TD-01-006

Revision C

FLIGHT LINE OPERATION AND MAINTENANCE MANUAL

HS-29900-30, -30-4, & -36 RESCUE HOIST SYSTEMS

TO: HOLDERS OF BREEZE-EASTERN OPERATION AND

MAINTENANCE MANUAL FOR HS-29900-30 AND -30-4 RESCUE
HOIST SYSTEMS, TD-01-006, REVISION B.

THIS IS TO INFORM YOU OF THE RELEASE OF

TD-01-006 REVISION C, DATED APRIL 30, 2010

HIGHLIGHTS
Revision C replaces in its entirety Revision B of TD-01-006, dated August 2, 2004. Please discard
revision B and replace it with Revision C. Thereafter, indicate on the Record of Revisions page the date
of this action, as well as the initials of the individual performing this task.
PARAGRAPH DESCRIPTION OF CHANGE

All Added HS-29900-36 Configuration to Manual.

All General Manual Revision.
Added / Deleted / Addressed
CO 21136, CO 21032, & IPL PN Change 11/04/05
CO21150
TPDR053106005 IPL PN Change 05/30/06
SIL01 Maintenance Hoist & Winch Maint. Concept Rev. B, 10/03/06
TPDR042805004 Cable Guide Roller IPL/IPB & Tension Rev. A, 04/28/05
Roller Change Out
TPDR101008006 & CO 21358 Cable Attach Screw PN Change 11/10/08
TPDR080509007 Add Gear Guard Clarifying Note 08/05/09
SB Wire Rope Cables 1500 cycle recommended change vs. 06/02/06
mandatory change
SIL05 Maintenance Electronics cleaning advisory 05/15/07
CO 27629 Pressure Cartridge Time Extension from 3 to 02/11/10
5 Years
SB HK-121-1, -2, -3, -4 -25-01 One time NDT inspection Rev. A 06/11/04
SB BL-4712-1, -2, -3 -25-01 Thrust Bearing Corrosion and Lubrication. Rev. A 06/11/04
DELETED FROM MANUAL – Not a Flight Line Maint. Task – Mid-Section
BSRP 0001 Bore Repair
TPDR010807006 Reviewed - No Effect On Manual
SB HK-121-1, -2, -3, -4-25-01 Slide Lock one time FPI. Notation made in Rev. A 06/11/04
manual Hook Assembly IPL.
NOTE: BREEZE-EASTERN CORPORATION HAS MOVED ITS CORPORATE AND
MANUFACTURING FACILITY TO: 35 MELANIE LANE, WHIPPANY, NJ 07981-1638
FROM 700 LIBERTY AVENUE, UNION, NJ 07083.
NEW MAIN PHONE 973-602-1001, 800-929-1919.

HIGHLIGHTS
Page H-1
April 30, 2010
 TD-01-006
Revision C

FLIGHT LINE OPERATION AND MAINTENANCE MANUAL

With
Illustrated Parts List
Rescue Hoist Systems
BREEZE-EASTERN PART NUMBERS
HS-29900-30, HS-29900-30-4, & HS-29900-36

SAFETY WARNING
For your own safety and the safety of all others, read and understand all of the procedures and information in this operation and
maintenance manual before installing, operating, and / or maintaining any components of the rescue hoist systems covered herein.
EXPORT CONTROLLED WARNING
This manual may contain information that is subject to the International Traffic in Arms Regulations (ITAR) or the Export
Administration Regulations (EAR), and may not be exported, released, or disclosed to foreign nationals, either in the United States or
overseas, without first complying with the export requirements/regulations of the ITAR and/or EAR. The recipient is responsible for
complying with all such export requirements / regulations. Include this notice with any reproduced portions of this document.
PROPRIETARY RIGHTS NOTICE
This manual contains information that is proprietary to Breeze-Eastern Corporation, is an unpublished work protected under
applicable copyright laws and constitutes trade secrets for the purpose of the Trade Secret and Freedom of Information Acts. It is
delivered on the express conditions that it is not to be, used, disclosed or reproduced, in any manner, in whole or in part without the
prior written authorization of Breeze-Eastern Corporation, 35 Melanie Lane, Whippany, NJ, 07981-1638, USA. Nothing contained
herein shall limit any rights granted by Breeze-Eastern under contract. This legend shall be included on any reproduction hereof. All
rights are reserved. Any act in violation of applicable law may result in civil and/or criminal penalties.

25-61-00
Page T-1
April 30, 2010
 TD-01-006
Revision C

FLIGHT LINE OPERATION AND MAINTENANCE MANUAL

HS-29900-30, HS-29900-30-4, & HS-29900-36 RESCUE HOIST SYSTEMS
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 December 19, 2001 - -
A January 31, 2003 - -
B August 02, 2004 - -
C April 30, 2010 - -

25-61-00
Page RR-1
April 30, 2010
Breeze-Eastern Confidential – use or disclosure of data contained on this sheet is subject to the restrictions on the title pages of this manual.
 TD-01-006
Revision C

FLIGHT LINE OPERATION AND MAINTENANCE MANUAL

HS-29900-30, HS-29900-30-4, & HS-29900-36 RESCUE HOIST SYSTEMS
RECORD OF TEMPORARY REVISIONS

Retain this record in the front of the manual. On receipt of temporary revisions, insert the temporary
revision pages in the manual and enter revision number, issue date, date inserted and initials of
individual incorporating temporary revision. Upon receipt of revision that replaces the temporary
revision, insert removal date and initials of individual removing temporary revision.

REV. ISSUE DATE REMOVAL INCORPORATOR’S REMOVER’S

NO. DATE INSERTED DATE INITIALS INITIALS

25-61-00
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April 30, 2010
Breeze-Eastern Confidential – use or disclosure of data contained on this sheet is subject to the restrictions on the title pages of this manual.
 TD-01-006
Revision C

FLIGHT LINE OPERATION AND MAINTENANCE MANUAL

HS-29900-30, HS-29900-30-4, & HS-29900-36 RESCUE HOIST SYSTEMS
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 / document is
incorporated into the manual via a revision, Breeze-Eastern will enter the date terminated.

SERVICE BULLETIN / TPDR / SUBJECT REVISION OPERATOR BREEZE-

ECO NUMBER AND DATE INCORPORATION EASTERN
DATE TERMINATION
DATE
TPDR 011003002 Page 501, Table 501 Tension 01/10/03 August 2, 2004
Roller Information Change
SB BL-11703-1-25-01 & CO 20485 Cable Guide Visual and Rev. A August 2, 2004
Dimensional Inspection 11/14/02
SB EC-23050-1,-2,-3,-4, -25-01 Motor Assembly Repair Rev. A April 30, 2010
08/17/06
ASB BL-12756-1-A25-01 Crushable Honeycomb Bumper Rev. D August 2, 2004
Replacement 06/23//03
SB EC-23000-2, -3, -6, -7-25-01 Controller Assembly Repair Rev. B April 30, 2010
08/17/06
CO 21136, CO 21032, & CO21150 IPL PN Change 11/04/05 April 30, 2010
TPDR053106005 IPL PN Change 05/30/06 April 30, 2010
SIL01 Maintenance Hoist & Winch Maint. Concept Rev. B April 30, 2010
10/03/06
TPDR042805004 Cable Guide Roller IPL/IPB & Rev. A April 30, 2010
Tension Roller Change Out 04/28/05
TPDR101008006 & CO 21358 Cable Attach Screw PN Change 11/10/08 April 30, 2010
TPDR080509007 Add Gear Guard Clarifying Note 08/05/09 April 30, 2010
SB Wire Rope Cables 1500 cycle recommended change 06/02/06 April 30, 2010
vs. mandatory change
SIL05 Maintenance Electronics cleaning advisory 05/15/07 April 30, 2010
CO 27629 Pressure Cartridge Time 02/11/10 April 30, 2010
Extension from 3 to 5 Years
SB HK-121-1, -2, -3, -4 -25-01 One time NDT inspection Rev. A April 30, 2010
06/11/04
SB BL-4712-1, -2, -3 -25-01 Thrust Bearing Corrosion and Rev. A April 30, 2010
Lubrication. 06/11/04
DELETED FROM MANUAL – Not a Flight Line Maint. Task – April 30, 2010
BSRP 0001 Mid-Section Bore Repair
TPDR010807006 Reviewed - No Effect On Manual April 30, 2010
SB HK-121-1, -2, -3, -4-25-01 Slide Lock one time FPI. Rev. A April 30, 2010
Notation made in manual Hook 06/11/04
Assembly IPL.

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April 30, 2010
Breeze-Eastern Confidential – use or disclosure of data contained on this sheet is subject to the restrictions on the title pages of this manual.
 TD-01-006
Revision C

FLIGHT LINE OPERATION AND MAINTENANCE MANUAL

HS-29900-30, HS-29900-30-4, & HS-29900-36 RESCUE HOIST SYSTEMS
LIST OF EFFECTIVE PAGES
*Indicates pages revised, added or deleted in latest revision.
Description Page Date
Highlights H-1 April 30, 2010
25-61-00, Title Page T-1 April 30, 2010
Record of Revisions RR-1 April 30, 2010
Record of Temporary Revisions RTR-1 April 30, 2010
Service Bulletin List SBL-1 April 30, 2010
List of Effective Pages LEP-1 April 30, 2010
LEP-2 April 30, 2010
LEP-3 April 30, 2010
LEP-4 April 30, 2010
LEP-5 April 30, 2010
Table of Contents T/C-1 April 30, 2010
T/C-2 April 30, 2010
T/C-3 April 30, 2010
T/C-4 April 30, 2010
T/C-5 April 30, 2010
T/C-6 April 30, 2010
Introduction INTRO-1 April 30, 2010
INTRO-2 April 30, 2010
Description and Operation 1 April 30, 2010
2 April 30, 2010
3 April 30, 2010
4 April 30, 2010
5 April 30, 2010
6 April 30, 2010
7 April 30, 2010
8 April 30, 2010
9 April 30, 2010
10 April 30, 2010
11 April 30, 2010
12 April 30, 2010
13 April 30, 2010
14 April 30, 2010
Testing and Troubleshooting 101 April 30, 2010
102 April 30, 2010
103 April 30, 2010
104 April 30, 2010
105 April 30, 2010
106 April 30, 2010
107 April 30, 2010

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Breeze-Eastern Confidential – use or disclosure of data contained on this sheet is subject to the restrictions on the title pages of this manual.
 TD-01-006
Revision C

FLIGHT LINE OPERATION AND MAINTENANCE MANUAL

HS-29900-30, HS-29900-30-4, & HS-29900-36 RESCUE HOIST SYSTEMS
Description Page Date
Testing and Troubleshooting (continued) 108 April 30, 2010
109 April 30, 2010
110 April 30, 2010
111 April 30, 2010
112 April 30, 2010
113 April 30, 2010
114 April 30, 2010
115 April 30, 2010
116 April 30, 2010
117 April 30, 2010
118 April 30, 2010
119 April 30, 2010
120 Blank
Schematics and Wiring Diagrams 201 April 30, 2010
202 April 30, 2010
203 April 30, 2010
204 April 30, 2010
Disassembly 301 April 30, 2010
302 April 30, 2010
303 April 30, 2010
304 April 30, 2010
305 April 30, 2010
306 April 30, 2010
307 April 30, 2010
308 April 30, 2010
309 April 30, 2010
310 April 30, 2010
311 April 30, 2010
312 April 30, 2010
313 April 30, 2010
314 April 30, 2010
315 April 30, 2010
316 April 30, 2010
317 April 30, 2010
318 Blank
Cleaning 401 April 30, 2010
402 April 30, 2010
403 April 30, 2010
404 April 30, 2010
405 April 30, 2010
406 Blank

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Breeze-Eastern Confidential – use or disclosure of data contained on this sheet is subject to the restrictions on the title pages of this manual.
 TD-01-006
Revision C

FLIGHT LINE OPERATION AND MAINTENANCE MANUAL

HS-29900-30, HS-29900-30-4, & HS-29900-36 RESCUE HOIST SYSTEMS
Description Page Date
Checks and Inspections 501 April 30, 2010
502 April 30, 2010
503 April 30, 2010
504 April 30, 2010
505 April 30, 2010
506 April 30, 2010
507 April 30, 2010
508 April 30, 2010
509 April 30, 2010
510 April 30, 2010
511 April 30, 2010
512 April 30, 2010
513 April 30, 2010
514 April 30, 2010
515 April 30, 2010
516 April 30, 2010
517 April 30, 2010
518 April 30, 2010
519 April 30, 2010
520 April 30, 2010
521 April 30, 2010
522 April 30, 2010
523 April 30, 2010
524 April 30, 2010
525 April 30, 2010
526 April 30, 2010
Repair 601 April 30, 2010
602 April 30, 2010
603 April 30, 2010
604 April 30, 2010
605 April 30, 2010
606 April 30, 2010
607 April 30, 2010
608 April 30, 2010
609 April 30, 2010
610 April 30, 2010
Assembly 701 April 30, 2010
702 April 30, 2010
703 April 30, 2010
704 April 30, 2010
705 April 30, 2010
706 April 30, 2010
25-61-00
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April 30, 2010
Breeze-Eastern Confidential – use or disclosure of data contained on this sheet is subject to the restrictions on the title pages of this manual.
 TD-01-006
Revision C

FLIGHT LINE OPERATION AND MAINTENANCE MANUAL

HS-29900-30, HS-29900-30-4, & HS-29900-36 RESCUE HOIST SYSTEMS
Description Page Date
Assembly (continued) 707 April 30, 2010
708 April 30, 2010
709 April 30, 2010
710 April 30, 2010
711 April 30, 2010
712 April 30, 2010
713 April 30, 2010
714 April 30, 2010
715 April 30, 2010
716 April 30, 2010
717 April 30, 2010
718 April 30, 2010
Fits and Clearances 801 April 30, 2010
802 April 30, 2010
803 April 30, 2010
804 April 30, 2010
805 April 30, 2010
806 April 30, 2010
807 April 30, 2010
808 April 30, 2010
809 April 30, 2010
810 April 30, 2010
811 April 30, 2010
812 April 30, 2010
Special Tools, Fixtures, & Test Equipment 901 April 30, 2010
902 April 30, 2010
903 April 30, 2010
904 Blank
Illustrated Parts List 1001 April 30, 2010
1002 April 30, 2010
1003 April 30, 2010
1004 April 30, 2010
1005 April 30, 2010
1006 April 30, 2010
1007 April 30, 2010
1008 April 30, 2010
1009 April 30, 2010
1010 April 30, 2010
1011 April 30, 2010
1012 April 30, 2010
1013 April 30, 2010
1014 April 30, 2010
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Breeze-Eastern Confidential – use or disclosure of data contained on this sheet is subject to the restrictions on the title pages of this manual.
 TD-01-006
Revision C

FLIGHT LINE OPERATION AND MAINTENANCE MANUAL

HS-29900-30, HS-29900-30-4, & HS-29900-36 RESCUE HOIST SYSTEMS
Description Page Date
Illustrated Parts List (continued) 1015 April 30, 2010
1016 April 30, 2010
1017 April 30, 2010
1018 April 30, 2010
1019 April 30, 2010

Breeze-Eastern Technical Publication Deficiency Report

25-61-00
Page LEP-5
April 30, 2010
Breeze-Eastern Confidential – use or disclosure of data contained on this sheet is subject to the restrictions on the title pages of this manual.
 TD-01-006
Revision C

FLIGHT LINE OPERATION AND MAINTENANCE MANUAL

HS-29900-30, HS-29900-30-4, & HS-29900-36 RESCUE HOIST SYSTEMS
TABLE OF CONTENTS
Section/Paragraph Title Page
Highlights Highlights ............................................................................. H-1
Cover Cover .................................................................................... T-1
Record of Revisions Record of Revisions ............................................................. RR-1
Record of Temporary Revisions Record of Temporary Revisions .......................................... RTR-1
Service Bulletin List Service Bulletin List ............................................................. SBL-1
List of Effective Pages List of Effective Pages ......................................................... LEP-1
Table of Contents Table of Contents ................................................................. T/C -1
Introduction Introduction
Paragraph 1 General ................................................................................. INTRO-1
Paragraph 2 Proprietary Status and Liability ............................................ INTRO-1
Paragraph 3 Verification ........................................................................... INTRO-2
Section 1 Description and Operation
Paragraphs 1A through 1B Description .............................................................................. 1
Paragraph 1C Breeze-Eastern Customer Service Contact Information .......... 1
Paragraph 1D Rescue Hoist Systems ............................................................. 2
Paragraph 1E Rescue Hoist ............................................................................ 2
Paragraph 1E(1) Tension Roller ......................................................................... 3
Paragraph 1E(2) Wire Rope Cable ..................................................................... 3
Paragraph 1E(3) Swivel Hook ............................................................................ 3
Paragraph 1E(4) Cycle Counter .......................................................................... 3
Paragraph 1E(5) Limit Switches (MS24547-1)................................................... 3
Paragraph 1E(6) Cable Guide ............................................................................. 5
Paragraph 1E(7) Cable Cutter ............................................................................. 5
Paragraph 1E(8) Hoist Controller Assembly....................................................... 6
Paragraph 1E(9) Potentiometer .......................................................................... 6
Paragraph 1F Control Pendant ....................................................................... 6
Paragraph 1G Crew Control Panel ................................................................. 6
Paragraph 1H Pilot Control Panel .................................................................. 6
Paragraph 1I Leading Particulars for Rescue Hoist System ......................... 7
Paragraph 2 Operation ................................................................................. 9
Paragraph 3 Flight Line / Ground Handling Hoist Operation Guidelines.... 13
Section 101 Testing and Troubleshooting
Paragraph 1 Testing .................................................................................. 101
Paragraph 2 Test Equipment and Materials .............................................. 101
Paragraph 3 Test Conditions .................................................................... 101
Paragraph 4 Test ....................................................................................... 101
Paragraph 4A Limit Switch Test ................................................................. 102
Paragraph 4B Digital Readout Test ............................................................. 109
Paragraph 4C Hook Load Test .................................................................... 110
Paragraph 4D Rated Load (Operational Flight) Test .................................. 110

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Breeze-Eastern Confidential – use or disclosure of data contained on this sheet is subject to the restrictions on the title pages of this manual.
 TD-01-006
Revision C

FLIGHT LINE OPERATION AND MAINTENANCE MANUAL

HS-29900-30, HS-29900-30-4, & HS-29900-36 RESCUE HOIST SYSTEMS
TABLE OF CONTENTS (continued)
Section/Paragraph Title Page
Section 101 (continued) Testing and Troubleshooting
Paragraph 4E Bumper Assembly and Full In Limit Switch Test ..................... 112
Paragraph 5 Troubleshooting Procedures ..................................................... 113
Section 201 Schematics and Wiring Diagrams ............................................. 201
Section 301 Disassembly
Paragraphs 1 and 2 General ...................................................................................... 301
Paragraph 3 Rescue Hoist Assembly ............................................................ 301
Paragraph 4 Pilot Control Panel Assembly ................................................... 302
Paragraph 5 Crew Control Panel Assembly .................................................. 303
Paragraph 6 Control Pendant Assembly and Pendant Cable Assembly ....... 303
Paragraph 7 Bumper Assembly and Swivel Hook Assembly ....................... 303
Paragraph 8 Wire Rope Cable ....................................................................... 304
Paragraph 9 Cable Cutter .............................................................................. 305
Paragraph 10 Midsection Support Covers, Forward, and Aft Cowling
Assemblies, and Cable Cutter Cable Assembly ........................ 306
Paragraph 11 Roller and Housing Assembly .................................................. 307
Paragraph 12 Motor Assembly ....................................................................... 309
Paragraph 13 Controller Assembly ................................................................. 310
Paragraph 14 Cyclocentric Drive Assembly (with Full Out, Emergency
Full Out, and Intermediate Speed Limit Switches) ................... 313
Paragraph 15 Full In Limit Switch .................................................................. 314
Paragraph 16 Cable Guide Assy.-Cable Roller Support, Guide, Spring, Press 314
Paragraph 17 Tension Roller Removal / Change Out ..................................... 315
Paragraph 18 Label and Identification Plate ................................................... 317
Section 401 Cleaning
Paragraph 1 General ...................................................................................... 401
Paragraph 2 Cable (if exposed to lubricants) ................................................ 403
Paragraph 3 Hoist, Hook and / or Cable (if exposed to saltwater) ................ 403
Paragraph 4 Cowling Windows .................................................................... 405
Paragraph 5 Wiring Harness Assembly ........................................................ 405
Section 501 Checks and Inspections
Paragraph 1 General ...................................................................................... 501
Paragraph 2 Inspections ................................................................................ 502
Paragraph 2A Overhaul of Rescue Hoist ......................................................... 502
Paragraph 2B General ...................................................................................... 503
Paragraph 2C Tension Roller ........................................................................... 504
Paragraph 2D Tension Roller Clutch Assy. and Overrunning Clutch Assy. .... 505
Paragraph 2E Wire Rope Cable ....................................................................... 507
Paragraph 2F Swivel Hook Assembly ............................................................ 513
Paragraph 2G Roller and Housing Assembly & Cable Guide Assy. Rollers ... 514

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Breeze-Eastern Confidential – use or disclosure of data contained on this sheet is subject to the restrictions on the title pages of this manual.
 TD-01-006
Revision C

FLIGHT LINE OPERATION AND MAINTENANCE MANUAL

HS-29900-30, HS-29900-30-4, & HS-29900-36 RESCUE HOIST SYSTEMS
TABLE OF CONTENTS (continued)
Section/Paragraph Title Page
Section 501 (continued) Checks and Inspections
Paragraph 2G(1) Roller and Housing Assembly Inspection ................................. 514
Paragraph 2G(2) Cable Guide Assembly Roller Inspection.................................. 515
Paragraph 2H Pilot and Crew Control Panels .................................................. 515
Paragraph 2I Preflight Inspection ................................................................... 516
Paragraph 2J Post Flight Inspection ............................................................... 518
Paragraph 2K Oil Servicing & Recommended Five Year Oil Change............. 520
Paragraph 2L Level Wind Shaft ...................................................................... 522
Paragraph 2M Cable Cutter and Cartridge ....................................................... 522
Paragraph 2N Inspection of Wiring ................................................................. 523
Paragraph 2O Recommended Integrity Check of Individual Limit Switches . 523
Paragraph 2O(1) Full-In Limit Switch Inspection ................................................ 523
Paragraph 2O(2) Full Out, Emerg. Full Out, Emerg. Bypass Limit Switch Insp.. 524
Paragraph 2O(3) Intermediate Slow In & Slow Out Limit Switch Inspection...... 525
Paragraph 2O(4) Limit Switch Test Completion Instructions................................ 526
Section 601 Repair
Paragraph 1 General ...................................................................................... 601
Paragraph 2 Refinish ..................................................................................... 605
Paragraph 3 Minor Surface Repair ................................................................ 605
Paragraph 4 Major Surface Repair ................................................................ 606
Paragraph 5 Application of Top Coat ........................................................... 606
Paragraph 6 Application of Coating on Cable .............................................. 606
Paragraph 7 Cable Foul Removal ................................................................. 607
Paragraph 8 Cable Alignment Adjustment ................................................... 608
Paragraph 9 General Wiring Harness Conn. Pin Replacement Procedures .. 609
Section 701 Assembly
Paragraph 1 General ...................................................................................... 701
Paragraph 2 Vital Point Inspection ................................................................ 701
Paragraph 3 Rescue Hoist System ................................................................ 702
Paragraph 4 Installation of Electrical Components ....................................... 702
Paragraph 4A Cyclocentric Drive Assembly (with Full Out, Emergency
Full Out, and Intermediate Limit Switches) ............................. 702
Paragraph 4B Full In Limit Switch .................................................................. 704
Paragraph 5 Roller and Housing Assembly .................................................. 704
Paragraph 6 Cable Guide Assembly – Cable Roller Support, Guide, Spring 706
Paragraph 7 Tension Roller Installation ........................................................ 707
Paragraph 8 Motor Assembly ....................................................................... 709
Paragraph 9 Controller Assembly ................................................................. 709
Paragraph 10 Midsection Support Covers, Cable Cutter Cable Assembly,
Forward, and Aft Cowling Assemblies ..................................... 710

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 TD-01-006
Revision C

FLIGHT LINE OPERATION AND MAINTENANCE MANUAL

HS-29900-30, HS-29900-30-4, & HS-29900-36 RESCUE HOIST SYSTEMS
TABLE OF CONTENTS (continued)
Section/Paragraph Title Page
Section 701 (continued) Assembly
Paragraph 11 Cable Cutter .............................................................................. 711
Paragraph 12 Wire Rope Cable ....................................................................... 712
Paragraph 13 Bumper Assembly and Swivel Hook Assembly ....................... 713
Paragraph 14 Nameplate and Label ................................................................ 715
Paragraph 15 Rescue Hoist Assembly ............................................................ 715
Paragraph 16 Crew Control Panel ................................................................... 716
Paragraph 17 Pilot Control Panel .................................................................... 716
Paragraph 18 Control Pendant and Pendant Cable ......................................... 717
Paragraph 19 Cartridge ................................................................................... 717
Paragraph 20 Storage ...................................................................................... 718
Section 801 Fits and Clearances ................................................................... 801
Section 901 Special Tools, Fixtures, and Test Equipment ........................... 901
Section 1001 Illustrated Parts List
Paragraph 1 Introduction .............................................................................. 1001
Paragraph 2 Notes ........................................................................................ 1002

LIST OF TABLES
Table Title Page
1 Rescue Hoist System Configuration Matrix ................................................................ 2
2 Leading Particulars for Rescue Hoist System ............................................................. 7
3 Control Pendant Display Interpretations ................................................................... 12
101 Troubleshooting Procedures .................................................................................... 114
401 Required Materials for Cleaning ............................................................................. 401
501 Inspection Requirements ......................................................................................... 501
601 Materials Required for Repair ................................................................................. 601
602 Allowable Material Removal .................................................................................. 602
701 Materials Required for Assembly ........................................................................... 701
801 Allowable Limit Values .......................................................................................... 802
901 Special Tools, Fixtures, and Test Equipment List ................................................... 901

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 TD-01-006
Revision C

FLIGHT LINE OPERATION AND MAINTENANCE MANUAL

HS-29900-30, HS-29900-30-4, & HS-29900-36 RESCUE HOIST SYSTEMS
LIST OF FIGURES
Figure Title Page
1 HS-29900-30, -30-4, and -36 Rescue Hoist Systems .................................................. 1
2 Limit Switch Actuation Locations .............................................................................. 4
101 Full Out and Emergency Full Out Limit Switch Settings ........................................ 103
102 Cyclocentric Drive Assembly .................................................................................. 103
103 Full In Limit Switch Adjustment Decision Tree ...................................................... 107
104 Cable Guide to Roller and Housing Measurement ................................................... 108
105 Pin to Roller and Housing Measurement ................................................................. 108
106 Deflection of Bumper Assembly with Hook at Full In Position .............................. 113
201 Electrical Schematic of the Rescue Hoist Assembly ............................................... 201
202 Rescue Hoist Assembly Wiring Diagram ................................................................ 202
203 Rescue Hoist Systems HS-29900-30 and HS-29900-30-4 Wiring Diagram ............ 203
204 Rescue Hoist System HS-29900-36 Wiring Diagram.................................................204
301 Emergency (Full Out) Bypass Switch Aft Cowling Access Hole ............................ 305
302 Rescue Hoist Front View ......................................................................................... 307
303 Roller and Housing Assembly .................................................................................. 308
304 Motor Assembly Electrical Connectors ................................................................... 309
305 Motor Assembly Connector Location ...................................................................... 311
306 Controller Assembly Removal Sequence ................................................................. 311
307 Location of Mid-Section Wiring Harness Clear Tape and Tie Wraps ...................... 312
308 Permanent Harness Attached to Controller .............................................................. 312
309 Controller Attaching Cap Screw and Washer Locations ......................................... 312
310 Cyclocentric Drive Assembly .................................................................................. 313
311 Full In Limit Switch Location................................................................................... 314
312 Cable Guide Assy. Guide, Spring, and Pressure Roller Assy. Locations. ................ 315
313 Tension Roller and Pressure Roller Spring View ..................................................... 316
314 Tension Roller End Cap and Motor Mount View ..................................................... 316
401 Example of Corrosion on Hook Assembly Parts ..................................................... 404
402 Example of Corrosion on Drum ............................................................................... 404
501 Examples of Unacceptable Damage to Gear ............................................................ 504
502 Tension Roller Replacement Criteria ....................................................................... 505
503 Tension Roller and Overrunning Clutch Assemblies ............................................... 506
504 Overrunning Clutch Assembly ................................................................................. 506
505 Example of Broken Strands in Wire Rope Cable ..................................................... 508
506 Example of Abrasion of Wire Rope Cable ............................................................... 508
507 Example of Kink in Wire Rope Cable ..................................................................... 509
508 Example of Bird Caging in Wire Rope Cable .......................................................... 509
509 Example of a Raised Strand in a Wire Rope Cable .................................................. 509
510 Hook Assembly Attachment to Wire Rope Cable ................................................... 511
511 Example of Knot in a Wire Rope Cable ................................................................... 511

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HS-29900-30, HS-29900-30-4, & HS-29900-36 RESCUE HOIST SYSTEMS
LIST OF FIGURES (continued)
Figure Title Page
512 Examples of Wire Rope Cable Looseness ............................................................... 512
513 Required Terminal Clamp Orientation ..................................................................... 513
514 Roller and Housing Assembly Cable Pressure Rollers ...............................................514
515 Visual Inspection and Dimension Measurement of Cable Guide Cover ...................515
516 Cable Guide Assembly Roller Replacement Criteria ............................................... 515
517 Various Hooks and Assembly .................................................................................. 517
518 Hook Assembly Attachment to Wire Rope Cable ................................................... 517
519 Deflection of Bumper Assembly with Hook at Full In Position .............................. 519
520 Dimensions of Crushable Bumper ........................................................................... 519
521 Oil Drain and Fill Bolt / Plug / Dipstick Positions ................................................... 521
522 Inspection of Level Wind Shafts .............................................................................. 522
523 Cyclocentric Limit Switch Positions.......................................................................... 526
601 Wire Rope Cable Coating Dimensions ..................................................................... 607
701 Location of Pins for Connector on Cyclocentric Drive Harness Assembly ............. 703
702 Cable Roller Support – Guide, Spring, and Pressure Roller Assembly Positioning. 707
703 Assembled Tension Roller ........................................................................................ 708
704 Cutaway of Correct Cable Cutter Orientation............................................................ 711
705 Required Terminal Clamp Orientation...................................................................... 714
801 Rescue Hoist Illustration BL-29900-30-1 & -30-4 .................................................. 804
802 Hoist Mid-Section Support (Post) Mount Illustration .............................................. 805
803 Pilot Control Panel, PN EC-23075-2 ....................................................................... 806
803A Pilot Control Panel, PN EC-23075-3 ....................................................................... 807
804 Crew Control Panel, PN EC-23100-2 ...................................................................... 808
804A Crew Control Panel, PN EC-23100-150 .................................................................. 809
805 Control Pendant, PN CP-1100-2 .............................................................................. 810
805A Control Pendant, PN CP-1700-2 .............................................................................. 811
901 BLT-10300-V, Retaining Ring Installation Tool...................................................... 901
902 TE-120-3 Cart (capable of carrying TE-120-1 Calibrated Weight) .......................... 902
903 BLT-27100-H, Table Top Maintenance Fixture ....................................................... 902
904 TE-132-1 Mobile Post Mount Maintenance Fixture ................................................. 903
1001 Rescue Hoist System ............................................................................................. 1003
1002 Rescue Hoist Assembly (Sheets 1 - 7) ................................................................... 1005
1003 Hook and Bumper Assemblies .............................................................................. 1018

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HS-29900-30, HS-29900-30-4, & HS-29900-36 RESCUE HOIST SYSTEMS
INTRODUCTION
1. General
The instructions in this manual provide the necessary information 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 (T-1) 7. Introduction (INTRO) 13. Checks and Inspections (501)
2. Record of Revision (RR-1) 8. Description and Operation (1) 14. Repair (601)
3. Record of Temporary Revisions (RTR-1) 9. Testing and Troubleshooting (101) 15. Assembly (701)
4. Service Bulletin List (SBL-1) 10. Schematics and Wiring Diagrams (201) 16. Fits and Clearances (801)
5. List of Effective Pages (LEP) 11. Disassembly (301) 17. Special Tools (901)
6. Table of Contents (T/C) 12. Cleaning (401) 18. Illustrated Parts List (1001)

Refer to the Table of Contents for the page location of applicable sections. An asterisked flag note
* ( ) in place of the page number indicates that no special instructions are provided since the
function can be performed using standard industry practices.

The beginning of the REPAIR section includes a list of the separate repairs (if appropriate) for the
flight line level of maintenance.

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.

One means of revising this manual to reflect current information and customer input is 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.

Also, attached to the back of the manual can be amending Alert Service Bulletins (ASB’s),
Service Bulletins (SB’s), Service Information Letters (SIL’s), Engineering Change Orders
(ECO’s) all of which constitute an official change to the manual.

2. Proprietary Status and Liability

This Flight Line Operation and Maintenance Manual contains proprietary data, which is the
property of Breeze-Eastern Corporation. Neither this manual, nor any part thereof, shall be
duplicated, used, or disclosed – in whole or in part – for any purpose other than those relating to
the operation and flight line maintenance of the Rescue Hoist Systems by the owner / operator /
maintenance facility.

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Any activity involving the operation, maintenance, and testing of the Rescue Hoist Systems 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 Corporation.

3. Verification:

Testing/Troubleshooting: December 17, 2001

Disassembly: December 17, 2001
Assembly: December 17, 2001

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HS-29900-30, HS-29900-30-4, & HS-29900-36 RESCUE HOIST SYSTEMS
DESCRIPTION AND OPERATION
Crew Control Panel
Control
Pendant

Pendant Cable

Pilot Control Panel

Rescue Hoist
Figure 1. HS-29900-30, -30-4, and -36 Rescue Hoist Systems.
1. Description
A. This publication explains the operation of, and provides flight line maintenance instructions for the
HS-29900-30, -30-4, and -36 Rescue Hoist Systems (see Figure 1). These instructions are to be used
to maintain the Rescue Hoist System(s), with select subassembly removals, in a safe and serviceable
condition while installed on the helicopter. Operators should be aware that maintenance training for
Breeze-Eastern Products is available from our Customer Service Training Group.
B. The Rescue Hoist System provides a means for raising and lowering personnel from an airborne
helicopter. It can be operated from the Control Pendant, or the Pilot Control Panel.
C. Operators are encouraged to coordinate all repair / overhaul work with Breeze-Eastern, or their
authorized Service Centers. Breeze-Eastern is a Federal Aviation Administration (FAA) and a Joint
Aviation Authorities (JAA) FAR / JAR-145 approved Repair Station (FAA Repair Station No.
BZ7R167O, JAR-145 Acceptance Certificate Reference No. JAA.5454), and can repair / overhaul
the system at competitive prices and lead-times. Please contact Breeze-Eastern Customer Services
as follows:
Breeze-Eastern Corporation
35 Melanie Lane
Whippany, New Jersey 07981-1638 USA
Phone Number: 973-602-1001, Ext.1083 or 1090, or 1-800-929-1919 (US and Canada only)
Fax Number: 973-739-9344
E-mail Address: customerservices@breeze-eastern.com
Web Site Address: www.breeze-eastern.com
Revision status of the Breeze-Eastern technical manuals can be checked on the Web Site listed
above.

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HS-29900-30, HS-29900-30-4, & HS-29900-36 RESCUE HOIST SYSTEMS

D. Rescue Hoist Systems

The Rescue Hoist Systems consist of the following components (See Table 1), which are considered
Line Replaceable Units (LRUs):
Control Pendant Pilot Control Crew Control Pressure
Rescue Hoist Rescue Hoist Hook
Pendant Cable Panel Panel Cartridge
System Assembly Assembly
Assembly Assembly Assembly Assembly Kit
HS-29900-30 BL-29900-30-1 CP-1100-2 EC-14170-2 EC-23075-2 EC-23100-2 HK-121-2 BL-11140-3
HS-29900-30-4 BL-29900-30-4 CP-1100-2 EC-14170-2 EC-23075-2 EC-23100-2 HK-102-3 BL-11140-3
HS-29900-36 BL-29900-30-1 CP-1700-2 EC-14170-2 EC-23075-3 EC-23100-150 HK-121-2 BL-11140-3
Table 1. Rescue Hoist System Configuration Matrix
The Rescue Hoist Systems, as shown in Figure 1, are comprised of an externally mounted Rescue
Hoist, Control Pendant with Pendant Cable, Pilot Control Panel, and Crew Control Panel, which are
all considered Line Replaceable Units (LRUs). The Rescue Hoist System main power requirement
is 200 VAC, 3 Phase, 24 Amperes, at 400 Hertz. The power required for the controls (Control
Pendant, Crew Control Panel, Pilot Control Panel, and the cable cutter for the Rescue Hoist) is 28
VDC, 5 Amperes. AC power, supplied by the helicopter is converted into DC power by the
controller assembly, which is integral to the Rescue Hoist. This controller assembly provides the
necessary DC power to the electric motor driving the drum on the Rescue Hoist. The power for the
electroluminescent panels on the Crew Control and Pilot Control Panels is supplied by separate
interfaces from the helicopter.
E. Rescue Hoist
The Rescue Hoist includes a brushless electric motor assembly, hoist assembly, controller assembly,
and aerodynamic fairings, and is designed for installation on the exterior of the helicopter. The hoist
assembly contains a rotating drum, which is driven by the electric motor through a gear train and
clutch assembly, raising and lowering a 290 ft. (88.4 m.) wire rope cable and swivel hook. The
Rescue Hoist operates at variable speeds from 0 to 350 feet per minute (1.78 meters per second).
The clutch assembly slips if the load on the hook exceeds 1200 to 1800 lb. (544 to 816 kg.),
protecting the wire rope cable and support structure. A level wind mechanism on the hoist assembly
ensures even wrapping of the wire rope cable on the drum. Redundant limit switches sense when the
cable approaches the full-in, or full-out positions to slow the speed of the hoist and sense when the
cable reaches these positions to stop the hoist.
Implementation of Conversion Kit KT-351, using Conversion Procedure TD-02-021, upgrades the
BL-29900-30 Rescue Hoist to the BL-29900-30-1 configuration. This conversion, which adds an
EMI filter to the connector on the cyclocentric drive harness assembly, and properly torques the
connectors mounted on the integral electronic controller, is required to meet the Electromagnetic
Vulnerability (EMV) requirements for the Rescue Hoist System.
Implementation of Conversion Kit KT-466 re-identifies BL-29900-30-1 Rescue Hoists with the
HK-102-3 Hook Assembly as BL-29900-30-4 Rescue Hoists. This conversion kit consists of a new
nameplate for the hoist with four new mounting screws. Implementation of this conversion kit also
re-identifies the Rescue Hoist System as PN HS-29900-30-4.

