Zephyr ZGS-12000-4 User manual

Fixed Hoist Test Facility Operation and Maintenance Manual ZOM-12000-4 rev 0
Page 1 of 33
This manual contains proprietary information and is not to be copied or disclosed without written
permission from Zephyr International LLC. Copyright 10-2-2006
ZGS-12000-4 Fixed Hoist Test Facility (FHTF)
Used in conjunction with the
ZGS-10000-2 Mobile Rescue Hoist Ground Support
Equipment (RHGSE)
Operation and Maintenance Manual
Fi
g
ure 1

Fixed Hoist Test Facility Operation and Maintenance Manual ZOM-12000-4 rev 0
Page 2 of 33
This manual contains proprietary information and is not to be copied or disclosed without written
permission from Zephyr International LLC. Copyright 10-2-2006
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 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), and a load weigh system. The UUT power and control signals
are provided by a customer supplied set of controllers and pendant and power supply.
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.
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.
Modifications to achieve full ATP capability
The FHTF has been supplied as requested without an auxiliary hydraulic power
supply, however with some modifications the FHTF and the RHGSE can be upgraded
to perform a complete ATP of the UUT. Please contact Zephyr International LLC for
details.

Fixed Hoist Test Facility Operation and Maintenance Manual ZOM-12000-4 rev 0
Page 3 of 33
This manual contains proprietary information and is not to be copied or disclosed without written
permission from Zephyr International LLC. Copyright 10-2-2006
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.
oShould 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 2

Fixed Hoist Test Facility Operation and Maintenance Manual ZOM-12000-4 rev 0
Page 4 of 33
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permission from Zephyr International LLC. Copyright 10-2-2006
System Floor Plan:
Figure 3

Fixed Hoist Test Facility Operation and Maintenance Manual ZOM-12000-4 rev 0
Page 5 of 33
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permission from Zephyr International LLC. Copyright 10-2-2006
System Interconnect Diagram -NA Interconnecting cables are to be provided
by Goodrich
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 4
oAttach all the bolts.
oOnce all bolts are in place and the beam has been positioned, tighten all
bolts securely.
oAttach the lower diagonal mounts as shown in figure 5.
Figure 5
Figure 4

Fixed Hoist Test Facility Operation and Maintenance Manual ZOM-12000-4 rev 0
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permission from Zephyr International LLC. Copyright 10-2-2006
Attach the upper diagonal mount and then the diagonal mounts as shown in figure 6.
Attach the upper hoist mount weldment and the chain hoist support brackets as shown
in figure 7.
Figure 7
Figure 6

Fixed Hoist Test Facility Operation and Maintenance Manual ZOM-12000-4 rev 0
Page 7 of 33
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permission from Zephyr International LLC. Copyright 10-2-2006
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.
Attach the lower stop bracket to the I beam to support the slider assembly.
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-12000-4 rev 0
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permission from Zephyr International LLC. Copyright 10-2-2006
Attach the slider assembly using the fixed and adjustable cam follower rollers as
shown in figure 9.
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.
Lift the hanging hoist mount assembly into place and attach it to the slider assembly
with the Pins as shown in Figure 11.
Figure 10
Cam Followers
Fixed Follower Eccentric Follower
Fi
g
ure 9

Fixed Hoist Test Facility Operation and Maintenance Manual ZOM-12000-4 rev 0
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permission from Zephyr International LLC. Copyright 10-2-2006
Hanging Hoist Mount
Figure 12
Raise the hanging hoist mount and slider assembly and
verify it raises and lowers smoothly with no binding. As
shown on figure 12.
Figure 11

Fixed Hoist Test Facility Operation and Maintenance Manual ZOM-12000-4 rev 0
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This manual contains proprietary information and is not to be copied or disclosed without written
permission from Zephyr International LLC. Copyright 10-2-2006
Attach the load cells and install the upper pins as shown in figure 13. Use a level to
adjust the rod ends such that the hanging mount assembly is level.
Install the load cell summing box and wire the load cells as shown in drawing ZGS-
12340-1.
Figure 13
Figure 14

