m be certain. Series 505 SilentFlo™ Hydraulic Power Unit Product Information Model 505.07 Model 505.
Copyright information Trademark information © 1999–2010 MTS Systems Corporation. All rights reserved. MTS and SilentFlo are registered trademarks of MTS Systems Corporation within the United States. These trademarks may be protected in other countries. DTE is a registered trademark of Exxon Mobil Corporation. Tellus is a registered trademark of Shell Oil Corporation. Molykote is a registered trademark of Dow Chemical Corporation. Synasol is a registered trademark of Union Carbide Corporation.
Contents Technical Support 5 How to Get Technical Support Before You Contact MTS 5 5 If You Contact MTS by Phone 6 Problem Submittal Form in MTS Manuals 7 Preface 9 Before You Begin Conventions 9 10 Documentation Conventions 10 Introduction 13 EU Declarations 13 Component Identification Functional Description 14 15 505.07/.11 HPU Hydraulic Schematic Auto-Cooling Valve (adjustable) Electrical Control 17 18 18 505.07 HPU Electrical Schematic 19 505.
Operation 37 505.07/.11 HPU Controls 38 Operating the HPU Locally or Remotely Recovering from an Interlock Changing the Water Flow 40 41 42 Resetting the Thermal Overloads 43 Adjusting the Hydraulic Pressure 44 Adjusting the HPU Output Pressure Level Adjusting the Auto-Cooling Level 45 45 Low/High Pressure Functionality 49 Maintenance 53 Routine Maintenance Overview Checklist 54 505.07/.
How to Get Technical Support Technical Support How to Get Technical Support Start with your manuals The manuals supplied by MTS provide most of the information you need to use and maintain your equipment. If your equipment includes software, look for online help and README files that contain additional product information. If you cannot find answers to your technical questions from these sources, you can use the Internet, e-mail, telephone, or fax to contact MTS for assistance.
If You Contact MTS by Phone Know information from prior technical assistance Identify the problem Know relevant computer information Know relevant software information If you have contacted MTS about this problem before, we can recall your file based on the: • MTS notification number • Name of the person who helped you Describe the problem and know the answers to the following questions: • How long and how often has the problem occurred? • Can you reproduce the problem? • Were any hardware or
Problem Submittal Form in MTS Manuals • Name • Company name • Company address • Phone number where you can be reached If your issue has a notification number, please provide that number. A new issue will be assigned a unique notification number.
Problem Submittal Form in MTS Manuals 8 Technical Support • In the back of many MTS manuals (postage paid form to be mailed to MTS) • www.mts.com > Contact Us > Problem Submittal Form button (electronic form to be e-mailed to MTS) Model 505.07/.
Before You Begin Preface Before You Begin Safety first! Other MTS manuals Before you use your MTS product or system, read and understand the Safety manual and any other safety information provided with your system. Improper installation, operation, or maintenance can result in hazardous conditions that can cause severe personal injury or death, or damage to your equipment and specimen. Again, read and understand the safety information provided with your system before you continue.
Conventions Conventions Documentation Conventions The following paragraphs describe some of the conventions that are used in your MTS manuals. Hazard conventions Hazard notices may be embedded in this manual. These notices contain safety information that is specific to the activity to be performed. Hazard notices immediately precede the step or procedure that may lead to an associated hazard. Read all hazard notices carefully and follow all directions and recommendations.
Documentation Conventions Hypertext links The electronic document has many hypertext links displayed in a blue font. All blue words in the body text, along with all contents entries and index page numbers, are hypertext links. When you click a hypertext link, the application jumps to the corresponding topic. Model 505.07/.
Documentation Conventions 12 Preface Model 505.07/.
EU Declarations Introduction The MTS Model 505.07 Hydraulic Power Unit (HPU) and Model 505.11 HPU provide high-pressure hydraulic fluid for test system operation. This section contains the functional description and the specifications of the HPU. Contents Component Identification Functional Description 14 15 505.07/.11 HPU Hydraulic Schematic Auto-Cooling Valve (adjustable) Electrical Control 17 18 18 505.07 HPU Electrical Schematic 19 505.
