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Operation & Service Manual Model: 5030 Hydraulic Power

1. 1 Bt da nd dud 2013 906 ONG st e t lu e a n i a a i a i 2 COG RA Ne ee Kit a 1 18 8 ai 1 H 1721 04 ceea Clamor a Ea a a nea al a eee d 1 Page 14 05 2004 Rev 01 TRONAIR Model 5030 Hydraulic Power Unit Aviation Phosphate Ester Type IV Fluids Pump Motor Assembly Part numbers given for Aviation Phosphate Ester Type IV Fluids Type Units only ITEM PART NUMBER DESCRIPTION QTY Mii HG A Muni ia is Mount Pump Motor c cccccccncccoccccnnconnnanancncnnconannnnncnnnnnos 1 FI2227 2 2 este este Coupling 1 Via H 2224 03 cc ee iin Coupling Body 1 222450 alei Coupling Body 1 Oti 51072 Pump 1 Diana ds 1077 ceea tata ea an Sedal Shaf su en meer 1 T ar W107 7 E E ec E D a Kit Seal Includes Item 6
2. C220 EC 1186 02 1186 02 1186 02 1186 02 1186 02 EC 1202 W50 3 1202 50 3 EC 1202 W43 3 EC 1202 W43 3 EC 1202 W43 EC 1170 01 0600 EC 1170 01 0600 EC 1170 01 0600 EC 1170 01 0600 EC 1170 01 0600 30 80 460 575 AC 00 20 80 440 Starter T 50 Hz Switch Y Motor Aaa ala eles aes eee al 3 1 05 2004 Rev 01 Page 12 TRONA Model 5030 Hydraulic Power Unit Aviation Phosphate Ester Type IV Fluids Reservoir Selector Valve Part numbers given for Aviation Phosphate Ester Type IV Fluids Type Units only SCREW a A gt Io TAPERED PLUG BOOT SPRING END CAP WASHER ITEM PART NUMBER DESCRIPTION QTY a TE A ea a Selector Valve 3 4 ui alada VALVE REPLACEMENT PARTS EIA AE a ea o a 00 de a che 1 NOTE For replacement of parts other than what is listed a complete valve 1 must be purchased 05 2004 Rev 01 Page 13 Model 5030 Ti AIR Hydraulic Power Unit Aviation Phosphate Ester Type IV Fluids Reservoir Sub Assembly Part numbers given for Aviation Phosphate Ester Type IV Fluids Type Units only ITEM PART NUMBER DESCRIPTION QTY Vase CAB 04a Rivet 1 8 diameter 14 4 HG amp 10302 2 4 ta Assembly
3. SELECTOR VALVE PRESSURE CONTROL FIGURE 1 External Components RESERVOIR FILLER CAP RESERVOIR D MANIFOLD wala I I lt __ CHECK VALVE FLOW METER 8 IN 985 9 3 I Sa D SAMPLE VALVE PRESSURE FILTER o ol Jo oo MOTOR FIGURE 2 Internal Components 05 2004 Rev 01 Page 1 TRONA Model 5030 Hydraulic Power Unit Aviation Phosphate Ester IV Fluids PRESSURE RETURN TO AIRCRAFT FROM AIRCRAFT Hydraulic Schematic Option T Return Back Pressure With Sight Gauge DUAL SYSTEM SELECTOR VALVES 2 PRESSURE BYPASS VALVE FANIFOLD PYROMETER OPTIONAL RESERVOIR FIGURE Hydraulic Schematics 05 2004 Rev 01 Page 2 Model 5030 Hydraulic Power Unit Aviation Phosphate Ester Type IV Fluids fi T TRONAIR MOTOR INPUT VOLTAGE CONNECTION HIGH VOLTAGE LINE Low VOLTAGE LINE T 3 T 1 15 3 T 7 T 8 T 9 T 4 T 5 T 6 1 1 1 2 T 8 0 1 9 T 6 T 7 e T 4 1 5 FIGURE 4 Electrical Schematic DUAL 05 2004 Rev 01 Page TRONA Model 5030 Power Unit Aviation Phosphate Ester Type IV Fluid
4. 1 See Appendix III pump manufacturer s service booklet for servicing of Item 5 and additional repair kits 05 2004 Rev 01 Page 15 Model 5030 Ti AIR Hydraulic Power Unit Aviation Phosphate Ester Type IV Fluids Filter Assembly Part numbers given for Aviation Phosphate Ester Type IV Fluids Type Units only HEAD ITEM PART NUMBER DESCRIPTION QTY Vase HG21084 22 22 22 ca ca t ent Assembly 1 FILTER PARTS 02 valea lt Kit Filter Element 1 Mia HE 2006 138 2 ae o iiss Ee Re RS 1 Item 2 includes ltem 3 O ring Page 16 05 2004 Rev 01 Model 5030 Ti AIR Hydraulic Power Unit Aviation Phosphate Ester Type IV Fluids Bypass Valve Part numbers given for Aviation Phosphate Ester Type IV Fluids Type Units only NUT COLOR RINGS NEEDLE N FOLLOMER BONNET ES BACK UP RING ry 4 f ve y WASHER Yih AR KR ADDY 2 AS 4 OUTLET PORT 2 4 A INLET PORT ITEM PART NUMBER DESCRIPTION QTY ze uzi cet cis Ba 05 2004 Rev 01 Page 17 Model 5030 Ti AIR Hydraulic Power Unit Aviation Phosphate Ester Type IV Fluids Sample Valve Part numbers given for Aviation Phosphate Ester Type IV Fluids Type Units only NUT COLOR RINGS FOLLOWER NEEDLE BACKUP RING BONNET