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HS-29900-30, HS-29900-30-4, & HS-29900-36 RESCUE HOIST SYSTEMS
(1) Tension Roller
The Rescue Hoist utilizes a tension roller that is driven by the drum gear through two clutches,
an overrunning clutch and tension roller clutch. This tension roller drive train provides for the
tangential speed of the tension roller to be faster than the tangential speed of the drum when
reeling out, maintaining a “pull” force on the wire rope cable even at no load, and the tangential
speed of the tension roller to be slower than the tangential speed of the drum when reeling in,
providing a “drag” force on the cable, thereby ensuring tight cable wraps on the drum under all
conditions.
(2) Wire Rope Cable
The cable for the Rescue Hoist consists of a wire rope with a swaged stainless steel ball / shank
fitting per MS20664C6. The wire rope is a 0.1875 inch (4.76 mm.) diameter, corrosion resistant,
preformed spin resistant type conforming to MIL-W-83140. It is proof-tested in accordance with
MIL-C-5688. During its fabrication an inert gas shielded electric arc process cuts off the drum
end of the wire rope cable, such that the end is sealed, which makes it suitable for attachment at
the drum anchor point.
(3) Swivel Hook
The swivel hook assembly rotates 360 degrees. It attaches to the ball end of the cable using a
terminal clamp captured in a threaded body / housing combination, secured by dual setscrews
and cotter pins. The hook assembly incorporates a lockable keeper to prevent the load from
inadvertently releasing.
(4) Cycle Counter
The Rescue Hoist has a counter, controlled by electronics in the controller assembly, which
records each revolution of the drum. The number on the counter, divided by 350, provides the
total number of Rescue Hoist cycles, which is defined as reeling the cable out from the full in to
full out position, and then reeling in the cable back to full in.
(5) Limit Switches (MS24547-1)
WARNING: WHEN NOT IN USE, THE HOOK MUST BE COMPLETELY HOMED IN THE
FULL IN POSITION TO AVOID FATIGUE OF THE CABLE NEAR THE BALL
END DUE TO VIBRATION.
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.
Redundant limit switches control full in, full out, emergency full out, and intermediate speed
with the following purpose (see Figure 2):
(a) The full in switch stops Rescue Hoist operation when the bumper assembly makes contact
with the cable guide pin.
(b) The up intermediate speed switch slows down the Rescue Hoist between 37 to 63 feet per
minute (11.28 to 19.20 meter per second) when reeling in, and within 10 to 12 feet (3.05 to
3.66 m) from full in switch actuation.

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FLIGHT LINE OPERATION AND MAINTENANCE MANUAL

HS-29900-30, HS-29900-30-4, & HS-29900-36 RESCUE HOIST SYSTEMS

Figure 2. Limit Switch Actuation Locations

(c) The down intermediate speed switch slows down the Rescue Hoist between 37 to 63 feet per
minute (11.28 to 19.20 meter per second) when reeling out, between 8 to 10 feet (2.44 to
3.05m) from full out switch actuation.
(d) The full out switch stops Rescue Hoist operation at 3 ½ to 4 ½ dead wraps on the drum.
(e) The emergency full out switch serves as a back-up for the full out switch and stops the
Rescue Hoist at 2 ½ to 3 ½ dead wraps on the cable drum (approximately one less wrap of
cable on the drum than full out).
Intermediate speed up, intermediate speed down, full out, and emergency full out switches are
directly coupled to the drum through the cyclocentric drive assembly to control operation at the
full out, emergency full out, and intermediate speed cable positions (hook approach to helicopter

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FLIGHT LINE OPERATION AND MAINTENANCE MANUAL

HS-29900-30, HS-29900-30-4, & HS-29900-36 RESCUE HOIST SYSTEMS
and hook approach to full extension). The full in switch is built into the cable guide assembly to
ensure proper homing of the hook.
A full out bypass switch, internally mounted on the cyclocentric drive assembly, can be
accessed through an opening in the aft cowling assembly during maintenance to override the full
out and emergency full out switches to allow replacement of the cable.
(6) Cable Guide
The cable guide assembly incorporates four rollers to assist in guiding the cable into the hoist
during large fleet angles (30° from vertical, 60° maximum cone angle), due to high winds or
helicopter movement by swiveling to follow the angle of the cable during these conditions.
(7) 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: THE CARTRIDGE SERVICE LIFE IS 5 YEARS WHEN REMOVED FROM
PACKAGING AND INSTALLED IN RESCUE HOIST. MAXIMUM CARTRIDGE LIFE
IS 9 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: 10 IS 2010), AND ONE LETTER, WHICH
IDENTIFIES THE MONTH, AS DEFINED BELOW:
A) JANUARY B) FEBRUARY C) MARCH D) APRIL
E) MAY F) JUNE G) JULY H) AUGUST
J) SEPTEMBER K) OCTOBER L) NOVEMBER M) DECEMBER
NOTE: IF THE CABLE HAS BEEN CUT, THE ANVIL, CARTRIDGE, CUTTER, O-RINGS,
AND COTTER PIN MUST ALL BE REPLACED. BREEZE-EASTERN REFIRE KIT PN
KT-493 INCLUDES THESE PARTS.
The cable cutter, contained in the cable guide assembly, is comprised of a pressure cartridge,
guillotine, and anvil. The minimum all-fire current of the cartridge is 5.0 amperes per bridge
wire at 28 VDC. If the cartridge needs to be replaced due to expired service, or shelf life the
cartridge can be purchased from Breeze-Eastern in a Pressure Cartridge Kit, PN BL-11140-3,
which consists of one cartridge in a hermetically sealed container, and one O-ring, to be used
with the installation of the new cartridge. In the event the cartridge has been fired during a cable
cut, Breeze-Eastern Refire Kit PN KT-493 can be ordered replacing the anvil, cutter, O-ring,
cotter pin, safety wire, and shims. KT-493 includes Pressure Cartridge Kit BL-11140-3, which
contains a new cartridge, O-Ring, and tie wire.

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HS-29900-30, HS-29900-30-4, & HS-29900-36 RESCUE HOIST SYSTEMS
(8) Hoist Controller Assembly
The integral hoist controller assembly processes electronic signals from the limit switches,
Control Pendant, Pilot Control Panel, and Crew Control Panel to start, slow down, and / or stop
hoist operation, and processes all speed and direction control signals transmitted from the
Control Pendant and Pilot Control Panel.
(9) Potentiometer
A potentiometer, coupled to the drum through the cyclocentric drive assembly, continuously
senses the cable position, which displays on a digital readout in the Control Pendant.
F. Control Pendant
The Control Pendant provides the crewmember with freedom of movement while utilizing the
thumb wheel on the pendant for direction and speed control of the Rescue Hoist. The direction /
speed control thumb wheel is centrally located on the shrouded upper portion of the handgrip. The
direction / speed control mechanism contains, and actuates, two switches and a potentiometer. The
two switches (one for either direction) provide an on / off signal to the controller indicating whether
to raise, or lower, the load. The potentiometer, rotated by the thumb wheel, provides a speed
command signal to the controller.
Note: Cable payout indication if for reference only. Accuracy is ± 5 feet (1.5 m).
The Control Pendant also is equipped with an electrical connector for interfacing with the Crew
Control Panel through the pendant cable, a four-way search light control, a digital display for cable
payout, and three indicator lights showing status of hoist operation. The green indicator lights
provide the operator with a visual indication of the following conditions:
(1) Cable has been fully extended from the Rescue Hoist (labeled “FULL OUT”).
(2) Cable has been fully reeled in onto the Rescue Hoist (labeled “FULL IN”).
(3) A motor over temperature condition has occurred (labeled “MTR HOT”).
These indicators, as well as cable payout digital display, are night vision goggle (NVG) compatible.
The pendants are retained to the structure either by a hook mounting bracket or a wall mounting
bracket on the back of the pendant.
G. Crew Control Panel
The Crew Control Panel has a connector for the cable to the Control Pendant, an arm / test switch, a
squib test light for the cable cutter circuit, a three-position (OFF, ON / NORMAL, and ON / NVG)
search light power switch, a guarded switch for actuating the cable cutter, and an electroluminescent
(EL) display for the front panel. Panel connector locations can vary aft, down, etc.
H. Pilot Control Panel
The Pilot Control Panel has an on / off switch to enable power to the Rescue Hoist, a pilot override
switch to actuate the Rescue Hoist up and down, a guarded switch for actuating the cable cutter, and
an illuminated display for the front panel. Panel connector locations can vary aft, down, etc.

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FLIGHT LINE OPERATION AND MAINTENANCE MANUAL

HS-29900-30, HS-29900-30-4, & HS-29900-36 RESCUE HOIST SYSTEMS
I. Leading Particulars for Rescue Hoist System

Rescue Hoist
Cable:
Type ............................. 19 x 7 strand wraps
Length .......................... 290 feet (88.4 meters) usable length
Diameter ...................... 0.1875 +0.0060 / -0.0010 inch (4.76 +0.15 / -0.03 mm.)
Cable Drum Layers ...... 5
Material ........................ Stainless Steel, flexible, preformed, spin resistant
Cable Speed:
600 pounds (272 kg.) ... 350 fpm (1.78 mps) average when raising load
Load:
Hoist Operating Load .. 600 lb. (272 kg.)
Cable Limit Load ......... 1800 lb. (816 kg.), applied to structure with slip clutch locked
Cable Ultimate Load .... 2700 lb. (1225 kg.), applied to structure with slip clutch locked
Overload Clutch ................. Slips between 1200 - 1800 lb. (544 - 816 kg.)
Cable Tensioning ............... Bi-Directional with dual Level Wind Shafts
Load Holding Brake .......... Optimized, fail-safe Weston-type
Fleet Angle ......................... 30° to centerline (cone angle 60°)
Temperature Range:
Operational .................. -50° F to +160° F ( -46° C to +71° C)
Non-Operational .......... -65° F to +194° F ( -54° C to +90° C)
Altitude .............................. Sea Level to 15,000 Feet (4572 m.)
Input Power ........................ 200 VAC, 3-Phase, 25 Amps, 400 Hz, input to Rescue Hoist
Electric Motor .................... Brushless DC motor with integral power electronics
Control Power .................... 28 VDC, 5 Amps, maximum
Limit Switches ................... Redundant switches, designed IAW MS24547-1
Guillotine ........................... Ballistic type, electrically fired (5 Amps per bridge wire, min.)
Gearbox Oil ....................... MIL-PRF-23699, Class STD (NATO Code No. O-156)
Weight ................................ 105 lb. (47.6 kg.), maximum

Table 2. Leading Particulars for Rescue Hoist System

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HS-29900-30, HS-29900-30-4, & HS-29900-36 RESCUE HOIST SYSTEMS

Control Pendant
Power 28 VDC, 2 amps, provided by integral hoist controller
Speed Control Incremental potentiometer, thumb wheel actuated, returns to neutral
position when force is removed
Directional Control Thumb wheel actuated
Cable Payout NVG compatible, digital display
Indicator Lights (NVG compatible):
“FULL OUT” light illuminates green when the cable is fully extended from the Hoist
“FULL IN” light illuminates green when the cable is fully reeled in onto the Hoist
“MTR HOT” light illuminates green when over temperature condition of motor occurs
Weight 1.5 lb. (0.7 kg.), maximum
Pendant Cable
Weight 1.5 lb. (0.7 kg.), maximum
Crew Control Panel
Power 28 VDC, 2 amps, provided by integral hoist controller
Cable Cut Switch Guarded and painted alternating black and yellow to indicate for emergencies
Cable Cut Power Arm/test switch for cable cut circuit with squib test light
Search Light Power Three position switch, OFF, ON/NORMAL, and ON/NVG
Front Panel Electroluminescent Panel IAW MIL-P-7788, Type V, Class 1, NVIS Green A
Weight 1.3 lb. (0.6 kg.), maximum
Pilot Control Panel
Power 28VDC, 5 Amps, provided by integral hoist controller, and helicopter
Cable Cut Switch Guarded and painted alternating black and yellow to indicate for emergency
situations
Hoist Enable Switch Two-position (ON and OFF) switch to provide power to system
Pilot Override Switch Two-position switch (UP and DOWN)
Front Panel Electroluminescent Panel IAW MIL-P-7788 Type V, Class 1, NVIS Green A
Weight 0.8 lb. (0.4 kg.), maximum

Table 2. Leading Particulars for Rescue Hoist System (continued)

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HS-29900-30, HS-29900-30-4, & HS-29900-36 RESCUE HOIST SYSTEMS
2. Operation
WARNING: DAMAGE WILL OCCUR TO THE RESCUE HOIST SYSTEM IF DC POWER IS
PRESENT ALONG WITH AN OPERATOR COMMAND FROM THE PILOT, CREW
CONTROL (IF APPLICABLE), OR THE PENDANT AND THEN AC POWER IS
APPLIED. POWER SHOULD BE APPLIED USING THE “HOIST POWER SWITCH”
ON THE PILOT CONTROL PANEL.
WARNING: SEARCH AND RESCUE OPERATIONS, AND ALL OTHER USES OF RESCUE
HOISTS FOR HOISTING AND LOWERING PERSONNEL, CAN RESULT IN INJURY
OR DEATH. PROPERLY TRAINED PERSONNEL MUST UTILIZE APPROPRIATE
OPERATION, MAINTENANCE, AND INSPECTION PROCEDURES TO MINIMIZE
THE HAZARDS INHERENT IN THE USE OF ALL RESCUE HOISTS.
WARNING: WORK GLOVES MUST BE WORN BY THE OPERATOR WHENEVER HANDLING
THE RESCUE HOIST CABLE TO PREVENT INJURY FROM BROKEN STRANDS AND
WIRES. EYE PROTECTION MUST BE WORN BY THE OPERATOR WHENEVER
OPERATING, OR MAINTAINING, THE RESCUE HOIST TO PREVENT INJURY
FROM LUBRICANTS, SOLVENTS, AND OTHER MATERIALS USED ON THE
RESCUE HOIST, AS WELL AS METAL PARTS AND OTHER DEBRIS.
WARNING: DO NOT TRY TO CLEAR A CABLE FOUL IN FLIGHT. A FOULED CABLE MAY
BREAK, AND THIS MAY RESULT IN INJURY OR DEATH.
CAUTION: THE TENSION ROLLER SYSTEM WORKS ON THE BASIS OF FRICTION, AND
THEREFORE, NO LUBRICANT SHOULD BE APPLIED TO THE CABLE.
CAUTION: WHEN REELING OUT, DO NOT HINDER, OR PULL 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 INTO THE FULL IN POSITION WITHOUT
HOLDING ONTO, AND GUIDING THE HOOK TO THIS POSITION. ALLOWING THE
HOOK TO SWING FREELY WHILE REELING INTO THE FULL IN POSITON MAY
CAUSE DAMAGE TO THE HOOK, CABLE, HOIST, AND HELICOPTER.
CAUTION: WHEN STOWING THE HOOK ALWAYS OPERATE THE HOIST AT MAXIMUM
INTERMEDIATE / SLOW SPEED (37 TO 63 FPM [0.19 TO 0.32 MPS]) BY
DEFLECTING THE CONTROL PENDANT THUMBWHEEL TO ITS MAXIMUM
POSITION / DEFLECTION. IF THE HOOK ASSEMBLY / BUMPER IS STOWED AT A
SLOWER SPEED THE CABLE LOAD MAY BE LOWER THAN REQUIRED AND CAN
LEAD TO CABLE FATIGUE FROM EXCESSIVE HOOK VIBRATION.
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 VIBRATING WHILE THE HELICOPTER IS IN FLIGHT. A LOOSE HOOK
MAY RESULT IN A FATIGUED, DAMAGED, OR BROKEN CABLE.

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HS-29900-30, HS-29900-30-4, & HS-29900-36 RESCUE HOIST SYSTEMS
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: TWO VISUAL MEANS OF FULL IN DETECTION ARE PROVIDED WITH THE
RESCUE HOIST. ONE IS ORANGE COATING ON THE CABLE INDICATING
APPROXIMATELY 21 FT. (6.4 M.) OF CABLE REMAINS UNTIL REACHING THIS
LIMIT. THE OTHER IS ILLUMINATION OF A GREEN INDICATOR LIGHT
LABELED “FULL IN” ON THE CONTROL PENDANT THAT IS TURNED ON WHEN
THE FULL IN LIMIT SWITCH IS ACTUATED.
NOTE: A VISUAL MEANS OF FULL OUT DETECTION IS PROVIDED WITH THE RESCUE
HOIST. ORANGE COATING IS APPLIED ON THE CABLE INDICATING
APPROXIMATELY 23 FT. (7.0 M.) OF CABLE REMAINS UNTIL REACHING THIS
LIMIT.
NOTE: ALWAYS KEEP A GLOVED 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
LIMIT SWITCHES.
NOTE: PRIOR TO TURNING POWER ON, THE RESCUE HOIST COMPONENTS MUST BE
VISUALLY INSPECTED FOR SOUND STRUCTURAL INTEGRITY AND PROPER
INTEGRATION.
A. The HS-29900-30, 30-4, and -36 Rescue Hoist Systems can be operated by either the Pilot Control
Panel, or the Control Pendant. Once the electronic controller receives the reel in or out signal, a
signal is sent to the electric motor, either to raise, or lower the cable. The motor will drive the gear
train, which will drive the level wind, tension roller, and drum, resulting in reeling in, or out of the
load cable.
B. Once the down signal is received, the cable will reel out. The speed will be faster as the thumb
wheel is moved farther from center. Observe the amount of cable on the storage drum. Reduce
speed as cable nears full extension. The motor should stop by the full out limit switch activation
when 3½ to 4½ wraps of cable remain on the drum.
C. Once the electronic controller receives the up signal, the cable will reel in. The speed will be faster
as the thumb wheel is moved farther from center. The motor rate allows for a cable speed of 350
fpm (1.78 mps). When the cable intermediate position is reached, the intermediate limit switch
slows the cable speed to 37 to 63 fpm (0.19 to 0.32 mps) until the full in limit switch position is
reached and operation is stopped.
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 wraps incorrectly on the drum
resulting in a cable foul, stop hoist operation immediately. Clear the cable foul on the ground by
reeling out the cable slowly under load. If this does not clear the foul, it must be removed from the
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HS-29900-30, HS-29900-30-4, & HS-29900-36 RESCUE HOIST SYSTEMS
drum using a cable / bolt cutter and cutting off sections of the fouled cable. In either case, the cause
of the cable foul must be identified, problem corrected, and cable replaced before the hoist can be
returned to a serviceable condition.
Always guide the hook by a gloved hand as the cable is reeled into the full in position at full
(Intermediate speed) control pendant thumbwheel deflection. Ensure the spring in the bumper is
compressed sufficiently to prevent the hook from moving when the helicopter is in flight.
WARNING: THE CARTRIDGE IS AN EXPLOSIVE DEVICE AND MUST BE SHIPPED, STORED
AND HANDLED IN COMPLIANCE WITH ALL LOCAL STANDARDS AND
REGULATORY PRACTICES.
WARNING: DO NOT PUSH THE CABLE CUT SWITCH ON THE CREW CONTROL, OR PILOT
CONTROL, PANELS UNTIL THE ARM / TEST SWITCH HAS BEEN MOVED TO THE
TEST POSITION. FAILURE TO MOVE THE ARM / TEST SWITCH TO THE TEST
POSITION WILL FIRE THE CARTRIDGE AND CUT THE CABLE.
D. The Rescue 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 on the Pilot Control Panel in
the cockpit. The crew also can actuate the cable cutter by using a switch located on the Crew
Control Panel. An arm / test switch with a squib test light is located on the Crew Control Panel for
arming, and testing of the cable cut electrical circuit.
CAUTION: HOIST OPERATION MAY CONTINUE WITH THE PENDANT MOTOR HOT LIGHT
ILLUMINATED FOR A SHORT PERIOD OF TIME, BUT SERIOUS DAMAGE MAY
RESULT REQUIRING MOTOR REPLACEMENT I.E. THE MOTOR MAY FAIL TO
OPERATE. THEREFORE, IT IS RECOMMENDED THAT MOTOR OPERATION
CEASE AS SOON AS POSSIBLE WHEN THE MOTOR HOT LIGHT IS ILLUMINATED
AND THE MOTOR BE ALLOWED TO COOL.
E. The Control Pendant is a handheld controller that allows the crewmember to raise, or lower, the
cable by using the directional thumb wheel. This thumb wheel also controls the speed of operation
proportional to the amount of deflection from the center null position. The Control Pendant also
incorporates a display indicating the amount of cable paid out, and indicator lights for a fully
extended cable (“FULL OUT”), a fully reeled in cable (“FULL IN”), and motor overheat (“MTR
HOT”). The motor overheat light will reset once the motor has cooled sufficiently, approximately
30 minutes, depending on ambient conditions, and the amount of time the light was illuminated
before operation was stopped.
The control pendant provides indicator lamp and / or payout display readings, which can be
interpreted in accordance with Table 3, titled “Control Pendant Display Interpretations.”

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Table 3. Control Pendant Display Interpretations

Note: Indicator lights

are green.

* Control Pendant Indicator Hoist Action Rescue Hoist System Failure Mode Operator Action
Lamp and / or Payout
Display Reading
Internal DC Voltages too low (15.5, Check DC Power Supply.
“All three indicators are Lock-out 12VDC) Check pin continuity.
illuminated green and payout operation Power phase down in the AC Supply Check AC Power Supply
display is illuminated ” Full In limit switch command Check intermediate (Up) limit
without a slow in limit switch switch continuity. Also, check
(green) + “888” command full in limit and intermediate
switch adjustment.
Both the intermediate up limit switch
and the full in limit switch can create
the 888 condition
Motor power module over Allow to cool approximately
temperature 30 minutes
Motor temperature too hot Allow to cool approximately
“MTR HOT” only (green) Speed reduced 30 minutes
by half Electronic controller base plate too Allow to cool approximately
hot 30 minutes
Simultaneous up / down crew Coordinate rescue hoist
Not Applicable No Motion command commands with helicopter
crew
* Notes:
On power start up the pay out display will momentarily indicate “888” and then will display cable payout reading.
See Section 101, Testing and Troubleshooting for further detail beyond initial operation.

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3. Flight Line / Ground Handling Hoist Operation Guidelines
WARNING: DAMAGE WILL OCCUR TO THE RESCUE HOIST SYSTEM IF DC POWER IS
PRESENT ALONG WITH AN OPERATOR COMMAND FROM THE PILOT, CREW
CONTROL (IF APPLICABLE), OR THE PENDANT AND THEN AC POWER IS
APPLIED. POWER SHOULD BE APPLIED USING THE “HOIST POWER SWITCH.”
A. When operating the hoist during maintenance or inspections, hoist speed shall be no greater than ¼
speed (unless the inspection is to verify hoist speed itself). Normal cable cleaning and hoist
maintenance and inspections do not need high-speed operation.
B. When operating the hoist never “pull” the cable from the hoist when lowering. Let the hoist do the
work lowering. Pulling the cable can actually apply a force opposing the cable tensioning system.
C. Always use a clean dry cloth when cleaning or checking the cable. Never use a cloth that contains
oil or any other lubricants. See Section 401, Cleaning for complete cleaning instructions of the
hoist.
D. When cleaning the hoist and / or cable, the cable collection container should be as large in diameter
as possible. The larger diameter reduces the possibility of cable damage. A “kiddie” pool is
recommended. See Section 401, Cleaning for complete cleaning instructions for the hoist.
E. When checking full-in or stowing the hook, always operate the hoist at maximum slow speed by
deflecting the control pendant thumbwheel to its maximum (“up”) position. If the bumper is stowed
at a slower speed, the residual cable load may be lower than required and can lead to cable fatigue
from excessive hook vibration.
F. When cleaning a cable, or inspecting the full-out switches, never use the limit switch as a “jog”
switch. When operating the hoist in this mode, depress the limit switch actuator and wait one
second before deflecting the control pendant thumbwheel – DO NOT have the thumbwheel
deflected and use the limit switch (actuator) to move the hoist. Also, always wait 1 second before
re-actuation of a limit switch.
G. If spinning occurs during hoisting operations, avoid using the top part of the hook as a brake. The
top part of the hook is mechanically connected to the cable and if rotated will try to “spin” the
cable. This will lead to premature cable replacement.
H. Salt water usage will require post-flight cleaning of exposed components. During this post-flight
cleaning procedure, it is also recommended to clean the cable drum, and this should be
accomplished as follows:
1) When cleaning the drum, make sure power to the hoist is removed.
2) Use a clean, damp rag to clean the drum.
3) Cleaning the drum will require multiple drum movements to clean the entire drum surface.
4) See Section 401, Cleaning, for complete cleaning instructions of the hoist.
5) Do not use a pressure washer to clean the hoist or use high-pressure air to dry the hoist.
Excessive pressure could damage hoist components.
I. Always wind, and unwind, the cable in a ‘race track’ fashion, never a ‘figure 8’ or a coil.

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J. Always ‘season’ new cables at the rated loads by performing the “Rated Load Test” in accordance
with Section 101, “Testing and Troubleshooting.”
K. Ice clearing. Remove any ice accumulation from the rescue hoist, especially visible ice from the
cable guide / bellmouth, or roller and housing assembly and ensure that the roller and housing
assembly is not frozen to the cable guide assembly and or / hook assembly prior to hoist operations.
.

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HS-29900-30, HS-29900-30-4, & HS-29900-36 RESCUE HOIST SYSTEMS

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 the Illustrated Parts List in Section 1001.
2. Test Equipment and Materials
The recommended method for testing the Rescue Hoist System at the flight line level is to
perform the procedures identified in this section with the equipment and materials identified
below, or equivalent, when the Hoist is mounted on the helicopter.
A. Electrical Power: 3 Phase, 400 Hz, 200 VAC phase-to-phase, 10 kW AC Power, minimum.
28 VDC, 3 amps, minimum.
B. Load Source
The Hoist shall be loaded by the use of known weights of 300 lb. (136 kg.), and 600 lb. (272
kg.) on the Hoist hook.
C. Tape Measure (in feet or meters).
D. Cable Speed Meter / Tachometer (for measuring cable speed 0 – 400 ft/min. [2.032
meter/second]) or Stopwatch. If a tachometer is not available, use a stopwatch and tape
measure to measure the time it takes the Hoist wire rope cable to travel over a known length.
E. Multimeter.
F. Indelible Felt Tip Marker for marking cable when setting limit switches
G. F-900 Torque Seal (Organic Products Company, Irving, Texas, USA, CAGE 01195) for
securing setting of potentiometer screws.
3. Test Conditions
The Rescue Hoist shall be supported using a post mount secured with two bolts (See Figure 801)
in such a manner that the cable is vertical. The recommended method is to test the Hoist when
mounted on the helicopter with the cowlings installed. 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.
Prior to the start of tests verify that the oil level is up to the mark on the dip stick, or sight gage,
located on the top of the motor mounting flange.
4. Test
WARNING: DAMAGE WILL OCCUR TO THE RESCUE HOIST SYSTEM IF DC POWER IS
PRESENT ALONG WITH AN OPERATOR COMMAND FROM THE PILOT,
CREW CONTROL (IF APPLICABLE), OR THE PENDANT AND THEN AC

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HS-29900-30, HS-29900-30-4, & HS-29900-36 RESCUE HOIST SYSTEMS
POWER IS APPLIED. POWER SHOULD BE APPLIED USING THE “HOIST
POWER SWITCH” ON THE PILOT CONTROL PANEL.
WARNING: KEEP HANDS, BODY, AND CLOTHING AWAY FROM RESCUE HOIST,
SPECIFICALLY “PINCH POINTS,” WHERE THE CABLE ENTERS THE CABLE
GUIDE AND CONTACTS THE DRUM.
WARNING: WORK GLOVES MUST BE WORN BY THE OPERATOR WHENEVER
HANDLING THE RESCUE HOIST CABLE TO PREVENT INJURY FROM
BROKEN STRANDS AND WIRES. EYE PROTECTION MUST BE WORN BY
THE OPERATOR WHENEVER OPERATING, OR MAINTAINING, THE RESCUE
HOIST TO PREVENT INJURY FROM LUBRICANTS, SOLVENTS, AND OTHER
MATERIALS USED ON THE RESCUE HOIST, AS WELL AS METAL PARTS
AND OTHER DEBRIS.
WARNING: SEARCH AND RESCUE OPERATIONS, AND ALL OTHER USES OF RESCUE
HOISTS FOR HOISTING AND LOWERING PERSONNEL, CAN RESULT IN
INJURY OR DEATH. PROPERLY TRAINED PERSONNEL MUST UTILIZE
APPROPRIATE OPERATION, MAINTENANCE, AND INSPECTION
PROCEDURES TO MINIMIZE THE HAZARDS INHERENT IN THE USE OF ALL
RESCUE HOISTS.
WARNING: TAKE PROPER ESD PRECAUTIONS TO AVOID FIRING THE CARTRIDGE
AND DAMAGING COMPONENTS DUE TO ELECTRICAL SHOCK FROM
ELECTROSTATIC DISCHARGE.
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 RESCUE HOIST COMPONENTS MUST
BE VISUALLY INSPECTED FOR SOUND STRUCTURAL INTEGRITY,
MOUNTING AND CONNECTIONS.
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 and 1002, Sheets 2 and 3)
(1) If a new cable has been installed, start this procedure at step (1) (a). If performing
maintenance checks and / or troubleshooting, start at step (2).
CAUTION: FAILURE TO HOLD THE FULL OUT BYPASS SWITCH WILL CAUSE
DAMAGE TO THE HOIST. DO NOT USE FULL OUT BYPASS SWITCH TO JOG
THE HOIST.
(a) Apply power to the system. Actuate and hold the full out bypass switch (S5), and
using control pendant, slowly reel in 4 ± ½ wraps. Release full out bypass switch.
(b) Proceed to step (3).
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(2) Apply power to the Rescue Hoist System, and with no load on the cable pay out cable at
less than half of full speed until the hoist stops at the full out position.
(3) Verify control pendant cable payout display is working properly and the full-out
indication is illuminated.
2½ to 3½ wraps
3½ to 4½ wraps Emergency
Full Out Switch Full Out Switch
Cable End
Half Drum Revolutions Cable Drum
Hook
Attachment Attachment
Pendant Indicators: Pendant Indicators:
Payout Display - ON Payout Display - OFF
Full Out - ON Full Out - OFF

Figure 101. Full Out and Emergency Full Out Limit Switch Settings
Symbol Function Cam Requirements
S1 Emergency Full Out A 3 ± ½ Wraps from Cable Termination
S2 Full Out B 4 ± ½ Wraps from Cable Termination
S3 Deceleration Lowering C 8 to 10 Feet (2.4 to 3.0 m) from Full Out
S4 Deceleration Hoisting D 10 to 12 Feet (3.0 to 3.7 m) from Full in
S5 Emergency Bypass - For Emergency Full Out
R1 Potentiometer Assy. - For Cable Payout Display (full in adjustment)
R3 Trim Potentiometer - For Cable Payout Display (full out adjustment)

Screws to be loosened to
S5 adjust Potentiometer
Assembly R1.

R3 Stacking Sequence
(from top to bottom)

R1 · Cam Locking Plate

S1 · Cam D
· Spacer
· Cam C
· Spacer
· Cam B
S4 · Spacer
S2
· Cam A
S3 · Cyclocentric Drive
Housing
Figure 102. Cyclocentric Drive Assembly

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(4) Mark cable using a marker, or equivalent, at the lengths specified per Figure 102.
(5) Using the control pendant, slowly reel in approximately 12 to 15 individual cable wraps.
(6) Using the control pendant, start to reel out the cable at half speed. Monitor hoist operation
for the slow down of cable speed.
(7) When cable speed automatically slows (lowering intermediate speed), stop the hoist and
visually inspect the cable for the mark on the cable. The mark should be near the cable
guide, and within the limits of the requirements of Figure 102 for deceleration lowering
(S3).
(8) Reel out the remaining cable until the full out limit switch (S2) actuates, and the hoist
stops.
(9) On the control pendant, verify the full out light is illuminated green, and the payout
display is on.
(10) Count the number of wraps of cable on the drum. There should be between 3½ to 4½
wraps of cable on the cable drum.
(11) Verify the Emergency Full Out Circuit (Refer to Figure 101):
CAUTION: FAILURE TO HOLD THE FULL OUT BYPASS SWITCH S5 WILL CAUSE
DAMAGE TO THE HOIST. DO NOT USE THE FULL OUT BYPASS SWITCH TO
JOG THE HOIST. WHEN OPERATING THE HOIST IN THIS MODE, DEPRESS
S5 AND WAIT ONE (1) SECOND BEFORE DEFLECTING THE CONTROL
PENDANT THUMBWHEEL. DO NOT HAVE THE THUMBWHEEL DEFLECTED
AND USE S5 TO MOVE THE HOIST. S5 IS LOCATED NEXT TO THE CYCLE /
EVENT COUNTER ON THE CYCLOCENTRIC. OPERATE THE HOIST WITH
THE PENDANT AT ¼ SPEED MAXIMUM BY DEFLECTING THE CONTROL
PENDANT THUMBWHEEL APPROXIMATELY 25%.
(a) Press and hold the full out bypass switch (S5).
(b) Using the control pendant, slowly rotate the drum approximately one half drum
revolution.
(c) Release the control pendant thumbwheel, and then release the full out bypass switch.
(d) The cable payout display and indicator lights should turn off. If any of the lights are
illuminated on the control pendant, repeat steps 11 (a) through 11 (c) until the cable
payout display and all indicator lights are off.
(e) When lights are off, count cable wraps on the drum. There should be 2½ to 3½ wraps
of cable on the cable drum.
(f) Press and hold the full out bypass switch (S5).
(g) Reel in cable past the full out setting, approximately 7 to 8 individual cable wraps.
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.

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(h) Release the full out bypass switch (S5), and after a brief pause the cable payout
display on the control pendant should be illuminated.
(12) Using the control pendant, start to reel in the cable at half speed. When cable speed slows
(hoisting intermediate speed), release control pendant thumbwheel, and measure length of
cable from hook to the cable guide. The dimensions should be as specified in Figure 102
for deceleration hoisting (S4).
(13) Using the control pendant, slowly reel in the cable; verify the hoist stops when the full in
switch is actuated.
(14) If any of the limit switches are inoperative, refer to Table 101 for Troubleshooting
Procedures. If the settings for any of the limit switches require adjustment, reset the
appropriate limit switch cam to obtain required setting as follows:
(a) Remove attaching hardware and aft cowling assembly (530, Figure 1002, Sheet 1) per
the instructions provided in the Disassembly Section 301.
(b) Remove screws (760 and 770, Figure 1002, Sheet 3) and potentiometer mounting
bracket (780).
(c) Remove cam locking plate (790), limit switch cams (800), and spacers (810).
(d) Adjust limit switch settings by repositioning cams as follows (see Figure 102):
NOTE: IT IS RECOMMENDED THAT ADJUSTMENTS BE MADE ONE (1) TOOTH AT
A TIME.
1) For the emergency full out, full out, and the deceleration lowering switches,
reposition respective cam clockwise if the switch actuates too soon,
counterclockwise if the switch actuates too late.
2) For the deceleration Hoisting switch, reposition respective cam counterclockwise
if the switch actuates too soon, clockwise if the switch actuates too late.
(e) After installing all cams (800, Figure 1002, Sheet 3) and spacers (810) per limit switch
setting requirements, and cam stacking sequence of Figure 102, install the cam locking
plate (790). Recheck limit switch settings per Figure 102 using the procedure defined
in Paragraph 4A(1) in this section.
NOTE: ALL PROCEDURES IDENTIFIED WITH THE NOTE VITAL POINT
INSPECTION AND PARTS WITH THEIR ITEM NUMBERS IDENTIFIED
WITH THE NOTE VP REQUIRE A TECHNICIAN, OTHER THAN THE
TECHNICIAN WHO PERFORMED THE OPERATION, TO INSPECT THE TASK
COMPLETED, DUE TO THE CRITICALITY OF THE OPERATION. THIS
INSPECTION MUST BE DOCUMENTED IN BOTH THE HELICOPTER, AND
HOIST MAINTENANCE LOG.
(f) VITAL POINT INSPECTION. After successfully testing limit switch settings,
torque cam locking plate (VP 790) to 20 to 30 in.-lb. (2.2 to 3.4 m-N), and install
potentiometer mounting bracket (780) and secure with screws (760) and (770). Torque
screws from 4.8 to 5.8 in.-lb. (0.54 to 0.66 m-N).

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(g) Install aft cowling assembly (530, Figure 1002, Sheet 1) by sliding aft cowling
assembly onto Hoist, and secure with screws (400) and washers (410) per Assembly,
Section 701.
(15) Check the operation of the full in limit switch (Refer to Figure 103).
NOTE: PERFORM THIS CHECK IF A PROBLEM WITH THE FULL IN LIMIT SWITCH
IS ENCOUNTERED, OR THE LIMIT SWITCHES THEMSELVES ARE
REPLACED.
(a) Preliminary Check (see Figure 1002, Sheet 5)
1) Remove screws (890), washers (900), cable clamp (430), cable guide cover (910)
and gasket (920). Retain gasket for future use.
2) Verify that Torque Seal compound had been applied to the heads of the switch
mounting screws (820). If there is no evidence of Torque Seal, do not loosen, but
verify that screws (820) are properly tightened, torque to 2.6 to 3.2 in.-lb. (0.29 to
0.36 m-N).
3) Operate hoist: ensure that the control pendant full in light turns on when hook is
fully retracted. Reel out a small amount of cable so that the spring bumper is no
longer contacting the Roller and Housing assembly; verify that the full in light
goes out. Repeat the full in and release procedure three times to confirm that the
pendant light consistently goes on and off.
(b) Check for switch activation prior to end of pin travel:
1) Apply Helicopter DC power to hoist.
2) Measure and record the distance from the lower face of the Cable Guide Assembly
to the upper face of the Roller and Housing Assembly (120, Figure 1002, Sheet 5)
using feeler gages, or equivalent means capable of measuring the distance with
0.001 in. (0.025 mm.) resolution / increments per Figure 104. This dimension is
typically between 0.145 and 0.185 in (3.68 and 4.70 mm.).
3) Assemble a stack of feeler gages that is 0.040 in. (1.02 mm.) smaller than the
dimension measured in the previous step. Place a common head screwdriver blade
or equivalent flat implement between the end of the Cable Guide Pin and the
Roller and Housing. Slowly depress the Pin into the Cable Guide until the feeler
gage stack just fits between the Pin and the Roller and Housing, do not compress
the pin beyond this point. The Full in light on the Pendant should be lit.
4) If the full in light on the Pendant is not lit, loosen screws (820) and adjust switches
(850). Torque screws (820) from 2.6 to 3.2 in.-lb. (0.29 to 0.36 m-N).
5) Repeat step 15 (b) 2 above.

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HS-29900-30, HS-29900-30-4, & HS-29900-36 RESCUE HOIST SYSTEMS

OK Torque Seal present on full in NOT OK

limit switch mounting screws
per Paragraphs 15 (a) 1 and 2?

Verify proper operation of Torque full in limit switch mounting

full in limit switch per screws from 2.6 to 3.2 in.-lb. (0.29
OK
OK Paragraph 15 (a) 3. to 0.36 m-N).

OK
NOT OK
Verify cable guide pin switch Adjust full in limit switch per
activation prior to end of pin Paragraphs 15 (a), (b), and (c).
travel per Paragraph 15 (b). NOT OK

OK NOT
OK
Verify switch release activation NOT OK
prior to end of pin travel per
Paragraph 15 (c).
If the full in limit switch is inoperative, or cannot be adjusted, per Paragraphs
OK
15 (a), (b), and (c), refer to Troubleshooting Procedures in Table 101.
Closure after check per
Paragraph 15 (d).

