Zephyr ZGS-12000-2 User manual

Fixed Hoist Test Facility Operation and Maintenance Manual ZOM-12000-2 rev 0
Page 1 of 20
This manual contains proprietary information and is not to be copied or disclosed without written
permission from Zephyr International LLC. Copyright 4-1-2006
ZGS-12000-2 Fixed Hoist Test Facility (FHTF)
Used in conjunction with the
ZGS-10000-2 Mobile Rescue Hoist Ground Support
Equipment (RHGSE)
Operation and Maintenance Manual
ZGS-12000-2 FHTF
ZGS-10000-2 RHGSE
Unit Under Test (UUT)

Fixed Hoist Test Facility Operation and Maintenance Manual ZOM-12000-2 rev 0
Page 2 of 20
This manual contains proprietary information and is not to be copied or disclosed without written
permission from Zephyr International LLC. Copyright 4-1-2006
Fixed Hoist Test Facility (FHTF)
Purpose: The FHTF when used in conjunction with the Mobile Rescue Hoist Ground
Support Equipment (RHGSE) provides the capability to operate the electric BL-29900
rescue hoist off of the aircraft in order to perform intermediate level maintenance and
troubleshooting.
Description of FHTF: The FHTF consists of an upright structure, including an upper
weldment assembly, a hanging hoist mount, a chain hoist for raising and lowering the
unit under test (UUT), a load weigh system, a set of interconnecting cables, a
receptacle for three phase 400 hz power and a 28 volt power supply. The UUT control
signals are provided by a customer supplied set of controllers and pendant.
Theory of Operation: The upright structure is equipped with a chain hoist to raise
the UUT up to the top of the structure where it is attached to two load cells. The two
load cells provide signals to a load cell summing box where the signals are summed
and sent to a display. The load readout can be set to zero to tare the readout with no
load applied to the rescue hoist hook.
The wire rope tensile load is provided by the RHGSE. The RHGSE provides the
capability to extend the wire rope under approximately 100 lbs. maximum load, and
provides the capability to retract the wire rope under approximately 600 lbs. maximum
load.
The 28 volts required to control the UUT control system is provided by a power supply
mounted in the junction box. The control pendant is mounted via its connector directly
to the front of the crew control panel, and the connectors are attached according to
figure 4.
A receptacle is provided to attach the connector from the 400 Hz power cart, and a
circuit breaker is provided to switch the three phase 400 Hz power.
Electrical loads:
200 volts 3 phase 400 Hz, approximately 8 KVA protected by a 30 Amp breaker
120 volts single phase approximately 15 amps
UUT operating criteria: The UUT is rated for 600 lbs and 350 feet per minute.

Fixed Hoist Test Facility Operation and Maintenance Manual ZOM-12000-2 rev 0
Page 3 of 20
This manual contains proprietary information and is not to be copied or disclosed without written
permission from Zephyr International LLC. Copyright 4-1-2006
FHTF Limitations:
The FHTF is not intended to provide the capability to perform a complete acceptance
test as per the OEMs requirements but to allow the maintenance personnel to perform
checks of the system performance, set the hoist’s limit switches, adjust the levelwind,
and replace and condition the wire rope before the UUT is mounted onto the aircraft;
thus minimizing aircraft down time and flight time required if those procedures were
carried out on the aircraft.
System Pictures:
The Location Installation Requirements:
oShould be far from aircraft or equipment movement.
oShould be as close as possible to the AC power plug.
oWhen the system is being used it should be located away from any other
activities in the hanger, in order to prevent any injuries which might occur to the
personnel while they are focusing on the UUT and RHGSE.
Figure 1 Figure 2

Fixed Hoist Test Facility Operation and Maintenance Manual ZOM-12000-2 rev 0
Page 4 of 20
This manual contains proprietary information and is not to be copied or disclosed without written
permission from Zephyr International LLC. Copyright 4-1-2006
System Floor Plan:
Top View
Dimensions in inches
Elevation View
Figure 3

Fixed Hoist Test Facility Operation and Maintenance Manual ZOM-12000-2 rev 0
Page 5 of 20
This manual contains proprietary information and is not to be copied or disclosed without written
permission from Zephyr International LLC. Copyright 4-1-2006
System Interconnect Diagram Figure 4

Fixed Hoist Test Facility Operation and Maintenance Manual ZOM-12000-2 rev 0
Page 6 of 20
This manual contains proprietary information and is not to be copied or disclosed without written
permission from Zephyr International LLC. Copyright 4-1-2006
Assembly of FHTF:
oUnpack the crates and verify all the parts arrived in good condition.
oSlide the base plate into close proximity of its final position. Insure the floor is
clear of any debris before sliding the plate off the pallet into position.
oWith two people or a crane stand up the I beam upright
oPlace the attaching brackets into position See figure 5
oAttach all the screws.
oOnce all bolts are in place and the beam has been positioned, tighten all
bolts securely.
oAttach the two diagonal braces using the attaching clips and the angle stop as
shown in figure 6 and 7.
Attaching brackets (3)
Figure 5
Figure 6 Figure 7
Diagonal braces (2qty)
A
ttachin
g
clips
Angle stop

