Attachment 1 - Component Maintenance Manual.pdf

CGTO 1H-65A-11-401100TP-6

TECHNICAL ORDER PAGE SUPPLEMENT

COMPONENT MAINTENANCE MANUAL

WITH ILLUSTRATED PARTS LIST

HOIST CONTROL SYSTEM

PART NUMBER. 80-25002-003-NVG

ELECTROSPACE SYSTEMS INC.

THIS TOPS SUPPLEMENTS CGTO 1H-65A-11-401100 DATED 25 OCTOBER 1983

THROUGH CHANGE 3 DATED 27 FEBRUARY 1987.

THIS TOPS SUPERSEDES 40-11-00 PAGE 1024 FROM CGTO 1H-65A-11-401100TP-5. REMOVE AND

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PUBLISHED UNDER THE AUTHORITY OF THE COMMANDANT OF THE U.S. COAST GUARD AND

UNDER THE DIRECTION OF THE CHIEF, OFFICE OF ENGINEERING, U.S. COAST GUARD

DISTRIBUTION STATEMENT D: Distribution authorized to the DHS/CG/DoD and their contractors for Administrative or Operational use, 31 July 2019. Other requests shall be referred to Aviation Logistics Center (ALC), Short Range Recovery (H-65) Technical Services.

WARNING: This document contains technical data whose export is restricted by the Arms Export Control Act (Title 22, U.S.C., Sec 2751, et.

Seq.) or the Export Administration Act of 1979, as amended, Title 50, U.S.C., App. 2401 et. Seq. Violations of these export laws are subject to severe criminal penalties. Disseminate in accordance with provisions of DoD Directive 5230.25.

DESTRUCTION NOTICE: For classified documents, follow the procedures in DoD 5200.22-M, National Industrial Security Program

Operating Manual, Section 5-705 or DoD 5200.1-R, information Security Program Regulation, Chapter VI, Section 7. For unclassified, limited documents, destroy by any method that will prevent disclosure of contents or reconstruction of the document.

31 July 2019

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CGTO 1H-65A-11-401100TP-5

TECHNICAL ORDER PAGE SUPPLEMENT

COMPONENT MAINTENANCE MANUAL

WITH ILLUSTRATED PARTS LIST

HOIST CONTROL SYSTEM

PART NO. 80-25002-003-NVG

THIS TOPS SUPPLEMENTS CGTO 1H-65A-11-401100 DATED 25 OCTOBER 1983

THROUGH CHANGE 3 DATED 27 FEB 1987.

NOTE: IF TECHNICAL MANUAL 1H-65A-11-401100 IS REVISED, DO NOT DISPOSE OF TOPS BEFORE

CONTACTING ALC TECHNICAL PUBLICATONS BRANCH, ELIZABETH CITY, NC.

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DESTROY TP-2, TP-3, AND TP-4 AND REPLACE WITH TP-5. THE ONLY ACTIVE TOPS FOR

CGTO 1H-65A-11-401100 IS TP-5.

PUBLISHED UNDER THE AUTHORITY OF THE COMMANDANT OF THE U.S. COAST GUARD AND

UNDER THE DIRECTION OF THE CHIEF, OFFICE OF ENGINEERING, U.S. COAST GUARD

DISTRIBUTION STATEMENT D: Distribution authorized to the DHS/CG/DoD and their contractors; Administrative or Operational Use, 5 July 2011. Other request shall be referred to Aviation Logistics Center (ALC), Short Range Recovery (H-65) Technical Services.

WARNING: This document contains technical data whose export is restricted by the Arms Export Control Act (Title 22, U.S.C., Sec 2751, et.

Seq.) or the Export Administration Act of 1979, as amended, Title 50, U.S.C., App. 2401 et. Seq. Violations of these export laws are subject to severe criminal penalties. Disseminate in accordance with provisions of DoD Directive 5230.25.

DESTRUCTION NOTICE: For classified documents, follow the procedures in DoD 5200.22-M, National Industrial Security Program Operating Manual, Section 5-705 or DoD 5200.1-R, information Security Program Regulation, Chapter VI, Section 7. For unclassified, limited documents, destroy by any method that will prevent disclosure of contents or reconstruction of the document.

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CGTO 1H-65A-11-401100

TECHNICAL MANUAL

COMPONENT MAINTENANCE MANUAL

WITH

ILLUSTRATED PARTS LIST

HOIST CONTROL SYSTEM

P/N: 80-25001-001

ELECTROSPACE SYSTEM

BASIC AND ALL REVISIONS

DISTRIBUTION STATEMENT D - Distribution authorized to the DHS/CG/DoD and their contractors for Administrative or Operational use, 27 February 1987. Other requests shall be referred to Short Range Recovery (SRR) Technical Services.

WARNING – The content of this document is the property of ELECTROSPACE SYSTEMS INC. It is supplied in confidence and commercial security on its contents must be maintained. It must not be used for any purpose other than for which it is supplied, nor may information contained in it be disclosed to unauthorized persons. It must not be reproduced in whole or in part without permission in writing from

ELECTROSPACE SYSTEMS INC.

HANDLING AND DESTRUCTION NOTICE – Comply with distribution statement and destroy by any method that will prevent disclosure of the contents or reconstruction of the document.

25 OCTOBER 1983 CHANGE 03 – 27 FEBRUARY 1987

BMJones1 TOPS 6 Cover

TOPS 5 Cover

This TOPS page updates the cover page.

HOIST CONTROL SYSTEM

PART NO. 80-25002-003-NVG

COMPONENT MAINTENANCE MANUAL

WITH

ILLUSTRATED PARTS LIST

40-11-00

ORIGINAL ISSUE:

CHANGE 1:

CHANGE 2:

CHANGE 3:

USCGT.O.1H-65A-11-401100

ELECTROSPACE SYSTEMS INC.

COMPONENT MAINTENANCE

HOIST CONTROL SYSTEM PART NO. 80-25001-001

OCT 25/63

JUN 21/65

JUN 01/86

FEB 27/87

HOIST CONTROL SYSTEM

PART NO. 80-25001-001

COMPONENT MAINTENANCE MANUAL

WITH

ILLUSTRATED PARTS LIST

40-11-00

SEE CG TOPS 5 ON

PREVIOUS PAGE

AEROSPATIALE HELICOPTER CORPORATION

SUBJECT: USCG T.O. IH-65A-11-401100

HOIST CONTROL SYSTEM

TO: Manual Holders

INSTRUCTION:

DATE: 9 November 1988

FILE: AHC/TDS/88M-234

Accomplish the following "pen and ink" changes to Figure 9 located on page 17 of DESCRIPTION AND OPERATION:

1. On P9 and P2 of the Boom Control Circuit, change pin designation "A" to "B".

2. On P9 and P2, change pin "B" to "A".

ElECTROSPACE SYSTEMS INC.

