153052-1 T.O_ (002).pdf

TM 153052-1

June 2016

HYDRAULIC TEST STAND

(ELECTRIC)

P/N 153052-100

OPERATION AND MAINTENANCE

INSTRUCTIONS

Prepared for

NORTHROP GRUMMAN CORPORATION

Prepared by Hydraulics International, Inc.

Chatsworth, California USA

Chap 1 JUNE 2016 Page 1

Chapter 1

DESCRIPTION

CONTENTS

Para.

1 Introduction

2 Abbreviations, glossary, cautionary expressions, and design standards

3 General description

4 Leading particulars

5 Detailed description

6 Safety devices

Fig.

1 Hydraulic Test Stand, location of components

2 Hydraulic schematic

3 Electrical schematic

Introduction 1 The Hydraulic Test Stand is a portable, self-contained, dual-output system hydraulic pumping unit designed to service and evaluate the hydraulic systems of the aircraft for which it is intended. It is driven by a single 7.5 H.P electric motor. The HTS performs the following functions:

1.1 Provides a source of hydraulic fluid at controlled pressures and flow rates to operate the aircraft hydraulic components for evaluation and/or testing purposes, eliminating the need to operate the aircraft’s engines for hydraulic power.

1.2 Tests the aircraft’s hydraulic systems for evidence of component malfunction or pressure leakage.

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Abbreviations, symbols, glossary, cautionary expressions, and design standards 2 The following abbreviations, symbols, glossary, cautionary expressions, and design standards are used in this publication:

Abbreviations and symbols

Short Description

GPM Gallons per minute

HTS Hydraulic test stand

IAW In accordance with kg Kilograms kW Kilowatt

NC Normally closed

NO Normally open

RPM Revolutions per minute

VDC Volts direct current

Glossary

Term Definition

Check Compare the item with the specified standard.

Disconnect Uncouple or detach cables, tubing, or controls from the item.

Drawing number Hydraulics International drawing number, unless stated otherwise.

Emergency stop Hard-wired safety function to immediately stop the AC motor and hydraulic functions.

Ensure Make certain that the specified conditions are met.

Examine Undertake a comprehensive scrutiny, supplemented by measurement and physical testing as necessary to determine the condition of the item.

Examine as far Within the physical constraints of the location of the item carry out an as possible examination.

Fit Correctly attach one item to another.

Inspect Measure, examine, test, gage, or otherwise compare the item with the applicable requirements.

Look for Undertake a visual check for signs of a specified unserviceability.

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Manufacturer Hydraulics International, Inc. Chatsworth, California United States of America.

Operator Personnel authorized to operate the HTS.

Part number Hydraulics International part number, unless noted otherwise.

Reconnect Re-couple or reattach cables, tubing, or controls previously disconnected from the item.

Refer to The reader can turn to the indicated chapter, paragraph, table, or figure for more detailed information.

Remove Correctly disconnect and detach the item from it’s mounting or position.

Replace Remove the item and fit a new and/or serviceable item.

Replenish Refill or restock a tank, bottle, or container to a predetermined level, pressure, or quantity.

See The reader is advised to turn to the indicated chapter, paragraph, table, or figure for prerequisite information.

Cautionary expressions

NOTE A remark containing additional information for the user. May also notify the user of possible problems.

CAUTION Alerts the user to the fact that equipment may be damaged if procedures are not carried out as described.

WARNING Warns the user of the fact that bodily injury or damage to the equipment may occur if procedures are not carried out as described.

General description 3 The HTS is comprised of the following major components (refer to Figure 1 for component locations):

3.1 A 7.5 H.P electric motor is used to drive the main pump.

3.2 A 12 U.S. gallon stainless-steel fluid reservoir. The reservoir operates at atmospheric pressure.

3.3 A high-pressure pump system, comprised of a high-pressure pump coupled to a low-pressure boost pump. The main pump hydraulic pressure is regulated by a pressure control valve. Relief valves prevent over-pressurization damage to the hydraulic system.

Each system incorporates a pressure reducing valve that allows the operator to set desire pressure for each system. In addition each system has a supply shut off valve and a bypass valve which bypass pressure and flow to return.

3.4 A radiator-type fluid heat exchanger, which is in turn cooled by outside air drawn in by a fan driven by an AC motor.

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Figure 1 HTS Hydraulic Test Stand, location of components (sheet 1 of 2)

MAIN PUMP

200-17

RESERVOIR

DRAIN VALVE

200-4

HEAT

EXCHANGER

200-7

FLOWMETER

200-32

MAIN RELIEF

VALVE

200-25

THERMAL RELIEF

VALVE

200-37

BOOST

RELIEF VALVE

200-12

TEMPERATURE

SWITH

200-15

BOOST PRESS.

SWITCH 200-11

CASE CHECK

VALVE

200-16

RESERVOIR

200-1 LEVEL GAUGE

200-35

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Figure 1 HTS, location of components (sheet 2)

RESERVOIR

SELECTOR VALVE

200-6

SUPPLY CHECK

VALVE

200-19

FAN MOTOR BOOST FILTER

200-8

BOOST PUMP

200-6

ELECTRIC

COMPARTMENT

MAIN CIRCUIT

BRAKER

SUPPLY FILTER

200-20

MAIN MOTOR

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RETURN

SAMPLING PORT

200-29

SELECTOR VALVE

200-31

TIE DOWN RING

SAMPLING

SHUTOFF VALVE

200-29

Page 6 JUNE 2016

3.5 A high-pressure filter which removes particulate matter down to 3 microns from the supply fluid, and a low-pressure (boost) filter which filters incoming fluid down to 10 microns.

3.6 All controls and indicators (warning lights, gauges, etc.) are located on the instrument panel and main manifold. Electrical power for the indicators is 24 VDC.

3.7 A sturdy welded steel structure comprised of rigid, steel housings, removable access panels, and a heavy-duty base assembly (chassis), which provides support and mobility for the HTS components. A foot-operated brake secures the front wheels to hold the unit in a stationary position.

Leading particulars 4 The following leading particulars apply to the HTS:

Unit performance:

Test medium MIL-H-5606H, MIL-PRF-83282

Main pump nominal output 0 to 3 GPM at 3000 PSI

Boost pump nominal output 0 to 18 GPM at 140 PSI

Operating conditions:

Ambient temperature range -40°F to +100°F

Altitude range Sea level to 6000 ft.

