Item 6) into body
(Item 3).
7. Install spacer (Item 17) over stem of hook assembly (Item 1). Install body (with components installed
inside) onto stem of hook assembly.

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8. Install castellated nut (Item 8) onto hook assembly, and hand tighten until body is fully seated onto hook
assembly.
9. VITAL INSPECTION POINT Back castellated nut (Item 8) off slightly to next nearest slot to allow pin
hole in hook stem and slot in nut to be in line. Tap in spring pin (Item 9 VP) using mallet and drift,
through hole in body (Item 3). Centralize pin with castellated nut.
CAUTION: Rotate hook while holding housing to check for binding of bearings (Item 2 & Item 5). If binding
exists, remove spring pin (Item 9), 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 to
occur, replace bearings (Item 2 & 5).
10. If label is damaged or removed, peel off backing of new label (Item 12), activate adhesive with alcohol,
and install new label onto rubber bumper (Item 10).
11. Install rubber bumper (Item 10) with label (Item 12) onto body (Item 3).
12. Install assembled hook parts onto nut (Item 14) by threading body (Item 3) and nut (Item 14) together
until bottomed.
13. VITAL INSPECTION POINT Back off nut (Item 14) to line up tapped holes with next nearest slots in
body (Item 3). Insert locking screw (Item 15 VP) and screw home to bottom of slot in body. Insure hook
rotates freely.
14. Power hoist to reel cable and hook assembly back to home position.

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Figure 4. BL-4740-1 Swivel Hook Assembly

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PN BL-5740-1, -7, -8, -11, -12, -14, -15 (Ref. Figures 7, 8, 9, 10, 11, 12 & 13)
Disassembly
1. Pay out approximately 6 feet (1.8 meters) of wire rope cable to allow the hook assembly to rest on flat
surface.
3. Separate the bumper assembly from the swivel hook assembly. Pull bumper assembly from top of sleeve
4. Remove and discard cotter pins (Item 16). Remove locking screws (Item 15) from hook assembly.
5. While holding the body (Item 3), unthread nut (Item 14), and remove bottom half of hook assembly.
6. Slide nut (Item 14) and sleeve (Item 13) up wire rope cable away from the ball end to expose terminal
clamp (Item 11).
7. Remove retaining ring (Item 18) from terminal clamp (Item 11) to allow removal of terminal clamp,
sleeve (Item 13), nut (Item 14), and bumper assembly from wire rope cable. Remove and retain the two
8. Remove rubber bumper (Item 10) with label (Item 12) from bottom half of hook assembly.
9. Remove label (Item 12) from rubber bumper (Item 10), if required.
11. Remove castellated nut (Item 8) from swivel hook assembly (Item 1).
12. Remove body (Item 3) from swivel hook.
13. Remove bearing retainer (Item 7) with preformed packing (Item 6), needle thrust bearing races (Items 4
and 19), needle thrust bearing (Item 5), ball bearing (Item 2), from body (Item 3).
15. Remove spacer (Item 17) from stem of hook.

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components, Magnetic Particle Inspect in accordance with ASTM-E1444. Criterion for
acceptance/rejection shall be in accordance with Breeze-Eastern specification BQC-290-1000. If
warranted for Aluminum Alloy components, Liquid Penetrant Inspect in accordance with ASTM-E1417.
Criterion for acceptance/rejection shall be in accordance with Breeze-Eastern specification BQC-290-7.
Assembly
1. Slide bumper assembly, nut (Item 14) and sleeve (Item 13) up wire rope cable toward rescue hoist
assembly. Install terminal clamp (Item 11) over ball end of cable and secure clamp with ring (Item 18)
over ball.
HOOK WITH THE CHAMFERED, OR CONE SHAPED, END OF THE TERMINAL CLAMP
2. Slide sleeve (Item 13) and nut (Item 14) down cable over terminal clamp (Item 11).
5. Completely coat needle thrust bearing (Item 5), and both thrust races (Items 4 and 19) with Dow
Corning 33 Bearing Grease, or equivalent, prior to installation.
6. Install ball bearing (Item 2), thrust race (Item 4), needle thrust bearing (Item 5), thrust race (Item 19),
and bearing retainer (Item 7) with preformed packing (Item 6) into body (Item 3).
assembly.

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11. Install rubber bumper (Item 10) with label (Item 12) onto body (Item 3).
until bottomed.
13. Back off nut (Item 14) to line up tapped holes with next nearest slots in body (Item 3). Insert locking
screws (Item 15) and screw home to bottom of slot in body. Insure hook rotates freely.
14. VITAL INSPECTION POINT Install cotter pins (Item 16 VP) in accordance with MS33540 through
the slot in locking screw (Item 15). If necessary back the screw off ¼ turn prior to installing cotter pins.
Insure hook rotates freely.

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PN’s BL-7480-3, -4, -5 (Ref. Figures 14, 15, & 16)

Disassembly
1. Pay out approximately 6 feet (1.8 meters) of wire rope cable to allow the swivel hook assembly to rest
on flat surface.
3. Separate the bumper assembly from the swivel hook assembly. Pull bumper assembly from top of nut
4. Remove locking screw (Item 15) from swivel hook assembly.
5. While holding the body (Item 3), unthread nut (Item 13), and remove bottom half of swivel hook
assembly.
6. Slide nut (Item 13) up wire rope cable away from the ball end to expose terminal clamp (Item 11).
7. Remove retaining ring (Item 16) from terminal clamp (Item 11) to allow removal of terminal clamp, nut
(Item 13) and bumper assembly from wire rope cable. Remove and retain the two terminal clamp pieces
in matched sets using retaining ring (Item 16).
8. Unthread setscrew (Item 14) enough to allow bumper (Item 10) to slide off the body (Item 3). Remove
rubber bumper (Item 10) with label from bottom half of swivel hook assembly.
9. Remove label (Item 12) from rubber bumper (Item 10), if required.
assembly. Gently tap out the spring pin (Item 9) using a punch and a mallet. Discard spring pin.
11. Remove castellated nut (Item 8) from swivel hook assembly.
12. Remove body (Item 3) from swivel hook (Item 1)
13. Remove bearing retainer (Item 7) with preformed packing (Item 6), thrust races (Items 4 and 19), needle
thrust bearing (Item 5), ball bearing (Item 2), from body (Item 3).
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15. Remove spacer (Item 17) from stem of hook.

components, Magnetic Particle Inspect in accordance with ASTM-E1444. Criterion for acceptance /
rejection shall be in accordance with Breeze-Eastern specification BQC-290-1000. If warranted for
Aluminum Alloy components, Liquid Penetrant Inspect in accordance with ASTM-E1417. Criterion for
acceptance/rejection shall be in accordance with Breeze-Eastern specification BQC-290-7.
Assembly
1. Slide bumper assembly and nut (Item 13) up wire rope cable toward rescue hoist assembly. Install
terminal clamp (Item 11) over ball end of cable and secure clamp with ring (Item 16) over ball.
HOOK WITH THE CHAMFERED, OR CONE SHAPED END OF THE TERMINAL CLAMP
2. Slide nut (Item 13) down cable until sleeve sits properly over terminal clamp (Item 11).
5. Completely coat needle thrust bearing (Item 5), and both thrust races (Items 4 and 19) with Dow
Corning 33 Bearing Grease, or equivalent, prior to installation.
6. Install ball bearing (Item 2), thrust race (Item 4), needle thrust bearing (Item 5), thrust race (Item 19),
and bearing retainer (Item 7) with preformed packing (Item 6) into body (Item 3).