HOIST CONTROL SYSTEM PART NO. 80-25001;

Subject

INTRODUCTION

DESCRI~TION AND OPERATION

General Description Operation

TESTING AND TROUBLESHOOTING

General Test Procedures Troubleshooting Procedures

DISASSEMBLY

General Disassembly Procedures

CLEANING

General Cleaning Procedure

INSPECTION AND CHECK

General Inspection and Check

REPAIR

General Component Replacement

TABLE OF CONTENTS

1/2

40-11-00

CONTENTS

Oct 25/83

ELECTROSPACE SYSTEMS INC.

HOIST CONTROL SYSTEM PART NO. 80-25001-001

TABLE OF CONTENTS - Continued

Subject

ASSEMBLY AND STORAGE

General Assembly Storage Special Handling Packing

SPECIAL TOOLS, FIXTURES AND EQUIPMENT

General Special Tools Special Fixtures and Test Equipment

ILLUSTRATED PARTS LIST

INTRODUCTION

General Detailed Parts List (DPL) Alphanumeric and Numeric Index

Alphanumeric List of Parts Detailed Parts List

INTRO 1001

INTRO 1001

INTRO 1001

NI ALPHA NUM 1001

40-11-00

CONTENTS

PaS1;e 2

SEE CG TOPS 5

ON NEXT PAGE

This TOPS page reflects the removal of the panel doors.

HOIST CONTROL PANEL

Hoist Control System Figure 1

40-11-00

1. General

COMPONENT MAINTENANCE MANUAL

HOIST CONTROL SYSTEM PART NO. 80-25001-001

INTRODUCTION

A. This manual is prepared in accordance with the requirements of Air Transport Association (ATA) Specification No. 100.

B. The manual provides maintenance instructions for the Hoist Control System part number 80-25001-001 supplied by Electrospace Systems, Inc., Richardson, Texas. The hoist control system consists of the hoist control panel part number 80-25002-003, pendant assembly part number EM-Y0024-00l and the pendant cable assembly part number 80-25003-001.

2. Presentation

A. The manual is divided into subsections, which contain page numbering as follows:

1-100 - DESCRIPTION AND OPERATION

101-200 - TESTING AND TROUBLESHOOTING

201-300 - UNASSIGNED

301-400 - DISASSEMBLY

401-500 - CLEANING

501-600 - INSPECTION AND CHECK

601-700 - REPAIR

701-800 - ASSEMBLY AND STORAGE

801-900 - FITS AND TOLERANCES - NOT REQUIRED

901-1000 - SPECIAL TOOLS, FIXTURES AND EQUIPMENT

1001-1100 - ILLUSTRATED PARTS LIST

B. The following publications contain supplemental information or in structions related to components within the hoist control panel and are referenced in the text of this manual:

PUBLICATION

NUMBER

USCG

T.O. IH-65A-11-40-11-01

NAVAIR03-30ET-55

TITLE

Maintenance and Service Instructions for Solenoid Valve, Model MV130, PiN 205883-1-0020

Maintenance Instructions for Hoist Control Valve Assembly, PiN 20101510

40-11-00

INTRODUCTION

1. r.\:n~ral

COMPONENT MAINTENANCE MANUAL

HOIST CONTROL SYSTEM PART NO. 80-25001-001

DESCRIPTION AND OPERATION

A. The hoic:t CO(lt-rol panel, pendant assembly, and pendant cable assembly (fi:::,urf> 1.) ma!<~ up a cont-rol system that is used to control the elec tric:ll .:nd hydr~·.llic functions of a hydraulic hoist system. The con tr·)l system is capable of providing continuous flow control over a range of 0 to 3.85 gallons per minute (gpm) with 3000 pounds per square inch (psi) supply pressure and a maximum hydraulic load of 2600 psi. Tr.e 3.85 gpm upper limit is the minimun acceptable. A flow rate greater. than 3.85 gpm is permissible. The hydraulically operated com- 90nent! receive power from a utility hydraulic system and can be con tr~lled electrically from the pilot's position, hoist control panel, or penci~111t, ~nd manually from the hydraulic valves in the hoist con ~rol panel. The electrical portion of the hoist control system is r~mDosed of two parts: the main +28VDC aircraft power used in normal operation, and +28VDC battery power used as an emergency backup.

B. The hoiRt control panel provides controls for normal operation, emer ger.cy op~ration, and manual operation of an electrically actuated hydraulic hoist system. The normal operating controls consist of a ro~~~ ~witc~J HOIST UP/DOWN switch, BOOM IN/OUT switch, BOOM STOW switch. SHEAR TEST switch, and a cable SHEAR switch. The emergency operating controls consist of an EMERGENCY HOIST POWER switch and a HOIST UP/DOWN switch. The manual controls consist of a manual over ride It:ver on the hoist control valve and an override control lever on the solenoid valve. The pendant assembly provides the capability of remote operation of the hoist system and contains a thumb operated HOIST UP/DOWN switch and a BOOM IN/OUT switch. The hoist control panel ~nd pendant assembly controls are shown in figure 2.

A. 1.1<; hot:t control panel is a panel mounted assembly and consists of COfltroJs. electronic circuits, and hydraulic valves. The top cover and front panel are removable to provide access to internal chassis compc~~uts. The chassis assembly contains a hoist control valve, a ~ol~ooid valve, a printed circuit card, switches, relays, and the nec essary hydraulic lines, fittings, and electrical connectors to inter face ~h~ control panel to an aircraft hydraulic hoist system.

40-11-00

INTRODUCTION

JUN 01/86

HOIST CONTROL SYSTEM PART NO. 80-25001;...001

PENDANT CABLE

80:[:]

STOWL]

ACTUATE

EMERGENCY~ :

~g~~~ ( c::::::; J I

HOIST CONTROL PANEL

Hoist Control System Figure 1 o

· ~O@!

- I f

I

UP

FAST t ~ ~LOWOFF

SLOW I

FAST t

DOWN

oUT

BOOM

I

PENDANT ASSEMBLY

8025021

40-11-00

OCT 25/83

Hoist Control System, Controls and Indicators

Figure 2 (Sheet 1 of 2)

HOIST CONTROL SYSTEM PART NO. 80-2500'~001

EB EEl

• UP

\I FAST t

LOWOF

SLOW I

.. FAST t

DOWN

I I I I EEl I I I

,-"",,-.;;jI..s:r,P 2

10 ~OFF

PENDANT ASSEMBLY

.STEP~ U

@Jl I I I I I

.')DWN

'. UP

DIRECnON ~L~ 9

ROTAT~~ I

Hoist Control System, Controls and Indicators Figure 2 (Sheet 1 of 2)

8025020

40-11-00

OCT 25/83

Index

ELECTROSPACE SYSTEMS INC.