Component Identification Component Identification Output Pressure Gage Nameplate Control Panel (other side of box) Auto-Cooling Valve Electrical Enclosure Power Discon Switch (other side of box) Pressure Relief Valve Low Level/ Overtemperature Sensor Fluid Level Gage Filler Cap Return Filter Temperature Gage Fluid Sample Port Control Manifold (shown rotated) Heat Exchanger Output Pressure Control High Pressure Filter Location (optional–not shown) Surge Supressor Mounted to Pump (optional) Drain V
Functional Description Component Descriptions (part 2 of 2) COMPONENT DESCRIPTION Drain Valve Drains the hydraulic fluid from the reservoir. Fluid Level Gage Displays the level of the hydraulic fluid. Fluid Sample Port Access port for obtaining hydraulic fluid samples from the HPU. A quick disconnect port is provided. Use the optional sampling kit that includes a needle valve to regulate the flow through the sample port.
Functional Description The unit automatically starts in low pressure to reduce the amperage needed for starting, which will extend pump and motor life. When operating at this setting, low-pressure fluid is available to the hydraulic circuit. Low pressure is achieved by diverting a portion of the hydraulic fluid through the high pressure solenoid and returning it to the reservoir.
505.07/.11 HPU Hydraulic Schematic 505.07/.11 HPU Hydraulic Schematic The hydraulic schematic shows the functional layout of the Series 505 Hydraulic Power Unit. P D D W W 0.06 inch Orifice 0.007 MPa (1.0 psi) Pressure Filter (optional) Pressure Gage R Accumulator Oil Sample Port Check Valve Optional Pressure Port Auto-cooling Valve (adjustable) High Pressure Solenoid Valve Pressure Relief Valve (factory set at 22.
Auto-Cooling Valve (adjustable) Auto-Cooling Valve (adjustable) The auto-cooling function is integrated into the control manifold. During periods of low flow demand from the external hydraulic circuit, this feature provides two important benefits: a re-circulating flow that ensures hydraulic fluid filtering whenever the unit is on, and safeguarding against hydraulic fluid overtemperature.
505.07 HPU Electrical Schematic 505.07 HPU Electrical Schematic The electrical schematic shows the electrical layout of the Model 505.07 Hydraulic Power Unit. Model 505.07/.
505.07 HPU Electrical Schematic 20 Introduction Model 505.07/.
505.11 HPU Electrical Schematic 505.11 HPU Electrical Schematic The electrical schematic shows the electrical layout of the Model 505.11 Hydraulic Power Unit. Model 505.07/.
505.11 HPU Electrical Schematic 22 Introduction Model 505.07/.
Series 505 HPU General Specifications Series 505 HPU General Specifications General Specifications PARAMETER SPECIFICATION Environmental For use in a controlled environment Operating temperature 5–40°C (41–104°F) Humidity 0–85% noncondensing Heat load <630 kcal/hr (2500 BTU/hr) Noise* rating at 1 m 60 dB (A) fully compensated Hydraulic fluid Exxon Mobil DTE 25 or Shell Tellus 46 AW Typical operating temperature range 43–49°C (110–120°F) Filtration 3 microns nominal Reservoir capacity 174
Series 505 HPU General Specifications Model Specific Specifications PARAMETER 505.07 SPECIFICATION 505.11 SPECIFICATION Pump/motor Line voltage starter configuration Wye-Delta starter configuration Maximum Continuous pressure 21 MPa (3000 psi) 21 MPa (3000 psi) Maximum Flow capacity 22.7 L/m (6 gpm) at 50 Hz 26.5 L/m (7 gpm) at 60 Hz 41.6 L/m (11 gpm) at 50/60 Hz Motor rating 11.2 Kw (15 hp) at 50/60 Hz 18.6 Kw (25 hp) at 50/60 Hz 10.0°C (50°F) 3.8 L/m (1.0 gpm) 7.2 L/m (1.9 gpm) 15.
