Zephyr ZGS-12000-1 User manual

ZOM-12000-1 rev 0
Page1 of 15
Fixed Hoist Test Facility (FHTF)
ZGS-12000-1

ZOM-12000-1 rev 0
Page2 of 15
Fixed Hoist Test Facility (FHTF)
Purpose: The FHTF when used in conjunction with the Mobile Ground Support
Equipment (MGSE) provides the capability to operate the hydraulic 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, 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 hydraulic power supply, a 28 volt power supply, a
differential pressure measuring system and a flow measuring system. The hydraulic
supply is powered by a 230 volt 3 phase electric motor, and two boost transformers are
used to boost the facility’s 208 volts 3 phase power to 230 volts.
The UUT control signals are provided by a government supplied controller and pendant.
Theory of Operation: The FHTF provides 3000 psi hydraulic power at a maximum 6.5
gallons per minute. The hydraulic supply includes a shut off valve to bypass the flow
when the hoist is not running. The hydraulic system uses MIL-H-83282 hydraulic fluid
and includes a high pressure filter rated at 3 microns and a low pressure filter rated at 3
microns.
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 MGSE. The MGSE provides the capability
to extend the wire rope under approximately 150 lbs. maximum load, and provides the
capability to retract the wire rope under approximately 600 lbs. maximum load.
The hydraulic system includes two pressure transducers in the pressure and return lines.
The transducers provide signals to a microprocessor that displays the differential pressure
the UUT requires to lift the load. The hydraulic system is also equipped with a turbine
flow meter that provides a signal to the flow display.
The 28 volts required to control the UUT hydraulic 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 junction box, and the electrical control box is
mounted to the front of the test table. Two electrical cables couple the control box to the
junction box and the electrical controller to the hoist.
Electrical loads:
208 volts 3 phase is approximately 16 KVA requires a 125 amp line fuse
120 volts single phase approximately 15 amps

ZOM-12000-1 rev 0
Page3 of 15
UUT operating criteria: The UUT is rated for 600 lbs and 215 feet per minute when
powered with a maximum of 2650 psi differential pressure and a flow of 5.5 gallons per
minute flow.
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, adjust the
flow control and replace and season 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 Picture:
Installation Requirements:
The hydraulic supply must be blocked to sit firmly on the Upright assembly base.
The location should be out of the way of aircraft or equipment movement.
The location should be as close as possible to the 208 VAC electrical disconnect box.
Upright Assembly
Hydraulic Supply
Pendant
Electrical
control box
UUT
MGSE
Figure 1

ZOM-12000-1 rev 0
Page4 of 15
The location should be located so that when the system is being used, personnel who are
using it can not be injured from other activities in the hanger that they will not be aware
of because of their focus on the UUT and MHGSE.
System Floor Plan:
Figure 2

ZOM-12000-1 rev 0
Page5 of 15
Figure 3
Figure 4
Figure 5
Mount controller here
Attach control box cable
ZGS-12129-1 here
Attach pendant cable
here
Junctio
nBox
Installing the UUT
To install the UUT the hanging hoist mount must 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 3.
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.
Attach the hydraulic adapter fittings to the input block as
shown in figure 4. The input or pressure line is the # 6
fitting and the return or tank line is the #8 fitting.
Attach the UUT electrical cable ZGS-12128-1 to the J1
connector. The J2 connector is for the AC power to run the
hoist fan, and the fan is not required when running the hoist
on the FHTF.
Mount the electrical control box in the opening on the
control table and attach the pendant and the control box
electrical cable as shown in figure 5.
Attach the control box cable and the UUT electrical cable as shown in figure 6.

ZOM-12000-1 rev 0
Page6 of 15
Figure 6
Check to insure all lines and fittings are secure and the area is clear.

