m be certain. Series 505G2 SilentFlo™ Hydraulic Power Unit Product Information Model 505G2.07 Model 505G2.
Copyright information Trademark information © 2013 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. All other trademarks or service marks are property of their respective owners.
Contents Technical Support 5 How to Get Technical Support Before You Contact MTS 5 5 If You Contact MTS by Phone 7 Problem Submittal Form in MTS Manuals 8 Preface 9 Before You Begin Conventions 9 10 Documentation Conventions 10 Introduction 13 EU Declarations Intended Use 13 13 Product Information CD 14 Component Identification Functional Description 15 17 Auto-Cooling Valve (adjustable) Electrical Control 18 18 Safety 19 General Safety Practices: Hydraulic Power Units and Hydraulic S
Operator’s Panel 36 Main Screen 36 Status Screen 39 Operating the HPU Locally or Remotely Recovering from an Interlock Changing the Water Flow 41 42 43 Resetting the Thermal Overloads and Circuit Breakers Adjusting the Hydraulic Pressure 44 45 Adjusting the HPU Output Pressure Level Adjusting the Auto-Cooling Level 47 47 Low/High Pressure Functionality 50 Maintenance 53 Routine Maintenance Overview Checklist Checking the Hydraulic Fluid 55 Replacing the Return Line Filter Sample the Hydr
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.
Before You Contact MTS Know information from prior technical assistance Identify the problem Know relevant computer information Know relevant software information 6 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 so
If You Contact MTS by Phone If You Contact MTS by Phone A Call Center agent registers your call before connecting you with a technical support specialist. The agent asks you for your: • Site number • 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 Problem Submittal Form in MTS Manuals Use the Problem Submittal Form to communicate problems with your software, hardware, manuals, or service that are not resolved to your satisfaction through the technical support process. The form includes check boxes that allow you to indicate the urgency of your problem and your expectation of an acceptable response time. We guarantee a timely response—your feedback is important to us.
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 505G2.07/.
Documentation Conventions 12 Model 505G2.07/.
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 general information about the HPU.
Product Information CD Product Information CD A Product Information CD is supplied with the HPU (MTS part number 100-227-354). The Product Information CD includes the electrical and hydraulic schematics along with the configuration drawings. The Product Information CD also contains the product specifications and other reference documents to aid MTS qualified service personnel.
Component Identification Component Identification Component Descriptions (part 1 of 2) Item Component Description 1 Output Pressure Gage Displays the hydraulic pressure being output from the HPU. 2 Auto-Cooling Valve Keeps the hydraulic fluid clean and cool by circulating the fluid through the return filter and the heat exchanger while the HPU is in high pressure mode and the fluid demand by the external circuit is very low. 3 Pressure Relief Valve Prevents the HPU from exceeding 22.
Component Identification Component Descriptions (part 2 of 2) Item Component Description 9 Reservoir Holds the hydraulic fluid and houses the hydraulic pump and motor. The surge suppressor (optional) is mounted to the pump. 10 Hydraulic and Water Connections Connection points for the hydraulic fluid distribution system, water source, and return lines. 11 Water Flow Regulator Sets the amount of water flowing through the heat exchanger.
Functional Description Functional Description Pump A variable volume pump draws hydraulic fluid from the reservoir and pressurizes it to the adjusted output pressure, typically 21 MPa (3000 psi). A check valve prevents hydraulic fluid from being siphoned back into the reservoir. The pressurized fluid is controlled by a control manifold that contains the high/low pressure solenoid valve and a non-adjustable relief valve set at 22.4 MPa (3250 psi).
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.
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 # 100-263-702 Caution To prevent equipment damage and impede performance, remove red shipping plug under filler cap before operating.
General Safety Practices: Hydraulic Power Units and Label Description Voltage hazard. High voltage exists in the vicinity where this icon is located. Be aware of possible electrocution when working in areas noted with this icon. Part # 100-223-270 Explosion hazard; release of pressure. High pressure fluid or gasses. Do not tamper with fittings or hoses. Wear appropriate protection such as safety goggles and hearing protection. Maintain safe pressure levels.
