7186-010 Manual (TO 33AA14-2-1).pdf

TO 33AA14-2-1

TECHNICAL MANUAL

OPERATION AND MAINTENANCE

INSTRUCTIONS WITH ILLUSTRATED PARTS

BREAKDOWN

UNIVERSAL JACK TESTER

7186-010

NSN 1730-01-329-6355

REGENT MFG., INC.

F41608-93-D-0452

DISCLOSURE NOTICE - This information is furnished upon the condition that it will not be released to another nation without the specific authority of the Department of the Air Force of the United States, that it will be used for military purposes only, that individual or corporate rights originating in the information, whether patented or not, will be respected, that the recipient will report promptly to the United States, any known or suspected compromise, and that the information will be provided substantially the same degree of security afforded it by the Department of Defense of the United States. Also, regardless of any other markings on the document, it will not be downgraded or declassified without written approval of the originating United States agency.

DISTRIBUTION STATEMENT - Distribution authorized to U.S. Government agencies and their contractors (Administrative or Operational Use), (15 April 1995). Other requests for this document shall be referred to WR-ALC/LEET, Robins AFB GA 31098. Questions concerning technical content should be directed to WR-ALC/LESB, Robins AFB GA 31098.

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.

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.

Published Under Authority of the Secretary of the Air Force

15 APRIL 1995 CHANGE 3 - 4 FEBRUARY 2005

BASIC AND ALL CHANGES HAVE BEEN MERGED TO MAKE THIS A COMPLETE PUBLICATION

NOTE: The portion of the text affected by the changes is indicated by a vertical line in the margins of the page. Changes to illustrations are indicated by miniature pointing hands. Changes to wiring diagrams are indicated by shaded areas.

INSERT LATEST CHANGED PAGES. DESTROY SUPERSEDED PAGES.LIST OF EFFECTIVE PAGES

*Zero in this column indicates an original page.

A Change 3

Title A i - iii iv Blank v - vii viii Blank 1-1 1-2 - 1-4 2-1 - 2-2 3-1 - 3-3 3-4 - 3-5 3-6 4-1 - 4-5 4-6 4-6A - 4-6B Added 4-7 - 4-8 4-9 Blank 4-10 5-1 - 5-18 5-19 5-20 - 5-21 5-22 Blank 6-1 6-2 Blank 6-3 6-4 Blank 7-1 - 7-8 7-9 Blank 7-10 - 7-18 8-1 8-2 Blank

Dates of issue for original and changed pages are:

Original . . . . . . . . . . . . . . .0 . . . . . . . . . . . . . . . . . 15 April 1995 Change . . . . . . . . . . . . . . .1 . . . . . . . . . . . . . . 15 February 1997

Change. . . . . . . . . . . . . . . 2 . . . . . . . . . . . . . . . 31 January 2002 Change. . . . . . . . . . . . . . . 3 . . . . . . . . . . . . . . . 4 February 2005

Page *Change No. No.

TOTAL NUMBER OF PAGES IN THIS PUBLICATION IS 80, CONSISTING OF THE FOLLOWING:

TABLE OF CONTENTS

Chapter Page Chapter Page

LIST OF ILLUSTRATIONS . . . . . . . . . . . . . . . . . . . iii

LIST OF TABLES . . . . . . . . . . . . . . . . . . . . . . . . . . . iii

SAFETY SUMMARY . . . . . . . . . . . . . . . . . . . . . . . . . v

1 INTRODUCTION AND GENERAL

INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1

1-1. General Information. . . . . . . . . . . . . . . . . 1-1 1-1.1. Purpose of Manual . . . . . . . . . . . . . . . . . . 1-1 1-1.2. Scope and Arrangement. . . . . . . . . . . . . . 1-1 1-1.3. List of Technical Manuals . . . . . . . . . . . . 1-1 1-1.4. Abbreviations/Acronyms . . . . . . . . . . . . . 1-1 1-2. Description. . . . . . . . . . . . . . . . . . . . . . . . 1-1 1-2.1. Purpose. . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 1-2.2. System . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 1-2.3. Control Box . . . . . . . . . . . . . . . . . . . . . . . 1-3 1-2.4. Electric Chain Hoist. . . . . . . . . . . . . . . . . 1-3 1-2.5. Leading Particulars . . . . . . . . . . . . . . . . . 1-3

2 SPECIAL TOOLS AND

TEST EQUIPMENT . . . . . . . . . . . . . . . . . . . . . . . 2-1

2-1. Special Tools and Test Equipment . . . . . 2-1 2-3. Other Equipment . . . . . . . . . . . . . . . . . . . 2-1 2-5. Consumables . . . . . . . . . . . . . . . . . . . . . . 2-1 2-7. Local Manufactured Items . . . . . . . . . . . . 2-2

3 PREPARATION FOR USE

AND SHIPMENT . . . . . . . . . . . . . . . . . . . . . . . . . 3-1

3-1. Preparation For Use . . . . . . . . . . . . . . . . . 3-1 3-1.1. Foundation Installation . . . . . . . . . . . . . . 3-1 3-1.2. Initial Setup . . . . . . . . . . . . . . . . . . . . . . . 3-2 3-1.2.1. 25 Foot Ceiling . . . . . . . . . . . . . . . . . . . . 3-2 3-1.2.2. 23 Foot Ceiling . . . . . . . . . . . . . . . . . . . . 3-4 3-1.3. Wiring/Power Connections . . . . . . . . . . . 3-4 3-1.4. Hoist Test/Beam Hookup. . . . . . . . . . . . . 3-5 3-1.5. Preoperational Inspection . . . . . . . . . . . . 3-5 3-2. Preparation For Shipment . . . . . . . . . . . . 3-6

