MTS 298 User Manual

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Series 298 Hydraulic Service Manifold
Product Information

011-563-103 C

Copyright information © 2009 MTS Systems Corporation. All rights reserved.

Trademark information MTS is a registered trademark of MTS Systems Corporation within the United

States. This trademark may be protected in other countries.

DTE is a registered trademark of Mobil Corporation. Tellus is a registered
trademark of Shell Oil Corporation. All other trademarks or service marks are
property of their respective owners.

Publication information

MANUAL PART NUMBER PUBLICATION DATE

011-563-103 A June 1998

011-563-103 B July 1999

011-563-103 C July 2009

2

Series 298 Hydraulic Service Manifold

Contents

Technical Support 5

Preface 9

Conventions 10

Introduction 13

Component Identification 15

Component Descriptions 16

Functional Description 17

Specifications 19

General Specifications 19

Dimensions 20

Safety Information 21

Installation 23

Installing the Actuator Manifold onto a Load Unit 24

Installing the Actuator Manifold on an Actuator 27

Connecting Hydraulics 29

Connecting Cables 30

Installing the Filter 32

Upgrading a 298.11 Actuator Manifold to a 298.12 33

Maintenance 35

Replacing the Filter 36

Series 298 Hydraulic Service Manifold Contents

3

4

Contents

Series 298 Hydraulic Service Manifold

Technical Support

How to Get Technical Support

Start with your

manuals

Technical support

methods

The manuals supplied by MTS provide most of the information you need to use
and maintain your equipment. If your equipment includes software, look for
online help and README files that contain additional product information.

If you cannot find answers to your technical questions from these sources, you
can use the Internet, e-mail, telephone, or fax to contact MTS for assistance.

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.

www.mts.com The web site provides access to our technical support staff by means of an

onlineform:

www.mts.com > Contact MTS > Service & Technical Support button

E-mail [e-mail]

Telephone MTS Call Center 800-328-2255

Weekdays 7:00 A.M. to 5:00 P.M., Central Time

Fax [phone]

Please include “Technical Support” in the subject line.

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 MTS > (choose your region in the right-hand
column) > (choose the location closest to you)

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

number and system

number

Series 298 Hydraulic Service Manifold Technical Support

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

5

Know information from

prior technical

If you have contacted MTS about this problem before, we can recall your file
based on the:

assistance

• MTS notification number

• Name of the person who helped you

Identify the problem Describe the problem and know the answers to the following questions:

• How long and how often has the problem occurred?

• Can you reproduce the problem?

• Were any hardware or software changes made to the system before the

problem started?

• What are the equipment model numbers?

• What is the controller model (if applicable)?

• What is the system configuration?

Know relevant

computer information

Know relevant

software information

For a computer problem, have the following information available:

• Manufacturer’s name and model number

• Operating software type and service patch information

• Amount of system memory

• Amount of free space on the hard drive where the application resides

• Current status of hard-drive fragmentation

• Connection status to a corporate network

For software application problems, have the following information available:

• The software application’s name, version number, build number, and (if

available) software patch number. This information can typically be found
in the About selection in the Help menu.

• The names of other applications on your computer, such as:

– Anti-virus software

– Screen savers

– Keyboard enhancers

– Print spoolers

Technical Support

6

– Messaging applications

Series 298 Hydraulic Service Manifold

If You Contact MTS by Phone

A Call Center agent registers your call before connecting you with a technical
support specialist. The agent asks you for your:

• Site number

• Name

• Company name

• Company address

• Phone number where you can be reached

If your issue has a notification number, please provide that number. A new issue
will be assigned a unique notification number.

Identify system type To enable the Call Center agent to connect you with the most qualified technical

support specialist available, identify your system as one of the following types:

• Electromechanical material test system

• Hydromechanical material test system

• Vehicle test system

• Vehicle component test system

Be prepared to

troubleshoot

Write down relevant

information

After you call MTS logs and tracks all calls to ensure that you receive assistance for your

• Aero test system

Prepare to perform troubleshooting while on the phone:

• Call from a telephone close to the system so that you can implement

suggestions made over the phone.

• Have the original operating and application software media available.

• If you are not familiar with all aspects of the equipment operation, have an

experienced user nearby to assist you.

In case Technical Support must call you:

• Verify the notification number.

• Record the name of the person who helped you.

