MTS 512-14 User Manual

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Model 512.14 Hydraulic Power Unit Product Information

100-103-876 B

Trademark information MTS is a registered trademark of MTS Systems Corporation.

DTE is a registered trademark of Mobil Corporation.

Tellus is a registered trademark of Shell Oil Corporation.

Synasol is a registered trademark of Union Carbide Corporation

Contact information MTS Systems Corporation

14000 Technology Drive Eden Prairie, Minnesota 55344-2290 USA Toll Free Phone: 800-328-2255 (within the U.S. or Canada) Phone: 952-937-4000 (outside the U.S. or Canada) Fax: 952-937-4515 E-mail: info@mts.com http://www.mts.com

Publication information

Manual Part Number Publication Date

100-103-876 A March 2004

100-103-876 B November 2005

Contents

Introduction 5

Component Identification 6

Functional Description 8

Specifications 10

Dimensions 11

Installation 13

Operation 17

Running the HPU 18

Recovering From an Interlock Condition 20

Reducing the Fluid Temperature 21

Adjusting the Air Flow 22

Adjusting the Water Flow 23

Resetting the Thermal Overloads 24

Adjusting the Output Pressure 25

Maintenance 27

Checking the Hydraulic Fluid 29

Replacing the Filter 31

Sampling the Hydraulic Fluid 32

Adding Hydraulic Fluid 35

Replacing the Hydraulic Fluid 36

Lubricating the Motor 39

512.14 Hydraulic Power Unit Contents

Contents

512.14 Hydraulic Power Unit

Introduction

Contents Component Identification 6

The Model 512.14 Hydraulic Power Unit (HPU) provides high-pressure hydraulic fluid for test system operation. This compact hydraulic power unit is designed for use with low force testing systems. The HPU is available with a water–cooled or an air–cooled heat exchanger.

This section contains the functional description and specifications of the HPU (also called a hydraulic power supply, or pump).

Functional Description 8

Specifications 10

Dimensions 11

Water Cooled Air Cooled

Model 512.14 Hydraulic Power Unit

512.14 Hydraulic Power Unit Introduction

Component Identification

Water-Cool ed

Pressure Gage

Sight Glass

Control Box

Pump Motor

Reservoir

Air-Cooled

Filter Change Gage

Filter

Heat Exchanger

Control Box

Pressure Gage

Sight Glass

Pump Motor

Heat Exchanger (Detached)

Reservoir

Major Components (Side View)

Introduction

512.14 Hydraulic Power Unit

Component Descriptions

Component Description

Component Identification

Control Box

Pressure Gage

Sight Glass

Reservoir

Heat Exchanger

Filter

Low Fluid and Overtemperature Sensor

Filter Change Gage

Houses the electronic controls of the pump, including the Stop button, and Low/High switch. It also houses the thermal overloads to protect the pump

motor. See “Resetting the Thermal Overloads” on page 24.

Shows the current output pressure from the hydraulic power unit. The output pressure is factory set to 21MPa (3000 psi). See “Adjusting the Output

Pressure” on page 25 to change the output pressure.

Combines a thermometer with a sight glass. You can quickly check the hydraulic fluid’s temperature, level, and condition (by its color).

Stores the hydraulic fluid. The reservoir has a 57 L (15 gal) capacity. It includes a magnetic drain plug to help catch metal particles.

Cools the hydraulic fluid. The heat exchanger can be either water-cooled or aircooled. See “Adjusting the Air Flow” on page 22 and “Adjusting the Water

Flow” on page 23 for more information.

Provides 3–micron filtration to fluid returning to the reservoir (see “Replacing

the Filter” on page 31).

(Not shown) Shuts the pump off if fluid gets too low or becomes hotter than 75ºC (160ºF). See “Reducing the Fluid Temperature” on page 21 or “Adding

Hydraulic Fluid” on page 35 for more information.

Shows when it’s time to change the hydraulic filter. The gage is marked with three zones; green, yellow, and blue.

Pump Motor

Green—The filter is good to use.

Yellow—Change the filter soon.

Red—Do not run the HPU until you have replaced the hydraulic filter element.

Drives a fixed displacement gear pump.

