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Technical Support

Series 505G2 SilentFlo™ Hydraulic Power Unit

7

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.

Technical support methods

MTS provides a full range of support services after your system is installed. If you have any questions
about a system or product, contact Technical Support in one of the following ways.

Type of

Support

Details

Web site

www.mts.com > Contact Us (upper-right corner) > In the Subject field, choose To
escalate a problem; Problem Submittal Form

E-mail

Worldwide: [email protected]
Europe: [email protected]

Telephone

Worldwide: 1 800 328 2255 - toll free in U.S.; +1 952 937 4000 - outside U.S.
Europe: +800 81002 222, International toll free in Europe

Outside the U.S.

For technical support outside the United States, contact your local sales and service office. For a list of
worldwide sales and service locations and contact information, use the Global MTS link at the MTS
web site:

www.mts.com > Global Presence > Choose a Region

Before You Contact MTS

MTS can help you more efficiently if you have the following information available when you contact us
for support.

Know your site (if applicable) and system numbers

The site number contains your company number and identifies your equipment type (such as material
testing or simulation). The number is typically written on a label on your equipment before the system
leaves MTS. If you do not know your MTS site number, contact your sales engineer.

Example site number: 571167

When you have more than one MTS system, the system job number identifies your system. You can
find your job number in your order paperwork.

Example system number: US1.42460

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Summary of Contents for SilentFlo 505G2 Series

Page 1: ...Series 505G2 SilentFlo Hydraulic Power Unit Model 505G2 07 Model 505G2 11 100 227 350 C ...

Page 2: ... and owned by MTS Systems Corporation and cannot be copied reproduced disassembled decompiled reverse engineered or distributed without express written consent of MTS Software Verification and Validation MTS software is developed using established quality practices in accordance with the requirements detailed in the ISO 9001 standards Because MTS authored software is delivered in binary format it ...

Page 3: ...You Contact MTS by Phone 9 Identify system type 9 Be prepared to troubleshoot 9 Write down relevant information 9 After you call 10 Problem Submittal Form in MTS Manuals 10 Preface 11 Before You Begin 11 Safety first 11 Other MTS manuals 11 Documentation Conventions 11 Hazard conventions 11 Other special text conventions 12 Special terms 12 Illustrations 12 Electronic manual conventions 12 Hyperte...

Page 4: ... 24 Check bolt ratings and torques 25 Practice good housekeeping 25 Protect hoses and cables 25 Provide proper hydraulic fluid filtration 25 Protect accumulators from moving objects 25 Do not exceed the Maximum Supply Pressure 25 Do not disable safety devices 25 Use appropriately sized fuses 26 Provide adequate lighting 26 Provide means to access out of reach components 26 Wear appropriate persona...

Page 5: ...n 58 Spare parts 58 Lockout tagout 58 Operating the HPU 58 Routine Maintenance Overview Checklist 58 Checking the Hydraulic Fluid 61 Replacing the Return Line Filter 62 Sample the Hydraulic Fluid 64 Appearance of Hydraulic Fluid Sample 66 Replacing the Hydraulic Fluid 67 Accessories 71 High Pressure Filter Kit 72 Replacing the Filter Element 72 Surge Suppressor Kit 73 Required equipment 73 Install...

Page 6: ...ilentFlo Hydraulic Power Unit 8 Hours Daily 82 40 Hours Weekly 82 160 Hours Biweekly 83 500 Hours 84 1000 Hours 85 2000 Hours 86 5000 Hours 87 10 000 Hours 87 Appendix B Declaration of Conformity 89 Example 90 Contents ...

Page 7: ...ll free in U S 1 952 937 4000 outside U S Europe 800 81002 222 International toll free in Europe Outside the U S For technical support outside the United States contact your local sales and service office For a list of worldwide sales and service locations and contact information use the Global MTS link at the MTS web site www mts com Global Presence Choose a Region Before You Contact MTS MTS can ...

