Zephyr ZGS-11000-2 v2, Operation And Maintenance Manual

Page 1: ...e Manual ZOM 11000 2 v2 rev E Zephyr International llc Page 1 of 40 United States Patent 7 429 031 B1 Rescue Hoist Ground Support Equipment Manually Operated ZGS 11000 2 v2 Operation and Maintenance Manual United States Patent 7 429 031 B1 ...

Page 2: ...nt 3 3 0 Unpacking the Equipment 4 4 0 Setup the Equipment 4 5 0 Theory of Operation 7 6 0 Operation of the Equipment 8 7 0 Maintenance of the RHGSE 20 8 0 Replacement Parts List 29 9 0 Illustrated Parts Breakdown 33 10 0 Technical Assistance 40 Before operation of the Ground Support Equipment thoroughly review the entire manual in order to prevent damage to the wire rope hoist helicopter or opera...

Page 3: ...m Allows one person to perform all inspections and maintenance operations in a minimum amount of time Maintains positive manual tension on the wire rope as it extends and applies a heavy load over the length as it retracts while protecting the wire rope in a rotating tub during hoist maintenance Accommodates any rescue hook and bumper configuration Cleans and dries the wire rope during post flight...

Page 4: ... R and using the front cover as a ramp Remove the screws that hold the wheel chock blocks Pull the pin and using the handle pull the RHGSE out of the box and down the ramp Check to insure 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 Lubridryer upright bracket and the can of Lubridry...

Page 5: ...11000 2 v2 rev E Zephyr International llc Page 5 of 40 United States Patent 7 429 031 B1 Assemble the Lubridryer assembly to the upright bracket Assemble the load indicator holder to the upright bracket Upright bracket Lubridryer Load Indicator Holder ...

Page 6: ...d 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 Load indicator holder ...

Page 7: ...elf 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 wire rope and provides lubrication via an oil reservoir if required the flow of oil from the reservoir can be started and stopped ...

Page 8: ... use The RHGSE operation requires Attaching the wire rope 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 wire rope in the down mode Setting and adjusting the clutch and operating the hoist in the up mode while o...

Page 9: ...pstans Wrap the wire rope around the capstans three times starting with the lower capstan innermost groove as shown while insuring the rope is pulled tight into the capstan grooves Start wrapping the cable in the first groove of the lower capstan Open the capstan cover and pay out approximately 16 feet of wire rope off of the helicopter hoist Open the Lubridryer by flipping the latch up and openin...

Page 10: ... Maintenance Manual ZOM 11000 2 v2 rev E Zephyr International llc Page 10 of 40 United States Patent 7 429 031 B1 Wrap around the first groove Wrap around the second groove Wrap around the third groove Close the Lubridryer cover ...

Page 11: ...edded in the grooves of the capstans Caution If the wire rope is not wrapped tightly around the capstans it may loosen up and come off the capstans Caution Insure the lower and the upper tensioner rollers are engaged when extending the cable Guide the wire rope 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 o...

Page 12: ...ue hoist to place the wire rope 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 Insure 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 insure the wire rope is loosely sit...

Page 13: ...tates Patent 7 429 031 B1 Engage and rotate handle clockwise to take up wire rope in down direction 6 6 Running the rescue hoist in the down direction extending Before extending verify the wire rope is properly installed on the RHGSE the wire rope is wrapped tight on the capstans and the cover is closed and latched ...

Page 14: ... 7 Running the rescue hoist in the up direction retracting Caution When starting to reel in the load lever must not be fully applied with the load adjusted to the maximum this is because the coefficient of static friction is greater then the coefficient of dynamic friction If the load lever is fully activated before starting the RHGSE will be lifted off of the ground and may cause damage to the ho...

Page 15: ...ion 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 580 lbs 264 kg when it is dry it will start to lift off the ground at approximately 580 lbs 264 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 t...

Page 16: ...e swivels once the wheels have be 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 Note When 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 fle...

Page 17: ...remove the plug at the bottom and drain into an approved drain If shop air is unavailable and the onboard compressor is not installed remove the water and dry out the Rotatub extend the cable into the empty tub and let dry Retract the wire rope onto the helicopter hoist with the load lever applied using a gloved hand and a clean cloth to dry the wire rope The Lubridryer includes a reservoir that c...

Page 18: ... 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 wire rope from the RHGSE 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 wire rope Unwrap the wire rope from the capstans and carefull...

Page 19: ...e wrapping of the wire rope to insure the wire rope stays tight on the capstans 6 16 Removing the wire rope from the hoist The RHGSE can coil the wire rope for removal and disposal Run the wire rope 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 wire rope can be removed from the hoist Dis...

Page 20: ...nstallation of a new wire rope Attach the ZGS 10454 1 Cable Reel Extension with its pin as shown Slide the shipping reel on the extension and attach the wire rope following the OEMs instructions The adapter can be used with both major OEM s cable shipping reels Once the wire rope is completely on the rescue hoist remove the cable reel and cable reel extension and run the wire rope on and off the h...

Page 21: ...trands The loose strands may disappear temporarily but will soon return as soon as the cable is extended with no load on it Cable conditioning should be done with a low load and at slow speed while gradually increasing the load up to the rated load Always extend with a low load of approximately 25 lbs and at a max speed of 100 feet per minute in either direction Perform 3 cycles Extend at 25 lbs a...