Pumps a 12.5 lpm output at 21 MPa (3.3 gpm at 3000 psi) @ 50 Hz.

Pumps a 15.1 lpm output at 21 MPa (4 gpm at 3000 psi) @ 60 Hz.

512.14 Hydraulic Power Unit Introduction

Functional Description

The hydraulic power unit (HPU) is the mechanical source of high-pressure hydraulic fluid required to operate the hydraulic components of a test system. See

“Component Identification” on page 6 for more information about the

components discussed in this section.

Pump A motor drives a hydraulic pump which draws hydraulic fluid from a reservoir

and pressurizes it to 21 MPa (3000 psi). The pressurized fluid is made available to the hydraulic components in your test system.

Pressure The HPU can produce low and high pressure outputs:

• The low pressure output is approximately 1.4 MPa (200 psi). Low pressure

is normally used while installing a specimen.

• The high pressure can be adjusted to 21 MPa (3000 psi) or less. High

pressure is used for an actual test. When operating in high pressure, the lowpressure vent is blocked.

Filtering The filtration system protects against silting by cleaning the hydraulic fluid to an

ISO particle count of 16/13/9 or better. The filter change gage indicates when the filter needs to be replaced.

A suction strainer protects the pump from larger particles when the fluid is pumped from the reservoir. It is located in the bottom of the hydraulic fluid reservoir.

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

fluid. The heat exchanger helps keep the temperature of the hydraulic fluid between 64–68°C (147–155°F). The temperature of the fluid is monitored by an overtemperature switch. If the fluid temperature exceeds 75ºC (170ºF), a switch opens and shuts down the HPU. The system cannot be restarted until the fluid cools. There are two kinds of heat exchangers:

• The water-cooled heat exchanger cools the hydraulic fluid as it passes over

water-filled tubes. A regulating valve can adjust the flow of water through the tubes, and this affects the amount of cooling the heat exchanger can accomplish.

• The air-cooled heat exchanger cools the hydraulic fluid as it passes through

a radiator. A fan blows air through the radiator to transfer heat from the radiator to the air. Louvers control the airflow over the hydraulic radiator, and this affects the amount of cooling the heat exchanger can accomplish.

Note For additional information, see the Heat Exchanger Care and Water

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

Introduction

512.14 Hydraulic Power Unit

Functional Description

Electronics The HPU has basic controls to turn it on to low pressure or high pressure and to

turn it off. The HPU includes an Emergency Stop switch that is connected to the interlock chain of your test system.

A hydraulic interlock can be generated by the hydraulic power supply if one of the following occurs:

• Low hydraulic fluid level

• High hydraulic fluid temperature

Hydraulic schematic The hydraulic schematic shows how the hydraulic components are connected in

the Model 512.14 Hydraulic Power Unit. Both types of heat exchangers are shown.

Pressure

Gage

Pressure

Motor

Pressure -8

37° JIC Flare

Relief Valve

0.714 MPa

(1002000 psi)

Check

Valve

Pump

Return -8

37° JIC Flare

0.125

See Heat

Exchangers

High/Low

Pressure Solenoid

Drain -06

SAE

Water Out

1/2 ID Hose

Water-Cooled Heat Exchanger

Fan and Motor

Water In

1/2 ID Hose

1/2 NPT

Strainer

Reservior

512.14 Hydraulic Power Unit Introduction

Filter

Overtemperature

Switch

Low Fluid

Switch

Air-Cooled Heat Exchanger

Specifications

Environmental

Parameter Specification

Operating temperature (ambient air)

Heat load

Noise rating† at 1 m

Pump

Flow capacity

Motor rating

Operating voltage

Hydraulic fluid

Nominal temperature

Filtration (microns)

Reservoir capacity

Maximum pressure

Heat exchanger

18–40°C (65–104°F)

1061 kcal/hr (4200 BTU/hr)

74 dB (A)

12.5 lpm (3.3 gpm) @ 50 Hz

15.1 lpm (4 gpm) @ 60 Hz

5.6 kW (7.5 hp)

208 V (AC) @ 24.2 A, 3 phase 230 V (AC) @ 22.0 A, 3 phase 460 V (AC) @ 11.0 A, 3 phase

Mobil DTE 25

63°C (145°F)

3 microns absolute

57 liters (15 gallons)

20.7 MPa (3000 psi)

Water cooled or air cooled

or Shell Tellus® 46 AW

Introduction

Flow requirements

Water pressure (differential)

Max input pressure

Cooling

Water hose

Hydraulic connections

Pressure Return Drain

Weight 115 kg (250 lb)

Specification is for 60 Hz operation.