Fixed Hoist Test Facility Operation and Maintenance Manual ZOM-12000-4 rev 0
Page 11 of 33
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permission from Zephyr International LLC. Copyright 10-2-2006
Install the load cell readout as shown.
Note: Relay sockets and relays have been provided in the event Goodrich wants to
utilize remote operation in the future. See drawing ZGS-12340-1.
Raise the hanging hoist mount and install
the lower pins as shown on figure 13.
Attach the UUT ( External Hoist)
With the hanging hoist support in the lower
position, carefully fit the UUT to the post
mount.
Use two ¼ inch pins to locate the hoist on
the post.
Figure 15
Figure 16

Fixed Hoist Test Facility Operation and Maintenance Manual ZOM-12000-4 rev 0
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permission from Zephyr International LLC. Copyright 10-2-2006
Raise the UUT into test Position
Using the chain hoist pendant raise the
hanging hoist mount until the load cell pins
can be inserted. Jog the chain hoist up and
down in order to engage both pins. Insert
the retaining pins and lower the chain hoist
to allow the load to be taken fully by the
load cells.
Internal Hoist Mount
The internal Hoist is attached to the slider
assembly via the two hoist mount pins as
shown in figure 18.
Figure 17
Pins
Figure 18

Fixed Hoist Test Facility Operation and Maintenance Manual ZOM-12000-4 rev 0
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permission from Zephyr International LLC. Copyright 10-2-2006
The internal hoist mount is deigned to
nest on the internal hoist dolly to facilitate
moving the internal hoist around.
The internal hoist reaction arm must be
in the number 2 position to allow
installation onto the internal hoist mount.
Figure 19
Figure 20
Reaction Arm in
# 2 position

Fixed Hoist Test Facility Operation and Maintenance Manual ZOM-12000-4 rev 0
Page 14 of 33
This manual contains proprietary information and is not to be copied or disclosed without written
permission from Zephyr International LLC. Copyright 10-2-2006
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 0-100 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
COCOOCCO
C= closed
O= open
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 input as 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-12000-4 rev 0
Page 15 of 33
This manual contains proprietary information and is not to be copied or disclosed without written
permission from Zephyr International LLC. Copyright 10-2-2006
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 designed 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-12340-1
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

Fixed Hoist Test Facility Operation and Maintenance Manual ZOM-12000-4 rev 0
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permission from Zephyr International LLC. Copyright 10-2-2006
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-12000-4 rev 0
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permission from Zephyr International LLC. Copyright 10-2-2006
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-12000-4 rev 0
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permission from Zephyr International LLC. Copyright 10-2-2006
Moment Diagram
Worst Case is with the internal hoist mount and no auxiliary power supply sitting on
base.
The FHTF must be either bolted to the floor or ballast added to the base plate in order
to apply 600 lbs to the wire rope on an internal hoist.
9.7 in
1380 lbs
38.25 in
350 lbs max
Fi
g
ure 21

Fixed Hoist Test Facility Operation and Maintenance Manual ZOM-12000-4 rev 0
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permission from Zephyr International LLC. Copyright 10-2-2006
11.7 in
12.5 in
1323 lbs
1245 lbs max

Fixed Hoist Test Facility Operation and Maintenance Manual ZOM-12000-4 rev 0
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permission from Zephyr International LLC. Copyright 10-2-2006
Modifications required for continuous FHTF and RHGSE Operations
Because the RHGSE is designed for flight line use it is powered by batteries. The
batteries will provide between 6 and 10 full length extension and retractions of the wire
rope. In order to achieve continuous operation an auxiliary hydraulic power supply is
required as shown in Figure 22, 23 and 24.
Fi
g
ure 22 Figure 23
Figure 24
Connector required
to apply 24 Volts to
coils in manifold