Page 8: ...on Know relevant computer information For a computer problem have the following information available l Manufacturer s name and model number l Operating software type and service patch information l Amount of system memory l Amount of free space on the hard drive where the application resides l Current status of hard drive fragmentation l Connection status to a corporate network Know relevant soft...

Page 9: ...fy your system as one of the following types l Electrodynamic material test system l Electromechanical material test system l Hydromechanical material test system l Vehicle test system l Vehicle component test system l Aero test system Be prepared to troubleshoot Prepare to perform troubleshooting while on the phone l Call from a telephone close to the system so that you can implement suggestions ...

Page 10: ...al 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...

Page 11: ...aragraphs 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 recommend...

Page 12: ...route you should follow to a referenced item in the software Example Examples show specific scenarios relating to your product and appear with a shaded background Special terms The first occurrence of special terms is shown in italics Illustrations Illustrations appear in this manual to clarify text They are examples only and do not necessarily represent your actual system configuration test appli...

Page 13: ...SilentFlo Hydraulic Power Unit 13 Introduction Overview 14 EU Declarations 14 Intended Use 14 Product Information CD 14 Component Identification 15 Functional Description 18 Auto Cooling Valve adjustable 19 Electrical Control 19 ...

Page 14: ...claration of Conformity is provided at the end of this manual Intended Use The intended use of the Hydraulic Power Unit HPU is l Hydraulic supply for servohydraulic testing systems l Power supply for other hydraulically operated machinery presses or test systems Product Information CD A Product Information CD is supplied with the HPU MTS part number 100 227 354 The Product Information CD includes ...

Page 15: ...ectrical Schematic 200 480 VAC 700004942 505 07 small PLC Electrical Schematic 575 VAC 700005293 505 07 large PLC Electrical Schematic 575 VAC 700005263 505 11 Configuration Drawing 700000264 505 11 Hydraulic schematic 700004965 505 11 small PLC Electrical Schematic 200 480 VAC 700005214 505 11 large PLC Electrical Schematic 200 480 VAC 700004966 505 11 small PLC Electrical Schematic 575 VAC 70000...

Page 16: ...lic fluid samples from the HPU A quick disconnect port is provided Use the optional sampling kit that includes a needle valve to regulate the flow through the sample port 5 Electrical Enclosure Houses the electrical and control components of the HPU The main power lines enter the unit at the top The power disconnect switch removes electrical power whenever the enclosure door is opened 6 Low level ...

Page 17: ...Location The high pressure filter is optional If provided it would be located where indicated in the figure 14 Output Pressure Control Sets the output pressure of the HPU 15 Heat Exchanger Cools the hydraulic fluid by using an oil to water heat exchanger The heat exchanger removes most of the heat generated by the HPU 16 Temperature Gage Displays the temperature of the hydraulic fluid 17 Return Fi...

Page 18: ...le relief valve set at 22 4 MPa 3250 psi Pressure The start low high switch on the front panel of the electrical enclosure controls the hydraulic pressure of the HPU The start low high switch operates like an automotive ignition switch turn and hold the switch in the start position until the motor starts running The switch returns to the low position The unit automatically starts in low pressure t...

Page 19: ...uit when external hydraulic demand for flow is low When the external demand increases this feature closes the path to provide the full flow of the HPU to the external demand The effective operating range of the auto cooling circuit is between system pressures of 14 MPa 2000 psi to 21 MPa 3000 psi In order for the Auto Cooling Valve to function properly it must be re adjusted anytime the output pre...

Page 20: ...ault has been detected and corrected l A dirty filter signal will not shut the unit down but will prevent the unit from starting l The power disconnect switch on the door of the main electrical enclosure ensures that power is removed whenever the door is opened This device is a TÜV certified lockable main disconnect switch ...