Relative humidity 95 to 100% at operating temperature

Hydraulic fluid temperature 175 ±7°F maximum

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Envelope dimensions:

Height 51 in.

Length 48 in.(with hose and hose hook 57 in)

Width 30 in.

Gross weight 1500 Ibs

Reservoir capacity 12 U.S. gallons

Boost system (low-pressure) filter 10 micron element

Supply system (high pressure) filter 3 micron absolute element

High pressure (supply) gauge 0 to 6000 PSI range

Boost Pressure gauge -30 InHg- 0 - 300 PSI range

Flow meter .1 to 20 GPM range

Hydraulic oil temperature gauge -20° to +200°F range

Pre-set components:

Hydraulic oil temperature switch 165 ± 7°F

Thermal relief valve Opens at 180 PSI

Boost pressure switch Opens at 10 PSI

Differential (high-pressure filter) pressure switch Closes at 75 PSI

Differential (low-pressure filter) pressure switch Closes at 35 PSI

Fluid heat exchanger Radiator-type, oil-to-air, fan cooled

Supply port -5 size, 37° flare

Return port -8 size, 37° flare

Electrical system 208 VAC 3 Phase 50/60 Hz, 50 Amp service

Base assembly (chassis) and housings:

Structure Painted steel

Housings Painted steel enclosures with removable access panels and hinged doors

Wheels Hard rubber caster type

Suspension Springs

Brakes Foot operated, rear caster

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Detailed description 5 Before operation the user should understand the two basic modes of operation of HTS:

5.1 Open loop The reservoir selector valve is set to TEST STAND position. In this mode the fluid in the HTS reservoir is directed to the aircraft hydraulic system, then returns to the HTS reservoir.

5.2 Closed loop The reservoir selector valve is set to AIRCRAFT position. In this mode the HTS reservoir is isolated (out of the loop), and the fluid in the aircraft hydraulic system is circulated through the HTS system filters, bypassing the HTS reservoir, and returns to the aircraft.

NOTE

Refer to Figure 2, Hydraulic Schematic, for the following description of the hydraulic system components.

Reservoir

5.3 The hydraulic fluid is contained in a one-piece welded stainless steel enclosure. The (usable) full capacity of the reservoir (1) is 12 U.S. gallons. The reservoir operates at atmospheric pressure (unpressurized). It is serviceable for cleaning by way of a secured lid on the top, and can be drained by means of a plug (4) at the bottom.

Reservoir selector valve

5.4 The reservoir selector valve (5) determines which mode of operation the HTS reservoir is in, open loop or closed loop (see definition above). Figure 2 shows the valve operating in open loop, or TEST STAND, position. The reservoir selector valve is a heavy-duty four-way plug valve, operated manually.

High-pressure hydraulic pump

5.5 The main hydraulic (high-pressure) pump (17) is a variable displacement, axial piston pump which employs a swash plate and nine pistons within a rotating cylinder barrel.

5.5.1 A check valve (16) prevents back flow of the line pressure into the main pump.

5.5.2 Pump pressure is controlled by the pressure control (18) on the main manifold (23).

5.5.3 Main pump maximum outlet flow can be controlled by flow control valve (26)

Boost pump

5.6 The boost pump (6) is a low-pressure gear-type pump, mounted directly on the output shaft of the main hydraulic (high-pressure) pump. It draws hydraulic fluid from the reservoir and supplies it to the high pressure pump.

Heat exchanger

5.7 Fluid circulating through the HTS system is cooled by the fluid heat exchanger (7).

The heat exchanger is a single core, cross-flow aluminum radiator, which is secured to the base assembly at the top of the unit. Outside air is drawn through the heat exchanger by means of two fans.

Low-pressure (boost) filter

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5.8 A low pressure filter assembly (8), utilizing a replaceable 10 micron filter element (9), removes particulate matter from the fluid before entering the high pressure pump. The filter incorporates a differential pressure (∆P) switch (10) that senses when the difference between input and output pressure is 35 ±2 PSI or greater, indicating a blocked filter element. This, in turn, energizes an indicator light on the instrument panel to alert the user to a possible fault condition.

Boost relief valve

5.9 The spring-loaded low-pressure boost relief valve (12) recirculates excess flow from the boost pump discharge to the boost pump suction depending on the flow requirements of the main pump.

Thermal relief valve

5.10 The thermal relief valve (37) is a spring loaded device which protects the HTS hydraulic system from over-pressurization during static (non-operating) conditions due to thermal expansion of the fluid. The valve opens when the return system fluid pressure exceeds 180 PSI, and directs the fluid overflow to the reservoir.

Pressure switch

5.11 Prior to the high pressure pump is the pressure switch (10). This switch detects the output pressure of the boost pump. If the output pressure does not reach the minimum 10 PSI within 5 seconds after start-up, or if the operating pressure drops below 10 PSI, the switch closes and the HTS electrical system shuts down after a 5 second delay, thereby shutting down the test stand.

Temperature switch and gauge

5.12 The temperature switch (15) closes if the hydraulic fluid temperature exceeds 175 ±7°F. This energizes the warning horn and an indicator light on the control panel to alert the operator to an over-temperature condition. After 5 seconds a time delay relay will automatically shut down the entire HTS system unless the problem is corrected before that time elapses.

5.12.1 The temperature gauge (14) monitors the system fluid temperature by way of a sensing bulb installed in the high-pressure pump inlet line. A capillary tube transmits the information to a dial-indicating thermometer covering the range of - 20°F to 200°F.

High-pressure (supply) filters

5.13 A high-pressure filter assembly (20) is incorporated into the HTS hydraulic system.

This filter employs replaceable 3 micron absolute element (21) that filter the fluid a final time before it exits the HTS hydraulic system and goes to the aircraft. The filter incorporates a differential pressure (∆P) switch (22) that senses when the difference between input and output pressure is 75 ±7 PSI or greater, indicating a contaminated/blocked filter element.

This, in turn, energizes an indicator light on the instrument panel to alert the user to a fault condition.

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High-pressure relief valve

5.14 The high pressure relief valve (25) is a safety feature that protects the aircraft hydraulic system from pressure surges, or from a possible high pressure pump malfunction.

The valve is set to open if the pressure reaches 3350 PSI and direct the fluid to the return system.

