Zephyr ZGS-11000-2 v2 User manual

Manual RHGSE Operation and Maintenance Manual ZOM-11000-2 v2 rev E
Zephyr International llc Page 1 of 40 United States Patent # 7,429,031 B1
Rescue Hoist Ground Support Equipment
Manually Operated
ZGS-11000-2 v2
Operation and Maintenance Manual
United States Patent # 7,429,031 B1

Manual RHGSE Operation and Maintenance Manual ZOM-11000-2 v2 rev E
Zephyr International llc Page 2 of 40 United States Patent # 7,429,031 B1
Table of Contents
1.0) Introduction....................................................................................................................... 3
2.0) Purpose of the Equipment................................................................................................ 3
3.0) Unpacking the Equipment................................................................................................. 4
4.0) Setup the Equipment........................................................................................................ 4
5.0) Theory of Operation.......................................................................................................... 7
6.0) Operation of the Equipment.............................................................................................. 8
7.0) Maintenance of the RHGSE ........................................................................................... 20
8.0) Replacement Parts List................................................................................................... 29
9.0) Illustrated Parts Breakdown............................................................................................ 33
10.0) Technical Assistance.................................................................................................... 40
Before operation of the Ground Support Equipment, thoroughly review the entire manual in
order to prevent damage to the wire rope, hoist, helicopter or operator.

Manual RHGSE Operation and Maintenance Manual ZOM-11000-2 v2 rev E
Zephyr International llc Page 3 of 40 United States Patent # 7,429,031 B1
1.0) Introduction
The purpose of this manual is to describe the operation and maintenance of the Zephyr
International LLC Manually Operated Rescue Hoist Ground Support Equipment (RHGSE) part number
ZGS-11000-2 v2. Cautions are noted in red where required.
2.0) Purpose of the Equipment
The equipment is designed to assist inspecting and maintaining the rescue hoist and the wire
rope on the ground.
Design Attributes:
Man portable to and from the helicopter in order to perform pre and post flight checks of the
wire rope and rescue hoist system.
Allows one person to perform all inspections and maintenance operations in a minimum
amount of time.
Maintains positive manual tension on the wire rope as it extends and applies a heavy load
over the length as it retracts, while protecting the wire rope in a rotating tub during hoist
maintenance.
Accommodates any rescue hook and bumper configuration.
Cleans and dries the wire rope during post flight inspections after salt water use.
Lubricates the wire rope if required by the manufacturer.
Specifically designed to season and tension the wire rope without having to fly the helicopter
after a complete cable inspection.
The system has been designed to provide approximately 580 lbs. maximum tension to the wire rope. It
is balanced so that the center of mass is in line with the wire rope as it applies the tension.
Maintains clean & tight wire rope storage
on the rescue hoist drum.

Manual RHGSE Operation and Maintenance Manual ZOM-11000-2 v2 rev E
Zephyr International llc Page 4 of 40 United States Patent # 7,429,031 B1
3.0) Unpacking the Equipment
The equipment is shipped in a sturdy plywood box specifically designed to transport and store
the RHGSE.
The box is designed to be opened by removing the screws that are marked “R” and using the
front cover as a ramp.
Remove the screws that hold the wheel chock blocks.
Pull the pin and using the handle, pull the RHGSE out of the box and down the ramp. Check to
insure the wheel locks are unlocked as soon as the swiveling wheels clear the box.
Unlock the swivel locks in order to freely move the RHGSE around.
Remove and unpack the Lubridryer upright bracket, and the can of Lubridryer pads.
4.0) Setup the Equipment
Remove the lubridryer, load indicator , load indicator holder from the Rotatub and unpack.
Load indicator
Lubridryer

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Zephyr International llc Page 5 of 40 United States Patent # 7,429,031 B1
Assemble the Lubridryer assembly to the upright bracket.
Assemble the load indicator holder to the upright bracket.
Upright bracket
Lubridryer
Load Indicator Holder

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Zephyr International llc Page 6 of 40 United States Patent # 7,429,031 B1
Thread the load cell wire through the cap for the load indicator holder and press the small grommet
into the hole in the cap.
Install the 9 volt battery.
Attach the wires to the load cell indicator as follows:
Red wire = + Ex on meter
Black wire = -Ex on meter
Green wire = +In on meter
White wire = -In on meter
Insert the load cell indicator into the holder. Wrap the excess wires up and stow them under the cover
and install the two screws.
Load indicator
holder