Page 22: ...he clutch has been preset at Zephyr to approximately 100 lbs If a high load is desired then make small clockwise adjustments until the empty RHGSE starts to lift When the RHGSE starts to lift the load in the wire rope is approximately 580 lbs To reduce the load turn the load adjuster counter clockwise Check operation in the retract mode 7 4 Clutch removal and replacement It is only required to rem...

Page 23: ...ation and Maintenance Manual ZOM 11000 2 v2 rev E Zephyr International llc Page 23 of 40 United States Patent 7 429 031 B1 Load adjuster Pivot bolt Clutch band Load cell clevis pin Load Clutch assembly shown Cotter pin ...

Page 24: ...ion and Maintenance Manual ZOM 11000 2 v2 rev E Zephyr International llc Page 24 of 40 United States Patent 7 429 031 B1 Load Cell Assembly Remove these bolts to remove load cell assembly Do not loosen or adjust this bolt ...

Page 25: ...nlatching 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 7 7 Capstan drive chain oiling Once a week and depending on usage drip a few drops of turbine oil ...

Page 26: ...o threaded rods To make any adjustments to the chain or vertical drive belt it requires the loosening and adjusting all of the ten 10 nuts from the top of the upright assembly down When making adjustments always loosen the large nuts on the threaded rod from the top down and then tighten from the bottom up while checking the belt or chain for proper tension Insure the upright components are square...

Page 27: ...ower vertical belt cover Adjust the lower capstan head upwards to obtain approximately 1 8 inch deflection with a light hand force 7 11 Vertical drive belt replacement Lower the lower capstan head enough that the vertical drive belt can be removed and replaced 7 12 Drum drive belt adjustment Loosen the two screws located underneath the base which hold the Anglegear assembly to the base Turn the dr...

Page 28: ...m speed which is the same speed as it is coming off the capstans As the cable starts to climb up on the spooler it starts to slow down due to the reduced diameter But the Rotatub must actually go faster in order to collect the cable and not allow it to back up in the Rotatub Therefore the clutch is slipping the most when the cable is at the bottom of the spooler If the clutch does not slip properl...

Page 29: ...ey do not abrade on each other under load and they do not tend to unwrap under load If the preforming and balancing is incorrect the cable will loosen up prematurely Effect of cable lubrication When a cable is new the internal spaces between the wires are full of the lubricant that is used to draw them down to size One rescue hoist manufacturer removes the external lubrication and the other does n...

Page 30: ...rect diameter is required There are several capstans available for the different size cables in use It is important to use the correct style capstans for the type of cable being serviced The following table lists the relevant dimensions for each capstan style Cable Diameter Lower Capstan Part number Measurement Pin diameter Minimum dimension over pin 3 16 inch ZGS 10113 20 1 185 6 745 in 4 5 mm ZG...

Page 31: ...nd If the display is not close to the weight marked on the base the display can be adjusted by turning the span screw on the display face Turning the span screw clockwise increases the displayed reading and counter clockwise decreases the displayed reading Once the maximum load span is adjusted then the zero displayed reading should be rechecked This is accomplished by moving the load lever to the...

Page 32: ...Spoolers ZGS 10022 1 Rotatub 1 ZGS 11134 1 Cable Spooler EC Hook 1 ZGS 10357 1 Cable Spooler Basic 1 ZGS 10149 1 Rotatub Plug Set of 5 Handles ZGS 11240 1 Manual Handcrank Bearing Assembly 1 ZGS 10111 1 Tow Handle 1 ZGS 11242 1 Tow Handle Quick Release Pin 1 Load Indicators ZGS 11099 2 Load Cell 1 ZGS 11100 2 Load Cell Indicator Display 1 Lubridryer ZGS 10126 1 Lubridryer Bushings Set of 2 ZGS 101...

Page 33: ...Manual RHGSE Operation and Maintenance Manual ZOM 11000 2 v2 rev E Zephyr International llc Page 33 of 40 United States Patent 7 429 031 B1 9 0 Illustrated Parts Breakdown ...

Page 34: ...Manual RHGSE Operation and Maintenance Manual ZOM 11000 2 v2 rev E Zephyr International llc Page 34 of 40 United States Patent 7 429 031 B1 ...

Page 35: ...Manual RHGSE Operation and Maintenance Manual ZOM 11000 2 v2 rev E Zephyr International llc Page 35 of 40 United States Patent 7 429 031 B1 ...

Page 36: ...Manual RHGSE Operation and Maintenance Manual ZOM 11000 2 v2 rev E Zephyr International llc Page 36 of 40 United States Patent 7 429 031 B1 ...

Page 37: ...Manual RHGSE Operation and Maintenance Manual ZOM 11000 2 v2 rev E Zephyr International llc Page 37 of 40 United States Patent 7 429 031 B1 ...

Page 38: ...Manual RHGSE Operation and Maintenance Manual ZOM 11000 2 v2 rev E Zephyr International llc Page 38 of 40 United States Patent 7 429 031 B1 ...

Page 39: ...Manual RHGSE Operation and Maintenance Manual ZOM 11000 2 v2 rev E Zephyr International llc Page 39 of 40 United States Patent 7 429 031 B1 ...

Page 40: ...l ZOM 11000 2 v2 rev E Zephyr International llc Page 40 of 40 United States Patent 7 429 031 B1 10 0 Technical Assistance Please contact Zephyr International LLC with any questions 1 843 365 2675 Send comments or suggestions to zephyrintl rcn com ...