General Safety Practices: Hydraulic Power Units and Safety General Safety Practices: Hydraulic Power Units and Hydraulic Service Manifolds The hydraulic power unit (HPU) provides high pressure hydraulic fluid to system components for system operation. The hydraulic service manifold (HSM) controls distribution of that hydraulic fluid pressure. This section provides general information about safety issues that pertain to system hydraulic supply and distribution components.
General Safety Practices: Hydraulic Power Units and It is very important that you study the following safety information to ensure that your facility procedures and the system’s operating environment do not contribute to or result in a hazardous situation. Remember, you cannot eliminate all the hazards associated with this system, so you must learn and remain aware of the hazards that apply to your system at all times.
General Safety Practices: Hydraulic Power Units and Have first aid available Accidents can happen even when you are careful. Arrange your operator schedules so that a properly trained person is always close by to render first aid. In addition, ensure that local emergency contact information is posted clearly and in sight of the system operator. Know potential crush and pinch points Be aware of potential crush and pinch points on your system and keep personnel and equipment clear of these areas.
General Safety Practices: Hydraulic Power Units and Practice good housekeeping Keep the floors in the work area clean. Hydraulic fluid that is spilled on any type of floor can result in a dangerous, slippery surface. Do not leave tools, fixtures, or other items not specific to the test, lying about on the floor, system, or decking. Protect hoses and cables Protect electrical cables from spilled hydraulic fluid and from excessive temperatures that can cause the cables to harden and eventually fail.
General Safety Practices: Hydraulic Power Units and Handle chemicals safely Whenever you use or handle chemicals (for example, cleaning fluids, hydraulic fluid, batteries, contaminated parts, electrical fluids, and maintenance waste), refer to the appropriate MSDS documentation for that material and determine the appropriate measures and equipment required to handle and use the chemical safely. Ensure that the chemical is disposed of appropriately.
General Safety Practices: Hydraulic Power Units and Know the causes of unexpected actuator motions Do not use RF transmitters Know compressed gas hazards The high force and velocity capabilities of MTS actuators can be destructive and dangerous (especially if actuator motion is unexpected).
General Safety Practices: Hydraulic Power Units and Consult MTS when in doubt about the safety or reliability of any system-related procedure or modification that involves devices that contain any type of compressed gas. The following labels and placards are typically located on the HPU. LABEL DESCRIPTION Hydraulic Power Unit information label. Part # 055-526-401 Overcurrent protection provided at machine supply terminals.
General Safety Practices: Hydraulic Power Units and LABEL DESCRIPTION Warning Disconnect unit from the electrical supply before opening enclosure. Part # 100-008-037 Wye-Delta Connections Use for single voltage 6 lead motors suitable for wye-delta starting. Part # 053-448-401 32 Safety Model 505.07/.
Install the HPU Installation This section describes how to install the Series 505 Hydraulic Power Unit (HPU). Note The HPU is designed for indoor use. The HPU should be stored and installed indoors. Install the HPU 1. Position the hydraulic power unit. Determine where to put the HPU. Review the following: • The HPU can fit through a standard 1-m or 36-in door. • The HPU can be moved by a fork lift, pallet jack, or dolly.
Install the HPU B. Connect the grounding wire to the lug labeled PE GND (protective earth ground). Electrical Power Feed Lugs (shown labeled for clockwise phase orientation) Ensure that lugs are secure. They should be checked periodically. See the Maintenance section. PE GND (Protective Earth Ground) Lug Power Disconnect cw HPU Power Requirement and Power Feed Phase Orientation Identifier 2. Connect the hydraulic lines. The following figure shows the hydraulic adapter ports to the HPU.
Install the HPU Note For hydraulic connections to air-cooled units, refer to the Air-Cooler to SilentFlo™ HPU Integration Product Information manual (MTS part number 100-135-073). The HPU requires connection to a suitable water supply, equipped with an appropriate shutoff valve, to cool the hydraulic fluid. The differential pressure required between the HPU water inlet and outlet connections is 0.24 to 0.34 MPa (35 to 50 psi). The maximum allowable water inlet pressure is 0.83 MPa (120 psi).