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assembly.
11. Install rubber bumper (Item 10) with label (Item 12) onto body (Item 3). Orient bumper to install
setscrew (Item 14) on flat of body (Item 3). Thread setscrew (Item 14) to lock bumper to body (Item 3).
until bottomed.
13. VITAL INSPECTION POINT Back off nut (Item 13) to line up tapped holes with next nearest slots in
body (Item 3). Insert locking screw (Item 15 VP) and screw home to bottom of slot in body. Insure hook
rotates freely.

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PN HK-112-1 (Ref. Figure 17)

Disassembly
1. Remove cotter pins (Item 16, Qty 2) securing locking screw (Item 15, Qty. 2).
2. Remove locking screws (Item 15, Qty. 2) from nut (Item 14, Qty. 1).
3. While holding hook body (Item 3, Qty. 1), unthread nut (Item 14, Qty. 1), from body (Item 3, Qty. 1).
(Item 11, Qty. 1).
5. Remove ring (Item 12, Qty. 1) securing terminal clamp (Item 11, Qty. 1). Remove and retain the two
7. Remove hand wheel assembly (Item 10, Qty. 1). (NOTE: Hand Wheel Assembly consists of Handwheel
PN BL-13676-1 & Ball Bearing PN AJ-9800-23-46).
9. Remove nut (Item 8, Qty. 1) from threaded stem of hook assembly (Item 1, Qty. 1), and remove hook
assembly (Item 1, Qty 1).
10. Remove retainer (Item 7, Qty. 1) with preformed packing (Item 6, Qty. 1), thrust races (Items 4, Qty. 1,
and 18, Qty. 1), with needle thrust bearing (Item 5, Qty. 1), ball bearing (Item 2, Qty. 1), and seal spacer
(Item 17, Qty. 1) from body (Item 3, Qty. 1).
1. Clean all metal parts with isopropyl alcohol, or equivalent. Remove caked on dirt with a stiff bristle
2. Inspect all parts for corrosion. If corrosion exists replace affected parts. If warranted, Magnetic Particle
Inspect in accordance with ASTM-E1444. Criterion for acceptance/rejection shall be in accordance with
MIL-STD-1907, or Liquid Penetrant Inspect in accordance with ASTM-E1417. Criterion for
acceptance/rejection shall be in accordance with MIL-STD-1907.

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Assembly
1. Install nut (Item 14, Qty.1), sleeve (Item 13, Qty 1), two-piece terminal clamp (Item 11, Qty. 1), onto
the cable with the cone portion of the clamp facing up toward the hoist/winch, and the ring groove
orientated toward the hook. Secure terminal clamp with ring (Item 12, Qty. 1).
equivalent. Install one thrust race (Item 4, Qty. 1) in body (Item 3, Qty. 1). Install needle thrust bearing
(Item 5, Qty. 1) on top of thrust washer, then install thrust washer (Item 18, Qty. 1) on top of needle
thrust bearing.
3. Lubricate preformed packing and bearing retainer with Dow Corning 33, and install in body (Item 3,
Qty.1). Install preformed packing (Item 6, Qty. 1) in groove on bearing retainer (Item 7, Qty. 1).
4. Install seal spacer (Item 17, Qty. 1), and bearing (Item 2, Qty. 1) on hook assembly (Item 1, Qty 1).
5. Align and install assembled body (Item 3, Qty. 1) on hook assembly (Item 1, Qty. 1).
6. Install nut (Item 8, Qty. 1) onto the hook assembly threaded shaft (Item 1, Qty. 1). Tighten nut snug,
then back off to line up hole with spring pin hole in body (Item 3, Qty. 1).
7. VITAL INSPECTION POINT Install spring pin (Item 9, Qty. 1VP) through body, nut and hook
assembly shaft.
9. Install handwheel assembly (Item 10, Qty. 1) on body (Item 3, Qty. 1).
enough to allow alignment and installation of locking screws (Item 15, Qty. 2).
12. VITAL INSPECTION POINT Insert cotter pins (Item 16, Qty. 2VP) through slot in locking screws

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VP
VP
Figure 17. HK-112-1 Swivel Hook Assembly

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PN HK-115-1, -2 (Ref. Figure 18)

Disassembly
(Item 11, Qty. 1).
5. Remove ring (PN BL-4718, Qty. 1, not shown) securing terminal clamp (Item 11, Qty. 1). Remove and
retain the two terminal clamp pieces in matched sets using retaining ring (PN BL-4718, Qty. 1, not
shown).
7. Remove rubber bumper (Item 10, Qty. 1), with cable size label (Item 12, Qty. 1).
Discard spring pin from the hook assembly.
9. Remove nut (Item 8, Qty. 1) from threaded stem of hook assembly (Item 1, or 17, Qty. 1), and remove
hook assembly (Item 1, or 17, Qty 1).
10. Remove from body (Item 3, Qty. 1), retainer (Item 7, Qty. 1) with preformed packing (Item 6, Qty. 1),
bearing thrust washers (Items 4, Qty. 1, and 19, Qty. 1), with needle thrust bearing (Item 5, Qty. 1), ball
bearing (Item 2, Qty. 1), and spacer (Item 18, Qty. 1).
Inspect in accordance with ASTM-E1444. Criterion for acceptance/rejection shall be in accordance with
MIL-STD-1907, or Liquid Penetrant Inspect in accordance with ASTM-E1417. Criterion for
acceptance/rejection shall be in accordance with MIL-STD-1907.

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Assembly
orientated toward the hook. Secure terminal clamp with ring (PN BL-4718, Qty. 1, not shown).
equivalent. Install one thrust washer (Item 4, Qty. 1) in body (Item 3, Qty. 1). Install needle thrust
bearing (Item 5, Qty. 1) on top of thrust washer, then install thrust washer (Item 19, Qty. 1) on top of
thrust bearing.
4. Install spacer (Item 18, Qty. 1) and bearing (Item 2, Qty. 1) on hook assembly (Item 1, or 17, Qty 1).
5. Align and install assembled body (Item 3, Qty. 1) on hook assembly (Item 1, or 17, Qty. 1).
6. Install nut (Item 8, Qty. 1) onto the hook assembly threaded shaft (Item 1 or 17, Qty. 1). Tighten nut
snug, then back off to line up hole with spring pin hole in body (Item 3, Qty. 1).
assembly shaft.
8. Check for binding while holding hook body (Item 3, Qty. 1), and rotating hook assembly (Item 1 or 17,
Qty. 1). If binding is found, remove pin, and back castellated nut off one slot to allow installation of
spring pin in body through stem of hook assembly. Continue this check until binding is eliminated and
the hook rotates smoothly.
9. Install rubber bumper (Item 10, Qty. 1), with cable size label (Item 12, Qty. 1) on body (Item 3, Qty. 1).
11. Check for binding while holding hook body (Item 3, Qty. 1), and rotating hook assembly (Item 1, or 17,
Qty. 1). If binding is found, remove pin, and back castellated nut off one slot to allow installation of
spring pin in body through stem of hook assembly. Continue this check until binding is eliminated and
the hook rotates smoothly.