†

Free field value [74 db. Your readings may be up to 10 db (A) more.

13 lpm @ 21°C (3.5 gpm @ 70°F)

0.2 MPa (30 psi)

1 MPa (150 psi)

4892 Kcal/hr (19,410 BTU/hr)

12.7 mm (0.5 in)—inside diameter

each requires a 37° flare

-8

-6

512.14 Hydraulic Power Unit

Dimensions

The following figure shows those dimensions which are useful when installing the hydraulic power unit.

Water Cooled

610 mm

(24 in)

610 mm

(24 in)

Air Cooled

671 mm (26.4 in)

406 mm

(16 in)

335 mm (13.2 in)

864 mm

(34 in)

559 mm

(22 in)

508 mm

(20 in)

512.14 Hydraulic Power Unit Introduction

Dimensions

Introduction

512.14 Hydraulic Power Unit

Installation

This section describes how to install a Model 512.14 Hydraulic Power Unit.

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. Since it is connected to the other hydraulic equipment through hydraulic lines, the HPU can be located remotely. Considerations include:

• The air cooled HPU must be located where adequate air movement for

cooling can occur.

• The water cooled HPU requires a source of water.

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

• The HPU produces 74 dB of sound pressure level in a free field acoustic

environment.

• The base of the HPU has four holes that may be used to secure the unit in

place.

Emergency Stop

Connection

Return Line Connection

Cooling Water In

Water Valve

Drain Line Connection

Pressure Line Connection

Connection Locations (Top View)

512.14 Hydraulic Power Unit Installation

Cooling Water Out

2. Connect the hydraulic lines.

See “Connection Locations (Top View)” on page 13 to determine the locations of the hydraulic connections to the HPU. The following table lists the size of each hydraulic connection.

Connector Size

Pressure, 37º flare -8

Return, 37º flare -8

Drain, 37º flare -6

3. Connect the water lines to the heat exchanger.

Note This applies only to the water-cooled version of the HPU.

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 0.2 MPa (30 psi). The maximum allowable water inlet pressure is 1 MPa (150 psi).

The water supply must be capable of maintaining the water flow rate given in the table, “Specifications” on page 10.

See “Connection Locations (Top View)” on page 13 to determine the locations of the water connections.

4. Connect an external Emergency Stop switch.

An optional Emergency Stop switch can be connected to the 14–pin CPC connector located on the control box. Before you can use this connector, remove the jumper from pins 1 and 3 located on the terminal block in the control box (see “Electrical Schematic” on page 15).

5. Connect the electrical service to the HPU.

Note Electrical connections must be made by qualified personnel and conform

to local codes and regulations. Local electrical codes supersede any information found here.

A. Open the control box.

B. Open a knock-out hole.

C. Install a wire grommet.

D. Feed the line through the grommet into the control box.

E. Connect the power source lines (L1–L3) to the terminal blocks

according to the required line voltage. See “Electrical Schematic” on page 15.

Installation

F. Connect the ground to the lug identified with a sticker showing the

ground symbol.

512.14 Hydraulic Power Unit

Three Phase

Remove Jumper if

Remote Emergency Stop

Switch Connected

1 A

1 FU

115 V (ac)

Varistor

Remote

Emergency

Stop Switch

CPC-14S

Stop Switch

Pressure

Start Switch

Low

High

Pressure

SS1

M1

TAS

T-1 Below

77° C (170° F)

Electrical Schematic

Low Fluid

Switch (opens at 70% full)

Varistor

SOV

Fan and Motor

(air-cooled only)

512.14 Hydraulic Power Unit Installation

Installation

512.14 Hydraulic Power Unit

Operation

Contents Running the HPU 18

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

Recovering From an Interlock Condition 20

Reducing the Fluid Temperature 21

Adjusting the Air Flow 22

Adjusting the Water Flow 23

Resetting the Thermal Overloads 24

Adjusting the Output Pressure 25

512.14 Hydraulic Power Unit Operation

Running the HPU

The following procedure is a guideline, and it assumes you are starting the hydraulic power unit (HPU) after the it has been turned off for some time (the hydraulic fluid is considered cool). You may want to incorporate portions of this procedure into your system startup sequence.

