MTS 505 User Manual

be certain.

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Series 505 SilentFlo™ Hydraulic Power Unit
Product Information

Model 505.07
Model 505.11

100-007-837 T

Copyright information © 1999–2010 MTS Systems Corporation. All rights reserved.

Trademark information MTS and SilentFlo are registered trademarks of MTS Systems Corporation

within the United States. These trademarks may be protected in other countries.
DTE is a registered trademark of Exxon Mobil Corporation. Tellus is a registered

trademark of Shell Oil Corporation. Molykote is a registered trademark of Dow
Chemical Corporation. Synasol is a registered trademark of Union Carbide
Corporation. All other trademarks or service marks are property of their
respective owners.

Publication information

MANUAL PART NUMBER PUBLICATION DATE

100-007-837 A July 1999
100-007-837 B August 1999
100-007-837 C March 2000
100-007-837 D July 2001
100-007-837 E September 2001
100-007-837 F May 2002
100-007-837 G February 2003
100-007-837 H July 2003

100-007-837J November 2003
100-007-837 K July 2005
100-007-837 L June 2006
100-007-837 M August 2006
100-007-837 N February 2008
100-007-837 P November 2008
100-007-837 R April 2009
100-007-837 S January 2010
100-007-837 T April 2010

Contents

Technical Support 5

How to Get Technical Support 5
Before You Contact MTS 5
If You Contact MTS by Phone 6
Problem Submittal Form in MTS Manuals 7

Preface 9

Before You Begin 9

Conventions 10

Documentation Conventions 10

Introduction 13

EU Declarations 13
Component Identification 14
Functional Description 15

505.07/.11 HPU Hydraulic Schematic 17
Auto-Cooling Valve (adjustable) 18
Electrical Control 18

505.07 HPU Electrical Schematic 19

505.11 HPU Electrical Schematic 21
Series 505 HPU General Specifications 23

Safety 25

General Safety Practices: Hydraulic Power Units and Hydraulic Service Manifolds 25

Installation 33

Install the HPU 33

Model 505.07/.11 SilentFlo™ HPU Contents

3

Operation 37

505.07/.11 HPU Controls 38
Operating the HPU Locally or Remotely 40
Recovering from an Interlock 41
Changing the Water Flow 42
Resetting the Thermal Overloads 43
Adjusting the Hydraulic Pressure 44
Adjusting the HPU Output Pressure Level 45
Adjusting the Auto-Cooling Level 45
Low/High Pressure Functionality 49

Maintenance 53

Routine Maintenance Overview Checklist 54

505.07/.11 HPU Maintenance Schedule 56
Checking the Hydraulic Fluid 58
Replacing the Return Line Filter 59
Sample the Hydraulic Fluid 62
Appearance of Hydraulic Fluid Sample 63
Replacing the Hydraulic Fluid 64

Accessories 67

High Pressure Filter Kit 68
Surge Suppressor Kit 69
Precharging the Surge Suppressor Accumulator 71
Lifting Kit 74
Caster Kit 75

Appendix A: HPU Maintenance and Service Logs 77

8 Hours/Daily 78
40 Hours/Weekly 79
160 Hours/Biweekly 80
500 Hours 81
1000 Hours 82
2000 Hours 83
5000 Hours 84
10,000 Hours 85

4

Contents

Model 505.07/.11 SilentFlo™ HPU

Technical Support

How to Get 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 inform ation.

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

Model 505.07/.11 SilentFlo™ HPU 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

If You Contact MTS by Phone

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

For a computer problem, have the following information available:

computer information

• 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

Know relevant

For software application problems, have the following information available:

software information

• 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
– Messaging applications

If You Contact MTS by Phone

Technical Supp ort

6

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

• Site number

Model 505.07/.11 SilentFlo™ HPU

Problem Submittal Form in MTS Manuals

• 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

• Aero test system

Be prepared to

Prepare to perform troubleshooting while on the phone:

troubleshoot

• 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.

Write down relevant

In case Technical Support must call you:

information

• Verify the notification number.

• Record the name of the person who helped you.

• Write down any specific instructions.

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

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.

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:

Model 505.07/.11 SilentFlo™ HPU Technical Support

7

Problem Submittal Form in MTS Manuals

• 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 Supp ort

8

Model 505.07/.11 SilentFlo™ HPU

Before You Begin

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).

Model 505.07/.11 SilentFlo™ HPU 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

Model 505.07/.11 SilentFlo™ HPU

Documentation Conventions

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

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

Model 505.07/.11 SilentFlo™ HPU Preface

11

Documentation Conventions

12

Preface

Model 505.07/.11 SilentFlo™ HPU

Introduction

Contents Component Identification 14

EU Declarations

The MTS Model 505.07 Hydraulic Power Unit (HPU) and Model 505.11 HPU
provide high-pressure hydraulic fluid for test system operation. This section
contains the functional description and the specifications of the HPU.

Functional Description 15

505.07/.11 HPU Hydraulic Schematic 17
Auto-Cooling Valve (adjustable) 18
Electrical Control 18

505.07 HPU Electrical Schematic 19

505.11 HPU Electrical Schematic 21
Series 505 HPU General Specifications 23

EU Declarations

EC Declaration of

Conformity (Machinery

Directive 2006/42/EC

Annex II 1A)

Model 505.07/.11 SilentFlo™ HPU Introduction

If applicable, a Declaration of Conformity is supplied with the machinery; an
example of the Declaration of Conformity is provided at the end of this manual.

13

Component Identification

Surge Supressor
Mounted to Pump
(optional)

Hydraulic and Water
Connections

Water Flow
Regulator

Drain Valve

High Pressure
Filter Location
(optional–not
shown)

Output
Pressure
Control

Heat
Exchanger

Temperature
Gage

Return
Filter

Power Discon Switch
(other side of box)

Control Panel
(other side of box)

Nameplate

Electrical Enclosure

Output
Pressure
Gage

Auto-Cooling
Valve

Pressure Relief
Valve

Control Manifold
(shown rotated)

Filler Cap

Fluid Level Gage

Low Level/
Overtemperature
Sensor

Fluid Sample
Port

Component Identification

C

Auto-Cooling Valve

Control Panel

Electrical Enclosure

Filler Cap
Filter

14

Component Descriptions (part 1 of 2)

OMPONENT DESCRIPTION

Keeps the hydraulic fluid clean and cool by circulating the fluid through the
return filter and the heat exchanger while the HPU is in high pressure mode
and the fluid demand by the external circuit is very low.

Controls the operation of the power unit and indicates the current status of
several detectors.

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.

Vents the hydraulic fluid reservoir. This is where you add hydraulic fluid.
Filters particles out of the hydraulic fluid as it is returned to the HPU.

Introduction

Component Locations

Model 505.07/.11 SilentFlo™ HPU

Component Descriptions (part 2 of 2)

C

OMPONENT DESCRIPTION

Functional Description

Drain Valve
Fluid Level Gage
Fluid Sample Port

Heat Exchanger

Hydraulic and Water
Connections

Low level/Overtemperature
Sensor

Output Pressure Control
Output Pressure Gage
Nameplate

Power Disconnect Switch

Drains the hydraulic fluid from the reservoir.
Displays the level of the hydraulic fluid.
Access port for obtaining hydraulic 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.

Cools the hydraulic fluid by using an oil-to-water heat exchanger. The heat
exchanger removes most of the heat generated by the HPU.

Connection points for the hydraulic fluid distribution system, wate r source,
and return lines.

Senses the hydraulic fluid level and temperature. Control interlocks
automatically shut the HPU down if the fluid level drops too low or the
hydraulic fluid temperature rises above the temperature sensor’s setting.

Sets the output pressure of the HPU.
Displays the hydraulic pressure being output from the HPU.
Provides basic product information such as model number, serial number, and

electrical information.
Disconnects the incoming power from the HPU. The switch is a lockable,

mechanical latch. Power is removed whenever the door to the electrical
enclosure is open (the switch is in the off position). However, incoming power
lines to the switch are live unless power is removed externally.

Pressure Relief Valve
Reservoir
Temperature Gage
Water Flow Regulator

Functional Description

Pump A variable volume pump draws hydraulic fluid from the reservoir and pressurizes

Pressure The start/low/high switch on the front panel of the electrical enclosure controls

Prevents the HPU from exceeding 22.4 MPa (3250 psi).
Holds the hydraulic fluid and houses the hydraulic pump and motor.
Displays the temperature of the hydraulic fluid.
Sets the amount of water flowing through the heat exchanger. Adjust the water

flow to regulate the temperature of the hydraulic fluid.

it to the adjusted output pressure, typically 21 MPa (3000 psi). A check valve
prevents hydraulic fluid from being siphoned back into the reservoir. The
pressurized fluid is controlled by a control manifold that contains the high/low
pressure solenoid valve and a non-adjustable relief valve set at 22.4 MPa (3250
psi).

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.

Model 505.07/.11 SilentFlo™ HPU Introduction

15

Functional Description

Filtering As hydraulic fluid returns to the reservoir, it is filtered by a 3-micron element.

Heat exchanger Hydraulic fluid temperature is maintained with a heat exchanger that cools the

The unit automatically starts in low pressure to reduce the amperage needed for
starting, which will extend pump and motor life. When operating at this setting,
low-pressure fluid is available to the hydraulic circuit. Low pressure is achieved
by diverting a portion of the hydraulic fluid through the high pressure solenoid
and returning it to the reservoir. Selecting high pressure blocks the low pressure
return path and makes all of the pressurized hydraulic fluid available to the
hydraulic circuit.

The output pressure can be adjusted from about 1 MPa (145 psi) to 21 MPa (3000
psi). The HPU is designed to provide 21 MPa (3000 psi). A nonadjustable relief
valve is set at 22.4 MPa (3250 psi) to protect the hydraulic system from excessive
pressure.

This ensures that all hydraulic fluid is filtered whether it travels out through the
circuit or returns by way of the unit’s control manifold under low pressure. Filter
cleanliness is automatically monitored. An indicator lights on the front panel
signaling when the filter needs an element change.

fluid. The water-cooled heat exchanger cools the hydraulic fluid as it passes over
water-filled plates. A regulating valve monitors the temperature of the hydraulic
fluid and adjusts the flow of water through the plates. The flow of cooling water
regulates the temperature of the hydraulic fluid.

• The typical operating temperature range of the hydraulic fluid is

43–49°C (110–120°F).

• If the hydraulic fluid temperature exceeds 55ºC (131ºF), a switch opens and

shuts down the HPU.

• When the HPU is shut off, the flow of water is also stopped by a shutoff

solenoid valve.

Note For additional information see the Heat Exchanger Care and Water

Quality Guide (part number 015-164-000).

16

Introduction

Model 505.07/.11 SilentFlo™ HPU

505.07/.11 HPU Hydraulic Schematic

PRDDWW

Water

Shutoff

Valve

Water

Regulator

Valve

Heat

Exchanger

Sight

Gage

Temperature

Gage

Pump Drain

Check Valve

0.007 MPa (1.0 psi)

Pump Drain

Check Valve

0.034 MPa (5.0 psi)

3 Micron

Filter

Reservoir

Pump

Motor

Surge

Suppressor

(optional)

Temperature

and Low Level

Sensor

Control Manifold

Pressure

Gage

Oil Sample

Port

Optional

Pressure

Port

Pressure

Filter

(optional)

Auto-cooling

Valve

(adjustable)

Check

Valve

Pressure

Relief Valve

(factory set at

22.4 MPa (3250 psi)

High Pressure

Solenoid Valve

Auto-cooling

Valve

(factory set)

Accumulator

0.06 inch Orifice

0.007 MPa (1.0 psi)

The hydraulic schematic shows the functional layout of the Series 505 Hydraulic
Power Unit.