4 OPERATION INSTRUCTIONS . . . . . . . . . . . . . . 4-1

4-1. Theory of Operation. . . . . . . . . . . . . . . . . 4-1 4-1.1. Jack Tester . . . . . . . . . . . . . . . . . . . . . . . . 4-1 4-1.2. Control Box . . . . . . . . . . . . . . . . . . . . . . . 4-1 4-1.3. Hoist. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1 4-1.4. Load Cell . . . . . . . . . . . . . . . . . . . . . . . . . 4-1

4-2. Operating Controls and Indicators . . . . . .4-1 4-4. Calibration . . . . . . . . . . . . . . . . . . . . . . . . .4-6 4-5.1. Using the Zero and Digital

Advance switches . . . . . . . . . . . . . . . . . .4-6 4-5.2. Calibration Procedure Using a Jack . . . . .4-6 4-6. Operation Instructions . . . . . . . . . . . . . . . .4-7 4-7. Normal Shutdown . . . . . . . . . . . . . . . . . . .4-8 4-8. Emergency Shutdown . . . . . . . . . . . . . . . .4-8

5 MAINTENANCE INSTRUCTIONS . . . . . . . . . . . 5-1

5-1. Operational Checkout . . . . . . . . . . . . . . . .5-1 5-3. Inspection and Preventive

Maintenance . . . . . . . . . . . . . . . . . . . . . .5-1 5-5. Troubleshooting. . . . . . . . . . . . . . . . . . . . .5-4 5-7. Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-9 5-8.1. Jack Tester Disassembly . . . . . . . . . . . . .5-10 5-8.1.1. High Ceiling Disassembly. . . . . . . . . . . .5-10 5-8.1.2. Low Ceiling Disassembly . . . . . . . . . . . .5-10 5-8.1.3. Beam Disassembly . . . . . . . . . . . . . . . . .5-11 5-8.2. Control Box Disassembly . . . . . . . . . . . .5-11 5-8.3. Hoist Disassembly. . . . . . . . . . . . . . . . . .5-11 5-8.3.1. Brake Disassembly . . . . . . . . . . . . . . . . .5-12 5-8.3.2. Driveshaft and Pinion

Disassembly . . . . . . . . . . . . . . . . . . . . .5-12 5-8.3.3. Hook Block Disassembly . . . . . . . . . . . .5-12 5-8.3.4. Swivel Hook Suspension

Disassembly . . . . . . . . . . . . . . . . . . . . .5-13 5-8.4. Cleaning. . . . . . . . . . . . . . . . . . . . . . . . . .5-13 5-8.5. Inspection . . . . . . . . . . . . . . . . . . . . . . . .5-13 5-8.6. Repair and Replacement . . . . . . . . . . . . .5-13 5-8.7. Load Chain Replacement . . . . . . . . . . . .5-14 5-8.8. Printed Circuit Board

Replacement . . . . . . . . . . . . . . . . . . . . .5-14 5-8.9. Hoist Assembly . . . . . . . . . . . . . . . . . . . .5-14 5-8.9.1. Swivel Hook Suspension

Assembly . . . . . . . . . . . . . . . . . . . . . . .5-14 5-8.9.2. Hook Block Assembly. . . . . . . . . . . . . . .5-15 5-8.9.3. Driveshaft and Pinion

Assembly . . . . . . . . . . . . . . . . . . . . . . .5-15 5-8.9.4. Brake Assembly . . . . . . . . . . . . . . . . . . .5-15 5-8.9.5. Hoist Component Assembly . . . . . . . . . .5-15 5-8.10. Control Box Assembly . . . . . . . . . . . . . .5-16 5-8.11. Jack Tester Assembly . . . . . . . . . . . . . . .5-17 5-8.11.1. Beam Assembly. . . . . . . . . . . . . . . . . . . .5-17 5-8.11.2. High Ceiling Assembly . . . . . . . . . . . . . .5-17 5-8.11.3. Low Ceiling Assembly . . . . . . . . . . . . . .5-17 5-8.11.4. Jack Tester Final Assembly . . . . . . . . . .5-18 i Change 2

Chapter Page

5-9. Testing . . . . . . . . . . . . . . . . . . . . . . . . . . 5-18 5-9.1. Jack Tester . . . . . . . . . . . . . . . . . . . . . . . 5-18 5-9.2. Motor Reversing Switch . . . . . . . . . . . . 5-18 5-9.3. Load Cell . . . . . . . . . . . . . . . . . . . . . . . . 5-19 5-10. Adjustments . . . . . . . . . . . . . . . . . . . . . . 5-19 5-10.1. Upper Limit Switch Adjustment . . . . . . 5-19 5-10.2. Lower Limit Switch Adjustment . . . . . . 5-21 5-10.3. Electric Brake Adjustment . . . . . . . . . . . 5-22

6 DIAGRAMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1

7 ILLUSTRATED PARTS BREAKDOWN . . . . . . . 7-1

8 DIFFERENCE DATA SHEETS . . . . . . . . . . . . . . . 8-1

ii Change 2

LIST OF ILLUSTRATIONS

Number Title Page

1-1. Universal Jack Tester. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-2 1-2. Control Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-4 1-3. Electric Chain Hoist. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-4 2-1. Fabrication Detail for the Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-2 3-1. Fabrication Detail for the Foundation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-3 4-1. Control Box Block Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-2 4-2. Controls and Indicators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-4 4-3. A/D Printed Circuit Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-9 5-1. Dead End Block Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-16 5-2. Switch Test Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-19 5-3. Limit Switch Adjustment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-20 6-1. System Electrical Schematic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-3 7-1. Universal Jack Tester. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-4 7-2. Electric Chain Hoist. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-10 7-3. Control Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-16

LIST OF TABLES

Number Title Page

1-1. Leading Particulars . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-3 2-1. Other Equipment List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-1 2-2. Consumable Materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-1 3-1. Foundation Materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-1 3-2. Preoperational Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-6 4-1. Controls and Indicators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-3 4-2. Display Indications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-5 4-3. Beam Heights/Clearances . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-10 4-4. Relief Valve Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-10 5-1. Jack Tester Inspection/Preventive Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-2 5-2. Troubleshooting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-4

Change 2 iii(iv blank)

SAFETY SUMMARY TO 33AA14-2-1

SAFETY SUMMARY

WARNING AND CAUTION STATEMENTS have been strategically placed throughout this text prior to operating or maintenance procedures, practices or conditions considered essential to the protection of personnel (WARNING) or equipment and property (CAUTION). A WARNING and CAUTION will apply each time the related step is repeated.