System pressure gauge

5.15 The high-pressure gauge (30) displays main system pressure and pressure gauge display pressure. These are a dial indicator-type gauge with internal dampening, with a range of 0 to 6000 PSI.

Bypass valve

5.16 The bypass valve (24) is used to direct each system supply pressure and flow back to the return system.

Supply shutoff valves

5.17 The supply shutoff valve (24) is manually operated push-in cartridge-type valve mounted in the main control manifold. When opened it permits the output flow of hydraulic fluid through each supply port to the aircraft.

Flow meter

5.18 Hydraulic fluid flow rate is monitored by a digital flow meter. This is a programmable LED-type electronic read-out that is pre-set by the manufacturer to indicate from 1 to 20 gallons per minute. The flow meter is connected to an in-line turbine with an integral magnetic pickoff that detects rotations of the turbine blade and relays the information to the digital read-out.

Hose hook

5.19 The HTS is equipped with one storage hook at the front end of the unit.

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Chassis and housings

5.20 A sturdy welded steel structure comprised of rigid housings, removable access panels, and a heavy-duty base assembly (chassis) provides support and mobility for the HTS components. The base assembly also serves as a drip pan to contain any hydraulic leakage. Four caster type wheels, two with foot-activated brake are provided for mobility

5.20.1 The housings are composed of a welded steel frame, which is bolted to the base assembly, and several housing assemblies and removable panels. The electrical components are housed under the electrical panel.

Motor

5.21 The electric motor is a 7.5 HP, open drip proof with 1.15 service factor and maintenance free motor. The voltage is 208-230/460 VAC 60 Hz and the RPM is 1200.

Operator controls

5.22 All instruments, controls, indicators, and warning lights are located on the instrument panel assembly and the main control manifold.

5.23 The following indicators and controls are located on the instrument panel assembly:

5.23.1 Three analogue pressure gauge (SYSTEM PRESSURE) in the 0 to 6000 PSI range for supply pressures.

5.23.2 An analogue pressure gauge in the -30 InHg 0 to 300 PSI range for monitoring, boost pressure.

5.23.3 An analogue temp gauge in the -20 to 200°F range for HTS system temperature readout.

5.23.4 A reservoir level sight tube.

5.23.5 An electrical control panel assembly, which contains a programmable LED-type digital read-out for indicating hydraulic flow rate, an hourmeter which displays the total elapsed time the motor has been run. Indicator and/or warning lights, and switches, (see Table 2-1 for specific function descriptions).

5.24 The following controls are located on the manifold control panel assembly:

5.24.1 A cartridge type supply shut off valve, a bypass valve for each system and a supply pressure control valve.

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Safety devices 6 The following devices have been incorporated into the HTS system and relate specifically to safety of operation:

Emergency stop

6.1 An emergency stop button is provided on the left-hand side (electrical control panel section) of the instrument control panel to immediately terminate operation of the HTS.

6.1.1 After the fault requiring an emergency shutdown has been remedied, the switch must be pulled out to reset it before the motor can be re-started.

Safety relief valves

6.2 The supply-pressure system is controlled by a supply shut off valve. Maximum pressure of the main pump is limited by a pre-set knob on the pump.

6.2.1 The system pressure is limited by a pre-set high-pressure safety relief valve, mounted on the pressure side of the manifold.

Vibration

6.3 The 7.5 H.P. motor and pump assembly is mounted on rubber shock mounts, secured to the base assembly, to minimize the vibration transmitted to the HTS frame. The motor is also protected by a phase monitor that will protect the pumping system from rotating to wrong rotation.

Leakage

6.4 A steel drip pan with drain plug is secured to the base assembly, and will contain leakage up to 12 gallons of hydraulic fluid to prevent environmental contamination.

Warning indicator lights

6.5 Indicator lights on the instrument panel alert the operator to the following error conditions:

a. low boost-pressure

b. out of phase

c. high fluid temperature level (overheating)

d. high fluid level (in the reservoir)

e. low fluid level (insufficient fluid in the reservoir)

f. low-pressure filter element contaminated/blocked (clogged)

g. high-pressure filter element(s) contaminated/blocked (clogged)

Electrical control box

6.6 The electrical control box is located under the instrument panel and contains relays timer relays, and various electrical components.

Hoses

6.7 The auxiliary hoses used to connect the HTS to the aircraft are electrically conductive over the full length of the hose assembly, including the fittings at each end.

6.7.1 The supply and return port on the HTS is placarded for each system.

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Figure 2. Hydraulic schematic (Sheet 1)

Page 14 JUNE 2016

Key to Figure 2

BF Boost (low) pressure filter

BP Boost pump

BPG Boost pressure gauge

BR Boost relief valve

BV Bypass valve

CV Check valve

DP Differential pressure switch

DV Drain valve

F Flowmeter

FCV Flow control valve

FM Flushing manifold

FP Fill port

HX Heat exchanger

LI Level indicator

LS Level switch

M Main manifold

MP Main pump

MRV Main relief valve

PCV Pressure control valve

PS Pressure switch

RH Return hose

RM Return mounting half

RSP Return sampling port

RSV Reservoir selector valve

RSVR Reservoir

SF Supply (high) pressure filter

SG Supply gauge

SH Supply hose

SM Supply mounting half

SSV Supply shut off valve

TG Temperature gauge

TRV Thermal relief valve

TS Temperature switch

VCV Volume charging valve

SV Selector valve

PHH primary half hose

SHH secondary half hose

PHM primary half mount

SHM secondary half mount

PRP purification return port

PSP purification supply port

Figure 2. Hydraulic schematic (sheet 2)

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Figure 3. Electrical schematic

Chap 2 JUNE 2016 Page 1

Chapter 2

OPERATING INSTRUCTIONS

CONTENTS

Para

1 Introduction

2 Operator controls

3 Pre-operational procedures

4 Pre-start up procedures

5 Emergency procedures

6 Operation

7 Shutdown procedures

8 Preparation for storage

Table

1 Description of operator controls

Fig

1 Operator controls

Introduction 1 This chapter provides operating instructions for the HTS Hydraulic Test Stand.

Operator controls 2 The HTS operator controls include the instrument panel (refer to Fig 1 and Table 1) and the manifold control panel. The instrument panel is further divided into a section for manometer-type gauges and an electrical control sub-panel.