CAGE CODE 08484

VP
VP
Figure 18. HK-115-1 and HK-115-2 Hook Assemblies

CAGE CODE 08484

PN HK-117-1 (Ref. Figure 19)

Disassembly
4. Hold nut (Item 14, Qty. 1) and sleeve (Item 13, Qty. 1) and push cable through to expose terminal clamp
(Item 11, Qty. 1).
5. Remove ring (PN BL-4718, Qty. 1, not shown) securing terminal clamp (Item 11, Qty. 1). Remove and
retain the two terminal clamp pieces in matched sets using retaining ring (PN BL-4718, Qty. 1).
7. Remove rubber bumper (Item 10, Qty. 1), with cable size label (Item 12, Qty. 1).
9. Remove nut (Item 8, Qty. 1) from threaded stem of swivel hook assembly (Item 1, Qty. 1), and remove
hook assembly (Item 1, Qty 1).
10. Remove from body (Item 3, Qty. 1), bearing retainer (Item 7, Qty. 1) with preformed packing (Item 6,
Qty. 1), thrust washer (Item 18, Qty. 1), with needle thrust bearing (Item 5, Qty. 1), thrust washer (Item
4, Qty. 1) and remove body from hook (Item 1, Qty. 1).
11. Remove ball bearing (Item 2, Qty. 1), and spacer (Item 17, Qty. 1) from top of hook.

CAGE CODE 08484

Assembly
orientated toward the hook. Secure terminal clamp with ring (PN BL-4718, Qty. 1, not shown).
2. Lubricate thrust washers, and pack the needle thrust bearing, with Dow Corning 33 Bearing Grease, or
equivalent. Install spacer (Item 17, Qty. 1), ball bearing (Item 2, Qty. 1), and thrust washer (Item 4, Qty.
1) in body (Item 3, Qty. 1). Install needle thrust bearing (Item 5, Qty. 1) on top of thrust washer, then
install remaining thrust washer (Item 18, Qty. 1) on top of thrust bearing.
4. Install spacer (Item 17, Qty. 1), and bearing (Item 2, Qty. 1) on hook assembly (Item 1, Qty 1).
5. Align and install assembled body (Item 3, Qty. 1) on swivel hook assembly (Item 1, Qty. 1).
6. Install nut (Item 8, Qty. 1) onto the swivel hook assembly threaded shaft (Item 1, Qty. 1). Tighten nut
snug, then back off to line up hole with spring pin hole in body (Item 3, Qty. 1).
assembly shaft.
8. Install rubber bumper (Item 10, Qty. 1), with cable size label (Item 12, Qty. 1) on body (Item 3, Qty. 1).

CAGE CODE 08484

VP VP
VP
Figure 19. HK-117-1 Swivel Hook Assembly

CAGE CODE 08484
TransTechnology Corporation 700 Liberty Avenue SB BL-5448 -25-01
Union NJ, 07083 USA SB BL-5448-1 -25-01
SERVICE BULLETIN Original Release 08/31/05, Page 1 of 12
Breeze-Eastern Hook Assembly Nut Part Numbers BL-5448, and BL-5448-1

Inspection Requirement
SUBJECT: Rescue Hoist / Cargo Winch operators should be aware of a stress corrosion potential, which may
cause cracking in a Hook Assembly Nut. The potential for this condition requires a 10x visual
inspection of the nut as a precautionary measure.
A. Effectivity.
This Service Bulletin (SB) pertains to Hook Assemblies incorporating Nut Part Numbers BL-5448, and
BL-5448-1, and their next higher assemblies as listed in Table 1, “Effectivity Matrix,” as well as any
operator who may have purchased the Nut and / or Hook Assembly combination as a spare.
Affected Hook Description 1st Level Next Description 2nd Level Next Description Technical
Assy. Part Higher Assembly Higher Assembly Manual & NHA
Number (0) (1) (2) Reference (*)
HK-105-1 Hook KT-181 Kit BL-10300-66 Rescue Hoist None(1)
Assembly TD-00-001(2)
KT-183 Kit BL-10300-67 Rescue Hoist None(1&2)
HK-112-1 Hook None Rescue Hoist None(0)
Assembly
HK-115-1 Hook BL-20200-130 Rescue Hoist HS-20200-122 Rescue Hoist None(1)
Assembly System TD-99-012(2)
HK-115-2 Hook BL-27100-85-1 Rescue Hoist None None(1)
Assembly
HK-117-1 Hook BL-10300-59-1 Rescue Hoist HS-10300-59-1 Rescue Hoist Sys. TD-98-001(1)
Assembly None(2)
BL-10300-59-2 Rescue Hoist None None(1)
BL-12900-1 Rescue Hoist None None(1)
BL-20200-1 (ORG) Rescue Hoist BL-20200-60 Rescue Hoist Sys. TD-93-006(1)
TD-94-000(1&2)
HS-20200-104 Rescue Hoist Sys. TD-99-012(2)
TD-99-012(2)
BL-20200-60 (ORG) Rescue Hoist HS-20200-107 Rescue Hoist Sys. TD-94-000(1)
TD-99-012(2)
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.
CAGE CODE 08484
Union NJ, 07083 USA SB BL-5448-1 -25-01
Breeze-Eastern Hook Assembly Nut Part Numbers BL-5448, and BL-5448-1

HK-117-1 Hook BL-20200-110 Rescue Hoist HS-20200-118 Rescue Hoist Sys. None(1)
Continued Assembly TD-98-005(2)
TD-99-012(2)
HS-20200-124 Rescue Hoist Sys. None(2)
BL-20200-120 Rescue Hoist HS-20200-119 Rescue Hoist Sys. None(1)
TD-98-005(2)
TD-99-012(2)
BL-5740-1 Hook BL-10300 Rescue Hoist None None(0&1)
Assembly
BL-10300-50A Rescue Hoist None None(1)
BL-10300-50B Rescue Hoist None None(1)
BL-10300-55 Rescue Hoist None TD-90-005(1)
BL-10300-55TBO Rescue Hoist None TD-83-003(1)
BL-20200-1 Rescue Hoist TD-93-006(1)
TD-94-000(1)
TD-99-012(2)
BL-22000-60 Rescue Hoist Sys. None(2)
TD-96-014(2)
TD-99-012(2)
BL-20200-2T Rescue Hoist None None(1)
BL-20200-60 Rescue Hoist HS-20200-107 Rescue Hoist Sys. TD-94-000(1)
TD-99-012(2)
TD-93-006(1)
TD-96-012(2)
TD-99-012(2)
BL-20200-70-1 Rescue Hoist HS-20200-128 Rescue Hoist Sys. None (1 & 2)
BL-20200-70-2 Rescue Hoist HS-20200-113 Rescue Hoist Sys. None(1)
TD-96-012(2)
TD-99-012(2)
HS-20200-503-01 R. Hoist Sys. None TD-03-005(1)
Table 1. Effectivity Matrix (Continued)
Service Bulletin BL-5448, & BL-5448-1 -25-01 ATA 100 Format