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Zephyr International llc Page 7 of 40 United States Patent # 7,429,031 B1
Rotatub
Spooler
Tow handle that can be
attached to two locations
Heavy base mounted
on three casters
Load indication system
Load application lever
Self disengaging hand
crank
Load adjusting knob
Lubricating and drying system
5.0) Theory of Operation
The wire rope is paid off of the helicopter hoist and is wrapped three times around the
capstans and the rescue hook is positioned in a rotating tub. A spooler holds the rescue hook and
establishes the starting position of the wire rope to achieve an even storage of the wire rope in the
rotating tub. The wire rope is held firmly in the special grooving of the capstans by two tension roller
assemblies. The tension roller assemblies are held open by pins when installing and removing the
wire rope from the capstans. The RHGSE is manually operated by rotating the crank handle when the
helicopter hoist is extending, and a band clutch applies a back torque on the capstans to develop a
heavy load in the wire rope when the helicopter hoist is retracting. The hand crank handle is self
disengaging so that when the RHGSE is used in the retracting direction the crank handle does not
rotate. The rotating tub is mounted to a clutch that is adjustable to compensate for the taper in the
spooler and tub. A set of pads installed in the Lubridryer clean the wire rope, and provides lubrication
via an oil reservoir if required, the flow of oil from the reservoir can be started and stopped by a shut
off valve. When the wire rope is to be cleaned using fresh water, the tub is filled with water and
compressed air can be fed to a dryer located below the oiler to dry the wire rope as it is retracted from
the rotating tub full of water. A ball valve has been added to allow the air supply to be shut off when
not being used. Air pressure required is 30 psi minimum. After the cleaning is finished the tub is easily
drained via a removable plug. The RHGSE can be used with different size wire rope by changing the
capstans.
The RHGSE weighs 580 lbs dry and is transported to the helicopter via a tow handle that is
held in the upright position by a set of spring clips attached to the base. The tow handle can be
attached to either side of the RHGSE as desired. A transparent cover is provided to enclose the
capstans while in use. An adapter is provided to facilitate installing a new cable into the rescue hoist.
The RHGSE consists of:
Upper and lower capstan rollers

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Zephyr International llc Page 8 of 40 United States Patent # 7,429,031 B1
6.0) Operation of the Equipment
The operation of the RHGSE is straightforward, but rescue hoist maintenance requires strict
attention to detail and situational awareness of the operation of the rescue hoist and the RHGSE at all
times during its use.
The RHGSE operation requires:
Attaching the wire rope to the system through the lubridryer over capstans and into the rotatub.
Adjusting the spooler position.
Adjusting the rotatub position fully clockwise to start.
Operating the rescue hoist controls while cranking the handle to the take up wire rope in the
down mode
Setting and adjusting the clutch and operating the hoist in the up mode while observing the
wire rope and the load on the wire rope.
Using the Lubridryer to Lubricate the cable
Filling with water and draining the rotating tub
Using the Lubridryer to dry the cable

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Zephyr International llc Page 9 of 40 United States Patent # 7,429,031 B1
6.1) Installing the wire rope in the lubridryer
6.2) Wrapping wire rope around capstans
Position the hook down with wire rope going upwards in the
Rotatub as shown before wrapping the wire rope around
the capstans. This is to allow the wire rope to twist in the
hook assembly as it is wrapped around the capstans.
Wrap the wire rope around the capstans three times starting with the lower capstan innermost groove
as shown, while insuring the rope is pulled tight into the capstan grooves.
Start wrapping the cable
in the first groove of the
lower capstan
Open the capstan cover and pay out approximately 16 feet of
wire rope off of the helicopter hoist. Open the Lubridryer by
flipping the latch up and opening the Lubridryer. Position the
wire rope in the Lubridryer and close the Lubridryer by lowering
the latch over the screw. After the cable is in position turn the
Red Valve Screw counter clockwise 3 turn to allow oil to flow to
the Lubridryer pads

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Zephyr International llc Page 10 of 40 United States Patent # 7,429,031 B1
Wrap around the first
groove Wrap around the second
groove
Wrap around the third
groove Close the Lubridryer
cover