Instrument panel

2.1 The main instrument panel contains system pressure gauges, a compound gauge, and a fluid temperature gauge.

Electrical panel

2.2 The electrical sub-panel contains instrumentation for monitoring the hydraulic flow rate, main motor functions, hydraulic fluid level, an emergency stop pushbutton, main motor start and stop pushbuttons, and all warning indicator lights.

Control manifold

2.3 The remaining controls are located on, an aluminum manifold block on the instrument panel. Hand operated cartridge-type control valves for supply pressure, bypass, and supply shutoff are mounted on the manifold block.

2.3.1 The reservoir selector valve (see Chap 1, Figure 1) is located inside the unit.

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Figure 1. Operator controls (sheet 1 of 3)

1 2

4 3

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Figure 1. Operator controls (sheet 2 of 3)

24 21 22

34 35

35A 34A

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Figure 1. Operator controls (sheet 3 of 3)

5 GAL

MIN

7.5

MAX

Page 6 JUNE 2016

Table 1 Description of operator controls

No. Description Function

1 EMERGENCY STOP pushbutton Breaks the electrical system circuit and shuts off current to the 50 H.P. motor when pressed. Turn CCW to reset.

2 LIGHT TEST button Pushing down illuminates all the indicator lights momentarily

3 OUT OF PHASE indicator light Illuminates when the unit is out of phase

4 LOW BOOST PRESSURE indicator light Illuminates when boost pump pressure falls below .10 PSI. After ten seconds the time delay relay will shut down the system unless the problem is corrected before that time elapses. This light also illuminates on start-up until sufficient boost pressure has built up.

5 HIGH FLUID TEMPERATURE indicator light Illuminates when fluid temperature exceeds 170°F. After ten seconds the time delay relay will shut down the system unless the problem is corrected before that time elapses.

6 HIGH FLUID LEVEL indicator light Illuminates when hydraulic fluid level in reservoir exceeds the maximum safe level. After ten seconds the time delay relay will shut down the system unless the problem is corrected before that time elapses.

7 LOW FLUID LEVEL indicator light Illuminates when hydraulic fluid level in reservoir falls below the minimum safe level. After five seconds the time delay relay will shut down the system unless the problem is corrected before that time elapses.

8 RETURN FILTER CLOGGED indicator light Illuminates when low-pressure (boost) filter ∆P switch detects a pressure difference of 35 PSI between filter input and output, indicating filter element blockage. After ten seconds the time delay relay will shut down the system.

9 SUPPLY FILTER CLOGGED indicator light Illuminates when low-pressure (boost) filter ∆P switch detects a pressure difference of 35 PSI between filter input and output, indicating filter element blockage. After ten seconds the time delay relay will shut down the system.

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Table 1 Description of operator controls

No. Description Function

10 FLOWMETER Digital meter indicating the return flow from aircraft system. Also indicates the flow setting of the high pressure pump if the system is operating with the system bypass valve open.

11 START BUTTON Push to start system.

12 STOP BUTTON Push to stop system.

13 HOURMETER Indicates motor run time.

14 HYD FLUID LEVEL SIGHT TUBE Shows hydraulic fluid level in reservoir.

15 GAUGE SELECTOR VALVE Select what system pressure is to be monitored by compound gauge (16) .

16 COMPUND PRESSURE GAUGE Monitors return, boost suction and boost pressure.

17 SYSTEM PRESSURE GAUGE Indicates main hydraulic pump system pressure.

18 HYDRAULIC FLUID TEMPERATURE gauge Indicates temperature of hydraulic fluid entering the high pressure pump.

19 VOLUME CONTROL valve Manually operated valve used to adjust high-pressure pump flow as indicated on system flow meter

20 SYSTEM SUPPLY SHUT OFF VALVE Manually operated valve control hydraulic supply flow and pressure to each system.

21 BYPASS VALVE Manually operated valve bypasses fluid flow and pressure to return system.

22 SYSTEM PRESSURE valve Manually operated cartridge-type valve.

Controls high-pressure pump system pressure.

23 HIGH PRESSURE RELIEF VALVE Pre-set cartridge valve. Opens at 4750 PSI to direct fluid to the return system.

24 MANIFOLD main manifold

25 MAIN PUMP Supplies hydraulic pressure to aircraft.

26 MAIN PUMP PRESSURE MODULE Used to set maximum pump output pressure.

27 Main pump volume control module Used to set main pump outlet flow.

28 Max volume stop Used to limit the maximum outlet flow of the main pump.

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No. Description Function

29 TEMPERATURE SWITCH Installed in boost circuit, automatically shut down the system if hydraulic fluid temperature exceed 180 ± 5 º F.

30 BOOST PRESSURE RELIEF VALVE Used to set boost pressure to main pump.

31 BOOST PUMP Boost pump is used to charge inlet port of main pump.

32 VENT VALVE Vents air-entrained fluid from the top of hydraulic cooler to the reservoir

33 Vent valve sight tube Provides for visual inspection of fluid being vented by the vent valve

34 CAL. PORT (calibration port) Allows for external calibration of pressure gauges

35 GSV (gage shutoff valve) Needle-type shutoff valves used to isolate the pressure gauges for calibration purposes

36 SUPPLY SELECTOR VALVE Four ways, two position high pressure selector valve is used to set the supply port to primary or secondary port.

Table 1 Description of operator controls (continued)

Page 6 JUNE 2016

Pre-operational procedures

3 Prior to operation of the HTS systems, the following pre-operational checks and procedures shall be completed:

a. Position the HTS within a distance from the aircraft sufficient to allow the supply and return hoses to be easily connected without the weight of the hoses stressing the hose ends or connections.

b. Engage the footbrake.

c. Ensure there is sufficient hydraulic fluid in the reservoir by inspecting the HYD FLUID LEVEL sight tube. It should read at least 3/4 full. If not, replenish the reservoir.

Pre-start-up procedures 4 Prior to start-up of the HTS systems, refer to Fig 1 and complete the following tasks:

a. Set the reservoir selector valve handle to the TEST STAND position.

b. Connect supply and return hose to flushing manifold .

c. Ensure that BYPASS valves (21) are fully open by turning handle CCW.

d. Ensure that the SUPPLY valves (20) is fully closed by turning handle clockwise (CW).

e. Ensure that SYSTEM PRESSURE valve (22) is fully open by turning handle CCW.

f. Ensure the emergency stop pushbutton (1) is pulled out.

g. Set SUPPLY SELECTOR VALVE (36) to desire outlet port.