ZOM-12000-1 rev 0
Page7 of 15
Figure 7
FHTF Controls and Indicator Switches
The hydraulic drive motor start and stop switches are
on the rear of the hydraulic power supply as shown in
Figure 7.
The pressure on and off switch and the indicator
switches are as shown in Figure 8.
Pressure
On
Flow &
Delta Press
Indicator
switch
Load
Indicator
switch Figure 8
Wire Rope Load Indicator
Panel Display
Flow Indicator Panel
Display
Delta Pressure Indicator
Panel Display
Start

ZOM-12000-1 rev 0
Page8 of 15
Hydraulic System Description
The hydraulic schematic is shown in figure 9. The system is powered by a 15 hp three
phase electric motor ( items 18, 14) that is wired to operate from 230 VAC. Two boost
transformers are supplied in order to use the available 208 VAC power if required. The
electric motor drives a 6.5 gallons per minute pump (item 15). With the pressure switch
turned off the fluid is by bypassed back to tank via a shut off valve (item 7). In this way
the system pressure can be adjusted via the pressure relief valve (item 4) and the flow
from the pump checked by the turbine flow meter (item 13) before the system pressure is
applied to the UUT. The high pressure fluid is filtered by a high pressure 3 micron filter (
item 11) before it is supplied to the UUT , and the returning low pressure fluid is filtered
by a low pressure 3 micron filter (item 9) before it returns to the tank. A 65 psi check
valve (item 8) is installed before the tank to simulate the pressurized hydraulic reservoir
of the aircraft.
Pressure transducers mounted in the pressure and return lines provide signals to the delta
pressure indicator. The hydraulic tank (item 1) has a 20 gallon capacity and uses MIL-H-
83282 hydraulic fluid.
System Startup Procedure
With the hydraulic lines installed and all fittings tightened, turn on the hydraulic supply
drive motor by pressing the start switch as shown in figure 7.
Turn on the Flow and Delta Pressure indicators and allow the indicators to start up. The
Flow indicator should show approximately 7 gallons per minute and the delta pressure
indicators should be showing a pressure of zero. The pressure gages on the power supply
should be indicating 65 psi.
Turn on the load indicator switch and allow the indicator to start up. The load indicated is
the combined weight of the UUT and the hanging hoist mount. Press the Tare button on
the load indicator panel and the load indicated should be zero.
Turn on the pressure on switch, this closes the shut off valve bypass and applies system
pressure to the UUT. Adjust the pressure relief valve to achieve 3000 psi on the pressure
gage.
System Operating Procedure
Figure 9

ZOM-12000-1 rev 0
Page9 of 15
System Operating Procedure
The system is design to be operated in conjunction with the Mobile RHGSE as shown in
figure 1. ZOM-10000-2 describes the operation and maintenance of the MRHGSE in
detail.
Test Procedures: Test procedures are as described in the OEM’s operation manuals and
also in A1-489QA-MDB-000 latest revision. Detailed test procedures are not included
herein as they are out of the scope of this instruction manual.
Detailed test procedures can be provided.
System Maintenance
The hydraulic fluid filters include pop up indicators. The filters should be changed as
required based on the pop up indicator positions.
The connections to the UUT should be capped and stored in such a position that dirt is
not entrained into the system. The system is not equipped with QD fittings due to the
possibility of the QD on the return line not being seated and the hydraulic heat exchanger
on the UUT being damaged.
The guide track on the upright beam should be lubricated with white lithium grease as
required to insure low friction at the hanging hoist mount interface.
Electrical Schematics
ZGS-12132-1 Junction Box Schematic
ZGS-12135-1 Hydraulic Supply Control Schematic
Component Manuals
Coffing Hoist Operating, Inspection and Maintenance Instructions with parts list EMC-
680
Load Cell Final Calibration Sheets
Load Cell Instruction Sheet M3000/SMB0996CRS
Load Cell Summing Box User’s Guide
Strain Gage Panel Meter User’s Guide
Hydac Display unit Operators Manual
Hydac pressure transmitter spec sheet
HAD 5500 Quick Setup instructions
Turbine Flow Sensors Bulletin #200
F5140K-Factor Scaler spec sheet
Signal Wiring for the F6600/F6700 Series Readouts FLIT 553
Flo-Tech Digital Display Spec Sheet

ZOM-12000-1 rev 0
Page10 of 15
Assembly Drawing and major parts list
ZGS-12000-1

ZOM-12000-1 rev 0
Page11 of 15

ZOM-12000-1 rev 0
Page12 of 15

ZOM-12000-1 rev 0
Page13 of 15

ZOM-12000-1 rev 0
Page14 of 15

ZOM-12000-1 rev 0
Page15 of 15