DEFINITIONS

The following definitions apply to WARNINGS and CAUTIONS found throughout this publication.

Highlights an operation or maintenance procedure, practice, statement, etc, which, if not strictly observed, could result in injury, long term health hazard or death to personnel.

Highlights an operation or maintenance procedure, practice, statement, etc, which, if not strictly observed, could result in damage or destruction to equipment o r l o s s o f m i s s i o n effectiveness.

NOTE

Highlights an essential operating or maintenance procedure, condition or statement.

GENERAL PRECAUTIONS

The following are general safety precautions that are not related to any specific procedure and therefore do not appear elsewhere in this technical manual.

These are general safety precautions and instructions that people must understand and apply during many phases of operation and maintenance to ensure per-sonal safety and health and the protection of Air Force property.

KEEP AWAY FROM LIVE CIRCUITS

Operating personnel must observe all safety regula-tions at all times. Do not replace components or make adjustments inside equipment with the electrical sup-ply turned on. Under certain conditions, danger may exist even when the power control is in the off position due to charges retained by capacitors. To avoid in-juries, always remove power, discharge, and ground a circuit before touching it. Adhere to all lock out/tag out requirements.

RESUSCITATION

Personnel working with or near dangerous voltage shall be trained in modem methods of resuscitation.

Information and training sources may be obtained from the Director of Base Medical Services.

FINGER RINGS/JEWELRY

Finger rings have caused many serious injuries. Re-move rings, watches and other metallic objects which may cause shock or bum hazards. Unless specifically allowed by shop safety procedures, remove finger rings during all maintenance activity.

COMPRESSED AIR

Use of compressed air can create an environment of propelled particles. Do not direct air streams towards self or other personnel. Air pressure shall be reduced to less than 30 PSIG and used with effective chip guarding and personal protective equipment.

DANGEROUS PRESSURES

Care must be taken during testing to ensure that all test connections are proper and tight. All system com-ponents must be compatible with pressure applied.

Personnel must be protected by a safety shield or located at a distance sufficient to prevent injury.

PERSONAL PROTECTIVE EQUIPMENT (PPE)

If unique local conditions make compliance with the protective clothing or other occupational health re-quirements specified in this manual unnecessary or impractical, obtain an evaluation of the operation from the Bioenvironmental Engineer. The Bioenvironmen-tal Engineer and Base Safety Office will determine the required precautions.

v

CLEANERS/CHEMICALS/PAINTS/PRIMERS

Some cleaners, chemicals, paints, and primers are toxic and produce adverse effects on skin, eyes, and respiratory tract. Therefore, to preclude or minimize potential exposure, follow manufacturer’s Warning Labels; Material Safety Data Sheets (MSDS) instruc-tions for proper handling, storage, and disposal; and current safety directives. Use only in authorized areas.

Unless otherwise indicated in the text, use as de-scribed in this TO should not result in any immediate health concerns. Consult the local Bioenvironmental Engineer and Base Safety Office for specific protec-tion equipment and ventilation requirements.

ELECTROSTATIC DISCHARGE SENSITIVE

(ESDS)

Electrostatic discharge sensitive (ESDS) is applied to low power solid state parts which could be damaged or destroyed when exposed to discharges of static electricity. Maintenance personnel are often not aware that the ESDS parts have been damaged or destroyed because electrostatic discharges at levels less than 4,000 volts cannot be seen, felt, or heard. Maintenance procedures identified by the ESDS symbol shall be in accordance with TO 00-25-234 to prevent damage to or destruction of ESDS parts.

When the ESDS symbol appears between a paragraph number and paragraph title the entire para-graph and all subparagraphs shall be considered ESD sensitive. When the ESDS symbol appears between a step number and the step text, the step shall be considered ESD sensitive.

SPRING-LOADED MECHANISM

A spring-loaded mechanism can cause injury if re-leased in an uncontrolled manner. Always take extra care when disassembling this type of mechanism.

DO NOT SERVICE OR ADJUST ALONE

Do not attempt internal service or adjustment of equip-ment unless another person capable of rendering aid and resuscitation is present.

LIFTING/HANDLING

The electric chain hoist weighs 136 pounds. The beam assembly and other universal jack tester components have significant weight. Use adequate number of per-sonnel or appropriately rated lifting and handling de-vices to move equipment.

LOCKOUT/TAGOUT

Personnel shall be aware of the hazards associated with unguarded machinery parts, capacitors, gaseous and wet pipe systems, spring loaded devices, etc.

Lockout/tagout the energy source prior to performing maintenance, adjustments, or other procedures that would bypass safety guards, barriers, or otherwise expose personnel to hazardous energy sources. Any equipment, machine, or process that could unexpect-edly energize, start-up, or release energy will be equipped with a means to lockout/tagout the energy source(s).