1. Check the fluid level in the sight gage.

The hydraulic fluid should be close to the top of the sight glass. If you need to add fluid, add 1 liter (1 quart) at a time.

Normal Fluid Level

Low Fluid Level

Check the Fluid Level

2. At your test controller, make sure hydraulic pressure is turned off.

Note Some controllers can remotely control the HPU.

3. Turn the start switch to LOW PRESS and wait for the motor to get up to speed.

Turn this switch to HIGH PRESS.

LOW

PRESS.

START

HIGH

PRESS.

LOW

START

HIGH

PRESS.

Operation

4. Check to make sure the filter change gage’s needle stays in the green zone.

Turn the HPU off and change its filter if the needle stays in the yellow or red zones.

Note Cold fluid may push it temporarily into the red zone.

512.14 Hydraulic Power Unit

Running the HPU

CAUTION

Do not run the HPU if the filter gage is in the red region.

When the gage needle stays in the red zone, some hydraulic fluid is bypassing the filter. This unfiltered fluid can wear or damage hydraulic components.

Turn the HPU off when the filter gage reaches the red zone and change the filter.

Yellow Zone (warning to change)

Green Zone (normal)

Red Zone (do not operate)

Check the Filter Change Gage

5. Check the output pressure gage for the correct output pressure. The pressure is factory set for 21 MPa (3000 psi).

6. Run the HPU for 20–30 minutes to get the hydraulic fluid up to operating temperature of 64–68°C (147–155°F).

Once the hydraulic fluid is up to the operating temperature, you can use the hydraulic system.

7. To turn the HPU off, switch to LOW PRESS, then press the STOP switch.

STOP

In the event of an emergency, press the STOP switch or the optional Emergency Stop switch.

8. If your HPU is water cooled, make sure the heat exchanger’s water valves are closed.

512.14 Hydraulic Power Unit Operation

Recovering From an Interlock Condition

Abnormal shutdowns Any one of the following conditions can cause your HPU to suddenly shut down.

You will not be able to restart your HPU until you correct the condition.

Interlock Conditions

Problem Solution

The hydraulic fluid exceeds 75ºC (160ºF). See “Reducing the Fluid

Temperature”

on page 21.

The hydraulic fluid cannot be seen in the sight glass (or it is at a low level).

A tripped thermal overload or blown fuse in the control box removed power from the unit.

See “Adding Hydraulic Fluid”

page 35

See “Resetting the Thermal

Overloads”

on page 24.

Operation

512.14 Hydraulic Power Unit

Reducing the Fluid Temperature

The hydraulic power unit (HPU) will be shut down if the hydraulic fluid reaches a temperature of 77°C (170° F).

77ºC (170ºF)

Note The thermometer is for reference only. Use a calibrated thermometer

submersed in the reservoir for an accurate reading.

To reduce the fluid temperature, you need to make adjustments to the heat exchanger.

• If you have the air-cooled version go to “Adjusting the Air Flow” on page

22.

• If you have the water-cooled version go to “Adjusting the Water Flow” on

page 23.

512.14 Hydraulic Power Unit Operation

Reducing the Fluid Temperature

Adjusting the Air Flow

Air-cooled heat exchangers use louvers to control airflow through the exchanger. You may have to adjust them to keep the fluid’s temperature between 64 and 68ºC (147 and 155ºF).

Adjust

Adjust the Louvers

Make sure the louvers are fully open.

1. Turn the start switch to LOW PRESS and hold it there to override the shutdown.

If overheated fluid caused the shutdown, the HPU will now start to run.

PRESS.

LOW

START

HIGH

PRESS.