If Switch Setting Cannot Be Accomplished After Several Attempts Check the Following:
1. Limit Switches and Switch Actuators are Orientated Incorrectly. Move the switch and the switch actuator to a
new position; there is very little play in the assembly, but movement that is nearly indiscernible may be
sufficient to allow proper actuation of the switch. If the switch had failed criteria in paragraph 4. A. (15) (b) 3),
rotate the switch components counterclockwise to translate the switch components toward the plunger button on
the microswitch (MS24547-1), or rotate the switch components clockwise to translate the switch components
away from the plunger button on the microswitch (MS24547-1).
2. (A) Power Supplied? (1) Check Circuit Breakers, confirm power is supplied to the hoist, and ensure pendant
light is illuminated.
(B) Circuit Problem? Trace electrical circuit per Section 201, Schematics and Wiring Diagrams.
3. Malfunctioning Switch? With a the flat on a common head screwdriver, or equivalent, press the cable guide pin
in and check that the pendant full in light goes on and off.
4. Roller and Housing Binding, Off Center / Damaged? Spin Roller and Housing and if a wobble is detected loosen
cap screws and reposition housing until the two mating surfaces are concentric with no axial movement then
tighten cap screws and washers.

Figure 103. Full In Limit Switch Adjustment Decision Tree

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Distance between
Cable Guide Assy.
and Roller and
Housing Assy.

Figure 104. Cable Guide to Roller and Housing Measurement

(c) Check for Switch Release Prior to End of Pin Travel (see Figure 1002, Sheet 5)
1) Energize hoist – DC power required for Full in Circuit activation.
2) Measure and record the distance from the Cable Guide Pin (940) to the upper face
of the Roller and Housing Assembly (120) using feeler gages, or equivalent means
of measuring the distance within 0.001 in. (0.025 mm.) per Figure 105. This
dimension is typically between 0.045 - 0.070 in. (1.14 - 1.78 mm.).

Distance between Pin and Roller

and Housing Assy.

Figure 105. Pin to Roller and Housing Measurement

3) Assemble a feeler gage stack, which is 0.016 in. (0.41 mm.) larger than the
dimension measured in the previous step. Depress the Pin (940) into the Cable
Guide so that the Full in light on the pendant is illuminated. Insert the stack of
feeler gages between the Pin and the Roller and Housing Assembly (120), then
release the pin even though the stack of feeler gages will prevent the full extension
of the Cable Guide Pin (940), the full in light on the pendant should go out.
(d) If the full in light on the pendant is still lit, loosen screws (820) and adjust switches
(850). Torque screws to 2.6 to 3.2 in.-lb. (0.29 to 0.36 m-N).
(e) Repeat step 4. A. (15) (b) 2) above.

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1) After unit has successfully passed checks outlined above in (15) (b) and (c), apply
F-900 Torque Seal, or equivalent, to screw (820) heads (if not previously applied).
2) Install cable guide gasket (920), cover (910), and cable clamp (430), and secure
with washers (900) and screws (890). Torque screws (890) to 2.6 to 3.2 in.-lb.
(0.29 to 0.36 m-N).
(f) If the full in limit switch is inoperative, or cannot be adjusted, refer to Table 101 for
Troubleshooting Procedures.
B. Digital Readout Test (see Figure 1001, Items 50 and 51)
(1) Apply power to the Rescue Hoist System, and check the digital readout. The numbers
“888” should be displayed on the readout for a moment initially, and then 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 Tables 3 and 101 for Troubleshooting Procedures.
(2) With no load on the cable, reel out the entire usable length of cable at less than ½ speed.
The full-out limit switch shall stop the Hoist with 3½ to 4½ wraps of cable remaining on
the drum.
(3) Check the readout. Acceptable limits for the readout is 285 to 295 feet.
(4) With no load on the cable, reel in the cable to the full in position.
(5) Check the readout. The readout should read 000 feet.
NOTE: CONTROL PENDANT CABLE PAYOUT INDICATION IS FOR REFERENCE ONLY.
ACCURACY IS +/- 5 FEET (+/- 1.5M)
(6) If the values are not met as specified above, adjust the potentiometer in the Hoist on the
cyclocentric drive assembly as follows:
(a) Remove attaching hardware and aft cowling assembly (530, Figure 1002, Sheet 1) per
the instructions provided in the Disassembly Section 301. Using an exacto knife, or
equivalent, carefully remove any locking / sealing compound from the screws on the
potentiometer R1 (see Figure 102). Rotate R1 until the display reads the desired value
000 feet with the hook at the full in position. Tighten screws when desired value is
obtained.
(b) Using the pendant reel out the cable at less than half speed until the hook is at the full
out position.
(c) Using an exacto knife, or equivalent, carefully remove any locking / sealing compound
from potentiometer R3. Adjust the screw on the potentiometer R3 (see Figure 102)
until the display reads the desired value of 285 to 295 feet with the hook at the full out
position.
(d) Reel in the cable and verify the value 000 feet with the hook in the full in position. If
value has changed, repeat steps (a), (b), and (c) above. If value 000 feet cannot be
obtained at full in, refer to Table 101 for Troubleshooting Procedures.

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(e) After the potentiometers are set properly, apply locking / sealing compound (F-900
Torque Seal, or equivalent) to the R1 mounting screws and R3 adjustment screw to
prevent inadvertent movement due to vibration.
(f) Install aft cowling assembly (530, Figure 1002, Sheet 1) and secure with attaching
screws and washers per the instructions in the Assembly, Section 701.
C. Hook Load Test.
NOTE: THIS HOOK LOAD TEST MUST BE PERFORMED AFTER ATTACHING THE
HOOK TO THE CABLE. IT IS NOT REQUIRED AFTER CABLE
REPLACEMENT. PERFORM THE RATED LOAD TEST AFTER THE CABLE IS
REPLACED.
NOTE: REEL IN THE CABLE APPLYING A TENSION WITH GLOVED HANDS TO
ENSURE SMOOTH AND EVEN WRAPPING. APPROXIMATELY 20 LB. (9.1
KG.) TENSION IS RECOMMENDED.
Check for proper installation of the hook by applying a load of 600 lb. (272 kg.) as follows:
(1) Run Hoist to reel out cable at half speed until the hook can be connected to a weight of
600 lb. (272 kg.) that is resting on the ground.
(2) Mount load on hook and slowly reel cable in until the weight is lifted off the ground.
Check that the hook does not slip or detach from the cable.
(3) Once weight is off the ground verifying hook attachment integrity, lower weight back to
the ground.
(4) Remove weight, and run Hoist to the full in position, at full pendant thumbwheel
deflection, to secure the hook and bumper assembly on the Hoist.
D. Rated Load Test (Operational Flight - Test to be performed with helicopter in a hover with
cowlings installed).
CAUTION: DURING OPERATION OF THE RESCUE HOIST, DO NOT TOUCH THE
MOTOR. THE MOTOR TEMPERATURE MAY BE VERY HOT, AND MAY
RESULT IN SEVERE BURNS IF TOUCHED.
NOTE: DURING THE RATED LOAD TEST VERIFY MOTOR FAN OPERATION
AND DIRECTION; AIRFLOW SHALL BE FORWARD TO AFT.
NOTE: THIS RATED LOAD TEST MUST BE PERFORMED AFTER EACH WIRE
ROPE CABLE CHANGE OUT AND / OR LRU REPLACEMENT. IT IS NOT
REQUIRED IF YOU JUST REMOVE AND REPLACE A HOOK ASSEMBLY.
PERFORM THE HOOK LOAD TEST IF A HOOK ASSEMBLY IS REMOVED
AND REPLACED WITHOUT CHANGING THE CABLE.
NOTE: THE RATED LOAD TEST REQUIRES TESTING OF THE HOIST ON THE
HELICOPTER, IN A HOVER, WITH THE COWLINGS INSTALLED.

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FLIGHT LINE OPERATION AND MAINTENANCE MANUAL

HS-29900-30, HS-29900-30-4, & HS-29900-36 RESCUE HOIST SYSTEMS
NOTE: DURING THE RATED LOAD TEST RECORD AND OBSERVE THAT THE
CYCLE / EVENTS COUNTER INCREASES BY 1 FOR EACH REVOLUTION
OF THE DRUM.
Record the Cable Speed using a stop watch, or equivalent, for each of the tests below:
(1) 300 lb. (136 kg.) Load Test
(a) Verify performance with the 300 lb. (136 kg.) by operating the Hoist using the pilot
control panel (if equipped), or control pendant through its full cable travel as follows:
1) Raise 300 lb. (136 kg.), and then allow the Hoist to cool for 30 seconds.
2) Lower 300 lb. (136 kg.), and then allow the Hoist to cool for 30 seconds.
3) Repeat steps 1 and 2 one more time, operating the Hoist using the control pendant,
and measuring the cable speed on the top layer.
When raising 300 lb. (136 kg.), with the cable on the top layer of the drum, the speed
shall be 205 ± 40 fpm (1.04 ± 0.20 mps) when controlling the Hoist using the pilot
control panel, and the minimum speed when the cable is on the top layer shall be 350
fpm (1.78 mps) when controlling the Hoist using the control pendant.
When lowering 300 lb. (136 kg.), with the cable on the top layer of the drum, the
speed shall be 205 ± 40 fpm (1.04 ± 0.20 mps) when using the pilot control panel, and
the minimum speed shall be 300 fpm (1.52 mps) when using the control pendant.
(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 25 amps when
raising 300 lb. (136 kg.), and shall not exceed 5 amps when lowering 300 lb. (136 kg.)
with the voltage set at 200 ± 10 VRMS.
If the helicopter power is correct, but the Hoist does not meet the speed requirements
specified above, the operator also may want to measure the temperature of the drum
flange at the end of the 300 lb. (136 kg.) load test. The temperature must be monitored
using an attached thermocouple, or equivalent, on the exposed surface of the large
hex-head bolt on the drum flange between the forward cowling assembly and the Hoist
assembly. The surface temperature shall not exceed 200°F (94°C) after completion of
testing.
(2) 600 lb. (272 kg.) Load Test
(a) Verify performance with 600 lb. (272 kg.) by operating the Hoist using the control
pendant through its full cable travel as follows:
1) Raise 600 lb. (272 kg.), and then allow the Hoist to cool for 30 seconds.
2) Lower 600 lb. (272 kg.), and then allow the Hoist to cool for 30 seconds.
3) Repeat steps 1) and 2) three more times.

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HS-29900-30, HS-29900-30-4, & HS-29900-36 RESCUE HOIST SYSTEMS
When raising 600 lb. (272 kg.) with the cable on the top layer of the drum, the
minimum speed shall be 350 fpm (1.78 mps) when controlling the Hoist using the
control pendant.
When lowering 600 lb. (272 kg.) with the cable on the top layer of the drum, minimum
speed shall be 300 fpm (1.52 mps) when using the control pendant.
(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 25 amps when
raising 600 lb. (272 kg.), and shall not exceed 5 amps when lowering 600 lb. (272 kg.)
with the voltage set at 200 ± 10 VRMS.
If the helicopter power is correct, but the Hoist does not meet the speed requirements
specified above, the operator also might want to measure the temperature of the drum
flange at the end of the 600 lb. (272 kg.) load test. The temperature must be monitored
using an attached thermocouple, or equivalent, on the exposed surface of the large
hex-head bolt on the drum flange between the forward cowling assembly and the Hoist
assembly. The surface temperature shall not exceed 200°F (94°C) after completion of
testing.
(3) Slow Speed Test
(a) Verify performance with 600 lb. (272 kg.) by operating the Hoist using the control
pendant through the slow up, (10 to 12 ft. [3.0 to 3.7 m.]) from full in cable travel.
When raising 600 lb. (272 kg.) with the cable on the top layer of the drum, the speed in
slow up shall be 37 to 63 fpm (0.19 to 0.32 mps) when using the control pendant. The
current draw shall not exceed 10 amps.
(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 10 amps when
raising 600 lb. (272 kg.) in slow up mode with the voltage set at 200 ± 10 VRMS.
E. Bumper Assembly and Full in Limit Switch Test
(1) Reel out approximately 20 feet (6.1 m.) of the cable at less than half speed.
(2) Reverse Hoist direction and reel in the cable at full pendant / panel thumbwheel deflection.
The intermediate up slow speed will actuate and the full in limit switch actuates stopping
the hoist.
(3) Verify that the hoist stops and the Full in light on the pendant illuminates.
(4) Observe the compression of the bumper assembly spring.
(5) Deflection should measure 1.50 to 2.00 inches (38.1 to 50.8 mm) as measured from the
bottom of the spring retainer to top of rubber bumper, refer to Figure 106.

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FLIGHT LINE OPERATION AND MAINTENANCE MANUAL

HS-29900-30, HS-29900-30-4, & HS-29900-36 RESCUE HOIST SYSTEMS

Figure 106. Deflection of Bumper Assembly with Hook at Full in Position

(6) If deflection of the bumper assembly is less, or greater, than allowable limits, adjust the
full in limit switch setting as identified in step 4. A. (15) above.
(7) If after continued adjustments desired bumper assembly dimensions cannot be achieved,
replace bumper assembly.
F. If during testing above, the Rescue 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 Procedures.
5. Troubleshooting Procedures
Troubleshooting is the process of using a logical sequence to locate and eliminate an equipment
malfunction. The troubleshooting process relies heavily on the abilities of qualified technicians.
Refer to Table 101 for Troubleshooting Procedures.

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FLIGHT LINE OPERATION AND MAINTENANCE MANUAL

HS-29900-30, HS-29900-30-4, & HS-29900-36 RESCUE HOIST SYSTEMS

Table 101. Troubleshooting Procedures

Trouble Probable Cause Remedy
Full Out or Respective Cam not set Adjust respective Cam to actuate Limit Switch at required
Emergency Full Out properly in Cyclocentric location (refer to Section 101, Paragraph 4A.[14], for
Switch inoperative Drive Assembly adjustment)
Defective Limit Switch Test Limit Switches (refer to Section 101, Paragraph 4A for
test and corrective action)
Electrical Connectors P3 Check Connectors (refer to Section 201, Figures 201, 202,
and J3 defective, or not 203, and 204 for wiring diagrams)
properly connected
Electrical wiring damaged Repair (using acceptable aviation practices), or replace,
wiring (refer to Section 201, Figures 201, 202, 203, and 204
for wiring diagrams)
Overload Clutch, or Remove Hoist and send for repair (refer to Section 301,
Weston Brake and / or Paragraph 3, for removal, and Section 701, Paragraph 15, for
motor brake is slipping installation)
Hoist fails to stop at Full in Limit Switch / Adjust full in limit switch actuation point (refer to Section
Full in or stops prior actuator out of adjustment 101, Paragraph 4A[15] for adjustment procedure)
to the Full in position Defective Limit Switch(s) Test Limit Switches (refer to Section 101, Paragraph 4A for
test and corrective action)
Electrical Connectors P3 Check Connectors (refer to Section 201, Figures 201, 202,
and J3 defective, or not 203, and 204 for wiring diagrams)
properly connected
Electrical wiring damaged Remove Hoist and send for repair (refer to Section 301,
Paragraph 3, for removal, and Section 701, Paragraph 15, for
installation)
Hoist fails to stop at Respective Cam not set Adjust respective Cam to actuate Limit Switch at required
Full Out (Emergency properly in Cyclocentric location (refer to Section 101, Paragraph 4A.[14], for
Full out stops hoist) Drive Assembly adjustment)
Defective Limit Switch Test Limit Switches (refer to Section 101, Paragraph 4A for
test and corrective action)
Electrical circuit between Check Circuit / Continuity (refer to Section 201, Figures
P3, E3 and E4, defective, 201, 202, 203, and 204 for wiring diagrams)
or not properly connected
Electrical wiring damaged Repair (using acceptable aviation practices), or replace,
wiring (refer to Section 201, Figures 201, 202, 203, and 204
for wiring diagrams)
Intermediate Speed Respective Cam not set Adjust respective Cam to actuate Limit Switch at required
Limit Switches properly in Cyclocentric location (refer to Section 101, Paragraph 4A.[14], for
inoperative Drive Assembly adjustment)
Intermediate Speed Defective Limit Switch Test Limit Switches (refer to Section 101, Paragraph 4A for
Limit Switches Inop. test and corrective action)

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FLIGHT LINE OPERATION AND MAINTENANCE MANUAL

HS-29900-30, HS-29900-30-4, & HS-29900-36 RESCUE HOIST SYSTEMS
Table 101. Troubleshooting Procedures
Trouble Probable Cause Remedy
Intermediate Speed Electrical Connectors P3 Check Connectors (refer to Section 201, Figures 201, 202,
Limit Switches Inop. and J3 defective, or not 203, and 204 for wiring diagrams)
(continued) properly connected
Electrical wiring damaged Repair (using acceptable aviation practices), or replace,
wiring (refer to Section 201, Figures 201, 202, 203, and 204
for wiring diagrams)
Full in Limit Switch Improper adjustment of Adjust full in limit switch actuation point (refer to Section
does not actuate switch actuator 101, Paragraph 4A[15] for adjustment procedure)
Defective Limit Switch Test Limit Switches (refer to Section 101, Paragraph 4A for
test and corrective action)
Electrical Connectors P3 Check Connectors (refer to Section 201, Figures 201, 202,
and J3 defective, or not 203, and 204 for wiring diagrams)
properly connected
Electrical wiring damaged Repair (using acceptable aviation practices), or replace,
wiring (refer to Section 201, Figures 201, 202, 203, and 204
for wiring diagrams)
Roller and Housing Loosen screws (190, Figure 1002, Sheet 6) securing roller
Assembly damaged, cover (260) reposition until Roller and Housing and cover
binding, or off center are concentric
Overload Clutch, or Remove Hoist and send for repair (refer to Section 301,
Weston Brake and / or Paragraph 3, for removal, and Section 701, Paragraph 15, for
motor brake is slipping, or installation)
binding
Hoist fails to hold Defective down limit Test Limit Switches (refer to Section 101, Paragraph 4A for
load, or operates switch test and corrective action)
intermittently during Defective Potentiometer inReplace Panel (refer to Section 301, Paragraph 5, for
lowering Crew Control Panel, or removal, and Section 701, Paragraph 16, for installation), or
Control Pendant Pendant (refer to Section 301, Paragraph 6, for removal, and
Section 701, Paragraph 18, for installation)
Defective Motor and / or Replace Motor (refer to Section 301, Paragraph 12, for
Controller Assembly* (See removal, and Section 701, Paragraph 8, for installation), and
Warning on Page 119) replace Controller (refer to Section 301, Paragraph 13, for
removal, and Section 701, Paragraph 9, for installation)
Degradation of digital Replace Panel (refer to Section 301, Paragraph 5, for
readout due to moisture removal, and Section 701, Paragraph 16, for installation), or
intrusion, or other Pendant (refer to Section 301, Paragraph 6, for removal, and
malfunction Section 701, Paragraph 18, for installation)
Defective helicopter Repair (using acceptable aviation practices), or replace,
wiring helicopter wiring (refer to helicopter wiring diagrams)
Digital readout has Check power up lamp test, replace pendant and send for
segment out repair if segment is confirmed out
Loss of Power or a phase Check helicopter power supply
is lost

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FLIGHT LINE OPERATION AND MAINTENANCE MANUAL

HS-29900-30, HS-29900-30-4, & HS-29900-36 RESCUE HOIST SYSTEMS
Table 101. Troubleshooting Procedures
Trouble Probable Cause Remedy
Control Pendant Full in Limit Switch Adjust full in limit switch actuation point (refer to Section
digital readout reads command without Slow 101, Paragraph 4A[15] for adjustment procedure)
888 and all indicator Up Limit Switch command Test Limit Switches (refer to Section 101, Paragraph 4A for
lights are illuminated test and corrective action)
Motor Power Module over Stop operation to allow Motor to cool
temperature
Motor electronics BIAS Replace Motor (refer to Section 301, Paragraph 12, for
voltage failure due to removal, and Section 701, Paragraph 8, for installation), and
defective wiring, or replace Controller (refer to Section 301, Paragraph 13, for
defective Motor and removal, and Section 701, Paragraph 9, for installation)
Controller* (See Warning Repair (using acceptable aviation practices), or replace,
on Page 119) wiring (refer to Section 201, Figures 201, 202, 203, and 204
for wiring diagrams)
Remove Hoist and send for repair (refer to Section 301,
Paragraph 3, for removal, and Section 701, Paragraph 15, for
installation)
Defective Hoist Remove Hoist and send for repair (refer to Section 301,
Paragraph 3, for removal, and Section 701, Paragraph 15, for
installation)
Erratic Cable Payout Defective Potentiometer Replace Potentiometer (refer to Section 301, Paragraph 14
readings on Hoist for removal, and Section 701, Paragraph 4A, for installation)
Electrical wiring damaged, Remove Hoist and send for repair (refer to Section 301,
cables not connected Paragraph 3, for removal, and Section 701, Paragraph 15, for
installation)
Defective Control Pendant Replace Pendant (refer to Section 301, Paragraph 6, for
removal, and Section 701, Paragraph 18, for installation)
Control Pendant Full Incorrectly adjusted Full in Adjust limit switch actuation point (refer to Section 101
in light stays Limit Switch Paragraph 4A[15] for adjustment procedure)
illuminated Electrical circuit / wiring Replace Pendant (refer to Section 301, Paragraph 6, for
damaged removal, and Section 701, Paragraph 18, for installation)
Repair (using acceptable aviation practices), or replace,
wiring (refer to Section 201, Figures 201, 202, 203, and 204
for wiring diagrams)
Defective Control Pendant Replace Pendant (refer to Section 301, Paragraph 6, for
removal, and Section 701, Paragraph 18, for installation)
Voltage low Check power under load
Hoist fails to make Excessive amount of oil in Check oil level (refer to Section 501, Paragraph 2K, for
speed Hoist checking level and servicing the Hoist with oil)
Defective Potentiometer in Replace Pendant (refer to Section 301, Paragraph 6, for
Control Pendant removal, and Section 701, Paragraph 18, for installation)

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FLIGHT LINE OPERATION AND MAINTENANCE MANUAL

HS-29900-30, HS-29900-30-4, & HS-29900-36 RESCUE HOIST SYSTEMS
Table 101. Troubleshooting Procedures
Trouble Probable Cause Remedy
Hoist fails to make Defective Motor and / or
Replace Motor (refer to Section 301, Paragraph 12, for
speed (continued) Controller* (See Warning
removal, and Section 701, Paragraph 8, for installation), and
on Page 119) replace Controller (refer to Section 301, Paragraph 13, for
removal, and Section 701, Paragraph 9, for installation)
Defective Hoist Remove Hoist and send for repair (refer to Section 301,
Paragraph 3, for removal, and Section 701, Paragraph 15, for
installation)
Loss of electrical power Check helicopter power supplies (AC & DC)
Hoist does not operate Electrical wiring damaged, Repair (using acceptable aviation practices), or replace,
cables not connected wiring (refer to Section 201, Figures 201, 202, 203, and 204
for wiring diagrams)
Pilot Control Hoist Enable Reposition Switch to ON position, or replace Panel (refer to
Switch in OFF position, or Section 301, Paragraph 4, for removal, and Section 701,
switch is defective Paragraph 17, for installation)
Defective Potentiometer in Replace Pendant (refer to Section 301, Paragraph 6, for
Control Pendant removal, and Section 701, Paragraph 18, for installation)
Defective Motor and / or Replace Motor (refer to Section 301, Paragraph 12, for
Controller* (See Warning removal, and Section 701, Paragraph 8, for installation), and
on Page 119) replace Controller (refer to Section 301, Paragraph 13, for
removal, and Section 701, Paragraph 9, for installation)
Defective Hoist Remove Hoist and send for repair (refer to Section 301,
Paragraph 3, for removal, and Section 701, Paragraph 15, for
installation)
Deflection of Bumper Defective Bumper Spring Replace Bumper (refer to Section 301, Paragraph 7, for
Spring exceeds limits removal, and Section 701, Paragraph 13 for installation)
Intermediate Speed Up, or Test Switches (refer to Section 101, Paragraph 4A for test
Full in, Limit Switches and corrective action)
inoperative
Defective Motor and Replace Motor (refer to Section 301, Paragraph 12, for
Controller* (See Warning removal, and Section 701, Paragraph 8, for installation), and
on Page 119) replace Controller (refer to Section 301, Paragraph 13, for
removal, and Section 701, Paragraph 9, for installation)
Cable wraps loosely Lubrication on Cable Clean Cable (refer to Section 401, Paragraphs 2 and 3)
on drum, or does not Worn Tension Roller Remove and replace tension roller (refer to Section 301,
lower smoothly Paragraph 17, for removal, and Section 701, Paragraph 7, for
installation)
Timing between Cable Realign Cable Guide by adjusting Level Wind Shaft timing
Guide and Drum is with Drum (refer to Section 601, Paragraph 8)
incorrect
Cable snaps at Timing between Cable Realign Cable Guide by adjusting Level Wind Shaft timing
turnaround points Guide and Drum is with Drum (refer to Section 601, Paragraph 8)
from one layer to the incorrect
next layer on Drum

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HS-29900-30, HS-29900-30-4, & HS-29900-36 RESCUE HOIST SYSTEMS
Table 101. Troubleshooting Procedures
Trouble Probable Cause Remedy
Cable fouls, or breaks Frayed, or broken Cable Replace Cable (refer to Section 301, Paragraph 8, for
removal, and Section 701, Paragraph 12, for installation)
Intermediate Speed Up, or Test Switches (see Section 101, Paragraph 4A for test and
Full in Limit Switch corrective action)
inoperative
Defective Bumper Replace Bumper (refer to Section 301, Paragraph 7, for
Assembly removal, and Section 701, Paragraph 13, for installation)
Worn Tension Roller Remove and replace tension roller (refer to Section 301,
Paragraph 17, for removal, and Section 701, Paragraph 7, for
installation)
Timing between Cable Realign Cable Guide by adjusting Level Wind Shaft timing
Guide and Drum is with Drum (refer to Section 601, Paragraph 8)
incorrect
Hoist hook fails to Defective, or improper Check installation, or replace, Hook (refer to Section 301,
support load attachment of Hook to Paragraph 7, for removal, and Section 701, Paragraph 13, for
Cable, or defective Hook installation). Inspect per Section 501, Paragraph 2I.
Hoist operates Defective Pilot Control Replace Panel (refer to Section 301, Paragraph 4, for
uncontrolled in either Panel, or Control Pendant removal, and Section 701, Paragraph 17, for installation), or
direction Pendant (refer to Section 301, Paragraph 6, for removal, and
Section 701, Paragraph 18, for installation)
Defective Motor and / or Replace Motor (refer to Section 301, Paragraph 12, for
Controller* (See Warning removal, and Section 701, Paragraph 8, for installation), and
on Page 119) replace Controller (refer to Section 301, Paragraph 13, for
removal, and Section 701, Paragraph 9, for installation)
Cable Cutter Defective Crew Control Replace Crew Control Panel (refer to Section 301,
inoperative, or fires Panel, or Pilot Control Paragraph 5, for removal, and Section 701, Paragraph 16, for
without switch Panel installation), or Pilot Control Panel (refer to Section 301,
actuation Paragraph 4, for removal, and Section 701, Paragraph 17, for
installation)
Defective wiring Repair (using acceptable aviation practices), or replace,
wiring (refer to Section 201, Figures 201, 202, 203, and 204
for wiring diagrams)
Defective cartridge Replace cartridge (refer to Section 301, Paragraph 3C, for
removal, and Section 701, Paragraph 19, for installation)
Loss of Power Check helicopter power supply

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HS-29900-30, HS-29900-30-4, & HS-29900-36 RESCUE HOIST SYSTEMS
*WARNING: DUE TO THE DIFFICULTY IN TROUBLESHOOTING THE ELECTRONICS IN
THE MOTOR AND CONTROLLER AT THE FLIGHT LINE LEVEL, IT IS
STRONGLY RECOMMENDED THAT THE HOIST BE SHIPPED TO
BREEZE-EASTERN FOR TROUBLESHOOTING AND CORRECTIVE ACTION.
HOWEVER, IF THE OPERATOR WANTS TO PERFORM MAINTENANCE ON
THE MOTOR AND / OR THE CONTROLLER, BOTH COMPONENTS MUST BE
REPLACED AS A SET. FAILURE TO REPLACE BOTH COMPONENTS AS A SET
COULD RESULT IN DAMAGE TO THE NEWLY REPLACED PART(S).
If defect cannot be corrected, contact Breeze-Eastern Customer Services at:
Breeze-Eastern Corporation
35 Melanie Lane
Whippany, New Jersey 07981-1638 USA
Phone Number: 973-602-1001, Ext.1083 or 1090, or 1-800-929-1919 (US and Canada only)
Fax Number: 973-739-9344
E-mail Address: customerservices@breeze-eastern.com
Web Site Address: www.breeze-eastern.com
Revision status of the Breeze-Eastern technical manuals can be checked on the Web Site listed
above.

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This Page Intentionally Left Blank

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HS-29900-30, HS-29900-30-4, & HS-29900-36 RESCUE HOIST SYSTEMS
SCHEMATICS AND WIRING DIAGRAMS
1. General
This section provides all schematic diagrams, wiring, and interconnecting diagrams of the
applicable components of the Rescue Hoist System. These schematics and diagrams are provided
for use during disassembly, assembly, installation, and troubleshooting of the Rescue Hoist
System.
CAUTION: WHEN REMOVING P3 ENSURE THAT THE EMI FILTER (EE SEAL) REMAINS
IN POSITION AND IS NOT DAMAGED IN ANY WAY.

EE Seal Location

Figure 201. Electrical Schematic of the Rescue Hoist Assembly

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HS-29900-30, HS-29900-30-4, & HS-29900-36 RESCUE HOIST SYSTEMS

Cyclocentric Drive Assembly

Wiring Diagram

Cable Guide Assembly

Wiring Diagram

Figure 202. Rescue Hoist Assembly Wiring Diagram

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HS-29900-30, HS-29900-30-4, & HS-29900-36 RESCUE HOIST SYSTEMS

BL-29900-30-1/-4

Figure 203. Rescue Hoist Systems HS-29900-30 and HS-29900-30-4 Wiring Diagram

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Figure 204. Rescue Hoist System HS-29900-36 Wiring Diagram

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HS-29900-30, HS-29900-30-4, & HS-29900-36 RESCUE HOIST SYSTEMS
DISASSEMBLY
1. General
NOTE: REVIEW GENERAL INSPECTION PROCEDURES IN SECTION 501,
PARAGRAPH 2B, PRIOR TO PERFORMING ANY MAINTENANCE.
Use of Testing and Troubleshooting procedures, in Section 101, will establish the condition of the
Rescue Hoist System or most probable cause for its malfunction. These procedures should be
followed to determine the extent of disassembly required for repair and maintenance of the
Rescue Hoist System, and to limit the amount of maintenance required to return it to a safe and
serviceable condition.
2. Disassemble the Rescue Hoist System in accordance with the following instructions. Reference
numbers in parentheses refer to Illustrated Parts List (IPL) in Section 1001 (Figures 1001, 1002,
and 1003). All mention of applying and disconnecting power to system components should be
accomplished using helicopter circuit breakers or equivalent acceptable means.
3. Rescue Hoist Assembly
WARNING: SEARCH AND RESCUE OPERATIONS, AND ALL OTHER USES OF RESCUE
HOISTS FOR HOISTING AND LOWERING PERSONNEL, CAN RESULT IN
INJURY OR DEATH. PROPERLY TRAINED PERSONNEL MUST UTILIZE
APPROPRIATE OPERATION, MAINTENANCE, AND INSPECTION
PROCEDURES TO MINIMIZE THE HAZARDS INHERENT IN THE USE OF
ALL RESCUE HOISTS.
CAUTION: THE MOTOR USES HIGH VOLTAGE POWER FROM THE CONTROLLER.
ENSURE ALL CIRCUIT BREAKERS ARE PULLED AND ALL POWER
SOURCES ARE OFF AND / OR DISCONNECTED PRIOR TO PERFORMING
MAINTENANCE.
Remove rescue hoist from helicopter as follows (see Figure 1001 unless specified below):
A. Disconnect power to hoist (10 and 11, Figure 1001) by pulling applicable circuit breakers.
B. Disconnect electrical connectors on the Rescue Hoist Assembly and install protective caps.
WARNING: THE CARTRIDGE MUST BE REMOVED BEFORE PERFORMING ANY
MAINTENANCE PROCEDURES INVOLVING THE RESCUE HOIST
ASSEMBLY AND MUST BE INSTALLED AFTER ALL MAINTENANCE
PROCEDURES ON THE RESCUE HOIST ASSEMBLY ARE COMPLETED.
WARNING: THE CARTRIDGE IS AN EXPLOSIVE DEVICE AND MUST BE SHIPPED,
STORED, AND HANDLED IN COMPLIANCE WITH ALL LOCAL
STANDARDS, AND REGULATORY PRACTICES. TAKE PROPER ESD
PRECAUTIONS TO AVOID SETTING OFF THE CARTRIDGE DURING
HANDLING DUE TO ELECTRICAL SHOCK FROM ELECTROSTATIC
DISCHARGE.

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C. Remove cable cutter cartridge (Item 10, Figure 1002, Sheet 5, part of 20, Figure 1001) from
rescue hoist assembly as follows:
NOTE: SPRING SHUNT AND PROTECTIVE CAP SAVED DURING INSTALLATION
OF CARTRIDGE SHOULD BE USED DURING REMOVAL OF CARTRIDGE.
(1) Disconnect harness assembly (480, Figure 1002, Sheet 1), and short all pins of the
cartridge together with the spring shunt supplied with cartridge (if spring shunt is not
available, short all pins of cartridge with equivalent alternative).
CAUTION: DO NOT USE TAPE, OR METAL CAP IN PLACE OF PROTECTIVE CAP
DURING REMOVAL OF CARTRIDGE.
(2) Place protective cap over connector end of cartridge (10, Figure 1002, Sheet 5) to hold
spring shunt, or equivalent, in place.
(3) Remove tie wire and cartridge with packing (20, Figure 1002, Sheet 5) from cable guide
housing, and discard packing.
CAUTION: RESCUE HOIST ASSEMBLY WEIGHS APPROXIMATELY 105 LB. (47.6 KG.)
AS MOUNTED ON THE HELICOPTER. TWO INDIVIDUALS MUST BE
AVAILABLE TO REMOVE THE RESCUE HOIST ASSEMBLY FROM THE
HELICOPTER UNLESS SUITABLE SUPPORT IS PROVIDED TO HOLD THE
WEIGHT OF EACH RESCUE HOIST ASSEMBLY WHEN REMOVED.
D. Remove screws (400, Figure 1002, Sheet 1), washers (410), and connector cover assembly
(420) from rescue hoist assembly.
E. To move cuff fairing assembly (440) away from hoist, remove screws (400), washers (410),
and clamp (430), then slide cuff fairing assembly (440) down along mount.
F. Remove attaching hardware (not part of system, not shown in IPL, and not supplied by
Breeze-Eastern) from mounting point, and remove hoist assembly and cuff fairing assembly
from helicopter.
4. Pilot Control Panel Assembly
Remove pilot control panel assembly from helicopter as follows (see Figure 1001, Items 30 and
31):
A. Disconnect power to pilot control panel assembly (30 and 31, Figure 1001) by pulling
applicable circuit breakers.
B. Remove four mounting screws (not part of system, not shown in IPL, and not supplied by
Breeze-Eastern), or four captive dzus fasteners from pilot control panel assembly and pull
panel forward to access electrical connectors attached to the back of the panel.
C. Disconnect electrical connector to pilot control panel assembly.
D. Remove pilot control panel assembly from helicopter.

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HS-29900-30, HS-29900-30-4, & HS-29900-36 RESCUE HOIST SYSTEMS
5. Crew Control Panel Assembly
Remove crew control panel assembly from helicopter as follows (see Figure 1001, Items 40 and
41):
A. Disconnect power to crew control panel assembly (40, 41, Figure 1001) by pulling applicable
circuit breakers.
B. Remove four captive mounting screws, or four dzus fasteners (not shown in IPL) from crew
control panel assembly and pull panel forward to access electrical connectors attached to the
back of the panel.
C. Disconnect the two electrical connectors to crew control panel assembly.
D. Remove crew control panel assembly from helicopter.
6. Control Pendant Assembly and Pendant Cable Assembly
Remove control pendant assembly and pendant cable assembly from helicopter as follows (see
Figure 1001, Items 50, 51, and 60):
A. Disconnect power to control pendant assembly (50, 51, Figure 1001) by pulling applicable
circuit breakers.
B. Disconnect and remove control pendant assembly (50) from pendant cable assembly (60,
Figure 1001) electrical connector.
C. Disconnect pendant cable assembly (60) electrical connector and remove pendant cable
assembly from helicopter.
7. Bumper Assembly and Swivel Hook Assembly
NOTE: ALERT SERVICE BULLETIN ASB BL-12756-1-A25-01 REMOVED BUMPER
ASSEMBLY PART NUMBER BL-12750-3 (30, FIGURE 1002, SHEET 1, AND 10,
FIGURE 1003), AND REPLACED IT WITH PART NUMBER BL-15975-3. ENSURE
THIS ASB HAS BEEN TERMINATED.
Remove and disassemble bumper assembly (30, Figure 1002, Sheet 1, and 10, Figure 1003) and
swivel hook assembly (39 and 40, Figure 1002, Sheet 1, and 19 and 20, Figure 1003) as follows
(see Figure 1003, unless specified below):
A. Apply power to rescue hoist assembly (10 and 11, Figure 1001).
B. Slowly reel out approximately 6 feet (1.8 meters) of cable (60, Figure 1002, Sheet 2) from
hoist to allow the bumper assembly (10, Figure 1003) and swivel hook assembly (19 or 20) to
rest on flat surface.
C. Disconnect power to rescue hoist assembly per Paragraphs 3A and 3B in this section.
D. Pull up on bumper assembly (10), and slide it along cable away from swivel hook assembly
(19 or 20).
E. Remove cotter pins (30) and locking screws (40) from nut (50).

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HS-29900-30, HS-29900-30-4, & HS-29900-36 RESCUE HOIST SYSTEMS
F. While holding housing (110) unthread and remove nut (50) and slide it along cable away from
swivel hook assembly.
NOTE: TERMINAL CLAMP (70) IS A TWO-PIECE MATCHED SET. KEEP BOTH
HALVES TOGETHER FOR FUTURE USE.
G. Remove terminal clamp (70) by removing ring (60). Remove terminal clamp, nut, and bumper
assembly from cable.
H. Lift up and remove rubber bumper (80) from housing (110).
I. Line up and remove hole in housing (110) with end of spring pin (90), and using a drift and a
mallet, gently tap out spring pin to remove it from the stem of the hook assembly (149 and
150).
J. Remove castellated nut (100) from stem of hook assembly (149 and 150).
K. Lift up and remove housing (110), thrust washer (120), ball bearing (130), and flat washer
(140) from hook (149 and 150).
L. For disassembly of the hook (150), proceed as follows:
(1) Unlock keeper by removing quick release pin (160).
WARNING: TO AVOID INJURY, EXTREME CAUTION MUST BE USED WHEN
REMOVING RIVET, KEEPER, AND SPRING. THE SPRING IS UNDER
COMPRESSION WHEN INSTALLED AND CAN FLY OFF HOOK WHEN
REMOVING RIVET.
(2) To remove quick release pin (160) and cable assembly (170), remove rivet (180) in the
hook by machining or chiseling off rivet head. Tap out rivet shank with a drift and a
mallet, and remove rivet, cable assembly, and quick release pin from hook (190).
8. Wire Rope Cable
WARNING: WORK GLOVES MUST BE WORN BY THE OPERATOR WHENEVER
HANDLING THE RESCUE HOIST CABLE TO PREVENT INJURY FROM
BROKEN STRANDS AND WIRES. EYE PROTECTION MUST BE WORN BY
THE OPERATOR WHENEVER OPERATING, OR MAINTAINING, THE RESCUE
HOIST TO PREVENT INJURY FROM LUBRICANTS, SOLVENTS, AND OTHER
MATERIALS USED ON THE RESCUE HOIST, AS WELL AS METAL PARTS
AND OTHER DEBRIS.
NOTE: ACCOMPLISH REMOVAL INSTRUCTIONS IDENTIFIED IN PARAGRAPHS 3C
(REMOVAL OF CABLE CUTTER CARTRIDGE) AND 7, (BUMPER ASSEMBLY
AND SWIVEL HOOK ASSEMBLY) PRIOR TO PERFORMING THE
PROCEDURE BELOW.
Remove cable from hoist as follows (see Figure 1002, Sheet 2):
A. Apply power to rescue hoist (Figure 1001, Items 10 or 11).