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6.3) Setting the tensioner arms
Remove the pins to apply the tension to the wire rope
after it is wrapped on the capstans.
Insert the pins into the pin storage hole in the tensioner base.
Give a strong tug on the wire rope to insure it is imbedded in the
grooves of the capstans.
Caution: If the wire rope is not wrapped tightly around the
capstans it may loosen up and come off the capstans.
Caution: Insure the lower and the upper tensioner rollers
are engaged when extending the cable.
Guide the wire rope through the guide rollers and through the
slot in the spooler then turn the hook assembly upside down and
position the cable in the slot of the spooler as shown below.
Set the tensioner
arms
Guide the cable
through the rollers
and into the tub and
then through the slot
in the spooler
Set the hook on top of the
spooler

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Zephyr International llc Page 12 of 40 United States Patent # 7,429,031 B1
6.4) Setting the rotatub and spooler orientation
With the wire rope wrapped on the capstans and the wire in the tub and through the guide
pulleys, rotate the rotatub clockwise to remove any excess slack.
The spooler can be relocated if required to adjust the relative position of the wire rope wrapped in the
rotatub to the capstans. This allows the user to adjust the relative wrapping of the rotatub to the
capstans if required for any reason at any time.
If not enough wire rope is paid out from the rescue hoist to place the wire rope in the spooler
correctly, run the hoist in the down direction while rotating the crank handle for a couple of feet to
allow adjustment of the spooler in the correct orientation. Insure the cable is placed in the cable guide
rollers as shown.
Once the spooler is in a good position push it down to firmly seat it in the rotatub. Check to
insure the wire rope is loosely sitting in the bottom of the cutout in the spooler.
Before operating the hoist close and latch the capstan cover.
6.5) Actuating the load lever
When reeling out the load lever must be in the released position and when reeling in the crank
handle should be disengaged and the load lever must be in the applied position to apply a heavy load
to the wire rope.
Load lever disengaged and
crank handle engaged Load lever engaged and
crank handle disengaged

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Zephyr International llc Page 13 of 40 United States Patent # 7,429,031 B1
Engage and rotate handle
clockwise to take up wire
rope in down direction.
6.6) Running the rescue hoist in the down direction (extending)
Before extending, verify the wire rope is properly installed on the RHGSE, the wire rope is
wrapped tight on the capstans, and the cover is closed and latched.

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Zephyr International llc Page 14 of 40 United States Patent # 7,429,031 B1
With one hand operating the hoist control pendant use the other hand to engage the slots in
the handle with the pin on the shaft to rotate the crank handle in the clockwise direction to develop a
small load in the wire rope. Actuate the pendant to start the hoist running in the down direction. Start
cranking slowly and observe the wire rope to insure it is completely seated in the capstan grooves. If it
begins to loosen on the third groove of the top capstan, stop and pull the wire rope down into the
capstan groove and then continue. Run the hoist in the down direction at a speed that allows you to
observe the hoist while cranking in the clockwise direction comfortably. Do not allow the wire rope to
get loose while extending. Extend the wire rope completely; always paying careful attention to the
helicopter hoist and to the condition of the wire rope. If the wire rope snags in the Lubridryer pads for
any reason such as a kink or a broken wire or broken strand; the wire rope will loosen between the top
of the Lubridryer and an increase in crank resistance will be felt. In this event, the wire rope needs to
be replaced; run the wire rope out into the drum and follow the manufacturer’s instructions for
replacing the hoist wire rope. Absent any deficiencies noted during inspection, run the hoist in the
down direction until the helicopter hoist is stopped by the full out limit switches.
6.7) Running the rescue hoist in the up direction (retracting)
Caution: When starting to reel in the load lever must not be fully applied with the load
adjusted to the maximum, this is because the coefficient of static friction is greater then the
coefficient of dynamic friction. If the load lever is fully activated before starting, the RHGSE
will be lifted off of the ground and may cause damage to the hoist, aircraft or to the operator.
If the system does lift off the ground unexpectedly stop lifting with the rescue hoist and lower
the system to the ground and release the load lever. Never try to lower the system by
releasing the load lever when the system is off the ground.
The wheel brakes on the RHGSE should be unlocked to
allow the equipment to center itself under the hoist.
Starting the application of the load
Rotate the crank handle counterclockwise to disengage
the pin, and start the hoist in the up (retracting) direction,
then apply the load lever and begin to increase the load
with the load adjuster. The clutch will start applying torque
to the capstans in a dynamic condition
Apply the load lever and adjust the load if required (see section 6.8)
With the hoist control pendant run the helicopter hoist in the up
direction. Observe the wrapping of the wire rope on the hoist drum.
Approximately 20 feet before the wire rope is completely retracted
onto the hoist drum, slow down and observe the Rotatub. Stop the
hoist operation when the spooler is in approximately the same
position as starting and there are no more cable wraps in the
Rotatub.
Observe the wire rope at all times.
Stop running immediately if the RHGSE lifts off the
ground and adjust clutch as required.
Caution: When reeling in the crank handle must be disengaged