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Emergency procedures 5 The HTS employs both manual and automatic emergency stop features in the event of a fault condition or other unforeseen event.

Manual emergency stop

5.1 If an emergency stop of the HTSis required during operation of the unit, the operator shall push the EMERGENCY STOP pushbutton(1) located on the electrical panel portion of the instrument panel. This causes the electronic control system to immediately break the circuit to the main motor and stop the rotation of the pump.

5.1.1 The EMERGENCY STOP pushbutton should be reset, after the conditions requiring the stop are remedied, by the following steps:

a. Recreate a safe operational condition of the HTS.

b. Reset the EMERGENCY STOP pushbutton (1, Fig 1) by pulling it out until it extends to the normal position.

c. Open the BYPASS valve (21) fully CCW to relief system pressure.

d. Disconnect power cable.

e. Refer to the procedures in paragraph 2.4 to prepare the HTS for operation.

Automatic stop

5.2 The HTS will automatically cease operations if the following conditions occur:

a. Low boost pressure (boost pump pressure of less than 10 PSI for ten seconds) unless the problem is corrected before that time elapses.

b. Reservoir fluid level too high (shutdown after ten seconds) unless the problem is corrected before that time elapses.

c. Reservoir fluid level too low (shutdown after ten seconds) unless the problem is corrected before that time elapses.

d. Hydraulic fluid temperature too high (exceeding 185 ±7°F for ten seconds) unless the problem is corrected before that time elapses.

5.3 If any of the preceding fault conditions are encountered, the fault must be remedied before the HTS can be restarted. After the cause of the shutdown has been corrected refer to the procedures in Para 4 to prepare the HTS for operation.

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Operation 6 The following instructions are for normal operation of the HTS. Emergency operations (shutdown) are covered in Para 5.

WARNING

(1) WHEN OPERATING THE HIP-E-.5-CAS, AT ALL TIMES OBSERVE THE

OPERATIONAL PROCEDURES WITH REGARDS TO SAFETY. THIS PREVENTS A

POSSIBLE FAULT CONDITION IN THE CONTROL SYSTEM FROM CAUSING INJURY

TO PERSONNEL OR DAMAGE TO THE EQUIPMENT.

NOTE

The HTS employs a time-delay relay to override the auto-shutdown safety feature during start-up. This allows the system time to build up the proper boost pressure and achieve minimum operating parameters.

Motor start

6.1 Refer to Fig 1, Operator controls, and proceed as follows:

a. Connect power cable to electrical source and set the main circuit breaker located inside the electric box to ON position. Verify OUT OF PHASE (3) light is not illuminated.

b. Press motor START (11) button.

c. Verify a flow condition by observing FLOWMETER (10)

d. Open SUPPLY SHUT OF VALVE (20) and close BYPASS VALVE (21) and let the system flush thru the flushing manifold for 5 minutes. This will remove air from system prior to connection to aircraft for each system.

Setting the system pressure valve

6.2 Refer to Fig 1, Operator controls, and proceed as follows:

a. With the HTS system up and running in TEST STAND mode, Open BYPASS VALVE

(21) and close the SUPPLY shutoff valve (20) fully CW.

b. Slowly close BYPASS valve (21) by turning handle fully CW.

c. Adjust SYSTEM PRESSURE valve (22) by turning knob CW until SYSTEM PRESSURE gauge (17) indicates the desired test pressure. Verify that FLOWMETER (10) indicates zero flow.

d. Open BYPASS VALVE (21) and using VOLUME CONTROL VALVE (19) set maximum main pump outlet flow as indicated by the FLOW METER (10).

e. The pressure and flow is now set and the HTS is ready to connect to the aircraft.

f. STOP(12) the motor

Page 10 JUNE 2016

Connecting the HTSto the aircraft

6.3 To connect the HTSto the aircraft for actual testing purposes proceed as follows:

NOTES

(1) Connection of hydraulic test lines to any aircraft shall be performed in accordance with the proper test procedures for that particular aircraft.

(2) Actual testing of the aircraft shall only be performed by personnel qualified.

Before testing, ensure personnel are properly trained and qualified for that task.

Open loop operation

6.4 To perform aircraft system tests with the HTS reservoir in line (open loop mode), refer to Fig 1 and proceed as follows:

a. Ensure that the reservoir selector valve is set to TEST STAND position

b. Connect PRIMARYSUPPLY port to the proper pressure ports of the test aircraft

c. Connect SECENDERY RETURN port to the proper pressure ports of the test aircraft

d. Ensure SUPPLY VALVE (20) is closed fully CW.

e. Set SUPPLY SELECTOR VALVE (36) to desire port.

f. Start the motor.

g. When aircraft is ready to accept hydraulic flow slowly open SUPPLY SHUT OFF valve (20).

h. When aircraft is ready to be pressurized, slowly close BYPASS VALVEs (21) by turning handle fully CW. Pressure will rise to preset value.

i. If needed adjust supply pressure using SYSTEM PRESSURE CONTROL valve (22) as indicated on SUPPLY SYSTEM PRESSURE gauge (17).

Operate the aircraft hydraulic systems in accordance with the proper test procedures for that particular aircraft

Closed loop operation

6.5 To perform aircraft system tests with the HTS reservoir not in line (closed loop mode), refer to Fig 1 and proceed as follows:

a. Ensure that the reservoir selector valve is set to AIRCRAFT position

b. Connect PRIMARYSUPPLY port to the proper pressure ports of the test aircraft

c. Connect SECENDERY RETURN port to the proper pressure ports of the test aircraft

d. Ensure SUPPLY VALVE (20) are closed fully CW.

e. Set SUPPLY SELECTOR VALVE (36) to desire port.

f. Start the motor.

g. When aircraft is ready to accept hydraulic flow slowly open SUPPLY SHUT OFF valve (20).

Page 10 JUNE 2016

h. When aircraft is ready to be pressurized, slowly close BYPASS VALVE (21) by turning handle fully CW. Pressure will rise to preset value.

i. If needed adjust supply pressure using SYSTEM PRESSURE CONTROL valves

(22) as indicated on SUPPLY SYSTEM PRESSURE gauge (17).