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HS-29900-30, HS-29900-30-4, & HS-29900-36 RESCUE HOIST SYSTEMS
B. Slowly reel out cable (60, Figure 1002, Sheet 2) at less than half speed until the hoist cable
reaches the 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 SETSCREW IS VISIBLE. ROTATING THE DRUM IN THE
LOWERING DIRECTION BEYOND THIS POSITION WILL CAUSE THE CABLE
TO BACKWIND RESULTING IN SERIOUS DAMAGE TO HOIST.
C. Actuate, and hold, the emergency (full out) bypass switch S5 (850, Figure 1002, Sheet 3)
through the 0.1875 in. (4.76 mm) diameter access hole (unmarked) in the lower front of the
aft cowling, refer to Figure 301. Wait one second then operate the hoist with the control
pendant. Slowly rotate the drum until the setscrew in the hoist flange (50, Figure 1002, Sheet
2) is visible and accessible (positioned between the mid-section and the level wind shafts),
and approximately 18 inches (0.45 meters) of cable remain on the hoist (less than 1 wrap).

0.1875 in. (4.76 mm) diameter cowling access hole

Figure 301. Emergency (Full Out) Bypass Switch Aft Cowling Access Hole
D. Disconnect power to hoist per paragraphs 3A and 3B of this section.
E. Using a 1/16 or 0.0625 in. (1.5875 mm.) size hex wrench, remove screw (50) from drum
flange to allow removal of cable.
CAUTION: ONCE THE CABLE IS REMOVED, DO NOT ROTATE DRUM IN EITHER
DIRECTION. THE DRUM IS IN POSITION FOR INSTALLATION OF NEW
CABLE. ROTATING THE DRUM WITHOUT THE CABLE ATTACHED WILL
CAUSE THE TIMING BETWEEN THE CABLE GUIDE AND DRUM TO BE
INCORRECT RESULTING IN DAMAGE TO THE DRUM AND CABLE.
F. Remove the end of cable (60) from the slot in the drum flange. Pull cable out from the front of
the drum and through the cable guide assembly.
9. Cable Cutter
WARNING: THE CARTRIDGE MUST BE REMOVED BEFORE PERFORMING ANY
MAINTENANCE PROCEDURES INVOLVING THE RESCUE HOIST
ASSEMBLY AND MUST BE INSTALLED AFTER ALL MAINTENANCE
PROCEDURES ON THE RESCUE HOIST ASSEMBLY ARE COMPLETED.

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HS-29900-30, HS-29900-30-4, & HS-29900-36 RESCUE HOIST SYSTEMS
WARNING: THE CARTRIDGE IS AN EXPLOSIVE DEVICE AND MUST BE SHIPPED,
STORED, AND HANDLED IN COMPLIANCE WITH ALL LOCAL
STANDARDS, AND REGULATORY PRACTICES.
NOTE: THE CARTRIDGE SERVICE LIFE IS 5 YEARS WHEN REMOVED FROM
PACKAGING AND INSTALLED IN RESCUE HOIST. MAXIMUM CARTRIDGE
LIFE IS 9 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 THE LETTERS IS THE DATE OF
MANUFACTURE, REPRESENTED AS TWO DIGITS, WHICH IDENTIFY THE
YEAR (EXAMPLE: 10 IS 2010), AND ONE LETTER, WHICH IDENTIFIES THE
MONTH, AS DEFINED BELOW:
A) JANUARY B) FEBRUARY C) MARCH D) APRIL
E) MAY F) JUNE G) JULY H) AUGUST
J) SEPTEMBER K) OCTOBER L) NOVEMBER M) DECEMBER
NOTE: ACCOMPLISH REMOVAL INSTRUCTIONS IDENTIFIED IN PARAGRAPH 8
(REMOVAL OF CABLE) PRIOR TO PERFORMING THE PROCEDURE BELOW.
Remove cable cutter as follows (see Figure 1002, Sheet 5):
A. Disconnect power to hoist per paragraphs 3A and 3B of this section, and if not previously
accomplished, unthread and remove cartridge (10), harness clocking shims (15, 15A, 15B, if
installed), and packing (20) from cable guide assembly per paragraph 3C.
B. Remove tie wire and unthread cutter anvil cap (70).
C. Remove cotter pin (80), cable cutter (90), and O-ring (100). Discard cotter pin and O-ring.
10. Midsection Support Covers, Forward and Aft Cowling Assemblies, and Cable Cutter Cable
Assembly
Remove midsection center support covers (500 and 510), forward and aft cowling assemblies
(520 and 530), and cable cutter cable harness assembly (480) as follows (See Figure 302 and
Figure 1002, Sheets 1 and 2):
A. Disconnect power to hoist per paragraphs 3A and 3B of this section.
B. Remove screws (405, Figure 1002, Sheet 1), washers (490), and remove midsection support
covers (500 and 510).
C. Remove screws (400, Figure 1002, Sheet 2), washers (410), clamp (450) and forward cowling
assembly (520).

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HS-29900-30, HS-29900-30-4, & HS-29900-36 RESCUE HOIST SYSTEMS

Cowling Attach Upper & Lower Forward Cowling

Screws/Washers Support Covers (Motor Side)
Aft Cowling

Figure 302. Rescue Hoist Front View

D. Remove screws (400, Figure 1002, Sheet 1), washers (410), connector cover assembly (420),
and aft cowling assembly (530).
E. Remove screws (460) and washers (470) from connector on support mount, and remove cable
cutter harness assembly (480).
11. Roller and Housing Assembly
NOTE: ACCOMPLISH REMOVAL INSTRUCTIONS IDENTIFIED IN PARAGRAPH 8
(REMOVAL OF CABLE) PRIOR TO PERFORMING THE PROCEDURE BELOW.
THIS MANUAL INCORPORATES SERVICE BULLETIN BL-11703-1-25-01.
Remove and disassemble roller and housing assembly (120, Figure 1002, Sheet 5) as follows
(accomplish actions identified in paragraph 8 [removal of cable] above prior to performing the
steps below, see Figure 1002, Sheets 5 and 6):
A. Disconnect power to hoist per paragraphs 3A and 3B of this section.
B. Remove screws (110, Figure 1002, Sheet 5) and separate roller and housing assembly (120)
from rescue hoist assembly.
C. Remove screws (140, Figure 1002, Sheet 6) and retainer (130) from roller and housing
assembly.
D. Remove spacer (150) with bearings (160 and 170) from roller housing (290).
E. Remove bearings (160 and 170) from spacer (150).
F. Remove actuator flange (180) by removing screws (190) and washers (200).
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G. Remove cable guide cover (210) by removing screws (220).
H. Remove cover assembly (230), which consists of spacers (240 and 250) and roller cover
(260), by removing shoulder screws (270).
NOTE: SPACERS (240 & 250) ARE SECURED TO THE CABLE GUIDE HOUSING WITH
LOCTITE SPEED BONDER #324. WHEN REMOVING SPACERS (240 & 250)
ROTATE CABLE GUIDE HOUSING (260) 180º (UPSIDE DOWN) TO ASSIST
REMOVAL SO THE TOP OPENING IS LAYING FLAT AND THE SPACERS FALL
OUT FROM THE BOTTOM. REFER TO FIGURE 303, AND FIGURE 1002, SHEET 6.
I. Using hand pressure, or a blunt punch and mallet, carefully tap / remove spacers (240 & 250)
out of cable guide housing (260).

240

230 250

260

270 200

190

210
220
Figure 303. Roller and Housing Assembly
J. Remove springs (280) from roller housing (290).
K. Loosen modified cap screws (300) and remove shafts (310 and 320).
L. Remove washers (330), shims (340 through 340C), and cable pressure roller assemblies (350)
from roller housing (290).
M. Remove bearings (360), shims (380 through 380C), and retaining rings (390) from rollers
(370).

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12. Motor Assembly
WARNING: DUE TO THE DIFFICULTY IN TROUBLESHOOTING THE ELECTRONICS IN
THE MOTOR AND CONTROLLER AT THE FLIGHT LINE LEVEL, IT IS
STRONGLY RECOMMENDED THAT THE HOIST BE SHIPPED TO BREEZE-
EASTERN FOR TROUBLESHOOTING AND CORRECTIVE ACTION.
HOWEVER, IF THE OPERATOR WANTS TO PERFORM MAINTENANCE ON
THE MOTOR AND / OR THE CONTROLLER, BOTH COMPONENTS MUST BE
REPLACED AS A SET. FAILURE TO REPLACE BOTH COMPONENTS AS A
SET COULD RESULT IN DAMAGE TO THE NEWLY REPLACED PART(S).
WARNING: MOTOR USES HIGH VOLTAGE POWER FROM CONTROLLER. ENSURE ALL
CIRCUIT BREAKERS ARE PULLED AND ALL POWER SOURCES ARE OFF
AND / OR DISCONNECTED PRIOR TO PERFORMING MAINTENANCE.
NOTE: ACCOMPLISH REMOVAL INSTRUCTIONS IDENTIFIED IN PARAGRAPH 10
(REMOVAL OF MIDSECTION SUPPORT COVERS, FORWARD COWLING
ASSEMBLY, AFT COWLING ASSEMBLY, AND CABLE CUTTER CABLE
ASSEMBLY) PRIOR TO PERFORMING THE PROCEDURE BELOW.
NOTE: SERVICE BULLETIN EC-23050-1,-2,-3,-4, -25-01 IS INCORPORATED IF THE
MOTOR ASSEMBLY IDENTIFICATION DATA PLATE (BREEZE-EASTERN
AND / OR MPC) HAS A SN PREFIX OF “G,” “H,” “I,” ETC. IF A PREFIX OF “A”
THROUGH “F” IS IN FRONT OF THE MOTOR ASSEMBLY IDENTIFICATION
PLATE SERIAL NUMBER THE SERVICE BULLETIN HAS NOT BEEN
INCORPORATED.
Remove motor as follows (see Figure 1002, Sheet 4):
A. Disconnect power to hoist per paragraphs 3A and 3B of this section.
B. Disconnect electrical connectors from motor harness assembly (580, Figure 1002, Sheet 3) and
controller assembly harness assembly (684) from motor. Refer to Figure 304.

Motor Assembly (610) J2

J4
Motor Assembly Electrical Connectors

Harness Assemblies (580 & 684)

P2 P4

Figure 304. Motor Assembly Electrical Connectors.

C. Remove four cap screws (590, Figure 1002, Sheet 4), washers (600), using a 5/16 or 0.3125 in.
(7.938 mm.) hex wrench.
D. Carefully slide motor assembly (610) splines out from the end flange.

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13. Controller Assembly
WARNING: DUE TO THE DIFFICULTY IN TROUBLESHOOTING THE ELECTRONICS IN
THE MOTOR AND CONTROLLER AT THE FLIGHT LINE LEVEL, IT IS
STRONGLY RECOMMENDED THAT THE HOIST BE SHIPPED TO
BREEZE-EASTERN FOR TROUBLESHOOTING AND CORRECTIVE ACTION.
HOWEVER, IF THE OPERATOR WANTS TO PERFORM MAINTENANCE ON
THE MOTOR AND / OR THE CONTROLLER, BOTH COMPONENTS MUST BE
REPLACED AS A SET. FAILURE TO REPLACE BOTH COMPONENTS AS A
SET COULD RESULT IN DAMAGE TO THE NEWLY REPLACED PART(S).
WARNING: MOTOR USES HIGH VOLTAGE POWER FROM CONTROLLER. ENSURE ALL
CIRCUIT BREAKERS ARE PULLED AND ALL POWER SOURCES ARE OFF
AND / OR DISCONNECTED PRIOR TO PERFORMING MAINTENANCE.
NOTE: ACCOMPLISH REMOVAL INSTRUCTIONS IDENTIFIED IN PARAGRAPH 10
(REMOVAL OF MIDSECTION SUPPORT COVERS, FORWARD COWLING
ASSEMBLY, AFT COWLING ASSEMBLY, AND CABLE CUTTER CABLE
ASSEMBLY) PRIOR TO PERFORMING THE PROCEDURE BELOW.
Remove controller assembly as follows (see Figure 1002, Sheet 3):
A. Disconnect power to hoist per paragraphs 3A and 3B of this section.
B. Disconnect electrical harness connectors (controller assembly base plate harness [smaller
connector], and motor assembly harness {larger connector}) from bottom of motor assembly
for harness assemblies (580, 860) to controller assembly, refer to Figures 201 and 305.

NOTE: TAKE NOTE OF ALL TIE WRAP, TAPE, AND SPIRAL WRAP LOCATIONS ON
THE HOIST FOR ASSEMBLY PURPOSES.
C. Refer to Figures 201 and 306 for location and sequence. Disconnect two electrical connectors;
motor cable #1 (580 [Figure 201, P2]) and cyclocentric drive harness assembly (860 [Figure
201, P3]) from side of controller assembly.
D. Carefully cut and remove tape (550) and tie wraps (540, 730, and 740) from wiring harnesses.
Separate spiral wraps (560, 570, 650, and 750) from binding the two (2) wiring harnesses
together routed from the bottom of the motor assembly across the front of the hoist to the
connectors on the side of the controller assembly. The base plate harness is permanently
attached to the controller assembly (680). Refer to Figures 306, 307, and 308.
E. Remove cap screw (620), washer (630), & harness clamp (640) from top of controller (680).
F. Remove screws (660), washers (670), and controller assembly (680). Refer to Figure 309.

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Remove two harness

connectors from bottom Refer to Section 201,
of motor assembly Electrical Schematics
and Wiring Diagrams,
for clarification

Motor Assembly Controller Assembly

harness (580) harness (684)
connector (P2) connector (P4)

Figure 305. Motor Assembly Connector Location

Note: Retain all hardware for future use.

Order Sequence

1. Remove P2 & P3 (Figure 201) wiring harness

connectors from the side of the controller

2. Separate tie wraps (730 & 740), tape (550), & spiral
wraps (750) from bound controller assembly harness

3. Remove cap screw (620), washer (630), & harness

clamp (640) from top of controller (680).

4. Remove four controller attach screws (660) and washers

(670) and remove controller (680).

Figure 306. Controller Assembly Removal Sequence

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Wiring Harness
Tape and Tie
Wrap Location

Figure 307. Location of Mid-Section Wiring Harness Clear Tape and Tie Wraps

Harness (684) Location on Controller Assembly

Figure 308. Permanent Harness Attached to Controller

Attachment Cap Screw (660) and Washer (670) Locations

Figure 309. Controller Attaching Cap Screw and Washer Locations

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14. Cyclocentric Drive Assembly
NOTE: ACCOMPLISH REMOVAL INSTRUCTIONS IDENTIFIED IN PARAGRAPH 10
(REMOVAL OF MIDSECTION SUPPORT COVERS, FORWARD COWLING
ASSEMBLY, AFT COWLING ASSEMBLY, AND CABLE CUTTER CABLE
ASSEMBLY) PRIOR TO PERFORMING THE PROCEDURE BELOW.
Remove and disassemble cyclocentric drive assembly (720) as follows (Refer to Figure 310 and
Figure 1002, Sheet 3, Views B and G):

Figure 310. Cyclocentric Drive Assembly (720, Figure 1002, Sheet 3)

WARNING: TAKE PROPER ESD PRECAUTIONS TO AVOID DAMAGING ELECTRICAL
COMPONENTS DURING MAINTENANCE DUE TO ELECTRICAL SHOCK
FROM ELECTROSTATIC DISCHARGE.
A. Disconnect power to hoist per paragraphs 3A and 3B of this section.
B. Remove screws (710), washers (700), wire clamp (430), spiral wrap (560, 570, 650, and 750),
and straps (540, 730, and 740) from cyclocentric drive harness assembly (860).
C. Unsolder wiring from potentiometer assembly (776).
D. Unthread retaining screws (772) with cleats (774) securing potentiometer assembly (776) to
the mounting bracket (780). Remove potentiometer assembly (776) from mounting bracket
(780).
E. Remove cam locking plate centering “O-rings” from potentiometer assembly shaft (778) and
discard.
F. Remove screws (760 and 770) and potentiometer mounting bracket (780).
G. Unsolder and remove potentiometer mounting bracket (780) from harness assembly (860).
H. Remove cam locking plate (790), limit switch cams (800), and spacers (810).
I. Remove screws (820), actuators with insulators (830 and 840), and switches (850).

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J. Unsolder and remove switches (850) from limit switch harness assembly (860). Remove EE
Seal filter (865) from connector of harness assembly (860).
K. Remove cyclocentric housing (870) by removing screws (690), washers (700).
15. Full In Limit Switch
WARNING: TAKE PROPER ESD PRECAUTIONS TO AVOID DAMAGING ELECTRICAL
COMPONENTS DURING MAINTENANCE DUE TO ELECTRICAL SHOCK
FROM ELECTROSTATIC DISCHARGE.
Remove full in limit switch as follows (Refer to Figure 311 and Figure 1002, Sheet 5)
A. Disconnect power to hoist per paragraphs 3A and 3B of this section.
B. Remove spiral wrap (880, Figure 1002, Sheet 3), screws (890, Figure 1002, Sheet 5), washers
(900), clamp (430), cable guide cover (910), and cable guide gasket (920), and discard gasket.
C. Remove retaining ring (930), cable guide pin (940), and spring (950). Discard retaining ring
(930).
D. Remove screws (820), actuator (830), insulators (part of 830), and switches (850).
E. Unsolder and remove switches (850) from wiring.
Cable guide cover (910) Torque Seal
and gasket (920)
Screws (820)
Screws (890) and
washers (900) Switches (850)

Reference: Screws (110) Actuator with insulators (830)

Clamp (430)
Cable guide pin (940)
Reference: Roller &
Housing Assembly (120) Spring (950)

Retaining ring (930)

Figure 311. Full In Limit Switch Location

16. Cable Guide Assembly – Cable Roller Support - Guide, Spring, and Pressure Roller Assemblies
If damaged, remove guide, spring, and pressure rollers as follows (Refer to Figures 312 and 1002,
Sheets 6 & 7):
Cut and remove safety wire securing rollers and shafts in cable guide assembly (1150).
A. Remove screws (1160), spring support (1170) and spring plate (1180) from cable guide
assembly.
B. Remove shaft (1190) and spring roller (1200) from cable guide assembly.
C. Remove shaft (1210), spacers (1220) and pressure roller assembly (1230) from cable guide
assembly.
D. If necessary, press stacked ball bearings (1240) out of roller (1250).

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E. Remove cotter pin (1260) from shaft (1270). Discard cotter pin.
F. Remove shaft (1270), cable roller support (1280), spacer (1290), washer (1300), and cable
guide roller assembly (1310) from cable guide assembly (1150).
G. If necessary, press needle bearing (1320 and 1320A) out of roller (1330).
Take note of part,
safety wire, cotter pin,
shaft etc. orientation
prior to disassembly.

Pressure Roller (1230)

Spring Roller (1200)

Spring (1180)
Shaft (1270)

Screws (1160)
Spring Support (1170)

Figure 312. Cable Guide Assembly Guide, Spring, and Pressure Roller Assembly Locations.
17. Tension Roller Removal / Change Out
If damaged or worn beyond limits found in Section 501 “Checks and Inspections” (see Figure
1002, Sheets 2, 4, and 5, Item 1060):
CAUTION: WHEN REMOVING THE TENSION ROLLER, DO NOT CONTACT THE
LEVELWIND SHAFT, BECAUSE THEIR SHARP EDGES MAY CAUSE INJURY.
COVER THE LEVELWIND SHAFT WITH A CLOTH, OR EQUIVALENT, TO
PREVENT INJURY.
A. Remove electrical power from the Rescue Hoist.
B. Remove motor side cowling (Figure 1002, Sheet 2, Item 520) by unthreading attach screws
(400) and washers (410).
C. Disconnect and remove two electrical motor harness connectors. Remove motor (Figure 1002,
Sheet 4, Item 610) by unthreading four capscrews (590) with washers (600). Set motor and
attaching hardware aside.
D. Record, or mark, the spring orientation and reinstall the same way. Remove pressure on
tension roller by removing the pressure roller spring (Figure 1002, Sheet 5, Item 1180) by
unthreading and removing two screws (1160) and spring support (1170). Set spring, screws,
and spring support aside. Refer to Figures 312 and 313.

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Note: Key located

here in tension
roller inside
diameter. The
Washer / spacer Remove tension roller through flange this way
are located on
Tension Roller Spring – Remove
shaft between the
by removing 2 screws, and spring
tension roller and
support. Set aside.
gear.
Note: Record, or mark, the spring orientation and reinstall
the same way. Two Capscrews securing spring
support and spring.

Figure 313. Tension Roller and Pressure Roller Spring View.

Note Motor end flange, motor mount

MS20995NC20 surface. Remove motor by
safety wire in a 3 unthreading four capscrews and
cap positive lock washers.
pattern.
TOP Tension Roller End Cap (1340) -
Remove this end cap only, with shims,
and bearing. Tension Roller will be
Reference - removed and installed through this bore.
level wind end
caps. Do not
remove these
caps.

Figure 314. Tension Roller End Cap and Motor Mount View

E. Cut and remove the safety wire from the tension roller and levelwind bearing end caps. Refer
to Figure 314.
F. Unthread the top tension roller (1340) end cap only. Set end cap aside. Refer to Figure 314.
G. Remove the tension roller shims and bearing from the end flange. Set shims and bearing
aside.
CAUTION: THE TENSION ROLLER IS HELD ON THE SHAFT BY A KEY. ENSURE THE
KEY IS NOT DROPPED OR LOST UPON REMOVAL. ALSO, ENSURE THE
TENSION ROLLER SPACER DOES NOT FALL AWAY AS WELL. PLACE A
SUITABLE CONTAINER UNDERNEATH TO PREVENT LOSS.

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H. Using a small screwdriver, pry bar, or equivalent, partially move the tension roller off by
pushing the shaft toward the motor end flange. Set key aside.
I. Using a soapy water mix, lightly soap up the tension roller over its entire surface area. Using a
pair of pliers, or equivalent, grasp the shaft from the motor side end flange and pull the
tension roller straight out the end flange bore. (Note: The tension roller shaft assembly is
discarded).
J. Properly discard old tension roller.
18. Label and Identification Plate
If damaged or illegible, remove label and identification plate as follows (see Figure 1002, Sheet 1):
A. All typed-in information on nameplates should be recorded prior to removal. This information
will be required when the new nameplate is installed during assembly. If nameplate is
illegible or missing, contact Breeze-Eastern with all known information concerning Hoist for
original or new data.
B. Remove fillister head screws (960, Figure 1002, Sheet 1) and identification plate (970).
C. Remove label (980) by using a sharp knife, razor blade, or equivalent.
D. Remove any residual adhesive from the parts the labels and identification plate are applied to
by using similar means as removing the label.

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This Page Intentionally Left Blank

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CLEANING
1. General
Cleaning instructions for the components of the Rescue Hoist Systems are provided in this
Section. To ensure satisfactory results, each cleaning procedure should be performed as described
with the equipment and materials, or equivalent, listed in Table 401. All dust, dirt, soot,
corrosion, rust and moisture must be removed, as these destructive agents will eventually cause
operational failure.
Equipment/Material* Name
ASTM-D3699 Kerosene
ASTM D770 or TT-I-735 Isopropyl Alcohol
Anti-Static Plastic and Glass Cleaner Plasti-Glass
Brush Soft Bristle Brush
Vacuum Cleaner Vacuum Cleaner
DC-33 (Medium), if applicable Grease for Hook Assembly – Thrust Bearing
MIL-G-81322, if applicable Grease for Hook Assembly used in sealed ball bearing
* Equivalent substitutes may be used.

Table 401. Required Materials for Cleaning

WARNING: SEARCH AND RESCUE OPERATIONS, AND ALL OTHER USES OF RESCUE
HOISTS FOR HOISTING AND LOWERING PERSONNEL, CAN RESULT IN
INJURY OR DEATH. PROPERLY TRAINED PERSONNEL MUST UTILIZE
APPROPRIATE OPERATION, MAINTENANCE, AND INSPECTION
PROCEDURES TO MINIMIZE THE HAZARDS INHERENT IN THE USE OF
ALL RESCUE HOISTS.
WARNING: WORK GLOVES MUST BE WORN BY THE OPERATOR WHENEVER
HANDLING THE RESCUE HOIST CABLE TO PREVENT INJURY FROM
BROKEN STRANDS AND WIRES. EYE PROTECTION MUST BE WORN BY
THE OPERATOR WHENEVER OPERATING, OR MAINTAINING, THE RESCUE
HOIST TO PREVENT INJURY FROM LUBRICANTS, SOLVENTS, AND OTHER
MATERIALS USED ON THE RESCUE HOIST, AS WELL AS METAL PARTS
AND OTHER DEBRIS.
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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WARNING: KEEP HANDS, BODY, AND CLOTHING AWAY FROM RESCUE HOIST
ASSEMBLY, SPECIFICALLY “PINCH POINTS,” WHERE CABLE ENTERS THE
CABLE GUIDE AND CONTACTS THE DRUM.
CAUTION: DO NOT LET KEROSENE, ISOPROPYL ALCOHOL, HYDRAULIC FLUIDS,
LUBRICANTS, SOLVENTS, DETERGENTS, OR FUELS COME INTO CONTACT
WITH HOIST TENSION ROLLERS.
CAUTION: THE TENSION ROLLER SYSTEM WORKS ON THE BASIS OF FRICTION;
THEREFORE, NO LUBRICANT SHOULD BE APPLIED TO THE CABLE. IF
OIL, OR GREASE, GETS ON THE CABLE, CLEAN THE CABLE WITH A
CLOTH AND ISOPROPYL ALCOHOL. SOLVENTS MAY BE DETRIMENTAL
TO THE TENSION ROLLERS; THEREFORE, A CABLE CLEANED IN THIS
MANNER MUST BE DRY BEFORE BEING REELED IN.
A. Clean all metal parts with kerosene, isopropyl alcohol, or equivalent. Remove caked-on dirt
with a stiff-bristle, non-metallic brush and solvent.
WARNING: COMPRESSED AIR USED FOR CLEANING CREATES AIRBORNE PARTICLES
THAT MAY ENTER THE EYES. PRESSURE SHALL NOT EXCEED 15 PSIG (1.0
BAR). EYE PROTECTION IS REQUIRED.
B. Thoroughly dry parts with a lint-free cleaning cloth. Blow off extra cleaning materials from
hard-to-reach areas with moisture-free compressed air.
C. Wipe parts using a clean, lint-free cloth to prevent contamination of parts.
D. Place cleaned parts on a clean dust-free surface.
WARNING: DO NOT WATER HOSE SOAK THE ELECTRONICS; SUCH AS PILOT
CONTROLS, CREW CONTROLS, PENDANTS, WIRING HARNESSES, ETC., OR
ELECTRICAL SHORTS MAY OCCUR.
E. Wipe electronics i.e. pilot and crew control panels, pendants, switches, electrical receptacles,
and connectors with a clean cloth and isopropyl alcohol, or equivalent non-flammable,
non-corrosive volatile solution suitable for electrical cleaning applications.
F. Do not attempt to clean painted parts in a vapor degreaser, as paint will be removed.
G. For cleaning of bearings, thoroughly clean all bearings with soft-bristle brush and kerosene or
isopropyl alcohol. Dry the bearing with clean, dry compressed air at a maximum pressure of
15 psig (1.0 bar), or with a clean, lint-free cloth. Do not allow bearings to spin when drying
with compressed air.
H. Prior to installation of label or nameplate, clean surface with isopropyl alcohol to remove any
dirt, dust, soot, or grease prior to assembly. Dry surface with clean, dry compressed air at a
maximum pressure of 15 psig (1.0 bar), or with a clean lint-free cloth.
I. For all faying or mating surfaces, specifically where gaskets, O-rings, packings, and seals are
to be installed, clean surface with isopropyl alcohol to remove any dirt, dust, soot, or grease,

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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.
2. Cable (if exposed to lubricants)
If cable has been exposed to lubricants, proceed as follows:
A. Slowly reel out cable to exposed affected area.
B. Wipe affected area with a clean cloth saturated with isopropyl alcohol to remove
contaminants and clean surface of cable.
C. Pass the cable through a clean cloth when reeling in to thoroughly dry the cable and remove
any excess isopropyl alcohol.
3. 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.
A. Remove and disassemble hook and bumper assembly as specified in Disassembly, Section
301.
B. 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. If applicable, relubricate the thrust bearing
with DC-33 (Medium) grease, or equivalent, refer to Figure 401. Some hook assemblies have
sealed ball bearings, which are lubricated with MIL-G-81322 grease. Assemble hook
assembly components per Section 701, Assembly. Do not install hook and bumper assembly
onto cable at this time.

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

NOTE: ALWAYS WIND, AND UNWIND, THE CABLE IN A “RACE TRACK”
FASHION, NEVER A “FIGURE 8” OR A COIL.
C. Fill a container with fresh water and reel out cable into a large diameter kiddy pool, or
equivalent, until hoist reaches the full out position.
NOTE: DO NOT RINSE OFF HOIST WITH FRESH WATER UNDER HIGH
PRESSURE. HIGH PRESSURE WATER MAY DAMAGE SEALS IN HOIST.
USE LOW PRESSURE FRESH WATER TO RINSE OFF HOIST
(RECOMMENDED PRESSURE TO BE THAT OF WATER SUPPLY, NO
GREATER THAN 5 PSI [0.34 BAR]).
D. While cable is immersed in fresh water, rinse off hoist drum and cable guide assembly with
fresh water. Failure to thoroughly rinse saltwater contamination off drum will result in
corrosion (Figure 402).

Figure 402. Example of Corrosion on Drum (Typical)

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E. Pass cable through clean, dry cloth as cable is being reeled in onto hoist.
F. After reeling in cable, assemble and install hook and bumper assembly components per
Assembly, Section 701.
G. Perform hook load test as directed in Section 101, Testing and Troubleshooting.
4. Cowling Windows
Clean sight glass windows in forward and aft cowling assemblies with non-abrasive, plastic
window cleaner (i.e., Plasti-Glass), or equivalent. Wipe windows with clean cloth.
5. Wiring Harness Assembly
A. Remove any loose contamination by hand.
B. Using a vacuum cleaner, remove dust, dirt, soot, and grime accumulations on the harness
assembly.
C. Use a non-metallic soft bristle brush to loosen accumulations of dust, dirt, soot, and grime that
remain, and vacuum the area again.
D. Remove any remaining dust, dirt, soot, and grime by wiping with isopropyl alcohol and a
clean cloth.

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CHECKS AND INSPECTIONS
1. General
The items listed in Table 501 shall be inspected while installed on the helicopter and does not
pertain to rescue hoist systems kept in storage. The inspections shall be conducted in accordance
with the procedures contained in this section at the recommended frequency, or greater frequency.
In addition, a maintenance log must be maintained for each Rescue Hoist System in order to keep
track of hoist cycles, maintenance actions, and inspections. It is recommended that the helicopter
logbook be notated as to task completion as well.
Recommended Frequency of Inspections Part Name Figure and Inspection Required
(whichever occurs first)* (Para. Ref. in Section 501) Item Number
At the beginning (pre-flight), or at the end Swivel Hook / Hook / Bumper Figures 513 & 1002, Sheet Pre-Flight and Post-Flight
(post-flight) of the day Assemblies (Para. 2F) 1, Items 30, 39, and 40, Inspections
and Figure 1003, Items 10,
19, and 20
Cable Cutter Cotter Pin Figure 1002, Sheet 5, Item Pre-Flight and Post-Flight
(Para. 2M) 80 Inspections
Hoist Assy. (Para. 2A, 2I and Figure 1001, Items 10 and Pre-Flight and Post-Flight
2J) 11 Inspections
At the end of the day Wire Rope Cable (Para. 2E) Figure 1002, Sheet 2, Item Post-Flight Inspection
60
As applicable for all visual inspections General (Para. 2B) - Inspection for wear,
damage, or corrosion
As required Hoist Assy. (Para. 2A, 2I and Figure 1001, Items 10 and Test
2J) 11
Cable Alignment (Section 601, - Required if cable is
Paragraph 8) leading, or lagging
Perform every month, 100 flight hours, or Swivel Hook / Hook / Bumper Figures 513 & 1002, Sheet Inspect for defects and
25 hoist cycles Assemblies (Para. 2F) 1, Items 30, 39, and 40, bearing binding when
and Figure 1003, Items 10, installed
19, and 20
Wire Rope Cable (Para. 2E) Figure 1002, Sheet 2, Item Inspect for defects
60
Perform every 6 months at the pre-flight Oil Level (Para. 2K[1]) Figure 1002, Sheet 4, Item Pre-Flight Inspection
inspection using the dipstick 1020
Perform every 6 months, 400 flight hours, Roller and Housing Assembly Figures 514, 515, and Clean and inspect for
or 100 hoist cycles (Para. 2G.1) 1002, Sheet 5, Item 120, wear
and Sheet 6, Items 130
through 390
Tension Roller Figures 502 and 1002, Inspect for wear, and
(Para. 2C) Sheet 4, Item 1060 defects
Cable Guide Pressure Rollers Figures 516 and 1002, Clean and inspect for
(Para. 2G.2) Sheet 7, Items 1230, 1310 wear
Level Wind Shaft (Para. 2L) Figures 522 and 1002, Inspect for wear
Sheet 4, Item 1070
Tension Roller Clutch & Figures 503, 504, & 1002, Inspect for proper
Overrunning Clutch (Para. 2D) Sheet 4, Items 1080, 1140 operation, and wear
Wiring Harness Assemblies Figure 1002, Sheet 3, Inspect wiring and
(Para. 2N) Items 580, 684 and 860 connectors
Table 501. Inspection Requirements

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Recommended Frequency of Inspections Part Name Figure and Inspection Required
(whichever occurs first)* (Para. Ref. in Section 501) Item Number
Perform every 12 months, 1000 flight Hoist Assy. (Para. 2A, 2I and Figure 1001, Items 10
Rated Load Test (Section
hours, or 400 hoist cycles 2J) and 11
101, Para. 4D, if not
conducted in the previous
12 months, 1000 flight
hours, or 400 hoist
cycles)
Pilot and Crew Control Panels Figure 1001, Items 30, Inspect for cable cut
(Para. 2H) 31, 40, and 41 switch, and functionality
A. Packaged in hermetically sealed Cable Cutter Cartridge (Para. Figures 1001, Item 20 & Mandatory Replacement
container; 9 years from date of mfg, but 2M) 1002, Sheet 5, Item 10
not more than 5 years have elapsed after
opening the container.
B. packaged in other than the hermetically
sealed container; 5 years from date of mfg
Perform every 1500 hoist cycles** Wire Rope Cable (Para. 2E) Figure 1002, Sheet 2, Recommended
Item 60 Replacement
Perform every 5 years Oil Change (Para. 2K[2]) Figures 521 & 1002, Recommended oil change
Sheet 4, Items 1020 and
1040
Limit Switch Integrity Check Figure 523 & Figure Recommend integrity check
(Para. 2O) 1002 Sheets 3 & 5 of individual limit switches
Perform every 10 years, Hoist Assy. (Para. 2A, 2I and Figure 1001, Items 10 Overhaul
or 2000 hoist cycles 2J) and 11
Table 501. Inspection Requirements (Continued)
* 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.
Table 501 Inspections do not pertain to rescue hoists kept in storage.
** 1500 hoist cycle replacement criteria is under ideal laboratory conditions, not normal operating conditions.

2. Inspections
A. Overhaul of Rescue Hoist
The Rescue Hoist must be overhauled every 10 years, or 2000 hoist cycles, whichever occurs first
as installed on the helicopter. This overhaul is required to properly maintain the assembly, and is
recommended for all Rescue Hoists of this type design manufactured by Breeze-Eastern.
Rescue Hoist System electronic LRU’s; Pilot Control, Crew Control, Pendant Cable Assembly
are classified as “On-Condition” maintenance.
Operators are encouraged to coordinate all repairs / overhaul work with Breeze-Eastern, or their
authorized Service Centers. Breeze-Eastern is a Federal Aviation Administration (FAA) and a
Joint Aviation Authorities (JAA) FAR / JAR-145 approved Repair Station (FAA Repair Station
No. BZ7R167O, JAR-145 Acceptance Certificate Reference No. JAA.5454), and can repair /
overhaul the system at competitive prices and lead-times. Please contact Breeze-Eastern
Customer Services as follows:

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HS-29900-30, HS-29900-30-4, & HS-29900-36 RESCUE HOIST SYSTEMS
Breeze-Eastern Corporation
35 Melanie Lane
Whippany, New Jersey 07981-1638 USA
Phone Number: 973-602-1001, Ext.1083 or 1090, or 1-800-929-1919 (US and Canada only)
Fax Number: 973-739-9344
E-mail Address: customerservices@breeze-eastern.com
Web Site Address: www.breeze-eastern.com
B. General
WARNING: SEARCH AND RESCUE OPERATIONS, AND ALL OTHER USES OF RESCUE
HOISTS FOR HOISTING AND LOWERING PERSONNEL, CAN RESULT IN
INJURY OR DEATH. PROPERLY TRAINED PERSONNEL MUST UTILIZE
APPROPRIATE OPERATION, MAINTENANCE, AND INSPECTION PROCEDURES
TO MINIMIZE THE HAZARDS INHERENT IN THE USE OF ALL RESCUE HOISTS.
WARNING: KEEP HANDS, BODY, AND CLOTHING AWAY FROM RESCUE HOIST,
SPECIFICALLY “PINCH POINTS,” WHERE THE CABLE ENTERS THE CABLE
GUIDE AND CONTACTS THE DRUM.
WARNING: WORK GLOVES MUST BE WORN BY THE OPERATOR WHENEVER HANDLING
THE CABLE TO PREVENT INJURY FROM BROKEN 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 RESCUE HOIST, AS WELL
AS METAL PARTS AND OTHER DEBRIS.
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.
NOTE: PRIOR TO TURNING POWER ON, THE RESCUE HOIST COMPONENTS 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 gears, splines and shafts shall be free of nicks, burrs, sharp edges, and wear (see
Figure 501).
(3) Check the four mounting holes for the hoist interface with the helicopter for cracks,
scoring, and elongation (see Figure 801).
(4) Examine threads for stripping, distortion, nicks, and cross threading.