505.07/.11 HPU Hydraulic Schematic

Model 505.07/.11 SilentFlo™ HPU Introduction

17

Auto-Cooling Valve (adjustable)

Auto-Cooling Valve (adjustable)

The auto-cooling function is integrated into the control manifold. During periods
of low flow demand from the external hydraulic circuit, this feature provides two
important benefits: a re-circulating flow that ensures hydraulic fluid filtering
whenever the unit is on, and safeguarding against hydraulic fluid over­temperature. It functions by opening a hydraulic flow path through the fluid
conditioning circuit 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 Auto­Cooling Valve to function properly, it must be re-adjusted anytime the output
pressure will be changed for longer than 10 minutes.

Note If the test condition requires a maximum pressure level less than 14 MPa

(2000 psi), consult MTS.

Electrical Control

The HPU can be controlled locally using the front panel controls, or remotely
through a controller via the J1 connector. The controls included in the electrical
enclosure include the following:

• A start/low/high switch ensures that the system starts in low pressure, and

permits quick selection of low or high pressure. Wye-delta starting (505.11
only) reduces the initial current rush to the motor when electrical service to
the HPU is turned on.

• Thermal overload indicators protect the HPU from excessive current draw.

• A latchable Stop button prevents inadvertent starts.

• Interlocks protect the HPU against low hydraulic fluid level,

overtemperature, and dirty filters.

• Front panel indicators provide a quick indication of the unit’s condition.

These include power on, low level, overtemperature, and dirty filter lights.
–A Reset button brings the unit back into operation after a fault has been

detected and corrected.

– A dirty filter signal will not shut the unit down, but will prevent the

unit from starting.

• An hour meter is provided to help you determine maintenance intervals.

• The power disconnect switch on the door of the electrical enclosure ensures

that power is removed whenever the door is opened. It is a lockable, main­disconnect switch.

18

Introduction

Model 505.07/.11 SilentFlo™ HPU

505.07 HPU Electrical Schematic

The electrical schematic shows the electrical layout of the Model 505.07
Hydraulic Power Unit.

505.07 HPU Electrical Schematic

Model 505.07/.11 SilentFlo™ HPU Introduction

19

505.07 HPU Electrical Schematic

20

Introduction

Model 505.07/.11 SilentFlo™ HPU

505.11 HPU Electrical Schematic

The electrical schematic shows the electrical layout of the Model 505.11
Hydraulic Power Unit.

505.11 HPU Electrical Schematic

Model 505.07/.11 SilentFlo™ HPU Introduction

21

505.11 HPU Electrical Schematic

22

Introduction

Model 505.07/.11 SilentFlo™ HPU

Series 505 HPU General Specifications

General Specifications

ARAMETER SPECIFICATION

P

Series 505 HPU General Specifications

Environmental

Operating temperature
Humidity
Heat load

Noise

Hydraulic fluid

Typical operating
temperature range

Filtration
Reservoir capacity

Heat exchanger

Flow requirements
Water pressure
Maximum pressure
Cooling
Water hose

*

rating at 1 m

For use in a controlled environment
5–40°C (41–104°F)
0–85% noncondensing
<630 kcal/hr (2500 BTU/hr)
60 dB (A) fully compensated

Exxon Mobil DTE 25 or Shell Te llus
43–49°C (110–120°F)

3 microns nominal
174 L (46 gal) maximum
Water-cooled stainless steel plate
See “Water flow rating (input temperature)”

0.24–0.34 MPa (35–50 psi differential)

0.83 MPa (120 psi)
see the Model Specific Specifications table
19 mm (0.75 in)–inside diameter

46 AW

Hydraulic connections

Pressure
Return
Drain

Water Connections -12 (3/4 in NPT) for both In and Out
Electrical power

Line voltage
Control voltage

Dimensions

Height
Length
Width

* Sound pressure level [db (A)] is expressed as a free field value. Readings may vary with

the acoustic environment.

Each requires an O-ring face seal

-12

-12

-8 and -6 (two connections)

200–575 V AC, 3∅ at 50/60 Hz
24 V DC

1067 mm (42 in)
990 mm (39 in)
711 mm (28 in)

Model 505.07/.11 SilentFlo™ HPU Introduction

23

Series 505 HPU General Specifications

Model Specific Specifications

ARAMETER 505.07 SPECIFICATION 505.11 SPECIFICATION

P

Pump/motor

Maximum
Continuous pressure

Maximum Flow
capacity

Motor rating

Water flow rating
(input temperature)

10.0°C (50°F)

15.5°C (60°F)

21.1°C (70°F)

26.7°C (80°F)

32.2°C (90°F)
Heat load (maximum)
Weight with maximum oil

174 L (46 gal))

Line voltage starter configuration
21 MPa (3000 psi)

22.7 L/m (6 gpm) at 50 Hz

26.5 L/m (7 gpm) at 60 Hz

11.2 Kw (15 hp) at 50/60 Hz

3.8 L/m (1.0 gpm)

4.9 L/m (1.3 gpm)

6.1 L/m (1.6 gpm)

8.3 L/m (2.2 gpm)

15.9 L/m (4.2 gpm)

12.3 kW (42,000 Btu/hr)
450 kg (992 lb) 473 kg (1042 lb)

Wye-Delta starter configuration
21 MPa (3000 psi)

41.6 L/m (11 gpm) at 50/60 Hz

18.6 Kw (25 hp) at 50/60 Hz

7.2 L/m (1.9 gpm)

9.1 L/m (2.4 gpm)

12.1 L/m (3.2 gpm)

18.9 L/m (5.0 gpm)

49.2 L/m (13.0 gpm)

20.5 kW (70,000 Btu/hr)

24

Introduction

Model 505.07/.11 SilentFlo™ HPU

General Safety Practices: Hydraulic Power Units and

Safety

General Safety Practices: Hydraulic Power Units and Hydraulic Service Manifolds

The hydraulic power unit (HPU) provides high pressure hydraulic fluid to system
components for system operation. The hydraulic service manifold (HSM)
controls distribution of that hydraulic fluid pressure. Th is section provi des
general information about safety issues that pertain to system hydraulic supply
and distribution components. These issues include statements to the intended use
and foreseeable misuse of the system and definition for the graphical hazard
labeling that is affixed to your product, and other (more general) safety
information that relates to the high-pressure and high-performance characteristics
of MTS servohydraulic and electromechanical systems.

When you prepare to operate a system that includes environmental components,
ensure the following:

• Do not use or allow personnel to operate the system who are not

experienced, trained, or educated in the inherent dangers associated with
high-performance servo hydraulics and who are not experienced, trained, or
educated with regard to the intended operation as it applies to this test
system.

• Do not disable safety components or features (including limit detectors,

light curtains, or proximity switches/detectors).

• Do not attempt to operate the system without appropriate personal safety

gear (for example, hearing, hand, and eye protection).

• Do not modify the system or 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.

• Do not use the system in a test area where uncontrolled access to the test

system is allowed when the system is in operation.

• For servohydraulic systems, do not operate the system unless an interlock is

installed to monitor supply pressure into the HSM and initiate a system
interlock if a low or no pressure event occurs.

If you have system related responsibilities (that is, if you are an operator, service
engineer, or maintenance person), you should study safety information carefully
before you attempt to perform any test system procedure.

You should receive training on this system or a similar system to ensure a
thorough knowledge of your equipment and the safety issues that are associated
with its use. In addition, you should gain an understanding of system functions
by studying the other manuals supplied with your test system. Contact MTS for
information about the content and dates of training classes that are offered.

Model 505.07/.11 SilentFlo™ HPU Safety

25

General Safety Practices: Hydraulic Power Units and

It is very important that you study the following safety information to ensure that
your facility procedures and the system’s operating environment do not
contribute to or result in a hazardous situation. Remember, you cannot eliminate
all the hazards associated with this system, so you must learn and remain aware
of the hazards that apply to your system at all times. Use these safety guidelines
to help learn and identify hazards so that you can establish appropriate training
and operating procedures and acquire appropriate safety equipment (such as
gloves, goggles, and hearing protection).

Each test system operates within a unique environment which includes the
following known variables:

• Facility variables (facility variables include the structure, atmosphere, and

utilities)

• Unauthorized customer modifications to the equipment

• Operator experience and specialization

• Test specimens

Because of these variables (and the possibility of others), your system can
operate under unforeseen circumstances that can result in an operating
environment with unknown hazards.

Improper installation, operation, or maintenance of your system can result in
hazardous conditions that can cause death, personal injury, or damage to the
equipment or to the specimen. Common sense and a thorough knowledge of the
system’s operating capabilities can help to determine an appropriate and safe
approach to its operation.

Read all manuals Study the contents of this manual and the other 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

Specimen temperature

changes

Know facility safe

procedures

Find, read, and follow the hazard placard instructions located on the equipment.
These placards are placed strategically on the equipment to call attention to areas
such as known crush points, electrical voltage, and high pressure hazards.

During environmental testing, the specimen temperature can become hot enough
to cause burns. Wear personal protection equipment (gloves) when handling
specimens.

Most facilities have internal procedures and rules regarding safe practices within
the facility. Be aware of these safe practices and incorporate them into your daily
operation of the system.

Know controls Before you operate the system for the first time, make a trial run through the

operating procedures with the power off. Locate all hardware and software
controls and know what their functions are and what adjustments they require. If
any control function or operating adjustment is not clear, review the applicable
information until you understand it thoroughly.

26

Safety

Model 505.07/.11 SilentFlo™ HPU

General Safety Practices: Hydraulic Power Units and

Have first aid available Accidents can happen even when you are careful. Arrange your operator

schedules so that a properly trained person is always close by to render first aid.
In addition, ensure that local emergency contact information is posted clearly and
in sight of the system operator.

Know potential crush

and pinch points

Be aware of

component movement

with hydraulics off

Know electrical

hazards

Be aware of potential crush and pinch points on your system and keep personnel
and equipment clear of these areas.

Remember, when hydraulic power is interrupted on a servohydraulic system, it is
likely that stored accumulator pressure will persist for some time within the
system. In addition, it is likely that as stored energy dissipates, gravity will cause
portions of the system to move.

The actuator rod can also drift down when hydraulics are turned off hitting
anything in its path. This uncommanded movement is because of oil movement
between the pressure/return ports and oil blow by across the piston hub. Be aware
that this can happen and clear the area around the actuator rod when hydraulics
are turned off.

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
to any electrical system component. Observe the same precautions as those given
for any other high-voltage machinery.

Make sure that all electrical components are adequately grounded. Grounds must
remain connected and undisturbed at all times.

Keep bystanders

safely away

Keep bystanders at a safe distance from all equipment. Never allow bystanders to
touch specimens or equipment while the test is running.

Wear proper clothing Do not wear neckties, shop aprons, loose clothing or jewelry, or long hair that

could get caught in equipment and result in an injury. Remove loose clothing or
jewelry and restrain long hair.

Remove flammable

fluids

Check bolt ratings and

torques

Remove flammable fluids from their containers or from components before you
install the container or component. If desired, you can replace the flammable
fluid with a non-flammable fluid to maintain the proper proportion of weight and
balance.