Install the HPU Installation This section describes how to install the Series 505 Hydraulic Power Unit (HPU). Note Contents The HPU is designed for indoor use. The HPU should be stored and installed indoors. Install the HPU HPU Setup 27 30 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) L1 PE GND (Protective Earth Ground) Lug L2 L3 Ensure that lugs are secure. They should be checked periodically. See the Maintenance section. 3. Connect the hydraulic lines. The following figure shows the hydraulic adapter ports to the HPU. Note Each hydraulic connection requires an O-ring face seal.
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).
HPU Setup D. Verify the motor rotation (the pump motor can start with the wrong rotation). Press the High Pressure switch. • If pressure begins to increase, proceed to the next step. • If the oil pressure value 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. E. Check for unusual noises or leaks. If a problem is found, press the Stop button.
HPU Setup 3. On the user interface Main screen ensure that the Remote Operation button is not selected (gray), indicating the HPU is in local mode. 4. On the user interface panel, press and hold the Setup button for five seconds to display the Setup HMI (human-machine interface) screen. Model 505G2.07/.
HPU Setup 5. The following table describes the pushbuttons and indicators on the Setup screen. Name and Location Description Use Buttons Below To Change Parameters Indicator - blue-green: Provides instruction for the setup screen. Remote Fault Normal/Remote Fault Reverse Pushbutton /Indicator. The HPU generates fault signals for remote monitoring. This button is used to define the polarity of the output signal.
HPU Setup Name and Location Description Mean Temp/numeric display and Deadband/numeric display Mean Temp (deg) - blue-green: Indicator used as a label for the pushbutton switch below it. Part of the Analog Option;only displayed if the Analog Option was purchased. Deadband (deg) - blue-green: Indicator used as a label for the pushbutton switch below it. Mean Level numeric display - pushbutton/indicator - gray: Used to set the mean level operating temperature of the hydraulic fluid.
HPU Setup 34 Model 505G2.07/.
Operation This section describes the front panel controls and indicators, and provides operating instructions for the Series 505 Hydraulic Power Unit (HPU).
Operator’s Panel Operator’s Panel Main Screen The Main screen is displayed initially when the HPU is powered up. The following table describes the pushbuttons and indicators on the Main screen. 36 Model 505G2.07/.
Main Screen Name and Location Description Faulted/Ready/Running/High Pressure/Alarm/Overtemp Bypass Indicator. Indicate the various state of the HPU Faulted - red: Initial condition. Also displayed when an interlock has occurred and the HPU has been shut down. Ready - green: Indicates the interlocks are cleared and the HPU is ready to start. Running - green: Indicates the HPU is running in low pressure. High Pressure - green: Indicates the HPU is running in low pressure.
Main Screen Name and Location Description Oil Temp(erature) Indicator/Display: Indicates the temperature of the hydraulic fluid in the reservoir. Part of the Analog Option;only displayed if the Analog Option was purchased. Oil Level Part of the Analog Option;only displayed if the Analog Option was purchased. Main Indicator/Display: Displays the level of the hydraulic fluid in the reservoir in 1/8 increments. The level is relative to the bottom of the sensor, not the bottom of the reservoir.
Status Screen Status Screen The Status screen is displayed by pressing the Status button on the Main screen. The following table describes the pushbuttons and indicators on the Status screen. Name and Location Description Watchdog OK/Watchdog Fault Indicator. Used to indicate the status of the watchdog timer. Watchdog OK - gray: Indicates the PLC that controls the HPU is operating normally.