Operate the aircraft hydraulic systems in accordance with the proper test procedures for that particular aircraft

Shutdown procedures 7 To perform a normal shutdown of the HTS systems, refer to Fig 1 and proceed as follows:

a. Reduce supply pressure by opening SYSTEM PRESSURE valve (22) fully CCW.

b. Close SUPPLY VALVE (20) by turning handles fully CW.

c. Open BYPASS VALVE (21) by turning handle fully CCW.

d. Push STOP BUTTON (12).

e. Disconnect power cable from the electrical source and store it in cable storage compartment.

f. Disconnect hoses from the aircraft and HTS and stow them on the hose hooks.

g. Close the access door for the operator control panels and fasten the latches.

Preparation for storage 8 If the HTS is not to be used for a period of up to one year it may be placed in storage after proper preparations have been carried out.

Storage time of up to one year

8.1 If the HTS is to be stored for a period up to one year, prepare the test stand as follows:

a. Secure the supply and return hoses on their storage hooks.

b. Place several bags of desiccant material inside the HTS housings.

c. Close all access doors and secure the latches.

d. Seal all seams and openings with waterproof tape/cover material.

Preparation for use after long-term storage

8.2 When the test stand is again needed after extended storage it shall be prepared for use by following the procedures outlined here. Prepare the HTS for operation after long-term storage as follows:

a. Remove waterproof tape/covering material from all seams and openings.

b. Remove all bags of desiccant material from inside the housings.

c. Replenish the reservoir (if necessary).

d. Perform all pre-operational and pre-start-up steps described in paragraph 4.

e. Operate the HTS as described in Para 6. Allow the test stand to operate at least 15 minutes to circulate the hydraulic fluid.

Chap 3 JUN 2016 Page 1

Chapter 3

MAINTENANCE, SETTINGS AND ADJUSTMENTS

CONTENTS

Para.

1 Safety

2 Hydraulic component setting and adjustments

3 Electrical component setting and adjustments

4 Troubleshooting

Table

1 Troubleshooting

Fig.

1 Servicing the hydraulic filters

2 Hydraulic Reservoir

Safety 1 Before beginning any inspection or maintenance task, the following safety- advises shall be noted:

WARNING

(1) SOLVENT. SOLVENTS ARE HAZARDOUS SUBSTANCES. REFER TO THE

SOLVENT WARNING IN THE PRELIMINARY PAGES OF THIS PUBLICATION.

(2) NEVER PERFORM ANY INSPECTION OR PREVENTATIVE MAINTENANCE TASK

DURING ACTUAL TESTING. FAILURE TO COMPLY MAY RESULT IN INJURY TO

PERSONNEL.

(3) UNAUTHORIZED ALTERATIONS TO THE HIP-E-.5-CAS STRUCTURE, SYSTEMS, OR

COMPONENTS ARE NOT PERMITTED AS THIS MAY SEVERELY AFFECT

PERFORMANCE AND LIFE EXPECTANCY OF THE TEST STAND, AND PRESENT A

POTENTIAL SAFETY HAZARD TO PERSONNEL. FAILURE TO COMPLY MAY RESULT

IN INJURY TO PERSONNEL.

(4) DO NOT ATTEMPT TO REMOVE/LIFT HEAVY HOUSINGS OR COMPONENTS FROM

THE TEST STAND ALONE. USE ADEQUATE PERSONNEL AND LIFTING EQUIPMENT

(HOISTS, ETC.) TO LIFT HEAVY ITEMS. REFER TO LOCAL RULES FOR THE SAFE USE

OF HOISTS/SLINGS. FAILURE TO COMPLY MAY RESULT IN INJURY TO PERSONNEL.

(5) THE APPLICABLE HINGED ACCESS DOORS SHALL BE REMOVED DURING

EXTENDED PERIODS OF MAINTENANCE INSIDE THE HIP-E-.5-CAS TO PREVENT

ACCIDENTAL CLOSING OF THE DOOR ON PERSONNEL DUE TO WIND OR

ACCIDENTAL IMPACT. FAILURE TO COMPLY MAY RESULT IN INJURY TO

PERSONNEL.

Page 2 JUN 2016

Hydraulic component settings and adjustments 2 These are the manufacturers recommended settings for all new and repaired hydraulic components.

Thermal relief valve

2.1 Refer to Chap 1, Figure 1 for location of the thermal relief valve. The cracking pressure need be set only if the valve is disassembled or replaced with a new unit.

a. Apply a source of measurable hydraulic pressure to the inlet port.

b. Remove the hex cap and loosen the locking nut. Turn the adjusting screw until the valve opens at 180 PSI.

Low-pressure relief valve

2.2 The low-pressure relief valve (Chap 2 Fig 1, 30) is mounted on the right side of the high-pressure pump, and is accessed through the side cover access door. The opening pressure need be set only if the valve has been replaced with a new unit, or has been disassembled. Refer to Chap 2, Figure 1 and proceed as follows:

a. Loosen the locknut.

b. Connect the power cable to electrical source Press start button to start system.

c. Open system pressure valve (22) and close supply valve (20) and bypass valve (21) to obtain a reading of zero flow on the flowmeter (10).

d. Turn the adjusting screw on the valve (26) until a reading of 140 ±10 PSI is indicated on the BOOST PRESSURE GAUGE (15). Tighten the locknut.

High-pressure relief valves setting.

2.3 High pressure system safety relief valves consist of main relief valve (23) set at 3400 and main pump relief valve (26) set at 3250 PSI ± 50 PSI. The relief valve needs to be set at the same time. Refer to Chap 2, Figure 1 and proceed as follows:

a. Close main pump relief valve (26) fully CW

b. Close high pressure relief valve (23) fully CW

c. Open bypass valve (21) fully CCW.

d. Open system pressure valve (22) fully CCW.

e. Close supply shut off valve (20) fully CW.

f. Start the motor.

g. Close Bypass valve (21) while monitoring supply pressure gauge (17)

h. Slowly adjust the supply pressure using system pressure valve (22) until supply pressure gauge reads 3500 PSI. Verify flow meter (10) reads zero.

i. Slowly open high pressure relief valve (23) until system pressure gauge (17) reads 3400 ± 50 PSI. Lock the locking nut.

j. Adjust main pump relief valve (26) until supply pressure gauge reads 3250 PSI ± 50 PSI, lock the locking nut.