Page 21: ...Safety Series 505G2 SilentFlo Hydraulic Power Unit 21 Safety General Safety Practices Hydraulic Power Units and Hydraulic Service Manifolds 22 ...

Page 22: ... replace system components using parts that are not MTS component parts or effect repairs using parts or components that are not manufactured to MTS specifications l Do not use the system in a test area where uncontrolled access to the test system is allowed when the system is in operation l For servohydraulic systems do not operate the system unless an interlock is installed to monitor supply pre...

Page 23: ...manuals provided with your system before attempting to perform any system function for the first time Procedures that seem relatively simple or intuitively obvious may require a complete understanding of system operation to avoid unsafe or dangerous situations Locate and read hazard placards labels Find read and follow the hazard placard instructions located on the equipment These placards are pla...

Page 24: ...d clear the area around the actuator rod when hydraulics are turned off Know electrical hazards When the system electrical power is turned on minimize the potential for electrical shock hazards Wear clothing and use tools that are properly insulated for electrical work Avoid contact with exposed wiring or switch contacts Whenever possible turn off electrical power when you work on or in proximity ...

Page 25: ...tures that can cause the cables to harden and eventually fail Ensure that all cables have appropriate strain relief devices installed at the cable and near the connector plug Do not use the connector plug as a strain relief Protect all system hoses and cables from sharp or abrasive objects that can cause the hose or cable to fail Never walk on hoses or cables or move heavy objects over them Consid...

Page 26: ...atory system or eyes 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 app...

Page 27: ...g equipment avoid crush points Stay clear of mechanical linkages connecting cables and hoses that move because you can get pinched crushed tangled or dragged along with the equipment High forces generated by the system can pinch cut or crush anything in the path of the equipment and cause serious injury Stay clear of any potential crush points Most test systems can produce sudden high force motion...

Page 28: ...ise level that can damage your hearing l Ensure that all pressurized air or gas is bled out of a pneumatic or gas charged device before you start to disassemble it A thorough understanding of the assembly and its pressurized areas is necessary before you undertake any maintenance Refer to the appropriate product information for the correct bleeding procedure It may not be obvious or intuitive whic...

Page 29: ...er cap before operating Replace with black plastic snap in strainer Part 050 174 101 Part 100 223 270 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 Explosion hazard release of pressure High pressure fluid or gasses Do not tamper with fittings or hoses Wear appropriate protection such as sa...

Page 30: ...Power Unit Label Description protection Maintain safe pressure levels Disconnect from electrical power before servicing Read the manuals Wye Delta Connections Use for single voltage 6 lead motors suitable for wye delta starting Part 053 448 401 ...

Page 31: ...Installation Series 505G2 SilentFlo Hydraulic Power Unit 31 Installation Install the HPU 32 HPU Setup 35 ...

Page 32: ...vironment l Connect the electrical service to the HPU Note Local electrical codes supersede any information found here 2 Electrical connections must be made by qualified personnel and conform to local codes and regulations The electrical box has a power disconnect switch that must be off O in order to open the electrical box An electrical service panel to provide the electrical power feed line vol...

Page 33: ...ctions 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 allowabl...

Page 34: ...f the reservoir The screen is shipped in the electrical enclosure B Rotate the power disconnect switch to the on position Caution Incorrect motor rotation at high pressure for longer than 10 seconds can cause severe damage to your HPU If the pressure as observed on the pressure gage does not increase within 10 seconds after High is selected stop the unit C Start the HPU by pressing the Start switc...

Page 35: ...rtant If a controller is not used the installed jumper plug must be used or the unit will not start Connect the controller cable to the connector located at the lower left side of the electrical enclosure HPU Setup The following procedure should only be performed at HPU installation to verify settings when you replace the user interface panel or if you need to change a selection 1 Rotate the power...

Page 36: ...Pushbutton Indicator The HPU generates fault signals for remote monitoring This button is used to define the polarity of the output signal Remote Fault Normal gray The remote fault signal is active high meaning the fault contact is closed when a fault is present Remote Fault Normal black The remote fault signal is active low meaning the fault contact is open when a fault is present Aux Contact On ...