Install the HPU E. Verify the motor rotation (the pump motor can start with the wrong rotation). Turn the High/Low/Start switch to the High position. • If pressure begins to increase, proceed to the next step. • If the output pressure gage shows no pressure, press the Stop button to shut down the unit (do not run more than 10 seconds in the wrong direction). Have a qualified electrician make a change in the electrical phase to the motor. F. Check for unusual noises or leaks.
Operation This section describes the front panel controls and indicators, and provides operating instructions for the Series 505 Hydraulic Power Unit (HPU). Contents 505.07/.11 HPU Controls 38 Operating the HPU Locally or Remotely Recovering from an Interlock Changing the Water Flow 41 42 Resetting the Thermal Overloads 43 Adjusting the Hydraulic Pressure 44 Adjusting the HPU Output Pressure Level Adjusting the Auto-Cooling Level 45 Low/High Pressure Functionality 49 Model 505.07/.
505.07/.11 HPU Controls 505.07/.11 HPU Controls The controls shown in this figure are described on the following page. Hydraulic Power Unit Control Power On Stop Low Level Reset Overtemperature Dirty Filter Low High Start Hour Meter 0000000 Front Panel Controls 38 Operation Model 505.07/.
505.07/.11 HPU Controls CONTROL/INDICATOR FUNCTION Power On Indicates when power is applied to the HPU from the main electrical circuit. Low Level Indicates when the hydraulic fluid falls below a preset level. A low fluid level will cause an interlock and turn the HPU off. The interlock signal can be monitored by your system controller. After adding hydraulic fluid to the reservoir, press the Reset button to clear the interlock and turn the indicator off.
Operating the HPU Locally or Remotely Operating the HPU Locally or Remotely The HPU can be operated locally using the front panel controls or remotely using your system controller. Local operation 1. Make a general inspection of the HPU. Ensure that all cooling water valves are open and that the external hydraulic circuit is ready for pressure to be applied. Ensure that the Stop button is released. 2. Turn the start switch to the Start position until the pump motor starts.
Recovering from an Interlock Recovering from an Interlock This section describes how to reset each type of HPU interlock. If one of the interlock indicators (Low Level, Overtemperature, Dirty Filter) is lit, the HPU will not start. You must determine the source of the interlock (which indicator is lit) and correct the cause before using the HPU.
Changing the Water Flow 5. Press the Reset button to clear the overtemperature interlock at the HPU. You may need to clear the interlock at the controller, (see your controller manual). 6. You may want to continue running the HPU to cool it off even further. Turn the High/Low/Start switch to the Start position (the High/Low/Start switch returns to the Low position). Continue to run the HPU in the low pressure mode until the hydraulic fluid is sufficiently cooled.
Resetting the Thermal Overloads 2. Observe the temperature gage as the hydraulic fluid temperature rises. Note the temperature where the hydraulic fluid stabilizes. 3. Adjust the water-regulating valve. One full turn (360°) of the adjusting screw produces a change in hydraulic fluid temperature a few degrees. • Adjust the screw clockwise to decrease the operating temperature. • Adjust the screw counterclockwise to increase the operating temperature. 4. Note the effect after 15 minutes. 5.
Adjusting the Hydraulic Pressure 1. Turn the main disconnect switch counterclockwise to remove power from the electrical control box. 2. Loosen the two bolts securing the door of the electrical enclosure and open the door. 3. Locate the thermal overload switch. Press the Reset button to clear the switch. If the thermal overload switch trips again, wait until it cools.
Adjusting the HPU Output Pressure Level CAUTION The pump and motor are designed to operate below a specified pressure. Setting the hydraulic pressure above 21 MPa (3000 psi) can damage the pump and its motor. Do not adjust the output pressure higher than 21 MPa (3000 psi). Adjusting the HPU Output Pressure Level 1. Turn on high hydraulic pressure. Ensure that there are no flow demands by the system. 2. Loosen the nut securing the output pressure control. 3.