Keep holding the start switch to LOW PRESS until the HPU stays running when

you let go of this switch. (It can take up to

hold

two hours for the fluid to cool down if you do not run the HPU.)

If the HPU still does not run, some other condition has caused the shutdown.

2. Set the HPU’s output to HIGH PRESS. Put the HPU in a no-flow condition (no fluid flowing to other hydraulic equipment).

3. Let the HPU run for 15 minutes to stabilize the fluid temperature. Check the fluid temperature in the sight glass.

• If the temperature is between 64 and 68ºC (147 and 155ºF), stop.

Operation

• If not, open or close the louvers as needed and repeat this step.

512.14 Hydraulic Power Unit

Adjusting the Water Flow

On water-cooled heat exchangers, the water control valve regulates the flow of water through the exchanger. MTS sets this valve to keep the hydraulic fluid temperature between 64 and 68ºC (147 and 155ºF).

An out-of-adjustment water control valve can cause rapid overheating.

Check the Heat Exchanger

Changes in your water supply’s temperature may require adjustment of this valve.

Reducing the Fluid Temperature

Water Valve

1. Start with the hydraulic fluid at room temperature. Make sure the heat exchanger’s water supply valves are open.

2. Turn the start switch to LOW PRESS. Then turn the switch to HIGH PRESS.

Put the HPU into a no-flow condition (where no fluid is flowing to other hydraulic equipment).

3. Run the HPU for approximately 15 minutes to stabilize the temperature. Check the fluid temperature in the sight glass.

• If the temperature is between 64 and 68ºC (147 and 155ºF), stop.

• If the temperature is

outside the operating temperature range, turn the valve’s screw to raise

Decrease

Increase

or lower the water temperature and repeat this step. (Do not turn the

1/2 Turn Maximum

valve screw more than 1/2 turn at a time).

–Adjust the valve screw clockwise to decrease the reservoir

temperature.

–Adjust the valve screw counterclockwise to increase the reservoir

temperature.

512.14 Hydraulic Power Unit Operation

Resetting the Thermal Overloads

The thermal overloads of the hydraulic power unit (HPU) can be tripped by the following conditions:

• Poor motor ventilation

• The output pressure is set too high

• A pump or motor is seizing

The thermal overloads are located in the control box.

CAUTION

Do not open the control box unless the line voltage is turned off. When power is present in the control box, high voltage and amperages are also present.

You can be electrocuted if you touch the wrong component in the control box.

Disconnect the HPU from power before opening the control box.

1. Check the thermal overloads of the power source to the HPU.

• If it has tripped, reset it and try restarting the HPU.

• If the thermal overloads have not

tripped, remove power from the

Inside Control Box

HPU before opening the control panel.

Tripped Indicator

2. Unscrew the clamps holding the control panel’s door shut.

Reset

3. Check the thermal overloads tripped

Button

indicator. If it has tripped, press RESET on the overload.

4. Check for a blown fuse. The replacement fuse must have the same rating as the blown fuse.

Thermal Overloads

Fuse

5. Shut the control box door. Use the clamps to hold it in place.

Operation

6. Reconnect the HPU to its electrical power source.

7. Restart the HPU. If the HPU will not restart or shuts down right away, call MTS.

512.14 Hydraulic Power Unit

Adjusting the Output Pressure

The HPU comes with its output pressure set at 21 MPa (3000 psi). Special testing needs may require you to lower this pressure.

Output Pressure Adjustment

Adjusting the Output Pressure

CAUTION

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

Setting the output pressure above 21 MPa (3,000 psi) can damage the pump and its motor.

Set the output pressure no higher than 21 MPa (3000 psi).

Procedure To adjust the output pressure:

1. Set the HPU’s output to HIGH PRESS. Put the HPU into a no-flow condition (where no fluid is flowing to other hydraulic equipment).