• Write down any specific instructions.

problem or request. If you have questions about the status of your problem or
have additional information to report, please contact Technical Support again and
provide your original notification number.

Series 298 Hydraulic Service Manifold Technical Support

7

Problem Submittal Form in MTS Manuals

Use the Problem Submittal Form to communicate problems with your software,
hardware, manuals, or service that are not resolved to your satisfaction through
the technical support process. The form includes check boxes that allow you to
indicate the urgency of your problem and your expectation of an acceptable
response time. We guarantee a timely response—your feedback is important to
us.

Access the Problem Submittal Form:

• In the back of many MTS manuals (postage paid form to be mailed to MTS)

• www.mts.com > Contact Us > Problem Submittal Form button (electronic

form to be e-mailed to MTS)

Technical Support

8

Series 298 Hydraulic Service Manifold

Preface

Before You Begin

Safety first! Before you use your MTS product or system, read and understand the Safety

manual and any other safety information provided with your system. Improper
installation, operation, or maintenance can result in hazardous conditions that can
cause severe personal injury or death, or damage to your equipment and
specimen. Again, read and understand the safety information provided with your
system before you continue. It is very important that you remain aware of
hazards that apply to your system.

Other MTS manuals In addition to this manual, you may receive additional manuals in paper or

electronic form.

You may also receive an MTS System Documentation CD. It contains an
electronic copy of the manuals that pertain to your test system, such as:

• Hydraulic and mechanical component manuals

• Assembly drawings

• Parts lists

• Operation manual

• Preventive maintenance manual

Controller and application software manuals are typically included on the
software CD distribution disc(s).

Series 298 Hydraulic Service Manifold Preface

9

Conventions

DANGER

WARNING

CAUTION

Conventions

Documentation Conventions

The following paragraphs describe some of the conventions that are used in your
MTS manuals.

Hazard conventions Hazard notices may be embedded in this manual. These notices contain safety

information that is specific to the activity to be performed. Hazard notices
immediately precede the step or procedure that may lead to an associated hazard.
Read all hazard notices carefully and follow all directions and recommendations.
Three different levels of hazard notices may appear in your manuals. Following
are examples of all three levels.

Note For general safety information, see the safety information provided with

your system.

Danger notices indicate the presence of a hazard with a high level of risk which,
if ignored, will result in death, severe personal injury, or substantial property
damage.

Warning notices indicate the presence of a hazard with a medium level of risk
which, if ignored, can result in death, severe personal injury, or substantial
property damage.

Caution notices indicate the presence of a hazard with a low level of risk which,
if ignored, could cause moderate or minor personal injury or equipment damage,
or could endanger test integrity.

Notes Notes provide additional information about operating your system or highlight

easily overlooked items. For example:

Note Resources that are put back on the hardware lists show up at the end of

the list.

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 application, or
software.

Electronic manual

conventions

This manual is available as an electronic document in the Portable Document
File (PDF) format. It can be viewed on any computer that has Adobe Acrobat
Reader installed.

10

Preface

Series 298 Hydraulic Service Manifold

Conventions

Hypertext links The electronic document has many hypertext links displayed in a blue font. All

blue words in the body text, along with all contents entries and index page
numbers, are hypertext links. When you click a hypertext link, the application
jumps to the corresponding topic.

Series 298 Hydraulic Service Manifold Preface

11

Conventions

12

Preface

Series 298 Hydraulic Service Manifold

Introduction

Contents Component Identification 15

The Series 298 Actuator Manifolds act as the interface between the Series 252
Servovalves, the Series 318 Load Units, and the Series 244 Actuators. The
actuator manifold can be mounted directly to the load unit or actuator and can
accommodate up to two servovalves. Three models are available:

• The Model 298.10 Actuator Manifold ports hydraulic fluid through the

actuator. Hydraulic control is at the hydraulic power unit (HPU).

• The Model 298.11 Actuator Manifold turns hydraulic pressure to the

actuator on and off.

• The Model 298.12 Actuator Manifold applies low hydraulic pressure and

ramps the pressure between low and high pressure.