CAGE CODE 08484
Union NJ, 07083 USA SB BL-5448-1 -25-01
Breeze-Eastern Hook Assembly Nut PN’s BL-5448, and BL-5448-1

BL-5740-1 Hook KT-209-1 Kit None None(1)
Continued Assembly
BL-5740-2 Hook None None(0)
Assembly
BL-5740-5 Hook BL-4600-3 Winch Assy. None None(1)
Assembly
BL-4600-10 Winch Assy. None TD-95-003(1)
BL-4600-10MODA Winch Assy. None None(1)
BL-4600-30 Winch Assy. None None(1)
BL-4600-50 Winch Assy. None None(1)
BL-4600-60 Winch Assy. None TD-95-003(1)
BL-5740-7 Hook KT-209-2 Kit None None(1)
Assembly
BL-5740-8 Hook BL-20200-75 Rescue Hoist HS-20200-115 Rescue Hoist Sys. None(1)
TD-99-012(2)
TD-99-012(2)
TD-99-012(2)
BL-5740-11 Hook BL-10300-150 Rescue Hoist None TD-98-008(0)
Assembly None(1)
TD-93-016(2)
TD-99-013(2)
KT-209-3 Kit, Hook None None(1)
KT-370 Kit, Spares None None(1)
KT-371 Kit, Spares None None(1)
None(2)
BL-5740-14 Hook BL-29700-7 Rescue Hoist HS-29700-107 Rescue Hoist Sys. None(1&2)
Assembly
TD-01-002(2)
TD-99-001(2)
CAGE CODE 08484
Union NJ, 07083 USA SB BL-5448-1 -25-01

BL-5740-14 Hook HS-29700-207 Rescue Hoist Sys. TD-01-002(2)
Continued Assembly
TD-01-002(2)
TD-99-001(2)
TD-01-002(2)
TD-99-001(2)
TD-01-004(2)
TD-01-002(2)
TD-01-002(2)
HS-29700-100 R. Hoist Sys. None None(1)
BL-5740-15 Hook BL-20200-80 Rescue Hoist HS-20200-108 Rescue Hoist Sys. TD-94-000(1)
TD-99-012(2)
HS-20200-503-02 Rescue Hoist None(1)
KT-209-4 Kit None(1)
Assembly
Assembly
Assembly
BL-10300-66-1 Rescue Hoist HS-10300-172 Rescue Hoist Sys. None(1)
TD-02-020(2)
BL-10300-66-2 Rescue Hoist None TD-01-011(1)
TD-01-012(1)
TD-01-015(1)
BL-10300-66-3 Rescue Hoist HS-10300-170 Rescue Hoist Sys. None(1&2)

CAGE CODE 08484
Union NJ, 07083 USA SB BL-5448-1 -25-01

BL-14831-1 Hook KT-238 Kit BL-10300-66-2 Rescue Hoist None(1)
Continued Assembly TD-01-011(2)
TD-01-012(2)
TD-01-015(2)
KT-260 Kit BL-10300-66-1 Rescue Hoist None(1&2)
BL-10300-59-1 Rescue Hoist HS-10300-59-1 R. Hoist Sys. TD-98-001(0)
Assy. None(1)
Assy.
Assy.
BL-12900-1 Hook Assy. None None(0)
BL-12900-2 Hook Assy. None None(0)
B. Reason.
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
Assemblies 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 as shown in Figure 2, 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.

CAGE CODE 08484
Union NJ, 07083 USA SB BL-5448-1 -25-01

C. Description.
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, refer to Figure 3. When the replacement nut is installed
in the hook assembly this Service Bulletin is terminated.
E. Manpower.
A hook assembly inspection is estimated to take one (1) maintenance technician approximately twenty
minutes to disassemble, clean, visually inspect, reassemble, and test the hook assembly.
The preferred hook assembly nut replacement is part number BL-5448-1 (interchangeable with
BL-5448), in leiu of BL-5448 , because of its dual locking features. The BL-5448-1 requires two
locking screws and cotter pins for reassembly. Refer to Figure 2.
For price and availability for the purchase of the hook assembly nut part number BL-5448-1 contact:
Breeze-Eastern’s Programs and Contracts Department, After Market Sales Coordinator

Phone Number: Direct (908) 206-3875, or 1-800-929-1919 (Toll-Free US and Canada only)
Fax: (908) 686-9292, or E-Mail: cpalleschi@breeze-eastern.com (Attention: Cathy Palleschi)
Any questions pertaining to this SB should be directed to Breeze-Eastern’s Customer Services

contacts listed below
E-Mail: customer.services@breeze-eastern.com

CAGE CODE 08484
Union NJ, 07083 USA SB BL-5448-1 -25-01

No special tools are required for this inspection. Common hand tools are sufficient.
Not applicable.
Not affected.
Not applicable.
K. References.
Please correlate your Hook Assembly, incorporating the nut, to the next higher Rescue Hoist / Cargo
Winch Assembly level, and Rescue Hoist System level part numbers listed in Table 1, “Effectivity
Matrix.” Applicable Technical Documents (TD) Operation and Maintenance Manuals are listed in
Table 1. They provide the necessary maintenance instructions for the applicable rescue hoists / cargo
winches and rescue hoist systems. If there is no publication listed for your part number(s), use the
general instructions provided in Section II.
Military publications are not controlled, or distributed, by Breeze-Eastern.
Not applicable.

CAGE CODE 08484
Union NJ, 07083 USA SB BL-5448-1 -25-01

Please read the entire SB prior to initiating the accomplishment instructions. Once the SB has been read
through, follow the instructions provided to gain access to visually inspect the nut.
NOTE: If the 10x visual inspection reveals a crack 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. Please return any cracked nut(s)
found to Breeze-Eastern for analysis.
Gain access to the hook assembly nut by using the applicable instructions provided in the specific Technical
Document (TD) Operation and Maintenance Manuals listed in Table 1 for the appropriate rescue hoist,
rescue hoist system, and cargo winch, or use the following general instructions are applicable to most rescue
hoists and cargo winches.

CAGE CODE 08484
Union NJ, 07083 USA SB BL-5448-1 -25-01

GENERAL INSTRUCTIONS
Disassembly, Inspection, Cleaning, and Assembly Procedures
A. Remove Hook Assembly from the Cable.
Disassembly
1. Apply power to rescue hoist or cargo winch assembly.

