Zephyr ZGS-11000-2 v2 User manual

Manual RHGSE Operation and Maintenance Manual ZOM-11000-2 v2 Rev G
This manual contains proprietary information and is not to be copied or disclosed without written permission from Zephyr International LLC.
Copyright 2002-2015 Page 1 of 38
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 G
This manual contains proprietary information and is not to be copied or disclosed without written permission from Zephyr International LLC.
Copyright 2002-2015 Page 2 of 38
WARNING
WARNING
DEFINITIONS OF WARNINGS, CAUTIONS and NOTES contained in this manual
Shall be used when there is danger of injury or death to personnel.
CAUTION
Shall be used when there is danger of damage to equipment
NOTE
Shall be used to highlight essential procedures or statements which may facilitate performance
of a procedure or operation.
Table 1 - Warning and Caution Symbols used through the manual.
Warning
Warning Electrical Hazard
Warning Hot Surface Burn Hazard
Warning Lifting Hazard
Warning Moving Parts
Warning Strong Magnetic Field
Must Wear Eye Protection
Must Wear Hand Protection
Switch Off Before Operating
Limitations, Warnings and Cautions
Before operation of the Ground Support Equipment, thoroughly review the entire manual in order to prevent
damage to the cable, hoist, helicopter or operator.
LIMITATION CAUTION DURING REGULAR OPERATIONS
During regular cable maintenance using the RHGSE with a cable load up to a 600 lbs. (272.15kg) load is
possible. However the RHGSE should not be used repeatedly at 600 lbs. (272.15kg) without relieving the twist
from the cable by extended the cable in flight, because it can add a twist the cable. The maximum sustained
load should not be above 300 lbs. (136.08kg) for repetitive evolutions.
LIMITATION CAUTION DURING CABLE PRECONDITIONING
During cable pre-conditioning the RHGSE should be used with loads up to no more than 300 lbs. (136.08kg).
Then the cable should be extended in flight and retracted with 200 lbs. (90.71kg) maximum, to allow the cable to
relieve the twist imparted during the process of acclimating the cable to the Hoist Brake Drum.

Manual RHGSE Operation and Maintenance Manual ZOM-11000-2 v2 Rev G
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CAUTION
Do not operate the RHGSE with a new cable more than three evolutions before relieving the twist from the cable
by extended the cable in flight; otherwise, the cable will acquire additional twisting and damage to the equipment
and cable can occur.
CAUTION
Retracting with the motor drive engaged may damage the electronic control assembly.
CAUTION
The RHGSE uses a Brake Band and Brake Drum to generate the load in the cable in the retracting direction.
The Brake Band and Brake Drum will get very hot. The RHGSE should not be used more than three times
consecutively without letting the Brake Band and Brake Drum cool down.
CAUTION
The RHGSE is not to be used excessively at high loads without flying the rescue hoist and extending the cable
as part of normal operations. Excessive use of the RHGSE without extending the cable in flight traps the
induced twist in the cable.
CAUTION
Stop running immediately if the RHGSE lifts off the ground and adjust clutch as required.
CAUTION
When starting to reel in the load, the Brake Handle must not be fully applied with the load adjusted to the
maximum; this is because the coefficient of static friction is greater than the coefficient of dynamic friction. If the
Brake Handle 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 Brake Handle. Never try to lower the
system by releasing the Brake Handle when the system is off the ground.
CAUTION
Failure to stop the hoist before the hook comes out of the Rotatub may cause damage to the RHGSE and the
cable. Pay close attention to the number of turns in the Rotatub as the hook approaches the up limit position.
CAUTION
If the Cable is not wrapped tightly around the capstans it may loosen up and come off the capstans.
CAUTION
Ensure that the exit and pressure tensioner rollers are engaged when extending or retracting the cable.
CAUTION
Ensure the cable enters the bottom of cutout in the Spooler at the base of the Rotatub or the cable may start
wrapping too high on the Spooler and not have enough space to wrap the entire length of cable.
CAUTION
When retracting cable after unwinding it from the capstans use caution to prevent the cable hook from getting
entangled on the tensioner arms. Sever damage to the arms or cable may result.