Functional Description 17

Specifications 19

Series 298 Hydraulic Service Manifold Introduction

13

What you need to

know

MTS Systems Corporation assumes that you know how to use your controller.
See the appropriate manual for information about performing any controller­related step in this manual’s procedures. You are expected to know how to
perform the following procedures:

• Turning hydraulic pressure on and off

• Selecting a control mode

• Manually adjusting the actuator position

• Installing a specimen

• Defining a simple test

• Running a test

Related products The Series 298 Actuator Manifold works in conjunction with several other

products. See the following product information manuals for product-specific
information and maintenance procedures.

• The Series 111 Accumulator Product Information manual

(part number 011-553-304)

• The Series 244 Actuator Product Information manual

(part number 011-551-304)

• The Series 252 Servovalve Product Information manual

(part number 011-182-906)

14

Introduction

Series 298 Hydraulic Service Manifold

Component Identification

Servovalve Servovalve

Mounting
Cover Plate

Pressure
Accumulator

Return
Accumulator

Inlet
Filter

Shut-Off Valve

Proportional
Valve
(298.12 only)

Differential
Pressure
Switch

Hydraulic
Input
Port

Hydraulic
Return
Port

On/Off
Valve
(298.11 only)

Hydraulic
Ports for
Lifts, Locks,
and Grips (behind
filter manifold)

Refer to the following table for information on the components shown below.

Component Identification

Series 298 Hydraulic Service Manifold Introduction

15

Component Identification

Component Descriptions

COMPONENT DESCRIPTION

Servovalve

Shutoff valve

Servovalve mounting
cover plate

Return accumulator

Proportional valve
(298.12 only)

On/off valve (298.11 only)

A Series 252 Servovalves can be mounted on the actuator manifold. A second
servovalve of the same rating can be added to increase the maximum hydraulic
flow.

An optional shutoff valve allows the use of a second servovalve of a different
rating. The shutoff valve lets you select which servovalve to use on the actuator
manifold.

The plate covers the second servovalve mounting when only one servovalve is
used. The plate is removed when a second servovalve is installed.

An accumulator can be installed on the hydraulic return line. The accumulator
reduces hydraulic pressure fluctuations.

The proportional valve (also called an electrical pressure reducing valve)
controls the hydraulic pressure to the servovalve without affecting the rest of the
hydraulic system. It allows the hydraulic pressure to be ramped from off to low
and from low to high pressure. The ramp rates are also applied when turning the
hydraulics off except when an interlock occurs and the pressure is stepped to
zero.

The ramp rates are set by the system controller. The system controller can also
set the level of low pressure.

The on/off valve on the Model 298.11 Actuator Manifold allows hydraulic
pressure to be applied to or removed from the servovalve without affecting the
rest of the system. The valve is controlled by the system controller.

Hydraulic input/return
ports

Differential pressure
switch (included with the
inlet filter)

Pressure accumulator

Inlet filter (optional)

Hydraulic Ports

The input and return ports are the connections to the hydraulic lines controlled
by the hydraulic power unit.

The differential pressure switch is mounted across the inlet filter. It provides an
indication of a dirty filter condition. One type of switch is a pop-up visual
indicator; another type provides an electrical indication of a dirty filter condition
(this requires appropriate cabling to the system controller).

An accumulator can be installed on the hydraulic high pressure line. The
accumulator smooths the hydraulic power unit output and provides additional
hydraulic fluid for high instantaneous flow demands.

A 3-micron or 10-micron (absolute) inlet filter prevents passage of dirt particles
into the servovalve(s).

Hydraulic ports for lifts, locks, and grips support load units with hydraulically
controlled crosshead lifts and locks. Hydraulic grips also use these ports. The
high pressure port is not affected by the high and low pressure control of the
actuator manifold. A hydraulic return port completes the optional hydraulic
circuit.

16

Introduction

Series 298 Hydraulic Service Manifold

Functional Description

The Series 298 Actuator Manifold contains the required porting for single or dual
servovalves, two accumulators, and an actuator (see “Component Identification”
on page 7). The hydraulic schematic shows the Model 298.10 with darker lines.
The additional components for the Model 298.11 and Model 298.12 are also
shown. Any Series 298 Actuator Manifold can be changed to become another
model. The hydraulic pressure to the actuator manifold is controlled by the
hydraulic controls on the system controller.

Filter The optional filter prevents contamination of the servovalve(s). A 3- or 10-

micron (absolute) inlet filter may be added to the actuator manifold. This filter
prevents the passage of dirt particles that might enter the system as a result of
opening hydraulic lines and adding hydraulic fixtures. A differential pressure
switch is mounted across the filter to provide a visual indication of a dirty filter
condition. A differential pressure switch with an electrical output may be used to
send a signal, indicating a dirty filter condition, to your controller. This requires
an additional cable and special connections to the controller.