Page 37: ...e normal polarity Press the Aux Polarity button to display Aux Polarity Reverse to cause the contact to open when it is active The other Aux contact is set for motor pump running only Its function and polarity are not selectable Mean Temp numeric display and Deadband numeric display Part of the Analog Option only displayed if the Analog Option was purchased Mean Temp deg blue green Indicator used ...

Page 38: ...or Fahrenheit Push to alternate between the two temperature scales Temp Display in F gray Temp Display in C black Pressure Display In units Part of the Analog Option only displayed if the Analog Option was purchased Pushbutton Indicator Used to select the units for pressure displays in either psi or MPa Push to alternate between the two pressure units Pressure Display in psi gray Pressure Display ...

Page 39: ...Operation Series 505G2 SilentFlo Hydraulic Power Unit 39 Operation Operator s Panel 40 ...

Page 40: ...ont panel controls and indicators and provides operating instructions for the Series 505 Hydraulic Power Unit HPU 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 ...

Page 41: ...ic fluid level reaches an acceptable temperature Run Stop Bypass Pushbutton Indicator Pushbutton used to start and stop the HPU Run gray black letters In this state press to start the HPU Stop gray red letters In this state press to stop the HPU Bypass blue white letters In this state press to start the HPU in bypass mode The Faulted state will turn to Overtemp Bypass Bypass mode only occurs durin...

Page 42: ...essure Part of the Analog Option only displayed if the Analog Option was purchased Indicator Display Indicates output pressure of the HPU Oil Temp erature Part of the Analog Option only displayed if the Analog Option was purchased Indicator Display Indicates the temperature of the hydraulic fluid in the reservoir Oil Level Part of the Analog Option only displayed if the Analog Option was purchased...

Page 43: ...he Main screen Status black The Status screen is selected and displayed Status blue A blue indicator means action is required When the status indicator is blue press the status button to go to the status screen and resolve any condition that requires action Setup Pushbutton Indicator Pushbutton used to select the Setup screen Setup gray In this state one of the other screens is selected for exampl...

Page 44: ...E Stop OK gray Indicates the safety relay has not tripped E Stop Fault red Indicates the safety relay has tripped The cause of a safety relay trip is either the main panel E stop button an external e stop button or the HPU watchdog timer 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 l...

Page 45: ...e limits This state will not generate an active interlock but alerts the user that the filter requires maintenance The HPU cannot be started with an active return filter warning Pressure Filter OK Pressure Filter Fault Part of the Pressure Filter Option only displayed if the Pressure filter Option was purchased Indicator Used to indicate if the pressure filter is within acceptable limits Press Fil...

Page 46: ...re mode press the High Pressure button to return to low pressure mode 9 To stop the HPU press the Stop button Remote operation Remote operation can occur at a remote control panel or from your system controller The controller must be connected to the HPU 1 Make a general inspection of the HPU Ensure that all cooling water valves are open Ensure the Emergency Stop button is released 2 If not alread...

Page 47: ...it status back to normal Hyd fluid overtemperature A hydraulic fluid overtemperature interlock is indicated on the Main screen by a flashing red Faulted indicator a blue Bypass indicator a red Oil Temp indicator and a blue Status indicator The interlock is generated when the temperature exceeds 55 C 131 F The interlock will automatically shut down the HPU The HPU cannot return to normal operation ...

Page 48: ...ure Filter Dirty indicator s The interlock is generated when the filter capacity has reached a critical level A dirty filter condition will prevent the HPU from being started but it will not stop the HPU while it is running 1 Replace the dirty hydraulic fluid filter Refer to procedures for return line filter replacement and high pressure filter replacement as required 2 Press Reset to clear the in...