Adjusting the Auto-Cooling Level An incorrect adjustment may cause one of two conditions: • An over-temperature interlock as indicated by the front panel indicator. A mis-adjustment of the Auto-Cooling Valve may prohibit the flow of hydraulic fluid across the heat exchanger • Unexpectedly reduced system performance.
Adjusting the Auto-Cooling Level Important Adjustment of the Auto-Cooling Valve to a level too close to the desired output pressure may cause an unstable condition characterized by rapid valve shifting. This condition will produce an audible flutter and can be seen as an erratic movement of the needle on the pressure gage. Adjustment of the Auto-Cooling Valve at or above the desired output pressure may prevent the valve from shifting and result in the HPU overheating.
Adjusting the Auto-Cooling Level Important Adjustment of the Auto-Cooling Valve to a level too close to the desired output pressure may cause an unstable condition characterized by rapid valve shifting. This condition will produce an audible flutter and can be seen as an erratic movement of the needle on the pressure gage. Adjustment of the Auto-Cooling Valve at or above the desired output pressure may prevent the valve from shifting and result in the HPU overheating.
Low/High Pressure Functionality Low/High Pressure Functionality This section clarifies the low and high pressure functionality of the HPU. There are certain cases where it is advantageous to use the HPU in low pressure versus high pressure.
Low/High Pressure Functionality Once the HPU has cleaned the reservoir hydraulic fluid, sections of the system should be isolated and sequentially cleaned. Flushing of hard line sections takes place in high pressure mode. If the HPU is run in low pressure, flow losses in the system will minimize the external flow and reduce the effectiveness of the system flushing and fluid conditioning.
Low/High Pressure Functionality Note Model 505.07/.11 SilentFlo™ HPU If the test condition requires a maximum pressure level less than 14 MPa (2000 psi), consult MTS.
Low/High Pressure Functionality 52 Operation Model 505.07/.
Maintenance This section describes preventive maintenance requirements and their recommended intervals for the HPU. 505.07/.11 HPU Maintenance Schedule Checking the Hydraulic Fluid 58 Replacing the Return Line Filter Sample the Hydraulic Fluid 59 62 Appearance of Hydraulic Fluid Sample Replacing the Hydraulic Fluid Model 505.07/.
Routine Maintenance Overview Checklist Routine Maintenance Overview Checklist Recommended service to be performed at each running time interval noted CALENDAR TIME USING 8 HOUR RUNNING TIME RATE PER DAY DAILY WEEKLY MONTHLY RUNNING TIME-HOURS 8 40 160 Check electronic enclosure ventilation X* Check dirty filter indicators X Check for leaks X Check oil level X Check pressure X ANNUALLY 500 1000 1,500 2,000 Check all accumulators for proper precharge pressure and oil MTS MTS MTS MTS
Routine Maintenance Overview Checklist Recommended service to be performed at each running time interval noted CALENDAR TIME USING 8 HOUR RUNNING TIME RATE PER DAY DAILY WEEKLY MONTHLY RUNNING TIME-HOURS 8 40 160 ANNUALLY 500 1000 1,500 2,000 Replace all filters MTS MTS Verify operation and settings of psi control and relief valves MTS MTS Check pump/motor coupling for wear and debris MTS Check pump voltage and current MTS Check case drain flow MTS Recommend MTS Hydraulix oil sample
505.07/.11 HPU Maintenance Schedule 505.07/.11 HPU Maintenance Schedule The following table lists the recommended interval for each maintenance procedure. Maintenance Schedule (part 1 of 2) WHAT TO DO WHEN TO DO IT HOW TO DO IT Make daily visual inspections Before the start of each day’s testing. Check electronic enclosure ventilation. Check status of dirty filter indicator. Look for signs of fluid leakage. Check the fluid level in the sight gage.