Accumulators The Series 111 Accumulators suppress line-pressure fluctuations. The

accumulators thread directly into the actuator manifold (one-pint or onequart size
accumulators can be used). The pressure-line accumulator provides fluid storage
to maintain a constant line pressure at the servovalves for maximum
performance. The return-line accumulator minimizes return-line pressure
fluctuations. The Series 111 Accumulators are piston-type accumulators. Other
piston- or bladder-type accumulators may be used. Contact MTS for more
information.

Functional Description

Ports The Series 298 Actuator Manifold contains the required porting to accommodate

single or dual servovalves, and servovalves with four or five ports. For one
servovalve, the mounting ports for the second servovalve are covered with a
plate. When two servovalves are used, they operate in parallel. This increases the
flow capacity of the actuator manifold to a maximum of 114 L/min (30 gpm). If
the system requires a four-port servovalve, a blocking plate is used to cover the
fifth port.

On/off solenoid The Model 298.11 Actuator Manifold contains an on/off solenoid valve to apply

and remove full system hydraulic pressure to the servovalve(s). The on/off
solenoid controls a high pressure poppet which applies the hydraulic pressure to
the servovalve ports. However, high pressure is always available at the pilot
pressure port (for servovalves that support pilot pressure).

Series 298 Hydraulic Service Manifold Introduction

17

Functional Description

Proportional valve The Model 298.12 Actuator Manifold can produce a low output pressure, ramp to

and from high operating pressure, and it can perform a rapid shutoff function.
Some controllers require the Model 413.07 Service Manifold Interface to provide
the necessary control for the proportional valve. The proportional valve controls
a high pressure poppet which applies the hydraulic pressure to the servovalve
ports. However, high pressure is always available at the pilot pressure port (for
servovalves that support pilot pressure).

550 ms

Rapid
ShutdownHydraulic Control Switches

21 MPa
(3000 psi)

10 MPa
(1500 psi)

Low Pressure
Adjustment Range

1 MPa
(120 psi)

Low

2-5 Second Ramp

High

Low

50 ms

Off

Low pressure mode The low output pressure is adjustable from 0.8 to 10.3 MPa (116 to 1500 psi),

which corresponds with the adjustable current from 130 mA to 340 mA to the
proportional valve. This limits the force of the actuator without lowering the
hydraulic power unit output pressure. The maximum flow rate is 18.9 L/min (5
gpm).

Ramp to high pressure The ramp from low pressure to high pressure can be adjusted from 2 to 5

seconds. The ramp also applies to the high to low pressure transition. The ramp
allows systems to slowly apply hydraulic pressure to the test specimen or
assembly. This prevents damage to the test specimen by eliminating any sudden
bumps (or unexpected actuator movement) when hydraulic pressure is supplied
to the actuator.

18

Rapid shutoff The rapid shutoff allows hydraulic pressure to be quickly removed from the

actuator manifold without causing turbulence in the hydraulic lines.

Introduction

Series 298 Hydraulic Service Manifold

Specifications

General Specifications

PARAMETER SPECIFICATION

Operating pressure 21 MPa (3000 psi)

Specifications

Maximum average full flow
pressure mode)

Maximum peak flow 182 L/min. (48 gpm)

Pressure drop through manifold
(less filter)

Filtration (optional) 3 micron (Beta3 = 75) or 10 micron (Beta7.4 = 75)

*

(high

114 L/min (30 gpm)

<0.7 MPa @ 114 L/min (<100 psi @ 30 gpm)

THE FOLLOWING ONLY APPLY TO THE MODEL 298.11

On/off solenoid valve 0 V DC= Off 24 V DC= On

THE FOLLOWING ONLY APPLY TO THE MODEL 298.12

Variable low pressure setting

Low-to-high, high-to-low ramp

†

time

Ramp time for rapid shutoff 550 ms

Maximum pressure transient 0.7 MPa (100 psi)

Maximum current to the electrical
pressure reducing valve

* With dual 56 L/min (15 gpm) servovalves.
† Adjustable at the controller.