Manual RHGSE Operation and Maintenance Manual ZOM-11000-2 v2 Rev G
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Table of Contents
1.0) Introduction................................................................................................................................. 5
2.0) Purpose of the Equipment ......................................................................................................... 5
3.0) Unpacking the Equipment.......................................................................................................... 5
4.0) Setup the Equipment.................................................................................................................. 6
5.0) Theory of Operation.................................................................................................................. 10
6.0) Operation of the Equipment..................................................................................................... 11
7.0) Maintenance of the RHGSE...................................................................................................... 23
8.0) Replacement Parts List ............................................................................................................ 30
9.0) Illustrated Parts Breakdown..................................................................................................... 31
10.0) Technical Assistance ............................................................................................................. 38
Table of figures
Figure 1 Manual RHGSE..................................................................................................................... 5
Figure 2 RHGSE usage results in tight wraps......................................................................................5
Figure 3 Shipping crate........................................................................................................................6
Figure 4 Loose components................................................................................................................. 6
Figure 5 Misc. Components................................................................................................................. 6
Figure 6 Setting Up..............................................................................................................................7
Figure 7 Upper Upright Bracket assembly............................................................................................ 7
Figure 8 Lubridryer Assembly..............................................................................................................7
Figure 9 Attaching the Load Cell to the Display....................................................................................8
Figure 10 Load cell display terminals...................................................................................................8
Figure 11 Old Style Load Indicator Holder ...........................................................................................8
Figure 12 Load indicator setup.............................................................................................................9
Figure 13 600 lb. Hook Check Adapter ...............................................................................................9
Figure 14 RHGSE Description........................................................................................................... 10
Figure 15 Lubridryer........................................................................................................................... 11
Figure 16 Cable wrapping sequence.................................................................................................. 12
Figure 17 Tensioner Arms.................................................................................................................. 13
Figure 18 Spooler Cutout.................................................................................................................. 14
Figure 19 Proper cable positioning in Rotatub and Spooler................................................................ 14

Manual RHGSE Operation and Maintenance Manual ZOM-11000-2 v2 Rev G
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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.
2.0) Purpose of the Equipment
The equipment is designed to facilitate inspecting and maintaining the rescue hoist and the cable.
Design Attributes:
•Man portable to and from the helicopter in order to perform pre and post
flight checks of the cable 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 cable as it extends and applies
a heavy load over the length as it retracts, while protecting the cable in a
rotating tub during hoist maintenance.
•Accommodates any rescue hook and bumper configuration.
•Cleans and dries the cable during post flight inspections after salt water
use.
•Lubricates the cable if required by the manufacturer.
•Specifically designed to tension the cable without having to fly the
helicopter after a complete cable inspection.
•The system has been designed to provide approximately 605 lbs.
maximum tension to the cable. It is balanced so that the center of mass
is in line with the cable as it applies the tension.
Figure 1 Manual RHGSE
Maintains clean & tight cable
storage on the rescue hoist
drum.
Figure 2 RHGSE usage results in tight wraps

Manual RHGSE Operation and Maintenance Manual ZOM-11000-2 v2 Rev G
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3.0) Unpacking the Equipment
The equipment is shipped in a sturdy plywood crate
specifically designed to transport and store the
RHGSE. The crate is designed to be opened by
removing ONLY the screws that are marked “R”
on the front and side panels and using the front
cover as a ramp.
➢Remove the screws that hold the wheel
chock blocks.
➢Cut the zip tie and pull the pin, then using the
handle pull the RHGSE out of the crate and
down the ramp. Check to ensure 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 parts stored in the
Rotatub.
Figure 3 Shipping crate
New style
load indicator
with AA
Batteries
Old style Load
Indicator with 9-volt
battery
Tub plugs (spares)
Load Indicator Holder
Lubridryer Pads
(spares)
Cable
Reel
Extension
Lubridryer
Figure 4 Loose components
Figure 5 Misc. Components
MagSens Cable Standards
(only supplied if MagSens
was purchased with the
RHGSE)
600 lb. Hook
Checkpoint
Upper Upright Bracket