505.07/.11 HPU Maintenance Schedule Maintenance Schedule (part 2 of 2) WHAT TO DO WHEN TO DO IT HOW TO DO IT Verify proper operation of hydraulic valves† Every 1000 hours or 6 months (whichever occurs first). Contact MTS Systems Corporation. Conduct a hydraulic fluid analysis‡ Every 1000 hours or 6 months (whichever occurs first), or sooner if duty is severe. Obtain a sample and submit it for analysis. MTS recommends that the sample be analyzed by our contracted service.
Checking the Hydraulic Fluid Checking the Hydraulic Fluid Hydraulic fluid contamination and deterioration normally occur in most hydraulic systems. Failure to keep your fluid sufficiently free of contaminants or to change the fluid before severe fluid breakdown occurs will cause poor system performance and may lead to expensive system cleanups. Servovalves are especially susceptible to damage from dirty hydraulic fluid. To avoid these problems, you must maintain a clean hydraulic system.
Replacing the Return Line Filter 5. Check and adjust the hydraulic fluid delivery system so that: • Hydraulic fluid temperature stabilizes within the parameters given in the Specifications table when the HPU is operating at high pressure. • Pressure line reading is maintained at 21 MPa (3000 psi) maximum static value. • Maximum drain line back pressure is limited to 0.1 MPa (15 psi).
Replacing the Return Line Filter 2. Open the top of the HPU with an 8-mm (5/16-inch) allen wrench. Output Pressure Gage Filter Assembly Return Line Filter Component Identification 3. Check the output pressure gage. Ensure that the pressure is at zero before proceeding. 4. Unscrew the filter cover. The filter element, bypass assembly, and filter bowl can be removed as one assembly. Be careful not to spill any hydraulic fluid. 5. Remove the disposable element from the bowl.
Replacing the Return Line Filter 8. Insert a new filter element into the bowl and reinstall the bowl assembly. Align the 90° elbow outlet at the bottom of the assembly such that it directs hydraulic fluid flow towards the side of the reservoir as shown in the following illustration. Screw the filter cover back on. Align the 90° elbow outlet at the bottom of the assembly such that it directs hydraulic fluid flow in the direction of the arrow in the graphic above. Model 505.07 HPU Top View 9.
Sample the Hydraulic Fluid Sample the Hydraulic Fluid This section describes how to check the quality of the hydraulic fluid. Review the following hints before obtaining your sample: • Prerequisite Procedure Avoid contamination. – Keep the sample bottle in the storage box of the hydraulic fluid sampling kit until it is needed. – Do not remove the cap from the bottle until immediately before taking the sample. – Do not set the cap down on a dirty surface or in an area where airborne dust can settle.
Appearance of Hydraulic Fluid Sample 1. Operate the HPU until the hydraulic fluid is at normal operating temperature (about 30 minutes). 2. Close the needle valve. Connect the hose valve assembly to the sample port located on the hydraulic manifold on top of the HPU. (See illustration.) 3. Open the needle valve on the hose valve assembly and flush 1 liter (1 quart) of hydraulic fluid though the sampling assembly. This fluid can be directed to a waste container or back into the HPU reservoir. 4.
Replacing the Hydraulic Fluid FLUID PROPERTIES PROBLEM WHAT TO DO Opaque fluid Indicates chemical breakdown Replace the fluid Milky appearance Indicates water is present in the fluid Check the heat exchanger for damage. Look for other water sources if the water does not appear to be coming from the heat exchanger. Identify and correct the source of the water leakage and replace the fluid if necessary.
Replacing the Hydraulic Fluid 1. Prepare the HPU. A. Press the Stop button to turn off the HPU. B. Remove the electrical power to the HPU via a circuit breaker at the power source. C. Use an 8-mm (5/16-inch) allen wrench to unlatch the HPU cover. D. Remove the filler cap. E. Remove the reservoir cover. 2. Remove the hydraulic fluid. A. Use the transfer pump to remove the old hydraulic fluid from the reservoir and into an appropriate container. B.