†

0.7 to 7 MPa (100 to 1000 psi)

2 to 5 seconds

0.8 A

Series 298 Hydraulic Service Manifold Introduction

19

Specifications

Dimensions

Note Dimensions and weights listed are approximate.

MODEL

*

A

B

†

C

WEIGHT

‡

NUMBERS

298.10 597 mm (23.5 in) 254 mm (10.0 in) 140 mm (5.5 in) 31 kg (68 lb)

298.11 597 mm (23.5 in) 271 mm (10.7 in) 195 mm (7.7 in) 38 kg (84 lb)

298.12 597 mm (23.5 in) 271 mm (10.7 in) 195 mm (7.7 in) 38 kg (84 lb)

* Add 152 mm (6 in) if a quart accumulator is used.
† Add 160 mm (6.32 in) if the filter option is used.
‡ Add 4.1 kg (9 lb) to the weights listed for the optional filter assembly.

B

C

A

20

Introduction

Series 298 Hydraulic Service Manifold

Safety Information

Sudden actuator movement can cause
severe personal injury or damage
to equipment.

Drain line hose must be connected before
applying pressure to this service manifold.

115

A

Hazard Placard Placement

Hazard placards contain specific safety information and are affixed directly to the
system so they are plainly visible.

Each placard describes a system-related hazard. When possible, international
symbols (icons) are used to graphically indicate the type of hazard and the
placard label indicates its severity. In some instances, the placard can contain text
that describes the hazard, the potential result if the hazard is ignored, and general
instructions about how to avoid the hazard.

The following labels are typically located on the HSM.

L

ABEL DESCRIPTION

Warnin g

Sudden actuator movement can
cause severe personal injury or
damage to equipment.

Drain line hose must be
connected before applying
pressure to this service
manifold.

Part # 048-124-501

Voltage Label

Part # 057-130-001

Voltage Label

Part # 057-130-002

Identification Label Part # (varies based on model)

Service Manifold
model no. s/n
ass’y no. rev.
3000 psi 20.7 MPa

Series 298 Hydraulic Service Manifold Safety Information

21

Safety Information

22

Series 298 Hydraulic Service Manifold

Installation

Contents Installing the Actuator Manifold onto a Load Unit 24

This section describes how to install the actuator manifold onto a Series 318
Load Unit or onto a Series 244 Actuator. It also describes how to upgrade from a
Model 298.11 Actuator Manifold to a Model 298.12 Actuator Manifold.

Installing the Actuator Manifold on an Actuator 27

Connecting Hydraulics 29

Connecting Cables 30

Installing the Filter 32

Upgrading a 298.11 Actuator Manifold to a 298.12 33

Series 298 Hydraulic Service Manifold Installation

23

Installing the Actuator Manifold onto a Load Unit

Load Unit
Base P

Actuator
End Cap

Spacer Block
(if needed)

O-rings

Series 298
Actuator
Manifold

Manifold
Adapter Bolts

Installing the Actuator Manifold onto a Load Unit

The Series 298 Actuator Manifold is designed to be mounted directly to the load
unit base plate and lower end cap of the hydraulic actuator on a Series 318 Load
Unit.

In some cases a ported spacer block is also needed between the actuator manifold
and the load unit base plate. See the Adapter Mounting Manifold drawing (part
number 428669-xx) to determine the necessary spacer blocks for the particular
manifold/load unit combination.

To mount the actuator manifold:

1. Ensure that system hydraulic pressure has been reduced to zero before
proceeding. To do this, turn off the hydraulic power unit and exercise the
actuator until it stops moving.

2. Turn off the electrical power to the controller.

3. Remove any existing servovalves and manifolds from the load unit base
plate and actuator end cap.

4. Remove the cover plates protecting the ports on the rear of the actuator
manifold.

5. Loosen, but do not remove, the two manifold adapter bolts securing the
manifold adapter to the top of the manifold.

24

Installation

6. Lightly oil the O-rings with clean hydraulic fluid. Position the O-rings on
both actuator manifold ports and the actuator end cap (if a spacer block is
used).

Series 298 Hydraulic Service Manifold

Installing the Actuator Manifold onto a Load Unit

7. Some actuator manifolds use threaded rods instead of cap screws to mount
the actuator manifold to the actuator end cap. Perform one of the following.

• If cap screws are used—Install the lower two mounting bolts into the

actuator manifold. Place the spacer block onto the lower mounting
bolts. Ensure that the O-rings remain seated.