COMPONENT MAINTENANCE MANUAL

HOIST CONTROL SYSTEM PART NO. 80-25001~001

Control/Indicator

Hoist UP/OFF/DWN switch/ potentiometer (S6/Rl)

BOOM IN/OUT SWITCH (52)

BOOM STOW switch (51)

EMERGENCY HOIST POWER

switch (S])

SHEAR TEST switch (S3)

TEST LAMP (DSl)

POWER ON/OFF switch/light

(SS/DS2)

SHEAR switch (54)

Solenoid Valve (Step 1)

Hoist Control Valve (Step 2)

Function

Spring-loaded thumbwheel switch/ potentiometer used to select direction and speed of hoist cable.

Thumb actuated slide switch used to rotate boom assembly.

Momentary-action toggle switch used to stow boom when not in use.

Guarded, 2-position toggle switch used to apply battery power for emergency operation.

Guarded, 2-position toggle switch used to test cable shear circuits.

Press-to-test lamp. Provides visual indication when testing cable shear circuits.

Press-to-operate power on/off switch. Illumination On indicates power is applied.

Guarded, 2-position toggle switch used to initiate cable shear capability.

Solenoid actuated shut-off valve used to open/close hydraulic supply for manual operation of hoist.

Hoist control valve lever used to operate hoist manually.

Hoist Control System, Controls and Indicators Figure 2 (Sheet 2 of 2)

40-11-00

HOIST CONTROL SYSTEM PART NO. 80-25001-001

(1) The hoist co~trol valve is a 2-stage, 4-way, electrohydraulic valve assembly. The valve assembly incorporates a pressure regulator valve to maintain constant flow with varying loads. The assembly consists of a torque mot0t" ~.,ith a manual override capability for hoist up/do~n. operarion. The valve housing contains metering pas sages, a mete~ing sparl vqlve, s regulator spool assembly, a filter assembly, and Lhe por~ing requir.ed for hydraulic system operation and ':esting. A munual override lever permits valve operation in the event of a~ electrical power loss or malfunction, or when manual operation is desired. Refer to technical manual NAVAIR 03-30ET-S5 for information pertaining to description, operation, and maintenanc~ of the hoist control valve.

(2) The solenoid vulve it a 2·~ay, 2-position solenoid actuated shut off valve assembly. The solenoid valve is operated by +28VDC and is E'ither open (en,:>rgl.Zed) or closed (de-energized). A manual override capability is provided to open the valve during power failure or when desired. Refer to maintenance and service instruc tion manual €or informati0n pertaining to the solenoid valve, PiN 20Sf83-l-0020.

(3) The printed circuit card con~ains the electronic circuits for generation of the control current (~20 rnA) which controls th~ oper aticn of the hoist contcol valve.

B. The po~table pendant ass~~bly is attached to the hoist control panel througb a retract:lhle cable assembly to allow remote operation of the hoist system. The retra~table cable allows the pendant to be extended up to 7.S ft.

Operation.

A. The el€:,::trical poi.·cion of the h()ist control system (figure 3) can be operated in two mod<:!s: t~e ilvrtUal mode of operation, which uses the main +2avnc aircr..tEt power system, and the emergency mode of opera tion, which uses '·28VuC aattery power. In the normal mode of opera tion, +28VDC is applied to connector pin Jl-B of the hoist control panel and routed to the llormally closed contacts 7 and 8 of the EMERGENCY HOIST pm-mR switch 57. In the emergency mode of operation, +28VDC is applieJ by placin~ the EMERGENCY HOIST POWER switch S7 in the ON position. This ~nplies +28VDC battery power through connector pin J7-& to switch S7 contacts 9 and 8. Pin 8 of S7 is connected to time delay relay K6, the acceleration/deceleration control board, SHEAR TEST lamp/switch DSl, and through the normally closed contacts 4 and 5 of switch S7 to POWER ON/OFF switch S5. Placing S5 in the ON position applies operating power to the circuits which normally func tion using the centrols on the hoist control panel and pendant

40-11-00

M/W J~ OF

EM· 'tOOZ4-001

PENDANT

(OfHROl

SEE SCH£HA:IC

F I GUIlE 1

ELECTROSPACE SYSTEMS INC.

COMPONENT MAINTENANCE MANUAL

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Hoist Control Panel, Schematic Diagram Figure 3

40-11-00

ELECTROSPACE SYSTEMS INC .

. COMPONENT MAINTENANCE MANUAL

HOIST CONTROL SYSTEM PART NO. 80-25001-001

assembly. Power for the cable shear capability is supplieu by t11e main aircraft power through connector pin Jl-A for pilot shear and Jl-C for Control Panel shear or by an external battery lhrou:::h conaec·· tor pin J7-C. The hoist and boom control circuits are made u~ of th~ pilot's hoist control circuit, the control paael hoist contrn! cir cuit, and the boom control circuit.

1) pilot's hoist control circuit. The pilot's hoist contr0i circui~ is controlled by a hoist switch and a cable shear swj tci: that art:!

external to the hoist control panel. The lwitch inp<·ts are "pplied to the hoist control panel through connector Jl.

(a) pilot's cable shear circuit (figure 4). The pilot's ~ablc shear circuit receives +28VDC from the main aircraft power anJ A?pll~s this +28VDC through connector pin Jl-A when the pilo'";;; ~h€:'a!."

switch is closed. The +28VDC is applied to contact H~ and to the coil of relay K4. The relay energizes and +28VDC 1::; ."~ppll~d through contacts Bl and B2 to resistor R2l and contRcts u a~d ) of swi tch 83 to connec tor pins J4-A and .T4-C. Th is ':0 ltage is used to set off an explosive charge that shears thl:: "'oi~1.. r.:af-le.

(b) Pilot's hoist control circuit (figure 5) This cir(~tti t. which overrides the hoist control switches on the hoist control panel and pendant, receives +28VDC through connector pin .JI-K or Jl-L and is used to control the up and down movement of the hoist cable in an aircraft installation. In the down direction, "28VDC enters the hoist control panel through connector pin .Tl-L and is routed to CR13 and CR14. The +28vDC pas8es through CR14 to cou nector pin J3-G, diode CR17, and to diodes CR6 and CR20. Thi~ provides reverse bias to blocking diodes CR6 and CR20. Diode CR17 passes the +28VDC to the coil of relay K5. The relay energizes and, through contacts Al and A2, completes the circuit for the down signal voltage from connectc.r pin Jl-O LO be :1r-plied to JIO-2 of the acceleration/deceleration control boa~d. TI-t~ +28VDC at pin J3-G is returned, through bn external switch, to J3-H and routed through diode CR18 to diode CR28 , a':d tr:rough resistor R17 to the junction of VR2 and contact 132 (If rt:'l~y ~l.

