SOW Attachment_2 (Test Stand Specifications).pdf

TM 122255-915 004 00

15 August 2018

OPERATION AND INTERMEDIATE MAINTENANCE

WITH ILLUSTRATED PARTS BREAKDOWN

PREPARATION FOR USE, STORAGE, OR SHIPMENT

HYDRAULIC COMPONENTS TEST STAND

PART NUMBERS 180347-100, 180348-100

Reference Material

Operation Instructions, Main Hydraulic Console ................................................................................................. 005 00

Troubleshooting ................................................................................................................................................... 006 00

Maintenance Instructions, Main Hydraulic Console ............................................................................................ 007 00

Aviation Hydraulics Manual .....................................................................................................................NA 01-1A-17

Military Specification for Barrier Materials, Watervapor-proof, Greaseproof, Flexible, Heat-Sealable...... MIL-B-131

Military Standard Procedures for Packaging of Parts and Equipment......................................................MIL-STD-794

Support Equipment Cleaning, Preservation and Corrosion Control ...........................................................NA 17-1-125

Support Equipment Required

Nomenclature Part Number/Type Designation CAGE

Storage Container (10 gallon capacity) - -

Storage Container (20 gallon capacity) - -

Storage Container (60 gallon capacity) - -

Materials Required

Nomenclature Specification/Part No. HMWS Index Number

Cap, push-on, straight-thread PO-20 through PO-180 -

Cloth, cleaning, low lint A-A-59323 -

Hydraulic fluid MIL-PRF-83282 4

Lubricant Bitzer BSE 55 10

Lubricating oil, 10W MIL-PRF-2104 8

Nitrogen, Type I - 6

Sealant, anaerobic, thread (SWAK) MS-PTS-250 3

1-1 PREPARATION FOR USE.

1-2 This work package (WP) provides instructions for installation, preparation for use after storage or shipment, and preparation for storage or shipment of the A/F27T-12 Hydraulic Component Test Stand (HCTS).

1-3 UNPACKING. HCTS major components (Main Hydraulic Console, and Pump and Motor Test Console) are shipped completely assembled and requires no major assembly of components prior to preparing the unit for use.

Before use, perform the following procedures:

1. Carefully unpack and remove HCTS from shipping containers.

2. Open all access doors and thoroughly inspect interior of HCTS to ensure removal of all packing material used to protect internal components during shipment.

3. Small areas of normally exposed metal surfaces may be wrapped with protective paper covering or tape during shipment. Be certain all such coverings are removed.

4. Inspect all loose equipment items for obvious defects affecting serviceability.

5. Remove and retain any covers that protect equipment openings.

Use of compressed air can create an environment of propelled particles. Do not direct air streams towards self or other personnel. Air pressure shall be reduced to no more than 5 PSIG for the cleaning of electrical equipment and shall be used with effective chip guarding and personal protective devices. Failure to comply may cause severe injury or death.

6. Use a low pressure air hose to clean shipping or packing residue.

1-4 INITIAL INSPECTION. Carefully inspect HCTS for any damage which may have occurred during shipment. Proceed as follows:

1. Visually examine housings and verify that all housing latches are functional.

2. Inspect controls for damage.

3. Visually examine the unit for instrument panel markings and model nameplate data.

4. Verify all electrical connections are properly secure.

5. Verify all hoses and tubing are properly clamped and all the fittings are tight. Inspect tubing and hoses for kinks, abrasions, or loose connections.

6. Check all mechanical connections and hardware for security.

1-5 HCTS INSTALLATIONS. Facility mounting requirements for HCTS components (MHC and P&MTC) are detailed in Figures 1 through 5.

2-1 MHC INSTALLATION.

2-2 CONNECTIONS BETWEEN FACILITY AND MHC. The connections required between the facility and MHC are for power, service air, and coolant water.

2-3 POWER REQUIREMENTS. The MHC requires 440 - 480 ± 5% VAC, 3 phase, 60 Hz facility power with a 300A fusible disconnect service.

2-4 SERVICE AIR REQUIREMENTS. The MHC requires filtered/dry service (shop) air at 90 - 125 PSI max.

2-5 COOLANT REQUIREMENTS. The MHC requires coolant water of 35 GPM at 60°F and 45 - 70 PSI.

2-6 NITROGEN REQUIREMENTS. The MHC requires bottled nitrogen (K bottle) at 500 to 3000 PSI.

2-7 MAIN HYDRAULIC CONSOLE. Refer to Figure 1 for installation requirements. Position the Main Hydraulic Console (MHC) on a level concrete foundation (shore based) with adequate access to facility supplies for AC input power, chilled water, compressed air, and bottled nitrogen. Provide a minimum clearance all sides of the unit IAW Figure 1.

NOTE

Mounting requirements are optional for shore based activities.

2-8 N/A.