Replacing the Hydraulic Fluid 66 Maintenance Model 505.07/.
Accessories Contents High Pressure Filter Kit Surge Suppressor Kit 68 69 Precharging the Surge Suppressor Accumulator Lifting Kit 74 Caster Kit 75 Model 505.07/.
High Pressure Filter Kit High Pressure Filter Kit This section describes how to install the high pressure filter kit (part number 100008-737). To install the high pressure filter kit: 1. Ensure that system hydraulic pressure has been reduced to zero before proceeding. To do this, turn off the hydraulic power unit and exercise the actuator until it stops moving. 2. Remove the hose assembly connecting the high pressure port on the manifold assembly to the high pressure output port. 3.
Surge Suppressor Kit To replace the filter: 1. Ensure that system hydraulic pressure has been reduced to zero before proceeding. To do this, turn off the hydraulic power unit and exercise the actuator until it stops moving. 2. Unscrew the filter bowl and remove the filter element. 3. Lift the filter element out of the filter bowl. Be careful to catch any hydraulic fluid dripping from the filter element with a rag or drip pan. 4. Insert the replacement filter into the filter assembly. 5.
Surge Suppressor Kit Required equipment Installation procedure You will need the following to install the Surge Supressor kit: • A Model 505.07 Surge Suppressor kit (part number 100-008-667) or a Model 505.11 Surge Suppressor kit (part number 100-008-665). • Optional Remote Charging kit (part number 100-056-912) • A transfer pump with a 10-micron filter (such as the Model 590.01 Fluid Transfer Pump). • A cleaning solvent such as Synasol. • A charging kit (part number 037-698-601).
Precharging the Surge Suppressor Accumulator A. Press the Start switch. B. Run the HPU at low pressure for about three hours to filter the new hydraulic fluid. C. Run the HPU in high pressure to check for leaks. D. Press the Stop button. Precharging the Surge Suppressor Accumulator It is normal for a small amount of surge suppressor precharge loss to occur during operation.
Precharging the Surge Suppressor Accumulator 4. Open the bleed valve on the accumulator charging kit and remove the chuck valve from the accumulator. Replace the valve stem cap and protective cover on the accumulator.
Precharging the Surge Suppressor Accumulator WARNING Mixing gases can produce unpredictable results. Do not use another gas to precharge a surge suppressor. Use only dry nitrogen gas to precharge surge suppressors. 3. Connect the nitrogen supply hose from the supply bottle pressure regulator output to the input check valve on the charging kit. 4. Open the nitrogen bottle valve. Check the nitrogen bottle pressure gage on the regulator.
Lifting Kit Lifting Kit CAUTION The balance of the load unit can become unsettled. The weight of the HPU can injure you or damage the HPU if it should become unbalanced and fall off the lift. Before moving the HPU, test the balance of the lift by raising the HPU a short distance off the ground.
Caster Kit Caster Kit The caster kit (part number 100-025-327) is a couple of channel supports with casters (two rigid, two locking swivel) connected by support angle brackets. The caster kit allows the hydraulic power unit to be easily moved. The caster kit is designed to hold the Model 505.07 or Model 505.11. MODEL APPROXIMATE WIEGHT (WITH FLUID) 505.07 451 kg (992 lb) 505.11 474 kg (1042 lb) Caster Kit Model 505.07/.
Caster Kit 76 Accessories Model 505.07/.