To ensure a reliable product, fasteners (such as bolts and tie rods) used in MTS­manufactured systems are torqued to specific requirements. If a fastener is
loosened or the configuration of a component within the system is modified, refer
to information in this product manual to determine the correct fastener, fastener
rating, and torque. Overtorquing or undertorquing a fastener can create a
hazardous situation due to the high forces and pressures present in MTS test
systems.

On rare occasions, a fastener can fail even when it is correctly installed. Failure
usually occurs during torquing, but it can occur several days later. Failure of a
fastener can result in a high velocity projectile. Therefore, it is a good practice to
avoid stationing personnel in line with or below assemblies that contain large or
long fasteners.

Model 505.07/.11 SilentFlo™ HPU Safety

27

General Safety Practices: Hydraulic Power Units and

Practice good

housekeeping

Protect hoses and

cables

Provide proper

hydraulic fluid

filtration

Protect accumulators

from moving objects

Do not exceed the

Maximum Supply

Pressure

Keep the floors in the work area clean. Hydraulic fluid that is spilled on any type
of floor can result in a dangerous, slippery surface. Do not leave tools, fixtures,
or other items not specific to the test, lying about on the floor, system, or decking.

Protect electrical cables from spilled hydraulic fluid and from excessive
temperatures 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. Consider hydraulic distribution system layout and route hoses and
cables away from areas that expose them to possible damage.

If the system is equipped with a non-MTS hydraulic power unit, ensure proper
filtration to the hydraulic distribution system and testing component s. Particles
present in hydraulic fluid and cause erratic or poor system response.

Protect accumulators with supports or guards. Do not strike accumulators with
moving objects. This could cause the accumulator(s) to separate from the
manifold resulting in equipment damage and personal injury.

For hydraulic grips and fixtures. make sure that the hydraulic supply pressure is
limited to the maximum pressure defined by the grip or fixture identification (ID)
tag.

Do not disable safety

devices

Use appropriately

sized fuses

Provide adequate

lighting

Provide means to

access out-of-reach

components

Wear appropriate

personal protection

Your system may have active or passive safety devices installed to prevent
system operation if the device indicates an unsafe condition. Do not disable such
devices as it may result in unexpected system motion.

Whenever you replace fuses for the system or supply, ensure that you use a fuse
that is appropriately sized and correctly installed. Undersized or oversized fuses
can result in cables that overheat and fuses that explode. Either instance creates a
fire hazard.

Ensure adequate lighting to minimize the chance of operation errors, equipment
damage, and personal injury. You need to see what you are doing.

Make sure you can access system components that might be out of reach while
standing on the floor. For example, ladders or scaffolding might be required to
reach load cell connectors on tall load units.

Wear eye protection when you work with high-pressure hydraulic fluid,
breakable specimens, or when anything characteristic to the specimen could
break apart.

W ear ear protection when you work near electric motors, pumps, or other devices
that generate high noise levels. Some systems can create sound pressure levels
that exceed 70 dbA during operation.

W ear appropriate personal protection equipment (gloves, boots, suits, respirators)
whenever you work with fluids, chemicals, or powders that can irritate or harm
the skin, respiratory system, or eyes.

28

Safety

Model 505.07/.11 SilentFlo™ HPU

General Safety Practices: Hydraulic Power Units and

Handle chemicals

safely

Know system

interlocks

Whenever you use or handle chemicals (for example, cleaning fluids, hydraulic
fluid, batteries, contaminated parts, electrical fluids, and maintenance waste),
refer to the appropriate MSDS documentation for that material and determine the
appropriate measures and equipment required to handle and use the chemical
safely. Ensure that the chemical is disposed of appropriately.

Interlock devices should always be used and properly adjusted. Interlock devices
are designed to minimize the chance of accidental damage to the test specimen or
the equipment. Test all interlock devices for proper operation immediately before
a test. Do not disable or bypass any interlock devices as doing so could allow
hydraulic pressure to be applied regardless of the true interlock condition. The
Reset/Override button is a software function that can be used to temporarily
override an interlock while attempting to gain control of the system.

Know system limits Never rely on system limits such as mechanical limits or software limits to

protect you or any personnel. System limits are designed to minimize the chance
of accidental damage to test specimens or to equipment. T est all limits for proper
operation immediately before a test. Always use these limits and adjust them
properly.

Do not disturb sensors Do not bump, wiggle, adjust, disconnect, or otherwise disturb a sensor (such as

an accelerometer or extensometer) or its connecting cable when hydraulic
pressure is applied.

Ensure secure cables Do not change any cable connections when electrical power or hydraulic pressure

is applied. If you attempt to change a cable connection while the system is in
operation, an open control loop condition can result. An open control loop
condition can cause a rapid, unexpected system response which can result in
severe personal injury, death, or damage to equipment. Also, ensure that all
cables are connected after you make any changes in the system configuration.

Stay alert A void long periods of work without adequate rest. In addition, avoid long periods

of repetitious, unvarying, or monotonous work because these conditions can
contribute to accidents and hazardous situations. If you are too familiar with the
work environment, it is easy to overlook potential hazards that exist in that
environment.

Contain small leaks Do not use your fingers or hands to stop small leaks in hydraulic or pneumatic

hoses. Substantial pressures can build up, especially if the hole is small. These
high pressures can cause the oil or gas to penetrate your skin, causing painful and
dangerously infected wounds. Turn off the hydraulic supply and allow the
hydraulic pressure to dissipate before you remove and replace the hose or any
pressurized component.

Stay clear of moving

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. Never
assume that your reactions are fast enough to allow you to escape injury when a
system fails.

Model 505.07/.11 SilentFlo™ HPU Safety

29

General Safety Practices: Hydraulic Power Units and

Know the causes of

unexpected actuator

motions

Do not use RF

transmitters

Know compressed gas

hazards

The high force and velocity capabilities of MTS actuators can be destructive and
dangerous (especially if actuator motion is unexpected). The most likely causes
of unexpected actuator response are operator error and equipment failure due to
damage or abuse (such as broken, cut, or crushed cables and hoses; shorted wires;
overstressed feedback devices; and damaged components within the servocontrol
loop). Eliminate any condition that could cause unexpected actuator motion.

Keep radio frequency (RF) transmitters away from the workstation computers,
remote terminals, and electronics consoles. Intense RF fields can cause erratic
operation of the more sensitive circuits in the system.

Some environmental chambers use liquid nitrogen or some inert gas to achieve a
required test atmosphere. Typically these gasses are supplied in pressurized
tanks.

Observe the following safety practices when you work with high-pressure air or
gases:

• When you charge an accumulator, follow all the charging instructions

provided in the appropriate product information manuals. When precharging
accumulators, properly identify the type of gas to be used and the type of
accumulator to be precharged.

• Use only dry-pumped nitrogen to precharge nitrogen-charged accumulators.

(Dry-pumped nitrogen can also be labeled “oil pumped” or “dry water
pumped.”) Do not use compressed air or oxygen for precharging: the
temperature increase caused by rapid gas compression can result in highly
explosive conditions when hydraulic fluid is in the presence of oxygen or
compressed air.

• Always follow the recommended bleeding procedures before you remove or

disassemble components that contain pressurized gas. When you bleed a gas
or remove a fitting, hose, or component that contains a gas, remember that
many gases cannot support life. Therefore, as the ratio of released gas to
oxygen increases, so does the potential for suffocation.

• Wear appropriate safety devices to protect your hearing. Escaping air or gas

can create a noise level that can damage your hearing.

• 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 which bolts or fittings are used to restrain
a pressurized area. On some assemblies, you must remove a cover plate to
gain access to the structural bolts. Sometimes, to protect you from a rapid
release of trapped gases, a small port is exposed when you remove this
cover plate. Exposing this port ensures that the gas precharge is fully bled
before disassembly. However, this is not the recommended procedure for
bleeding a pneumatic or gas-charged device, because it can expose you to
the dangers of escaping compressed gas and particulates that are expelled
from the chamber or around the seals. Do not assume that cover plates and
ports are installed in all the critical locations.

30

Safety

Model 505.07/.11 SilentFlo™ HPU

General Safety Practices: Hydraulic Power Units and

Consult MTS when in doubt about the safety or reliability of any system-related
procedure or modification that involves devices that contain any type of
compressed gas.

The following labels and placards are typically located on the HPU.

ABEL DESCRIPTION

L

Hydraulic Power Unit information
label.

Part # 055-526-401

Overcurrent protection provided at
machine supply terminals.

Part # 100-008-434

Caution
To prevent equipment damage and

impede performance, remove red
shipping plug under filler cap before
operating.

Replace with black plastic snap in
strainer.

Part # 050-174-101

Model 505.07/.11 SilentFlo™ HPU Safety

31

General Safety Practices: Hydraulic Power Units and

L

ABEL DESCRIPTION

Warning
Disconnect unit from the electrical

supply before opening enclosure.

Part # 100-008-037

Wye-Delta Connections
Use for single voltage 6 lead motors

suitable for wye-delta starting.

Part # 053-448-401

32

Safety

Model 505.07/.11 SilentFlo™ HPU

Installation

CAUTION

Install the HPU

Install the HPU

This section describes how to install the Series 505 Hydraulic Power Unit (HPU).

Note The HPU is designed for indoor use. The HPU should be stored and

installed indoors.

1. Position the hydraulic power unit.
Determine where to put the HPU. Review the following:

• The HPU can fit through a standard 1-m or 36-in door.

• The HPU can be moved by a fork lift, pallet jack, or dolly.

• Placement considerations should include proximity to the facility

electric power, water, and the hydraulic components. Positioning the
HPU close to the hydraulic components can reduce the cost of
hydraulic distribution.

• The HPU produces no more than 60 dB (A) of sound pressure level

fully compensated in a free field acoustic environment.

• Connect the electrical service to the HPU.

Note Local electrical codes supersede any information found here.

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 voltage) to the HPU
is not necessary, but may be required by local electrical codes.

A. Connect the three electrical power feed wires to the input lugs of the

power disconnect in a clockwise phase orientation as indicated by the
L1, L2, and L3 labels shown in the following figure (the Model 505.07/
.11 high voltage configuration is shown).

Incorrect motor rotation at high pressure for longer than 10 seconds can
cause severe damage to your HPU.

It is imperative that you verify proper motor rotation to assure proper operation of
the HPU and to prevent damage to the HPU.

Model 505.07/.11 SilentFlo™ HPU Installation

33

Install the HPU

cw

PE GND (Protective
Earth Ground) Lug

Power
Disconnect

Electrical Power Feed
Lugs (shown labeled for
clockwise phase
orientation)

Ensure that lugs are
secure. They should be
checked periodically.
See the Maintenance
section.

HPU Power Requirement
and Power Feed Phase
Orientation Identifier

Pressure

-12 (3/4 in)

Water In

-12 (3/4 in NPT)

Return

-12 (3/4 in)

Water Out

-12 (3/4 in NPT)

Drain

-8 (1/2 in)

Drain

-6 (3/8 in)

B. Connect the grounding wire to the lug labeled PE GND (protective

earth ground).

2. Connect the hydraulic lines.
The following figure shows the hydraulic adapter ports to the HPU.

Note Each hydraulic connection requires an O-ring face seal.

3. Connect the water lines.

34

Installation

Model 505.07/.11 SilentFlo™ HPU

Install the HPU

CAUTION

Note For hydraulic connections to air-cooled units, refer to the Air-Cooler to

SilentFlo
number 100-135-073).