2. Slowly reel out approximately 6 feet (1.8 meters) of cable from the hoist / winch, or as needed, to
allow the hook and bumper assemblies to rest on a clean flat surface with 3 feet (.91 meter) of slack.
3. Remove power from the hoist / winch.
4. If the hoist / winch incorporates a bumper assembly, pull up on the bumper assembly, which consists
of a bumper retainer, a compression spring, and an over travel bumper, and slide it up along the cable
away from the hook and toward the hoist to separate the bumper assembly from the nut in the hook
assembly.
5. Remove and discard cotter pin(s) securing the locking screws.
6. Unthread and remove locking screw(s), which retain the nut and body together in the hook assembly.
7. While holding the body / housing, unthread nut BL-5448, or BL-5448-1, and remove bottom half of
hook assembly. Set the bottom half of the hook assembly aside for reassembly.
8. Slide nut, and sleeve (if applicable) up wire rope cable away from the cable ball end to expose the
terminal clamp. Refer to Figure 1. Figure 1. Terminal
clamp with ring
NOTE: THE TERMINAL CLAMP IS A TWO-PIECE MATCHED SET. installed.
KEEP THE HALVES TOGETHER FOR FUTURE USE.
9. Remove retaining ring from terminal clamp to allow removal of terminal clamp, sleeve (if applicable),
and nut from wire rope cable.
B. Cleaning and Inspection of Nut.
1. Clean the nut with isopropyl alcohol, or equivalent, and a clean cloth.
2. Using a 10x magnifying glass, visually examine the entire nut, especially the areas surrounding the
access holes, as well as the outside diameter of the nut. Refer to Figure 2.
3. If no cracks are found reinspect the nut every six months. The requirement of this recurring 10x visual
inspection may be combined and satisified with any maintenance action requiring hook assembly
removal and replacement i.e. cable change out, hook assembly cleaning, etc.

CAGE CODE 08484
Union NJ, 07083 USA SB BL-5448-1 -25-01

4. 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, contact Breeze-Eastern to obtain a new nut in acccodance
with Section I, Paragraph F.
Using a 10x magnifying BL-5448
glass, visually inspect BL-5448-1
entire nut, especially in the Side View
areas surronding the access
holes and outside diameter
of nut.
BL-5448-1 Nut Shown with

locking secrews installed
BL-5448 Nut
Figure 2. Visual Inspection of BL-5448 and -1 Nut. (Note: BL-5448-1 Nut has two additional holes).
C. Install Hook Assembly
Assembly
NOTE: All procedures with the note VITAL INSPECTION POINT and parts identified with the note VP
require 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 shall be
documented in both the helicopter and rescue hoist / cargo winch maintenance log.
1. Slide nut, then sleeve (if applicable) over the ball end of the cable then up the wire rope cable toward
the rescue hoist or cargo winch assembly.

CAGE CODE 08484
Union NJ, 07083 USA SB BL-5448-1 -25-01

HOOK WITH THE CHAMFERED, OR CONE SHAPED, END OF THE TERMINAL CLAMP
2. Install two piece terminal clamp around ball end of cable and secure clamp with ring around cable ball
end. Refer to Figure 3. Note: “H1025”
Marking Surface
Terminal Cable
Clamp Shown with nut
threaded into
corresponding housing
Retaining / body.
Cotter Pins &
Ring Locking Screws
Nut
Sleeve
Figure 3. Proper Terminal Clamp Orientation and Installation.
3. Slide sleeve (if applicable), and nut down cable until sleeve, and / or nut, sit properly over terminal
clamp.
4. Slide bumper assembly down to top surface of nut. Snap bumper assembly spring onto nut. Bumper
assembly must sit flush with top of nut.
5. Install assembled hook parts onto nut by threading body, or housing, and nut together until bottomed.
6. Back off nut to line up tapped holes with next nearest slots in body, or housing. Insert two locking
screws and thread down until it bottoms in slot in body or housing.
7 VITAL INSPECTION POINT Install two cotter pins (VP), which secure the hook assembly through
the slot in the locking screws. Insure hook assembly rotates freely without binding.
8. Apply power to hoist to reel cable and hook assembly back to the full in position.
D. Hook Load Test
Test
After the inspection is completed, and the hook has been reassembled on the rescue hoist, or cargo winch,
a hook load test shall be accomplished to ensure proper assembly.
The test procedure to check for proper installation of the hook is by applying the rated load of the hoist, or
winch, as follows:

CAGE CODE 08484
Union NJ, 07083 USA SB BL-5448-1 -25-01

1. Apply power to hoist / winch and reel out cable until the hook assembly can be connected to a weight
for the rated load of the hoist / winch that is resting on the ground.
2. Attach load on hook assembly and slowly reel cable in until the weight is lifted off the ground, or in
the case of a winch the load begins to move.
3. Once weight is lifted off the ground, or movement is observed, lower weight back to the ground, or
stop operation.
4. Remove weight and run rescue hoist / cargo winch to the full in position to secure the hook and
bumper assembly.
5. Remove power to the rescue hoist / cargo winch.

CAGE CODE 08484
TransTechnology Corporation 700 Liberty Avenue SB HK-121-SERIES-25-01
Union NJ, 07083 USA
SERVICE BULLETIN Original Release 08/15/05
Page 1 of 11
Part Number HK-121-Series Hook Assembly

Configuration Substitution on Rescue Hoist
SUBJECT: This Service Bulletin provides general instructions to install the HK-121-Series Hook
Assemblies on the applicable Rescue Hoist(s).
A. Effectivity.
This Service Bulletin (SB) is limited in effect and distribution to the following operator, applicable
hoist serial numbers, helicopter model, and registration numbers listed in Table 1. “Effectivity Matrix.”

New Hook Replaces Rescue Hoist Hoist Helicopter Helicopter Requested
Assembly Hook PN Serial Registration Model By*
Part Number Assembly PN Number Number
(PN)
HK-121-7 BL-5740-14 BL-29700-23 042 N109HP AS350 B3 CHP
046 N708HP AS350 B3 CHP
050 N216HP AS350 B3 CHP
055 N811HP AS350 B3 CHP
059 N414HP AS350 B3 CHP
062 N617HP AS350 B3 CHP
065 N341HP AS350 B3 CHP
067 N314HP AS350 B3 CHP
068 N217HP AS350 B3 CHP
084 N108HP AS350 B3 CHP
093 N64HP AS350 B3 CHP
* California Highway Police
B. Reason.
The helicopter operator, as defined in Table 1. “Effectivity Matrix” above requested a substitute hook
assembly be installed on their hoist(s). Breeze-Eastern investigated / researched the operator’s request
and has “No Technical Objection” to the hook assembly substitution.
C. Description.
The hook assembly on the existing hoist configuration will be removed and replaced with the
HK-121-Series Hook Assembly (Note: HK-121 Series Hook Assemblies have several dash number
NOTICE: This Service Bulletin contains Breeze-Eastern, a Division of TransTechnology 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.
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.
CAGE CODE 08484
Union NJ, 07083 USA
Page 2 of 11
Part Number HK-121-SERIES Hook Assembly