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No Breakage or
Nicks Permitted
on Gear Tips

Figure 501. Examples of Unacceptable Damage to Gear

(5) All bearings shall be inspected by approved industry standard bearing inspection methods
and procedures.
General Guidelines:
(a) Visually inspect ball bearings for radial wear, binding, sticking, loss of lubrication,
contamination, corrosion, scoring, cracks, bent, dented, warped, seized, brinelling,
spalling, scuffing, excessive heat, excessive play, shield placement (if applicable), or
any physical or chemical decomposition.
(b) Hold the inner race with one hand while rotating the outer race. Note the sound and
vibration of the bearings during rotation. This inspection helps detect defects large
enough to be visible but hidden from sight. Reject bearings that bind or that is
exceptionally noisy.
(c) Inspect prepackaged bearings for binding, excessive looseness (possibly indicating
loss of lubricant), or noise. Reject prepackaged bearings having any of these
indications.
(d) Inspect bearings for corrosion which will be evidenced by reddish coloring in
advanced stages of staining. Clean and polish external surfaces that exhibit corrosion.
If possible, check for corrosion on the race paths. Deep pits will serve as stress raisers
causing fatigue and flaking. Reject bearings having pits on the ball paths.
(e) Do not attempt to magnetic particle inspect ball and roller bearings.
(6) Inspect all mating and faying surfaces for possible damage.
(7) Check retaining ring and seal grooves for obstructions, or damage that might prevent
assembly.
C. Tension Roller (see Figures 502, 503, and 1002, Sheet 4)
(1) Visually inspect rubber roller (1060, Figure 1002, Sheet 4) for any abnormal wear, or
obvious defects of rubber material (i.e., cracks, tears, abrasion and degradation). Replace
rubber roller if any abnormal wear, or any of these conditions exist (see Figures 502 and
503).

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Figure 502. Tension Roller Replacement Criteria

(2) Measure using a vernier caliper the outside diameter of roller at most seriously worn
areas. Replace hoist if diameter is below 0.801 inches (20.35 mm.) at any area.
D. Tension Roller Clutch Assembly and Overrunning Clutch Assembly (see Figures 503, 504
and Figure 1002, Sheet 4, View D, Items 1080 and 1140)
(1) Inspect overrunning clutch assembly (1140, Figure 1002, Sheet 4) for broken, cracked, or
damaged gear teeth. Replace if any defects are found.

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Figure 503. Tension Roller and Overrunning Clutch Assemblies

(Cyclocentric End is on left and Motor End is on right)

Overrunning Clutch Assembly (1140)

Figure 504. Overrunning Clutch Assembly

(2) Remove the overrunning clutch assembly (1140) by removing the screws (1090), washers
(1100), gear guard (1110), bolt (1120), and spacer (1130). See Figures 503, and 504.
NOTE: THE GEAR GUARD IS NOT REMOVED FROM THE RESCUE HOIST
ASSEMBLY IT IS ONLY TO BE DISPLACED TO ALLOW REMOVAL OF THE
OVERRUNNING CLUTCH ASSEMBLY (1140).
(a) Inspect tension roller clutch assembly (1080) for free rotation in the
counterclockwise direction, and that it is driving / locked in the clockwise
direction when viewed from the small gear side (as installed on the tension roller).
Replace if clutch binds in counterclockwise direction, or slips, in the clockwise
direction.

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(b) Inspect overrunning clutch assembly (1140) for free rotation in counterclockwise
direction, and that it is driving/locks in clockwise direction when viewed from the
small gear side (as installed on the cyclocentric end flange). Replace if clutch
binds in counterclockwise direction, or slips in the clockwise direction.
(3) Check overrunning clutch assembly for wear. If lateral movement measured at face of
large gear at outside diameter measures 0.050 inch (1.27 mm.), or more, replace the
overrunning clutch assembly.
(4) Install the overrunning clutch assembly (1140), spacer (1130), bolt (1120), gear guard
(1110), washers (1100), and screws (1090).
E. Wire Rope Cable (see Figure 1002, Sheet 2, for ball end of cable (60) and for drum
attachment screw (50) for cable)
WARNING: SEARCH AND RESCUE OPERATIONS, AND ALL OTHER USES OF RESCUE
HOISTS FOR HOISTING AND LOWERING PERSONNEL, CAN RESULT IN
INJURY OR DEATH. PROPERLY TRAINED PERSONNEL MUST UTILIZE
APPROPRIATE OPERATION, MAINTENANCE, AND INSPECTION
PROCEDURES TO MINIMIZE THE HAZARDS INHERENT IN THE USE OF
ALL RESCUE HOISTS.
WARNING: KEEP HANDS, BODY, AND CLOTHING AWAY FROM THE RESCUE HOIST,
SPECIFICALLY “PINCH POINTS,” WHERE THE CABLE ENTERS THE CABLE
GUIDE AND CONTACTS THE DRUM.
WARNING: WORK GLOVES MUST BE WORN BY THE OPERATOR WHENEVER
HANDLING THE RESCUE HOIST CABLE TO PREVENT INJURY FROM
BROKEN STRANDS AND WIRES. EYE PROTECTION MUST BE WORN BY
THE OPERATOR WHENEVER OPERATING, OR MAINTAINING, THE RESCUE
HOIST TO PREVENT INJURY FROM LUBRICANTS, SOLVENTS, AND OTHER
MATERIALS USED ON THE RESCUE HOIST, AS WELL AS METAL PARTS
AND OTHER DEBRIS.
CAUTION: THE TENSION ROLLER 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.
NOTE: PRIOR TO TURNING POWER ON, THE RESCUE HOIST COMPONENTS MUST
BE VISUALLY INSPECTED FOR SOUND STRUCTURAL INTEGRITY AND
PROPER INTEGRATION.
NOTE: WHEN REELING IN THE CABLE WITH NO LOAD, APPLY TENSION WITH
GLOVED HANDS TO ENSURE SMOOTH AND EVEN WRAPPING.
APPROXIMATELY 20 LB. (9.1 KG.) TENSION IS RECOMMENDED.

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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. 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 using
rigid standards of acceptance and rejection requirements and should include careful visual
checks for the following defects:
(1) Broken wires
The number of broken wires on the outside of a wire rope is an indication of its general
condition (see Figure 505). However, 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, and will result in cable fouling or some other problem that may lead to a more
severe situation. It is for this reason that no broken wires are allowed for the hoist
cable. If broken wires are detected, the cable shall be removed and replaced immediately.

Figure 505. Example of Broken Strands in Wire Rope Cable

(2) Evidence of dragging over obstacles or worn cable guides
Cable abrasion is caused by contact with other cable sections or any material that may
contact the cable such as helicopter structural members, auxiliary equipment, or almost
any abrasive surface (see Figure 506). Abrasion removes metal from the external wires in
the outer strands and thus weakens the cable. Nicking, scarring and scrubbing are also
referred to as abrasion. Severe abrasion resulting from dragging a cable across the
helicopter structure can result in a catastrophic cable failure and possibly loss of life.
Severe abrasion as evidenced by a worn, shiny, 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 in cables, caused by a loop in a cable 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
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permanent bend that tends to open the layering of strands in the cable. A “closed” kink is
caused in the same manner, but creates a sharp permanent bend that tends to close the lay
of the cable. Continued use of a kinked cable can result in the kink being caught in the
cable guide assembly upon paying out and 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) Bird caging (permanent deformation or “opening up” of cable strands)
Bird caging is the permanent deformation or “opening up” of the strands and wires of the
wire rope itself. This condition results from torsion imbalance that occurs, because of
mistreatments such as sudden stops, the wire rope being worked through tight sheaves, or
a hook bearing that is binding (see Figure 508). Any evidence of bird caging requires
immediate replacement of the load cable.

Figure 508. Example of Bird Caging in Wire Rope Cable

(5) Improperly adjusted or defective cable guide
Cables showing damage, such as broken wires at the turnaround, or at cable crossovers,
are an indication that the hoist needs to have the level wind readjusted, or replaced (see
Figure 509). 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.

Figure 509. Example of a Raised Strand in a Wire Rope Cable

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(6) Severe overload and shock loading
Severe overloading can result if the load being hoisted is greater than 600 lb. (272 kg.), or
if the hoist hook becomes snagged on an object on the ground. Shock loading can result if
the load on the hoist hook freefalls when the cable is slack. In either case, the result is a
cable that has been severely overloaded, which may, or may not, show immediate results
of the overload. Broken strands are the most obvious defects. Broken core wires may also
result from overload. “Necking-down” of a section of cable is an indication of broken core
wires. A cable that has been knowingly overloaded should be replaced immediately even
if no obvious physical damage is detected. Any obvious reduction in diameter that is noted
is cause for immediate cable replacement.
(7) Internal wear caused by grit or dirt penetration
Internal wear caused by grit, dirt, sand, etc. embedded between the strands of the cable is
extremely difficult to detect. Preventive maintenance, in the form of carefully wiping off
the cable to remove gritty material as it is reeled in during inspection is recommended.
Prolonged use of a cable loaded with gritty material will result in broken wires.
(8) Improperly attached or defective fittings
Carefully inspect the cable in the area of the hook ball end attachment. Do not bend, or
twist, 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.
(9) 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
have 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.

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Wire Rope Cable

Check this area for damage; necking

down, broken strands, etc.

Top of Swaged (Ball) End of Cable

Top of Terminal Clamp
Top of Hook Assembly Nut
(with Bumper Assembly Removed)

Figure 510. Hook Assembly Attachment to Wire Rope Cable

(10) Knots in Cable
Knots are formed in the cable by passing one free cable section, or end, through a loop
and drawing it tight, or by a tangle drawn tight (See Figure 511). Cable knots are
generally caused by improper ground maintenance handling, or if cable inadvertently
loops / tangles while operating the rescue hoist. A knotted cable should not be run
back onto hoist for any reason and requires immediate cable replacement.

Figure 511. Example of Knot in a Wire Rope Cable (Typical)

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(11) Cable Looseness

NOTE: REPEATED OPERATION OF A WIRE ROPE CABLE EXHIBITING A
LOCALIZED LOOSE CONDITION MAY RESULT IN PERMANENT
DEFORMATION OF THE STRANDS NECESSITATING REMOVAL OF THE
CABLE FROM SERVICE.
When a wire rope cable is cycled predominantly over a small range (less than 50 feet
[15.2 meters] from the hook end) of its overall length, cable strands may loosen. The
strands will appear visibly loose, or will feel rough (see Examples A and B in Figure 512),
typically near the hook end, over a short length of cable (not the entire length of cable). If
the cable is no longer taut, it may appear damaged.

Early Indications of Advanced Indications

Cable Looseness of Cable Looseness

A B

Figure 512. Examples of Wire Rope Cable Looseness

Note: MILD LOOSENESS IN THE CABLE MAY BE ELIMINATED BY REMOVAL
AND STORAGE OF THE CABLE FOR SEVERAL DAYS.
To remove the looseness in the cable, apply a weight equal to the rated load of the hoist,
and cycle the cable five (5) times from full in to full out positions.
After cycling the cable under load, slowly reel out approximately 5 feet (1.5 meters) of
cable, and inspect for looseness. If visible looseness was successfully removed, no
further action is required. If early indications of cable looseness are still visible (as
shown in Example A of Figure 512), repeat the rated load cycling as stated above. If this
does not remove the looseness, remove the cable from service, and store for several
days. If looseness is still evident after several days of storage, discard cable.
Repeat the full-length, rated load cycling whenever inspection indicates cable looseness.

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(12) Recommended Replacement of Wire Rope Cables
NOTE: RECOMMENDED 1500 HOIST CYCLE CABLE REPLACEMENT
REQUIREMENT IS BASED ON THE FATIGUE LIFE OF WIRE ROPE DURING
HOIST OPERATIONS IN LABORATORY CONDITIONS. ACTUAL
CONDITIONS WITH THE HOIST ON THE HELICOPTER WILL VARY FROM
THESE IDEAL CONDITIONS. THEREFORE, INSPECTION OF THE CABLE IS
NOT TO BE ELIMINATED DUE TO THIS RECOMMENDED REPLACEMENT
INTERVAL.
In addition to the inspection identified above, every 1500 cycles, the cable (Figure 1002,
Sheet 2, Item 60) is recommended to be replaced on the hoist. See the procedures in
Disassembly, Section 301, for removal of the cable and in Assembly, Section 701, for
installation of the cable.
F. Swivel Hook Assembly (see Figure 1003)
(1) Inspect hook parts for cracks, corrosion, damaged threads, gouges, and damaged, or
missing, dowel pins, and ball plunger / detents.
(2) Check the keeper and lock in hook operates without binding, locks properly, and the rivet
holding the keeper is properly fastened.
(3) Check that the hook freely swivels / rotates in a smooth and non-binding manner. If
binding occurs, disassemble hook per Section 301, and inspect the bearing for corrosion,
galling, imperfections, or signs of roughness during rotation. If the bearing is found to be
unacceptable, discard. Replace with new bearing, and assemble hook per Section 701.
(4) After assembly, check that the hook swivels freely without binding.
(5) Check the terminal clamp and retaining 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).
(6) Check to see that locking screws are properly seated in the body and locked in place with
cotter pins.
Cable
Terminal Clamp
Retaining Ring

Sleeve / Nut

Figure 513. Required Terminal Clamp Orientation (Cone facing up - typical)

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HS-29900-30, HS-29900-30-4, & HS-29900-36 RESCUE HOIST SYSTEMS
G. Roller and Housing Assembly and Cable Guide Assembly Rollers (see Figures 514 and
Figure 1002, Sheets 5 and 6)
1. Roller and Housing Assembly Inspection.
(a) Remove Roller and Housing Assembly (120, Figure 1002, Sheet 5) from Rescue Hoist
per Disassembly, Section 301.
(b) Check cable guide roller assemblies (Figures 514 and 1002, Sheet 6, Item 370) if
visual inspection indicates wear, binding, corrosion, etc. Ensure bearings (160, 170)
allow free housing rotation. If any of these conditions exist, replace defective parts per
Disassembly, Section 301, and Assembly, Section 701.

inch
mm
Figure 514. Roller and Housing Assembly Cable Pressure Rollers (370) part of (350).
(c) Visually inspect the Roller and Housing Assembly to ensure that the alignment of the
metallic spacer has not infringed into the cable guide cover cross diameter /
dimension. It should not infringe as shown in Figure 515.
If the spacer is infringing into the cable guide cover cross open area, remove and
replace per procedures in Disassembly, Section 301, and Assembly, Section 701. If it
is not visibly infringing, continue with the dimensional measurement in step (d).
(d) Using a vernier caliper, measure the space in each cross (see Figure 515). The
measurement should be less than 0.296 inches (7.512 mm).
(e) If the measurements are within the specified limits, assemble roller and housing
assembly per procedures in Assembly, Section 701.
(f) Cable guide cover (Figure 1002, Sheet 6, and Item 210) is a sacrificial silicon copper
alloy and is designed to give / wear as fleet angles occur to protect the cable. If the
four points of the cable guide cover (210) wear excessively to the inner radius refer to
Figure 515, whereby the cable may get caught between the rollers and damage the
cable, replace cover.

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If cable guide cover (210) wears

beyond the four points to radius,
whereby the cable may slip past
and get caught between the < 0.296 in.
rollers and damage the cable, (7.512 mm.)
replace cover.

Edge clear of steel

spacer. Accept.

If steel spacer protrudes

beyond the edge, Reject.
Note: This inspection in accordance
with SB BL-11703-1-25-01
(Incorporated in manual)

Figure 515. Visual Inspection and Dimensional Measurement of Cable Guide Cover
2. Cable Guide Assembly Roller Inspection.
(a) Inspect Cable Guide Assembly (Figure 1002, Sheet 5, View G) on Rescue Hoist.
(b) Visually inspect cable guide roller assemblies (Figures 516 and 1002, Sheet 7, Items
1230, 1310) if inspection indicates excessive cable imprint, wear, binding, corrosion,
etc. hindering free roller rotation, replace roller. Replace defective part(s) per
Disassembly, Section 301, and Assembly, Section 701.

Wearing / Worn Normal Wear

(Note: Deep impression Replace roller if diameter of groove is
of cable in groove). less than 0.628 inches (15.95 mm.).
Replace roller.
Note: Thick / staked flange of
pressure roller assembly should
be oriented to the right side
when installed looking at the
rescue hoist.
Figure 516. Cable Guide Assembly Roller Replacement Criteria

H. Pilot and Crew Control Panels (Items 30, 31, 40, and 41 Figure 1001)

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HS-29900-30, HS-29900-30-4, & HS-29900-36 RESCUE HOIST SYSTEMS
Check the cable cut switches on each panel as follows:
WARNING: DO NOT PUSH THE CABLE CUT SWITCH ON THE PANELS UNTIL THE ARM
/ TEST SWITCH HAS BEEN MOVED TO THE TEST POSITION. FAILURE TO
MOVE THE ARM / TEST SWITCH TO THE TEST POSITION WILL FIRE THE
CARTRIDGE AND CUT THE CABLE.
(1) Move the cable cut arm / test switch to the test position on the Crew Control Panel (40,
41).
(2) On the Crew Control Panel (40, 41), open the guard over the cable cut pushbutton, depress
the cable cut pushbutton, and verify the squib test light illuminates.
(3) Release the cable cut pushbutton, ensure the guard closes, and verify the squib test light
goes out.
WARNING: DO NOT PUSH THE CABLE CUT SWITCH ON THE PANELS UNTIL THE ARM
/ TEST SWITCH HAS BEEN MOVED TO THE TEST POSITION. FAILURE TO
MOVE THE ARM / TEST SWITCH TO THE TEST POSITION WILL FIRE THE
CARTRIDGE AND CUT THE CABLE.
NOTE: TO PERFORM THE CABLE CUT TEST USING THE PILOT CONTROL PANEL
(30, 31), 2 PEOPLE ARE REQUIRED. ONE TO PUSH THE CABLE CUT SWITCH
ON THE PILOT CONTROL PANEL (30, 31), AND THE OTHER TO CHECK THE
SQUIB TEST LIGHT ON THE CREW CONTROL PANEL (40, 41).
(4) On the Pilot Control Panel (30, 31), open the guard over the cable cut pushbutton, depress
the cable cut pushbutton, and verify the squib test light illuminates on the Crew Control
Panel.
(5) Release the cable cut pushbutton, ensure the guard closes, and verify the squib test light
on the Crew Control Panel (40, 41) goes out.
(6) When testing is completed, move the cable cut arm / test switch into the arm position.
I. 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 imperfection.
(2) Check swivel hook assembly for smooth and non-binding bearing operation / rotation,
freeness of latch, corrosion, etc. Inspect hook parts for cracks, damaged threads, and
gouges. Check that the keeper / spring in the hook operates without binding, locks
properly, and the rivet (180, Figure 1003) holding the keeper is properly fastened. If
applicable, ensure locking pin and its attaching lanyard (Figure 1003, Items 160 and 170)
are undamaged and secure. Check to see that the dual locking screws (Figure 517, and
Figure 1003, Item 40) are properly seated in the body and locked in place with dual cotter
pins (Figure 517 and Figure 1003, Item 30). Ensure slide lock (Figure 1003, Item 149)

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HS-29900-30, HS-29900-30-4, & HS-29900-36 RESCUE HOIST SYSTEMS
ball plungers, dowel pins, lock, pins, etc. are in place and undamaged. Check that the lock
moves freely over plungers and stops at dowel pins. Check to see that the individual
springs in the dual lock in the keeper actuate properly. Check the cable to hook assembly
interface is proper and free of damage, refer to Figure 518.

Bumper Locking
Threads Assembly Screws &
Rivet Springs - Grommet Cotter Pins
- Spring (Qty. 2)
Keeper - Retainer

Lock

Plungers
(Qty. 2) Hook and
Handwheel Keeper
Dowel bearings
Pins (not shown)
(Qty. 2) Lock Pin and
Lanyard

Utility bag attach only – not for primary load attachment

Figure 517. Various Hooks and Assembly (Typical)

Wire Rope Cable

Check this area for damage; necking

down, broken strands, etc.

Top of Swaged (Ball) End of Cable

Top of Terminal Clamp
Top of Hook Assembly Nut
(with Bumper Assembly Removed)

Figure 518. Hook Assembly Attachment to Wire Rope Cable

(3) Check all covers, plugs, and guards for proper attachment and tie wire installation.
(4) Visually inspect hoist for any oil leakage. If oil leak is evident, check oil level immediately.
(5) Check that all visible hoist electrical connectors are properly installed and secure. Also
check for any indications of chaffing or conductor separation from the connectors.

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HS-29900-30, HS-29900-30-4, & HS-29900-36 RESCUE HOIST SYSTEMS
(6) Perform the following operational check for the Rescue Hoist System:
(a) Apply power to Rescue Hoist System by pushing in applicable circuit breakers and
turning on hoist power at Pilot Control Panel.
(b) Using the pendant, slowly pay out approximately 30 feet (9.1 meters) of cable from
the hoist under no load, and actuate the hoist using the pilot control panel to verify the
hoist can be controlled from this location, and the controls on the pilot control panel
override the pendant controls.
(c) Using the pendant, slowly pay out the cable at half speed until the full out limit switch
stops the hoist. Check the display on the control pendant; verify the reading is within
286 to 294 feet.
(d) Reel in the cable using the Control Pendant.
(e) Reel in the cable to the full in position and verify full in switch operates normally
stopping the hoist.
J. 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) Check swivel hook assembly for smooth and non-binding operation, corrosion, and
freeness of latch. Check to see that locking screws (Figure 517 and Item 40, Figure 1003)
are properly seated in the body, and locked in place with the cotter pin (Figure 517 and
Item 30, Figure 1003). Check the rivet (180, Figure 1003) holding the keeper on the hook
assembly is secure. Check the lock, dowel pins and ball plungers (149) for freeness of
movement and absence of damage. Check that the ball end of the wire rope cable has no
signs of damage (see Figure 518).
(5) Check height of bumper assembly (30, Figure 1002, Sheet 1) when hook is at full in
position (see Figure 519). Measure height from top of the bumper retainer to bottom of
spring. If height is not 1.50 to 2.00 inches (38.1 to 50.8 mm.), check the full in limit
switch operation using procedure in Testing and Troubleshooting, Section 101, and check
the condition of bumper assembly.
(6) Check the height of the crushable bumper in the bumper assembly (30), incorporating
Alert Service Bulletin [ASB] BL-12756-1-A25-01) when hook is at full in position (see
Figure 520). Measure the height from the top of the crushable bumper to the bottom of the
spring retainer. If height is not 3.15 inches (80 mm.), check full in limit switch operation
using test procedure in Paragraph 4A (4) of Testing and Troubleshooting (Section 101).

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FLIGHT LINE OPERATION AND MAINTENANCE MANUAL

HS-29900-30, HS-29900-30-4, & HS-29900-36 RESCUE HOIST SYSTEMS
Note: This hoist should include new
bumper assembly (Item 30, Figure
1002, Sheet 1) in accordance with
Alert Service Bulletin (ASB)
BL-12756-1-A25-01.

Figure 519. Deflection of Bumper Assembly with Hook at Full In Position

Figure 520. Dimensions of Crushable Bumper

(7) Check concavity in two sections of the crushable bumper in bumper assembly (30),
incorporating Alert Service Bulletin (ASB) BL-12756-1-A25-01 when hook is at full in
position (see Figure 520). Measure depth of bumper at its deepest point. If depth exceeds
0.375 in. (9.5 mm.), replace bumper assembly, and check full in limit switch operation
using test procedure in Paragraph 4A(4) of Testing and Troubleshooting (Section 101).
(8) Check that all visible hoist electrical connectors are properly installed and secure. Also
check for any indications of chaffing or conductor separation from the connectors.

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HS-29900-30, HS-29900-30-4, & HS-29900-36 RESCUE HOIST SYSTEMS
NOTE: THE HOIST IS MOUNTED ON THE HELICOPTER WITH THE FORWARD END
HIGHER THAN THE AFT END AT AN ANGLE OF 4.2 DEGREES. THE OIL
LEVEL MUST BE CHECKED WITH THE HOIST PARALLEL TO THE GROUND
IN THE INSTALLED ORIENTATION.
K. Oil Servicing and Recommended Five (5) Year Oil Change Instructions
CAUTION: THE RESCUE HOIST OIL FILL INTERNAL PASSAGEWAYS ARE SMALL IN
DIAMETER. THEREFORE, OIL MUST BE ADDED IN SMALL VOLUME AND
POURED SLOWLY (NURSED) OR OVERFLOW WILL OCCUR.
NOTE: USE DIP STICK FOR VOLUME REFERENCE, REFER TO FIGURE 521.
(1) Oil Servicing - Remove cowling (520, Figure 1002, Sheet 2) per Disassembly, Section 701
and verify the proper quantity of oil in the hoist by checking the oil level every 6 months
during preflight inspection using the dipstick (1020, Figure 1002, Sheet 4) as follows:
While the hoist is installed on the helicopter, remove forward cowling (520) from over the
motor, remove tie wire, and dipstick (1020) with seal (1030), and check the oil level.
CAUTION: DO NOT ALLOW OIL TO SPILL ONTO MOTOR WHILE FILLING HOIST.
PLACE A CLOTH AROUND AND UNDER OIL FILL PORT, AND OVER
MOTOR WHEN FILLING HOIST.
If hoist oil level is low, very slowly add oil MIL-PRF-23699 until level rises to desired
level. When the oil level is at the proper level, replace dipstick with seal, tie wire, and
install forward cowling.
If hoist oil level is high, remove tie wire, and slowly back off plug (1040) with O-ring
(1050) until oil starts to leak out. When oil level is at the proper level, tighten plug, install
tie wire, and forward cowling.
(2) Recommended 5 Year Oil Change – Install rescue hoist on TE-132-1 Post Mount
Maintenance Fixture, or equivalent.
(a) Remove Rescue Hoist from Helicopter (refer to Section 301, Disassembly) and install
hoist on TE-132-1 Clevis Mount Maintenance Fixture, BLT-27100-H, or equivalent
(Figures 903 and 904).
(b) Remove cowling (520, Figure 1002, Sheet 2) and motor (610, Figure 1002, Sheet 4)
per Disassembly, Section 701. Cut and remove safety wire from three oil plugs, Refer
to Figure 521.
(c) Rotate TE-132-1 fixture until oil plugs are facing down over a suitable oil drain pan.
NOTE: IT IS RECOMMEDNED THAT OIL BE ALLOWED TO DRAIN OUT
OVERNIGHT / SEVERAL HOURS TO DRAIN OUT AS MUCH OIL AS
POSSIBLE. IF POSSIBLE, MEASURE THE AMOUNT OF OIL THAT DRAINS
OUT AS A GAGE OF HOW MUCH TO REFILL HOIST. HOIST IS SHIPPED
FROM THE FACTORY WITH 16.5 TO 17 OZ OF OIL.
(d) Unthread and remove three oil plugs (1020, 1040, 1052 with seals 1030, 1040, 1054
Figure 1002, Sheets 1 & 4) and allow oil to drain. When oil stops draining, tilt hoist

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FLIGHT LINE OPERATION AND MAINTENANCE MANUAL

HS-29900-30, HS-29900-30-4, & HS-29900-36 RESCUE HOIST SYSTEMS
up, wait 10 minutes, then return to the drain position to remove residual oil between
the internal gear, flange, etc. Repeat tilt / drain sequence for a total of 3 times.
(e) After draining oil, position hoist upright and re-install bottom oil Dyna-seal and drain
bolt into housing. Using a funnel with a small hose, or equivalent, slowly fill hoist
with approximately 14 – 17 oz. (or measured drain out) of MIL-PRF-23699 until the
oil level is between the dip stick indents / lines, refer to Figure 521.
(f) After adding oil, install / thread three Dyna-seals and oil fill bolts / plugs. Install new
safety wire on all three drain bolts / plugs in accordance with in accordance with
NASM33540 using MS20995NC20.
(g) Wipe any residual oil from hoist and check for leaks.
(h) Install motor and electrical connectors in accordance with Section 701, Assembly.
(i) Install cowlings in accordance with Section 701, Assembly.
(j) Install Rescue Hoist on Helicopter in accordance with Section 701, Assembly.
(k) Perform functional check, after an oil change, by reeling the cable out a minimum of
50 feet (15.24 m) then reeling the cable back to the full in position. Check for leaks, if
tight the oil change is complete.
(l) If leaks are found recheck bolt tightness / integrity, and repeat functional check above.
If leaks persist remove rescue hoist and send for repair.
(m) Record oil change date in the helicopter and rescue hoist maintenance logs.
Disconnect electrical
connectors, remove
four motor with bolts
with washers and
remove motor.
Suggest to Dipstick
slowly refill oil
Remove safety wire
through side
and unthread 3 oil
flange port. It
bolts / plugs; top, side,
will take some
& bottom with seals to
time to refill.
drain oil.

After draining oil,

install bottom bolt and
refill oil until fill.
Check with dipstick.
Safety wire when
complete.

Figure 521. Oil Drain and Fill Bolt / Plug / Dipstick Positions.

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FLIGHT LINE OPERATION AND MAINTENANCE MANUAL

HS-29900-30, HS-29900-30-4, & HS-29900-36 RESCUE HOIST SYSTEMS
L. Level Wind Shaft (Figure 522)
CAUTION: USE CAUTION WHEN HANDLING THE LEVEL WIND SHAFT. THE POINTS
ARE VERY SHARP AT THE INTERSECTION OF THE HELICAL GROOVES.
Every 6 months, or 400 cycles, the level wind shaft (1070, Figure 1002, Sheet 4) must be
inspected to ensure that it is free of cracks, grease, debris, corrosion, or any other foreign
material. After cleaning the level wind shaft, visually inspect the points at the intersection of
the helical grooves. In addition there is a dimensional check for reference that can be
measured using a vernier caliper, or equivalent. If the points are bent / broken, or the grooves
of the level wind shaft are out of tolerance the Rescue Hoist must be removed from the
helicopter and sent for repair.

0.155 +0.004 / -0.001 in. (3.94 +0.10 / -0.03 mm)

Figure 522. Inspection of Level Wind Shafts

M. Cable Cutter and Cartridge
NOTE: AFTER THE CABLE HAS BEEN CUT, THE ANVIL, CARTRIDGE, CUTTER,
O-RINGS, AND COTTER PIN MUST ALL BE REPLACED.
NOTE: CARTRIDGE SERVICE LIFE IS 5 YEARS WHEN REMOVED FROM THE
PACKAGING AND INSTALLED IN THE RESCUE HOIST. MAXIMUM
CARTRIDGE LIFE IS 9 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 THE LETTERS IS THE DATE OF
MANUFACTURE, REPRESENTED AS TWO DIGITS, WHICH IDENTIFY THE
YEAR (EXAMPLE: 10 IS 2010), AND ONE LETTER, WHICH IDENTIFIES THE
MONTH, AS DEFINED BELOW:
A) JANUARY B) FEBRUARY C) MARCH D) APRIL
E) MAY F) JUNE G) JULY H) AUGUST
J) SEPTEMBER K) OCTOBER L) NOVEMBER M) DECEMBER
Visually inspect the date on the cable cutter cartridge (should be less than 9 years from
current date, and less than 5 years from the date of installation on the hoist). If date has
expired, replace cartridge.

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HS-29900-30, HS-29900-30-4, & HS-29900-36 RESCUE HOIST SYSTEMS
Visually inspect the cotter pin (80, Figure 1002, Sheet 5) in the cable guide for condition, and
proper installation. If missing, or damaged, remove and replace cotter pin per procedures in
Disassembly, Section 301, and Assembly, Section 701.
N. 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.
O. Recommended Integrity Check of Individual Limit Switches (Every 5 year period ONLY)
NOTE: THE RECOMMEDNDED FIVE YEAR LIMIT SWITCH INSPECTION INTERVALS
CAN BE COORDINATED WITH THE 10 YEAR OVERHAUL PERIOD. THE LIMIT
SWITCHES ARE CHECKED AT OVERHAUL. ALSO, THIS INSPECTION CAN BE
COORDINATED WITH OTHER CHECKS AND INSPECTIONS WHENEVER
CONVENIENT TO THE OPERATOR AS LONG AS THE INSPECTION IS
CONDUCTED EVERY FIVE YEARS. THIS INSPECTION ONLY PERTAINS TO
RESCUE HOISTS INSTALLED ON THE HELICOPTER I.E. NOT IN STORAGE.
The rescue hoist incorporates redundant limit switches, for the full-in (located in the cable
guide assembly), full-out (located on a cyclocentric cam), emergency full-out (located on a
cyclocentric cam), intermediate slow (up and down located on cyclocentric cams) and the
emergency bypass limit switch functions. An operator may not know if one of the redundant
limit switches has malfunctioned, depending on how the switch fails. Therefore; to ensure the
redundant limit switches are both operating properly, a recommended 5 year inspection has
been incorporated. The check essentially checks each individual switch as defined below:
(Ref. Section 201 for electrical wiring schematics)
NOTE: THE LIMIT SWITCH INSPECTIONS SHOULD BE CONDUCTED AT NO LOAD, ON
THE HELICOPTER. THERE IS NO SET SEQUENCE FOR CHECKING S1
THROUGH S6 LIMIT SWITCHES. THE SEQUENCE IS WHAT IS MOST
CONVENIENT TO THE TECHNICIAN.
(1) Full-In (S6) Limit Switch Inspection (Figure 523 and Figure 1002, Sheet 5)
a. Apply power and using the control pendant reel-out 10 to 15 ft (3 - 4.5m) of cable.

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b. Remove power to rescue hoist and gain access to the Full In (S6) limit switches by
removing the cable guide limit switch cover (910) by removing screws (890),
washers (900), harness clamp (430) and gasket (920) in accordance with Section
301, Disassembly.
c. Apply power and use the control pendant to slowly reel-in the cable while
depressing one limit switch plunger with a small non-conductive flat jeweler
screwdriver surface, or equivalent, ensure the rescue hoist stops operation.
d. Repeat process for the remaining limit switch plunger. If both limit switch plungers
individually stop the hoist the full-in limit switch check is complete. If an individual
limit switch does not stop hoist operation replace limit switch.
e. Using the control pendant reel-cable back to the Full-In position at full control
pendant thumbwheel deflection and verify the cable stops automatically. If so, this
check is complete. Remove power, and install gasket (920), cover (910), harness
clamp (430) and secure with washers (900) and attach screws (890) in accordance
with Section 701, Assembly.
(2) Full Out (S2), Emergency Full Out (S1), and Emergency Bypass Switch (S5) Limit
Switch Inspection (Figure 523 and Figure 1002, Sheets 1 and 3).
a. Gain accesses to cyclocentric assembly by removing aft cowling attach screws (400),
washers (410), and aft cowling (530).
b. Apply power and using the control pendant slowly reel-out cable to the Full Out
position and verify the cable stops automatically. Note that the limit switch actuator
will be off the cam and positioned in the cam indent / radius.
c. To test the individual full out limit switch apply power and depress one (S2) limit
switch plunger with a small non-conductive flat jewelers screwdriver surface, or
equivalent. Use the control pendant to slowly out, the rescue hoist cable. The rescue
hoist should not operate. This ensures the other full out limit switch, whose plunger is
not depressed, is working properly.
d. Repeat process for the remaining full out limit switch plunger. If both limit switch
plungers individually do not allow the rescue hoist to operate in the reel in, or out,
mode the full out limit switch check is complete. If an individual limit switch allows
hoist operation, replace the opposite limit switch than the one tested with the
depressed plunger.
e. Check the Emergency Bypass Switch (S5) limit switches while at the full out position
by depressing and holding one individual limit switch plunger of the Emergency
Bypass Switch (S5) and use the control pendant to slowly reel the cable in, then out.
The rescue hoist should not operate. Repeat process for the remaining (S5) switch
plunger. If both limit switch plungers individually do not allow the rescue hoist to
operate in the reel out mode the full out limit switch check is complete. If an
individual limit switch allows hoist operation replace the opposite limit switch than
the one used with the depressed plunger. This ensures switch integrity for both
Emergency Bypass Switch (S5) positions.

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FLIGHT LINE OPERATION AND MAINTENANCE MANUAL

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f. Check the Emergency Full Out Limit Switch (S1) by depressing and holding both
Emergency Bypass Switches (S5) and use the control pendant to slowly reel out the
cable until the hoist stops at the Emergency Full Out Limit Switch (S1) position. To
test the individual (S1) limit switch apply power and depress one (S1) limit switch
plunger with a small non-conductive flat jewelers screwdriver surface, or equivalent.
Depress and hold the Emergency Bypass Switches (S5) and use the control pendant to
slowly reel out the rescue hoist cable. The rescue hoist should not operate. This
ensures the other emergency full out limit switch, whose plunger is not depressed, is
working properly.
g. Depress and hold the Emergency Bypass Switches (S5) and repeat the process for the
remaining full Emergency Full Out Limit Switch (S1) limit switch plunger. If both
limit switch plungers individually do not allow the rescue hoist to operate in the reel
out mode the Emergency Full Out Limit Switch check is complete. If an individual
limit switch allows hoist operation replace the opposite limit switch than the one used
with the depressed plunger, due to the design of the circuit.
h. Using the control pendant reel-cable back to the Full-In position at full control pendant
thumbwheel deflection and verify the cable stops automatically. If so, this check is
complete.
(3) Intermediate Slow In (S4) and Intermediate Slow Out (S3) Limit Switch Inspection
(Figure 523 and Figure 1002, Sheets 1 and 3).
a. Gain accesses to cyclocentric assembly by removing aft cowling attach screws (400),
washers (410), and aft cowling (530).
b. Check the intermediate slow in (S4) limit switches by using the control pendant and
reeling the cable out approximately 20 ft. (6 m). Deflect the control pendant
thumbwheel to a higher full in speed position, when the hoist reverts to slow speed
between 10 and 12 ft. (3 - 3.7 m) from full in, stop the hoist by removing control
pendant thumbwheel input. Note that the switch actuator will be positioned in the cam
indent / cut out. Depress an individual slow in (S4) limit switch plunger, and provide a
full in high speed signal command via the control pendant thumbwheel. The rescue
hoist should still only operate at slow speed and not at variable high speed.
c. Repeat process for the remaining intermediate slow in (S4) limit switch plunger. If
both limit switch plungers individually revert and stay at the slow speed operation this
check is complete. If an individual (S4) limit switch allows variable high speed hoist
operation replace the opposite limit switch than the one used with the depressed
plunger due to the design of the circuit.
d. Check the intermediate slow out (S3) limit switches by reeling out the cable until (S3)
actuates and reverts the rescue hoist to slow speed operation between 10 and 8 ft. (3 –
2.4 m) from the full out position. Stop the hoist by removing control pendant
thumbwheel input. Note that the switch actuator will be positioned in the cam indent /
cut out. Depress an individual slow out (S3) limit switch plunger, and provide a full

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out high speed signal command via the control pendant thumbwheel. The rescue hoist
should still only operate at slow speed and not at variable high speed.
e. Repeat process for the remaining intermediate slow out (S3) limit switch plunger. If
both limit switch plungers individually revert and stay at the slow speed operation this
check is complete. If an individual (S3) limit switch allows variable high speed hoist
operation replace the opposite limit switch than the one used with the depressed
plunger due to the design of the circuit.
(4) When cyclocentric limit switch testing is complete ensure the cable is reeled in at full
control pendant thumbwheel deflection for proper homing. Replace aft cowling (530) and
secure with washers (410) and screws (400). Safety cable or tie wire screws in accordance
with AS3510-01 for safety cable and NASM33540 using MS20995C20 for safety wire.
Refer to Section 701, Assembly. Record results in helicopter and rescue hoist maintenance
logs.