™

HPU Integration Product Information manual (MTS part

The HPU requires connection to a suitable water supply, equipped with an
appropriate shutoff valve, to cool the hydraulic fluid. The differential
pressure required between the HPU water inlet and outlet connections is

0.24 to 0.34 MPa (35 to 50 psi). The maximum allowable water inlet
pressure is 0.83 MPa (120 psi).

The water supply must also be capable of maintaining water flow at a rate
listed in the following table.

WATER INLET TEMPERATURE MODEL 505.07 MODEL 505.11

10.0°C (50°F) 3.8 L/m (1.0 gpm) 7.2 L/m (1.9 gpm)

15.5°C (60°F) 4.9 L/m (1.3 gpm) 9.1 L/m (2.4 gpm)

21.1°C (70°F) 6.1 L/m (1.6 gpm) 12.1 L/m (3.2 gpm)

26.7°C (80°F) 8.3 L/m (2.2 gpm) 18.9 L/m (5.0 gpm)

32.2°C (90°F) 15.9 L/m (4.2 gpm) 49.2 L/m (13.0 gpm)

A. Connect the water supply to the HPU Water In port. Connect the

Water Out port to your drain/return line.

B. A regulating valve must be adjusted according to your water

temperature.

4. Test the HPU.
A. The unit is shipped with a plug in the filler cap. Remove the red filler

cap plug and install the screen in the fill port on the top of the reservoir.
The screen is shipped in the electrical enclosure.

B. Rotate the power disconnect switch to the on (|) position.
C. Pull the Stop button so it is released from its latched position. When

the Stop button is released, it enables the interlock circuit.

D. Start the HPU by turning the High/Low/Start switch to the Start

position. When you hear the pump motor run, release the switch (it will
return to the Low position).

Note The following step only applies when the HPU is first turned on after

the electrical power has been connected (see Step 2).

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.

Model 505.07/.11 SilentFlo™ HPU Installation

35

Install the HPU

E. Verify the motor rotation (the pump motor can start with the wrong

rotation). Turn the High/Low/Start switch to the High position.

• If pressure begins to increase, proceed to the next step.

• If the output pressure gage shows no pressure, press the Stop button to

shut down the unit (do not run more than 10 seconds in the wrong
direction). Have a qualified electrician make a change in the electrical
phase to the motor.

F . Check for unusual noises or leaks. If a problem is found, press the Stop

button. You must correct the problem before you continue.

G. Tu rn the High/Low/Start switch to the High position.
H. Verify the correct output pressure, as shown on the pressure gage.
I. Press the Stop button to shut down the unit.

5. Connect the controller cable (if used).
The controller cable provides a means to connect your controller to the

HPU. When connected, your controller can remotely start and stop the unit
and switch between the low and high pressure selections. The cable also
permits the controller to monitor the low level, overtemperature, and dirty
filter status.

Important 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.

36

Installation

Model 505.07/.11 SilentFlo™ HPU

Operation

Contents 505.07/.11 HPU Controls 38

This section describes the front panel controls and indicators, and provides
operating instructions for the Series 505 Hydraulic Power Unit (HPU).

Operating the HPU Locally or Remotely 40
Recovering from an Interlock 41
Changing the Water Flow 42
Resetting the Thermal Overloads 43
Adjusting the Hydraulic Pressure 44
Adjusting the HPU Output Pressure Level 45
Adjusting the Auto-Cooling Level 45
Low/High Pressure Functionality 49

Model 505.07/.11 SilentFlo™ HPU Operation

37

505.07/.11 HPU Controls

Hydraulic Power Unit Control

Overtemperature

Low Level

Hour Meter

Reset

Power On

Dirty Filter

Hydraulic Power Unit Control

High

Start

Low

0 0 0 0 0 0 0

Stop

505.07/.11 HPU Controls

The controls shown in this figure are described on the following page.

Front Panel Controls

38

Operation

Model 505.07/.11 SilentFlo™ HPU

C

ONTROL/INDICATOR FUNCTION

505.07/.11 HPU Controls

Power On
Low Level

Overtemperature

Dirty Filter

Stop

Reset

High/Low/Start

Indicates when power is applied to the HPU from the main electrical circuit.
Indicates when the hydraulic fluid falls below a preset level. A low fluid level

will cause an interlock and turn the HPU off. The interlock signal can be
monitored by your system controller.

After adding hydraulic fluid to the reservoir, press the Reset button to clear the
interlock and turn the indicator off.

Indicates when the temperature of the hydraulic fluid exceeds 55°C (131°F).
Overtemperature will cause an interlock and turn the HPU off. The interlock
signal can be monitored by your system controller.

Indicates when the filter needs replacement. A dirty filter condition will
prevent the HPU from being started, but it will not stop the HPU while it is
running. The signal can be monitored by your system controller.

After replacing the filter, press the Reset switch to clear the interlock and turn
the indicator off.

Turns the pump motor off. The Stop button is a latching switch. Once it is
pressed, it remains pressed until it is reset. Pull the button out to reset the Stop
button.

Clears any interlocks caused by the HPU. This switch operates independently
from any other reset functions in your control system.

Starts the pump motor and selects the pressure setting. Turn the start switch to
the Start position and hold it until the pu mp motor runs. Releasing the switch
returns it to the Low position, which indicates the HPU is running in the low
pressure mode. Turn the switch to the High position to permit high pressure
output.

Hour Meter

Records how long the pump has been running. Use the hour meter to schedule
maintenance.

Main disconnect switch Allows access to the electrical enclosure to perform maintenance.

The main disconnect switch is located on the upper right corner of the electrical
enclosure door. The red switch on a yellow background has two functions:

• Disconnects electrical power from the electrical enclosure when the

switch is off (O).

• Contains a mechanical release so the door of the electrical enclosure

cannot be opened when the switch is on (|).

Turn the switch counterclockwise to disconnect electrical power and release
the front panel (additional screws help secure the front panel).

Model 505.07/.11 SilentFlo™ HPU Operation

39

Operating the HPU Locally or Remotely

Operating the HPU Locally or Remotely

The HPU can be operated locally using the front panel controls or remotely using
your system controller.

Local operation 1. Make a general inspection of the HPU. Ensure that all cooling water valves

are open and that the external hydraulic circuit is ready for pressure to be
applied. Ensure that the Stop button is released.

2. Turn the start switch to the Start position until the pump motor starts. When
the switch is released, it will return to the Low position.

3. Check the HPU for leaks and unusual sounds. Stop the HPU immediately if
leaks or unusual sounds are noticed. Determine the cause and fix the
problem before restarting the HPU.

4. Turn the start switch to the High position to operate the HPU at full
pressure.

Note If the HPU generates an interlock during operation (low fluid level or

high temperature), the HPU will be stopped. Once the cause has
been corrected, press the Reset button before restarting.

5. To stop the HPU, press the red Stop button.

Remote operation Remote operation of the HPU can occur at a remote control panel or from your

system controller software. The controller must be connected to the HPU.

Note MTS controllers can issue the off, low, and high signals to the HPU to

control the hydraulic pressure.

This procedure requires the controller to be connected to the HPU.

1. Make a general inspection of the HPU.
A. Ensure that all cooling water valv es are open and that the external

hydraulic circuit is ready for pressure to be applied.

B. Ensure the Stop button is released.

2. Start the HPU at your controller.

3. Check the HPU for leaks and unusual sounds. Stop the HPU immediately if
leaks or unusual sounds are noticed. Determine the cause and fix the
problem before restarting the HPU.

4. Select high pressure at your controller.

Note If the HPU generates an interlock during operation (low fluid level or

high temperature), the HPU will be stopped. Once the cause has
been corrected, press the Reset button before restarting.

40

Operation

5. Stop the HPU with the controller.

Model 505.07/.11 SilentFlo™ HPU

Recovering from an Interlock

Recovering from an Interlock

This section describes how to reset each type of HPU interlock. If one of the
interlock indicators (Low Level, Overtemperature, Dirty Filter) is lit, the HPU
will not start. You must determine the source of the interlock (w hich indicator is
lit) and correct the cause before using the HPU.

Low level The Low Level indicator lights when the hydraulic fluid falls below the setting

of the low level/overtemperature sensor which is mounted on top of the reservoir.
Perform the following steps to correct a low level interlock:

1. Add hydraulic fluid to the reservoir until the fluid level gage indicates the
proper level.

2. Press the Reset button to clear the interlock and turn the indicator off.

Overtemperature The Overtemperature indicator lights when the temperature exceeds 55°C

(131°F). The temperature is detected by the low level/overtemperature sensor
mounted on top of the reservoir. The HPU cannot be restarted until the fluid has
cooled. Perform the following steps to correct an overtemperature interlock:

1. Check the temperature gage to ensure that the hydraulic fluid is actually
overheated. If not, the overtemperature switch may need replacement.

Cooling the

hydraulic fluid

2. If necessary, cool the hydraulic fluid as described in this section.

3. Determine if the hydraulic fluid is receiving adequate cooling.

• Verify the operation of the Auto-Cooling Valve.

• The auto-cooling circuit provides a path for circulating hydraulic fluid

through the heat exchanger during periods of high pressure operation
with low demand by the system.

Note The cooling water inlet temperature affects the efficiency of cooling the

hydraulic fluid.

• Check the cooling water inlet-to-outlet pressure differential. It should be

between 0.24–0.34 MPa (35–50 psi). Adjust the water pressure at its source.

4. Press the Reset button to clear the interlock and turn the indicator off.

If the HPU shuts down due to overheated hydraulic fluid, you may need to
perform the following procedure to circulate hydraulic fluid through the heat
exchanger to cool the fluid:

1. Open the HPU cover to monitor the temperature of the hydraulic fluid.

2. Turn the High/Low/Start switch to the Start position and hold it there. This

overrides the interlock and runs the pump mo to r.

3. Continue to hold the High/Low/Start switch in the Start position to

circulate the hydraulic fluid through the heat exchanger. Observe the
temperature gage.

4. Release the switch when the fluid temperature falls below 53°C (129°F).

Model 505.07/.11 SilentFlo™ HPU Operation

41

Changing the Water Flow

Water Regulation Valve

Adjustment

Water Solenoid Valve

Dirty filter The Dirty Filter indicator lights when the differential pressure across the filter

increases. A dirty filter condition will prevent the HPU from being started, but it
will not stop the HPU while it is running.

Changing the Water Flow

The flow of water is the only way to maintain the temperature of the hydraulic
fluid on a water-cooled HPU. The water-regulating valve, located on the water
inlet line of the HPU, senses the hydraulic fluid temperature and automatically
controls water flow to the heat exchanger.

5. Press the Reset button to clear the overtemperature interlock at the HPU.

You may need to clear the interlock at the controller, (see your controller
manual).

6. You may want to continue running the HPU to cool it off even further. Turn

the High/Low/Start switch to the Start position (the High/Low/Start
switch returns to the Low position). Continue to run the HPU in the low
pressure mode until the hydraulic fluid is sufficiently cooled.

1. Replace the hydraulic fluid filter.

2. Press the Reset button to clear the interlock and turn the indicator off.

Note When the HPU is turned off, a solenoid valve also shuts off the flow of

water to the heat exchanger.

The water-regulating valve is adjusted at MTS Systems Corporation to maintain
the hydraulic fluid temperature at 43°C (110°F). However, the temperature of
your water may require you to readjust the regulator.

42

Operation

To set the operating temperature of the hydraulic fluid:

1. Start the HPU and switch to high-pressure mode.

Model 505.07/.11 SilentFlo™ HPU

2. Observe the temperature gage as the hydraulic fluid temperature rises. Note

Transformer Fuses

FU4FU6

Line Fuses

FU1FU3

Thermal

Overload

the temperature where the hydraulic fluid stabilizes.