Page 49: ... F Resetting the Thermal Overloads and Circuit Breakers The electrical power feed line for each pump motor has a circuit breaker with integrated thermal overload switch in the main electrical enclosure If any pump motor draws too much current its thermal overload switch trips and disconnects that pump motor from the electrical power feed Additional protection is provided by circuit breakers A trip...

Page 50: ...a 3000 psi If you have a special testing requirement you can reduce the HPU output pressure If you do so you should also adjust the Auto Cooling Valve Control Locations To change the output pressure see the appropriate procedure 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 h...

Page 51: ...ernal hydraulic demand for flow is low When the external demand increases this feature closes the path to provide the full flow of the HPU to the external demand The effective operating range of the auto cooling circuit is between system pressures of 14 MPa 2000 psi to 21 MPa 3000 psi In order for the Auto Cooling Valve to function properly it must be re adjusted anytime the output pressure will b...

Page 52: ... at this point An alternative to listening for a change in pump pitch is to hold the return line hose at the manifold while making the valve adjustment to feel when the resultant flow stops or starts Important Adjustment of the Auto Cooling Valve to a level too close to the desired output pressure may cause an unstable condition characterized by rapid valve shifting This condition will produce an ...

Page 53: ...ted and the valve has been fully closed go to step 3 Important Adjustment of the Auto Cooling Valve to a level too close to the desired output pressure may cause an unstable condition characterized by rapid valve shifting This condition will produce an audible flutter and can be seen as an erratic movement of the needle on the pressure gage Adjustment of the Auto Cooling Valve at or above the desi...

Page 54: ...ted in low pressure to reduce the amount of current inrush at motor startup A solenoid valve that opens a direct flow path to the return line commands the pressure setting Because this direct path offers little resistance to the full flow minimal system pressure is developed low pressure Low pressure operation of a Series 505 HPU provides several useful functions when high pressure is not required...

Page 55: ...fluid with a lower BTU per gallon heat content to the heat exchanger The heat exchanger operates with greater efficiency when flows are near the designed flow rate as boundary layers are minimized Energy consumption All Series 505 HPUs have variable volume pumps Switching from high to low pressure operation when external demands are absent will conserve energy and water l Leaving an HPU idling in ...

Page 56: ...d occurs just below the output pressure level Whenever system pressure is above the shift level of the Auto Cooling Valve indicating low system demand the valve opens to port hydraulic fluid through the return filter to the heat exchanger When system pressure drops below the shift level indicating an increase in system demand the valve closes and full flow is available to the system The effective ...

Page 57: ...Maintenance Series 505G2 SilentFlo Hydraulic Power Unit 57 Maintenance Before You Begin 58 Routine Maintenance Overview Checklist 58 ...

Page 58: ...eeded Routine Maintenance Overview Checklist Calendar Time using 8 hour Running Time rate per day Daily Weekly Monthly Annually Running Time Hours 8 40 160 500 1000 1 500 2 000 5 000 10 000 Check electronic enclosure ventilation X 1 Check dirty filter indicators X Check for leaks X Check oil level X Check pressure X Check fluid color and odor X Check interlock devices X Recommended service to be p...

Page 59: ...n of all electrical cables and cable connections MTS MTS MTS MTS Check HPU hydraulic fluid color and odor MTS MTS MTS MTS Check HPU operating pressure and temperature MTS MTS MTS MTS Clean control cabinet air filter replace if required MTS MTS MTS MTS Inspect heat exchanger for leaks or flow when off MTS MTS MTS MTS Inspect pump MTS MTS MTS MTS 1Symbol denotes service performed by trained field se...

Page 60: ...n 505 MTS MTS MTS MTS Verify dirty filter indicators status MTS MTS MTS MTS Verify HPU hydraulic fluid level MTS MTS MTS MTS Verify warning and interlock devices MTS MTS MTS MTS 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 MT...