CLEANING SOLVENT

Cleaning solvent is toxic to skin, eyes, and respiratory tract. Skin and eye protection are required. Avoid repeated or prolonged contact. Good general venti-lation is normally adequate. Observe manufacturers warning labels; Material Safety Data Sheets (MSDS) instructions for proper handling, storage, and dis-posal; and current safety directives.

SPILLED HYDRAULIC FLUID

Spilled hydraulic fluid can cause personnel to slip and fall. Clean up all hydraulic fluid spills immedi-ately. Dispose of hydraulic fluid in accordance with local regulations.

DO NOT PLACE TOOLS ON SUPPORT

Do not place tools or other objects on the top column support. Do not allow persons to sit on, stand on, or hang from the top column support. Such actions can result in personnel injury.

DO NOT PLACE TOOLS ON BEAM

Do not place tools or other objects on the beam as-sembly during lifting or lowering. Do not allow per-sons to sit on, stand on, hang from, or interfere with the beam assembly during lifting or lowering. Such actions can result in personnel injury. Ensure per-sonnel and obstacles are clear of the beam assembly and load chain during lifting or lowering.

WORN LOAD CHAIN

A worn load chain can break without giving an in-dication of failure, causing injury to personnel. Meas-ure chain wear periodically in accordance with instructions in this TO. Dispose of worn load chain by cutting into small pieces. Do not use worn load chain for other tasks.

vi

CUTTING LOAD CHAIN

Cutting the load chain can cause flying particles. Make sure you wear eye protection. Put a shield over the chain to prevent flying particles.

DISCONNECT MAIN POWER

Always disconnect/deenergize the main power supply from the electric chain hoist before attempting any maintenance or repair procedures, or working with the hoist electrical connections. Failure to do so can result in severe electrical shock.

POWER SUPPLY RATING

Ensure the electrical power supply is the correct rating as specified in this TO. An improper electrical power supply can cause damage to the hoist and may result in a fire.

APPROVED LUBRICANTS

Use only approved lubricants for the hoist and load chain. Other lubricants are inadequate and can cause failure of hoist components, resulting in personnel injury and damage to equipment. Do not lubricate the load chain with used motor oil. Used motor oil can contain unknown carcinogenic materials, causing long-term health hazards to personnel.

OPERATOR TRAINING

Operators must be trained in general hoisting/rigging procedures before performing any operation or main-tenance on the universal jack tester. Operators must be familiar with all controls, indicators, and compo-nent parts of the equipment and all Warnings and Cautions before performing any operation or main-tenance on the universal jack tester.

LOAD CHAIN TENSION

You must always permit the load chain to be loose in the area between the liftwheel and the loose end.

If the load chain is tight in this area, it can cause a failure of the hoist, resulting in injury to personnel and/or damage to equipment.

APPROVED REPLACEMENT PARTS

Do not use replacement parts for the hoist that are not listed in the Illustrated Parts List. Use of substitute parts that are not approved can cause failure of the hoist, resulting in severe injury to personnel and/or damage to equipment.

LOAD CHAIN CONNECTION

Do not connect the hoist/load chain to loads other than the beam assembly. Doing so can cause failure of the hoist and/or load chain, resulting in personnel injury and damage to equipment.

LOAD CHAIN RUNOUT

The loose end of the load chain is not connected to the hoist. Do not allow the loose end of the load chain to run out of the hoist by accident. Doing this can cause injury to persons or damage to equipment.

Make sure the lower limit switch is set correctly to prevent this problem.

LIMIT SWITCH SETTING

Do not permit the hook block to hit the hoist or the chain bucket as this will damage these components.

Make sure the upper limit switch is set correctly to prevent this problem.

AVOID DAMAGE TO PARTS

Handle equipment carefully to avoid damage to threads and sealing surfaces. Do not tighten vise or place wrench on other than wrench flats. Damage to unit may result.

vii (viii blank)

T.O. 33AA14-2-1

CHAPTER I

INTRODUCTION AND GENERAL INFORMATION

1-1. GENERAL INFORMATION.

1-1.1. Purpose of Manual. This technical manual contains operation and maintenance instructions for the Universal Jack Tester, Part Number 7186-

010. This unit (shown in Figure 1-1) is made by Regent Mfg., Inc., 11905 Regentview Ave., Downey, CA 90241-5587. In the remaining parts of this manual we will use the name “jack tester” in place of the full name “universal jack tester”.

1-1.2. Scope and Arrangement. This manual is divided into eight chapters: Introduction and Gen-eral Information, Special Tools and Test Equip-ment, Preparation for Use and Shipment, Operat-ing Instruct ions, Maintenance Instructions, Diagrams, Illustrated Parts Breakdown and Differ-ence Data Sheets. Chapters I through VIII of this manual give all the necessary instructions to oper-ate and maintain the jack tester.

1-1.3. List of Technical Manuals. The following technical manuals are referred to in this manual:

AWS D1.1 American Welding Society Structural Welding Code - Steel

MLSTD-116

ML-STD-129

T.O. 00-25-234

T.O. 1-1A-3

T.O. 1-1A-15

T.O. 35-1-3

Preservation, Methods of Marking for Shipment and

Storage General Shop Practice

Requirements for the Repair, Maintenance, and Test of Electronic Equipment

Engineering Manual Series, Aircraft Missiles and Related Aerospace Ground Support Equipment (AGE) Repair-Structural Hardware

General Maintenance Instructions for Ground Support Equipment (GS)

Painting and Marking of USAF Aerospace Ground Support Equipment

T.O. 351-246WC-1 Periodic Inspection Workcards for Ground Support Equipment

T.O. 35A2-1-1 General Inspection Procedures and Overhaul for Hydraulic Jacks

T.O. 35A2-2-94-3 Overhaul, Repair and Test Procedures Aircraft Hydraulic Jacks

1-1.4. Abbreviations/Acronyms. Refer to MIL- STD-12 (D) for definitions of standard abbrevia-tions and acronyms used in this manual. Nonstan-dard abbreviations and acronyms used in this man-ual are specified below. All weights and dimensions are shown in English standard units, with the met-ric equivalent in parenthesis.