3. Adjust the water-regulating valve. One full turn (360°) of the adjusting
screw produces a change in hydraulic fluid temperature a few degrees.

• Adjust the screw clockwise to decrease the operating temperature.

• Adjust the screw counterclockwise to increase the operating

temperature.

4. Note the effect after 15 minutes.

5. Repeat Step 3 and Step 4 until the hydraulic fluid temperature stabilizes
between 43°C–49°C (110°F–120°F).

Resetting the Thermal Overloads

Each incoming electrical power feed line has a thermal overload switch. If any
line draws too much current, its thermal overload switch trips and disconnects the
HPU from the electrical power feed.

Additional protection is provided by line fuses (FU1–FU3) and transformer fuses
(FU4–FU6). These cartridge-type fuses must be replaced with fuses of the same
size, type, and rating, which vary according to the voltage configuration.

Resetting the Thermal Overloads

A tripped thermal overload or a blown fuse indicates a potential short circuit, too
much current in the motor, or a component failure (mechanical or electrical).

To reset the thermal overload switches or replace the fuses:

Model 505.07/.11 SilentFlo™ HPU Operation

43

Adjusting the Hydraulic Pressure

Output
Pressure
Control

Control Manifold
(shown rotated)

Return Line
Hose

Output
Pressure
Gage

Auto-Cooling
Valve

1. Turn the main disconnect switch counterclockwise to remove power from
the electrical control box.

2. Loosen the two bolts securing the door of the electrical enclosure and open
the door.

3. Locate the thermal overload switch. Press the Reset button to clear the
switch. If the thermal overload switch trips again, wait until it cools.

Adjusting the Hydraulic Pressure

The output pressure can be adjusted from a low pressure value of 1 MPa (145
psi) to the factory setting of 21 MPa (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 Va lve.

44

Operation

To change the output pressure, see the appropriate procedure.

Control Locations

Perform the procedure for adjusting the auto-cooling level if the adjusted output
pressure is between 14 MPa (2000 psi) and 21 MPa (3000 psi) and the HPU will
be operated in high pressure mode for an extended period of time (longer than 10
minutes).

Model 505.07/.11 SilentFlo™ HPU

The pump and motor are designed to operate below a specifie d pressure.

CAUTION

Setting the hydraulic pressure above 21 MPa (3000 psi) can damage the
pump and its motor.

Do not adjust the output pressure higher than 21 MPa (3000 psi).

Adjusting the HPU Output Pressure Level

1. Turn on high hydraulic pressure. Ensure that there are no flow demands by
the system.

2. Loosen the nut securing the output pressure control.

3. Monitor the hydraulic pressure gage located on the control manifold. Adjust
the output pressure as follows until the desired pressure is displayed.

• Turn the output pressure control clockwise to increase the pressure.

Adjusting the HPU Output Pressure Level

• Turn the output pressure control counterclockwise to decrease the

pressure.

Note If this pressure level is to be used for longer than 10 minutes, proceed to

“Adjusting the auto-cooling level” procedure.

4. Hold the output pressure control to prevent it from moving and tighten the
nut to secure it.

5. Check the hydraulic pressure gage to ensure that the desired hydraulic
pressure is being maintained.

Adjusting the Auto-Cooling Level

The auto-cooling function is integrated into the control manifold . During periods
of low flow demand from the external hydraulic circuit, this feature provides two
important benefits: a re-circulating flow that ensures hydraulic fluid filtering
whenever the unit is on, and safeguarding against hydraulic fluid over­temperature. It functions by opening a hydraulic flow path through the fluid
conditioning circuit 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 fo r the Auto­Cooling Valve to function properly, it must be re-adjusted anytime the output
pressure will be changed for longer than 10 minutes.

Note If the test condition requires a maximum pressure level of less than 14

MPa (2000 psi), consult MTS.

Model 505.07/.11 SilentFlo™ HPU Operation

45

Adjusting the Auto-Cooling Level

An incorrect adjustment may cause one of two conditions:

• An over-temperature interlock as indicated by the front panel indicator. A

mis-adjustment of the Auto-Cooling Valve may prohibit the flow of
hydraulic fluid across the heat exchanger

• Unexpectedly reduced system performance. A mis-adjustment of the Auto-

Cooling Valve may reduce the full flow of the pump to the external circuit

The Auto-Cooling Valve is factory set for an output pressure setting of 21 MPa
(3,000 psi). If the HPU will be operated with a 0.2 MPa (25 psi) or larger
decrease (or increase from a lower set pressure) for a period exceeding 10
minutes, an adjustment to this valve will ensure that neither of these conditions
occurs. The Auto-Cooling Valve is located on the control manifold.

Adjusting the Auto-

Cooling Valve to

correspond with a

change in HPU output

pressure

Perform the following procedure whenever the HPU will be operated with a
change in output pressure for longer than 10 minutes.

The following procedure assumes that Steps 1 through 3 of “Adjusting the HPU
output pressure level” have already been completed.

1. With the HPU running in high, loosen the nut on the Auto-Cooling Valve
located on the control manifold (see the previous figure).

2. Adjust the Auto-Cooling Valve to shift at the desired level.

• When increasing the output pressure, adjust the Auto-Cooling Valve

clockwise to the desired shift level.

• When decreasing the output pressure, adjust the Auto-Cooling Valve

counterclockwise to the desired shift level.

Note The number of turns required to reach the transition level will depend on

the how much the output pressure is changed. For example, going from
an output pressure of 21 MPa (3000 psi) to 14 MPa (2000 psi) may
require as much as three full turns on the Auto-Cooling Valve before you
approach the transition level.

While adjusting the Auto-Cooling Valve, listen to the pump. When the valve
shifts a sudden change in pitch will be heard from the pump. Reversing the
valve adjustment a number of times will aid in identifying the proper
setting. Make a final counter-clockwise adjustment, an increase in pump
pitch will be heard that corresponds with the opening of the valve. Stop
adjusting at this point.

46

Operation

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.

Model 505.07/.11 SilentFlo™ HPU

Adjusting the Auto-Cooling Level

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 desired
output pressure may prevent the valve from shifting and result in
the HPU overheating.

Adjustment of the Auto-Cooling Valve that results in the valve
shifting at a level substantially below the desired output pressure
may result in reduced flow to the system.

3. Confirm the Auto-Cooling Valve setting by slowly cycling the HPU Output
Pressure Control. Decrease the HPU output pressure and note a decrease in

pump pitch when the valve closes. At the point when the valve closes, the
pressure on the gage will momentarily hesitate during the adjustment.
Increase the pump output pressure to the desired pressure setting and note an
increase in pump pitch when the valve opens. Once again the pressure gage
will show a momentary hesitation when the valve opens.

4. If necessary, repeat Steps 2 and 3 until the Auto-Cooling Valve is stable and
the HPU cools properly.

Adjusting the Auto­Cooling Valve if the

HPU shuts down due
to an over-temperature
condition or if the HPU

fails to deliver the full

flow to the external

circuit.

5. After the final adjustment tighten the nut to secure the setting.
A. Hold the HPU Output Pressure Control to prevent it from turning while

tightening the nut.

6. Verify that the output pressure remained at the desired level and tighten the
nut to secure the setting.

A. Hold the Auto-Cooling Valve stem to prevent it from turning while

tightening the nut.

Adjust the Auto-Cooling Valve if:

• The HPU shuts down due to an overtemperature condition that has been

determined to not be caused by a fault in the heat exchanger circuit or

• If the HPU fails to deliver the full flow of the HPU to the external circuit.

1. With the HPU running in high and the HPU set for the desired output
pressure, loosen the nut on the Auto-Cooling Valve located on the control
manifold.

2. Adjust the Auto-Cooling Valve setting by slowly turning the valve
clockwise. If the valve shifts, a sudden change in pitch will be heard from
the pump. Reversing the valve adjustment a number of times will aid in
identifying the proper setting. Make a final counter-clockwise adjustment.
An increase in pump pitch will be heard that corresponds with the opening
of the valve. Stop adjusting at this point. If no valve shift is audibly or
visually detected and the valve has been fully closed go to step 3.

Model 505.07/.11 SilentFlo™ HPU Operation

47

Adjusting the Auto-Cooling Level

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 desired
output pressure may prevent the valve from shifting and result in
the HPU overheating.

Adjustment of the Auto-Cooling Valve that results in the valve
shifting at a level substantially below the desired output pressure
may result in reduced flow to the system.

3. Adjust the Auto-Cooling Valve by slowly turning the valve counter
clockwise. When the valve shifts a sudden change in pitch will be heard
from the pump. Reversing the valve adjustment a number of times will aid
in identifying the proper setting. Make a final counter-clockwise
adjustment, an increase in pump pitch will be heard that corresponds with
the opening of the valve. Stop adjusting at this point.

4. Confirm the Auto-Cooling V alve setting by slowly cycling the HPU Output
Pressure Control. Decrease the HPU output pressure and note a decrease in
pump pitch when the valve closes. At the point when the valve closes the
pressure on the gage will momentarily hesitate during the adjustment.
Increase the pump output pressure to the desired pressure setting and note an
increase in pump pitch when the valve opens. Once again the pressure gage
will show a momentary hesitation when the valve opens.

5. If necessary, repeat steps 2 and 3 until the Auto-Cooling Valve is stable and
the HPU cools properly.

6. After the final adjustment, hold the HPU Output Pressure Contr ol to prevent
it from moving while tightening the nut to secure the setting.

7. Verify the output pressure remained at the desired level and the nut to secure
the setting.

A. Hold the Auto-Cooling Valve stem to prevent it from turning while

tightening the nut.

48

Operation

Model 505.07/.11 SilentFlo™ HPU

Low/High Pressure Functionality

High Pressure Flow to
External System

Return Flow from System

Auto-cooling

HPU Manifold

Low Pressure
Flow

Heat Exchanger Filter

Reservoir

This section clarifies the low and high pressure functionality of the HPU. There
are certain cases where it is advantageous to use the HPU in low pressure versus
high pressure. Low/High functionality is illustrated in the block diagram below:

Low/High Pressure Functionality

Low pressure Series 505 HPUs are started 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 by the external system.

System commissioning Best practices for system commissioning include flushing the hard line and

related equipment. This process “conditions” the hydraulic fluid to a cleanliness
level that supports high performance servovalve systems. (Refer to the Hydraulic
Fluid Care Guide (part number 050-000-536) for information on fluid
cleanliness.)

A logical progression of fluid conditioning that begins at the HPU is required to
minimize problems when commissioning a system.

• With the HPU running in low pressure, acceptable particle counts are

obtained in a relatively short time.

• Keeping the HPU in low pressure effectively isolates the external or system

flow because the relative back pressure is normally much higher in the
external system circuit.

• Running the HPU in low pressure maximi zes fluid flow, allowing the HPU

to circulate the reservoir contents across the filter more times per hour.

• Starting the commissioning process with an isolated HPU reduces the

possible number of problems encountered during startup.

Model 505.07/.11 SilentFlo™ HPU Operation

49

Low/High Pressure Functionality

Once the HPU has cleaned the reservoir hydraulic fluid, sections of the system
should be isolated and sequentially cleaned. Flushing of hard line sections takes
place in high pressure mode. If the HPU is run in low pressure, flow losses in the
system will minimize the external flow and reduce the effectiveness of the
system flushing and fluid conditioning.