Manual RHGSE Operation and Maintenance Manual ZOM-11000-2 v2 Rev G
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ZGS-10245-1 Upper
Upright Bracket
Upright Bracket
Attach to this
hole location
4.0) Setup the Equipment
Remove the lubridryer, load indicator , load indicator holder, upper upright bracket, and 600 lbs. hook checkpoint
from the Rotatub and unpack.
Note
Upper Upright Bracket may remain in place permanently.
Attach the Upper Upright Bracket to the inside of the Upright Bracket with the supplied (1) ¼-20 x ¾” long screw
and locknut.
Upright bracket
Load indicator
Lubridryer
Upper Upright
bracket
Figure 6 Setting Up
600 lbs. Hook
Checkpoint
Figure 7 Upper Upright Bracket assembly
Attach Lubridryer and
Load Indicator holder
using the supplied
hardware.
Figure 8 Lubridryer Assembly

Manual RHGSE Operation and Maintenance Manual ZOM-11000-2 v2 Rev G
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Load
Indicator
Load
Indicator
Holder Cap
Load Cell Wire
Grommet
Figure 9 Attaching the Load Cell to the Display
For the old-style indicator, 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.
Figure 10 Load cell display terminals
Load Indicator
Holder
Load
Indicator
Figure 11 Old Style Load Indicator Holder

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For the new style load indicator, (2 AA) batteries are included and need to be installed under the back plate of
the load display. Insert load display into the load display holder, connect the 90 degree connector by aligning the
key and install the cover onto the load display holder securing it with (2) screws. Ensure the white load cell wire
is in the slot on the back of display holder cover.
Load cell wire slot
Figure 12 Load indicator setup
Attach the hook 600 lb. adapter into the
two holes of the Upper Upright bracket
using the Quick Release Pins.
CAUTION
ZGS-11443-1 Hook Check MUST BE
removed from Upper Upright Bracket prior
to wrapping the cable around the
capstans.
Figure 13 600 lb. Hook Check Adapter

Manual RHGSE Operation and Maintenance Manual ZOM-11000-2 v2 Rev G
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5.0) Theory of Operation
The cable 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 cable
to achieve an even storage of the cable in the rotating tub. The cable 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 cable 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 cable 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 cable, 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 cable 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 cable 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 cable by changing the capstans.
The RHGSE weighs 605 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
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
600 lb Hook Checkpoint
Figure 14 RHGSE Description

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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 cable 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 cable in the down mode
•Setting and adjusting the clutch and operating the hoist in the up mode while observing the cable and
the load on the cable.
•Using the Lubridryer to Lubricate the cable.
•Filling with water and draining the rotating tub.
•Using the Lubridryer to dry the cable.
6.1) Installing the cable in the Lubridryer
Open the capstan cover and pay out approximately 16 feet of cable off of the helicopter hoist. Open the
Lubridryer by flipping the latch up and opening the Lubridryer. Position the cable 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 turns to allow oil to flow to the Lubridryer pads
Red Valve Screw
Latch
Figure 15 Lubridryer

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6.2) Wrapping cable around capstans
NOTE
Three groove capstans are shown but the process is the same for the four groove capstans.
Position the hook down with cable going upwards in the Rotatub as shown before wrapping the cable around the
capstans. This is to allow the cable to twist in the hook assembly as it is wrapped around the capstans.
Wrap the cable around the capstans three times starting with the lower capstan innermost groove as shown,
while insuring the cable is pulled tight into the capstan grooves.
Wrap around the first
groove
Start wrapping the cable in
the first groove of the lower
capstan
Wrap around the second
groove
Wrap around the third
groove
Close the Lubridyer cover
Figure 16 Cable wrapping sequence

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Pin
Pin
Pressure Roller
Tensioner Arm
Exit Roller
Tensioner Arm
Figure 17 Tensioner Arms
6.3) Setting the tensioner arms
Remove the pins to apply the tension to the cable 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 cable to ensure it is imbedded in the grooves of the
capstans.
CAUTION
If the Cable is not wrapped tightly around the capstans it may loosen up and come off the capstans.
CAUTION
Ensure that the exit and pressure tensioner rollers are engaged when extending or retracting the cable.
Guide the cable 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.
CAUTION
Ensure the cable enters the bottom of cutout in the Spooler at the base of the Rotatub or the cable may start
wrapping too high on the Spooler and not have enough space to wrap the entire length of cable.
CAUTION
When retracting cable after unwinding it from the capstans use caution to prevent the cable hook from getting
entangled on the tensioner arms. Severe damage to the arms or cable may result.