CR28 passes the voltage to contact CI of the time delay ~elay K6. Relay K6 energizes and, through contacts Al and A2, energizes (opens) the solenoid valve. Tre energizin?- of relay K6 also removes +28VDC from the boom control circuits whjle <::1(, hoist is in motion. The +28VDC from Jl-1 also pass~:; through diode CR13 to the coil of relays Kl and 1<2, energizing both relays. The energizing of relay K2 removes ground from the variable speed control in the hoist control pknel and pendant, placing the pilot's hoist switch in complete control of ch~

40-11-00

+28 VDC

PILOTS CABLE

SHEAR SWITCH

ELECTROSPACE SYSTEMS INC.

COMPONENT MAINTENANCE MANUAL

HOIST CONTROL SYSTEM PART NO. 80-25001-001

r-........... --- .... _,-..-- -- _I-'W ____ ....-. __ "'--- ------ ----..., 1 I Jl

1 S4 2 A'

A CONTROL

PANEL

CABLE

SHEAR

SHITCH Xl I

1 I .~ I

I I

2 I J41

B2

°B3 4

K4

R21 A 6

L ___ ~~ _________ ~______ .J'

Pilot's Cable Shear Circuit Figure 4

8025018

40-11-00 Page '}

JUN 01/86

..... TO f.ABI E

SHEAR

PILOT'S HOIST SWITCH

'- ___ 1X>~ ___ 1

I"'CJ

1-" t-' o rt fJl s I-J:j 1-" l-',fJl

(/Q rt s:: (") 1"1 0

(l) ::l Ul rt

1"1 o t-'

1-" 1"1 o s::

1-" rt

___ I

ELECTRO SPACE SYSTEM::; INv.

COMPONENT MAINTENANCE MANUAL

HOIST CONTROL SYSTEM PART NO. 80-25001-001

HOIST CONTROL PANEL

:----------------I ~---------I --------- B2

J10 r, ------

R23

+28 II VDe

I J:A3'1 R24

2 - A1

CR14 I

b--f7 Rl 3 CR17 CR25

L---

ICR~

I

1 K1 I

• )1

- B1 o-f1 B3

I I 1 B2 R17

VR2

A2

I

P8 A1 A1 • o----n

+28

VOC

ACCELERA Tl ON/

2 DECELERAT JON

CONTROL BOARD L (SEE SCIIEMATIC

J rIGURE 8) lfuST

C CONTROL

VALVE

K6

CR19

CR5

J3

A

B

G

I I I

J2 I

I I

A? CR20 CR22 I

TO 56A-3 (UP) I

L---- I

L- _______ SOLENOID VALVE ~TO S6B-3 (OWN)I ____________________________ J

0----1).

A3

+7H VUC

Pilot's Hoist Control Circuit Figure 5

8075010

40-11-00

HOIST CONTROL SYSTEM PART NO. 80-25001-001

hoist. With relay Kl energized, the voltage on contact B2 is routed through contact Bl to the second down contact in the pilot's hoist switch through connector pin Jl-E. The pilot's hoist switch is in the down position; therefore, this voltage is passed through Jl-D, resistors R23 and R24, contacts 1 and 2 of S7, and contacts Al and A2 of energized relay K5. This voltage is then applied to connector pin JlO-2 of the acceleration/de celeration control board. In the up direction the +28VDC enters the hoist control panel through connector pin Jl-K and is routed to the junction of diodes CR15 and CR16. The +28VDC passes through CR15 to J3-B, and to the junction of diodes CR5 and CR22. CR5 and CR22 are reverse-biased; therefore, the hoist cable cannot be operated from the hoist control panel or pen dant. The +28VDC at pin J3-B is returned, through an external switch, to J3-A and routed through CR19 to diode CR28 and through Rl7 to the junction of VR2 and contact B2 of relay Kl. The remainder of the +28VDC circuit is the same as described for the down direction except that the second up contact in the pilot's hoist switch receives the voltage input through connector pin Jl-F. With the pilot's hoist switch in the up position, the voltage at Jl-F is routed through the switch to Jl-D. From JI-D, the voltage is routed the same as for the down voltage to con tacts B3 and Al of relay KS. Relay KS is de-energized and the voltage passes through contacts B3 and B2 to connector pin JlO-l of the acceleration/deceleration control board.

(2) Control panel hoist control circuit. The'control panel hoist control circuit is controlled by the HOIST UP/DOWN switch and the cable SHEAR switch on the hoist control panel. The cable shear circuit can be tested using the cable SHEAR TEST switch and indicator.

(a) Control panel cable shear circuit (figure 6). In the normal mode of operation, the cable shear circuit receives +28VDC through connector pin Jl-C. The +28VDC is routed through contacts 10 and 11 of S7 to contact 3 of SHEAR switch S4. If the switch is set to SHEAR, the +28VDC passes through contact 2 to the coil and to contact B2 of relay K4. With SHEAR TEST switch S3 set to FIRE, contacts 1 and 2 of S3 provide a ground to the coil of relay K4 and the relay engergizes. With K4 energized, the +28VDC is routed through contacts Al and A2 to lamp DSI and the lamp lights, indicating that the shear circuit functioned properly.

The +28VDC is also routed through contacts Bl and B2 of relay K4 and through resistor R21 to contact 5 of SHEAR TEST switch S3.

With S3 in the 'FIRE position, the +28VDC is routed through con tacts 4 and 5 to connector pins J4-A and J4-C to set off an ex plosive charge that shears the hoist cable. In the emergency

40-11-00

HOIST CONTROL SYSTEM PART NO. 80-25001-001

PILOTS' CABLE

SHEAR SWrrCH

+28 VDC (+2BVDC WHEN CLOSED)

J1

J7 hATTERY C ~ 11 +"8ViJ'" ~~

!"JWER 12 57

EMERGENCY

HOIST POWER

S4 ~\ CONT PNL ~~~Ii'

1 CA SHEAR SW

R21

DS1

S3

SHEAR TEST

swrrCH

E4

TEST~FIRE

Control Panel Cable Shear Circuit Figure 6

B3 o-y B1 I B2

I

P;-f I

I A2 I

A1 I rRESS TO TEST

+28 VDC

J4

Xl

K4

CR10

X2

TO

SHEAR

DEVICE

FROM

SHEAR

DEVICE

8025011

40-11-00

ELECTRO SPACE SYSTEMS INC.