System cooling A Series 505 HPU running in low pressure maximizes the cooling efficiency of

the unit:

• Because the motor is not working to pressurize the fluid, it runs at a low

power level, producing less waste heat.

• Flow rates are high in low pressure mode, providing an ample volume of

coolant (hydraulic 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:

• Leaving an HPU idling in high pressure mode uses roughly 40% more

electrical power than idling in low pressure mode.

• When the hydraulic fluid is pressurized, cooling water usage is higher.

When operating in low pressure, the motor consumes less energy and less
heat needs to be removed by the heat exchanger.

Hydraulic fluid

replacement

Overtemperature

recovery

New fluid right out of the barrel is the dirtiest the fluid will ever be in a properly
maintained system. Particle counts are well beyond safe limits for servohydraulic
components. Use the system commissioning methodology (filter new fluid first
when possible) to condition the fluid when introducing new fluid into a system.

Cooling tower, chiller failures, or shut-off valves cause a large number of over­temperature interlock conditions in the field. Low pressure mode is the fastest
way to get the tank temperature back to normal. Each HPU has an override
feature to force the unit into low pressure for fast over temperature recovery.

High pressure When the Series 505 HPUs are running in high pressure, a considerable amount

of heat is generated. During normal testing, this heat is dissipated by running the
hydraulic fluid through the systemfrom the return line to the heat exchanger.
During periods of low system demand, this heat is dissipated by running the
hydraulic fluid through the auto-cooling circuit to the heat exchanger.

Auto-cooling The Auto-Cooling Valve is adjusted such that the shift between valve closed and

valve opened occurs just below the output pressure level. Whenever system
pressure is above the shift level of the Auto-Cooling Valve (indicatin g 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.

50

Operation

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 Auto­Cooling Valve to function properly, it must be re-adjusted anytime the output
pressure will be changed for longer than 10 minutes.

Model 505.07/.11 SilentFlo™ HPU

Low/High Pressure Functionality

Note If the test condition requires a maximum pressure level less than 14 MPa

(2000 psi), consult MTS.

Model 505.07/.11 SilentFlo™ HPU Operation

51

Low/High Pressure Functionality

52

Operation

Model 505.07/.11 SilentFlo™ HPU

Maintenance

This section describes preventive maintenance requirements and their
recommended intervals for the HPU.

505.07/.11 HPU Maintenance Schedule 56
Checking the Hydraulic Fluid 58
Replacing the Return Line Filter 59
Sample the Hydraulic Fluid 62
Appearance of Hydraulic Fluid Sample 63
Replacing the Hydraulic Fluid 64

Model 505.07/.11 SilentFlo™ HPU Maintenance

53

Routine Maintenance Overview Checklist

Routine Maintenance Overview Checklist

Recommended service to be performed at each running time interval noted

ALENDAR TIME USING 8 HOUR

C

UNNING TIME RATE PER DAY

R

DAILY WEEKLY MONTHLY ANNUALLY

RUNNING TIME-HOURS 8 40 160 500 1000 1,500 2,000 5,000 10,000

Check electronic enclosure
ventilation

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
Check cables and connectors X
Check console air filter

Check all accumulators for
proper precharge pressure
and oil

Check condition of all
electrical cables and cable
connections

X

*

†

MTS

MTS MTS MTS MTS

MTS MTS MTS MTS

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)”

Inspect pump hoses for leaks MTS MTS MTS MTS
Lubricate-grease motor

bearings (non 505)
Verify dirty filter indicators

status
Verify HPU hydraulic fluid level MTS MTS MTS MTS
Verify warning and interlock

devices

Maintenance

54

MTS MTS MTS MTS

MTS MTS MTS MTS

MTS MTS MTS MTS

MTS MTS MTS MTS

MTS MTS MTS MTS

MTS MTS MTS MTS

MTS MTS MTS MTS

Model 505.07/.11 SilentFlo™ HPU

Routine Maintenance Overview Checklist

Recommended service to be performed at each running time interval noted

ALENDAR TIME USING 8 HOUR

C

UNNING TIME RATE PER DAY

R

DAILY WEEKLY MONTHLY ANNUALLY

RUNNING TIME-HOURS 8 40 160 500 1000 1,500 2,000 5,000 10,000

Replace all filters MTS MTS
Verify operation and settings

of psi control and relief valves
Check pump/motor coupling

for wear and debris
Check pump voltage and

current
Check case drain flow MTS
Recommend MTS Hydraulix oil

sample
Recommend replacement or

rebuild of heat exchanger
Recommend replacement of

hoses
Recommend replacement of

motor bearings
Recommend replacement or

rebuild of pump
Recommend replacement or

rewind of motor
Recommend hydraulic fluid

change & clean pump inlet
strainer

MTS MTS MTS MTS

MTS MTS

MTS

MTS

MTS MTS

MTS

MTS MTS

MTS

MTS

MTS

*Symbol denotes services performed by equipment operators. Most of these procedures involve visual checks that
should not interfere with test system operation. These checks are also completed by trained field service engineers
on each Routine Maintenance visit.

†Symbol denotes service performed by trained field service engineers as part of an MTS Routine Maintenance
plan. Some of these procedures require special service tools and/or specific service training to complete.

Model 505.07/.11 SilentFlo™ HPU Maintenance

55

505.07/.11 HPU Maintenance Schedule

505.07/.11 HPU Maintenance Schedule

The following table lists the recommended interval for each maintenance
procedure.

Maintenance Schedule (part 1 of 2)

HAT TO DO WHEN TO DO IT HOW TO DO IT

W

Make daily visual
inspections

Check fluid quality and
condition

Check functionality of
warning and interlock
devices

Check the precharge
pressure in optional
surge suppressor

Conduct external
inspection of the heat

exchanger

*

Before the start of each day’s
testing.

Every 40 hours or 1 week
(whichever occurs first).

Every 40 hours or 1 week
(whichever occurs first).

Every 160 hours or 1 month
(whichever occurs first).

Every 500 hours or 3 months
(whichever occurs first).

Check electronic enclosure ventilation.
Check status of dirty filter indicator.
Look for signs of fluid leakage.
Check the fluid level in the sight gage.
Check system operating pressure and adjust

as required.
Compare the condition (including odor and

color) of the fluid to that of your sample.
Depress emergency stop button(s) to verify

that warning and interlock devices are
functioning properly.

Depress fault indicator light bezel to test
bulb.

Refer to the appropriate procedure.

Look for dents, bulges, leaks, damaged
gaskets, corrosion, and worn, frayed, or
leaking hoses.

Inspect hydraulic hoses,
replace as required

Inspect incoming power
lines for loose
connections or defects

Replace fluid filter

Check auto-cooling
circuit functionality

Verify functionality of
HPU interlocks

Check motor overload
functionality

Maintenance

56

†

†

Every 1000 hours or 6 months
(whichever occurs first).

Every 1000 hours or 6 months
(whichever occurs first), or when
electric power is disconnected.

Every 1000 hours or 6 months
(whichever occurs first), or when
the dirty-filter indicator lights.

Every 1000 hours or 6 months
(whichever occurs first).

Every 1000 hours or 6 months
(whichever occurs first).

Every 1000 hours or 6 months
(whichever occurs first).

Look for signs of wear, check for fluid
leaks, tighten connections as needed.

Have inspection performed by a qualified
electrician. Observe all local codes and
safety precautions. Ensure all connections
are secure. Screws should be torqued to
values specified on associated labeling.

Refer to the appropriate filter replacement
procedures.

Refer to the appropriate procedure.

Contact MTS Systems Corporation.

Contact MTS Systems Corporation.

Model 505.07/.11 SilentFlo™ HPU

505.07/.11 HPU Maintenance Schedule

Maintenance Schedule (part 2 of 2)

HAT TO DO WHEN TO DO IT HOW TO DO IT

W

Verify proper ope ration of
hydraulic valves

Conduct a hydraulic fluid
analysis

Replace hydraulic fluid
Conduct internal

inspection of heat
exchanger

Check case drain flow of
hydraulic pump

Replace heat
exchanger

Inspect the motor and
pump. Replace motor

bearings

‡

†

†

‡

*,†

*,†

Every 1000 hours or 6 months

Contact MTS Systems Corporation.

(whichever occurs first).
Every 1000 hours or 6 months

(whichever occurs first), or sooner
if duty is severe.

Obtain a sample and submit it for analysis.
MTS recommends that the sample be
analyzed by our contracted service. Ask
your Field Service Engineer for
information.

See related procedure.

As determined by analysis. Refer to the appropriate procedure.
Every 2000 hours or yearly

(whichever occurs first).

Look for signs of fouling or corrosion,
conduct chemical or mechanical internal
cleaning as inspection warrants.

Every 2000 hours or yearly

Contact MTS Systems Corporation.

(whichever occurs first).
Every 5000 hours or 3 years

(whichever occurs first).
Every 30,000 hours or 5 years

(whichever occurs first).

Replace as inspection warrants.
Contact MTS Systems Corporation.

Motors may be rewound or replaced as
required by inspection.

Hydraulic pumps may be rebuilt or replaced
as required by inspection.

Contact MTS Systems Corporation.

Replace hydraulic hoses

Every 10,000 hours or 5 years

Contact MTS Systems Corporation.

†

(whichever occurs first).

*See the Heat Exchanger Care and Water Quality Guide (part number 015-164-000).
† Special training required. Contact MTS Systems Corporation.
‡See the Hydraulic Fluid Care Guide (part number 050-000-536).

Spare parts Parts that are specified in the maintenance procedures of this section can be

obtained from MTS Systems Corporation. See “Contact information” on the back
of the title page to order spare parts.

Lockout/tagout For your safety, follow all appropriate lockout/tagout procedures while

performing HPU maintenance.

Operating the HPU When running the HPU, become familiar with the sounds and smells of the HPU.

Changes in the sounds and smells of the HPU might indicate that maintenance or
service is needed.

Model 505.07/.11 SilentFlo™ HPU Maintenance

57

Checking the Hydraulic Fluid

Checking the Hydraulic Fluid

Hydraulic fluid contamination 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.

T o avoid these problems, you must maintain a clean hydraulic system. Regularly
test samples of your hydraulic fluid and follow the recommended maintenance
procedures described here. For more information on hydraulic fluid care, refer to
the Hydraulic Fluid Care Guide (part number 050-000-536).

Important To prevent problems with inconsistent and inferior fluids, MTS

Procedure Perform the following checks of the hydraulic fluid weekly. If you suspect

contamination of the hydraulic fluid, take a sample and have it analyzed.

1. Check the fluid level in the HPU sight gage to verify the fluid level is
correct.

recommends only ExxonMobil DTE 25 or Shell Tellus 46 to its
customers.

• A low level can indicate a leak. If necessary, add enough fluid to bring

the reservoir level up to the proper operating level.

• A high level can indicate water contamination from the heat exchanger .

2. Check the hydraulic fluid color. Clean hydraulic fluid is amber in color.
Keep a sample of brand-new hydraulic fluid in a clean glass container for

comparison. A change in color can mean that the fluid is contaminated or
that it has broken down chemically. Refer to the table, “Appearance of
Hydraulic Fluid Sample,” if the hydraulic fluid appears different than the
clean sample.

3. Check the smell 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
Engineer to determine if changes or adjustments to your hydraulic system
are required.

58

Maintenance

Model 505.07/.11 SilentFlo™ HPU

5. Check and adjust the hydraulic fluid delivery system so that:

• Hydraulic fluid temperature stabilizes within the parameters given in

• Pressure line reading is maintained at 21 MPa (3000 psi) maximum

• Maximum drain line back pressure is limited to 0.1 MPa (15 psi).