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Load adjuster Load cell
Caution: Failure to stop the hoist before the hook comes out of the Rotatub may cause
damage to the RHGSE and the wire rope. Pay close attention to the number of turns in the
Rotatub as the hook approaches the up limit position.
6.8) Adjusting the load
Reeling in (retracting) under maximum load
If a maximum load is desired turn the Load Adjuster clockwise until the
RHGSE just starts to lift off the ground and then back off the adjuster 1/16
of a turn. Do not operate the RHGSE with it lifted off the ground. Always
place one foot on the RHGSE when adjusting to a high load.
Using Load Indication System
The load indication is for reference only
A load cell is included in the system to allow the operator to monitor and
adjust the load applied to the rescue hoist cable.
The maximum load the RHGSE can apply to the wire rope is a function of its own weight and
any additional ballast weight that may be added such as when the Rotatub is full of water. The
RHGSE weighs 580 lbs (264 kg) when it is dry, it will start to lift off the ground at approximately 580
lbs (264 kg). To verify or adjust the load indication system place one foot on the RHGSE and retract
the load at a moderate speed and increase the load with the load adjuster until the GSE just starts to
lift off the ground. Adjust the display by turning the screw to adjust the span of the display to display
580 lbs or 264 kg as the cable is being retracted.
Normally the RHGSE will only be extended and retracted once during the course of a preflight,
post flight or a daily hoist inspection. However in the case where a new wire rope has been installed it
might be cycled repeatedly to condition the wire rope. In this situation the load should be set at
approximately 100 lbs (46 kg) and then increased to the maximum load in order to condition the wire
rope properly. The brake disc should be allowed to cool after 2 or 3 consecutive cycles. When
conditioning a new cable go slow to allow the cable to acclimate itself to the rescue hoist drum.
Load adjuster
Load indicator display

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Zephyr International llc Page 16 of 40 United States Patent # 7,429,031 B1
Caution: The load cell attachment bolt should not be loosened or adjusted as this will disrupt
the zero and span adjustments that were made at the factory. Should the load display require
adjustment please see section 7.16 for detailed instructions.
6.9) Setting Swivel Locks
The system is supplied with locks to prevent the front wheels from swiveling. The swivels
should be allowed to rotate for moving the RHGSE around the hanger and aircraft and then locked
once the RHGSE has been positioned under the rescue hoist cable. To lock the swivels once the
wheels have be positioned, rotate the ring to a horizontal orientation and engage the detent on the
wheel with the pin. To unlock the swivels pull the ring out of engagement and rotate the ring to a
vertical orientation.
Note: When using the MagSens system the swivel locks should be in the unlocked position to allow
the RHGSE to center itself under the hoist and thus prevent any fleet angle during the checking of the
cable.
6.10) Replacement of the Lubridryer pads
The lubridryer pads are replaced by removing the four thumbscrews, removing the bushings by
lifting them up, and removing the old lubridryer pads by sliding the pad up the slot and installing new
pads by sliding the pad down the slot.
Locked position Unlocked position
Swivel locking
mechanism
Shown used pads Shown one set of screws,
bushing and pad New pads installed
Thumbscrews
Bushing
Pads