2. Wait for the fluid to reach the operating temperature of 64 and 68ºC (147 and 155ºF).

3. Hold the setscrew with a 5/32–inch hex key. Loosen the locknut with a 9/ 16–inch wrench.

512.14 Hydraulic Power Unit Operation

Adjusting the Output Pressure

Pressure Gage

Locknut

Setscrew

4. Turn the setscrew while watching the gage until you get the output pressure you want.

5. Hold the setscrew and tighten down the locknut.

Operation

512.14 Hydraulic Power Unit

Maintenance

Contents Checking the Hydraulic Fluid 29

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

Replacing the Filter 31

Sampling the Hydraulic Fluid 32

Adding Hydraulic Fluid 35

Replacing the Hydraulic Fluid 36

Lubricating the Motor 39

Scheduling

maintenance

What to Do When to Do It How to Do It

Make daily visual inspections

Check fluid quality and condition

Check functionality of warning and interlock devices

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

Maintenance Schedule (part 1 of 2)

Before the start of each day’s testing.

Every 40 hours or 1 week. Compare the condition of the fluid to that of

Every 40 hours or 1 week. Depress emergency stop button(s) to verify

Check the fluid level in the sight gage and replenish as required.

Look for signs of fluid leakage.

Check status of dirty filter indicator and replace filter if required.

Check system operating pressure and adjust as required.

your sample, including odor and color.

Perform “Checking the Hydraulic Fluid” on page 29.

that warning and interlock devices are functioning properly.

Conduct external inspection of the heat

exchanger

Inspect hydraulic hoses, replace as required

Replace fluid filter

512.14 Hydraulic Power Unit Maintenance

Every 500 hours or 3 months. Look for dents, bulges, and leaks, damaged

gaskets, corrosion, and worn, frayed, or leaking hoses.

Every 1000 hours or 6 months Look for signs of wear, check for fluid leaks,

tighten connections as needed.

Every 1000 hours or 6 months, or when the filter gage needle stays in the yellow or red zone; and whenever you replace the hydraulic fluid.

Perform “Replacing the Filter” on page 31.

Maintenance Schedule (part 2 of 2)

What to Do When to Do It How to Do It

Verify functionality of

HPU interlocks

Lubricate pump motor

Check motor overload

functionality

Verify proper operation of

hydraulic valves

Conduct a hydraulic fluid analysis

Replace hydraulic fluid

Conduct internal inspection of heat

exchanger

†

‡

*,†

Every 1000 hours or 6 months Contact MTS Systems Corporation.

Every 1000 hours or 6 months Perform “Lubricating the Motor” on page 39.

Every 1000 hours or 6 months Contact MTS Systems Corporation.

Every 6 months or sooner if duty is severe

‡

Obtain a sample and submit it for analysis. Most oil or other qualified companies can analyze hydraulic fluid or consult MTS Systems Corporation.

Perform “Sampling the Hydraulic Fluid” on page 32.

Every 6 months or sooner if fluid analysis is not to specifications.

Perform “Replacing the Hydraulic Fluid” on page 36.

Yearly, or every 2000 hours Look for signs of fouling or corrosion,

conduct chemical or mechanical internal cleaning as inspection warrants.

Consult the Heat Exchanger Care Guide for more information.

Check case drain flow of hydraulic pump

Replace heat exchanger

Yearly, or every 2000 hours Contact MTS Systems Corporation.

†

Every 3 years or 5,000 hours Replace as inspection warrants. Contact MTS

Systems Corporation for special training.

†

Replace motor bearings

Replace hydraulic hoses,

motors, pumps

†

Every 3 years or 5,000 hours Contact MTS Systems Corporation.

Every 5 years or 10,000 hours Replace as inspection warrants. Hydraulic

pumps may be rebuilt or replaced as required by inspection. Motors may be rewound or replaced as required by inspection. Contact MTS Systems Corporation for special training.

*See the MTS Heat Exchanger Care Guide (part number 015-164-000). † Special training required. Contact MTS Systems Corporation. ‡See the MTS 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.

Maintenance

512.14 Hydraulic Power Unit

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.

To 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 MTS Hydraulic Fluid Care Guide.

Important To prevent problems with inconsistent and inferior fluids, MTS

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

Procedure Perform the following visual and olfactory checks of the hydraulic fluid's

condition weekly. If you suspect contamination of the hydraulic fluid, take a sample and have it analyzed.

Checking the Hydraulic Fluid

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

• 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,” on page 33 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.