NI Numerical Index

NOVRAM Non-Volatile Random Access Memory

RDl Ref Des Index

VIN Input Voltage

VREF Reference Voltage

1-2. DESCRIPTION.

1-2.1. Purpose. The jack tester is a permanently installed fixture used for the static testing of jacks with a lift capacity of 75 tons.

1-2.2. System. (Figure 1-1) The jack tester has two vertical columns connected together by top col-umn support and installed into a bottom column support in the foundation. The top column support holds a hoist which is connected to the beam assem-bly. A control box contains electrical controls and indicators for the hoist. A chain bucket is attached to the side of the hoist and contains the load chain when the main beam is raised. A hook block assem-bly is

Change 1 1-1

Figure 1-1. Universal Jack Tester

1-2

TO 33AA14-2 -1

mounted to the lifting chain. A load cell is installed on the underside of the beam assembly. The beam assembly is locked in place by two pairs of lock pins.

A ladder is installed on each column to permit access to the hoist. The ladder is connected to the column by brackets. A notch rail is attached to each ladder.

A sliding sleeve is installed on the notch rail to attach the safety belt.

1-2.3. Control Box. (Figure 1-2) The control box consists of a metal case which houses controls and indicators. Main control box components include an LED display, printed circuit boards, a transformer, terminal blocks, and switches.

1-2.4. Electric Chain Hoist. (Figure 1-3) The electric chain hoist consists of a motor housing, gear housing, backframe, and associated covers. The motor housing contains a rotor, stator, and end bell on one side.

The rotor connects to a liftwheel and chain guides on the other side of the motor housing. The liftwheel connects to a series of gears through a hole in the gear case. The backframe contains a limit switch and electric brake. Covers are removable for maintenance.

A swivel hook suspension provides attachment to the top support. Lifting capacity of the hoist is two tons.

1-2.5. Leading Particulars. Refer to Table 1-1 for leading particulars, main features, and technical char-acteristics of the jack tester.

Table 1-1. Leading Particulars

1-3

Figure 1-2. Control Box

Figure 1-3. Electric Chain Hoist

1-4

CHAPTER II

SPECIAL TOOLS AND TEST EQUIPMENT

2-1. SPECIAL TOOLS AND TEST EOUIPMENT. 2-3. OTHER EQUIPMENT.

2-2. No special tools or test equipment is required. 2-4. Equipment that may be necessary for mainte-nance or assembly/disassembly of the jack tester is listed in Table 2-1 You can use equivalent substitutes.

Table 2-1. Other Equipment List

2-5. CONSUMABLES.

2-6. Refer to Table 2-2 for consumable materials and expendable items necessary for maintenance.

Table 2-2. Consumable Materials

2-1

2-7. LOCAL MANUFACTURED ITEMS.

2-8. You must locally manufacture the cover for the control box (3, Figure 7-1). Refer to Figure 2-1 for instructions.

Figure 2-1. Fabrication Detail for the Cover

2-2

CHAPTER III

PREPARATION FOR USE AND SHIPMENT

3-1. PREPARATION FOR USE.

3-1.1. Foundation Installation. (Figure 3-1)

NOTE

Foundation installation instructions in this manual are typical of most installations.

Drawing number 7186-F, CAGE Code 02708, m a y b e r e q u e s t e d f r o m SA-ALC/TILDE, Kelly AFB TX 78241, for foundation instructions.

The jack tester cannot be installed if the ceiling height is less than the minimum specified below. b.

a. If the jack tester will be located indoors, you must calculate the ceiling height necessary to permit in-stallation. The minimum height necessary is 23 feet plus the height of the lifting device used to install the components into the foundation. This height is c.

not sufficient to permit installation of pre-assembled columns and top column support, but will permit you to install each part separately. More time is necessary to install components with this procedure.

You can install pre-assembled columns and top col-umn support if the available ceiling height is 25 feet plus the height of the hoist.

NOTE

The foundation drawing shown in Figure 3-1 is typical of most installations, but soil and topographical conditions at each location are different. It may be necessary to change the configuration of the foundation drawing to adjust to local conditions.

Minimum soil bearing pressure for the foundation is 1500 pounds per square foot. If the soil conditions do not permit this pressure, then the foundation de-sign must be changed. A civil engineer must adapt the design to adjust to local conditions.

The materials necessary to make the foundation are found in Table 3-1.

Table 3-1. Foundation Materials

3-1

d. To make the foundation, follow these instructions:

(1) Prepare the foundation area by removing ma-terial from a space 180 inches long x 180 inches wide x 48 inches deep as shown in Figure 3-1

(2)

(3)

(4)

If the bottom column support is not installed in the correct position, the location of the ladders and the operator’s station will be incorrect. This can prevent full use of the jack tester.

Upright parts of the bottom column support must be vertical to the floor within 0.5 degrees or the jack tester will not operate correctly.

Install the bottom column support (1, Figure 7-1) as shown in Figure 3-1. The word FRONT must point in the direction of the operator. Up-right parts of the bottom column support must be vertical to the floor within 0.5 degrees.

Install the rebar (2, Figure 3-1). Spotweld the rebar to the bottom column support (1) where the pieces touch, in accordance with AWSD 1.1.

Weld the stepbolts (3) to the angle pieces (4, 5). Weld the angle pieces (4, 5) together, in accordance with AWS.D1. 1.

The angle assembly must be level within

0.5 degrees or the jack tester will not operate correctly.