HOIST CONTROL SYSTEM PART NO. 80-25001-001

mode of operation, the EMERGENCY HOIST POWER switch S7 is set to ON and the +28VDC is supplied from the backup battery power. The +28VDC enters the hoist control panel through connector pin J7-C and is routed through S7 contacts 11 and 12 to the SHEAR switch

84. The shear circuit from 54 js the same as described for the normal mode of operatiC'n. when tr:o:: SHRAR TEST switch S3 is set to TEST, a ground path fo~ r.~lay K4 is est:lolished through con tacts 2 and 3 of S3 through tne sr.~ar device and back to ground point E4. When S4 is actuaten, +28VDC is applied to Xl of K4 and the relay close'!. Since 83 has previollsly established the ground path, the latching current for K4 is routed through the shear device, verifyi'1g continuity through the shear circuit.

NOTE: When perfo-;:ming a shear test fun~tiou, the following se quence ~'~ be followed:

1. Place 83 in TEST ~~sition.

2. Place S4 in SHEAR position and verify DSI illuminated.

3. Place 84 in OFF position.

4. Return S3 to FIl:lli position.

CAUTION: If 53 is returned to FIRE position before 54 is placed in the OFF ponition, detonation of the cable shear device will occur.

(b) Control panel hoist control. circuit (figure 3). This is a combination of the switch contacts and potentiometer S6al. S6A and S6B are wired such that in the off or no movement position the +28VDC that is applied to contact ~ of S6A and S6B is also applied to the pendant hoi~t switch. Any movement of the control panel hoist swit.ch, either up or down. removes the +28VDC from the pendant hoist switch. This causes the control panel hoist switch to have control ove~ tt~ pendant hoist switch. In the up direction, contects 3 and ~ of switch S6A are made to apply +28VDC to the j~nction of djodps CR22 and CR23. The +28VDC· passes through ciode CR22 and joins thp. same circuit as the pilot hoist switch up control. The +28VDC from S6A also passes through diode CR23 to the coil of relay K3. This relay controls the ap plication of the control panel and p~ndant variable speed control circuits. With the relay energized, the variable speed control voltage is routed through the control panel switch S6Rl. The remaining operation is the same as that described for the pilot's hoist switch except that relay Kl is not energized. With Kl

40-11-00

ELECTROSP ACE SYSTEMS INC.

HOIST CONTROL SYSTEM PART NO. 80-25001-001

de-energized, the control panel and pendant hoist switcr.~a con trol the hoist movement, and through contacts B2 and B3 of relay Kl, the +28VDC is applied to one end of the speed po~entiometers in the control panel and pendant. The control panel hoist switt~h is in the up position, and this voltage is applied to ~ue end ot S6Rl. A ground is applied to the other end of S6Rl ::hl."Oflg:l ::t~:':

closed contacts Bl and B2 of energized relay K3 and tbrot'gh con tacts A3 and A2 of de-energized relay K2 through connect~~ pi:, Jl-M. As the potentiometer S6Rl wiper is rotated fro·:t 3:.01\' t·::

FAST, the hoist will travel up at a speed f':orn 0 ft/nt.Ln tv i:i maximum of 200 ft/min. The hoist speed is determined by the voltage level present on the wiper of S6Rl. This voltage is routed through contacts Al and A2 of relay K3 (energiz~d), diuJ~ CR12, and resistor R24 to join the same cir~uit as th~ pilot's hoist switch up control. In the down direction, switch S6B closes contacts 4 and 3, applying the +28VDC to the juncc:io.! of diodes CR20 and CR2l. The +28VDC passes through diode ,::{:O 37id joins the down control circuit described in the pilot'~ hoist down control. The +28VDC also passes through diode C~21 to energize relay K3. The remaining operation is the S;,!r.IF as described for the control panel up control.

(c) Pendant assembly hoist control circuit. The schematic diagram for the pendant is shown in figure 7. The hoist contrel circuit is a combination of switches Sl and S2 and potentiometer RI.

Relay K3 in the hoist control panel controls the applicatio~ of the control panel and pendant variable speed control circuits.

With K3 de-energized, the variable speed control voltage is routed through the pendant hoist switch. The operation is the same as that described for the control panel hoist sWLtch exc~pt that relay K3 is de-energized. This causes the voltage level present on the wiper of Rl to be routed through connector pin J2-J joining the control panel hoist circuit through contacr.s A3 and A2 of de-energized relay K3.

(d) Manual hoist operation. Manual operation of the hoist (~ahle involves the hoist control valve and the so:enoid valv~ in the hoist control panel. If a power loss has o(:curred ano manual operation is necessary, the solenoid valve ~ust be manu~lly opened to allow hydraulic fluid flow. Once the solenoid valve is open, the hoist control valve can be operated manually co op_rBte the hoist cable. Placing the manual overriie lever in che UP or DOWN position provides hydraulic fluid to raise or lo, .. er the cable at a fixed rate of 50 ft/min.

(e) Hoist acceleration/deceleration control cir:uit (figure 8). The acceleration/deceleration (a/d) PCB establi~hes the speed and

40-11-00

J9 ,---

F

H

G

E

K

J

A

C

ELECTROSPACE SYSTEMS INC.

COMPONENT MAINTENANCE MANUAL

HOIST CONTROL SYSTEM PART NO. 80-25001-001

( L s'_L_1.1 3

4 1 j-- r----;-.J ~ > I

1?

52 ~

2 ~ 3 3

A

I J v OUi

0 /\ I

I IN

~ I

V I OUT

F I

C ~ IN

-.... ,.. G,m LUG

Pendant Assembly Schematic Diagram Figure 7

Rl

HOISi POT

AND SWITCHES

UP !

OFF

DOWN r

! S3 I 800M

, SWITCH

802SG12

direction of the hoist cable. A control voltage from thumb switches located on the control panel and the pendant assembly is applied to the aId circuit. The amplitude of the voltage (0 to 5VDC) determines hoist speed. Speeds of 0 to 200 ft/min in the up or down direction are possible when using either thumb switch. Hoist movement initiated from the pilot's hoist switch is limited to 100 ft/per min. When a thumb switch is pushed to UP, a control voltage of 0 to 5VDC is applied to Pl-l and ground is applied to Pl-2. When a thumb switch is placed in the DOWN position, the control voltage is applied to Pl-2 and ground is applied to Pl-l. The amplitude of the control voltage at pins 1 or 2 determines the speed at which the hoist travels. The aId

40-11-00

ELECTRO SPACE SYSTEMS INC.

HOIST CONTROL SYSTEM PART NO. 80-25001-001

e6 lDOpF

TPl R7 10K

~ +15 VDe I lOOK

R5 10K

+15 VDe TP3

+15 VDe

Rll 1K

R12 lK

+7.5 VDe

+7.5 VDe +7.5 vae

JANTX

2N2222A

R14 392:.

JANTX

2N2907A

R15 -:"

10K

Acceleration/Deceleration Control Board, Schematic Diagram Figure 8

TP2

R9 178 ..

~cn converts the 0 - 5VDC input signal into a proportional 0 to 20F~ current which is output from pins 4 and 5 of Pl to the servo val\Te.