2-9 FACILITY INPUT POWER TO MHC CONNECTION. Proceed as follows:

High voltages and currents cause severe injury or death. Ensure that all facility power has been removed/turned off. Failure to comply may cause severe injury or death.

1. Turn off, tag, and lock out facility power designated for MHC.

2. Ensure that MHC circuit breaker CB1 is set to OFF (Figure 1).

3. Remove MHC right rear access panel

4. Connect facility 440 - 480 ± 5% VAC, 3 phase, 60 Hz input main power cable power to power block TB1 and ground lug as shown (Table 1 and Figure 2)

5. Install the MHC right rear access panel.

2-10 FACILITY SERVICE AIR TO MHC CONNECTION. Proceed as follows:

1. Turn off facility service air supply line valve designated for MHC.

2. Remove rear access panel on MHC. Close air inlet shutoff valve BV8 (Figure 1, sheet 3) just below shop air inlet 3/4 NPT.

Figure 1. MHC Installation (Sheet 1)

Figure 1. MHC Installation (Sheet 2)

Figure 1. MHC Installation (Sheet 3)

Table 1. 440 - 480 ± 5% VAC, 3 phase, 60 Hz Facility Supply Power, Wire and Routing

Wire No. Routing

L1 ACPHASE 1-HI. 1CB-L1 (LINE Left)

L2 ACPHASE 2-HI. 1CB-L2 (LINE Center)

L3 ACPHASE 3-HI. 1CB-L3 (LINE Right)

GND GND BAR

Figure 2. MHC 460 VAC, 3 phase, 60 Hz at 300A and E-Stop E/S2 Electrical Installation

SEALANT, ANAEROBIC, THREAD, MS-PTS-250 3

3. Apply thread sealant to male pipe threads of shop air inlet 3/4 NPT. Attach hose to MHC.

4. Turn on facility service air supply line valve designated for MHC.

5. Open air inlet shutoff valve BV8 (Figure 1, sheet 3).

2-11 FACILITY COOLANT WATER TO MHC CONNECTIONS. Proceed as follows:

1. Turn off facility coolant supply and return line valves designated for MHC.

2. Remove rear access doors on MHC. Close chilled water shutoff valve BV7 (Figure 1, sheet 3) just below water inlet 1 1/4 NPT.

3. Remove protective caps from water inlet 1 1/4 NPT and water outlet 1 1/4 NPT ports on top of the MHC.

SEALANT, ANAEROBIC, THREAD, MS-PTS-250 3

4. Apply thread sealant to male pipe threads of water inlet and outlet fittings. Attach hoses to MHC.

5. Turn on facility coolant supply and return line valves designated for MHC. Observe for leakage.

6. Slowly open chilled water shutoff valve BV7 and allow air to bleed. Install rear access panel on MHC.

2-12 N2 BOTTLE TO MHC CONNECTION. Proceed as follows:

1. Ensure that nitrogen inlet shutoff valve BV9 (Figure 1, sheet 3) is closed.

Nitrogen gas under pressure. Do not puncture or incinerate container. Can cause rapid suffocation.

May cause severe frostbite. Do not direct gaseous nitrogen toward body or clothing. Serious injury or death may result from the high energy of compressed gas. Appropriate personal protection shall be used. Failure to comply may cause severe injury or death.

NOTE

Ensure N2 bottle is properly charged (500 to 3000 PSI) prior to connection.

NITROGEN, TYPE I 6

2. Connect hose assembly from facility N2 bottle to MHC nitrogen inlet top of the MHC.

3. Open valve on N2 bottle.

4. Open nitrogen inlet shutoff valve BV9 (Figure 1, sheet 3).

2-13 FILLING THE HYDRAULIC RESERVOIR. Proceed as follows:

1. Remove rear access door to MHC.

2. Ensure reservoir drain valve BV6 (Figure 1, sheet 3) is closed.

HYDRAULIC FLUID, MIL-PRF-83282 4

3. Remove the reservoir fill cap. Add hydraulic fluid as necessary (the MHC reservoir holds 55 gallons maximum) IAW NA 01-1A-17. Replace fill cap.

NOTE

It may be necessary to add additional hydraulic fluid to the reservoir once the main pumps have been turned on.

4. The air dryer desiccant filter above the reservoir has a shipping plug to prevent the desiccant from absorbing moisture during shipping/storage. Remove and discard this plug before operation.

2-14 E-STOP E/S2 INSTALLATION. A remote control emergency stop switch E/S2 is supplied for facility installation and is connected with a user supplied cable and conduit. Proceed as follows:

High voltages and currents cause severe injury or death. Ensure that all facility power has been removed/turned off. Failure to comply may cause severe injury or death.

1. Turn off, tag, and lock out facility power designated for MHC.

2. Ensure that MHC circuit breaker CB1 is set to OFF (Figure 1).

Figure 3. P&MTC Installation (Sheet 1)