Appendix A: HPU Maintenance and Service Logs Contents 8 Hours/Daily 78 40 Hours/Weekly 79 160 Hours/Biweekly 500 Hours 80 81 1000 Hours 82 2000 Hours 83 5000 Hours 84 10,000 Hours 85 Appendix A: HPU Maintenance and Service Logs 77
8 Hours/Daily 8 Hours/Daily 8 Hours/Daily Service Interval Recommendation DATE 78 CHECK CONSOLE VERIFICATION CHECK DIRTY FILTER INDICATORS CHECK FOR LEAKS CHECK OIL LEVEL CHECK PRESSURE PERFORMED BY PERFORMED BY PERFORMED BY PERFORMED BY PERFORMED BY Appendix A: HPU Maintenance and Service Logs NOTES
40 Hours/Weekly 40 Hours/Weekly 40 Hours/Weekly Service Interval Recommendation CHECK INTERLOCK CHECK FLUID COLOR AND ODOR DEVICES DATE PERFORMED BY PERFORMED BY NOTES Appendix A: HPU Maintenance and Service Logs 79
160 Hours/Biweekly 160 Hours/Biweekly 160 Hours/Monthly Service Interval Recommendation DATE 80 CHECK CABLES AND CONNECTORS CHECK CONSOLE AIR FILTER PERFORMED BY PERFORMED BY NOTES Appendix A: HPU Maintenance and Service Logs
500 Hours 500 Hours 500 Hours Service Interval Recommendation CHECK ALL ACCUMULATOR S FOR PROPER PRECHARGE PRESSURE AND OIL DATE CHECK CONDITION OF ALL ELECTRICAL CABLES AND CABLE CONNECTIONS PERFORMED BY PERFORMED BY CHECK HPU HYDRAULIC FLUID COLOR, AND ODOR CHECK HPU OPERATING PRESSURE AND TEMPERATURE CLEAN CONTROL CABINET AIR FILTER, REPLACE IF REQUIRED INSPECT HEAT EXCHANGER FOR LEAKS OR “FLOW (WHEN OFF)” PERFORMED BY PERFORMED BY PERFORMED BY PERFORMED BY NOTES 500 Hours Service Interval R
1000 Hours 1000 Hours 1000 Hours Service Interval Recommendation DATE 82 ALL 500 HR MAINTENANCE PROCEDURES REPLACE ALL FILTERS VERIFY OPERATION AND SETTINGS OF PSI CONTROL AND RELIEF VALVES PERFORMED BY PERFORMED BY PERFORMED BY Appendix A: HPU Maintenance and Service Logs NOTES
2000 Hours 2000 Hours 500 Hours Service Interval Recommendation DATE ALL 1000 HR MAINTENANCE PROCEDURES CHECK PUMP/ MOTOR COUPLING FOR WEAR AND DEBRIS CHECK PUMP VOLTAGE AND CURRENT PERFORMED BY PERFORMED BY PERFORMED BY CHECK CASE DRAIN FLOW RECOMMEND MTS HYDRAULIX OIL SAMPLE PERFORMED BY PERFORMED BY NOTES Appendix A: HPU Maintenance and Service Logs 83
5000 Hours 5000 Hours 500 Hours Service Interval Recommendation DATE 84 RECOMMEND R/R HEAT EXCHANGER RECOMMEND REPLACEMENT OF MOTOR BEARINGS PERFORMED BY PERFORMED BY NOTES Appendix A: HPU Maintenance and Service Logs
10,000 Hours 10,000 Hours 500 Hours Service Interval Recommendation DATE RECOMMEND R/R HEAT EXCHANGER RECOMMEND REPLACEMENT OF HOSES RECOMMEND REPLACEMENT OF MOTOR BEARINGS RECOMMEND REPLACEMENT OR REBUILD OF PUMP RECOMMEND REPLACEMENT OR REBUILD OF MOTOR RECOMMEND HYDRAULIC FLUID CHANGE & CLEAN PUMP INLET PERFORMED BY PERFORMED BY PERFORMED BY PERFORMED BY PERFORMED BY PERFORMED BY NOTES Appendix A: HPU Maintenance and Service Logs 85
10,000 Hours 86 Appendix A: HPU Maintenance and Service Logs
m MTS Systems Corporation 14000 Technology Drive Eden Prairie, Minnesota 55344-2290 USA Toll Free Phone: 800-328-2255 (within the U.S. or Canada) Phone: 952-937-4000 (outside the U.S. or Canada) Fax: 952-937-4515 E-mail: info@mts.com http://www.mts.