If you need to adjust the water-regulating valve, overtemperature switch or
pressure control valves, see the procedure for Changing the Water Flow.

Replacing the Return Line Filter

The filter element of the HPU should be replaced for the following reasons:

• When the dirty-filter indicator lights

• Whenever the hydraulic fluid is changed

• The maximum interval recommended by the filter manufacturer has passed

(1000 hours or 6 months)

Replacing the Return Line Filter

the Specifications table when the HPU is operating at high pressure.

static value.

Prerequisite You will need a filter element (MTS part number 100-009-495) or a filter kit

(MTS part number 100-030-195).

Procedure To change the filter element:

Note The dirty-filter indicator may light when the HPU is first started due to low

hydraulic fluid temperature. When the HPU is at normal operating
temperature, recheck the indicator to determine if the element actually
needs replacement.

1. Turn off the HPU.

Model 505.07/.11 SilentFlo™ HPU Maintenance

59

Replacing the Return Line Filter

Output
Pressure
Gage

Filter
Assembly

2. Open the top of the HPU with an 8-mm (5/16-inch) allen wrench.

Return Line Filter Component Identification

3. Check the 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. Inspect the O-rings in the manifold for any sign of deterioration. If
necessary, replace the defective O-ring(s).

60

Maintenance

Model 505.07/.11 SilentFlo™ HPU

Replacing the Return Line Filter

Align the 90° elbow outlet at the bottom of the assembly such that it directs hydraulic fluid
flow in the direction of the arrow in the graphic above.

8. Insert a new filter element into the bowl and reinstall the bowl assembly.
Align the 90° elbow outlet at the bottom of the assembly such that it directs
hydraulic fluid flow towards the side of the reservoir as shown in the
following illustration. Screw the filter cover back on.

Model 505.07 HPU Top View

9. Turn on the HPU and switch to high-pressure mode. Inspect the seal
between the housing and the manifold for any signs of leakage. If leakage
occurs, repeat this procedure (without replacing the filter element). If
leakage persists, contact MTS Systems Corporation.

10. If you are changing the filter because the dirty filter indicator tripped, run
the HPU for two to four hours to remove contaminants. Then take a fluid
sample and have it analyzed.

Continue to clean the fluid if it does not meet an ISO 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.

Model 505.07/.11 SilentFlo™ HPU Maintenance

61

Sample the Hydraulic Fluid

Bypass Valve

Hose V a lv e Assembly

Needle Valve

Sample Port

Sample the Hydraulic Fluid

This section describes how to check the quality of the hydraulic fluid. Review the
following hints before obtaining your sample:

• Avoid contamination.

• For additional information on hydraulic fluid care, see the Hydraulic Fluid

• Hold the hose valve assembly still when taking a sample.

• Do not let the hose sample assembly line touch the mouth of the bottle or go

– Keep the sample bottle in the storage box of the hydraulic fluid

sampling kit until it is needed.

– Do not remove the cap from the bottle until immediately before taking

the sample.

– Do not set the cap down on a dirty surface or in an area where airborne

dust can settle.

Care Guide (part number 050-000-536) found in the documentation package
inside the electrical control box.

into the bottle.

Prerequisite You will need a hydraulic fluid sampling kit (part number 055-589-601).

Procedure Take a fluid sample from the reservoir to get a visual indication of the fluid level

and relative contamination. Clean hydraulic fluid is clear and has an amber color.
If the composition of the fluid appears to have changed, obtain a sample of the
hydraulic fluid from the sample port and check the fluid qualities.

62

Maintenance

Control Manifold

Model 505.07/.11 SilentFlo™ HPU

Appearance of Hydraulic Fluid Sample

1. Operate the HPU until the hydraulic fluid is at normal operating temperature
(about 30 minutes).

2. Close the needle valve. Connect the hose valve assembly to the sample port
located on the hydraulic manifold on top of the HPU. (See illustration.)

3. Open the needle valve on the hose valve assembly and flush 1 liter (1 quart)
of hydraulic fluid though the sampling assembly. This fluid can be directed
to a waste container or back into the HPU reservoir.

4. Obtain a sample of the hydraulic fluid after flushing the valve hose
assembly.

A. Without closing the valve, quickly place the sample bottle into the fluid

stream (keep the sample bottle sealed until the sample is to be taken).
B. Fill the sample bottle (175 mL/6 oz) with fluid.
C. Close the valve on the hose valve assembly and cap the sample bottle.

5. Check the fluid qualities of the sample by comparing it to a small jar of
clean hydraulic fluid. Clean hydraulic fluid has an amber color.

See the table, “Appearance of Hydraulic Fluid Sample,” for unacceptable
fluid qualities.

6. If there still is any uncertainty regarding fluid quality, obtain another sample
of the fluid and have it analyzed. The fluid tests should include chemical
analysis, particle count, and viscosity checks. Most oil companies have
facilities for performing these tests, or consult MTS Systems Corporation.

7. Close the needle valve and remove the hose and valve assembly. Open the
needle valve.

Appearance of Hydraulic Fluid Sample

FLUID PROPERTIES PROBLEM WHAT TO DO

Dark colored fluid

Burnt odor

Indicates chemical breakdown or
the hydraulic fluid has been allowed
to rise above the maximum
recommended temperature (severe
overheating)

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 adjustments to your
hydraulic system are required.

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 adjustments to your
hydraulic system are required.

Model 505.07/.11 SilentFlo™ HPU Maintenance

63

Replacing the Hydraulic Fluid

CAUTION

LUID PROPERTIES PROBLEM WHAT TO DO

F

Opaque fluid
Milky appearance

Indicates chemical breakdown Replace the fluid
Indicates water is present in the

fluid

Sediment at the bottom of
the sample containe r (after
sample has stood
overnight)

Indicates collapsed, ruptured, or
clogged filter(s)

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

• A transfer pump with a 10-micron filter (such as the Model 590.01 Fluid

Transfer Pump)

• Synasol

®

or a similar cleaning solvent

Check the heat exchanger for damage.
Look for other water sources if the

water does not appear to be coming
from the heat exchanger.

Identify and correct the source of the
water leakage and replace the fluid if
necessary.

Analyze the fluid and replace all filter
elements.

Clean the fluid or replace it as required
by the analysis.

• Lint-free cloths or manufactured rags

• A container for the used hydraulic oil and a small drain pan that will fit

underneath the drain plug

• A hydraulic fluid sampling kit (MTS part number 055-589-601).

• A new filter—see “Replacing the Return Line Filter”

Prerequisite Perform the procedure “Sampling the Hydraulic Fluid” to determine if the

hydraulic fluid should be replaced.
Identify and correct any sources of contamination.

Mixing different brands of hydraulic fluid can contaminate your sy stem.
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 ExxonMobil DTE-25 or Shell Tellus 46 AW hydraulic fluid.

Procedure See “Component Identification” to identify the components called out in the

following procedure.

64

Maintenance

Model 505.07/.11 SilentFlo™ HPU

Replacing the Hydraulic Fluid

1. Prepare the HPU.

A. Press the Stop button to turn off the HPU.
B. Remove the electrical power to the HPU via a circuit breaker at the

power source.
C. Use an 8-mm (5/16-inch) allen wrench to unlatch the HPU cover.
D. Remove the filler cap.
E. Remove the reservoir cover.

2. Remove the hydraulic fluid.
A. 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 Synasol.
Clean the pump, motor, and bottom of the cover plate as well.

4. Use a dry cloth to wipe away the solvent.

5. Install the reservoir cover.

6. Replace the HPU filter element—see “Replacing the Return Line Filter”.

7. Add new hydraulic fluid to the reservoir.
A. Close the fluid drain.
B. Replace the filter in the transfer pump and transfer fresh hydraulic fluid

(filtered to 10 microns) into the reservoir. Stop when the fluid level is
full.

C. Reinstall the strainer assembly of the filter cap.

8. Run the HPU.
A. Press the Start switch.
B. Run the HPU in low pressure for three hours to clean the new hydraulic

fluid.

C. Run the HPU in high pressure to check for leaks.
D. Press the Stop button.
E. Check the dirty filter indicator. Replace the filter element as needed.

Model 505.07/.11 SilentFlo™ HPU Maintenance

65

Replacing the Hydraulic Fluid

66

Maintenance

Model 505.07/.11 SilentFlo™ HPU

Accessories

Contents High Pressure Filter Kit 68

Surge Suppressor Kit 69
Precharging the Surge Suppressor Accumulator 71
Lifting Kit 74
Caster Kit 75

Model 505.07/.11 SilentFlo™ HPU Accessories

67

High Pressure Filter Kit

High
Pressure
Port

Elbow

High
Pressure
Hose

High
Pressure
Output Port

Control Manifold

Filter
Assembly

Check Valve

Free
Flow

High Pressure Filter Kit

This section describes how to install the high pressure filter kit (part number 100­008-737).

To install the high pressure filter kit:

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

2. Remove the hose assembly connecting the high pressure port on the
manifold assembly to the high 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.

Replacing the Filter

68

Accessories

Element

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 and check for leaks.

The high pressure filter should be changed every 1000 hours or six months, or
when the Dirty Filter indicator is lit. You will need a filter element (MTS part
number 100-030-007) or a filter kit (MTS part number 100-030-194).

Model 505.07/.11 SilentFlo™ HPU

Surge Suppressor Kit

Optional Remote Charging Kit
consists of adapter, hose,
charging valve, and bulkhead
fitting that allows you to mount
the charging valve above the
fluid level for easier access

Fluid Level

Surge Suppressor Kit

To replace the filter:

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. Unscrew the filter bowl and remove the filter element.

3. Lift the filter element out of the filter bowl. Be careful to catch any
hydraulic fluid dripping from the filter element with a rag or drip pan.

4. Insert the replacement filter into the filter assembly.

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.

The surge suppressor kit smooths out the ripple caused by the pulsing action of
the pump as it pressurizes the hydraulic fluid. The surge suppressor is a cylinder
that has an outer sleeve that is pressurized with nitrogen. The gas pressurized
sleeve dampens the pressure pulses.

The surge suppressor is mounted to the output of the hydraulic pump inside the
reservoir.

Model 505.07/.11 SilentFlo™ HPU Accessories

69

Surge Suppressor Kit

Required equipment You will need the following to install the Surge Supressor kit:

• A Model 505.07 Surge Suppressor kit (part number 100-008-667) or a

Model 505.11 Surge Suppressor kit (part number 100-008-665).

• Optional Remote Charging kit (part number 100-056-912)

• A transfer pump with a 10-micron filter (such as the Model 590.01 Fluid

Transfer Pump).

• A cleaning solvent such as Synasol.

• A charging kit (part number 037-698-601).

Installation procedure To install the Surge Suppressor Kit.

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

2. Remove the electrical power to the HPU via a circuit breaker at the power
source.

3. Open the top cover of the HPU. Use a 8-mm (5/16-inch) allen wrench to
unlatch the cover.

4. Remove the filler cap and reservoir cover.

5. Remove the hydraulic fluid.
Use the transfer pump to remove the old hydraulic 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. Install the O-ring into the pump output port.

9. Install the surge suppressor assembly into the pump output port. Use the
hardware from the hose removed in Step 6.

10. Install the new hose between the surge suppressor assembly and the bottom
of the control manifold.

11. Precharge the surge suppressor.

12. If available, install the remote charging hose and bulhead fitting.

70

Accessories

13. Add new hydraulic fluid to the reservoir.
Pump hydraulic fluid (filtered to 10 microns) into the reservoir. Stop when

the fluid level is full. Reinstall the strainer assembly of the filter cap.
Change the filter.