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Zephyr International llc Page 17 of 40 United States Patent # 7,429,031 B1
6.11) Lubrication of wire rope
6.12) Using fresh water wash
Fill the rotating tub ¾ of the way with fresh water and extend the wire rope all the way down.
Using a hose, rinse off the helicopter hoist and the wire rope between the helicopter hoist and the
rotatub. If shop air is available, attach an air line to the lubridryer via the quick disconnect nipple
supplied with the RHGSE. (See section 6.13) Run the hoist in the up direction with the load brake
applied. Before operating with water rotate the load adjuster counter clock wise to reduce the load to
approximately 100 lbs.
Carefully observe the wire rope at all times on the capstans. Retract the entire wire rope out of the
rotatub, and position the drum so that the pug is above the hole in the frame then remove the plug at
the bottom and drain into an approved drain.
If shop air is unavailable and the onboard compressor is not installed, remove the water and
dry out the Rotatub extend the cable into the empty tub and let dry. Retract the wire rope onto the
helicopter hoist with the load lever applied using a gloved hand and a clean cloth to dry the wire rope.
The Lubridryer includes a reservoir
that can be filled with oil. Use oil only as per
the hoist manufacturer’s recommendations.
The reservoir can be used to store spare
Lubridryer pads. The Lubridryer includes a
valve that shuts off the flow of oil when not in
use
When oil is added to the reservoir and
the valve is open the oil seeps through a
small hole to lubricate the rear pad. The front
pad should be soaked in oil before installing it,
open the oil reservoir and dip the pads into
the oil filled reservoir. Therefore, it is
recommended to always keep a spare set of
pads in the reservoir of oil to use as the next
set.
Wipe excess oil off of the frame and
use a clean cloth to keep the oil off of the
capstans when the RHGSE is not in use.

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Zephyr International llc Page 18 of 40 United States Patent # 7,429,031 B1
6.13) Using the Dryer
After extending the wire rope into the Rotatub, and filling the Rotatub with water, then applying
the load lever, and just prior to running the wire rope up into the helicopter hoist, attach an air line to
the airline connection located at the back of the Lubridryer. The air pressure required is 30 psi or 2 bar
minimum. The air supply can be turned on or off via a ball valve. Replace the Lubridryer pads to clean
off any excess salt and turn on the valve attached to the back of the Lubridryer.
The compressed air will force the majority of the water off the cable prior to leaving the Lubridryer.
6.14) Removing the wire rope from the RHGSE
Remove the hitch pins from their storage hole and rotate the tensioner assemblies away from
the capstans and reinstall the hitch pins to hold the tensioner wheel off the wire rope. Unwrap the wire
rope from the capstans and carefully remove the twist by lifting the hook out of the spooler slot and
placing it hook facing down into the slot. Retract the remaining wire rope onto the helicopter hoist
using a glove hand to apply tension and being careful not to catch the wire rope on the RHGSE or
anything else. Store the hook fully as per the manufacturers’ instructions.
Caution: Observe wire rope at all times to prevent damage.
Air line connection
Shut off
valve

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Zephyr International llc Page 19 of 40 United States Patent # 7,429,031 B1
Note: When capstans are removed note
that the upper capstans have the longer
screws. It is important not to reverse the
upper and lower capstans.
Upper capstan
Lower capstan
Exit Roller
Pressure
Roller
6.15) Changing the capstans to accommodate a different wire rope size.
(Optional if purchased different capstans to accommodate for a different size wire rope)
Remove the capstans and mark them according to their location, i.e. top or bottom. Install the different
capstans using the screws that were removed. Check the wrapping of the wire rope to insure the wire
rope stays tight on the capstans.
6.16) Removing the wire rope from the hoist
The RHGSE can coil the wire rope for removal and disposal. Run the wire rope completely out into the
Rotatub. Bypass the full out limit switch on the hoist as directed in the OEM manual, and run the hoist
in the down direction until the wire rope can be removed from the hoist. Disconnect the wire rope from
the hoist and run the remaining rope into the Rotatub.
Remove the hook assembly from the wire rope. Then reach down through the slot in the spooler and
collect the wire rope spool in your hand and pull the spooler away from the tension rollers and lift the
spooler and wire rope coil out of the Rotatub. Flip the spooler upside down and the wire rope will slide
off in a neat coil. Discard or store the wire rope as appropriate.

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Zephyr International llc Page 20 of 40 United States Patent # 7,429,031 B1
Goodrich Cable Reel
Breeze Cable Reel
6.17) Installing a new wire rope with the cable reel extension
The RHGSE has the ability to attach the wire rope shipping reel in order to facilitate installation of a
new wire rope.
Attach the ZGS-10454-1 Cable Reel Extension with its pin as shown.
Slide the shipping reel on the extension and attach the wire rope following the OEMs instructions. The
adapter can be used with both major OEM’s cable shipping reels.
Once the wire rope is completely on the rescue hoist, remove the cable reel and cable reel
extension and run the wire rope on and off the hoist onto the RHGSE three or four times
while increasing the load incrementally on each cycle in order to condition the wire rope.