S5

S1

S2 S4 S6

S3

Figure 523. Cyclocentic Limit Switch Positions.

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HS-29900-30, HS-29900-30-4, & HS-29900-36 RESCUE HOIST SYSTEMS
REPAIR
1. General
WARNING: SEARCH AND RESCUE OPERATIONS, AND ALL OTHER USES OF RESCUE
HOISTS FOR HOISTING AND LOWERING PERSONNEL, CAN RESULT IN
INJURY OR DEATH. PROPERLY TRAINED PERSONNEL MUST UTILIZE
APPROPRIATE OPERATION, MAINTENANCE, AND INSPECTION
PROCEDURES TO MINIMIZE THE HAZARDS INHERENT IN THE USE OF
ALL RESCUE HOISTS.
NOTE: COORDINATE REPAIR SECTION WITH SECTION 501, CHECKS AND
INSPECTIONS.
Material Name Supplier
-- 240 grit, or finer, aluminum oxide abrasive cloth (Scotch Brite) 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
Orange Wire Rope Paint / Orange Staining Color ITW Dykem / Dymon
Dykem (PN 81448 = 8 oz. Bottle, PN 81748 = 1 gal. Bottle, PN 81848 805 E. Old 56 Hwy.
= 5 Gal. Can.) Olathe, KS 66061
Iridite Solution #14-2, or #5025, or NCP acceptable MacDermid Inc.
245 Freight St.
Waterbury, CT 06702
MIL-R-25134 Solvent Type Paint and Lacquer Remover Commercially Available
ASTM D770, Isopropyl Alcohol Commercially Available
or TT-I-735

Table 601. Materials Required for Repair (Suitable equivalents acceptable)

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).
NOTE: DO NOT INTERCHANGE ALUMINUM OXIDE CLOTH (SCOTCH BRITE) PADS
WHEN CLEANING ALUMINUM AND STEEL PARTS.

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(1) Remove surface scratches, nicks, pitting, or corrosion by using 240 grit, or finer,
aluminum oxide cloth (Scotch Brite). Limits and dimensions specified 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.
(4) Clean thoroughly with TT-I-735 isopropyl alcohol after blending is completed.

Table 602. Allowable Material Removal

NOMENCLATURE DAMAGE REPAIR LIMITS
Figure 1001
Pilot Control Panel (30,Surface Corrosion, Clean with scotch brite, and protect surface with conductive
31) Nicks, Blemishes corrosion preventive compound, or paint, as required
Moderate to Heavy Damage greater than 0.002 in. (0.05 mm.), replace
Crew Control Panel (40, Surface Corrosion, Clean with scotch brite, and protect surface with conductive
41) Nicks, Blemishes corrosion preventive compound, or paint, as required
Moderate to Heavy Damage greater than 0.002 in. (0.05 mm.), replace
Figure 1002
Hardware (Screws, None Allowed Replace
Washers, Nut, Bolts,
Etc.)
Electrical Connectors Surface Corrosion, Clean with scotch brite, and protect surface with conductive
Nicks, Blemishes corrosion preventive compound, as required
Electrical Switches None Allowed Replace
Controller Assy. (680) Surface Corrosion, Clean with scotch brite, and protect surface with conductive
Nicks, Blemishes corrosion preventive compound, as required
Moderate to Heavy Replace Controller and Motor, or return hoist to repair station /
Corrosion depot for repair
Potentiometer Bracket None Allowed Replace
(780)
Cam Locking Plate (790) None Allowed Replace
Cyclocentric Housing None Allowed Replace
(870)
Level Wind Gear (990) Surface Clean with scotch brite, and protect surface with conductive
corrosion preventive compound, as required
Moderate to Heavy Replace
Corrosion
Motor Assy. (610) Surface Corrosion, Clean with scotch brite, and protect surface with conductive
Nicks, Blemishes corrosion preventive compound, or paint, as required
Moderate to Heavy Replace Controller and Motor, or return hoist to repair station /
Corrosion depot for repair

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Table 602. Allowable Material Removal (Continued)
NOMENCLATURE DAMAGE REPAIR LIMITS
Figure 1002 (continued)
Cuff, Cowlings, and Surface Corrosion, Nicks, Clean with scotch brite, and protect surface with
Covers (420, 440, 500, Blemishes corrosion preventive compound, or paint, as required
510, 520, and 530) 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
Cable Guide Cover (910) Surface Corrosion, Nicks, Clean with scotch brite, and protect surface with
Blemishes corrosion preventive compound, or paint, as required
Spring (950) None Allowed Replace
Retaining Ring (930) None Allowed Replace
Cable Guide Pin (940) None Allowed Replace
Cable Cutter (90) None Allowed Replace
Cutter Anvil Cap (70) None Allowed Replace
Roller Assemblies (1230), None Allowed Replace
(1310)
Cable Guide Support Surface Corrosion, Nicks, Clean with scotch brite, and protect surface with
(1280) Blemishes corrosion preventive compound, or paint, as required
Moderate to Heavy Damage greater than 0.002 in. (0.05 mm.), replace
Retainer (130) Surface Corrosion, Nicks, Clean with scotch brite, and protect surface with
Blemishes corrosion preventive compound, or paint, as required
Moderate to Heavy Damage greater than 0.002 in. (0.05 mm.), replace
Bearing (160 and 170) None Allowed Replace
Spacer (150) Surface Corrosion, Nicks, Clean with scotch brite, and protect surface with
Blemishes corrosion preventive compound, or paint, as required
Moderate to Heavy Replace
Roller Housing (290) Surface Corrosion, Nicks, Clean with scotch brite, and protect surface with
Blemishes corrosion preventive compound, or paint, as required
Moderate to Heavy Damage greater than 0.002 in. (0.05 mm.), replace
Retaining Ring (390) None Allowed Replace
Actuator Ring (180) Surface Corrosion, Nicks, Clean with scotch brite, and protect surface with
Blemishes corrosion preventive compound, or paint, as required
Moderate to Heavy Damage greater than 0.002 in. (0.05 mm.), replace
Spacer (240) None Allowed Replace
Spacer (250) None Allowed Replace

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HS-29900-30, HS-29900-30-4, & HS-29900-36 RESCUE HOIST SYSTEMS

NOMENCLATURE DAMAGE REPAIR LIMITS

Figure 1002 (continued)
Roller Cover (260) Surface Corrosion, Nicks, Clean with scotch brite, and protect surface with
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.) inch depth, replace component
Cable Guide Cover (210) Surface Corrosion, Nicks, Clean with scotch brite, and protect surface with
Blemishes corrosion preventive compound, or paint, as required
Moderate to Heavy Damage greater than 0.002 in. (0.05 mm.), replace
Figure 1003
Hook Assembly (19 and Surface Corrosion, Nicks, Clean with scotch brite, and protect surface with
20) Blemishes corrosion preventive compound, or paint, as required
Moderate to Heavy Damage greater than 0.002 in. (0.05 mm.), replace
Quick Release Pin (160) None Allowed Replace
Table 602. Allowable Material Removal (continued)

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HS-29900-30, HS-29900-30-4, & HS-29900-36 RESCUE HOIST SYSTEMS
C. Removal of corrosion on steel parts (see Table 601 for list of materials required for repair).
NOTE: DO NOT INTERCHANGE ALUMINUM OXIDE CLOTH (SCOTCH BRITE) PADS
WHEN CLEANING ALUMINUM AND STEEL PARTS.
(1) Remove surface scratches, nicks, pitting, or corrosion by using 240 grit, or finer,
aluminum oxide cloth (Scotch Brite). Limits and dimensions specified in Fits and
Clearances, Section 801.
(2) Remove moderate to heavy corrosion with fine file or non-woven abrasive wheel.
(3) Blend repaired areas. See Table 602 for allowable material removal.
(4) Clean thoroughly with TT-I-735 isopropyl alcohol after blending is completed.
D. Superficial damage to primed surfaces may be touched up locally using primer procedures
listed in the refinishing section below.
2. Refinish
A. If primed surfaces of the hoist are worn or bared due to repair sanding, touch-up / refinish
using the following materials:
Primer: MIL-PRF-23377J, Type I, Class C2, one coat recommended, or equivalent
Top Coat: MIL-C-46168, Color #34031 (helicopter green) per FED-STD-595, or
equivalent (2 coats recommended)
B. If the cable requires additional orange coating on the extreme ends, refinish using the
following material (Refer to Figure 601):
Coating: Orange Staining Color (ITW Dykem / Dymon, Olathe, Kansas USA.
Manufacturer – Dykem Company, St. Louis, Missouri, USA)
3. Minor Surface Repair (Damage of Surface Area with no exposed metal)
A. Remove contamination from damaged area using clean cloths moistened with isopropyl
alcohol, or equivalent.
B. Wipe surface area until free of oil, grease, or other contamination.
C. Lightly sand damaged area with 320 grit or finer abrasive paper.
CAUTION: AVOID OVER SANDING SURFACE AREA. REMOVE SANDING RESIDUE WITH
CLEAN CLOTH MOISTENED WITH ISOPROPYL ALCOHOL.
D. Mask, or protectively cover, all areas not being treated or primed.
E. Aluminum will not require a surface treatment if primer is applied immediately. If a delay of
more than two hours occurs, use Iridite #14-2 solution (4 ounces per gallon [32 ml. per liter]).
Apply by brush or swab at room temperature. A contact time of 15 to 30 seconds will usually
produce a golden yellow color. Rinse thoroughly and dry. (Iridite #5025 or NCP acceptable –
follow manufacturer’s instructions).

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F. Primer application should be accomplished under the following conditions:
Temperature: 50° F (10° C) minimum
Relative Humidity: 85% maximum
G. Using a cotton swab or brush, apply Primer to the affected area and allow to dry. The
minimum drying time prior to service use is 48 hours when cured under 75° F (24° C) and 24
hours when cured above 75° F (24° C).
H. Apply topcoat as specified in paragraph 5 below.
4. Major Surface Repair (Damage of Surface Area with exposed metal, see Table 601 for list of
materials required for repair)
A. To strip primer, and coating, from damaged area using approved strippers per MIL-R-25134,
or equivalent. The viscosity of this primer is high enough so that it can be applied by brush, or
swab, to the specific area to be stripped without running. It is to be used in the as received
condition at temperatures above 50° F (10° C).
B. Follow procedures A through H listed in 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).
Primer: MIL-PRF-23377J, Type I, Class C2, one coat recommended, or equivalent
Top Coat: MIL-C-46168, Color #34031 (helicopter green) per FED-STD-595, or
equivalent (2 coats recommended)
6. Application of Coating on Cable
WARNING: WORK GLOVES MUST BE WORN BY THE OPERATOR WHENEVER
HANDLING THE RESCUE HOIST CABLE TO PREVENT INJURY FROM
BROKEN STRANDS AND WIRES. EYE PROTECTION MUST BE WORN BY
THE OPERATOR WHENEVER OPERATING, OR MAINTAINING, THE RESCUE
HOIST TO PREVENT INJURY FROM LUBRICANTS, SOLVENTS, AND OTHER
MATERIALS USED ON THE RESCUE HOIST, AS WELL AS METAL PARTS
AND OTHER DEBRIS.

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HS-29900-30, HS-29900-30-4, & HS-29900-36 RESCUE HOIST SYSTEMS
CAUTION: THE TENSION ROLLER SYSTEM WORKS ON THE BASIS OF FRICTION;
THEREFORE, NO LUBRICANT SHOULD BE APPLIED TO THE CABLE. IF OIL
OR GREASE GETS ON THE CABLE, CLEAN THE CABLE WITH A CLOTH AND
ISOPROPYL ALCOHOL. SOLVENTS MAY BE DETRIMENTAL TO THE
TENSION ROLLERS; THEREFORE, A CABLE CLEANED IN THIS MANNER
MUST BE DRY BEFORE BEING REELED IN.
A. 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:
Temperature: 50° F (10° C) minimum
Relative Humidity: 85% maximum
D. Refer to Figure 601, use a quality natural-bristled paintbrush and apply two (2) coats of
orange Dykem Coating (thickness not to exceed 0.0005 inches (0.013 mm) on cable
diameter).
Coating: Orange Staining Color (ITW Dykem / Dymon, Olathe, Kansas USA. Manufacturer,
Dykem Company, St. Louis, Missouri)

Figure 601. Wire Rope Cable Coating Dimensions

E. Allow cable to air dry for 30 minutes between coats and prior to coiling or installing cable on
hoist.
7. Cable Foul Removal (see Figure 1002, Sheet 2)
WARNING: DO NOT TRY TO CLEAR CABLE FOUL IN FLIGHT. A FOULED CABLE MAY
BREAK, AND THIS MAY RESULT IN INJURY OR DEATH.
WARNING: KEEP HANDS, BODY, AND CLOTHING AWAY FROM RESCUE HOIST,
SPECIFICALLY “PINCH POINTS,” WHERE THE CABLE ENTERS THE CABLE
GUIDE AND CONTACTS THE DRUM.
A. To clear cable foul, carefully pull on the cable (Figure 1002, Sheet 2, Item 60) as it is being
slowly paid out.

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B. If cable starts to backwind, or fouled cable cannot be paid out, use heavy-duty bolt cutter /
shears to cut off sections of cable until foul is removed.
NOTE: CABLE EXTREMES ARE COATED 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 the cable that was involved in the cable foul per Disassembly, Section 301. Identify
cable as scrap (recommend painting ends of cable red and / or tagging cable with red tag
labeled “SCRAP, NOT FOR FLIGHT USE”), and install new cable per Assembly, Section
701.
D. Investigate and correct the cause of the cable foul.
E. Install a new cable per section 701, Assembly. Perform all test procedures in Testing and
Troubleshooting (Section 101) after installation of new cable.
8. Cable Alignment Adjustment (see Figure 1002, Sheets 2 and 3):
WARNING: LEVELWIND SHAFT HAS VERY SHARP EDGES AND CAN CAUSE SERIOUS
INJURY. OPERATOR MUST WEAR GLOVES WHEN HANDLING SCREW
(LEVELWIND) SHAFT.
A. Slowly reel out cable (60, Figure 1002, Sheet 2) to full out hoist position.
B. 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 and through the cable guide.
NOTE: ADVANCE LEVEL WIND SHAFT SPROCKET (990, FIGURE 1002, SHEET 3)
ONE TOOTH AT A TIME IN ORDER TO PROPERLY ADJUST CABLE GUIDE
POSITION TO CORRECTLY ALIGN CABLE.
D. If alignment has to be adjusted, follow the cyclocentric drive assembly removal procedure in
Disassembly, Section 301, to gain access to the level wind gear (990) to allow it to be
repositioned.
E. Remove the level wind gear by lifting the tab on the lock washer (1010), and removing nut
(1000). Remove the level wind gear (990), and reposition as defined below:
Cable lagging: Rotate gear clockwise to correct for lag.
Cable leading: Rotate gear counterclockwise to correct for overtravel.
F. After alignment of cable is complete, install the nut, lock it in place with the lock washer, and
follow the cyclocentric drive assembly installation procedure in Assembly, Section 701.

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G. After installing the cyclocentric drive assembly, perform steps A, B, and C above to check
cable alignment.
9. General Wiring Harness Connector Pin Replacement Procedures – for bent or otherwise damaged
connector pin contacts (Refer to Section 201, Figures 201 – 204, and to SAE AS95049 / Series
Specification, or equivalent. Requires crimp, insertion, and extraction tools, which are
commercially available):
A. Extract connector pin (contact) as instructed below:
(1) Remove hardware from connector plug, or receptacle, and slide hardware back along wire
bundle.
(2) Using a proper plastic, or metal, extraction tool with proper color code corresponding to
contact size, place wire in tool.
(3) Insert tool into contact cavity until the tool tip bottoms against the contact shoulder,
expanding clip retaining tines.
(4) Hold wire firmly in tool and extract wired contact and tool. Repeat operation for all
contacts to be extracted.
(5) Fill any empty wire cavities with wire sealing plugs.
(6) Reassemble connector plug or receptacle.
B. Crimp (new) contact as instructed below:
(1) Strip insulation from end of wire to be crimped. Do not cut or damage wire strands.
(2) Insert stripped wire into contact crimp pot. Wire must be visible through inspection hole.
(3) Using correct crimp tool and locator, cycle the tool once to be sure the indentors are open.
Insert contact and wire into locator. Squeeze tool handles firmly and completely to insure
a proper crimp. The tool will not release unless the crimp indentors in the tool head have
been fully actuated.
(4) Release crimped contact and wire from tool. Ensure the wire is visible through inspection
hole in contact.
C. Insert (new) contact as instructed below:
(1) Remove hardware from connector plug, or receptacle, and slip over wire bundle in proper
order for reassembly.
(2) Using a proper plastic, or metal, insertion tool for corresponding contact, position wire in
tip of the tool so that the tool tip butts up against the contact shoulder.
(3) Press tool against contact shoulder and, with firm and even pressure, insert wire contact
and tool tip into center contact cavity. A slight click may be heard as metal retaining ring
tines snap into place behind contact shoulder.

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(4) Remove tool and pull back lightly on wire to make sure contact is properly seated. Repeat
operation with remainder of contacts to be inserted, beginning with the center cavity and
working outward in alternating rows.
(5) After all contacts are inserted, fill any empty cavities with wire sealing plugs. Reassemble
connector plug or receptacle hardware.

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FLIGHT LINE OPERATION AND MAINTENANCE MANUAL

HS-29900-30, HS-29900-30-4, & HS-29900-36 RESCUE HOIST SYSTEMS
ASSEMBLY
1. General
Assemble the Rescue Hoist System in accordance with the following procedures. Reference
numbers in parenthesis refer to IPL in Section 1001. All mention of applying and disconnecting
power to the system components should be accomplished using helicopter circuit breakers or
equivalent acceptable means. Materials Required for Assembly, suitable equivalents acceptable,
are identified in Table 701 below:
Material Name and Application
MIL-PRF-23699 Lubricating Oil for Rescue Hoist Assembly 16.5 to 17 Ounces
MIL-G-46886 Grease for springs in roller and housing assy., and cable ball end
Loctite Activator #7075 Adhesive for spacers and roller cover
Loctite Speed Bonder #324 Adhesive
MS20995NC20 and 32 Safety / Tie Wire or
AS3510-02 (UNS 32100) Safety Cable
Vibra-tite Formula 3 (ND Thread Locking Compound
Industries)
SN60-63WRMAP2/3, or Solder
SN60-63WRP2/P3, or
IPC J-STD-004
IPC J-STD-004 Flux - Requirements for soldering fluxes
MIL-A-46146, or 3145 RTV Adhesive / Sealant for switch terminal / solder connections
Sealant (Dow Corning)
TT-L-58E, Type I, Class I Clear Gloss Lacquer for protective coating on labels
MIL-PRF-83483, or Anti-Seize Compound for screw threads at installation
Loctite 767
MIL-S-46163, Type II, Low Strength Threadlocker Compound
Grade M, or Loctite 222MS
DC-55 (Dow Corning) O-Ring Lubricant – All
Isopropyl Alcohol TT-I-735 Clean parts after assembly of Loctite Activator and Bonder
Soft Wooden Wedge Local Manufacture
Table 701. Materials Required for Assembly (suitable equivalents acceptable)
2. All procedures identified with the note VITAL POINT INSPECTION and parts with their
item numbers identified with the note VP require a technician, other than the technician who
performed the operation, to inspect the task completed, due to the criticality of the operation. This
inspection must be documented in both the helicopter, and rescue hoist maintenance logs.

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FLIGHT LINE OPERATION AND MAINTENANCE MANUAL

HS-29900-30, HS-29900-30-4, & HS-29900-36 RESCUE HOIST SYSTEMS
3. Assemble the Rescue Hoist System in accordance with the following instructions and the Figures
1001 through 1003.
WARNING: SEARCH AND RESCUE OPERATIONS, AND ALL OTHER USES OF RESCUE
HOISTS FOR HOISTING AND LOWERING PERSONNEL, CAN RESULT IN
INJURY OR DEATH. PROPERLY TRAINED PERSONNEL MUST UTILIZE
APPROPRIATE OPERATION, MAINTENANCE, AND INSPECTION
PROCEDURES TO MINIMIZE THE HAZARDS INHERENT IN THE USE OF
ALL RESCUE HOISTS.
WARNING: WORK GLOVES MUST BE WORN BY THE OPERATOR WHENEVER
HANDLING THE RESCUE HOIST CABLE TO PREVENT INJURY FROM
BROKEN STRANDS AND WIRES. EYE PROTECTION MUST BE WORN BY
THE OPERATOR WHENEVER OPERATING, OR MAINTAINING, THE RESCUE
HOIST TO PREVENT INJURY FROM LUBRICANTS, SOLVENTS, AND OTHER
MATERIALS USED ON THE RESCUE HOIST, AS WELL AS METAL PARTS
AND OTHER DEBRIS.
4. Installation of Electrical Components (refer to Figure 202 for Wiring Diagram, and Figure 1002,
Sheets 1 through 5)
WARNING: ALL ELECTRICAL WORK SHALL BE ACCOMPLISHED WITH HOIST POWER
DISCONNECTED AND TOOLS THAT DO NOT CONDUCT ELECTRICITY.
PROPER GROUNDING IS REQUIRED. TAKE PROPER ESD PRECAUTIONS TO
AVOID DAMAGING ELECTRICAL COMPONENTS DURING MAINTENANCE
DUE TO ELECTRICAL SHOCK FROM ELECTROSTATIC DISCHARGE.
NOTE: ALL WORK INVOLVING ELECTRICAL WIRING, SPECIFICALLY WORK
INVOLVING SOLDERING, MUST BE PERFORMED BY A QUALIFIED
TECHNICIAN.
A. Install cyclocentric drive assembly (720) with full out emergency full out and intermediate
limit switches (850), as follows (see Figure 1002, Sheet 3, Figures 102, 201 – 204, 310, 523):
(1) Install cyclocentric drive housing (870) using screws (690) and washers (700).
CAUTION: TO TORQUE THE CAM LOCKING PLATE, USE THE WRENCH FLATS
PROVIDED. DO NOT USE A SCREWDRIVER IN THE SLOT.
CAUTION: DO NOT OVER TORQUE THE CAM LOCKING PLATE.
(2) VITAL POINT INSPECTION. Install limit switch cams (800), and spacers (810).
Install cam locking plate (790). Using a ½ in. (13 mm.) wrench, torque cam locking plate
(VP 790) to 20 to 30 in.-lb. (2.2 to 3.4 N-m) above the free running torque.
(3) Apply a light coat of MIL-PRF-83483, or equivalent, anti seize compound to screw
threads. Install screws (820), actuators (830 and 840), insulators (part of 830 and 840),
and switches (850) onto cyclocentric drive housing (870). Torque screws to 1.2 to 1.6
in.-lb. (0.14 to 0.18 N-m).

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FLIGHT LINE OPERATION AND MAINTENANCE MANUAL

HS-29900-30, HS-29900-30-4, & HS-29900-36 RESCUE HOIST SYSTEMS
(4) Install new centering O-rings (778, View G) on each side of the potentiometer (776) shaft.
(5) Apply a light coat of MIL-PRF-83483, or equivalent, anti seize compound to screw
threads. Install potentiometer (776) onto potentiometer mounting bracket (780), and
secure using screws (772), and cleats (774). Torque screws to 1.2 to 1.6 in.-lb. (0.14 to
0.18 N-m).
(6) Apply a light coat of MIL-PRF-83483, or equivalent, anti seize compound to screw
threads. Carefully position potentiometer shaft with center of slot in the cam locking plate.
Install potentiometer mounting bracket (780) onto cyclocentric drive housing (870).
Secure with screws (760 and 770). Torque screws to 4.8 to 5.8 in.-lb. (0.54 to 0.66 N-m).
(7) Using SN60-63WRMAP2/3, or SN60-63WRP2/P3 solder, attach wire connections to
switches (850) and potentiometer (776) per wiring diagram on Figure 202.
(8) Apply Dow Corning 3145 Sealant (MIL-A-46146), or equivalent, to switch terminals, and
apply Glyptal 1201 Red Enamel, or equivalent, to potentiometer terminals after soldering.
(9) Refer to Figure 701 and install EE Seal Filter (865) by orienting the label “EESEAL™”
on the filter toward the pins in the connector on the cyclocentric drive harness assembly
(part of 720). Slightly cup the filter so that hole position “A” can be easily slipped down
over the corresponding pin “A” on electrical connector for harness assembly. Gently use
your fingertip to push the filter down over the head of pin “A.” Work the rest of the pins
on the connector through the filter in the same manner.

Figure 701. Location of Pins for Connector on Cyclocentric Drive Harness Assembly
(10) Apply a light coat of MIL-PRF-83483, or equivalent, anti seize compound to screw
threads. Install tiedown straps (730 and 740), spiral wraps (560, 570, 650, 750, and 880),
wire clamps (430), washers (700) and screws (710) to hold wiring in place from
cyclocentric drive harness assembly (720). Torque screws to 2.6 to 3.2 in.-lb. (0.29 to 0.36
N-m). Refer to Figures 102, 306, and 310 for visual references.

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FLIGHT LINE OPERATION AND MAINTENANCE MANUAL

HS-29900-30, HS-29900-30-4, & HS-29900-36 RESCUE HOIST SYSTEMS
(11) Perform test procedures in Paragraphs 4A(1) through 4A(14), and 4B of Testing and
Troubleshooting, Section 101 after installation of the wire rope cable in Paragraph 12 of
this section.
B. Install full in limit switch as follows (see Figure 1002, Sheets 3 and 5, and Figures 201, 202,
and 311):
(1) Using SN60-63WRMAP2/3, or SN60-63WRP2/P3 Solder, attach wire connections of
harness assembly (860) to switches (850) per wiring diagram on Figure 202.
(2) Apply 3145 Sealant to switch terminals after soldering.
(3) Install insulators (part of 830), actuators (830), switches (850), and secure with screws
(820), into cable guide. Torque screws to 1.4 ± 0.2 in.-lb. (0.158 ± 0.022 N-m).
(4) VITAL POINT INSPECTION Install spring (950), and cable guide pin (940). Install
retaining ring 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
(950) and install the retaining ring (VP 930). 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 retaining ring (930) and install a new retaining ring (930) per
these instructions.
(5) Install cable guide gasket (920), cable guide cover (910), cable clamp (430), washers
(900), and screws (890). Torque screws to 2.6 to 3.2 in.-lb. (0.294 to 0.362 N-m).
(6) Perform Limit Switch Test per Section 101, Paragraph 4A (15).
5. Roller and Housing Assembly
NOTE: THIS MANUAL INCORPORATES SERVICE BULLETIN BL-11703-1-25-01.
Assemble and install roller and housing assembly as follows (see Figure 1002, Sheet 6, and
Figure 303):
A. For proper installation of shims (380 through 380C), install bearings (360) in rollers (370)
with retaining rings (390) only.
B. For each roller, push bearing (360) and retaining ring (390) down into roller (370) to fully seat
both, using a vernier caliper or a depth micrometer, measure depth from side of roller to
retaining ring. Record depth for each roller.
C. Push bearing against retaining ring, using a vernier caliper or a depth micrometer, measure
same depth as in step B. Record depth for each roller.
D. To calculate required shims (380 through 380C), take the value from step B and subtract
0.002 in. (0.051 mm.) and the value from step C as follows:
B – 0.002 in. (or 0.051 mm.) – C = Thickness of shims
E. Remove retaining ring (390), install required shims (380 through 380C), and reinstall
retaining ring.

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FLIGHT LINE OPERATION AND MAINTENANCE MANUAL

HS-29900-30, HS-29900-30-4, & HS-29900-36 RESCUE HOIST SYSTEMS
F. For proper installation of shims (340 through 340C), using a vernier caliper or an inside
micrometer, measure openings in roller and housing (290). Record this value for each
opening.
G. Using a vernier caliper or an outside micrometer, measure the thickness of inner race of the
bearing (360) for each cable pressure roller assembly (350), and the thickness of the washer
(330) to be installed with each cable pressure roller assembly. Add these values together and
record this value for each roller.
H. To calculate required shims (340 through 340C), take the value from step F and subtract 0.002
in. (0.051 mm.) and the value from step G for each roller, and then take this value and divide
it by 2.
(F – 0.002 in. (or 0.051 mm.) – G)/ 2 = Thickness of shims on each side of bearing
I. This value is the thickness of shims (340 through 340C) required on each side of the bearing
(360) in each cable pressure roller assembly (350). Place these shims next to the inner race of
the bearing (360), place the washer (330) next to the shims located on the side of the bearing,
which is held in place by the retaining ring (390), and install cable pressure rollers (350),
shims (340 through 340C), and washers (330) into roller and housing (290).
J. VITAL POINT INSPECTION. Install shafts (310 and 320) into roller housing (290) to
hold cable pressure roller assemblies in place, and secure with modified cap screws (300 VP)
into roller housing (290) to hold shafts in place. Torque screws to 2.6 to 3.2 in.-lb. (0.294 to
0.362 N-m).
K. Install cable guide cover (210) on roller cover (260), and secure with screws (220). Torque
screws to 2.6 to 3.2 in.-lb. (0.29 to 0.36 N-m).
NOTE: THE CABLE GUIDE COVER (210) INSTALLATION IS USED AS A TEMPLATE /
GUIDE TO ALIGN SPACERS (240) AND (250).
L. Coat spacers (240 and 250) and inside surface of roller cover (260) with thin wet film of
Loctite activator #7075, and allow to dry for approximately 15 to 20 minutes.
M. Coat contact surface of spacer (250) with Loctite speed bonder #324. Align spacer (250) so
the holes in the spacer align with the screw holes in the roller cover (260), and the cross in the
spacer aligns with the cross in the cover (210). Install spacer (250) flat in base of roller cover
(260).
N. Coat beveled contact surface of spacer (240) with Loctite speed bonder #324. Align spacer
(240) with beveled side down toward the housing base, so the radius cutouts in the spacer
align with the screw holes inside the roller cover (260). Install spacer (240) flat in base of
roller cover (260). Ensure metal spacer (250) does not infringe into the cross of cover (210). If
this occurs, try realigning per the instructions above. If it infringes after realignment, replace
spacer (250). Refer to Figure 515.
O. Apply pressure to the assembled parts for approximately 20 minutes. Allow to cure per the
manufacturer’s instructions at 65° to 75° F (18.3° to 23.8° C).
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FLIGHT LINE OPERATION AND MAINTENANCE MANUAL

HS-29900-30, HS-29900-30-4, & HS-29900-36 RESCUE HOIST SYSTEMS
P. Remove any excess adhesive using isopropyl alcohol TT-I-735, or equivalent, and a clean
cloth.
Q. Install actuator flange (180) on roller housing (290), and secure with washers (200) and
screws (190). Torque screws to 1.2 to 1.6 in.-lb. (0.14 to 0.18 N-m).
R. Coat springs (280) with MIL-G-46886 grease, and install springs in roller housing (290).
S. Align the four holes in the cable guide housing (260) with the threaded inserts on the cable
guide actuator flange (180), as well as the roller and housing shoulder screw inserts with the
side slots in the cable guide housing (260). Secure the assembled parts in the roller cover
assembly (230) with four screws (190) and washers (200).
T. Install cover assembly (230) to the roller housing (290), and secure using two shoulder screws
(270) through the slots in the cable guide housing into the roller and housing threaded inserts.
Torque shoulder screws to 20 to 25 in.-lb. (2.26 to 2.83 N-m).
U. Install bearings (160 and 170) and spacer (150) onto roller housing (290).
V. Install retainer (130), and secure with screws (140). Torque screws to 1.2 to 1.6 in.-lb. (0.14 to
0.18 N-m).
NOTE: IT IS RECOMMENDED THAT ROLLER AND HOUSING ASSEMBLY ATTACH
SCREWS (110) NOT BE REUSED MORE THAN TWICE.
W. VITAL POINT INSPECTION. Install roller and housing assembly (120, Figure 1002, Sheet
5) into cable guide. Apply a light coat of MIL-S-46163 (Loctite 222MS), or equivalent, thread
locker compound to screw threads. Secure using screws (110 VP). Torque screws (VP) to 4.8
to 5.8 in.-lb. (0.54 to 0.66 N-m).
6. Cable Guide Assembly – Cable Roller Support - Guide, Spring, and Pressure Roller Assemblies.
If removed, install guide, spring, and pressure rollers as follows (Refer to Figures 312, 702, and
1002, Sheets 5 and 7):
A. If necessary (normally replaced as an assembly) , assemble cable guide roller assembly (1310)
by pressing needle bearing (1320 and 1320A) into roller (1330) and staking bearing at 4
places, 90 degrees apart, on both side of roller.
B. Place cable guide roller assembly (1310) and washers (1300) on each side between the flanges
of the cable roller support (1280) aligned with largest holes in the cable roller support.
C. Place cable guide roller assembly (1310), washers (1300) and cable roller support (1280)
between tabs in cable guide assembly (1150), align holes, and secure with shaft (1270).
D. Place spacer (1290) on shaft (1270), and secure shaft with new cotter pin (1260).
E. Bend one leg of new cotter pin (1260) around shaft (1270). Trim other leg of cotter pin as
required. Refer to Figure 702.

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Revision C

FLIGHT LINE OPERATION AND MAINTENANCE MANUAL

HS-29900-30, HS-29900-30-4, & HS-29900-36 RESCUE HOIST SYSTEMS

MS9245-25 Cotter pin Shaft MS20995NC32

/ shaft heads safety wire and thick flange
positioned this left of pressure roller
side. positioned right side.

Figure 702. Cable Roller Support - Guide, Spring, and Pressure Roller Assembly Positioning
F. If necessary (normally replaced as an assembly), assemble pressure roller assembly (1230) by
pressing two ball bearings (1240) into roller (1250). If reusing, position so ring staking is not
in previous stake position. Ring stake bearings to secure in roller at six equidistant places.
G. Place pressure roller assembly (1230), with spacer (1220) on each side, with thick / staked
side facing safety wire hole in shaft for cable guide roller assembly. Refer to Figures 516 and
702.
H. Install shaft (1210) through pressure roller assembly (1230), spacers (1220) and cable guide
roller support (1280).
I. Place spring roller (1200) in cable guide roller support (1280).
J. Install shaft (1190) through spring roller (1200) and cable guide roller support (1280).
CAUTION: FAILURE TO PROPERLY INSTALL ROLLER SHAFT TIE WIRE MAY RESULT
IN A CABLE FOUL.
K. Secure three shafts with safety wire at locations noted during disassembly. Refer to Figure
702.
L. Check movement of cable roller support (1280). The cable roller support shall be able to
rotate on shaft (1270) a minimum of a 60-degree arc.
M. Install spring plate (Figure 1002, Sheet 5, Item 1180) and spring support (1170), and secure
with screws (1160) to cable guide assembly (1150).
7. Tension Roller Installation
Install new tension roller (1060), refer to Figures 314, 703, and 1002, Sheet 4.
CAUTION: WHEN REMOVING THE TENSION ROLLER, DO NOT CONTACT THE
LEVELWIND SHAFT, BECAUSE THEIR SHARP EDGES MAY CAUSE INJURY.
COVER THE LEVELWIND SHAFT WITH A CLOTH, OR EQUIVALENT, TO
PREVENT INJURY.

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FLIGHT LINE OPERATION AND MAINTENANCE MANUAL

HS-29900-30, HS-29900-30-4, & HS-29900-36 RESCUE HOIST SYSTEMS

NOTE: PRIOR TO INSTALLING A NEW TENSION ROLLER ASSEMBLY, CHECK THE

MOTOR END FLANGE FOR SHARP EDGES, ETC. DEBURR IF NECESSARY
TO PREVENT DAMAGE TO THE NEW TENSION ROLLER.

A. Using a soapy water mix, lightly soap up the new tension roller over its entire surface area.
B. Install new tension roller (1060) positioned with the key slot toward the overrunning clutch
(1140). Align tension roller with the end flange bore and the tension roller shaft and push the
tension roller through the motor end flange.
C. Align and install tension roller, key, and washer / spacer together, refer to Figure 703.
D. Align and install tension roller bearing and shim pack in end flange, refer to Figure 703.
E. Use a dial indicator, or equivalent, check the tension roller end play. Ensure end play is
between .005 - .010 in. (.127 – 254 mm). If end play cannot be achieved re-measure and
re-shim as necessary.
F. Thread end cap (1340) into motor end flange until bottomed.

Figure 703. Assembled Tension Roller

G. Using MS20995NC20 safety wire the three bearing caps; the tension roller bearing end cap
with the levelwind end caps, safety wire in a three cap positive locking pattern. Refer to
Figures 314 and 703.
H. Install pressure roller spring (1180) and spring support (1170) and secure with two screws
(1160).