T~len an UP command is initiated, the control voltage is routed from Pl-l to the inverting input of operational amplifier UlA.

The DOWN command control voltage is routed through Pl-2 to the ~oa-inverting input of UlA. The output of UlA is amplified by U1B and UlC and applied to the base of transistors Ql and Q2.

The output of Ql and Q2 is positive for an up movement and nega tive for a down movement. Resistor R6 and capacitor Cl, in the input circuit of UlC, establish a voltage ramp with a rise time of 250 ms from 0 to SVDC. The 250ms voltage ramp provides for Goft starts and stops by generating a force of only .5 GIS from full stop to full go. A positive pulse on the base of Ql and

P1

4jHOIST SPEED

SIG

5 OUT

8025013

40-11-00

HOIST CONTROL SYSTEM PART NO. 80-25001-001

Q2 causes Ql to conduct and Q2 to cut off. The output of Ql is applied to Pl-4 and to the inverting input of UlD as a positive dc current. The output of UID is applied to Q4 as reverse bias and to Q3 as forw~rd bi~~. fransistor Q3 cuts off and Q4 con ducts, providing a low lev~l whi~h is applied through level con trol Rl6 to PI-5. With Pl-5 at groynd potential and the dc cur rent level applied tl' Pl-4) the hoist control valve's torque motor provides hydraulic fluid flow in a direction to drive the hoist ca~al~ up. Potentiometer R16 is used to balance the level between rp2 and TP5. A negativ~ pulse on the base of Ql and Q2 causes C2.to conduct and a low level is applied to Pl-4 and U1D.

The output of UlD is then positive, which causes Q3 to conduct, and the ic level is applied to Pl-5. With the dc level applied to Pl-5 and a low on Pl-4, th~ Lorque motor in the hoist control valve r~verses the hydraulic fluid flow to drive the hoist cable down.

(3) Boom control circuit (figure 9). Boom operation can be initiated from the rOOM switch ,>n the h,.,ist c.oncrol panel or pendant assembly as long ae there is no hoist movement (relay K6 de-energized).

With relay K6 de-energized, +28VDC is applied to the BOOM IN/OUT switch S2 in the hoist cuIli:.rol panel and the BOOM IN/OUT switch Sl in the pendant. Activation of either switch applies this +28VDC, through ccnnector pins J6-A (~oom out) or J6-B (boom in), to the boom assewbly. Swit::la S2 iTI the hoist control panel also applies +28VDC to the coil at relay K2. This energizes K2 and the +28VDC to the pendant BOOM sWLtch 81 is removed, allowing the hoist con trol panel to override the pendant. Switch Sl, in the hoist con trol panel is the BOOM STOW switch. This switch is a momentary action toggle switch that, upon activation, automatically reposi tions the boom to the in-flight (least drag) position.

B. The hydraulic components of the ::ontrol system consist of two main units: a load compensat~d hoist control valve and an on/off solenoid valve. The hoist contr~l valv~ provides a mechanical means for closing the control loop and maintains a constant flow with varying loads. The valve accepts a control signal from either the control panel or pendant, and deliv~rs p flow proportional to the input con trol current from the acceleration/deceleration control circuit. The solenoid valve, which i~ locatp.d in serie~ with the hoist control valve, serves to block hydraulic flow when the hoist control valve is not active. l30th of theae valve~ have the capability for manual over ride such that the system can be operated if the control system mal functions electrically. For additional information pertaining to these valves, refer to the applicable documents listed in the intro duction of this manual.

C. The electrical/hydraulic interface incorporates a means of limiting system accelecation for fast start/stop conditions. The maximum rate

40-11-00

1------- --I 1 J1 I P9 I 1 -r---Q-l.--~ I I I...I-__ r-...J I

1 BOOM

1 S 1 I 1 _________ oJ

PENDANT ASSEMBLY

ELECTROSPACE SYSTEMS INC.

COMPONENT MAINTENANCE MANUAL

HOIST CONTROL SYSTEM PART NO. 80-2S001~001

BOOM OUT

+28 VDC

BOOM IN

J 6:--"""";;''''''';;''''''';;'--1'' +28 V DC 1

I

BOOM STOW

CR1 Sl

CR2

CR3

B3

A

D

B

C

CR4

BOOM

S2

E

B2

OUT

IN

:~1 I I I

I K6

I I I I I I I I I I I I

'7 I 1... ___________________________ J

HOIST CONTROL PANEL

Boom Control Circuit Figure 9

8025014

40-11-00

HOIST CONTROL SYSTEM PART NO. 80-25001-001

of change of the control current for the hoist control valve is limited to 20 rnA in 250 ms. This corresponds to ~ load acc~leration of apporoximately 1/2 G. To preclude the solenol.el val,'c frc!1i sl.smming shut and causing undesirable pressure spike tran3i~uts, tim~ delay relay K6 provides a 300 ms delay after its 28Vclc 1:; re~o':~::! whi=h allows the hoist control valve to close completely ~wfore tht solp~oid valve closes. Any tendency for the hoist control va~J~ ~~ cLeep while in the stationary mode is eliminated by the solen·.,id ,,·al\l(! b:!.c~king hydraulic flow when the hoist speed con-:rol is retur~1ed to th~ OFF position. The electrical/hydraulic interface also provide$ for directional control, as well as proportional flow centrol. A hydraulic schematic of the control syst':!m and hoi..;:- motor i.s shown in figure 10.

40-11-00

HOIST CONTROL SYSTEM PART NO. 80-25001~001

V-2

---I I I I I

L..!-.J

V-l TWO WAY SOLENOID VALVE WITH MANUAL OVERRIDE

V-2 FLOW CONTROL SERVO VALVE WITH MANUAL OVERRIDE

M-1 HOIST HYDRAULIC MOTOR

Control System Hydraulic Schemati~ Figure 10

V-l

8025015

40-11-00

COMPONENT MAINTENANCE MANUAL

HOIST CONTROL SYSTEM PART NO. 80-25001~001

TESTING AND TROUBLESHOOTING

A. The testing and troubleshooting procedures contain specific checks and tests required to determine the operational condition of the hoist control system. The procedures also serve as a troubleshooting guide to fault isolate to the component level.

B. The test equipment and materials required are listed below. Equiv alent items may be used if the recommended items are not available.

Model No.

TL8-3

8012-A

80-25096-001

80-25093-001

80-25102-001

2. Test Procedures

Function

Dc power supply

Oscilloscope

Volt-ohmmeter

Digital multi meter

Electrical Test Set

Test Flow Stand

Printed Circuit Board Test Set

Manufacturer Quantity

Systron Donner Corp. 2

Tektronix, Inc. 1

Fluke 1

Data Precision Corp. 1

E1ectrospace Systems, Inc. 1

Electrospace Systems, Inc. 1

Electrospace Systems, Inc. 1

The test procedures are performed to determine and verify the nature of a malfunction before troubleshooting, and to ensure that the unit is func tioning properly after a repair is made. The following procedure provides step-by-step instructions to test the equipment, and identifies normal indications. If an abnormal indication is observed during testing, refer to paragraph 3, Troubleshooting.