Status Screen Name and Location Description Oil Level OK/Oil Level Fault Indicator. Used to indicate if the hydraulic fluid level is within acceptable limits. Oil Level OK - gray: Indicates the hydraulic fluid level is within acceptable limits. Oil Level Fault - red: Indicates the hydraulic fluid level is not within acceptable limits and an interlock is active. Oil Temp OK/Oil Temp Fault Indicator. Used to indicate if the hydraulic fluid temperature is within acceptable limits.
Operating the HPU Locally or Remotely Name and Location Description Pressure Filter OK/Pressure Filter Fault Indicator. Used to indicate if the pressure filter is within acceptable limits. Part of the Pressure Filter Option; only displayed if the Pressure filter Option was purchased. Press Filter OK - gray: Indicates the contamination in the pressure filter is within acceptable limits. Press Filter Dirt y- yellow: Indicates the contamination in the pressure filter is not within acceptable limits.
Recovering from an Interlock 2. If not already displayed, press the Main button to display the Main screen. 3. Verify that the Remote Operation button is green. If the button is not green, press the button to change it to green (indicating remote mode). 4. Start the HPU in low pressure at your controller. 5. Check the HPU for leaks and unusual sounds. Stop the HPU immediately if leaks or unusual sounds are noted. Determine the cause and fix the problem before restarting the HPU. 6.
Changing the Water Flow 1. Start cooling the hydraulic fluid by circulating hydraulic fluid through the heat exchanger (Overtemp Bypass mode). A. If necessary, press the Main button to select the Main screen. B. Ensure that Module #1 Enabled is green. C. Press the Bypass button. Pump module #1 will start and run to circulate the hydraulic fluid through the heat exchanger. The red flashing Faulted indicator changes to yellow Overtemp Bypass and the Bypass button changed to Stop. 2.
Resetting the Thermal Overloads and Circuit Breakers Note When the HPU is turned off, a solenoid valve also shuts off the flow of water to the heat exchanger. The water-regulating valve is adjusted at MTS Systems Corporation to maintain the hydraulic fluid temperature at 43°C (110°F). However, the temperature of your water may require you to readjust the regulator. Adjustment Water Regulation Valve Water Solenoid Valve To set the operating temperature of the hydraulic fluid: 1.
Adjusting the Hydraulic Pressure Additional protection is provided by circuit breakers. A tripped thermal overload or circuit breaker indicates a potential short circuit, too much heat in the electrical box, or a component failure (mechanical or electrical). Before operating the HPU, locate and remedy the cause of the tripped thermal overload or circuit breaker. Reset the thermal overload switches or circuit breakers as follows: 1.
Adjusting the Hydraulic Pressure Perform the procedure for adjusting the auto-cooling level if the adjusted output pressure is between 14 MPa (2000 psi) and 21 MPa (3000 psi) and the HPU will be operated in high pressure mode for an extended period of time (longer than 10 minutes). 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.
Adjusting the HPU Output Pressure Level 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. Monitor the hydraulic pressure gage located on the control manifold. Adjust the output pressure as follows until the desired pressure is displayed. • Turn the output pressure control clockwise to increase the pressure.
Adjusting the Auto-Cooling Level Adjusting the AutoCooling Valve to correspond with a change in HPU output pressure Perform the following procedure whenever the HPU will be operated with a change in output pressure for longer than 10 minutes. The following procedure assumes that Steps 1 through 3 of “Adjusting the HPU output pressure level” have already been completed. 1. With the HPU running in high, loosen the nut on the Auto-Cooling Valve located on the control manifold (see the previous figure). 2.
Adjusting the Auto-Cooling Level 5. After the final adjustment tighten the nut to secure the setting. 6. Hold the HPU Output Pressure Control to prevent it from turning while tightening the nut. 7. Verify that the output pressure remained at the desired level and tighten the nut to secure the setting. A. Adjusting the AutoCooling Valve if the HPU shuts down due to an over-temperature condition or if the HPU fails to deliver the full flow to the external circuit.