Fixed Hoist Test Facility Operation and Maintenance Manual ZOM-12000-2 rev 0
Page 7 of 20
This manual contains proprietary information and is not to be copied or disclosed without written
permission from Zephyr International LLC. Copyright 4-1-2006
Attach the upper weldment and hoist support as shown in figure 8, using two people or
a crane and a ladder:
oAttach the upper weldment to the upright beam
oAttach the two hoist support angles as shown.
oAttach the crane hoist with the U bolt provided and secure the upper hook of
the hoist to the hoist support angle.
oAttach the chain capture bag to the hoist and place the chain inside the bag.
Figure 8
Upper Weldment
Upright Beam
Hoist Support Angles (2qty)
Hoist Crane
Chain Capture Bag
Not shown
U Bolt
Upper Hook (of hoist)

Fixed Hoist Test Facility Operation and Maintenance Manual ZOM-12000-2 rev 0
Page 8 of 20
This manual contains proprietary information and is not to be copied or disclosed without written
permission from Zephyr International LLC. Copyright 4-1-2006
Hanging Hoist Mount
Figure 11
Lift the hanging hoist mount assembly into place and attach it to the I beam with the
adjustable cam followers provided. As shown on figure 9 and 10
Adjust the (4) adjustable cam followers so there is .002 to .005 inches clearance
between the inside face of the I-Beam and the cam follower.
Attach an extension cord to the hoist and lower the chain to
attach the hanging hoist mount. Raise the hanging hoist
mount and verify it raises and lowers smoothly with no
binding. As shown on figure 11.
Figure 9
Hanging Hoist Mount Assembly
Figure 10
Cam Followers

Fixed Hoist Test Facility Operation and Maintenance Manual ZOM-12000-2 rev 0
Page 9 of 20
This manual contains proprietary information and is not to be copied or disclosed without written
permission from Zephyr International LLC. Copyright 4-1-2006
Figure 12
Upper Pins
Load Cells (2qty)
Load Cell Summing Box
Figure 13
Lower Pins
Attach the load cells and install the upper pins as
shown in figure 12.
Install the load cell summing box and attach the load
cell as shown in drawing ZGS-12216-1. Install the load
cell readout as shown in the ZGS-12216-1 drawing
attachment.
Raise the hanging hoist mount and install the lower
pins as shown on figure 13.

Fixed Hoist Test Facility Operation and Maintenance Manual ZOM-12000-2 rev 0
Page 10 of 20
This manual contains proprietary information and is not to be copied or disclosed without written
permission from Zephyr International LLC. Copyright 4-1-2006
Control Frame
3 phase Input Power Receptacle
Figure 14
Mount the controls frame and the 3 phase input power
receptacle as shown in figure 14.
Mount the Load Cell Readout and 28 VDC power supply box as shown on figure 15.
Figure 15
Load Cell Readout and
power supply

Fixed Hoist Test Facility Operation and Maintenance Manual ZOM-12000-2 rev 0
Page 11 of 20
This manual contains proprietary information and is not to be copied or disclosed without written
permission from Zephyr International LLC. Copyright 4-1-2006
ZGS-12216-1
Load Cell Calibration
Set up and adjust the J-Box according to J-Box user Guide Section 4.2
Configure the load cell readout according to section 4 of the DP25B-S User manual.
Input type is +/- 50 mV
Set the decimal point to the default 0000
Refer to table 4.2 For Dip switch settings the range is 0-30 mV
Dip switch setting is
12345678
XOCOOXXO
Set Rd.CF R.2=2
If a 600 lbs load is available Scale the meter according to section 4.3.1.
With the UUT mounted on the hanging hoist mount with no load on it and with the
mount attached to the load cells, store the IN 1 value as the unscaled display reading
shown and set the RD 1 value to zero.
Then lower the UUT hook and attach the load and raise the 600 lbs weight until the
weight is off the ground.
Store the IN 2 reading and input the Rd 2 value as 600 lbs.
Note: This procedure can be performed with a lower or a higher load, and the Rd 2
value is then adjusted to the exact weight used. Using a value of 600 lbs insures
maximum accuracy, but is not essential.
If no known load is available. The meter can be scaled as per J-Box user Guide
section 4.3.2.
Using this method the weight of the hanging hoist mount and the UUT can be
measured, and then the readout must be set to zero (Tared) when running the UUT
under load to measure the load on the wire rope.