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Cutout in bottom of Spooler
Figure 18 Spooler Cutout
Guide Rollers
Spooler Cutout
Set the hook on top of the spooler.
Figure 19 Proper cable positioning in Rotatub and
Spooler
NOTE
It is important that the cable be at the bottom of the cut out in the spooler.
6.4) Setting the Rotatub and Spooler orientation
With the cable 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 cable 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 cable is paid out from the
rescue hoist to place the cable 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. Ensure 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 ensure the cable is
loosely sitting in the bottom of the cutout in the spooler. Before operating the hoist close and latch the capstan
cover.

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Shown is the Brake Handle disengaged
Shown is the Brake Handle engaged and
crank handle disengaged
Brake Handle
Hand Crank
Figure 20 Brake Handle Actuation
6.5) Actuating the Brake Handle
When reeling out the Brake Handle must be in the released position and when reeling in the crank handle
should be disengaged and the brake handle must be in the applied position to apply a heavy load to the cable.
6.6) Running the rescue hoist in the down direction (extending)
Before extending, verify the cable is properly installed on the RHGSE, the cable is wrapped tight on the
capstans, and the cover is closed and latched.
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 cable. Actuate
the pendant to start the hoist running in the down direction. Start cranking slowly and observe the cable to
ensure 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 cable 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 cable to get loose while extending.
Extend the cable completely; always paying careful attention
to the helicopter hoist and to the condition of the cable. If the
cable snags in the Lubridryer pads for any reason such as a
kink or a broken wire or broken strand; the cable will loosen
between the top of the Lubridryer and an increase in crank
resistance will be felt. In this event, the cable needs to be
replaced; run the cable out into the drum and follow the
manufacturer’s instructions for replacing the hoist cable.
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)
The wheel brakes on the RHGSE should be unlocked to allow
the equipment to center itself under the hoist.
Engage and
rotate handle
clockwise to take
up cable in down
direction.
Figure 21 Hand crank

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CAUTION
When reeling in, the crank handle must be disengaged.
6.7.1.Starting the application of the Retracting load
Rotate the crank handle counterclockwise to disengage the pin, and start the hoist in the up (retracting)
direction, then apply the brake handle 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 brake handle 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 cable on the hoist drum. Approximately 20 feet
before the cable 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 cable at all times.
CAUTION
Stop running immediately if the RHGSE lifts off the ground and adjust clutch as required.
CAUTION
When starting to reel in the load, the Brake Handle must not be fully applied with the load adjusted to the
maximum; this is because the coefficient of static friction is greater than the coefficient of dynamic friction. If the
Brake Handle 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 Brake Handle. Never try to lower the
system by releasing the Brake Handle when the system is off the ground.
CAUTION
Failure to stop the hoist before the hook comes out of the Rotatub may cause damage to the RHGSE and the
cable. Pay close attention to the number of turns in the Rotatub as the hook approaches the up limit position.
6.7.2. 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.
6.7.3.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.
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 7.15
for detailed instructions.
The maximum load the RHGSE can apply to the cable 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 605 lbs (275 kg) when

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Load adjuster
Load cell
it is dry, it will start to lift off the ground at approximately 605 lbs (275 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.
Even though the RHGSE can apply a 600 lbs. load to a cable, it should not be used repeatedly at 600
lbs. because it will twist the cable more and more. The maximum sustained load should not be above
300 lbs. for repetitive evolutions. During cable conditioning, it should be used up to 300 lbs. and then the
cable should be extended and then retrieved with 200 lbs. maximum to allow the cable to relieve the
twist imparted during the process of acclimating the cable to the hoist drum.
IMPORTANT NOTE
When conditioning a new cable, go slow to allow the cable to acclimate itself to the smaller diameter rescue
hoist drum.
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 cable has been installed it might be cycled repeatedly
to condition the cable. 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 cable properly. The brake disc should be allowed to
cool after 2 or 3 consecutive cycles.
6.9) Setting Swivel Locks
CAUTION
If 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.
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
been 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.
Load indicator display
Locked position
Unlocked position
Figure 22 Swivel Locks