Low/High Pressure Functionality 5. If necessary, repeat steps 2 and 3 until the Auto-Cooling Valve is stable and the HPU cools properly. 6. After the final adjustment, hold the HPU Output Pressure Control to prevent it from moving while tightening the nut to secure the setting. 7. Verify the output pressure remained at the desired level and the nut to secure the setting. A. Hold the Auto-Cooling Valve stem to prevent it from turning while tightening the nut.
Low/High Pressure Functionality A logical progression of fluid conditioning that begins at the HPU is required to minimize problems when commissioning a system. • With the HPU running in low pressure, acceptable particle counts are obtained in a relatively short time. • Keeping the HPU in low pressure effectively isolates the external or system flow because the relative back pressure is normally much higher in the external system circuit.
Low/High Pressure Functionality High pressure When the Series 505 HPUs are running in high pressure, a considerable amount of heat is generated. During normal testing, this heat is dissipated by running the hydraulic fluid through the system from the return line to the heat exchanger. During periods of low system demand, this heat is dissipated by running the hydraulic fluid through the auto-cooling circuit to the heat exchanger.
Maintenance This section describes preventive maintenance requirements and their recommended intervals for the HPU. Routine Maintenance Overview Checklist Checking the Hydraulic Fluid 55 Replacing the Return Line Filter Sample the Hydraulic Fluid 57 59 Appearance of Hydraulic Fluid Sample Replacing the Hydraulic Fluid Spare parts Lockout/tagout Operating the HPU 54 60 61 Parts that are specified in the maintenance procedures of this section can be obtained from MTS Systems Corporation.
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
Checking the Hydraulic Fluid 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 Recommend
Checking the Hydraulic Fluid To avoid these problems, you must maintain a clean hydraulic system. Regularly test samples of your hydraulic fluid and follow the recommended maintenance procedures described here. For more information on hydraulic fluid care, refer to the Hydraulic Fluid Care Guide (part number 050-000-536). Important Procedure To prevent problems with inconsistent and inferior fluids, MTS recommends only ExxonMobil DTE 25 or Shell Tellus 46 to its customers.
Replacing the Return Line Filter Replacing the Return Line Filter The filter element of the HPU should be replaced for the following reasons: Prerequisite Procedure • When the dirty-filter indicator lights • Whenever the hydraulic fluid is changed • The maximum interval recommended by the filter manufacturer has passed (1000 hours or 6 months) You will need a filter element (MTS part number 100-009-495) or a filter kit (MTS part number 100-030-195).
Replacing the Return Line Filter 6. Wipe out any remaining sludge in the filter housing with a lint-free cloth. 7. Inspect the O-rings in the manifold for any sign of deterioration. If necessary, replace the defective O-ring(s). 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.
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 Procedure See “Component Identification” to identify the components called out in the following procedure. 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.
High Pressure Filter Kit Accessories Contents High Pressure Filter Kit Surge Suppressor Kit 63 65 Precharging the Surge Suppressor Accumulator Lifting Kit 69 Caster Kit 71 66 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.
High Pressure Filter Kit 3. Connect the elbow to the input of the filter assembly. Connect the straight tube to the output of the filter assembly. Check Valve Filter Assembly Control Manifold Free Flow High Pressure Hose Elbow High Pressure Port High Pressure Output Port High Pressure Filter Components 4. Connect the elbow of the filter assembly to the high pressure port on the manifold assembly. 5. Connect the high pressure hose between the filter assembly and the high pressure output port. 6.
Surge Suppressor Kit 5. Screw the filter bowl back onto the filter assembly. Torque the filter bowl to 27.1 N•m (20 lbf-ft). 6. Press the Reset button on the HPU control panel to reset any interlocks and turn off the Dirty Filter indicator. Surge Suppressor Kit The surge suppressor kit smooths out the ripple caused by the pulsing action of the pump as it pressurizes the hydraulic fluid. The surge suppressor is a cylinder that has an outer sleeve that is pressurized with nitrogen.