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FLIGHT LINE OPERATION AND MAINTENANCE MANUAL

HS-29900-30, HS-29900-30-4, & HS-29900-36 RESCUE HOIST SYSTEMS
I. Install motor (Figure 1002, Sheet 4, Item 610) and secure with four capscrews (590) and
washers (600).
J. Install two electrical harness motor connectors (580 & 684). Match P2 (580, larger conn.) - J2
and P4 (684, smaller conn.) to J4. Refer to Section 201, Figures 201 – 204.
K. Install and secure cowling motor side cowling (Figure 1002, Sheet 2, Item 520).
8. Motor Assembly
Install motor as follows (see Figure 1002, Sheet 4, and Figures 201, 304 and 305):
WARNING: DUE TO THE DIFFICULTY IN TROUBLESHOOTING THE ELECTRONICS IN
THE MOTOR AND CONTROLLER AT THE FLIGHT LINE LEVEL, IT IS
STRONGLY RECOMMENDED THAT THE HOIST BE SHIPPED TO
BREEZE-EASTERN FOR TROUBLESHOOTING AND CORRECTIVE ACTION.
HOWEVER, IF THE OPERATOR WANTS TO PERFORM MAINTENANCE ON
THE MOTOR AND / OR THE CONTROLLER, BOTH COMPONENTS MUST BE
REPLACED AS A SET. FAILURE TO REPLACE BOTH COMPONENTS AS A
SET COULD RESULT IN DAMAGE TO THE NEWLY REPLACED PART(S).
WARNING: MOTOR USES HIGH VOLTAGE POWER FROM CONTROLLER. ENSURE ALL
CIRCUIT BREAKERS ARE PULLED AND ALL POWER SOURCES ARE OFF
AND / OR DISCONNECTED PRIOR TO PERFORMING MAINTENANCE.
NOTE: ALL MATING AND FAYING SURFACES, ESPECIALLY THOSE SURFACES IN
CONTACT WITH GASKETS, SHALL BE CLEANED PRIOR TO ASSEMBLY.
NOTE: SERVICE BULLETIN EC-23050-1,-2,-3,-4, -25-01 IS INCORPORATED IF THE
MOTOR ASSEMBLY IDENTIFICATION DATA PLATE (BREEZE AND / OR
MPC) HAS A SN PREFIX OF “G,” ‘H,” ‘I,’ ETC. IF A PREFIX OF “A-F,” IS IN
FRONT OF THE MOTOR ASSEMBLY IDENTIFICATION PLATE SERIAL
NUMBER THE SB HAS NOT BEEN INCORPORATED.
A. Position splined shaft of motor assembly (610, Figure 1002, Sheet 4), motor flange mounting
holes with the end flange mounting holes and coupling. Position motor so that electrical
connectors are facing downward and toward mounting points of hoist.
B. Install and secure motor assembly to flange using four cap screws (590), and washers (600).
Alternately torque cap screws to 82 to 90 in.-lb. (9.27 to 10.18 N-m).
L. Install two electrical harness motor connectors (Figure 1002, Sheet 3, Items 580 & 684).
Match P2 (580- larger conn.) - J2 and P4 (684, smaller conn.) to J4. Refer to Section 201,
Figures 201 - 204. Perform Rated Load Test per Section 101, Paragraph 4D.
9. Controller Assembly
Install controller assembly as follows (see Figure 1002, Sheet 3, and Figures 201, 306, 307, 308,
and 309):

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Revision C

FLIGHT LINE OPERATION AND MAINTENANCE MANUAL

HS-29900-30, HS-29900-30-4, & HS-29900-36 RESCUE HOIST SYSTEMS
WARNING: DUE TO THE DIFFICULTY IN TROUBLESHOOTING THE ELECTRONICS IN
THE MOTOR AND CONTROLLER AT THE FLIGHT LINE LEVEL, IT IS
STRONGLY RECOMMENDED THAT THE HOIST BE SHIPPED TO
BREEZE-EASTERN FOR TROUBLESHOOTING AND CORRECTIVE ACTION.
HOWEVER, IF THE OPERATOR WANTS TO PERFORM MAINTENANCE ON
THE MOTOR AND / OR THE CONTROLLER, BOTH COMPONENTS MUST BE
REPLACED AS A SET. FAILURE TO REPLACE BOTH COMPONENTS AS A
SET COULD RESULT IN DAMAGE TO THE NEWLY REPLACED PART(S).
WARNING: MOTOR USES HIGH VOLTAGE POWER FROM CONTROLLER. ENSURE ALL
CIRCUIT BREAKERS ARE PULLED AND ALL POWER SOURCES ARE OFF
AND / OR DISCONNECTED PRIOR TO PERFORMING MAINTENANCE.
NOTE: SERVICE BULLETIN EC-23000-2,-3,-6,-7 -25-01 IS INCORPORATED IF THE
CONTROLLER ASSEMBLY IDENTIFICATION DATA PLATE PN IS
EC-23000-14 (PRE SB EC-23000-2,-3,-6,-7 -25-01 PN WAS EC-23000-2). IN
ADDITION, THE LETTER “M” SHOULD BE STAMPED AFTER THE SERIAL
NUMBER ON THE RESCUE HOIST IDENTIFICATION PLATE.
A. Position controller assembly’s (680) four mounting feet / holes with the end flange mounting
holes. Secure using four cap screws (660), and washers (670). Alternately torque cap screws
to 22 to 28 in.-lb. (2.49 to 3.16 N-m).
B. Install two electrical connectors (motor assembly harness [larger], and cyclocentric drive
harness [smaller]) to side of controller assembly connectors (P2) and (P3).
C. Install cyclocentric drive wiring harness in harness clamp (640), and secure with washer (630)
and cap screw (620) to top of controller assembly.
D. For positioning; ensure the connectors of the controller assembly and motor assembly
harnesses will reach the bottom of the motor assembly connectors. Position properly, then
install spiral wraps (750), tape (550), and tie wraps (730 and 740) binding together the two
harnesses leading to the motor assembly.
E. Install two harness connectors motor assembly (P2 larger [580]) and controller assembly
connector (P4 smaller [684]) onto bottom of motor assembly (610).
F. Perform Rated Load Test per Section 101, Paragraph 4D.
10. Midsection Support Covers, Cable Cutter Cable Assembly, Forward and Aft Cowling Assemblies
CAUTION: CAREFULLY INSTALL SUPPORT COVERS AND COWLINGS TO PREVENT
CUTTING, CHAFFING, OR DAMAGE TO THE WIRING HARNESS
ASSEMBLIES.
Install midsection support covers, cable cutter cable assembly, forward and aft cowling
assemblies as follows (see Figure 1002, Sheets 1 and 2, and Figure 302):

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FLIGHT LINE OPERATION AND MAINTENANCE MANUAL

HS-29900-30, HS-29900-30-4, & HS-29900-36 RESCUE HOIST SYSTEMS
A. Install forward cowling assembly (520, Figure 1002, Sheet 2) over motor assembly onto hoist,
and install clamp (450), washers (410), and screws (400) to hold forward cowling assembly
into place. Torque screws to 2.6 to 3.2 in.-lb. (0.294 to 0.362 N-m).
B. Install washers (Figure 1002, Sheet 1, Item 470), screws (460), and connector of cable cutter
harness assembly to mount support. Torque screws to 2.6 to 3.2 in.-lb. (0.294 to 0.362 N-m).
C. Install aft cowling assembly (530) over controller assembly onto hoist, and install washers
(410) and screws (400) to hold aft cowling assembly into place.
D. Install midsection support covers (500 and 510), and secure with washers (490) and screws
(405). See Figure 302.
11. Cable Cutter
NOTE: IF THE CABLE HAS BEEN CUT, THE ANVIL, CARTRIDGE, CUTTER,
O-RINGS, AND COTTER PIN SHALL ALL BE REPLACED IN ACCORDANCE
WITH REFIRE KIT PN KT-493.
Install cable cutter as follows (see Figures 704 & 1002, Sheet 5):
A. Lightly coat O-ring (100) with “O”-Ring lubricant Dow Corning DC-55, and insert into
groove in cable guide assembly.
B. Insert cable cutter (90) into cable guide with blade facing toward the opening for the cutter
anvil cap (70). Using a needle nose pliers or equivalent, install and position cable cutter (90)
into cable guide cutter bore with blade facing toward the opening for the cutter anvil (70).
Press in until seated in O-ring (100) and until it bottoms out in bore. Move cutter in and out
axially for alignment as required, and align the cutter so the cotter pin holes in cutter blade
align with the holes on the outside of the cable guide assembly, refer to Figure 704.

Figure 704. Cutaway of Correct Cable Cutter Orientation (Typical)

C. VITAL POINT INSPECTION. Align hole in cable cutter with hole in cable guide and
insert cotter pin (80 VP). Bend tabs to secure cotter pin.

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FLIGHT LINE OPERATION AND MAINTENANCE MANUAL

HS-29900-30, HS-29900-30-4, & HS-29900-36 RESCUE HOIST SYSTEMS
D. Thread anvil cap (70) into annulus of cable guide assembly until bottomed.
E. Tie wire anvil cap head to tab on cable guide assembly per NASM33540 with
MS20995NC20.
12. Wire Rope Cable
WARNING: WORK GLOVES MUST BE WORN BY THE OPERATOR WHENEVER
HANDLING THE RESCUE HOIST CABLE TO PREVENT INJURY FROM
BROKEN STRANDS AND WIRES. EYE PROTECTION MUST BE WORN BY
THE OPERATOR WHENEVER OPERATING, OR MAINTAINING, THE RESCUE
HOIST TO PREVENT INJURY FROM LUBRICANTS, SOLVENTS, AND OTHER
MATERIALS USED ON THE RESCUE HOIST, AS WELL AS METAL PARTS
AND OTHER DEBRIS.
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.
Install cable as follows (see Figure 1002, Sheet 2):
A. Feed welded end of cable (60) through cable guide (It may help to loosen, or pull back on the
pressure roller spring plate (1180) to relieve pressure and assist in feeding the cable through).
Ensure cable is captured in rollers (350) of roller housing (120) and between guide roller
(1310), pressure roller (1230) and rubber roller (1060), and spring roller (1200).
B. Insert welded end of cable in slot of drum. Check for proper installation of cable by looking
through screw hole in drum. Ensure welded end of cable is not visible in screw hole, but
strands of cable are visible.
C. VITAL POINT INSPECTION. Install screw (50 VP) and torque to 10 to 12 in.-lb.
(1.13 to 1.36 N-m).
D. VITAL POINT INSPECTION. Remove slack by putting tension on cable, and to check
security of setscrew (50 VP). Check holding force of setscrew by giving a tug on the cable.
Cable shall remain tight with no movement.
E. Apply power to hoist.
NOTE: ALWAYS REEL-IN TO CHECK CABLE ALIGNMENT, NEVER PAY OUT CABLE
TO CHECK ALIGNMENT (SEE REPAIR, SECTION 601, PARAGRAPH 8 FOR
CABLE ALIGNMENT PROCEDURE).
F. Operate hoist to reel-in cable at less than half speed until approximately 6 ft. (1.8 m.) 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, smiles, or snapping, at extremes
of layers on drum.
G. After cable installation is complete install the Bumper and Swivel Hook Assembly, then
perform a Rated Load Test per Section 101, Paragraph 4D.

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FLIGHT LINE OPERATION AND MAINTENANCE MANUAL

HS-29900-30, HS-29900-30-4, & HS-29900-36 RESCUE HOIST SYSTEMS
13. Bumper Assembly and Swivel Hook Assembly
Assemble and install bumper assembly (30, Figure 1002, Sheet 1, and 10, Figure 1003) and
swivel hook assembly (Figures 705, 1002, Sheet 1, Items 39, 40, and Figure 1003, Items 19, 20)
as follows (see Figure 1003, unless specified below):
A. For assembly of the hook assembly (150), proceed as follows:
WARNING: TO AVOID INJURY, CAUTION MUST BE USED WHEN INSTALLING RIVET,
KEEPER, AND SPRING. THE SPRING IS UNDER COMPRESSION WHEN
INSTALLED AND CAN FLY OFF HOOK WHEN INSTALLING RIVET.
WARNING: WORK GLOVES MUST BE WORN BY THE OPERATOR WHENEVER
HANDLING THE RESCUE HOIST CABLE TO PREVENT INJURY FROM
BROKEN STRANDS AND WIRES. EYE PROTECTION MUST BE WORN BY
THE OPERATOR WHENEVER OPERATING, OR MAINTAINING, THE RESCUE
HOIST TO PREVENT INJURY FROM LUBRICANTS, SOLVENTS, AND OTHER
MATERIALS USED ON THE RESCUE HOIST, AS WELL AS METAL PARTS
AND OTHER DEBRIS.
NOTE: ALERT SERVICE BULLETIN BL-15975-1-A25-01 IS INCORPORATED IF THE
BUMPER ASSEMBLY PN IS BL-15975-1 (PRE ASB BL-15975-1-A25-01 WAS PN
BL-12750-3).
(1) To install quick release pin (160) and cable assembly (170), install rivet (180) in hook
(190).
(2) VITAL POINT INSPECTION. Using a mallet and punch, or equivalent, round off,
or upset, the other end of rivet (180 VP) evenly to firmly secure keeper, spring, and cable
assembly on hook.
(3) Install quick release pin (160) into hook to lock keeper.
B. Lightly lubricate ball end of cable with MIL-G-46886 lubricant to ease installation of bumper
assembly onto cable. Do not allow any lubrication on wire rope cable itself, only the ball end.
C. Install the bumper assembly (10) onto the cable by pushing the ball end of cable (60, Figure
1002, Sheet 2) through the bumper.

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FLIGHT LINE OPERATION AND MAINTENANCE MANUAL

HS-29900-30, HS-29900-30-4, & HS-29900-36 RESCUE HOIST SYSTEMS
NOTE: TERMINAL CLAMP (70, FIGURE 1003) IS A TWO-PIECE MATCHED SET.
KEEP BOTH HALVES TOGETHER FOR FUTURE USE.
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.
D. VITAL POINT INSPECTION. Install nut (50) and terminal clamp (70 VP) onto cable
(60, Figure 1002, Sheet 2), and secure terminal clamp with ring (60, Figure 1003 VP).
E. VITAL POINT INSPECTION. Slide bumper assembly (10) down until terminal clamp
(70 VP) seats properly in nut (50). See Figure 705.

Cable
Terminal Clamp
Retaining Ring

Sleeve / Nut

Figure 705. Required Terminal Clamp Orientation (Cone facing up - typical)

F. Install flat washer (140) then housing (110) onto stem of the hook assembly (149 and 150).
G. Install ball bearing (130), and thrust washer (120) into housing (110).
H. With an applicator brush, completely cover the threads of the hook in the area where the nut
will be engaged when assembled with vibra-tite, or equivalent. Allow vibra-tite to dry.
CAUTION: ONLY TIGHTEN CASTELLATED NUT (100) 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.
I. Install castellated nut (100) onto stem of the hook assembly (149 and 150) until nut bottoms
out, then back off slightly so hole in stem of hook assembly is aligned with gaps in the nut.
J. VITAL POINT INSPECTION. Line up holes in housing (110) and hook (149 and 150),
and using a drift and a mallet, install new spring pin (90 VP).
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HS-29900-30, HS-29900-30-4, & HS-29900-36 RESCUE HOIST SYSTEMS
J. VITAL POINT INSPECTION. Rotate hook while holding housing to check for binding
of bearing (130). If binding exists, remove spring pin (90), and back off castellated nut one
additional gap. Install new pin (90), 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 / roughness continue to occur, replace bearing (130).
K. Install bumper (80), and thread housing (110) onto nut (50) until bottomed (hand tighten, DO
NOT OVER-TIGHTEN). If tapped holes in bottom flange of nut are not aligned with slots in
housing, then back off slightly to achieve alignment.
L. VITAL POINT INSPECTION. Install two locking screws (40 VP) through top flange
of nut (50) and screw home in tapped holes of bottom flange of nut, ensuring that screws
engage slots of housing (110). Secure screws with cotter pins (30 VP). Visually check that
locking screws are engaged in slots and cotter pins are bent to prevent locking screws from
turning.
M. Push down on bumper assembly (10) to mate / snap the spring onto top of nut (50). The
spring must be a firm hand press fit onto the housing; if not, replace spring.
N. Perform Hook Load Test per Section 101, Paragraph 4C.
14. Nameplate and Label
Install nameplate and label (970 and 980, Figure 1002, Sheet 1) as follows:
NOTE: ALL SURFACES SHALL BE CLEANED PRIOR TO INSTALLATION OF
NAMEPLATES OR LABELS (SEE SECTION 401 FOR CLEANING
INSTRUCTIONS).
All typed information should be added on nameplate from previously recorded data obtained
during disassembly. If information on nameplate was illegible or removed, contact
Breeze-Eastern with all known information concerning rescue hoist (part number, serial number,
date of manufacture, etc. if known) for original or new data.
A. Apply thread locking compound to fillister head screws (960).
B. Install nameplate (970, Figure 1002, Sheet 1) and secure using fillister head screws (960).
C. Safety wire fillister head screws (960) per NASM3350 using MS20995C20, or safety cable
AS3510-01 (UNS32100).
D. Remove backing of label (980) to expose adhesive, and install label.
E. Coat nameplate / label with TT-L-58E, Type I, Class I, Clear Gloss Lacquer.
15. Rescue Hoist Assembly
Install hoist onto helicopter as follows (see Figures 201 - 204, 801, Figure 1001, Items 10 or 11,
and Figure 1002, Sheet 1 and 3):

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FLIGHT LINE OPERATION AND MAINTENANCE MANUAL

HS-29900-30, HS-29900-30-4, & HS-29900-36 RESCUE HOIST SYSTEMS
CAUTION: THE HOIST WEIGHS APPROXIMATELY 109 LB. (49.5 KG) AS MOUNTED ON
THE HELICOPTER. TWO INDIVIDUALS MUST INSTALL THE HOIST ONTO
THE HELICOPTER UNLESS SUITABLE SUPPORT IS PROVIDED TO HOLD
THE WEIGHT OF THE HOIST WHEN INSTALLED.
CAUTION: MOTOR USES HIGH VOLTAGE POWER FROM CONTROLLER. ENSURE ALL
CIRCUIT BREAKERS ARE PULLED AND ALL POWER SOURCES ARE OFF
AND / OR DISCONNECTED PRIOR TO PERFORMING MAINTENANCE.
A. Place cuff fairing assembly (440, Figure 1002, Sheet 1) onto hoist mount, and install hoist (10
or 11, Figure 1001) onto helicopter using attaching hardware (not part of system, not shown in
IPL, and not supplied by Breeze-Eastern) to secure rescue hoist to post mount.
B. Install clamp (430, Figure 1002, Sheet 1), washers (410), screws (400), and cuff fairing
assembly (440) onto bottom of hoist over mount, and route limit switch harness assembly
(860, Figure 1002, Sheet 3) through clamp.
C. Connect electrical connectors to cable cutter harness assembly, and controller assembly per
Figures 201 and 202, and route cable cutter harness assembly (480) through clamp (450,
Figure 1002, Sheet 2) under forward cowling assembly (520).
D. Install connector cover assembly (420), and secure with washers (410), and screws (400).
F. Apply power to hoist by pushing in applicable circuit breakers.
G. Perform Rated Load Test per Section 101, Paragraph 4D.
16. Crew Control Panel
Install crew control panel as follows (see Figures 203, 204, 804, 804A, and 1001):
A. Connect electrical connectors to Crew Control Panel.
B. Install crew control panel (40, 41, Figure 1001) and secure with four mounting screws (not
part of system, not shown in IPL, and not supplied by Breeze-Eastern), or four dzus fasteners.
C. Apply power to controller by pushing in applicable circuit breakers.
D. Perform Pilot and Crew Control Check per Section 501, Paragraph 2H.
17. Pilot Control Panel
Install pilot control panel as follows (see Figures 203, 204, 803, 803A, and 1001):
A. Connect electrical connectors to Pilot Control Panel.
B. Install pilot control panel (30, 31, Figure 1001) using four mounting screws (not part of
system, not shown in IPL, and not supplied by Breeze-Eastern), or four dzus fasteners.
C. Apply power to controller by pushing in applicable circuit breakers.
D. Perform Pilot and Crew Control Check per Section 501, Paragraph 2H.

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FLIGHT LINE OPERATION AND MAINTENANCE MANUAL

HS-29900-30, HS-29900-30-4, & HS-29900-36 RESCUE HOIST SYSTEMS
18. Control Pendant and Pendant Cable
Install control pendant and pendant cable as follows (see Figures 203, 204, 805, 805A, and 1001):
A. Connect pendant cable (60, Figure 1001 [P24] & [P20]) connectors to control pendant (50, 51
[J24],) and to mating crew control panel connector (40, 41 [J20]).
B. Apply power to control pendant by pushing in applicable circuit breakers.
C. Perform Control Pendant Digital Readout Test per Section 101, Paragraph 4B.
19. Cartridge
Remove any grounding wires installed on cartridge pins (replacement supplied in pressure
cartridge kit (20, Figure 1001), and install cartridge (10, Figure 1002, Sheet 5) as follows:
WARNING: THE CARTRIDGE IS AN EXPLOSIVE DEVICE AND MUST BE SHIPPED,
STORED, AND HANDLED IN COMPLIANCE WITH ALL LOCAL
STANDARDS, AND REGULATORY PRACTICES. TAKE PROPER ESD
PRECAUTIONS TO AVOID SETTING OFF THE CARTRIDGE DURING
HANDLING DUE TO ELECTRICAL SHOCK FROM ELECTROSTATIC
DISCHARGE.
WARNING: THE CARTRIDGE MUST BE REMOVED BEFORE PERFORMING ANY
REMOVAL OR MAINTENANCE PROCEDURES INVOLVING THE HOIST,
AND INSTALLED LAST AFTER ALL MAINTENANCE AND INSTALLATION
PROCEDURES ARE ACCOMPLISHED.
WARNING: BREEZE-EASTERN RESCUE HOISTS UTILIZING PRESSURE CARTRIDGE KIT
PN BL-11140-3 INCORPORATE THE BREEZE-EASTERN IMPULSE
CARTRIDGE PN Y-1265-10-1. IT IS EQUIVALENT TO THE CARTRIDGE USED
IN THE MILITARY PN’S MARK 44 MOD O AND NAVAIR PN 2240772. THE
MILITARY PN’s ARE SHIPPED FROM THE MANUFACTURER WITH A
COLLAR AND DIFFERENT PACKING THAT MUST BE REMOVED AND
DISCARDED PRIOR TO INSTALLATION IN THE BREEZE-EASTERN RESCUE
HOIST. USE ONLY PARTS SUPPLIED IN PN BL-11140-3 OR MILITARY
EQUIVALENT. FAILURE TO REMOVE COLLAR AND INCORRECT PACKING
WILL DEGRADE OR PREVENT PROPER CABLE CUTTING WHEN REQUIRED
CREATING A DANGEROUS CONDITION.
A. Remove, record, and store kit supplied tags and tabs for record keeping purposes.
B. Apply O-Ring lubricant DC-55, or MIL-S-8660, to packing (20) prior to installation.
C. Remove protective shipping cap and spring shunt from cartridge. Retain shipping cap and
spring shunt for future storing and grounding use.
D. Install Breeze-Eastern packing (20) on cartridge. For first time cartridge installation utilize
KT-444 Installation Kit if a 45° or 90° cable cutter harness connector is utilized. Install
alignment / clocking shims (15, A, B). Install cartridge (10) by threading in cable guide
assembly cartridge bore until bottomed.

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FLIGHT LINE OPERATION AND MAINTENANCE MANUAL

HS-29900-30, HS-29900-30-4, & HS-29900-36 RESCUE HOIST SYSTEMS
E. Tie wire cartridge hex to tab on cable guide assembly per NASM33540 with MS20995NC32.
F. Install cable cut harness electrical connector to cartridge.
G. Apply power to hoist by pushing in applicable circuit breakers.
H. Perform Pilot and Crew Control Check per Section 501, Paragraph 2H, to test cable cutter
cartridge electrical circuit.
20. Storage
The following storage instructions are provided as general guidelines to assist the operators in
storing the rescue hoist in a safe, sustainable condition.
NOTE: WHEN THE RESCUE HOIST IS STORED THE PERIODIC INSPECTIONS LISTED
IN SECTION 501, “CHECKS AND INSPECTIONS” DO NOT HAVE TO BE
ACCOMPLISHED. SECTION 501, “CHECKS AND INSPECTIONS” APPLY WHEN
THE RESCUE HOIST IS INSTALLED ON THE HELICOPTER.
NOTE: LUBRICATING OIL, MIL-PRF-23699 (16.5 – 17 OZ.), IS IN THE RESCUE HOIST
MID-SECTION ASSEMBLY WHEN SHIPPED FROM BREEZE-EASTERN (AS
SPECIFIED BY THE CUSTOMER). IT IS RECOMMENDED TO STORE AS
SHIPPED. AT FIVE YEARS IT IS RECOMMENDED THAT THE OIL BE CHANGED.
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 protective container that meets the best commercial
practices to withstand normal handling and storage, and to withstand a low temperature of
-40° F (-40° C) and a high temperature of 160° F (71° C).
D. The Rescue Hoist Assembly shall be stored with packaging and preservation so that the
orientation of the rescue hoist is such that it is laying flat with the level wind / roller housing
visible / facing up. All packaging for the hoist shall be identified showing the proper
orientation for storage so that the hoist is laying flat.
E. If the Rescue Hoist Assembly is kept in storage as described above for more than one year,
then a rated load test must be performed per Section 101, “Testing and Troubleshooting” after
being installed on the helicopter, and before being placed in service. If the storage time
exceeds five years it is recommended an oil change be accomplished in accordance with
Section 501, “Checks and Inspections,” prior to installation on the helicopter, and before
being placed in service. If the storage time exceeds 10 years, the Rescue Hoist must be
returned to Breeze-Eastern, or one of its certified repair facilities for overhaul.

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FLIGHT LINE OPERATION AND MAINTENANCE MANUAL

HS-29900-30, HS-29900-30-4, & HS-29900-36 RESCUE HOIST SYSTEMS
FITS AND CLEARANCES
1. Table 801 and Figures 801 through 805A 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.
2. The values provided in the “Dimension Limits” column in Table 801 are the applicable minimum,
or maximum, permitted to ensure proper functioning of select parts and the rescue hoist line
replaceable units (LRU’s). If the parts / LRU’s fail to meet these requirements they should 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-29900-30, -30-4, and -36 Rescue Hoist
Systems. See the following figures contained in this section and IPL Figures in Section 1001 for
items referenced in Table 801:
A. Figure 801 Rescue Hoists – BL-29900-30-1 and BL-29900-30-4
B. Figure 802 Hoist Mid-Section Support (Post) Mount (Reference Only)
C. Figure 803 Pilot Control Panel, PN EC-23075-2
Figure 803A Pilot Control Panel, PN EC-23075-3 (For -36)
D. Figure 804 Crew Control Panel, EC-23100-2
Figure 804A Crew Control Panel, EC-23100-150 (For -36)
E. Figure 805 Control Pendant, PN CP-1100-2
Figure 805A Control Pendant, PN CP-1700-2 (For -36)

The dimensions in these figures are shown in inches (with millimeters in parentheses).

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FLIGHT LINE OPERATION AND MAINTENANCE MANUAL

HS-29900-30, HS-29900-30-4, & HS-29900-36 RESCUE HOIST SYSTEMS
Table 801. Allowable Limit Values

Fig. No. IPL Fig. No., Description of Location for Dimensional Dimension Limits in Inches
(in Sec. 801) Sheet No., Check (Millimeters)
and Item No. Minimum Maximum
Figure 801 Figure 1001, Axis of Four Holes for Mounting Bolts 28º 32º
Items 10 or 11 (from centerline for hoist drum)
Figure 802 Figure 1001, Diameter of Four Holes for Mounting Bolts 0.255 (6.48) 0.262 (6.65)
Items 10 or 11
Figure 802 Figure 1001, Inner Diameter of Mounting Support 2.980 (75.69) 2.984 (75.79)
Items 10 or 11
Figure 802 Figure 1001, Depth of Mounting Support (less than - 3.63 (92.20)
Items 10 or 11 maximum is acceptable)
Figure 802 - Mid-Section Support Post 0.255 (6.48) 0.262 (6.65)
Diameter of Four Holes for Mounting Bolts
Figure 802 - Mid-Section Support Post Inside Diameter 2.980 (75.69) 3.020 (76.71)
Figure 802 - Mid-Section Support Post Outside Diameter 3.550 (90.17) -
- Figure 1002, Diameter of Rubber Roller (greater than 0.801 (20.35) -
Sheet 4, minimum is acceptable)
Item 1060
- Figure 1002, Height of Bumper Assembly at Full In 2.750 (69.85) 3.750 (95.25)
Sheet 1, Position
Item 30
Figure 803 Figure 1001, Location of Pilot Control Panel Mounting 5.24 (133.10) 5.26 (133.60)
Item 30, 31 Holes Horizontally
Figure 803A 5.356 (136.04) 5.376 (136.55)
Figure 803 Figure 1001, Location of Pilot Control Panel Mounting 2.234 (56.74) 2.254 (57.25)
Item 30, 31 Holes Vertically
Figure 803A 1.865 (47.37) 1.885 (47.88)
Figure 803 Figure 1001, Diameter of Mounting Holes 0.199 (5.05) 0.204 (5.18)
Item 30, 31
Figure 803A 0.257 (6.53) 0.259 (6.58)
Figure 804 Figure 1001, Location of Crew Control Panel Mounting 5.356 (136.04) 5.376 (136.55)
Item 40, 41 Holes Horizontally
Figure 804A 5.356 (136.04) 5.376 (136.55)
Figure 804 Figure 1001, Location of Crew Control Panel Mounting 2.615 (66.42) 2.635 (66.93)
Item 40, 41 Holes Vertically
Figure 804A 2.615 (66.42) 2.635 (66.93)
Figure 804 Figure 1001, Diameter of Mounting Holes 0.257 (6.53) 0.259 (6.58)
Item 40, 41
Figure 804A 0.257 (6.53) 0.259 (6.58)
Figure 805 Figure 1001, Pendant Overall Length with connector - 7.500 (190.50)
Item 50, 51
Figure 805A 7.500 (190.50)

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FLIGHT LINE OPERATION AND MAINTENANCE MANUAL

HS-29900-30, HS-29900-30-4, & HS-29900-36 RESCUE HOIST SYSTEMS
Fig. No. IPL Fig. No., Description of Location for Dimensional Dimension Limits in Inches
(in Sec. 801) Sheet No., Check (Millimeters)
and Item No. Minimum Maximum
Figure 805 Figure 1001, Pendant Overall Width - 3.375 (85.73)
Item 50, 51
Figure 805A 3.3 (83.82)
Figure 805 Figure 1001, Pendant Overall Depth - 5.000 (127.00)
Item 50, 51
Figure 805A 5.000 (127.00)
Table 801. Allowable Limit Values (Continued)

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FLIGHT LINE OPERATION AND MAINTENANCE MANUAL

HS-29900-30, HS-29900-30-4, & HS-29900-36 RESCUE HOIST SYSTEMS

Figure 801. Rescue Hoist Illustration BL-29900-30-1 & -30-4

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FLIGHT LINE OPERATION AND MAINTENANCE MANUAL

HS-29900-30, HS-29900-30-4, & HS-29900-36 RESCUE HOIST SYSTEMS

OR

DIMENSIONS OF MID-SECTION SUPPORT (POST) PROVIDED FOR REFERENCE ONLY

Figure 802. Hoist Mid-Section Support (Post) Mount Illustration
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FLIGHT LINE OPERATION AND MAINTENANCE MANUAL

HS-29900-30, HS-29900-30-4, & HS-29900-36 RESCUE HOIST SYSTEMS

Figure 803. Pilot Control Panel, PN EC-23075-2

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FLIGHT LINE OPERATION AND MAINTENANCE MANUAL

HS-29900-30, HS-29900-30-4, & HS-29900-36 RESCUE HOIST SYSTEMS

Figure 803A. Pilot Control Panel, PN EC-23075-3

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FLIGHT LINE OPERATION AND MAINTENANCE MANUAL

HS-29900-30, HS-29900-30-4, & HS-29900-36 RESCUE HOIST SYSTEMS

Figure 804. Crew Control Panel, PN EC-23100-2

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FLIGHT LINE OPERATION AND MAINTENANCE MANUAL

HS-29900-30, HS-29900-30-4, & HS-29900-36 RESCUE HOIST SYSTEMS

Figure 804A. Crew Control Panel, PN EC-23100-150

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FLIGHT LINE OPERATION AND MAINTENANCE MANUAL

HS-29900-30, HS-29900-30-4, & HS-29900-36 RESCUE HOIST SYSTEMS

Figure 805. Control Pendant, PN CP-1100-2

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FLIGHT LINE OPERATION AND MAINTENANCE MANUAL

HS-29900-30, HS-29900-30-4, & HS-29900-36 RESCUE HOIST SYSTEMS

Figure 805A. Control Pendant, PN CP-1700-2

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 TD-01-006
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 TD-01-006
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FLIGHT LINE OPERATION AND MAINTENANCE MANUAL

HS-29900-30, HS-29900-30-4, & HS-29900-36 RESCUE HOIST SYSTEMS
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
Table Top Maintenance
Table top post mount (360 °
BLT-27100-H Fixture (see Figure - X X
rotation) maintenance fixture
903)
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)
Cart (for carrying Rescue Hoist 250 lb. (113 kg)
TE-120-3 weights, see Figure and 600 lb. (272 kg) Rated X - -
902) Load Tests
Mobile rescue hoist post
Post Mount
mount (360 ° rotation)
TE-132-1 Maintenance Fixture - X X
maintenance fixture. Eases oil
(See Figure 904)
change.

Table 901. Special Tools, Fixtures, and Test Equipment List

Figure 901. Retaining Ring Installation Tool

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Figure 902. TE-120-3 Cart (capable of carrying TE-120-1 Calibrated Weight)

Figure 903. BLT-27100-H, Table Top Maintenance Fixture (Allows 360° Rotation)

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HS-29900-30, HS-29900-30-4, & HS-29900-36 RESCUE HOIST SYSTEMS

Figure 904. TE-132-1 Mobile Post Mount Maintenance Fixture

(Allows 360° Rotation – Eases Oil Change Task)
Note: For information on the acquisition of special tools and test equipment contact:

Breeze-Eastern Corporation
35 Melanie Lane
Whippany, New Jersey 07981-1638 USA
Phone Number: 973-602-1001, Ext.1083 or 1090, or 1-800-929-1919 (US and Canada only)
Fax Number: 973-739-9344
E-mail Address:customerservices@breeze-eastern.com
Web Site Address:www.breeze-eastern.com
Revision status of the Breeze-Eastern technical manuals can be checked on the Web Site listed above.

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 TD-01-006
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HS-29900-30, HS-29900-30-4, & HS-29900-36 RESCUE HOIST SYSTEMS
ILLUSTRATED PARTS LIST
1. Introduction
A. Purpose
This section provides illustrations and parts breakdown of all parts of the assemblies shown
that can be disassembled, repaired or replaced, and reassembled.
B. Explanation and Usage of Section
(1) Assembly Order Indenture System
This indenture system used in the parts list shows the relationship of one part to another.
For a given item, the number of indentures depicts the relationship of the item to the
associated next higher assembly as follows:
1 2 3 4
Assembly
• Detail Parts for Assembly
• • Subassembly
• • • Detail Parts for Subassembly
(2) Part Numbering System
The part numbering system consists of each part number identifier by which a part may be
ordered or procured.
(3) Effectivity Code
Reference letters (A through Z except I and O) are assigned to the EFF. CODE column to
each top assembly in each IPL figure. The reference letter is also shown in EFF. CODE
column for each part used on the corresponding top assembly, or left blank, if used on all
top assemblies.
(4) Parts Replacement Data
The interchangeability between parts is identified in the NOMENCLATURE column of the
parts list. A list of terms used to show interchangeability and their definition is as follows:
Term Abbreviation Definition
Optional OPT This part is optional to and interchangeable with other parts in the same
number variant group or other item number as designated.
Alternate ALT Alternate designates a definitive sequence of parts. The part is optional to and
interchangeable with other parts in the same number variant group or other
item number as designated.
Preferred PREF When an alternate part is listed, the preferred part will be identified in the
same item number variant group or other item number as designated.
(5) Items Not Illustrated
Items not illustrated are indicated by a dash (-) ahead of the item number in the FIG. &
ITEM NO. Column.

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HS-29900-30, HS-29900-30-4, & HS-29900-36 RESCUE HOIST SYSTEMS
(6) Units per Assembly
The UNITS PER ASSY. column shows the total quantity of the specific part required per
assembly, per subassembly, and per sub-subassembly, as applicable. For bulk items, the
letters AR indicate, “As Required.” The letters RF indicate the item is listed for reference
purposes.
(7) Alpha Variant Item Numbers
(a) Alpha variants (A through Z except I and O) are assigned to existing item numbers
when necessary to show:
1) Added items.
2) Service bulletin modifications.
3) Configuration differences.
4) Optional or alternate parts.
5) Product improvement parts (non-service bulletin).
(b) Alpha variant item numbers are not shown on the exploded views when the appearance
and location of these items are the same as the basic items.
C. Vendors
26066 3M Industrial Tape Division
3M Center, Building 230, St. Paul, MN 55144-1428
Phone No.: (612) 733-1110
2. Notes:
A. The Terminal Clamp (Item 70, Figure 1003) consists of a two-piece, matched set clamp
machined as an assembly and a ring. Each half of the clamp cannot be purchased separately
and must be purchased together. The ring (60) must be replaced if the clamp is in need of
replacement, and can be purchased separately.
WARNING: THE CARTRIDGE IS AN EXPLOSIVE DEVICE AND MUST BE SHIPPED,
STORED AND HANDLED IN COMPLIANCE WITH ALL LOCAL STANDARDS
AND REGULATORY PRACTICES.
B. The Pressure Cartridge Kit (Item 20, Figure 1001) consists of the pressure cartridge (Item 10,
Figure 1002, Sheet 5) contained in hermetically sealed container, and packing (Item 20, Figure
1002, Sheet 5). The cartridge (equivalent to MARK 44 MOD O, NAVAIR No. 2240772) is not
part of the Rescue Hoist System, and must be purchased separately 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, but can be ordered separately if damaged or worn. KT-444 will be required for first
time cartridge installation for 45° and 90° angle cable cutter harness connector positioning.
C. Refire Kit PN KT-493 includes the Anvil, (Item 70, Figure 1002, Sheet 5), cutter (90), O-Ring
(100), and cotter pin (80), which must be replaced whenever the cable cutter has been actuated.
Also, shims are included for 45° and 90° angle cable cutter harness connector positioning
when applicable.
D. Pressure Roller (1230) and Guide Roller (1310) Assemblies are generally purchased as a
complete assembly for ease of replacement. Pressure roller (1230) has a staked ball bearing
and guide roller assembly (1310) has dual needle roller bearings.

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40 →
30 →
41
31
10 →
11 50 →
51

60 → 20 →

Figure 1001. Rescue Hoist System

NUMERICAL PARTS LIST INDEX
FIG. AND PART NOMENCLATURE USABLE UNITS
ITEM NO. NUMBER 1234 ON PER
CODE ASSY.
1001-
-1 HS-29900-30 HOIST SYSTEM, RESCUE A RF
-2 HS-29900-30-4 HOIST SYSTEM, RESCUE B RF
-3 HS-29900-36 HOIST SYSTEM, RESCUE C RF
10 BL-29900-30-1 • Hoist Assembly, Rescue (see IPL Figure 1002 for AC 1
Detailed Breakdown). Replaces BL-29900-30
with implementation of Kit KT-351, using
conversion procedure TD-02-021.
11 BL-29900-30-4 • Hoist Assembly, Rescue (see IPL Figure 1002 for B 1
Detailed Breakdown)
20 BL-11140-3 • Kit, Pressure Cartridge (kit contains cartridge * 1
equivalent to MARK 44 MOD O, NAVAIR No.
2240772, see Paragraph 2B)
30 EC-23075-2 • Panel Assembly, Pilot Control AB 1
31 EC-23075-3 • Panel Assembly, Pilot Control C 1
40 EC-23100-2 • Panel Assembly, Crew Control AB 1

- Not Illustrated

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FLIGHT LINE OPERATION AND MAINTENANCE MANUAL

HS-29900-30, HS-29900-30-4, & HS-29900-36 RESCUE HOIST SYSTEMS

NUMERICAL PARTS LIST INDEX (Continued)

FIG. AND PART NOMENCLATURE USABLE UNITS

ITEM NO. NUMBER 1234 ON PER
CODE ASSY.
1001-
41 EC-23100-150 • Panel Assembly, Crew Control C 1
50 CP-1100-2 • Pendant Assembly, Control AB 1
51 CP-1700-2 • Pendant Assembly, Control C 1
60 EC-14170-2 • Cable Assembly, Pendant 1
* BL-11140-3 - Pressure Cartridge Kit is not part of Rescue Hoist System, and must be purchased separately.
Included in the kit is the container, cartridge, O-Ring, tags, tab, and tie wire.
KT-444 - Installation Kit is used for first time cartridge installation and includes shims for 45° and 90°
angle cable cutter harness connector positioning (if applicable), and includes the O-Ring PN
MS28778-5.
KT-493 - Refire Kit is used if cable cutter / cartridge is activated / fired. It includes Pressure Cartridge Kit
BL-11140-3, anvil, cutter, shims for 45° and 90° angle cable cutter harness connector
positioning (if applicable), O-Ring, cotter pin, tie wire, etc. See Note 2.C.