• If threaded rods are used—Screw the threaded rods into the actuator

end cap. Place the spacer block onto the threaded rods. Ensure that the
O-rings remain seated.

8. If you are using a spacer block, loosely mount the upper portion of the
actuator manifold to the load unit base plate. Ensure that the O-rings remain
seated. Tighten the two socket head cap screws (orthreaded rods) to 7 N·m
(5 lbf·ft).

9. Loosely mount the actuator manifold to the actuator end cap. Ensure that the
O-rings remain seated. Tighten the two socket head cap screws (or threaded
rods) to 7 N·m (5 lbf·ft).

10. Tighten the mounting bolts and manifold adapter bolts in 25% increments in
the order shown here.

➄➅

➂➃

➀➁

Mounting Bolt Tightening Order

A. Tighten the manifold adapter bolts to 33.9 N·m (25 lbf·ft).

B. Tighten the mounting bolts to 47 N·m (35 lbf·ft).

C. Check the final torque value at least twice before proceeding.

11. If applicable, install the servovalve(s). Go to the appropriate servovalve
manual and perform the installation procedure.

12. Connect the hydraulic hoses. See “Connecting Hydraulics” on page 18.

Series 298 Hydraulic Service Manifold Installation

25

Installing the Actuator Manifold onto a Load Unit

13. Connect the appropriate cables to the servovalve(s). See “Connecting

Cables” on page 19.

• If a Model HSM 298.11 was installed, connect the on/off solenoid

valve.

• If a Model HSM 298.12 was installed, connect the proportional valve.

26

Installation

Series 298 Hydraulic Service Manifold

Installing the Actuator Manifold on an Actuator

Servovalve Mounting
Location (one on the
other side too)

244 Series

Actuator

Adapter Manifold

End Cap

End Cap

O-ring

Mounting Bolt

Model 298.12
Actuator Manufold

Installing the Actuator Manifold on an Actuator

The Series 298 Actuator Manifold is designed to be mounted to any of the Series
244 Actuators. The displacement of the actuator determines which adapter
manifold is required.

1. Ensure that system hydraulic pressure has been reduced to zero before
proceeding. To do this, turn off the hydraulic power unit and exercise the
actuator until it stops moving.

2. Turn off the electrical power to the controller.

3. Remove the cover plates protecting the ports on the rear of the actuator
manifold.

4. Remove any existing servovalves and manifolds from the actuator.

5. Loosen, but do not remove, the two manifold adapter bolts securing the
manifold adapter to the top of the manifold.

Actuator Manifold to 244 Actuator Installation

6. Lightly oil the O-rings with clean hydraulic fluid. Position the O-rings on
both actuator manifold ports and the adapter manifold.

Series 298 Hydraulic Service Manifold Installation

27

Installing the Actuator Manifold on an Actuator

7. Insert the mounting bolts into the adapter manifold and position the adapter
manifold on the adapter manifold. Ensure that the O-rings remain seated.

8. Thread the mounting bolts into the actuator end caps and tighten to 47 N·m
(35 lbf·ft).

9. Lightly oil the O-rings with clean hydraulic fluid and position them between
the actuator manifold ports and the actuator ports.

10. Position the actuator manifold over the adapter manifold. Ensure the O­rings remain seated.

11. Insert the mounting bolts into the adapter manifold and thread them into the
actuator. Tighten to 47 N·m (35 lbf·ft).

12. If applicable, install the servovalve(s). Go to the appropriate servovalve
manual and perform the installation procedure.

13. Connect the hydraulic hoses. See “Connecting Hydraulics” on page 18.

14. Connect the appropriate cables to the servovalve(s). See “Connecting

Cables” on page 19.

• If a Model HSM 298.11 was installed, connect the on/off solenoid

valve.

• If a Model HSM 298.12 was installed, connect the proportional valve.

28

Installation

Series 298 Hydraulic Service Manifold

Connecting Hydraulics

Hydraulic connections to the actuator manifold from the HPU are made to
the ports as shown in the following figure.

High pressure ports for load
unit lifts, locks, and grips.
Fitting size -4 (298.10 only).

High pressure ports for load
unit lifts, locks, and grips.
Fitting size -4 (298.11/.12 only).

High pressure port from
HPU. Fitting size -12.

Connecting Hydraulics

Return pressure port to
HPU. Fitting size -12.