(5) Install the angle (4, 5) assembly. Angle assembly must be level within 0.5 degrees.

NOTE

The concrete must have a minimum compressive strength of 3000 psi.

NOTE

If the building has a concrete slab, the foundation must be made flush with the slab.

A preformed 3/4 inch expansion joint is necessary around the outer edge of the foundation.

Do not fill in the drain holes with concrete or moisture will collect at bottom of the support and cause corrosion. Refer to Figure 3-1 for drain hole location.

The concrete floor must be level within 0.5 degrees or the jack tester will not operate correctly.

If the concrete does not cure for the specified time, the foundation will be unstable.

(6) Fill the foundation area with concrete. Fill the bottom column support (1, Figure 3-1) posts with concrete up to the level of the 1/2 inch drain holes. The concrete must cure for 30 days, minimum.

3-1.2. Initial Setum (Figure 7-1)

NOTE

Most components of the jack tester are assembled by the manufacturer before shipment. Only primary components must be assembled during initial setup.

3-1.2.1. E25 Foot Ceiling. You can use the subsequent procedure to save assembly time, but only if the ceil-ing height is 25 feet or more, plus the height of the hoist (Table 2-1). If the ceiling height is less than this quantity, refer to paragraph 3-5 .

NOTE

Ensure pins (52) on beam assembly (46) are located to the front. Refer to Figure 3-1.

a. Set the beam assembly (46, Figure 7-1) on to the bottom column support (58). Use the hoist (Table 2-1). Align the bore holes in the beam assembly and the bottom column support.

b. Install the columns (55, 56) in the top column support (41). Install the screws (42), the lockwashers (43), the washers (44) and the nuts (45).

c. Attach the hoist (2) to the top column support (41).

3-2

Figure 3-1. Fabrication Detail for the Foundation

3-3

NOTE

Top column support is stenciled “FRONT”.

d. Lift the top column support (41) and attached parts (55, 56). Put the columns (55, 56) into the bottom column support (57). Install the screws (42) the lockwashers (43), the washers (44) and the nuts (45). Do not tighten the nuts.

e. Install adjusting screws (62) in the bottom column sup-port (57) and tighten until columns (55, 56) are vertical within 0.5 degrees. Tighten nuts (45).

f. Install the brace (32) and the bracket (35) on the ladder

(24) with the screws (25) the washers (26) and the nuts (27).

g. Install the ladder (24) and attached parts (32, 35) on the column (55) with the screws (33, 36) and the washers (34, 37). Ensure ladder with control box bracket (11) is mounted on front left side.

h. Install the brace (32) and the bracket (38) on the column

(56) with the screws (33, 39) and the washers (34, 40).

i. Install the ladder (28) on the brace (32) and the bracket

(38) with the screws (29) the washers (30), and the nuts (31).

3-1.2.2. 23 Foot Ceiling. Use the subsequent procedure if the ceiling height is 23 feet or more plus the height of the hoist, but less than 25 feet plus the height of the hoist. If the ceiling height is 25 feet or more plus the height of the hoist, refer to paragraph 3-4 to save time during assembly.

a. Install the columns (55, 56) into the bottom column sup-port (57). Install the screws (42) the lock washers (43), the washers (44), and the nuts (45). Do not tighten the nuts.

b. Install adjusting screws (62) in the bottom column sup-port (57) and tighten until columns (55, 56) are vertical within 0.5 degrees. Tighten nuts (45).

NOTE

Ensure pins (52) on beam assembly (46) are located to the front. Refer to Figure 3-1.

c. Install the beam assembly (46, Figure 7-1) on the col-umns (55, 56) so that it rests on the bottom column support (57). Use the hoist (Table 2-1).

NOTE

Top column support is stenciled “FRONT”.

d. Attach the hoist (2) to the top column support (41).

Install the top column support (41) on the columns (55, 56). Use the hoist (Table 2-1). Install the screws (42) the lockwashers (43) the washers (44) and the nuts (45).

e. Install the brace (32) and the bracket (35) on the ladder

(24) with the screws (25) the washers (26) and the nuts (27).

f. Install the ladder (24) and attached parts (32, 35) on the column (55) with the screws (33, 36) and the washers (34, 37). Ensure ladder with control box bracket (11) is mounted on front left side.

g. Install the brace (32) and the bracket (38) on the column

(56) with the screws (33, 39) and the washers (34, 40).

h. Install the ladder (28) on the brace (32) and the bracket

(38) with the screws (29), the washers (30), and the nuts (31).

Failure to insert flat side of load cell (1, Figure 7-1) in the beam Assembly (54) with the stud (53) can result in death or serious injury to personnel or dam-age to equipment. Ensure flat side of load cell is fully flush with beam assembly prior to use.

3-1.3. Wiring/Power Connections. (Figure 7-1)

a. Install bracket (11) on ladder (24) and secure using screws (12), washers (13), and nuts (14).

b. Install arm brace (7) on bracket (11) and secure using bearing (10), washer (9), and cotter pin (8).

c. Install control box (3) on bracket (7) using screws (4), washers (5), and nuts (6).

d. Install the load cell (1) on the beam assembly (46).

e. Refer to the electrical schematic provided in DIA- GRAMS (Chapter VI) and connect the cable (65) from the load cell (1) to the control box (3). Secure to beam

(46) and ladder (24) using loop clamps (58), screws (59) washers (60), and nuts (61).

3-4 Change 3

f. Connect the control and power cables (127, 128, Figure 7-2) from the hoist (2, Figure 7-1) to the control box (3).

Secure to support (41) and ladder (24) using loop clamps (58), screws (59), washers (60), and nuts (61).

g. Electrical wiring from the power source to the control box (3) is not provided with the jack tester and must be supplied by the user. Make sure the electrical power source is 115 VAC, single phase, 60 Hz.

h. Make sure the door on the control box (3) is closed and locked. Use the clips to lock the door.