Hook Assembly Configuration Substitution
variations from which the operator may choose for his rescue hoist). The HK-121-Series is completely
interchangeable functionally, and physically, with the hook assembly listed in Table 1. “Effectivity
Matrix.”
This Service Bulletin is for convenience and can be accomplished anytime the helicopters and hook
assemblies are available.
E. Manpower.
The hook assembly change out is estimated to take one (1) maintenance technician approximately
twenty (20) minutes to disassemble, reassemble, and test.
The applicible operator selected dash number for the HK-121 Hook Assembly will have to be
purchased.
For price and availability of the hook assembly contact:
After Market Sales Coordinator

Phone Number: Direct (908) 206-3875, or 1-800-929-1919 (Toll-Free US and Canada only)
Fax: (908) 686-9292 Attention: Cathy Palleschi, or E-Mail: cpalleschi@breeze-eastern.com
Any questions pertaining to this SB should be directed to Breeze-Eastern’s Customer Services

contacts listed below
E-Mail: customer.services@breeze-eastern.com
Not applicable.
Not applicable.
Service Bulletin HK-121-SERIES-25-01 ATA 100 Format

CAGE CODE 08484
Union NJ, 07083 USA
Page 3 of 11

Not affected.
Not applicable.
K. References.
Technical Document (TD) 01-002 “Flight Line Operation and Maintenance Manual For The HS-29700
Series Rescue Hoist System” can be used for reference information and hook disassembly.
Not applicable.
The following modifications, which were requested by the operator, shall apply as listed in Table 2.
Table 2. Family Tree Modification Relationship
Original Configuration Operator Requested Configuration
BL-29700-23 Rescue Hoist BL-29700-23 Rescue Hoist

• BL-5740-14 Hook Assembly • HK-121-7 Hook Assembly
Complete disassembly, cleaning, routine maintenance, and assembly instructions are provided for the
HK-121-7 Hook Assembly. Please follow the instructions provided for removing the BL-5740-14 Hook
Assembly and replacing it with the HK-121-7 Hook Assembly. Use the additional instruction as
necessary.
This Service Bulletin number (SB HK-121) shall be registered on the applicable rescue hoist log card, as
well as the rescue hoist identification plate by either ink stamping and overcoating with clear lacquer, or
lightly steel stamping by hand, or equivalent after the customer part number line of the identifcation
plate.
CAGE CODE 08484
Union NJ, 07083 USA
Page 4 of 11

PN BL-5740-14
Disassembly Procedure.
IIA. BL-5740-14 Hook Assembly Removal (Refer to Figure 1).
1. Remove Hook Assembly from cable.

A. Apply power to hoist.
B. Pay out approximately 6 feet (1.8 meters) of cable from hoist, or as needed, to allow the hook and
bumper assemblies to rest on a clean flat surface with 3 feet (.91 meter) of slack.
C. Disconnect power from Hoist Assembly.
D. Separate the bumper assembly from the swivel hook assembly. Pull bumper assembly from top of sleeve
(Item 13) and slide it up wire rope cable toward the Hoist Assembly.
E. Remove and discard cotter pins (Item 16). Remove locking screws (Item 15) from hook assembly.
F. While holding the body (Item 3), unthread nut (Item 14), and remove bottom half of hook assembly.
G. Slide nut (Item 14) and sleeve (Item 13) up wire rope cable away from the cable ball end to expose
terminal clamp (Item 11).
CAUTION: THE TERMINAL CLAMPS OF THE BL-5740-14 AND HK-121-7 ARE NOT
INTERCHANGEABLE.
H. Remove retaining ring (Item 18) from terminal clamp (Item 11) to allow removal of terminal clamp,
sleeve (Item 13), nut (Item 14), and bumper assembly (if necessary) from wire rope cable. Remove and
retain the two terminal clamp pieces in a matched set using retaining ring (Item 18).
NOTE: NO FURTHER DISASSEMBLY IS REQUIRED FOR BL-5740-14 HOOK ASSEMBLY
CHANGE OUT. THE FOLLOWING INSTRUCTIONS ARE PROVIDED ONLY IF THE
OPERATOR WANTS TO FULLY DISASSEMBLE THE HOOK ASSEMBLY, REATTACH
PARTS TO HOOK ASSEMBLY AND STORE AS NECESSARY.
I. Remove rubber bumper (Item 10) with label (Item 12) from bottom half of hook assembly.
J. If necessary, remove label (Item 12) from rubber bumper (Item 10).

CAGE CODE 08484
Union NJ, 07083 USA
Page 5 of 11

K. Align the holes in the body (Item 3) to allow access to the spring pin (Item 9) in the swivel hook
L. Unthread castellated nut (Item 8) from swivel hook assembly (Item 1).
M. Remove body (Item 3) from swivel hook.
N. Remove bearing retainer (Item 7) with preformed packing (Item 6), needle thrust bearing races (Items 4
and 19), needle thrust bearing (Item 5), ball bearing (Item 2), from body (Item 3).
P. Remove spacer (Item 17) from stem of hook (1).
Figure 1. BL-5740-14 Section View and Parts List.

CAGE CODE 08484
Union NJ, 07083 USA
Page 6 of 11

PN HK-121-7
Assembly Procedure.
IIB. HK-121-7 Hook Assembly Installation (Reference Figure 2).
Note: All procedures with the note VITAL INSPECTION POINT and parts with item numbers that are
inspection shall be documented in both the helicopter and Hoist maintenance log.
1. Install HK-121-7 hook assembly onto cable as follows:

A. Remove cotter pins (Item 12, Qty. 2) securing locking screws (Item 11, Qty. 2) and back out locking
screws enough to allow removal of nut (10) on replacement hook assembly.
CAUTION: PARTS LOCATED INSIDE OF THE HOOK ASSEMBLY WILL FALL FREE AFTER
DISENGAGEMENT OF THE NUT FROM THE BODY. PLACE THE HOOK ASSEMBLY
ON A FIRM SURFACE BEFORE REMOVING THE NUT.
B. Hold hook housing (Item 2, Qty. 1) and unthread nut (Item 10, Qty. 1) from assembly.
C. Remove ring (Part of Item 17, PN 4718, Qty. 1) securing terminal clamp (Item 17, Qty. 1) together.
D. Slide nut (Item 10, Qty. 1) over ball end of cable.
E. VITAL INSPECTION POINT Assemble two halves of terminal clamp (VP Item 17, Qty. 1), with the
cone orientated upward toward the hoist and the ring orientated down toward the hook, around ball end
of cable and secure clamp with ring (VP Part of Item 17, PN 4718, Qty. 1).
F. Slide nut (Item 10, Qty. 1) down over terminal clamp and ball end of cable.
G. Thread nut (Item 10, Qty. 1) and hook housing (Item 2, Qty. 1) together until bottomed. Then back off
to line up tapped hole with nearest slot in housing.
H. Check for binding while holding hook housing (Item 2, Qty. 1), and rotating hook (Item 1, Qty. 1). If
binding is found, remove pin, and back castellated nut off one slot to allow installation of spring pin in
body through stem of hook assembly. Continue this check until binding is eliminated and the hook
rotates smoothly.
I. VITAL INSPECTION POINT Install locking screws (VP Item 11, Qty. 2) and thread down to bottom
of slot in body and secure with cotter pins (VP Item 12, Qty. 2).
J. Push down and snap bumper assembly spring coil onto nut (Item 10, Qty. 1) top surface.
K. Apply power to hoist.
L. Perform Hook Load Test in accordance with Paragraph IIC.
M. Run hoist to the full in position to secure to hook and bumper assembly on hoist.