Fixed Hoist Test Facility Operation and Maintenance Manual ZOM-12000-2 rev 0
Page 12 of 20
This manual contains proprietary information and is not to be copied or disclosed without written
permission from Zephyr International LLC. Copyright 4-1-2006
Installing the UUT
To install the UUT the hanging hoist mount is lowered by raising the hoist
mount with the chain hoist hand control just enough to allow removing the
pins from the lower load cell clevis. Remove the pins and then lower the
hanging mount to the lower position as shown in figure 16.
Install the UUT onto the post mount and install two ¼ inch pins.
Using the hand control raise the hanging hoist mount up to reattach the two
clevis pins, then lower the chain hoist to apply all the weight to the load cells.
Mount the electrical control boxes in the opening on the frame as shown in figure 17.
Figure 16
Pilot Control Panel
Crew Control Panel
3 phase power receptacle
Load Cell Readout
28 VDC power on switch
Figure 17

Fixed Hoist Test Facility Operation and Maintenance Manual ZOM-12000-2 rev 0
Page 13 of 20
This manual contains proprietary information and is not to be copied or disclosed without written
permission from Zephyr International LLC. Copyright 4-1-2006
Attach the plug from the Ground Power Cart to the receptacle provided.
Attach the 110 V AC power
Attach the ZGS-12201-1 (figure 19) , ZGS-12202-1 (figure 20 ) and the ZGS-12203-1
(figure 21) cable assemblies,
Figure 19
3 phase breaker switch
110 VAC 60 Hz input power
Figure 18

Fixed Hoist Test Facility Operation and Maintenance Manual ZOM-12000-2 rev 0
Page 14 of 20
This manual contains proprietary information and is not to be copied or disclosed without written
permission from Zephyr International LLC. Copyright 4-1-2006
Figure 20
Figure 21

Fixed Hoist Test Facility Operation and Maintenance Manual ZOM-12000-2 rev 0
Page 15 of 20
This manual contains proprietary information and is not to be copied or disclosed without written
permission from Zephyr International LLC. Copyright 4-1-2006
System Startup Procedure
Turn on the load indicator switch and allow the indicator to start up. Depending on the
calibration method used the load indicated is either zero or is the combined weight of
the UUT and the hanging hoist mount. To zero the reading press the Tare button on
the load indicator panel and the load indicated should go to zero.
System Operating Procedure
The system is design to be operated in conjunction with the Mobile RHGSE as shown
on the cover of the manual. . ZOM-10000-2 describes the operation and maintenance
of the Mobile RHGSE in detail.
A checklist is provided to facilitate system operation, see page 16 and 17.
Test Procedures:
Test procedures are as described in the OEM’s operation. Detailed test procedures
are not included herein as they are out of the scope of this instruction manual.
System Maintenance
The connections to the UUT should be capped and stored in such a position that dirt is
not entrained into the system.
Attachments:
oElectrical Schematic ZGS-12216-1
oComponent Manuals
oCoffing Hoist Operating, Inspection and Maintenance Instructions with
parts list EMC-680
oLoad Cell Final Calibration Sheets
oLoad Cell Instruction Sheet M3000/SMB0996CRS
oLoad Cell Summing Box User’s Guide
oStrain Gage Panel Meter User’s Guide
oJWS Power Supply Information

Fixed Hoist Test Facility Operation and Maintenance Manual ZOM-12000-2 rev 0
Page 16 of 20
This manual contains proprietary information and is not to be copied or disclosed without written
permission from Zephyr International LLC. Copyright 4-1-2006
Rescue Hoist FHTF
Check List
Startup
1)Lower hanging hoist mount
2)Install hoist
a.Install electrical connectors and tighten
b.Insert (2) ¼ inch bolts or pins through one
side
3)Raise hanging hoist mount
a.Install two load bolts
b.Lower chain hoist to apply load to load cells
4)Connect Control Boxes
5)Connect Pendant
6)Move mobile GSE into position beneath hoist
7)Push Circuit Breaker Switch - on
8)Turn Indicator switch – on
a.Zero the load reading if necessary
9)Lower wire rope and hook with pendant control
10) Attach wire rope and hook to mobile GSE
11) Operate mobile GSE per instruction

Fixed Hoist Test Facility Operation and Maintenance Manual ZOM-12000-2 rev 0
Page 17 of 20
This manual contains proprietary information and is not to be copied or disclosed without written
permission from Zephyr International LLC. Copyright 4-1-2006
Shut Down
1)Remove wire rope and hook from mobile GSE
2)Raise and stow hook against hoist bell mouth
3)Turn Indicator Switch - off
4)Push Circuit Breaker Switch – off
5)Remove mobile GSE from under the rescue
hoist
6)Detach connectors from hoist
7)Detach connectors from control box- if desired
8)Detach connector for pendant – if desired
9)Lower hanging hoist mount
a.Raise chain hoist to unload load cell pins
b.Remove load cell pins
c. Lower hanging hoist assembly
10) Remove electrical cable connectors from
hoist
11) Remove hoist

Fixed Hoist Test Facility Operation and Maintenance Manual ZOM-12000-2 rev 0
Page 18 of 20
This manual contains proprietary information and is not to be copied or disclosed without written
permission from Zephyr International LLC. Copyright 4-1-2006
Moment
Diagram

Fixed Hoist Test Facility Operation and Maintenance Manual ZOM-12000-2 rev 0
Page 19 of 20
This manual contains proprietary information and is not to be copied or disclosed without written
permission from Zephyr International LLC. Copyright 4-1-2006
Assembly Drawing and major parts list
ZGS-12000-2
Illustrated Parts List

Fixed Hoist Test Facility Operation and Maintenance Manual ZOM-12000-2 rev 0
Page 20 of 20
This manual contains proprietary information and is not to be copied or disclosed without written
permission from Zephyr International LLC. Copyright 4-1-2006