3-1.4. Hoist Test/Beam Hookup. (Figure 7-1)

Make sure the area around the jack tester is clear of objects that could hit or catch the load chain or beam assembly during operation.

• Never walk under beam if load pins are not in the locked position.

• Only use the ladder to climb on the unit. Never climb on the ladder without using the safety belt.

a. Place the ON switch on the control box (3) in the ON

(up) position. Permit the control box to do a self-check for approximately 3 minutes. It is necessary for the elec-tronic system to be stable before you do a test.

b. Test the electrical connections by operating the UP and DOWN switches on the control box. (3). Make sure the lower hook (57, Figure 7-2) moves in the specified direction. If the hoist (2, Figure 7-1) does not operate correctly, refer to TROUBLESHOOTING (Chapter V).

c. Operate the DOWN switch on the control box (3) until a sufficient length of load chain is available to connect the lower hook to the beam assembly (46).

Make sure that the load chain is tight, with no slack, before releasing the stop pins.

d. Make sure the stop pins (52) on the beam assembly (46) are locked in the disengaged position. Operate the UP and DOWN switches on the control box (3) until the beam assembly is at the necessary height.

e. Release the upper two (spring loaded) stop pins (52) on the beam assembly (46). Operate the UP and DOWN switches on the control box (3) until the upper two stop pins engage the holes in the columns (55, 56). Engage the lower two stop pins (52) in the holes in the columns.

Make sure all the stop pins are locked in position.

f. Operate the DOWN switch on the control box (3, Figure 7-1) for one second to make sure the stop pins (52) fully engage the holes in the columns (55, 56).

g. The control box (3) must be calibrated before initial use.

Refer to CALIBRATION (Chapter IV) for instructions.

3-1.5. Preoperational Inspection. (Figure 7-1) Do a preoperational inspection as specified in Table 3-2. You must replace or repair any component that shows wear or damage before operating the hoist. You must tighten any component that is loose.

NOTE

A fast visual inspection is sufficient when jack tester components are new. A full inspection is necessary when components show signs of use or damage.

Change 3 3-5

Table 3-2. Preoperational Inspection

COMPONENT

All jack tester components

Control box (3)

INSPECT FOR

Obvious damage, loose or missing parts

AFTO Form 244, Status of Unit, must show current inspection dates

Safety belt (15) Distortion, sharp edges, burrs, cracks, wear or corrosion on metal parts

Spring tension on snap ring keeper that is not sufficient to make keeper close flat, and stay closed, against the snap;

keeper that has sideways play

Belt fibers that are frayed or broken, belt material that has tears, burns, mold, abrasions, pulled stitches, or discolor-ation. Examine webbing by bending belt over 1-1/2 inch diameter tubing

Rivets and grommets that are not securely attached

Sleeve (19) Damaged hooks or latches, damaged rollers, spring on sleeve body with insufficient pressure to fully lock the latching mechanism

3-2. PREPARATION FOR SHIPMENT.

a. Foundation components are permanantly installed.

Other jack tester components must be disassembled before shipment. Refer to DISASSEMBLY (Chapter V) for instructions.

b. Do the preservation and packaging procedures found in MIL-STD-281 for all components.

c. All components must be marked and identified. Refer to MIL-STD-162 for instructions.

Do not store the safety belt in an area that is hot or open to sunlight. Doing this will cause damage to the belt and can cause it to wear quickly.

d. If the equipment is not used, it must be kept in a location that is clean and dry.

3-6

CHAPTER IV

OPERATION INSTRUCTIONS

4-1. THEORY OF OPERATION.

4-1.1. Jack Tester. The jack tester uses an electrical chain hoist to lift and lower a beam assembly. The hoist is operated by a control box. A load cell attached to the beam assembly connects to the the control box.

The beam assembly is positioned over the jack to be tested and locked in position. Then the jack is operated to apply pressure against the load cell. This pressure is indicated on a display on the control box.

4-1.2. Control Box. When the ON switch is put in the ON position, 115 VAC from the main power source goes to the control box, and causes the POWER light to come on. Power will not be provided if the door interlock (S6) is open or if the circuit breaker (S5) is open. The detailed theory of operation for the con-trol box is shown in the block diagram, Figure 4-1 .

There are three input sources for the control box: the load cell output signal, a zero reference, and a full scale voltage signal. These three sources go into a multiplex unit and are used each time a weight is calculated. A microprocessor uses the zero and full scale data to correct any change in the amplifier, filter, or analog-to-digital converter signals when a weight is calculated. The strength of these signals is increased by an amplifier to keep background noise to a mini-mum. A filter is used to decrease any high frequency signals that are more than 10 Hz. The filtered signal goes to the analog-to-digital converter. The analog-to-digital converter changes the analog voltage signal from the load cell to a digtal value. This is necessary because the microprocessor uses data to calculate the weight, but the load cell output is an analog voltage.

The value of the input voltage (VIN) is divided by the value of the reference voltage (VREF). This makes allowance for any internal changes, such as the load cell excitation voltage. The output from the analog-to-digital converter goes to the microprocessor in in-crements of one bit at a time. This value is compared to a zero value and to the full scale signal value and corrected with a span constant. The zero value is the quantity subtracted from the load cell output to make the scale show zero when no weight is applied against the load cell. The zero value is set using the ZERO switch on the front panel. The span constant controls the proportion of weight shown on the display to the strength of the full scale signal. The span constant is set by applying a known weight to the load cell and writing that known weight value into the micro-processor. This procedure is done at three weights:

1/3, 2/3, and full capacity. The span constant is then applied automatically during the weighing procedure.