Pressure port for hydrostatic
bearing actuators (all models).
Also a test post for the
proportional valve (298.12 only).
Fitting size -4.

Hydraulic ports The Model 298.10 Actuator Manifold contains an extra high-pressure port to

provide system hydraulic pressure to load unit hydraulic lift and lock controls, or
to a set of hydraulic grip controls. This port provides full system hydraulic
pressure anytime hydraulic pressure is available to the actuator manifold. The
Models 298.11 and 298.12 contain two high pressure ports for this purpose.

Pressure fittings A pressure fitting is located on the bottom of the actuator manifold and provides

controlled pressure for use with actuators with hydrostatic bearings, or other
hydraulic accessories. On the Model 298.12,this fitting is also used as a test port
for checking the operation of the proportional valve. This fitting provides low
pressure when the manifold is in the lowpressure mode and full system hydraulic
pressure when the manifold is in the high-pressure mode.

Mixing different brands of hydraulic fluid can contaminate your system.

Contaminated hydraulic fluid can cause premature wear of the hydraulic
components in your system.

Do not mix different brands of hydraulic fluid. MTS Systems Corporation
recommends using Mobil DTE-25® or Shell Tellus® 46 AW hydraulic fluid.

Series 298 Hydraulic Service Manifold Installation

29

Connecting Cables

On/Off
Solenoid
Valve

From
Controller

24 Vdc

P1J1

AA

BB

Com

Proportional
Valve

From
Controller

P1J1

AA

BB

- Proportional Valve

+ Proportional Valve

Connecting Cables

The actuator manifold has three possible electrical connections.

• On/off control of the station (actuator) pressure (Model 298.11 only)

• Proportional control of the station (actuator) pressure (Model 298.12 only)

• Dirty filter indication (option for all models)

Note Controllers usually label the connection to the actuator manifold as HSM

(hydraulic service manifold). The actuator manifold functions the same
as a hydraulic service manifold.

On/off (Model 298.11

only)

Proportional valve

(Model 298.12 only)

The on/off solenoid valve connects to the system controller (or a hydraulic
control panel). MTS Systems Corporation controllers label this connection HSM.
See the controller manual for cabling information.

The proportional valve connects to the system controller. MTS Systems
Corporation controllers that support proportional valves label this connection
HSM Proportional (or Prop HSM). See the controller product manual for cabling
information. If you are not sure if your controller supports a proportional output,
contact MTS Systems Corporation.

Installation

30

Series 298 Hydraulic Service Manifold

Connecting Cables

2

3

1

2

3

1

4

Filter Pressure Switch

To Controller

Filter pressure switch The filter pressure switch signals the controller that a dirty filter condition exists.

The filter switch contacts change states when a dirty filter is detected. The dirty
filter signal can be input to the controller through any of several inputs
(depending how you want to use the signal). For example, you could connect it to
the hydraulic interlock chain, the program interlock chain, or as a digital input.

Series 298 Hydraulic Service Manifold Installation

31

Installing the Filter

Installing the Filter

The following procedure describes how to install an inlet filter onto any Series
298 Actuator Manifold.

1. Ensure that system hydraulic pressure has been reduced to zero before
proceeding. To do this, turn off the hydraulic power unit and exercise the
actuator until it stops moving.

2. Turn off the electrical power to the controller.

3. Disconnect and cap the -12 hydraulic hose connected to the high pressure
port of the actuator manifold. This helps prevent contamination from
entering the hydraulic system.

4. Remove the elbow from the pressure port on the actuator manifold.

5. Install a 1-1/16-12 boss nipple to the pressure port on the actuator manifold.
Install a 1-1/16-12 female-to-1-5/16 male boss adapter on the boss nipple.

6. Remove the plugs from the ports of the inlet filter.

7. Examine the inlet filter housing by the model number placard to determine
the direction of fluid flow. This direction will be indicated by an arrow
which is etched into the filter housing.

8. Observing the proper direction for fluid flow, connect the filter housing to
the boss adapter.

9. Install the elbow (which was removed in Step 4) to the port on the inlet filter
housing.

10. Reconnect the hydraulic hose removed in Step 3.

32

Installation

Series 298 Hydraulic Service Manifold

Upgrading a 298.11 Actuator Manifold to a 298.12

Upgrading a 298.11 Actuator Manifold to a 298.12

This procedure describes how to change the Model 298.11 Actuator Manifold to
a Model 298.12 Actuator Manifold. This is done by replacing the on/off solenoid
valve and manifold with a proportional valve and manifold.