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Airline connection
Shut off valve
Air outlet
Figure 25 Compressed Air attachment
6.10) Replacement of the Lubridryer pads
Open the Lubridryer by unlatching and unscrew the (4) thumbscrews. Remove the two lubridryer bushings.
Remove the used Lubridryer pad by sliding them up the channel. Discard of the used pads properly. Insert new
pad by sliding the pads down the channel, install the bushing and thumbscrews. Replace the bushings when
excessively worn.
6.11) Lubrication of cable NOTE
Use oil only as per the hoist manufacturer’s recommendations.
The Lubridryer includes a reservoir that can be filled with oil. 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.
6.12) Performing a fresh water wash
Fill the rotating tub ¾ of the way with fresh water and extend the cable all the way down. Using a hose, rinse off
the helicopter hoist and the cable between the helicopter hoist and the rotatub. If shop air is available, attach an
airline 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 cable at all times on the capstans.
Retract the entire cable out of the Rotatub, and position the drum so that the plug is above the hole in the frame
then remove the plug at the bottom and drain into an approved drain.
Shown used pads
New pads installed
Shown one set of screws,
bushing and pad
Thumbscrews
Bushing
Pads
Figure 23 Lubridryer Components
Oil reservoir
Valve
Figure 24 Lubrication Valve

Manual RHGSE Operation and Maintenance Manual ZOM-11000-2 v2 Rev G
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Align the RHGSE cut out with the
drainage hole in the tub as shown.
Figure 26 Water Drains
If shop air is unavailable remove the water and dry out the Rotatub extend the cable into the empty tub and let
dry. Retract the cable onto the helicopter hoist with the brake handle applied using a gloved hand and a clean
cloth to dry the cable.
6.13) Using the Lubridryer
After extending the cable into the Rotatub, and filling the Rotatub with water, then applying the brake handle,
and just prior to running the cable up into the helicopter hoist, attach an airline 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 cable from the RHGSE
CAUTION
Observe Cable always to prevent damage.
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 cable. Unwrap the cable 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 cable onto the helicopter hoist using a glove hand to apply tension and being careful not
to catch the cable on the RHGSE or anything else. Store the hook fully as per the manufacturers’ instructions.
6.15) Changing the capstans to accommodate a different cable size.
(Optional if purchased different capstans to accommodate for a different size cable)
NOTE
It is important not to reverse the upper and lower capstans.
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 cable to ensure the cable stays tight on the
capstans.
Upper capstan
Lower capstan
Exit Roller
Pressure
Roller
Figure 27 Changing Capstans

Manual RHGSE Operation and Maintenance Manual ZOM-11000-2 v2 Rev G
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Figure 28 Cable Reel Adapter Pin
Figure 29 Cable Reel Adapter Components
Figure 30 Mounting Goodrich
Style
6.16) Removing the cable from the hoist
The RHGSE can coil the cable for removal and disposal. Run the cable 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 cable can be removed from the hoist. Disconnect the cable from the hoist and run the remaining cable into
the Rotatub.
Remove the hook assembly from the cable. Then reach down through the slot in the spooler and collect the
cable spool in your hand and pull the spooler away from the tension rollers and lift the spooler and cable coil out
of the Rotatub. Flip the spooler upside down and the cable will slide off in a neat coil. Discard or store the cable
as appropriate.
6.17) Installing a new cable with the universal cable reel extension
A universal cable reel adapter is provided to attach the Cable shipping
reel to facilitate installation of a new cable.
Attach the ZGS-10794-1-1 Cable Reel Extension with its pin
as shown.
Remove the clutch, the B style adapter and the nut.
Slide G style cable reel onto the shaft and install the clutch and the nut.