k. Open bypass valve (21)

l. Stop the motor

JUN 2016 Page 3

Low boost-pressure switch

2.4 Refer to Chap 1, Figure 1 for location of the low boost pressure switch. The switch need be adjusted only if the unit has been replaced with a new unit:

a. Remove the adjusting screw cover secured by two screws on the side of switch.

b. Start the test stand long enough to build up boost pressure. Push the stop button.

c. Observe falling pressure on the boost pressure gauge and note when the LOW BOOST PRESSURE light illuminate. Adjust screw CW to decreases pressure and CCW to in cress pressure. Repeat step b and c until LOW BOOST PRESSURE light illuminate at 5 ± 2 PSI.

d. Install the cover

High temperature switch

2.5 Refer to Chap 1, Figure 1 for location of the high temperature switch, the switch is located in main pump inlet manifold. Refer to Chap 2, Figure 1 and proceed as follow:

a. Remove the temperature switch cover.

b. Operate the test stand at 3000 PSI and 3 GPM using BYPASS valve to heat up the fluid.

c. Observe rising temperature on HYDRULIC FLUID TEMP. Gauge and note when the HIGH FLUID TEMP. Light illuminate. Turn the adjusting screw in to raise the temperature and out to lower the temperature. Repeat step b and c until HIGH FLUID TEMP light illuminate at 185 ± 5 ºF.

d. Install the cover.

Page 4 JUN 2016

Servicing the boost-and supply filters

2.6 There are no regularly recommended maintenance intervals for the filter assemblies. The filter elements should be replaced when they become clogged enough to activate the differential pressure switch, or in the event of severe contamination. Refer to Figure 2 and proceed as follows:

e. Place RESERVOIR SELECTOR VALVE (21) to Aircraft.

f. Open BYPASS VALVE (Chap 2, Figure 1, ref. 17) and SYSTEM SUPPLY VALVE

(18) to relieve any residual system pressure.

g. Remove the filter bowl (1), O-ring (2), and backup ring (3). Support the bowl in an upright position to prevent fluid spillage.

h. Remove the filter element (4) and O-ring (5).

i. Install a new element, O-rings, and backup ring, and refit the filter bowl.

j. Place reservoir selector valve to Test Stand.

Servicing the hydraulic reservoir

2.7 The hydraulic reservoir requires no regular maintenance, other than replenishing and periodic inspections for leakage or contamination. Refer to Figure 2 and proceed as follows:

WARNING

HYDRAULIC FLUID. THIS UNIT EMPLOYS MIL-H-5606 HYDRAULIC FLUID,

WHICH IS A HAZARDOUS SUBSTANCE. REFER TO THE HYDRAULIC

FLUID WARNING IN THE PRELIMINARY PAGES OF THIS PUBLICATION.

a. Position a bin or tray of sufficient capacity under the reservoir tank (1).

b. Remove the drain plug (2) and allow all hydraulic fluid to drain from the reservoir. Recycle or dispose of the fluid according to local guidelines.

c. Clean the filler cap (3) with a suitable solvent and allow to air dry.

d. Remove the HPS top panel and the reservoir top lip.

e. Visually inspect the reservoir for cleanliness or damage.

f. Examine the wiring (5) to the reservoir level switch (4) for broken insulation or signs of overheating. Broken insulation may be repaired according to local guidelines for electrical wiring. Burnt insulation requires the removal and replacement of the switch in question. There is no adjustment or servicing of the level switch other than replacement.

JUN 2016 Page 5

KEY

1. Filter bowl

2. O-ring

3. Backup ring

4. Filter element

5. O-ring

Figure 1. Servicing the hydraulic filters

Page 6 JUN 2016

Figure 2. Hydraulic reservoir

KEY

1. Reservoir tank

2. Drain plug

3. Filler cap

4. Level switch

5. Electrical connection

6. Purification return port

7. Purification supply port

8. Level gauge

JUN 2016 Page 7

Main pump volume control system.

2.8 If maintenance has been performed on the volume compensator system (i.e. the panel mounted valve, pump mounted volume control, or hydraulic lines between the two removed) the system must be recharged with hydraulic fluid. Refer to Figure 3 and proceed as follows:

a. Refer to operating procedures and bring the unit to operating status.

b. Ensure bypass valve is open fully CCW. Verify 40 to 50 PSI boost pressure on BOOST PRESSURE GAUGE (16).

c. Maximum output flow of the main pump can be set simply by adjusting the manual stop screw (1), CW to reduce and CCW to increase the flow. Set the max flow to 7 ± 1 GPM

d. Open volume compensator valve (3) fully CCW.

e. Open the volume compensator bleed valve (5) at least two turns CCW.

f. Place a container below the volume control valve and open bleed plug.

g Open and close volume control valve (3) couple of time to bleed all the trapped air inside the lines.

h Operate until only clear fluid is visible coming from the bleed plug. Close and tighten bleed plug snugly.

g. Close bleed valve (5) CW.

h. Stop the motor.

JUN 2016 Page 7

Figure 3 Volume Compensator System

JUN 2016 Page 7

Electrical component settings and adjustments

3. The electronic components of the HTS are pre-set and do not require adjustment as part of normal use.

Flow meter

3.1 The flowmeter digital indicator is matched to it’s flowmeter and should only be adjusted in the event of indicator/flowmeter replacement. Proceed as follows:

b. Disconnect main power from the flow meter.

c. Press both front keys and switch on the supply voltage or, if the supply voltage is already on, press both keys simultaneously for 5 seconds.

d. The display shows PROG, followed by no.

e. Press the right key to switch to YES.

f. Press and hold the left key, then press the right key.

g. After releasing the keys, the display alternates between Mode and last default.

h. Press the right key until tAcho is displayed.

i. Press and hold the left key, then press the right key.

j. After releasing the keys, the display alternates between InPol and last default.

k. Press the right key until PnP is displayed.

l. Press and hold the left key, then press the right key.

m. After releasing the keys, the display alternates between FiLtEr and last default.

n. Press the right key until OFF is displayed.

o. Press and hold the left key, then press the right key.

p. After releasing the keys, the display alternates between FActor and a preset value.

q. Press the right key and use the right key to change the digit value and left key to scroll to the next digit.

r. Set the factor as indicated on the flow meter using the formula 60/(K x 100).

s. Press and hold the left key, then press the right key. The display alternates between drUrSo and a pre-set value.

t. Press right key and use the right key to change the present value to 00.0100. Use the left key to scroll to next digit.

u. Press and hold the left key, then press the right key. The display alternates between dP and a pre-set value.