The microprocessor selects the correct span constant to use for each weight to be calculated. The span constant is set with the ZERO (S1) and DIGIT AD- VANCE (S2) switches. The value that results from the zero and span calculations is sent to the display driver and a liquid crystal display. The span constants and zero value data is stored on the non-volatile ran-dom access memory (NOVRAM) chip. The incre-ments of the display are controlled by a graduation value. The graduation value is set with the ZERO (S1) and DIGIT ADVANCE (S2) switches. The volt-age from the power supply is divided into voltages for the analog system (+5 volts, -5 volts), and the digital system (+5 volts). Operating voltage is com-pared against a reference voltage and the system closes down if the operating voltage is insufficient.

4-1.3. Hoist. When the UP or DOWN switch on the control box is pressed, electrical power goes through a terminal board to an upper or lower limit switch and to a contactor to operate the electric motor in the specified direction. When the UP or DOWN switch is released, the electric brake is energized to stop the travel of the hook. A motor reversing switch is provided to change the direction of hook travel. When hook travel reaches the set limit, the upper or lower limit switch is opened to cut electrical power to the motor and stop the hook.

4-1.4. Load Cell. The load cell contains strain gauges that convert an excitation (input) voltage to a smaller output voltage in direct proportion to the weight against the load cell.

4-2. OPERATING CONTROLS AND INDICA-

TORS.

4-3. The function of operating controls and indicators is specified in Table 4-1 . Component locations are shown in Figure 4-2 . Control box display indications are shown in Table 4-2 . Refer to paragraph 4-16 for instructions to use the controls for calibration.

4-1

T O 33AA14-2-1

Figure 4-1. Control Box Block Diagram

4-2

Table 4-1. Controls and Indicators

CONTROL OR INDICATOR FUNCTIONAL DESCRIPTION

DIGIT ADVANCE switch (S2) Permits the entry of calibration values. Press this switch to move the value in the display one position to the left (“1” becomes “10”). Press this switch and the ZERO switch at the same time to set that value and move the display forward

Display Shows the weight against the load cell. Also shows messages and number values. The display is a liquid crystal unit and contains one line of five digits

DOWN Switch (S3) Controls motor rotation to lower the load chain and hook

ON Switch In the ON (up) position applies power to the control box.

The down position turns off power to the control box

POWER Lamp (D1) Comes on when power is applied to the control box

UP Switch (S4) Controls motor rotation to lift the load chain and hook

ZERO Switch (S1) Sets the weighing system to read zero pounds. If there is weight against the load cell, that value becomes zero. You can do the zero procedure at any weight up to the total capacity of the scale. The ZERO switch does not operate when a weight change is sensed. You can also use this switch to enter a value from 0 to 9 in the display.

4-3

Figure 4-2. Controls and Indicators

4-4

Table 4-2. Display Indications

INDICATION

DISE

DATA

Tells you that a switch is pressed or a value is being calculated.

Tells you that the number you are writing cannot be shown on the display. An example of this would be a number with six numerals.

The display can show only five numerals, so trying to add a sixth numeral would cause the “DISE” indication.

EEPE Tells you that there is an EEPROM error. You must do the CALIBRATION procedure.

LL-00 Tells you that you must set the zero value by pressing both the ZERO and DIGIT ADVANCE switches.

LL-01 Tells you that the next value you must enter is a weight that is about 1/3 of the maximum capacity of the unit.

LE-02 Tells you that the next value you must enter is a weight that is about 2/3 of the maximum capacity of the unit.

LL-03 Tells you that the next value you must enter is a weight that is almost the full capacity of the unit.

OE Tells you that the weight input is more than the maximum permit-ted, or the load cell is not connected to the control box. This indica-tion also can tell you that a printed circuit board (PCB) is damaged.

18888 Tells you that the display is doing an initial procedure after the electrical power is turned on but before the unit can do a test.

Permit this initial procedure to complete before you try to do a test.

The time necessary for this is about three minutes.

4-5

4-4. CALIBRATION. (Figure 7-1) 4-5. Calibration is necessary once a year or if the control box has been repaired or a new printed circuit board is installed. Calibration is also neces-sary if a new load cell is installed on the jack tester.

4-5.1. Using the ZERO and DIGIT ADVANCE Switches. Use the ZERO and DIGIT ADVANCE switches to set the necessary number values. The display shows a number with a blinking digit.

Press the ZERO switch to increase the blinking digit shown in the display from “0” to “9” and back to “0” in increments of 1. Press the DIGIT ADVANCE switch to move the blinking digit one place to the left. When the blinking digit is in the left-most position, pressing the DIGIT ADVANCE switch moves the blinking digit to the right-most position. Press the ZERO switch and the DIGIT ADVANCE switch at the same time to set that value and move the display forward.

4-5.2. Calibration Procedure Using A Jack. (Table 4-1) This procedure permits you to test the load cell at same time. Only one jack type is required for this procedure.

The jack must be centered under the load cell before testing.

Never walk under beam if load pins are not in the locked position.

Only use the ladder to climb on the unit. Never climb on the ladder with-out using the safety belt.

Ensure correct adapter is installed on load cell.

NOTE

Jack must have a capacity of 50 tons minimum.

a. Install appropriate adapter on load cell (3).

Disconnect main power before opening control box door.

b. Open door to control box (3). Refer to Figure 4-3 and locate CAL 1 jumper on A/D printed circuit board. Move the jumper from the lower two pins (normal position) to the upper two pins (calibrate enable). Close the door to control box.

c. Locate the jack under the load cell (3, Figure 7-1).

d. Connect main power to control box. Put the ON switch on the control box (3, Figure 7-1) in the ON (up) position. Permit the control box to do a self-check for approximately 3 minutes.