Required equipment The following additional equipment is required:

• A Model 298.12 upgrade kit (part number 047-804-201)

• Appropriate cables

Procedure 1. Ensure that system hydraulic pressure has been reduced to zero before

proceeding. To do this, turn off the hydraulic power unit and exercise the
actuator until it stops moving.

2. Turn off the electrical power to the controller.

3. Remove the electrical cable between the on/off solenoid valve and the
system console.

4. Remove the four #10-24 UNC socket head cap screws securing the on/off
solenoid valve assembly to the actuator manifold.

5. Remove the on/off solenoid valve assembly.

6. Unplug the ports on the back of the proportional valve manifold.

7. Lightly oil the O-rings and position them on the ports of the proportional
valve manifold.

8. Loosely mount the proportional valve manifold to the actuator manifold
with the mounting bolts removed in Step 4. Ensure the O-rings remain in
place.

9. Tighten the four #10-24 UNC socket head cap screws to 65.1 N·m (48
lbf·ft).

10. Reconnect all hydraulic hoses.

11. Connect the cable provided between the proportional valve and the
controller. See page 19 for more information.

Series 298 Hydraulic Service Manifold Installation

33

Upgrading a 298.11 Actuator Manifold to a 298.12

34

Installation

Series 298 Hydraulic Service Manifold

Maintenance

Pressure
Accumulator

Return
Accumulator

Inlet
Filter

Dirty
Filter
Indicator

The Series 298 Actuator Manifold requires the filter be changed periodically.

Maintenance for other products can be found in their associated product
information manuals. See “Related products” on page 6 for more information.

For accumulators not manufactured by MTS Systems Corporation, use the
vendor literature to determine the accumulator maintenance.

Component Identification

Mixing different brands of hydraulic fluid can contaminate your system.

Contaminated hydraulic fluid can cause premature wear of the hydraulic
components in your system.

Do not mix different brands of hydraulic fluid. MTS Systems Corporation
recommends using Mobil DTE-25 or Shell Tellus 46 AW hydraulic fluid.

Series 298 Hydraulic Service Manifold Maintenance

35

Replacing the Filter

Replacing the Filter

The filter element should be replaced whenever:

• The indicator on the top of the filter housing is in the bypass position, which

indicates a dirty filter condition.

• The hydraulic fluid in the hydraulic power unit is changed.

Replace the filter element with one of the same rating or better.

F

ILTER

3 micron (Beta3 = 75) 011-395-937 044-205-301

10 micron (Beta

To change the filter element:

1. Ensure that system hydraulic pressure has been reduced to zero before
proceeding. To do this, turn off the hydraulic power unit and exercise the
actuator until it stops moving.

2. Turn off electrical power at the controller.

3. Place a waste fluid pan beneath the filter housing, which will accumulate
any small amount of drainage from the filter housing.

4. Remove the inlet filter bowl.

5. Remove the disposable filter element from the filter bowl.

6. Empty the oil in the filter bowl into the pan. Wipe out any remaining
sediment with a clean lint-free cloth.

7. Inspect the O-ring in the filter housing for any sign of deterioration. If
necessary, replace the defective O-ring (part number 010-010-726).

7.4 = 75) 011-395-936 044-205-201

PART NUMBER KIT NUMBER

36

Maintenance

8. Lubricate the filter element and filter housing O-rings with clean hydraulic
fluid. Insert the replacement filter element into the filter bowl. Tighten the
filter bowl to 34–41 N·m (25–30 lbf·ft).

9. Apply low, then high, hydraulic pressure to the actuator manifold and
inspect the seal between the filter bowl and housing for any signs of
leakage. If leakage exists, turn off system hydraulic and electrical power and
repeat Steps 4 through 9.

Series 298 Hydraulic Service Manifold

m

MTS Systems Corporation

14000 Technology Drive
Eden Prairie, Minnesota 55344-2290 USA
Toll Free Phone: [phone]

(within the U.S. or Canada)

Phone: [phone]

(outside the U.S. or Canada)
Fax: [phone]
E-mail: [e-mail]
Internet: www.mts.com

ISO 9001 Certified QMS