JUN 2016 Page 9

v. Press the right key until display is set to 0.

w. Press and hold the left key, then press the right key. Display alternates between diSPm and a preset value.

x. Press the right key until SEC-1 is displayed.

y. Press and hold the left key, then press the right key.

z. Display indicates Wait0 and a preset value.

aa. Use the right key to change the preset value to 00.1. Use the left key to scroll to the next digit.

bb. Press and hold the left key. Then press the right key.

cc. Display should indicate EndPro and no.

dd. Press the right key until display indicates YES.

ee. Press and hold the left key, then press the right key. This will end the programming.

ff. Reconnect main power.

Electrical component setting

3.2 Set electrical controls as follows:

a. Circuit breaker 1 15 Amp (main CB MSP) not adjustable.

b. Circuit breaker 2 set @ 1.3 Amp (phase relay MSP).

c. Circuit breaker 10 Amp (power supply MSP) not adjustable.

d. Circuit breaker 4 set @ 1.3 Amp (fan motor MSP).

e. Circuit breaker 5 set @202 amp

f. Time relay 1 – TR1 set @ 10 sec.

JUN 2016 Page 9

Troubleshooting 4 The HTS incorporates several electronic devices that will detect a fault during operation and automatically cause the unit to shut down completely. In the event such a shutdown does occur, fault finding (troubleshooting) procedures must be implemented before the HTS is re-started. This will prevent test stand from shutting down again (due to the same problem), and from possible damage to the equipment or injury to personnel from component failure.

4.1 To facilitate fault diagnosis, a listing of symptoms, probable causes, and solutions are listed in Table 1. The table also covers hydraulic faults and mechanical problems.

Table 1. Troubleshooting

Trouble Probable cause Remedy

Starting Procedure Troubles

Operating troubles High-pressure pump fails to deliver sufficient pressure.

Incorrect setting of SYSTEM PRESSURE valve.

Adjust SYSTEM PRESSURE valve until desired pressure is indicated on SYSTEM PRESSURE gauge.

SYSTEM PRESSURE valve failure. Replace valve cartridge.

Damaged or worn out pump. Repair or replace pump.

Pump fails to compensate. Incorrect setting of SYSTEM

PRESSURE valve.

Adjust SYSTEM PRESSURE valve until desired pressure is indicated on SYSTEM PRESSURE gauge.

BYPASS VALVE open or leaking. Close valve. Replace cartridge if leakage is present.

Power cable connected but OUT of phase light illuminate

Wrong phase Switch one of the phases on the power source.

Wrong phase Replace lamp.

(continued)

Page 10 JUN 2016

Table 1. Troubleshooting – continued

Trouble Probable cause Remedy Operating troubles (cont’d) System pressure too high. Incorrect setting of SYSTEM

PRESSURE valve.

Adjust SYSTEM PRESSURE valve until desired pressure is indicated on SYSTEM PRESSURE gauge.

SYSTEM PRESSURE valve failure.

Replace valve cartridge.

Boost pump insufficient pressure.

Low-pressure filter clogged (indicator light is illuminated).

Replace filter element.

Incorrect setting of low- pressure relief valve

Set according to Chap 3

Low-pressure relief valve failure. Replace valve.

Damaged or worn out pump. Repair or replace pump.

Pump excessive noise Pump incorrectly being started or stopped under load.

Refer to Chapter 2 for proper pre-start and shutdown procedures.

Fluid level low (indicator light should be illuminated).

Check HYD FLUID LEVEL gauge. Replenish reservoir, if necessary.

Insufficient boost charge to main pump, resulting in pump cavitation.

Refer to ‘Boost pump insufficient pressure’ section.

Air entering system. Check all hydraulic connections.

HIGH FLUID LEVEL indicator light illuminated

Reservoir is over-filled. Open the drain plug and drain the fluid amount necessary to extinguish the light.

Defective switch. Replace the entire level switch.

LOW FLUID LEVEL indicator light illuminated.

Hydraulic fluid level in reservoir too low.

Check HYD FLUID LEVEL gauge.

Replenish, if necessary.

Defective switch. Replace the entire level switch.

LOW BOOST PRESSURE

indicator light illuminated (this light also illuminates on start-up until sufficient boost pressure is built up).

Boost pump failure (pressure below 10 PSI).

Replace boost pump.

Low-pressure (boost) filter element clogged.

Verify LP FILTER CLOGGED indicator light illuminated.

Replace element.

(continued)

JUN 2016 Page 11/12 blank

Table 1. Troubleshooting – continued

Trouble Probable cause Remedy

Operating troubles (cont’d)

HIGH FLUID TEMPERATURE

indicator light illuminated.

Heat exchanger cores blocked. Check air intake screen and heat exchanger core for foreign matter.

High-pressure pump fails to deliver sufficient volume.

BYPASS VALVE open or leaking. Close valve. Replace cartridge if leakage is present.

SYSTEM SUPPLY VALVE

closed.

Open valve.

Incorrect setting of high-pressure relief valve

Set according to Chap 3, High-pressure relief valve failure. Replace valve cartridge.

Hydraulic fluid very cold (fluid viscosity high). Low-pressure filter ∆P light may be lit.

Allow fluid to warm up. If ∆P indicator light remains illuminated replace element.

Fan blades damaged. Replace fan.

Aircraft reservoir drains during operation with reservoir selector valve set to AIRCRAFT position.

Reservoir selector valve improperly installed.

Ensure that valve is correctly oriented.

Reservoir selector valve leaking. Remove and replace.

Thermal relief valve defective. Repair or replace valve.

Chap 4 JUNE 2016 Page 1

Chapter 4

PARTS LISTS

CONTENTS

Para.

1 Introduction

2 Item numbers

3 Hydraulic components

4 Electrical components

5 Recommended spare parts list

Introduction 1 This section lists and describes the major components and parts for the hydraulic portable test stands. The parts list may be used with the hydraulic and electrical schematic diagrams for location and description of components.

Item numbers 2 Item numbers listed in the parts list correspond to component identification numbers on the hydraulic and electrical schematic diagrams; and by referring to the item number column in the parts list, the part number and description can be found.

Hydraulic components 3 Major…