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Zephyr ZGS-10000-5 Operation And Maintenance Manual Download Page 14

Fixed Hoist Test Facility Operation and Maintenance Manual 

ZOM-12000-7 rev 0 

 

Page 14 of 24 

 This manual contains proprietary information and is not to be copied or disclosed without written 
permission from Zephyr International LLC.   Copyright 2006-2008 

Controls Frame 

3 Phase input power receptacle 

Load Cell Readout and 28 
VDC power Box 

 

o

  Mount the controls frame and the 3 phase input power receptacle as shown. 

 
 
 
 
 
 
 
 
 

 

 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 

o

  Mount the Load Cell Readout and 28 VDC power supply box as shown. 

 

o

  Open up the summing box and attach the load cells and the summing box 

output to the load meter readout as per ZGS-12216-2. 

 
 
 
 
 
 
 
 
 
 
 
 
 
 

Summary of Contents for ZGS-10000-5

Page 1: ...ins proprietary information and is not to be copied or disclosed without written permission from Zephyr International LLC Copyright 2006 2008 ZGS 12000 7 Fixed Hoist Test Facility FHTF Used in conjunction with the ZGS 10000 5 Mobile Rescue Hoist Ground Support Equipment RHGSE Operation and Maintenance Manual ...

Page 2: ...sclosed without written permission from Zephyr International LLC Copyright 2006 2008 Table of Contents Fixed Hoist Test Facility FHTF 3 System Floor Plan 5 System Interconnect Diagram 6 Assembly of FHTF 7 Load Cell Calibration 16 System Procedures 20 Rescue Hoist FHTF Check List 21 Startup 21 Shut Down 22 Moment Diagram 23 Assembly Drawing and Major Parts List 24 ...

Page 3: ...d 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 ca...

Page 4: ... 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 o Should be far from aircraft or equipment movement o Should be as close...

Page 5: ...ual ZOM 12000 7 rev 0 Page 5 of 24 This manual contains proprietary information and is not to be copied or disclosed without written permission from Zephyr International LLC Copyright 2006 2008 System Floor Plan Top View Dimensions in inches Elevation View ...

Page 6: ...nd Maintenance Manual ZOM 12000 7 rev 0 Page 6 of 24 This manual contains proprietary information and is not to be copied or disclosed without written permission from Zephyr International LLC Copyright 2006 2008 System Interconnect Diagram ...

Page 7: ...ritten permission from Zephyr International LLC Copyright 2006 2008 Assembly of FHTF o Unpack the crates and verify all the parts arrived in good condition o Use a forklift and lift the base weldment off the pallet and place it close to its final position o Attach the base attachment angles to the I Beam using the labels to align each bracket properly Base Attachment Angles I Beam ...

Page 8: ...prietary information and is not to be copied or disclosed without written permission from Zephyr International LLC Copyright 2006 2008 o Locate the upper brace mount and attach it to the I beam with its fasteners o Attach the load cell summing box to the I beam Load Cell Summing Box Upper Brace Mount I Beam I Beam ...

Page 9: ...oprietary information and is not to be copied or disclosed without written permission from Zephyr International LLC Copyright 2006 2008 o Flip the I beam over and attach the Hoist Hanging Weldment to it o Use the beveled washers on the back surface of the beam flange as shown Hoist Hanging Weldment Beveled Washers ...

Page 10: ...anual contains proprietary information and is not to be copied or disclosed without written permission from Zephyr International LLC Copyright 2006 2008 o With two people or a crane stand up the I beam upright o Place the attaching brackets into position and attach all the screws Attaching brackets ...

Page 11: ...national LLC Copyright 2006 2008 o Place the lower brace corner mount into position and loosely attach the brackets with one bolt in each corner Identify the left and right diagonal braces and mount them between the lower and the upper braces loosely Once all the holes have been lined up and the bolts inserted then tighten all the bolts securely Left Right Diagonal Braces Upper Brace Mount Lower B...

Page 12: ... chain hoist support to the top of the hoist hanging weldment o Then attach the chain hoist with the chain cover facing outwards o Tighten the nuts on the u bolts securely to prevent the chain hoist from escaping the u bolt o Install the S shaped load cells to the upper clevis mounts o Attach the hitch pins to prevent the clevis pins from escaping the clevis mounts Chain Hoist Chain Hoist Support ...

Page 13: ...ain hoist and lower the hook to allow the hanging hoist mount to be attached o Using the chain hoist control lift the hanging hoist mount up so it can be attached to the slider assembly with its two pins o Insert the hitch pin retainer pins into the slider assembly pins o Using the chain hoist raise the hanging hoist mount and slider upwards o Engage the lower tie rod ends of the load cell assembl...

Page 14: ... from Zephyr International LLC Copyright 2006 2008 Controls Frame 3 Phase input power receptacle Load Cell Readout and 28 VDC power Box o Mount the controls frame and the 3 phase input power receptacle as shown o Mount the Load Cell Readout and 28 VDC power supply box as shown o Open up the summing box and attach the load cells and the summing box output to the load meter readout as per ZGS 12216 ...

Page 15: ...of 24 This manual contains proprietary information and is not to be copied or disclosed without written permission from Zephyr International LLC Copyright 2006 2008 Locate the FHTF in its final position and bolt the base to the floor if desired with the floor attachment angles provided ...

Page 16: ...Dip switch setting is 12345678 COCOOCOO Set Rd CF R 2 1 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 w...

Page 17: ... just enough to allow removing the pins from the lower load cell clevis o Remove the pins and then lower the hanging mount to the lower position as shown o Install the UUT onto the post mount and install two inch pins o 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 o Mount the electrical ...

Page 18: ...or disclosed without written permission from Zephyr International LLC Copyright 2006 2008 Attach the plug from the Ground Power Cart to the receptacle provided o Attach the 220 V AC power o Attach the ZGS 12201 1 ZGS 12202 1 and the ZGS 12203 1 cable assemblies ZGS 12201 1 High Speed Hoist Test Stand Main Cable 3 phase breaker switch 220 VAC 50 Hz input power ...

Page 19: ...M 12000 7 rev 0 Page 19 of 24 This manual contains proprietary information and is not to be copied or disclosed without written permission from Zephyr International LLC Copyright 2006 2008 ZGS 12203 1 28 VDC Input Power Cable ZGS 12202 1 3 Phase Power Input Cable ...

Page 20: ...ated 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 5 describes the operation and maintenance of the Mobile RHGSE in detail A checklist is provided to facilitate system operation see page 21 and 22 Test Procedures Test procedures are as described in the OEM s operation and maintenan...

Page 21: ...Install hoist a Install electrical connectors and tighten b Insert 2 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 w...

Page 22: ...e 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 cel...

Page 23: ...tion and Maintenance Manual ZOM 12000 7 rev 0 Page 23 of 24 This manual contains proprietary information and is not to be copied or disclosed without written permission from Zephyr International LLC Copyright 2006 2008 Moment Diagram ...

Page 24: ...OM 12000 7 rev 0 Page 24 of 24 This manual contains proprietary information and is not to be copied or disclosed without written permission from Zephyr International LLC Copyright 2006 2008 Assembly Drawing and Major Parts List ZGS 12000 7 Illustrated Parts List ...

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