Page 61: ...mination and deterioration normally occur in most hydraulic systems Failure to keep your fluid sufficiently free of contaminants or to change the fluid before severe fluid breakdown occurs will cause poor system performance and may lead to expensive system cleanups Servovalves are especially susceptible to damage from dirty hydraulic fluid To avoid these problems you must maintain a clean hydrauli...

Page 62: ...ll of the hydraulic fluid Burnt smelling hydraulic fluid can indicate a chemical breakdown If you detect a distinct change in the smell of hydraulic fluid have it chemically analyzed by the manufacturer 4 Keep records of the maximum reservoir temperature High operating temperatures can cause the fluid to break down If your records indicate a pattern of overheating consult your MTS Field Service En...

Page 63: ... output pressure gage Ensure that the pressure is at zero before proceeding 4 Unscrew the filter cover The filter element bypass assembly and filter bowl can be removed as one assembly Be careful not to spill any hydraulic fluid 5 Remove the disposable element from the bowl Discard any fluid contained in the filter bowl 6 Wipe out any remaining sludge in the filter housing with a lint free cloth 7...

Page 64: ... cleanliness level of 13 9 or better 11 Press the Reset button on the HPU control panel to reset any interlocks and turn off the Dirty Filter indicator Sample the Hydraulic Fluid This section describes how to check the quality of the hydraulic fluid Review the following hints before obtaining your sample l Avoid contamination l Keep the sample bottle in the storage box of the hydraulic fluid sampl...

Page 65: ...lities Control Manifold 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...

Page 66: ...d Properties Problem What to Do Dark colored fluid Indicates chemical breakdown or the hydraulic fluid has been allowed to rise above the maximum recommended temperature severe overheating Analyze the fluid and replace as required by the analysis If the cause was overheating flush the entire system to remove varnish or residue Consult your MTS Field Service Engineer to determine if changes or adju...

Page 67: ...place it as required by the analysis Replacing the Hydraulic Fluid Replace the hydraulic fluid in the HPU reservoir whenever you have determined that the hydraulic fluid is no longer suitable for use Recommended equipment l A transfer pump with a 10 micron filter such as the Model 590 01 Fluid Transfer Pump l ethanol or a similar cleaning solvent l Lint free cloths or manufactured rags l A contain...

Page 68: ...ulic fluid A Use the transfer pump to remove the old hydraulic fluid from the reservoir and into an appropriate container B Open the fluid drain to remove any remaining fluid C Drain the hydraulic fluid from hoses and accumulators in the system 3 Clean the inside of the reservoir using clean cloths dampened with ethanol Clean the pump motor and bottom of the cover plate as well 4 Use a dry cloth t...

Page 69: ...Maintenance Series 505G2 SilentFlo Hydraulic Power Unit 69 D Press the Stop button E Check the dirty filter indicator Replace the filter element as needed ...

Page 70: ......

Page 71: ...Accessories Series 505G2 SilentFlo Hydraulic Power Unit 71 Accessories High Pressure Filter Kit 72 Surge Suppressor Kit 73 Precharging the Surge Suppressor Accumulator 75 Lifting Kit 77 Caster Kit 78 ...

Page 72: ...igh pressure output port 3 Connect the elbow to the input of the filter assembly Connect the straight tube to the output of the filter assembly 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 Turn on the hydraulic pressure an...

Page 73: ...sembly 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 cylind...

Page 74: ... fluid out of the reservoir and into an appropriate container Open the fluid drain to remove any remaining fluid Note Every part to be installed must be cleaned and wiped dry 6 Remove the hose from the pump output port to the bottom of the control manifold 7 Install the elbow and reducer for the 505 11 to the surge suppressor cylinder Torque the fixtures to 33 9 N m 25 lbf ft 8 Remove manifold fro...

Page 75: ...month or 160 operating hours If the precharge pressure changes more than 200 psi during this time period recharge the surge suppressor and check the pressure twice as often in the future If the precharge pressure changes less than 200 psi check the pressure half as often When you have established a regular interval for checking the precharge pressure note the amount of pressure loss that occurs ea...