Precharging the Surge Suppressor Accumulator 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 electrical power to the HPU via a circuit breaker at the power source. 3. Open the top cover of the HPU. Use a 8-mm (5/16-inch) allen wrench to unlatch the cover. 4. Remove the filler cap and reservoir cover. 5. Remove the hydraulic fluid.
Precharging the Surge Suppressor Accumulator Determining a pressure check interval The precharge pressure checking intervals of your surge suppressor depends on how your system is used. Vigorous use causes more rapid pressure loss and thus requires checking and recharging more often. Initially, check the surge suppressor precharge pressure every month or 160 operating hours.
Precharging the Surge Suppressor Accumulator 1. Slowly open the bleed valve on the charging kit until gas begins to escape. When the pressure reading on the appropriate pressure gage drops to the level required, close the bleed valve. 2. Close the locknut. Open the bleed valve on the accumulator charging kit and remove the chuck valve from the accumulator. 3. Install the valve stem cap and protective cover. Increasing pressure To increase the precharge pressure: 1.
Lifting Kit 7. Open the locknut. Slowly open the regulator shut-off valve until the pressure indicator on either the high or low charging kit pressure gage begins to rise. When the pressure is at the required pressure level, close the regulator shutoff valve. 8. Close the locknut. 9. Open the bleed valve on the charging kit and remove the chuck valve from the accumulator. 10. Install the valve stem cap and protective cover. Close the valve on the nitrogen bottle.
Lifting Kit The slings and brackets should be positioned as shown. Bracket Slings Brackets Lifting Support Brackets and Slings 70 Model 505G2.07/.
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 505G2.07/.
Caster Kit 72 Model 505G2.07/.
Appendix A: HPU Maintenance and Service Logs Contents 8 Hours/Daily 74 40 Hours/Weekly 75 160 Hours/Biweekly 500 Hours 76 77 1000 Hours 78 2000 Hours 79 5000 Hours 80 10,000 Hours 81 73
8 Hours/Daily 8 Hours/Daily 8 Hours/Daily Service Interval Recommendation Date 74 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 Notes
40 Hours/Weekly 40 Hours/Weekly 40 Hours/Weekly Service Interval Recommendation Date Check Fluid Color and Odor Check Interlock Devices Performed by Performed by Notes 75
160 Hours/Biweekly 160 Hours/Biweekly 160 Hours/Monthly Service Interval Recommendation Date 76 Check Cables and Connectors Check Console Air Filter Performed by Performed by Notes
500 Hours 500 Hours 500 Hours Service Interval Recommendation Date Check All Accumulators for Proper Precharge Pressure and Oil Check Condition of All Electrical Cables and Cable Connections 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 Performed by Performed by Notes 500 Hours Service Interval
1000 Hours 1000 Hours 1000 Hours Service Interval Recommendation Date 78 All 500 hr Maintenance Procedures Replace All Filters Verify Operation and Settings of psi Control and Relief Valves Performed by Performed by Performed by Notes
2000 Hours 2000 Hours 2000 Hours Service Interval Recommendation Date All 1000 hr Maintenance Procedures Check Pump/ Motor Coupling for Wear and Debris Check Pump Voltage and Current Check Case Drain Flow Recommend MTS Hydraulix Oil Sample Performed by Performed by Performed by Performed by Performed by Notes 79
5000 Hours 5000 Hours 5000 Hours Service Interval Recommendation Recommend R/R Heat Exchanger Date 80 Performed by Notes
10,000 Hours 10,000 Hours 10,000 Hours Service Interval Recommendation Date Recommend R/R Recommend Heat Exchanger Replacement of Hoses Inspect Motor Bearings Determine if Replacement or Rebuild of Pump needed Determine if Replacement or Rebuild of Motor needed Recommend Hydraulic Fluid Change & Clean Pump Inlet Performed by Performed by Performed by Performed by Performed by Performed by Notes 81
10,000 Hours 82
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.