512.14 Hydraulic Power Unit Maintenance

Checking the Hydraulic Fluid

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

• Hydraulic fluid temperature stabilizes within the parameters given in

“Specifications” on page 10 when the HPU is operating at high

pressure.

If you need to adjust the water-regulating valve, refer to “Adjusting the

Wate r F low” on page 23.

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

static value.

If you need to adjust the pressure control valves, refer to “Adjusting the

Output Pressure” on page 25.

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

Other system adjustments are described in the Operation chapter.

Maintenance

512.14 Hydraulic Power Unit

Replacing the Filter

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

• When the filter change gage’s needle stays in the yellow or red zone with the

hydraulic fluid at operating temperature

• Whenever the hydraulic fluid is changed

• The filter manufacturer’s recommended maximum interval has passed

(1000 hours or 6 months)

Prerequisite You will need an oil filter wrench and a 3–micron oil filter (MTS part number

119515-21).

Procedure Perform the following procedure to change the filter element.

1. Press STOP to turn off the HPU.

2. Check the output pressure gage. Ensure that the pressure is at zero before proceeding.

Replacing the Filter

3. Use an oil filter wrench to loosen the old filter. Screw the filter counterclockwise to remove it.

Change Filter when needle stays in yellow or red zone

CCW

4. Wet the new filter’s gasket with clean hydraulic fluid.

5. Screw the filter clockwise to install it. Turn the new filter until the gasket touches its sealing surface, then hand tighten the filter 1/2 turn.

Note Tightening the filter with a wrench will not make it seal better, but it will

make it more difficult to remove.

6. Start the pump in low to purge the air from the hydraulic lines and components.

7. Set the HPU’s output to HIGH PRESS. Let the HPU run a few minutes and check for leaks.

512.14 Hydraulic Power Unit Maintenance

Sampling 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.

– 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.

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

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

• 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

into the bottle.

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

fluid analysis kit (MTS part number 011-860-301) or a clean, 180 ml sample bottle.

Adapter

Needle Valve

Hose Valve Assembly for Fluid Sampling

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.

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.

Maintenance

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.

512.14 Hydraulic Power Unit

Sampling the Hydraulic Fluid

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. The table,

Appearance of Hydraulic Fluid Sample, below indicates 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 (part 1 of 2)

Fluid Properties Problem What to Do

Dark colored fluid

Indicates chemical breakdown or the hydraulic fluid has been allowed

Analyze the fluid and replace as

required by the analysis. to rise above the maximum recommended temperature (severe overheating)

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.

Burnt odor

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.

Opaque fluid

Indicates chemical breakdown Replace the fluid

512.14 Hydraulic Power Unit Maintenance

Sampling the Hydraulic Fluid

Fluid Properties Problem What to Do

Appearance of Hydraulic Fluid Sample (part 2 of 2)

Milky appearance

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

Indicates water is present in the fluid

Indicates collapsed, ruptured, or clogged filter(s)

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 the filter element.

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

Maintenance

512.14 Hydraulic Power Unit

Adding Hydraulic Fluid

1. The hydraulic power unit (HPU) will shut down when fluid drops below the sight glass. Normally, it should be close to the top of the sight glass.

No Fluid Visible

Adding Hydraulic Fluid

Normal Level

CAUTION

Check the Fluid Level

Do not mix different brands of hydraulic fluid.

Mixing different brands of hydraulic fluid can contaminate your system.

Call MTS if you’re not sure what brand of hydraulic fluid your system uses.

Note New fluid should be prefiltered with a 10 micron filter since it may not be

clean.

2. Open the filler cap. Add 1 liter (1 quart) of fluid at a time until the fluid level is normal.

3. Replace the cover cap.

4. Start the HPU.

512.14 Hydraulic Power Unit Maintenance

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)

• A 125 kg (250 lb) capacity hoist

• Synasol® or a similar cleaning solvent

• Lint-free cloths or manufactured rags

• A container for the used hydraulic oil and a 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 Filter” on page 31)

Prerequisite Perform the procedure “Sampling the Hydraulic Fluid” on page 32 to determine

if the hydraulic fluid should be replaced.

Identify and correct any sources of contamination.