- Not Illustrated

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FLIGHT LINE OPERATION AND MAINTENANCE MANUAL

HS-29900-30, HS-29900-30-4, & HS-29900-36 RESCUE HOIST SYSTEMS
NUMERICAL PARTS LIST INDEX
FIG. AND PART NOMENCLATURE USABLE UNITS
ITEM NO. NUMBER 1234 ON CODE PER ASSY.
1002-
-1 BL-29900-30-1 RESCUE HOIST ASSEMBLY A RF
Replaces BL-29900-30 with installation of Kit KT-
351 using conversion procedure TD-02-021.
-2 BL-29900-30-4 RESCUE HOIST ASSEMBLY B RF
10 BL-11140-3 • Kit, Pressure Cartridge (kit contains cartridge * 1
equivalent to MARK 44 MOD O, NAVAIR No.
2240772, see Note 2.B)
15 BL-2095-R480 • • Shim .005 in. (.127 mm) thickness, see Note 2C 1
15A BL-2095-R481 • • Shim .010 in. (.254 mm) thickness, see Note 2C 2
15B BL-2095-R482 • • Shim .031 in. (.787 mm) thickness, see Note 2C 1
20 MS28778-5 • • Packing 1
30 BL-15975-5 • Bumper Assembly (see IPL Figure 1003 for Detailed 1
Breakdown). BL-12750-3 replaced with ASB BL-
12756-1-A25-01 termination.
39 HK-121-2 • Hook Assembly, Swivel (see IPL Figure 1003 for A 1
Detailed Breakdown)
40 HK-102-3 • Hook Assembly, Swivel (see IPL Figure 1003 for B 1
Detailed Breakdown)
50 BL-9182 • Screw 1
60 BL-10653-3 • Cable, Wire Rope 1
70 BL-11224-1 • Cap, Cutter Anvil (see Paragraph 2C) 1
80 MS9245-10 • Pin, Cotter 1
90 BL-6331 • Cutter, Cable 1
100 AN6227-10 • O-Ring 1
110 MS51038-114 • Screw 3
120 BL-11274-8 • Roller and Housing Assembly 1
130 BL-11295-1 • • Retainer 1
140 MS51957-4 • • Screw 3
150 BL-11223-1 • • Spacer 1
160 AJ-9800-10-7 • • Bearing, Ball 1
170 AJ-9800-10-3 • • Bearing, Ball 1
180 BL-11236-50 • • Flange, Actuator 1
190 MS16995-9 • • Screw 4
200 AN960C4 • • Washer 4
210 BL-11703-1 • • Cover, Cable Guide 1
220 MS51959-13 • • Screw 4
* Pressure Cartridge Kit not part of Rescue Hoist System, must be purchased separately.

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NUMERICAL PARTS LIST INDEX (continued)
FIG. AND PART NUMBER NOMENCLATURE USABLE UNITS
ITEM NO. 1234 ON CODE PER ASSY.
1002-
230 BL-11739-50 • • Cover Assembly, Roller 1
240 BL-11740-1 • • • Spacer 1
250 BL-16045-1 • • • Spacer (Replaces BL-11743-1) 1
260 BL-11238-1 • • • Cover, Roller 1
270 BL-11278-1 • • Screw, Shoulder 2
280 BL-11716-1 • • Spring 4
290 BL-11252-1 • • Housing, Roller 1
300 BL-15367-1 • • Screw, Cap, Modified 2
310 BL-11221-1 • • Shaft, Cable Pressure (long) 2
320 BL-11220-1 • • Shaft, Cable Pressure (short) 2
330 AL-1256-C167 • • Washer 4
340 BL-2095-R400 • • Shim .002 in. (.051 mm) thickness AR
340A BL-2095-R401 • • Shim .003 in. (.076 mm) thickness AR
340B BL-2095-R402 • • Shim .005 in. (.127 mm) thickness AR
340C BL-2095-R403 • • Shim .010 in. (.254 mm) thickness AR
350 BL-11274-10 • • Roller Assembly, Cable Pressure 4
360 MS27641-3G • • • Bearing, Ball 4
370 BL-11425-1 • • • Roller, Cable Pressure 4
380 BL-2095-R441 • • • Shim .002 in. (.051 mm) thickness AR
380A BL-2095-R442 • • • Shim .003 in. (.076 mm) thickness AR
380B BL-2095-R443 • • • Shim .005 in. (.127 mm) thickness AR
380C BL-2095-R444 • • • Shim .010 in. (.254 mm) thickness AR
390 Y-1176-1-62 • • • Ring, Retaining 4
400 MS35275-215 • Screw, Fillister Head 17
405 MS35275-216 • Screw 6
410 AN960C4L • Washer, Flat 14
420 BL-14766-1 • Cover Assembly, Connector 1
430 MS21219 WDG4 • Clamp, Cushioned 3
440 BL-14656-1 • Cuff Fairing Assembly 1
450 MS21919 WCH4 • Clamp, Cushioned 1
460 MS51957-14 • Screw, Pan Head 2
470 AL-1256-C2 • Washer, Flat 2
480 BL-11579-2 • Cable Assembly, Cable Cutter 1
490 AL-1256-C59 • Washer, Flat 5
500 BL-14647-1 • Cover, Support, Midsection (Upper) 1
510 BL-14651-1 • Cover, Support, Midsection (Lower) 1

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FLIGHT LINE OPERATION AND MAINTENANCE MANUAL

HS-29900-30, HS-29900-30-4, & HS-29900-36 RESCUE HOIST SYSTEMS

NUMERICAL PARTS LIST INDEX (continued)

FIG. AND PART NUMBER NOMENCLATURE USABLE UNITS
ITEM NO. 1234 ON CODE PER ASSY.
1002-
520 BL-14659-1 • Cowling Assembly, Forward 1
530 BL-14658-1 • Cowling Assembly, Aft 1
540 MS3367-1-9 • Strap, Tie Down 3
550 8671 • Tape, Glossy, 3 in. long (76.2 mm.), 2
Vendor Code 26066 (see paragraph 1C)
560 Y-1199-2-5 • Spiral Wrap 1
570 Y-1199-2-4 • Spiral Wrap 1
580 BL-14524-1 • Harness Assembly (P2) 1
590 MS16996-32 • Screw, Cap 4
600 AN960C516L • Washer, Flat 4
610 EC-23050-2 • Motor Assembly 1
(SB EC-23050-1, -2, -3, -4-25-01
terminated motor assemblies will have a
“G,” “H,” “I,” etc. in front of the motor
identification plate & MPC serial number.
Example: G0134, H0138, I0140 etc.)
620 MS16995-19 • Screw, Cap 1
630 AN960C6 • Washer, Flat 1
640 MS25281-R7 • Clamp, Wire, Support 1
650 Y-1199-2-5 • Spiral Wrap 1
660 MS16996-11 • Screw, Cap 4
670 AN960C10L • Washer, Flat 4
680 EC-23000-14 • Controller Assembly 1
(EC-23000-2 replaced with SB EC-23000
-2, -3, -6, -7-25-01 termination. The letter
“M” suffix to the Rescue Hoist SN
designates termination.)
684 BL-14333-2 • • Harness Assembly (P4) 1
690 MS16995-10 • Screw, Cap 2
700 AN960C4L • Washer, Flat 3
710 MS51957-14 • Screw, Pan Head 1
720 BL-14342-2 • Drive Assembly, Cyclocentric 1
730 MS3367-4-9 • • Strap, Tie Down 5

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FLIGHT LINE OPERATION AND MAINTENANCE MANUAL

HS-29900-30, HS-29900-30-4, & HS-29900-36 RESCUE HOIST SYSTEMS

NUMERICAL PARTS LIST INDEX (continued)

FIG. AND PART NUMBER NOMENCLATURE USABLE UNITS
ITEM NO. 1234 ON CODE PER ASSY.
1002-
740 MS3367-4-9 • • Strap, Tie Down 4
750 Y-1199-2-1 • • Spiral Wrap 1
760 MS35206-228 • • Screw 1
770 MS24693-C26 • • Screw 1
772 MS51957-13 • • Screw 3
774 Y-1249-1-1 • • Cleat, Mounting 3
776 BL-12668-6 • • Potentiometer Assembly 1
778 M83248/1-003 • • • O-Ring 2
780 BL-14340-1 • • Bracket, Mounting, Potentiometer 1
790 BL-13011-1 • • Locking Plate, Cam 1
800 BL-13005-1 • • Cam, Limit Switch 4
810 BL-11319-1 • • Spacer 3
820 MS51957-8 • • Screw 12
830 BL-6074 • • Actuator, Switch (with insulators) 5
840 Y-1184-5-1 • • Actuator, Leaf (with insulators) 1
850 MS24547-1 • • Switch 12
860 BL-14525-1 • • Harness Assembly, Limit Switch 1
865 Y-1215-14-2 • • Filter (EE Seal) 1
870 BL-11296-4 • • Housing, Cyclocentric 1
880 Y-1199-2-4 • Spiral Wrap 1
890 MS51957-15 • Screw 3
900 AN960C4 • Washer 3
910 BL-11258-1 • Cover, Cable Guide 1
920 BL-11257-1 • Gasket, Cable Guide Cover 1
930 MS16633-4018 • Ring, Retaining 1
940 BL-11276-2 • Pin, Cable Guide 1
950 Y-1182-6-28 • Spring 1
960 MS35275-212 • Screw, Fillister Head 4
970 BL-13051-1 • Plate, Identification 1
980 BL-12925-1 • Label, Caution 1
990 BL-12126-1 • Gear, Level Wind 1
1000 MS172323 • Nut 1

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FLIGHT LINE OPERATION AND MAINTENANCE MANUAL

HS-29900-30, HS-29900-30-4, & HS-29900-36 RESCUE HOIST SYSTEMS

NUMERICAL PARTS LIST INDEX (continued)

FIG. AND PART NUMBER NOMENCLATURE USABLE UNITS
ITEM NO. 1234 ON CODE PER ASSY.
1002-
1010 MS172273 • Washer, Lock 1
1020 BL-14396-1 • Plug, Dipstick 1
1030 Y-1125-1-7 • Seal 1
1040 BL-11561-1 • Plug 1
1050 NAS617-5 • O-Ring 1
1052 BL-11563-1 • Plug 1
1054 Y-1126-12-907 • O-Ring 1
1060 BL-10455 • Roller, Tension 1
1070 BL-12919-1 • Shaft, Screw (Levelwind) 1
1080 BL-10451 • Clutch Assembly, Tension Roller 1
1090 MS51957-46 • Screw, Pan Head 2
1100 AL-1256-C3 • Washer, Flat 2
1110 BL-14590-1 • Guard, Gear 1
1120 NAS1224-C416L • Bolt 1
1130 BL-8033 • Spacer 1
1140 BL-12905-1 • Clutch Assembly, Overrunning 1
1150 BL-11273-6 • Cable Guide Assembly 1
1160 MS16995-27 • Screw 2
1170 BL-13026-1 • Support, Spring 1
1180 BL-13023-1 • Plate, Spring 1
1190 BL-11260-1 • Shaft 1
1200 BL-13037-1 • Roller, Spring 1
1210 BL-6753 • Shaft 1
1220 BL-6752 • Spacer 2
1230 BL-6759-3 • Roller Assembly, Pressure (See Note 2.D) 1
1240 AJ-9800-31-3 • • Bearing, Ball 2
1250 BL-11698-1 • • Roller 1
1260 MS9245-25 • Pin, Cotter 1
1270 BL-11416-1 • Shaft 1
1280 BL-11584-2 • Support, Cable Guide Roller 1
1290 AL-1256-C166 • Washer 1
1300 AL-1256-C10 • Washer 2

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FLIGHT LINE OPERATION AND MAINTENANCE MANUAL

HS-29900-30, HS-29900-30-4, & HS-29900-36 RESCUE HOIST SYSTEMS
FIG. AND PART NUMBER NOMENCLATURE USABLE UNITS
ITEM NO. 1234 ON CODE PER ASSY.
1002-
1310 BL-11266-2 • Roller Assembly, Cable Guide 1
(See Note 2.D)
1320 Y-1028-9-2 • • Bearing, Needle 1
Torrington Co. / Bearings Div.
Torrington, CT 06790
(JTT-47)
1320A Y-1028-9-2 • • Bearing, Needle 1
INA Bearing Company
Cheraw, SC 29520
(SCE47PP)
1330 BL-11581-1 • • Roller 1
1340 BL-11217-1 • Cap, Bearing, Tension Roller 1

25-61-00
Page 1017
April 30, 2010
Breeze-Eastern Confidential – use or disclosure of data contained on this sheet is subject to the restrictions on the title pages of this manual.
 TD-01-006
Revision C

FLIGHT LINE OPERATION AND MAINTENANCE MANUAL

HS-29900-30, HS-29900-30-4, & HS-29900-36 RESCUE HOIST SYSTEMS

25-61-00
Page 1018
April 30, 2010
Breeze-Eastern Confidential – use or disclosure of data contained on this sheet is subject to the restrictions on the title pages of this manual.
 TD-01-006
Revision C

FLIGHT LINE OPERATION AND MAINTENANCE MANUAL

HS-29900-30, HS-29900-30-4, & HS-29900-36 RESCUE HOIST SYSTEMS

NUMERICAL PARTS LIST INDEX

FIG. AND PART NUMBER NOMENCLATURE USABLE UNITS

ITEM NO. 1234 ON CODE PER ASSY.
1003-
10 BL-15975-3 BUMPER ASSEMBLY RF
(ASB BL-12756-1-A25-01 replaces BL-12750-3)
19 HK-121-2 HOOK ASSEMBLY, SWIVEL A
20 HK-102-3 HOOK ASSEMBLY, SWIVEL B RF
30 MS24665-88 • Pin, Cotter 2
40 BL-9920 • Screw, Locking 2
50 BL-11685-1 • Nut, Bushing 1
60 BL-11682-1 • Clamp, Terminal (See Note 2.A) 1
70 BL-4718 • • Ring (See Note 2.A) 1
80 BL-4719 • Bumper 1
90 BL-14792-2 • Pin, Spring 1
100 BL-8089 • Nut, Castellated 1
110 BL-11686-1 • Housing, Hook 1
120 BL-11684-1 • Washer, Thrust 1
130 AJ-9800-95-8 • Bearing, Ball 1
140 AN960C816 • Washer, Flat 1
149 BL-15704-2 • Hook Assembly (Terminates one time FPI & A 1
serialization] SB HK-121-1, -2, -3, -4 -15-01)
150 HK-201-1 • Hook Assembly B 1
160 Y-1223-1-1 • Pin, Quick Release B 1
170 Y-1096-11-2 • • Cable Assembly B 1
180 MS20613-4C16 • • Rivet B 1
190 HK-201-10 • • Hook B 1

25-61-00
Page 1019
April 30, 2010
Breeze-Eastern Confidential – use or disclosure of data contained on this sheet is subject to the restrictions on the title pages of this manual.
 TECHNICAL PUBLICATION DEFICIENCY REPORT
Page 1 of 1
BE-Tracking #
Customer: Date:
Type: O&M Type: CMM Manual
Manual: Revision Date:
Number: Number: Revision:
Section: Page: Para:
Figure: Table: Part Number:
Discrepancy (Provide as much detail as possible):

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

Breeze Eastern Use Only

Engineering Services Disposition:

Engineering Services: Date:

Customer Services: Date:

QC1334 Rev.A 04/28/10

 TECHNICAL PUBLICATION DEFICIENCY REPORT
Page 1 of 1
BE-Tracking #TD01006TPDR092310008
Customer: Sikorsky Aircraft Date: 9/21/10
Type: O&M X Type: CMM Apr.
Manual Revision
Manual: TD-01- C 30,
Number: Number: Revision: Date:
006 2010
Section: Page: Para:
Figure: 1002 Table: Part Number: BL-29900-30-1
Discrepancy (Provide as much detail as possible):
Breeze Eastern Operation and Maintence manual (Figure 1002) calls out to use a AN960C4L washer to attach BL-11538 CUFF FAIRING at
all locations. Some holes are Slotted and this size is to small. I am told correct size is AL-1256-C113.
Please update manual accordingly.

Initiator: Stephen Shea Title: Airframe Engineering Lead

Submit to: B-E Customer Services.
via email Customerservices@breeze-eastern.com or FAX (973) 739 - 9344
Breeze Eastern Use Only
Engineering Services Disposition:

Revise page 1013, Table 1002 – Add Item 407; Part Number: AL-1256-C113; Nomenclature: Washer, Flat; Units Per
Assy: 3.
FIG. AND PART NUMBER NOMENCLATURE USABLE ON UNITS
ITEM NO. CODE PER ASSY.
407 AL-1256-C113 Washer, Flat 3

Revise page 1005, Figure 1002, Sheet 1 of 7, from 410 to 407:

Revise page 302, Paragraph E, from washers (410) to washers (407).

Revise page 716, Paragraph B, from washers (410) to washers (407).

Engineering A. Razon Date: 9/23/10

Services:
Customer Services: C. Duncan, R. Gaffin Date: 9/23/10

QC1334 Rev.A
 TECHNICAL PUBLICATION DEFICIENCY REPORT
Page 1 of 3
BE-Tracking #: TD01006TPDR051712001
Customer: Global Aerospace Logistics Date: 14MAY2012
Type: O&M Type: CMM Manual
Manual: C Revision Date:
Number: TD-01-006 Number: Revision:
Section: Page: 1005 Para:
Figure: 1002 Table: Part Number:
Discrepancy (Provide as much detail as possible):
This is figure 1002, page 1 of 7. Item Number 440: BL-14656-1 Cuff Assembly

There are four clips shown on the bottom of the cuff, but there are no part numbers given for these.

Initiator: Thomas R. Cooper Title: Supervisor Hoist Department

Submit to: B-E Customer Services.
via email Customerservices@breeze-eastern.com or FAX (908) 688 6495

Breeze Eastern Use Only

Engineering Services Disposition:
Part number Y-1148-4-1 Floating Nut Clip (quantity 4) will be added to the IPL for Figure 1002 as item 445, a second-
level item, reporting to item 440 BL-14656-1 Cuff Fairing Assembly (see below).

Figure 1002, Sh 1, (See attached), two find number callouts labeled 445 will be added to the Cuff Fairing Assembly
view, pointing to the existing Floating Nut Clips currently shown on the near-side of the Cuff Fairing Assembly (item
440). Two additional Floating Nut Clips (labeled 445) will be added to the far-side of the Cuff Fairing Assembly. Find
number callouts (labeled 445) will be added for the two added Floating Nut Clips on the far-side of the view.

Engineering Services: Rich Preston Date: 5/17/12

Customer Services: Zoltan Varsanyi, Mike Koons, Chuck Duncan, Date: 5/17/12
Bob Gaffin,

QC1334 Rev.-
 TECHNICAL PUBLICATION DEFICIENCY REPORT
Page 2 of 3
BE-Tracking #: TD01006TPDR051712001

The IPL for Figure 1002 will be changed as follows: Red shows the addition.

FIG. AND PART NUMBER NOMENCLATURE USABLE UNITS

ITEM NO. 1234 ON PER
CODE ASSY.
1002-
440 BL-14656-1 ● Cuff Fairing Assembly 1
445 Y-1148-4-1 ●●Nut Clip, Floating 4

Change to Figure 1002, Sheet 1 is marked on the graphic below

QC1334 Rev.-
 TECHNICAL PUBLICATION DEFICIENCY REPORT
Page 3 of 3
BE-Tracking #

QC1334 Rev.-
 CAGE CODE 08484

35 Melanie Lane SIL01 Maintenance

Whippany, NJ 07981 USA

Revision C, 04/30/10, Highlights

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

THIS IS TO INFORM YOU OF THE RELEASE OF

SIL01 MAINTENANCE REVISION C, DATED APRIL 30, 2010

HIGHLIGHTS
Revision C replaces in its entirety Revision B of SIL01 Maintenance, dated October 03, 2006. Please
discard revision B and replace it with Revision C. Record the revision change in your records.

PAGE / PARAGRAPH DESCRIPTION OF CHANGE

Added / Deleted / Addressed

Highlights Added
Page 1, Subject Added Overhaul Clarification Note
Page 4 Revised Table 1. “Breeze-Eastern’s Hoist / Winch Time Between
Overhaul (TBO) Period,” with added configurations.
Revised Note (2)
Page 5 Revised Breeze-Eastern Maintenance Contacts.

NOTE: BREEZE-EASTERN CORPORATION HAS MOVED ITS CORPORATE AND MANUFACTURING

FACILITY TO: 35 MELANIE LANE, WHIPPANY, NJ 07981-1638 FROM 700 LIBERTY AVENUE,
UNION, NJ 07083.
NEW MAIN PHONE: 973-602-1001, 800-929-1919.

PROPRIETARY RIGHTS NOTICE: This Service Information Letter contains information that is proprietary to Breeze-Eastern Corporation, is an
unpublished work protected under applicable copyright laws and constitutes trade secrets for the purpose of the Trade Secret and Freedom of
Information Acts. It is delivered on the express conditions that it is not to be used, disclosed or reproduced, in any manner, in whole or in part
without prior written authorization of Breeze-Eastern Corporation, 35 Melanie Lane, Whippany, NJ 07981-1638, USA. Nothing contained herein
shall limit any rights granted by Breeze-Eastern Corporation under contract. This legend shall be included on any reproduction hereof All rights are
reserved. Any act in violation of applicable law may result in civil and / or criminal penalties
EXPORT CONTROLLED – WARNING This Service Information Letter may contain information that is subject to the International Traffic in
Arms Regulations (ITAR) or the Export Administration Regulations (EAR), and may not be exported, released, or disclosed to foreign nationals,
either in the United States or overseas, without first complying with the export requirements/regulations of the ITAR and/or EAR. The recipient is
responsible for complying with all such export requirements/regulations. Include this notice with any reproduced portions of this document.
 CAGE CODE 08484

35 Melanie Lane SIL01 Maintenance

Whippany, NJ 07981 USA
Revision C, 04/30/10, Page 1 of 5
SERVICE INFORMATION LETTER
Breeze-Eastern Rescue Hoist and Cargo Winch Maintenance Concept
(Includes Time Between Overhaul Definition)
SUBJECT: Breeze-Eastern has modified its maintenance concept for Rescue Hoists and Cargo Winches to
reflect revised government aviation authority requirements, as well as current industry and
military standards. C

Notes: This SIL pertains to Breeze-Eastern Rescue Hoists and Cargo Winches. System
Electronics such as Pendants, Pilot and Crew Control Panels are considered “On
Condition” Maintenance.

This Service Information Letter replaces CAB-100-45, “Recommended Intervals For

Planned Maintenance of Breeze-Eastern Hoists And Winches” in its entirety.

INFORMATION.

A. Reason.

Revisions made to the Federal Aviation Regulations (FAR), specifically FAR 27, “Airworthiness
Standards: Normal Category Rotorcraft,” and FAR 29, “Airworthiness Standards: Transport
Category Rotorcraft,” as well as the corresponding European Aviation Safety Agency (EASA)
Certification Specifications (CS), CS-27, “Small Rotorcraft,” CS-29, “Large Rotorcraft,” mandate
a stringent set of design requirements on the handling of external loads, both human and
non-human.

To meet the FAR / EASA requirements for helicopter type certification the commercial helicopter
manufacturers require an additional in depth level of detail in analyses, test, inspection, and
maintenance.

Although the military is not bound by the commercial FAR’s and EASA CS’s, their design
requirements on the handling of external loads, both human and non-human are as stringent, if not
more stringent, than the civil aviation authorities.

Therefore, Breeze-Eastern is adopting and implementing a maintenance concept that will meet the
changing / evolving requirements for safe Rescue Hoist and Cargo Winch design, operation, and
maintenance.

B. Effectivity.

This Service Information Letter pertains to all Rescue Hoist and Cargo Winch Systems
manufactured by Breeze-Eastern.

PROPRIETARY RIGHTS NOTICE: This Service Information Letter contains information that is proprietary to Breeze-Eastern Corporation, is an
unpublished work protected under applicable copyright laws and constitutes trade secrets for the purpose of the Trade Secret and Freedom of
Information Acts. It is delivered on the express conditions that it is not to be used, disclosed or reproduced, in any manner, in whole or in part without
prior written authorization of Breeze-Eastern Corporation, 35 Melanie Lane, Whippany, NJ 07981-1638, USA. Nothing contained herein shall limit
any rights granted by Breeze-Eastern Corporation under contract. This legend shall be included on any reproduction hereof All rights are reserved.
Any act in violation of applicable law may result in civil and / or criminal penalties
EXPORT CONTROLLED – WARNING This Service Information Letter may contain information that is subject to the International Traffic in Arms
Regulations (ITAR) or the Export Administration Regulations (EAR), and may not be exported, released, or disclosed to foreign nationals, either in
the United States or overseas, without first complying with the export requirements/regulations of the ITAR and/or EAR. The recipient is responsible
for complying with all such export requirements/regulations. Include this notice with any reproduced portions of this document.
 CAGE CODE 08484

35 Melanie Lane SIL01 Maintenance

Whippany, NJ 07981 USA
Revision C, 04/30/10, Page 2 of 5
SERVICE INFORMATION LETTER
Breeze-Eastern Rescue Hoist and Cargo Winch Maintenance Concept
(Includes Time Between Overhaul Definition)
C. Maintenance Concept Description.
Breeze-Eastern has revised its maintenance concept to three (3) levels of established
maintenance. They encompass both commercial and military definitions as defined below.

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

Service Information Letter01 Maintenance, Revision C

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

35 Melanie Lane SIL01 Maintenance

Whippany, NJ 07981 USA
Revision C, 04/30/10, Page 3 of 5
SERVICE INFORMATION LETTER
Breeze-Eastern Rescue Hoist and Cargo Winch Maintenance Concept
(Includes Time Between Overhaul Definition)
(Note: For certain export controlled items (ITAR), intermediate, or depot-level repair, and
maintenance information may be exported to a location outside the United States only
under a Technical Assistance Agreement approved specifically for that purpose).

D. Breeze-Eastern Maintenance Services.

Breeze-Eastern has revised its available maintenance services as defined in the following
information.

1. Scheduled Maintenance:

Breeze-Eastern’s maintenance action at this level is to perform scheduled maintenance on a

Hoist or Winch System, returned by operators who do not have the capability, or who do not
want to attempt, to accomplish these maintenance actions on their own.

2. Repair / Unscheduled Maintenance:

Breeze-Eastern’s maintenance action at this level is to go to the repair level necessary to

return the Hoist or Winch System to service. It will include functional testing, as well as any
Breeze-Eastern mandated improvements that are known to enhance the performance and / or
safety of the assembly.

3. Overhaul:

Breeze-Eastern’s maintenance action at this level is to bring the Hoist or Winch System to a
zero time / zero cycles condition regarding its overhaul status (see Table 1). The unit is
completely disassembled and the torque path / load critical parts are inspected to engineering
design criteria. Consumable, wear parts, and mandated parts are replaced, or reworked, in
accordance with customer instructions / contract. The unit is reassembled, and acceptance
tested, prior to being returned to service.

Overhaul Interval:

NOTE: If operators consistently sortie at excessive utilization rates, operate in adverse

environmental conditions, etc. it is the operator’s responsibility to increase the
scope, and frequency of all Hoist, or Winch, maintenance actions to ensure safe
operation of the equipment.

More frequent inspections can be made, but inspections cannot be accomplished

less frequently.

Service Information Letter01 Maintenance, Revision C

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

35 Melanie Lane SIL01 Maintenance

Whippany, NJ 07981 USA
Revision C, 04/30/10, Page 4 of 5
SERVICE INFORMATION LETTER
Breeze-Eastern Rescue Hoist and Cargo Winch Maintenance Concept
(Includes Time Between Overhaul Definition)
Breeze-Eastern’s Hoist / Winch Time Between Overhaul (TBO) period is either five (5) years
or two thousand (2,000) cycles from date of manufacture, whichever comes first, or ten (10)
years or two thousand (2,000) cycles from date of manufacture, whichever comes first. Refer
to Table 1 for the applicable Hoist / Winch Time Between Overhaul (TBO) period.

NOTE: A Hoist, or Winch, cycle is defined as reeling out the cable from full-in to full-out,
and then reeling back to full-in.

Table 1. Breeze-Eastern’s Hoist / Winch Time Between Overhaul (TBO) Period.

Hoist / Winch PN Cycles Years Note(s)

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

BL-10300-59-4, -63-1 2000 10 (2) and (3)

BL-20200-400-2 2000 10 (2)
BL-20200-41X Series and higher within the 2000 10 (2) and (3)
41X, 42X, 43X, etc. Series of Rescue Hoists
only.
BL-20200-516, 517 2000 10 (2) and (3)
BL-27100 Series 2000 10 (2) and (3)
All others 2000 5 (3)

If incorporated, a Hoist or Winch cycle is defined by the cycle counter. If a Hoist, or Winch,
does not have a cycle counter, then tracking of the number of cycles is dependent on the
operator’s records / usage logs.

Note(s):

(1) With the exception of those cargo winches used in hoisting operations (5 year TBO). C
(2) With a 10 year overhaul period, an oil change and limit switch integrity check is
recommended every 5 years.
(3) If the part number is not listed in Table 1 then the TBO is 5 years or 2000 cycles.

Service Information Letter01 Maintenance, Revision C

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

35 Melanie Lane SIL01 Maintenance

Whippany, NJ 07981 USA
Revision C, 04/30/10, Page 5 of 5
SERVICE INFORMATION LETTER
Breeze-Eastern Rescue Hoist and Cargo Winch Maintenance Concept
(Includes Time Between Overhaul Definition)

E. Breeze-Eastern Maintenance Contacts. C

Operators are encouraged to coordinate all repair / overhaul work with Breeze-Eastern, or their
authorized Service Centers. Breeze-Eastern is a Federal Aviation Administration (FAA) and a
Joint Aviation Authorities (JAA) FAR / JAR-145 approved Repair Station (FAA Repair Station
No. BZ7R167O, JAR-145 Acceptance Certificate Reference No. JAA.5454), and can repair /
overhaul the system at competitive prices and lead-times. Please contact Breeze-Eastern
Customer Services as follows:
Breeze-Eastern Corporation
35 Melanie Lane
Whippany, New Jersey 07981-1638 USA
Phone Number: 973-602-1001, Ext.1175 or 1102, or 1-800-929-1919 (US and Canada only)
Fax Number: 973-739-9344
E-mail Address: customerservices@breeze-eastern.com
Web Site Address: www.breeze-eastern.com

Service Information Letter01 Maintenance, Revision C

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

SIL07 Maintenance
Original Release, 04/21/11
Page 1 of 4
SERVICE INFORMATION LETTER

Improved Wire Rope Cable Marking

SUBJECT: Wire Rope (cable) extremes will now be identified using a marking
process that will provide a more durable marking of the Wire Rope.

I. PLANNING INFORMATION.
A. Reason.

1. Provide a more durable marking of wire rope cable assemblies that require a visual
indication of travel extremes, i.e. Full Out, Full In, or both by replacing a painting
process with a metal staining process. (See Table 1.)

2. Provide a visual indication that the end of the wire rope cable that attaches to the
cable storage drum is positioned correctly prior to securing with the attachment
screw. (See Table 2.)

B. Effectivity.

This Service Information Letter (SIL) pertains to cable assemblies in Tables 1 and 2.

Wire Rope Cable Assemblies

BL-1572 BL-6542 BL-12524
BL-5283 BL-7505 BL-12552
BL-5485 BL-8439 BL-12606
BL-5583 BL-8827 BL-15677
BL-5866 BL-9149 BL-16204
BL-6260 BL-10653 BL-18222

Table 1. Wire Rope Cable Assemblies Affected

PROPRIETARY RIGHTS NOTICE: This Service Information Letter contains information that is proprietary to Breeze-Eastern
Corporation, is an unpublished work protected under applicable copyright laws and constitutes trade secrets for the purpose of the Trade
Secret and Freedom of Information Acts. It is delivered on the express conditions that it is not to be used, disclosed or reproduced, in any
manner, in whole or in part without prior written authorization of Breeze-Eastern Corporation, 35 Melanie Lane, Whippany, NJ 07981-
1638, USA. Nothing contained herein shall limit any rights granted by Breeze-Eastern Corporation under contract. This legend shall be
included on any reproduction hereof All rights are reserved. Any act in violation of applicable law may result in civil and / or criminal
penalties

EXPORT CONTROLLED – WARNING This Service Information Letter may contain information that is subject to the International
Traffic in Arms Regulations (ITAR) or the Export Administration Regulations (EAR), and may not be exported, released, or disclosed to
foreign nationals, either in the United States or overseas, without first complying with the export requirements/regulations of the ITAR
and/or EAR. The recipient is responsible for complying with all such export requirements/regulations. Include this notice with any
reproduced portions of this document.
 CAGE CODE 08484

SIL07 Maintenance
Original Release, 04/21/11
Page 2 of 4
SERVICE INFORMATION LETTER
Improved Wire Rope Cable Marking
L

Part Number L (Length of white mark.)

BL-6542 0.97 ± 0.03 in 24.6 ± 0.7 mm
BL-8439
BL-8827
BL-9149
0.50 ± 0.03 in 12.7 ± 0.7 mm
BL-10653
BL-12606
BL-18222

Table 2. Wire Rope Cables with White Marking.

C. Maintaining Marking on Wire Rope Cables.

The following materials are required for maintenance of marking on wire rope cables:

Material Description Supplier

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

WARNING: WORK GLOVES MUST BE WORN BY THE OPERATOR WHENEVER

HANDLING THE WIRE ROPE CABLE TO PREVENT INJURY FROM
BROKEN STRANDS AND WIRES. EYE PROTECTION MUST BE
WORN BY THE OPERATOR WHENEVER OPERATING, OR
MAINTAINING, THE RESCUE HOIST TO PREVENT INJURY FROM
LUBRICANTS, SOLVENTS, AND OTHER MATERIALS USED ON
THE RESCUE HOIST, AS WELL AS METAL PARTS AND DEBRIS.

Service Information Letter - Maintenance ATA 100 Format

Use or disclosure of data contained on this sheet is subject to the restriction on the title page of this Service Information Letter.
 CAGE CODE 08484

SIL07 Maintenance
Original Release, 04/21/11
Page 3 of 4
SERVICE INFORMATION LETTER
Improved Wire Rope Cable Marking
1. If the marking on the wire rope cable becomes worn, reapply using the following
procedure:
a) Remove any surface contamination from the area to be marked by using
isopropyl alcohol (Federal Spec TT-I-735A) applied with a clean, lint-free
cloth.
b) Apply stain to the area using a soft, clean cloth, or a brush.
c) Allow the stain to dry for at least 30 minutes. (Drying time is dependent upon
environmental conditions.)
d) Apply a second coat per step b.
e) Allow the stain to dry per step c.
f) If required, apply a third coat per step b.
g) Allow the stain to dry per step c.
h) With the use of a micrometer, confirm that the final diameter of the marked area
is no more than 0.001 inch (0.025 mm) greater than the uncolored wire rope
cable diameter.
D. Using the White Marking for Wire Rope Cable Installation. (For wire rope cables
with white marking at the attachment point. See Figure 1.)

Figure 1. White Marking at The Wire Rope Cable Attachment Point.

Add the following note to the wire rope cable installation instructions in the Operation
and Maintenance Manual, Section 701.

NOTE: CONFIRM THAT THE WIRE ROPE CABLE IS INSERTED FULLY

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

Service Information Letter - Maintenance ATA 100 Format

Use or disclosure of data contained on this sheet is subject to the restriction on the title page of this Service Information Letter.
 CAGE CODE 08484

SIL07 Maintenance
Original Release, 04/21/11
Page 4 of 4
SERVICE INFORMATION LETTER
Improved Wire Rope Cable Marking

Figure 2. Acceptable Wire Rope Cable Attachment.

Figure 3. Unacceptable Wire Rope Cable Attachment.

Please consult your applicable Operation and Maintenance Manual for specific wire rope
installation procedure.

E. Contacts / Further Information.

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

Service Information Letter - Maintenance ATA 100 Format

Use or disclosure of data contained on this sheet is subject to the restriction on the title page of this Service Information Letter.
 CAGE CODE 08484

SIL08 Maintenance
Original Release, 08/11/11
Page 1 of 2
SERVICE INFORMATION LETTER

Information about Greases, Oils, Coatings, and Sealants

SUBJECT: Information on current grease, oils, coatings, and sealants for

B-E products.

I. PLANNING INFORMATION.

A. Reason.

To provide the operators of Breeze-Eastern products with updated information on

consumables due to component obsolescence, compatibility, compliance, and / or product
improvement.

B. Summary.

The following table lists alternate consumables for B-E products.

Consumable Replaced by / Alternate Remarks

Amovis 8-X Tribolube-9 grease Note 1
MIL-G-46886 A-A-59173 grease Note 2
DC-33 grease A-A-59173 grease Note 2
MIL-PRF-7808 oil MIL-PRF-23699 oil Note 3
MIL-PRF-7870 oil MIL-PRF-7808 oil Note 4
Iridite #14-2 Iridite NCP, Iridite #525 Note 5
Pliobond 30 Pliobond 35 Note 6
Table 1. Alternate Consumables.

C. Notes.

1. Tribolube-9 grease, made by Aerospace Lubricants Inc., replaces the discontinued

Amoco Amovis No. 8-X grease.

NOTE: DO NOT MIX TRIBOLUBE-9 AND AMOVIS 8-X GREASE. CLEAN

COMPONENTS BEFORE APPLYING TRIBOLUBE-9.

PROPRIETARY RIGHTS NOTICE: This Service Information Letter contains information that is proprietary to Breeze-Eastern Corporation, is an
unpublished work protected under applicable copyright laws and constitutes trade secrets for the purpose of the Trade Secret and Freedom of Information
Acts. It is delivered on the express conditions that it is not to be used, disclosed or reproduced, in any manner, in whole or in part without prior written
authorization of Breeze-Eastern Corporation, 35 Melanie Lane, Whippany, NJ 07981-1638, USA. Nothing contained herein shall limit any rights granted by
Breeze-Eastern Corporation under contract. This legend shall be included on any reproduction hereof All rights are reserved. Any act in violation of
applicable law may result in civil and / or criminal penalties

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 CAGE CODE 08484

SIL08 Maintenance
Original Release, 08/11/11
Page 2 of 2
SERVICE INFORMATION LETTER
Information about Greases, Oils, Coatings, and Sealants

2. A-A-59173 silicone grease replaces MIL-G-46886. Any A-A-59173 spec compliant

grease is interchangeable with DC-33 grease.

3. MIL-PRF-23699 oil is an acceptable alternate for MIL-PRF-7808 Grade 3 oil

EXCEPT for the side gearbox of two-speed BL-20200 series hoists.

NOTE: DRAIN HOIST COMPLETELY BEFORE REFILLING WITH NEW OIL.

Recommended Oil Minimum Operating Temperature.

MIL-PRF-7808 Below -40° F (-40° C)
MIL-PRF-23699 Over -40° F (-40° C)
Table 2. Recommended Oil for Minimum Operating Temperatures

4. MIL-PRF-7808 oil is an acceptable alternate for MIL-PRF-7870 oil.

NOTE: DRAIN HOIST COMPLETELY BEFORE REFILLING WITH NEW OIL.

5. Iridite NCP, Iridite #525, or any MIL-DTL-5541 Class 1A compliant coating is

interchangeable with Iridite #14-2.

6. Pliobond 35 sealant replaces Pliobond 30. Pliobond 35 is a Volatile Organic

Compound (VOC) regulation compliant adhesive.

D. Effectivity.

Wherever mentioned in B-E documentation, Table 1. Alternate Consumables applies.

Service Information Letter - Maintenance ATA 100 Format

Use or disclosure of data contained on this sheet is subject to the restriction on the title page of this Service Information Letter.