CAGE CODE 08484
Union NJ, 07083 USA
Page 7 of 11

2. Additional Instruction – Complete assembly of the HK-121-7 hook assembly piece parts as follows:
A. Slide nut (Item 10, Qty. 1) over ball end of cable.

B. VITAL INSPECTION POINT Assemble two halves of terminal clamp (VP Item 17, Qty. 1), with the
cone orientated upward toward the hoist and the ring orientated down toward the hook, around ball end
of cable and secure clamp with ring (VP Part of Item 17, PN 4718, Qty. 1). Slide nut (10) over terminal
clamp (17).
C. Install bearing (Item 3, Qty. 1) and thrust washer (Item 4, Qty. 1) into hook housing (Item 2, Qty. 1).
D. Install flat washer (Item 13, Qty. 1) and housing (Item 2, Qty. 1) onto stem of hook (Item 1, Qty. 1).
NOTE: ONLY TIGHTEN CASTELLATED NUT (5) HAND TIGHT (IF HAND THREADING IS
DIFFICULT A WRENCH CAN BE USED TO ASSIST), THEN BACK-OFF. NEVER TIGHTEN
THE NUT TO REACH THE NEXT AVAILABLE CASTELLATION.
E. Install castellated nut (Item 5, Qty. 1) onto stem of hook and tighten until bearing is fully seated in
housing.
F. VITAL INSPECTION POINT. Back castellated nut (Item 5, Qty. 1) off slightly to allow installation of
new orange colored spring pin (VP Item 6, Qty. 1) through stem of hook and castellated nut, with
access through the housing (Item 2, Qty. 1).
G. Install rubber bumper (Item 14, Qty. 1) onto housing (Item 2, Qty. 1).
H. Thread housing (Item 2, Qty. 1) and assembled hook parts onto nut (Item 10, Qty. 1) on cable. Then
back off to line up tapped hole with nearest slot in housing.
I. VITAL INSPECTION POINT. Install locking screws (VP Item 11, Qty. 2) and thread down to bottom
of slot in body and secure with cotter pins (VP Item 12, Qty. 2).
J. Check for binding while holding hook housing (Item 2, Qty. 1), and rotating hook (Item 1, Qty. 1). If
binding is found, remove pin, and back castellated nut off one slot to allow installation of spring pin in
body through stem of hook assembly. Continue this check until binding is eliminated and the hook
rotates smoothly.
K. Push down and snap bumper assembly spring coil onto nut (Item 10, Qty. 1) top surface.
L. Apply power to hoist.
M. Perform Hook Load Test in accordance with Paragraph IIC. After Verify hook rotates with smooth,
non-binding rotation.

CAGE CODE 08484
Union NJ, 07083 USA
Page 8 of 11

Cleaning and Inspection of Hook Assembly.
3. Cleaning / Inspection
A. Clean all metal parts with isopropyl alcohol, or equivalent. Remove caked on dirt with a stiff bristle
B. Inspect all parts for corrosion. If corrosion exists replace affected parts. If warranted, Magnetic Particle
Routine Maintenance Instructions.
4. Maintenance Practice.
A. Inspect hook parts for cracks, corrosion, damaged threads, and gouges.
B. Check that the keeper in the hook operates without binding, and locks properly, and the rivet holding
the keeper is properly fastened.
C. Check the terminal clamp and ring are properly installed in the hook, and properly oriented with the
cone end pointing toward the top of the hook to secure it to the ball end of the cable.
D. Check to see that locking screws are properly seated in the body and locked in place with the cotter
pins.
E. Check that the hook freely swivels / rotates in a smooth and non-binding manner. If binding occurs,
disassemble, and inspect the bearing 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.
F. After assembly, check that the hook swivels freely without binding.
G. On pre-flight check swivel hook assembly for smooth and non-binding operation, corrosion, and
freeness of latch. Check to see that locking screws are properly seated in the body, and locked in place
with the cotter pins. Check to see the slide lock is secure and travel limit rivets and ball detents are in
place. Check the rivet holding the keeper on the hook assembly is secure. Check that the ball end of
cable has no signs of damage.
H. If the hook assembly is immersed in water (Fresh or salt water), or operated in a high humidity
environment, corrosion may occur. Disassemble hook assembly, rinse with fresh water, clean, dry, and
relubricate, if necessary during post flight inspection after every rescue / training mission.
I. Recommended inspection frequency is as follows:
Recommended Frequency of Inspections Part Name Figure # Inspection Required
(whichever occurs first)*
Every month / 25 hoist cycles / 50 flight hours Hook Assy. Figure 2 Inspect for defects, corrosion, and binding when
installed

CAGE CODE 08484
Union NJ, 07083 USA
Page 9 of 11

HK-121-7 Hook Assembly Removal Instructions.
5. Remove HK-121-7 Hook Assembly from cable.
A. Apply power to hoist.

B. Pay out approximately 6 feet (1.8 meters) of cable from hoist, or as needed, to allow the hook and
bumper assemblies to rest on a clean flat surface with 3 feet (.91 meter) of slack.
C. Disconnect power from hoist.
D. Pull up on bumper assembly, which consists of a bumper retainer, a compression spring, and an over
travel bumper, and slide it along cable away from hook and toward the hoist to separate the bumper
assembly from the nut (Item 10, Qty. 1) in the hook assembly.
E. Remove cotter pins (Item 12, Qty. 2) and locking screws (Item 11, Qty. 2) from nut (Item 10, Qty. 1).
Discard cotter pins.
CAUTION: PARTS LOCATED INSIDE OF THE HOOK ASSEMBLY WILL FALL FREE AFTER
DISENGAGEMENT OF THE NUT FROM THE BODY. PLACE THE HOOK ASSEMBLY
ON A FIRM SURFACE BEFORE REMOVING THE NUT.
F. While holding hook housing (Item 2, Qty. 1), loosen and unthread nut (Item 10, Qty. 1) and remove
hook housing and hook parts from assembly.
CAUTION: THE TERMINAL CLAMPS OF THE BL-5740-14 AND HK-121-7 ARE NOT
INTERCHANGEABLE.
NOTE: TERMINAL CLAMP (ITEM 17 Qty. 1) IS A TWO-PIECE MATCHED SET. KEEP BOTH
G. Remove ring (part of Item 17, Qty. 1) from terminal clamp (Item 17, Qty. 1), and then remove terminal
clamp and nut (Item 10, Qty. 1) from cable.
H. Remove rubber bumper (Item 14, Qty. 1) from hook assembly.
I. Line up hole in hook housing (Item 2, Qty. 1) and, using a drift and a mallet, gently tap out orange
colored spring pin (Item 6, Qty. 1) to remove it from hook assembly.
J. Remove castellated nut (Item 5, Qty. 1) from top of the hook assembly.
K. Remove thrust washer (Item 4, Qty. 1), ball bearing (Item 3, Qty. 1), housing (Item 2, Qty. 1) from
hook (Item 1, Qty.1), and remove flat washer (Item 13, Qty. 1) from hook (Item 1, Qty. 1).
NOTE: HOOK (ITEM 1, QTY. 1) IS A PURCHASED ITEM AND THIS INSTRUCTION DOES NOT
INCLUDE DISASSEMBLY OF THIS ITEM.