CAUTION

Mixing different brands of hydraulic fluid can contaminate your system.

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

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

Procedure 1. Prepare the HPU.

Maintenance

A. Press STOP to turn off the HPU.

B. Remove electrical power to the HPU via the circuit breaker at the

power source or by unplugging the HPU.

C. Remove the filler cap’s strainer assembly.

512.14 Hydraulic Power Unit

Filler Cap

Replacing the Hydraulic Fluid

2. Remove the hydraulic fluid.

A. Remove the transfer pump’s filter (you do not need to filter the dirty

hydraulic fluid when removing it).

B. Use the transfer pump to remove the old hydraulic fluid from the

reservoir.

C. Remove the drain plug to drain any remaining fluid.

D. Drain the hydraulic fluid from hoses and accumulators in the system.

Reservoir Cover Screws (one each

Stop Switch

Sight Gage

Filter

Hydraulic Fluid Hoses (to the heat exchanger)

Reservoir

Drain

Component Locations (Top and Side Views)

512.14 Hydraulic Power Unit Maintenance

Replacing the Hydraulic Fluid

CAUTION

Synasol is toxic and flammable.

Use the Synasol solvent in a ventilated area and keep it away from an open flame.

Follow the cautions and warnings on its container.

3. Clean the reservoir.

A. Disconnect the heat exchanger’s two hydraulic fluid lines.

B. Unscrew the cover screws attaching the cover plate to the reservoir.

C. Attach straps to the cover plate’s two lifting eyes. Lift the cover plate

clear of the reservoir.

D. Clean the inside of the reservoir using clean cloths dampened with

Synasol. Clean the pump and bottom of the cover plate as well.

E. Inspect the pump’s suction strainer. Replace this strainer if it is plugged

or damaged.

F. Lower the cover plate back down onto the reservoir.

G. Wipe off the magnetic drain plug and install it.

H. Tighten the four screws that attach the cover plate to the reservoir.

4. Add new hydraulic fluid to the reservoir.

A. Close the fluid drain.

A. Install the transfer pump’s 10–micron filter.

B. Pump clean hydraulic fluid into the reservoir. Stop when the fluid level

gets close to the top of the sight glass.

C. Install the filler cap’s strainer assembly.

5. Replace the HPU filter (see “Replacing the Filter” on page 31).

6. Run the HPU.

Turn the HPU to LOW PRESS. Run the HPU in a no-flow condition (no fluid is flowing to other hydraulic equipment) for about one hour to filter the new hydraulic fluid.

7. Check the filter change gage’s needle. Replace the filter if the needle remains in the yellow or red zone.

Maintenance

512.14 Hydraulic Power Unit

Lubricating the Motor

The pump’s motor bearing needs lubrication every six months.

Lubricating the Motor

Grease Fittings

CAUTION

1. Turn off the HPU.

2. Wipe off both grease fittings.

3. Using a grease gun, apply grease to each fitting. MTS recommends Shell Dolium R. Chevron SRI No. 2, or Texaco Premium RB grease.

Do not overgrease the motor.

Too much grease could short out the motor.

512.14 Hydraulic Power Unit Maintenance

Lubricating the Motor

Maintenance

512.14 Hydraulic Power Unit

MTS Systems Corporation

14000 Technology Drive Eden Prairie, Minnesota 55344-2290 USA Toll Free Phone: 800-328-2255

(within the U.S. or Canada)

Phone: 952-937-4000

(outside the U.S. or Canada) Fax: 952-937-4515 E-mail: info@mts.com http://www.mts.com

ISO 9001:2000 Certified QMS

MTS 512-14 User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual

Introduction

Component Identification

Functional Description

Specifications

Dimensions

Installation

Operation

Running the HPU

Recovering From an Interlock Condition

Reducing the Fluid Temperature

Adjusting the Air Flow

Adjusting the Water Flow

Resetting the Thermal Overloads

Adjusting the Output Pressure

Maintenance

Checking the Hydraulic Fluid

Replacing the Filter

Sampling the Hydraulic Fluid

Adding Hydraulic Fluid

Replacing the Hydraulic Fluid

Lubricating the Motor