14. Run the HPU and check for leaks.

Model 505.07/.11 SilentFlo™ HPU

A. Press the Start switch.
B. Run the HPU at low pressure for about three hours to filter the new

hydraulic fluid.

C. Run the HPU in high pressure to check for leaks.
D. Press the Stop button.

Precharging the Surge Suppressor Accumulator

It is normal for a small amount of surge suppressor precharge loss to occur during
operation. Because of this gradual reduction in precharge pressure, the pressure
should be checked and recharged (if necessary) at regular intervals.

Precharging the Surge Suppressor Accumulator

Determining a

pressure check

interval

Checking precharge

pressure

The precharge pressure checking intervals of your surge suppressor depends on
how your system is used. Vigorous use causes more rapid pressure loss and thus
requires checking and recharging more often.

Initially, check the surge suppressor precharge pressure every month or 160
operating hours. 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 each time the pressure is
checked. An increase in pressure loss during the period between checks may
indicate that the surge suppressor seals or bladder require replacement.

The nitrogen precharge should be about 50–60% of the output pressure. To check
the surge suppressor precharge:

1. Turn off the HPU and ensure that the pressure is at zero before proceeding.

2. Connect the charging kit chuck valve to the valve stem on the surge
suppressor, or to the remote charge valve on the reservoir top, if supplied.

3. With an open-end wrench, turn the locknut counterclockwise on the
accumulator valve assembly to open the valve. Read the pressure on the
high pressure gage.

• If the pressure reading is outside the range of 10.3–12.5 MPa (1500–

1800 psi), perform the procedure “Changing the precharge pressure.”

• If the pressure level is within the range of 10.3–12.5 MPa (1500–1800

psi), turn the locknut clockwise to close the valve and continue this
procedure.

Model 505.07/.11 SilentFlo™ HPU Accessories

71

Precharging the Surge Suppressor Accumulator

Low Pressure

High Pressure Gage
0–21 MPa (0–3000 psi)

Gage Protector
(factory set to
limit pressure to

Extension

Bleed

Input

Nitrogen Supply

Regulator

Nitrogen

Core-Type Valve

To Open and

Nitrog

Nitrogen

Regulator

Regulator

Y ou must supply these

Check

Lockn

Valve

Ope

Clos

Poppet-Type Valve

T o Op en and Close

Clos

Valve

Valve

Ope

Ope

Clos

4. Open the bleed valve on the accumulator charging kit and remove the chuck
valve from the accumulator. Replace the valve stem cap and protective
cover on the accumulator.

Charging Kit

Changing the

precharge pressure

The nitrogen precharge should be within the range of 10.3–12.5 MPa (1500–
1800 psi) which is 50–60% of the output pressure (21 MPa or 3000 psi). Perform
one of the following procedures to change the precharge pressure.

Decreasing pressure To decrease the precharge pressure:

1. Slowly open the bleed valve on the charging kit until gas begins to escape.
When the pressure reading on the appropriate pressure gage drops to the
level required, close the bleed valve.

2. Close the locknut. Open the bleed valve on the accumulator charging kit and
remove the chuck valve from the accumulator.

Increasing pressure To increase the precharge pressure:

3. Install the valve stem cap and protective cover.

1. Close the locknut on the surge suppressor.

2. Open the bleed valve two turns.

72

Accessories

Model 505.07/.11 SilentFlo™ HPU

Precharging the Surge Suppressor Accumulator

WARNING

CAUTION

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 bottle valve. Check the nitrogen bottle pressure gage on
the regulator. (The bottle must contain sufficient pressure to provide an
adequate gas volume.)

5. Monitor the regulator output pressure gage and adjust the regulator output
pressure valve to the required level.

Avoid rapid and extreme pressure transitions.
Rapid flow rates with pressure differentials of more than 2.1 MPa (300 psi)

across the input check valve can damage the valve seal(s).

Do not allow rapid flow rates. Open the regulator shut-off valve only far enough to
permit a gradual transfer of gas.

6. Slowly open the regulator shut-off valve until gas is heard escaping from the
accumulator charging kit bleed valve.

A. Allow gas to slowly escape for approximately ten seconds, and then

close the bleed valve.

B. Immediately close the regulator shut-off valve before the pressure

reading on either the high or low charging kit pressure gage exceeds the
pressure level of the accumulator.

7. Open the locknut. Slowly open the regulator shut-off valve until the pressure
indicator on either the high or low charging kit pressure gage begins to rise.
When the pressure is at the required pressure level, close the regulator shut­off valve.

8. Close the locknut.

9. Open the bleed valve on the charging kit and remove the chuck valve from
the accumulator.

10. Install the valve stem cap and protective cover. Close the valve on the
nitrogen bottle.

Model 505.07/.11 SilentFlo™ HPU Accessories

73

Lifting Kit

CAUTION

Slings

Brackets

Bracket

Lifting Kit

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 moving the HPU, test the balance of the lift by raising the HPU a short
distance off the ground.

The lifting kit (part number 100-036-287) includes support brackets, slings, chain
connectors, eyebolts, and hardware to allow the hydraulic power unit to be lifted
and moved by an overhead device (such as an overhead crane). The support
brackets and slings help distribute the weight of the HPU so it is balanced when it
is lifted.

The slings and brackets should be positioned as shown.

74

Accessories

Lifting Support Brackets and Slings

Model 505.07/.11 SilentFlo™ HPU

Caster Kit

Caster Kit

The caster kit (part number 100-025-327) is a couple of channel supports with
casters (two rigid, two locking swivel) connected by support angle brackets. The
caster kit allows the hydraulic power unit to be easily moved. The caster kit is
designed to hold the Model 505.07 or Model 505.11.

M

ODEL APPROXIMATE WIEGHT (WITH FLUID)

505.07 451 kg (992 lb)

505.11 474 kg (1042 lb)

Caster Kit

Model 505.07/.11 SilentFlo™ HPU Accessories

75

Caster Kit

76

Accessories

Model 505.07/.11 SilentFlo™ HPU

Appendix A: HPU Maintenance and Service Logs

Contents 8 Hours/Daily 78

40 Hours/Weekly 79
160 Hours/Biweekly 80
500 Hours 81
1000 Hours 82
2000 Hours 83
5000 Hours 84
10,000 Hours 85

Appendix A: HPU Maintenance and Service Logs

77

8 Hours/Daily

8 Hours/Daily

8 Hours/Daily Service Interval Recommendation

HECK CONSOLE

C

ERIFICATION

V

CHECK DIRTY

ILTER

F

NDICATORS

I

CHECK FOR

EAKS

L

CHECK OIL

EVEL

L

CHECK

RESSURE

P

DATE PERFORMED BY PERFORMED BY PERFORMED BY PERFORMED BY PERFORMED BY NOTES

78

Appendix A: HPU Maintenance and Service Logs

40 Hours/Weekly

40 Hours/Weekly

40 Hours/Weekly Service Interval Recomme ndation

HECK FLUID

C

OLOR AND ODOR

C

DATE PERFORMED BY PERFORMED BY NOTES

CHECK INTERLOCK

EVICES

D

Appendix A: HPU Maintenance and Service Logs

79

160 Hours/Biweekly

160 Hours/Biweekly

160 Hours/Monthly Service Interval Recommendation

HECK CABLES AND

C

ONNECTORS

C

DATE PERFORMED BY PERFORMED BY NOTES

CHECK C ONSOLE

IR FILTER

A

80

Appendix A: HPU Maintenance and Service Logs

500 Hours

500 Hours

500 Hours Service Interval Recommendation

HECK ALL

C

CCUMULATOR

A

FOR PROPER

S

RECHARGE

P

RESSURE AND

P

IL

O

ATE PERFORMED BY PERFORMED BY PERFORMED BY PERFORMED BY PERFORMED BY PERFORMED BY NOTES

D

CHECK

ONDITION OF

C

LL ELECTRICAL

A

ABLES AND

C

ABLE

C

ONNECTIONS

C

CHECK HPU

YDRAULIC

H

LUID COLOR,

F

AND ODOR

CHECK HPU

PERATING

O

RESSURE AND

P

EMPERATURE

T

CLEAN

ONTROL

C

ABINET AIR

C

ILTER,

F

EPLACE IF

R

EQUIRED

R

INSPECT HEAT

XCHANGER FOR

E

EAKS OR

L

FLOW (WHEN

“

OFF)”

500 Hours Service Interval Recommendation

NSPECT PUMP

I

OSES FOR

H

EAKS

L

LUBRICATE-

REASE MOTOR

G

EARINGS (NON-

B

505)

V

ERIFY DIRTY
ILTER

F

NDICATORS

I

TATUS

S

VERIFY HPU

YDRAULIC F LUID

H

EVEL

L

VERIFY WARNING

AND INTERLOCK

EVICES

D

DATE PERFORMED BY PERFORMED BY PERFORMED BY PERFORMED BY PERFORMED BY NOTES

Appendix A: HPU Maintenance and Service Logs

81

1000 Hours

1000 Hours

1000 Hours Service Interval Recommendation

LL 500 HR

A

AINTENANCE

M

ROCEDURES

P

REPLACE ALL

ILTERS

F

VERIFY

PERATION AND

O

ETTINGS OF PSI

S

ONTROL AND

C

ELIEF VALVES

R

DATE PERFORMED BY PERFORMED BY PERFORMED BY NOTES

82

Appendix A: HPU Maintenance and Service Logs

2000 Hours

2000 Hours

500 Hours Service Interval Recommendation

LL 1000 HR

A

AINTENANCE

M

ROCEDURES

P

CHECK PUMP/

OTOR

M

OUPLING FOR

C

EAR AND

W

EBRIS

D

CHECK PUMP

OLTAGE AND

V

URRENT

C

CHECK CASE

RAIN FLOW

D

RECOMMEND
MTS

YDRAULIX OIL

H

AMPLE

S

DATE PERFORMED BY PERFORMED BY PERFORMED BY PERFORMED BY PERFORMED BY NOTES

Appendix A: HPU Maintenance and Service Logs

83

5000 Hours

5000 Hours

500 Hours Service Interval Recommendation

ECOMMEND R/R

R

EAT EXCHANGER

H

DATE PERFORMED BY PERFORMED BY NOTES

RECOMMEND

EPLACEMENT OF

R

OTOR BEARINGS

M

84

Appendix A: HPU Maintenance and Service Logs

10,000 Hours

10,000 Hours

500 Hours Service Interval Recommendation

ECOMMEND R/R

R

EAT EXCHANGER

H

RECOMMEND

EPLACEMENT

R

OF HOSES

RECOMMEND

EPLACEMENT

R

OF MOTOR

EARINGS

B

RECOMMEND

EPLACEMENT

R

OR REBUILD OF

UMP

P

RECOMMEND

EPLACEMENT

R

OR REBUILD OF

OTOR

M

RECOMMEND

YDRAULIC FLUID

H

HANGE & CLEAN

C

UMP INLET

P

DATE PERFORMED BY PERFORMED BY PERFORMED BY PERFORMED BY PERFORMED BY PERFORMED BY NOTES

Appendix A: HPU Maintenance and Service Logs

85

10,000 Hours

86

Appendix A: HPU Maintenance and Service Logs

87

88

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]
http://www.mts.com

ISO 9001 Certified QMS