CAGE CODE 08484
Union NJ, 07083 USA
Page 10 of 11

1 BL-11682-5
17 Clamp, Terminal
17 VP - 16 - Not Used
10 - 15 - Not Used
12 VP 1 BL-4719
14 Bumper, Rubber
11 1 AN960C816
13 Washer, Flat
VP 6
2 MS24665-88 Pin, Cotter
12
5 2 BL-9920
11 Screw, Locking
2 1 BL-11685-1
10 Nut
14 - 9 - Not Used
3 4 - 8 - Not Used
13 - 7 - Not Used
1 BL-14792-2
6 Pin, Spring
1 BL-8089
5 Nut, Castellated
1 BL-11684-2
4 Washer, Thrust
1 AJ-9800-95-
3 Bearing, Ball
8
1 2 BL-11686-1 Housing, Hook
1 1 BL-15704-2 Hook
QTY. ITEM PART DESCRIPTION
REQD NO. NUMBER
HK-121-7 HOOK ASSEMBY PARTS LIST
Note: Bumper Assembly PN BL-12816-1 (not shown)

1 is used with Hook Assembly HK-121-7
VP
Figure 2. HK-121-7 Section View and Parts List

CAGE CODE 08484
Union NJ, 07083 USA
Page 11 of 11

IIC. Hook Load Test.
1. Test for correct assembly as follows:
After the hook assembly change out is completed a hook load test shall be accomplished to ensure proper
assembly.
The test procedure to check for proper installation is to apply a 450 lb. (204 kg.) load to the hook:
A. Run hoist to slowly pay out cable until the hook can be connected to a weight of 450 lb. (204 kg.) that
is resting on the ground.
B. Connect load to hook and slowly reel cable in until the weight is lifted off the ground.
C. Once weight is off the ground, lower weight back to the ground.
D. Remove weight and run hoist to the full in position to secure the hook and bumper assembly.

Address: Date: 10/10/2008 Manual: TD-04-006
Breeze-Eastern (M. Koons)
700 Liberty Ave Manual Revision: Original Revision Date: 1/11/2005
Union, NJ 07083 Section 25-61-00 Page 1009 Para
Phone: 908 206-3811
Figure Table Item 1002-900
Part Number Affected: AJ-9800-31-2 Ball Bearing
E Mail: mkoons@breeze-eastern.com
The AJ9800-31-2 ball bearing listed as a component of BL-6759 roller assembly is incorrect. Per the BL-6759
drawing, the correct ball bearing is AJ-9800-31-3.
Initiator: M. Koons Title: VP of Contracts and Aftermarket Sales

Date Received: 10/10/08 Received By: Robert Kajor Tracking Number: TPDR04006101008002
BE Research Result:
There is a typo, the AJ9800-31-2 ball bearing listed as a component of BL-6759 roller assembly is incorrect. Per
the BL-6759 drawing, the correct ball bearing is AJ-9800-31-3.
Also, a general note on page 1009, items (890) and (920), stating that the Roller Assemblies are generally replaced
as an assembly, but the individual parts can be changed out.
Response to Customer:
This TPDR will be attached to the back of the manual as an approved change and will be incorporated at the next
revision.
Engineering Services: Robert Kajor Date: 10/10/08 Customer Services: Mike Koons, Chuck Date: 10/10/08
Duncan, Phil Lehrer

Attn: Engineering Services

TD-04-006 Rev

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EXPORT CONTROLLED – WARNING

REVISION REVISION DATE DATE REVISION REVISION DATE DATE

REV. ISSUE DATE REMOVAL INCORPORATOR’S REMOVER’S

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

DESCRIPTION AND OPERATION

Figure 1. HS-20200-511 Series Rescue Hoist System.

F. Wire Rope Cable

Figure 2. Limit Switch Actuation Positions

L. Cable Foul Indicator

O. Leading Particulars for Rescue Hoist System

Variable Speed Controller

CAUTION: THE TENSION ROLLER SYSTEM WORKS ON THE BASIS OF FRICTION,

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

TESTING AND TROUBLESHOOTING

Symbol Function Requirements

UP Limit Switch S3 Actuation

Cam Adjustment Screws

Figure 102. Limit Switch Actuation Positions

NOTE: Ensure Retaining Ring (710), Pin

Spring (730) for Pin (720)

Retaining Ring (710) for Pin (720)

Pin (720) for Actuating Full In Limit Switch

C. Cable Foul Indicator Test

Figure 104. Cable Foul Assembly Inspection and Adjustment

1.00 to 1.39 in.

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

Trouble Probable Cause Remedy

Trouble Probable Cause Remedy

Trouble Probable Cause Remedy

Trouble Probable Cause Remedy

Trouble Probable Cause Remedy

6. Rescue Hoist Assembly Electrical Continuity Check.

Table 102. Electrical Continuity Check

If defect cannot be corrected, contact Breeze-Eastern Customer Services at the following:

Figure 204. EC-14170-1 Pendant Cable Assembly Wiring Diagram

Cable Cutter Cartridge

Cable Guide Assembly

Figure 301. Cable Cutter Cartridge in Cable Guide Assembly

H. Remove rubber bumper (120) from hook assembly.

NOTE: TERMINAL CLAMP (100) IS A TWO-PIECE MATCHED SET. KEEP BOTH

Screws (40) and Washers (60)

Limit Switch Cover (90)

Identification Plate (1020)

Figure 302. Limit Switch Cover

15. Remove cable from hoist as follows:

WARNING: THE CARTRIDGE IS AN EXPLOSIVE DEVICE AND MUST BE SHIPPED,

Mount Cleats (830) and

Full Out Limit Switch S2 (110)

A– JANUARY E– MAY J – SEPTEMBER

Cotter Pin (165)

Figure 304. Cable Guide Assembly with Cable Guide (190)

18. Remove tension roller shaft assembly as follows:

20. Remove chain as follows (see Figure 305):

Figure 305. Chain, Sprocket, Follower, and Attaching Hardware

22. Remove follower as follows:

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

Figure 402. Example of Corrosion on Drum

Table 501. Inspection Requirements

Figure 501. Examples of Unacceptable Damage to Gear

Figure 502. Tension Roller Gear and Overrunning Clutch Assembly

Figure 503. Tension Roller Replacement Criteria

Figure 504. Overrunning Clutch Assembly (Typical)