Page 76: ...ressure 1 Close the locknut on the surge suppressor 2 Open the bleed valve two turns Warning Mixing gases can produce unpredictable results Do not use another gas to precharge a surge suppressor Use only dry nitrogen gas to precharge surge suppressors 3 Connect the nitrogen supply hose from the supply bottle pressure regulator output to the input check valve on the charging kit 4 Open the nitrogen...

Page 77: ...shut off 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 Caution The balance of the load unit can become unsettled The weight of the HPU can injure you or damage the HPU if it should become unbalanced and fall off the lift Before...

Page 78: ...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 ...

Page 79: ...Accessories Series 505G2 SilentFlo Hydraulic Power Unit 79 Caster Kit ...

Page 80: ......

Page 81: ...Service Logs Series 505G2 SilentFlo Hydraulic Power Unit 81 Appendix A HPU Maintenance and Service Logs 8 Hours Daily 82 40 Hours Weekly 82 160 Hours Biweekly 83 500 Hours 84 1000 Hours 85 2000 Hours 86 5000 Hours 87 10 000 Hours 87 ...

Page 82: ...draulic Power Unit 8 Hours Daily Check Console Verification Check Dirty Filter Indicators Check for Leaks Check oil Level Check Pressure Date Performed by Performed by Performed by Performed by Performed by Notes 8 Hours Daily Service Interval Recommendation 40 Hours Weekly ...

Page 83: ...heck Fluid Color and Odor Check Interlock Devices Date Performed by Performed by Notes 40 Hours Weekly Service Interval Recommendation 160 Hours Biweekly Check Cables and Connectors Check Console Air Filter Date Performed by Performed by Notes 160 Hours Monthly Service Interval Recommendation ...

Page 84: ... 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 Date Performed by Performed by Performed by Performed by Performed by Performed by 500 Hours Service Interval...

Page 85: ...erify HPU Hydraulic Fluid Level Verify Warning and Interlock Devices Date Performed by Performed by Performed by Performed by Performed by 500 Hours Service Interval Recommendation 1000 Hours All 500 hr Maintenance Procedures Replace All Filters Verify Operation and Settings of psi Control and Relief Valves Date Performed by Performed by Performed by Notes 1000 Hours Service Interval Recommendatio...

Page 86: ... psi Control and Relief Valves Date Performed by Performed by Performed by Notes 2000 Hours 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 Date Performed by Performed by Performed by Performed by Performed by Notes 2000 Hours Service Interval Recommendation ...

Page 87: ...heck Pump Motor Coupling for Wear and Debris Check Pump Voltage and Current Check Case Drain Flow Recommend MTS Hydraulix Oil Sample Date Performed by Performed by Performed by Performed by Performed by Notes 5000 Hours Recommend R R Heat Exchanger Date Performed by Notes 5000 Hours Service Interval Recommendation 10 000 Hours ...

Page 88: ...end 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 Date Performed by Performed by Performed by Performed by Performed by Performed by 10 000 Hours Service Interval Recommendation ...

Page 89: ...Appendix B Declaration of Conformity Series 505G2 SilentFlo Hydraulic Power Unit 89 Appendix B Declaration of Conformity Example 90 ...

Page 90: ...Appendix B Declaration of Conformity 90 Series 505G2 SilentFlo Hydraulic Power Unit Example ...

Page 91: ...Appendix B Declaration of Conformity Series 505G2 SilentFlo Hydraulic Power Unit 91 ...

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Page 94: ... 14000 Technology Drive Eden Prairie Minnesota 55344 2290 USA Toll Free Phone 800 328 2255 within the U S or Canada Phone 952 937 4515 outside the U S or Canada E mail info mts com Internet www mts com ISO 9001 certified QMS ...

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