A. Interconnect electrical test set-up as shown in figure 101. Elec trical test set schematic is shown in figure 102.

(1) Connect power supply 28V OUTPUT to test set 28V INPUT.

40-11-00

COMPONENT MAINTENANCE MANUAL.

HOIST CONTROL SYSTEM PART NO. 80-25001-001

rOWER SUPPLY

TL8-3

.-115 VAC

60 Hz

- + TEST SET HOIST CONTROL PANEL

80-25096-001 80-25001-001

Wl TB2-E76

+28 VDC INPUT

-GND ~

Jl Jl PWR. HOIST

\.;;;/- J3 J3 LIMIT SWITCH

HOIST CURRENT J4 J4 CABLE SHEAR

~ (~ P5 P5 HOIST VALVE

+ J5 J5 HOIST CaNT

- J6 J6 BOOM

S~~E TRI~ER J7 J 7 E~IERG PWR

( P8 DIGITAL P8 SOLENOID VALVE CONTROL

MULTI METER

245 r-- J2 PENDANT

115 VAC

60 Hz

OSCILLOSOPE

'-- CHl

INPUT

CH2

INPUT

Electrical Test, Test Set-up Figure 101

PENDANT

EM-Y0024-001

CABLE

80-25003~OOl

Jl

8025016

40-11-00

GlIDe::» • I.

COMPONENT MAINTENANCE MANUAL

HOIST CONTROL SYSTEM PART NO. 80-25001-001

J3 "i 'j' 1- ,- I i " j 'i I 'j , o o

UP LlMIT lNT SPEED DOWN LIMIT SWlTCH SWITCH SWlTCH

SHEAR CURRENT HO I ST CURRENT

+28YDC~

Sl

TEST SET

DC POWER

I I 4

S2

HOIST/CARGO 54 UP

POWER SWITCH PILOT HOIST

CONTROl SWITCH --y---r-'1

J7~

Jl = KPHI6E14-12S (ttS31l6E14-12S) J3= KPHI6E12-8P (ItS31l6E12-8P) J4= KPHI6El~-6P (HS3l16El~-6P) P5= KPT~lEl~-6P (MS3111El~-6P) J5= KPT~E1~-6S (HS31l6E10-6S) J6= KPT~E10-6P (MS3l16E10-6P)

SCOPE TRIGGER

P8 1 AlB 1 fiI }, DS4~ * CRI

SOlENOID IN4148

VALVE

w, 0

J1

() () 0 J3 .av GHO

0 ON ... © 0 OfF

PO ..

TEIT lET

0 DC1'OW£R

JO

.II

ON

0 © J7

OFF

S2

0> () () () . .

IHEA" CURRENT HOIST CUfUtENT

0 0 0 00, DC. DS3

IIOOMOUT OOOM'" IOOMfLT

PO<

ON Uf' ON ON

0 0 () 0

OFF DOWN OFF OFF

SO 54 .. II

TfUGGEfi SCOO •

GND

DS4

IOLVAl.VE

ON ,

0 ©

OFF 2

.7 SO

J7= KPT~6E8-3S (MS3116EB-3S) PO HOlSTI PILOT ,llOT UP LtMlT INT INEO DOWN LIMIT .... ""

P8= CA3101R10SL-4P (HS31~IRI0SL-4P)

51= MTA106D (ALCOl

52= MTA1~D (ALCO

53= tITA106D (ALCO)

S4= HS24524-27

55= MTA1~D (ALCO)

56= tITA1~D (ALCO)

57= MTAI06D (ALCO)

58= H5T205N (ALCO)

D51-DS4=LH73!1

Rl= RE65G1000

CR1= lN4148

Electrical Test Set Figure 102

CARGO """ .. CA.LE HOIST

SHEA" CONTROL

CURRENT

8025017

40-11-00

(2)

(3)

(4)"

(5)

ELECTROSPACE SYSTEMS INC.

COMPONENT MAINTENANCE MANUAL

HOIST CONTROL SYSTEM PART NO. 80-25001-001

Connect test set connector Jl to Jl on hoist control panel.

Attach pendant assembly to cable assembly and attach the cable sembly to connector J2 on the hoist control panel.

Connect test set connector J3 to J3 on the hoist control panel.

Connect test set connector J4 to J4 on the hoist control panel.

as-

(6) On the hoist control panel, disconnect connector PS from the hoist control valve and connect the test set connector J5 to the hoist control valve.

(7) Connect the test set connector P5 to the hoist control panel P5 disconnected in step (6).

(8) Connect test set connectors J6 and J7 to J6 and J7, respectively, on the hoist control panel.

(9) On the hoist control panel, disconnect P8 from the solenoid valve and connect this PS to the test set connector PS.

(10) Attach the test set jumper wire (Wl) alligator clip to TB2-E76 on the hoist control panel.

(11) Connect multimeter to HOIST CURRENT test jacks on test set, and set meter to measure 0-20 mA dc.

B. Perform electrical testing as follows.

(1) Set power supply POWER switch to ON and adjust output to +28VDC +0, -2VOC.

(2) On the test set, set switches as follows:

(a) TEST SET DC POWER switch (Sl) to ON

(b) HOIST/CARGO POWER switch (S2) to ON

(c) SHEAR CURRENT switch (S8) to the 1 position.

(3) On the hoist control panel, press POWER switch to ON. Power on switch/indicator illuminates.

(4) Press POWER switch on hoist control panel to OFF.

(5) On test set, set HOIST/CARGO POWER switch to OFF. Verify that all test set indicator lamps (OSl, OS2, OS3, and DS4) are off.

(6) Verify that multimeter indicat~~ 0.0 + 1.0 mAo

40-11-00

ELECTROSPACE SYSTEl',,1S INC.

HOIST CONTROL SYSTEM PART NO. 80-25001-001

(7) On test set, set PILOT HOIST CONTROL switch (S4) to UP position, then DOWN position. Verify that multimeter indicates 0.0 +1.0 mA in both positions. Return S4 to center OFF position.

(8) On the hoist control panel perform the following.

(a) Set HOIST UP/DOWN switch to UP, then DOHN position. Verify that the multimeter indicates 0.0 +1.0 rnA in both positions. Retcrn HOIST switch to OFF.

(b) Set the BOOM STOW switch to ACTUATE position. Verify that ttl!

BOOM FLT POS lamp (DS3) on the test set illuminates. Release the BOOM STOW switch.

(9) On the pendant assembly set the HOIST switch to full UP, then full OWN position. Verify that the multimeter indicates 0.0 +1.0 rnA in both positions. Return HOIST switch to OFF.

(10) Remove the multimeter from test set HOIST CURRENT test jacks ar.d set meter to measure 0 to 500 rnA dc. Connect multimeter to SHEAR CURRENT test jacks on the test set.

(11) Set the PILOT CABLE SHEAR switch (53) on the test set to ON posi tion. Verify that mu1timeter indicates 0.0 +1.0 mAo Return PILOT CABLE SHEAR switch to OFF.

(12) On the hoist control panel perform the following.

(a) Press and release the SHEAR TEST press-to-test lamp. Vp.rify that the lamp does not illuminate.

(b) Lift the SHEAR TEST switch safety cover and set the SHEAR TESJ' switch to the up position.

(c) Lift the SHEAR switch safety cover and set the SHEAR switch t:> the up position.

(d) Verify that the SHEAR TEST press-to-test lamp illuminates and the multimeter indicates 70 rnA +5 mAo

(e) Set SHEAR switch to down position. Verify that the press-to-~est lamp extinguishes and the multimeter indicates 0.0 +1.0 mAo

(f) Set SHEAR TEST switch to the down position. Set test set SHE.I.R CURRENT switch (S8) to position 2.

(g) Set SHEAR switch to up. Verify SHEAR TEST press-to-test lamp illuminates and multimeter indicates 279 +6.0 mAo

40-11-00 Pag!! 105

JUN (\l/S~

HOIST CONTROL SYSTEM PART NO. 80-25001-001

(h) Set SHEAR switch to the down position. Press-to-test lamp extinguishes and multimeter indicates 0.0 +1.0 rnA.

(i) Lift the EMERGENCY HOIST POWER switch safety cover and set switch to ON. Verify that the green lamp on the POWER switch/lamp is off.

(13) Set PILOT CABLE SHEAR switch (53) on the test set to ON. Verify that the mu1timeter indicates 0.0 +1.0 rnA. Return PILOT CABLE SHEAR switch to OFF.

(14) Repeat step (12) substeps (g) and (h) above.

(15) Remove the multimeter from test set SHEAR CURRENT test jacks and set meter to measure 0 to 20 rnA dc. Connect multimeter to HOIST CURRENT test jacks on the test set. Verify that multimeter in dicates 0.0 +1.0 rnA.

(16) Repeat steps (7), (8)(a), and (9) above.

(17) On the pendant assembly perform the following.

(a) Set and hold BOOM switch to OUT position. Verify that the test set BOOM OUT lamp (DSl) illuminates and that all other lamps are off.

(b) While holding the pendant BOOM switch to OUT position, set and hold the hoist control panel BOOM switch to the IN position. On the test set, verify that the BOOM IN lamp is illuminated and all other lamps are extinguished.

(c) Release the BOOM switches on the pendant and hoist control panel. Verify that all lamps on the test set are extinguished.

(d) Set and hold BOOM switch to IN position. Verify that BOOM IN lamp (DS2) on test set is illuminated.

(e) While holding BOOM switch IN, set and hold the hoist control panel BOOM switch in the OUT position. On the test set, verify that the BOOM OUT lamp is illuminated and all other lamps are extinguished.

(f) Release the BOOM switches on the pendant and hoist control panel.

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This TOPS page updates steps 2.B.(24)(d) and (e).

(d) Set UP LIMIT switch (S5) to OFF position. Verify that the multimeter indicates 0.0 mA ±1.0 mA and that all test set lamps are extinguished.

(e) Set INT SPEED switch (S6) and UP LIMIT switch (S5) to OFF. Verify that the multimeter indicates

0.0 mA ±1.0 mA and the SOL VALVE lamp (DS4) is not illuminated. All other lamps are extinguished.

HOIST CONTROL SYSTEM PART NO. 80-25001-001

(18) Pres~ the POWER switch on the hoist control panel to the ON posi tion. Verify that the power switch/lamp illuminates.

(19) On the pendant, set HOIST switch to full UP, then full DOWN posi tion. Verify that multimeter indicates +20 rnA +1.5 rnA (UP) and -20 rnA +1.5 rnA (DWN), and the test set SOL VALVE la;p (DS4) illuminates with HOIST switch in both positions.

(20) Return pendant HOIST switch to OfF position. Verify that the multimeter indicates 0.0 rnA +1.0 rnA and that all test set lamps are off.

(21) Repeat steps (19) and (20) using HOIST switch on the hoist control panel.

(22) Set PILOT HOIST CONTROL switch (S4) on test set to UP, then DOWN position. Verify that the multimeter indicates 0.0 +1.0 rnA and that no test set lamps are illuminated in either position. Return PILOT HOIST CONTROL switch to center OFF position.

(23) Set EMERGENCY HOIST POWER switch on hoist control panel to OFF and close safety cover. Verify that the POWER switch/lamp is off.

(24) On the test set perform the following.

(a) Set HOIST/CARGO POWER switch (S2) to ON position. Verify that the POWER switch/lamp on the hoist control panel illuminates.

(b) Set PILOT HOIST CONTROL switch (S4) to UP. Verify that multi meter indicates +10 rnA +.75 rnA and SOL VALVE lamp (DS4) illu minates. All other lamps are extinguished.

(c) Set INT SPEED switch (S6) to ON position. Verify that multimeter indicates +5.0 rnA +.375 rnA.

(d) Set UP LIMIT switch (S5) to ON position. Verify that the multi meter indicates 0.0 rnA +1.0 rnA and that all test set lamps are extinguished.

(e) Set INT SPEED switch (S6) and UP LIMIT switch (S5) to OFF.

Verify that the multimeter indicates +10 rnA +.75 rnA and the SOL VALVE lamp (DS4) is illuminated. All other lamps are extin guished.

(f) Set PILOT HOIST CONTROL switch (S4) to DOWN. Verify that multi meter indicates -10.0 rnA +.75 rnA and the SOL VALVE lamp (DS4) is illuminated. All other lamps are extinguished.

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TOPS 6 Odd

HOIST CONTROL SYSTEM PART NO. 80-25001~001

(g) Set INT SPEED switch (S6) to ON. Verify that multimeter indi cates -5 mA +.375 mAo

(h) Set DOWN LIMIT switch (S7) to ON. Verify that the multimeter indicates 0.0 mA +1.0 mA and all test set lamps are extinguished.

(i) Set INT SPEED switch (S6) and DOWN LIMIT switch (S7) to OFF.

Verify that multimeter indicates -10.0 mA +.75 mA and SOL VALVE lamp (DS4) is illuminated. All other lamp; are extinguished.

(j) Set PILOT HOIST CONTROL…