5. WASHER u OUTLET PORT ITEM PART NUMBER DESCRIPTION QTY lianas HG 120202 22 2 2 en Assembly 1 VALVE REPLACEMENT PARTS nen HO 4 0 Lita ea Handle Valve dida dd 1 Bass Me sa ss ar ten aa 2006 010 OTI 1 Page 18 05 2004 Rev 01 TRONAIR Model 5030 Hydraulic Power Unit Aviation Phosphate Ester Type IV Fluids Dual System Option C Crossover Check Option D Part numbers given for Aviation Phosphate Ester Type IV Fluids Type Units only ITEM PART NUMBER DESCRIPTION QTY A 1041 01 180 Assembly Return Hose 2 RT TF 1041 09 180 Assembly Pressure 2 ad m Oa Bici aa ea a iti 2 1654 03 00 Valve Pressure 2 Dia adi HO Oi a ValVe Check iia aaa aaa aaa 930 ine 1 Dunia HG 1425 04 Valve Return 2 05 2004 Rev 01 Page 19 Model 5030 Ti AIR Hydraulic Power Unit Aviation Phosphate Ester Type IV Fluids Pyrometer Option K Part numbers given for Aviation Phosphate Ester Type IV Fluids Type Units only
6. Pour one cup of good housing and align the bolt holes Rotate the shaft 3 grade hydraulic fluid into the intake port while slowly as the bolts are tightened to assure that the vanes are rotating the shaft in the direction shown by the not cocked rotation arrow 11 Torque the cover bolts 18 to 50 Ibs ft 67 8 Nm 15 The pump is now ready to test Refer to front of The shaft should turn by hand when assembly is this manual for start up procedure complete 0 07 1 78 mm One Vane Thickness 12 Lubricate the ID of the shaft seal 24 and press it into the housing to the depth shown below Note the to the inside orientation of the seal 13 Adjust the pressure adjustment screw 30 until it just touches the spring and then give it one more turn clockwise Form No 265664 Rev 2 05 7 Continental Hydraulics 12520 Quentin Avenue South ONTINENTAL Savage MN 55378 Phone 952 895 6400 Fax 952 895 6444 www continentalhydraulics com CON HYDRAULICS Because Continental Hydraulics is continually improving its products specifications and appearance are subject to change without notice Form No 265664 Rev 2 05 2005 Continental Hydraulics Printed in U S A TRONAIR APPENDIX IV MSDS Hydraulic Fluid Product name SKYDROL LD4 Fire resistant hydraulic fluid Solutia Inc Material Safety Data Sheet Reference Number 000000000183 MSDS A035 Page 1 8 Date 03
7. aircraft system or reservoir may result if either return line valve is closed while the machine is running 3 If equipped with the Dual System Crossover Check Option separate pressure gauges are located after each system pressure shut off valve This allows bleed down pressures to be read when the pressure valves are closed Follow aircraft manufacturer s instructions 05 2004 Rev 01 Page 7 TRONA Model 5030 Hydraulic Power Unit Aviation Phosphate Ester Type IV Fluids 4 6 OPTIONS continued 4 6 2 Return Back Pressure with Sight Gauge Option T Operation Option T consists of two valves and a pressure gauge mounted on the rear ofthe machine a sight glass mounted on the control panel and a third hose for connection to the aircraft reservoir The two valves are connected in parallel and consists of a 90 ball valve and an adjustable pressure relief valve Refer to Figure 4 Page 2 HPU Option T Hydraulic Schematic With the ball valve open all aircraft return oil will flow through this valve If however the valve is closed the flow path will be through the pressure relief valve The pressure relief valve may be adjusted to obtain any desired return line back pressure as specified in the Citation maintenance manual The return line back pressure may be read on the adjacent pressure gauge Since the Citation has an onboard unloading valve the hydraulic power unit reservoir should be used for all tests This allows the pum
8. 1 NO FLOW OR PRESSURE Flow control set too Increase flow setting Motor running in wrong direction See Section 3 0 Preparation for Use Insufficient oil in See Section 3 0 Preparation for Use Air in hydraulic 2 221 See Section 4 4 Bleeding Air From System Faulty pumpen ee Repair or replace pump 6 2 FLUCTUATING PRESSURE OR FLOW Pump 2444 4422 22 See Section 4 2 3 a Aircraft Reservoir Position Air in hydraulic 4122212 See Section 4 4 Bleeding Air From System 6 3 UNIT OVERHEATS Low fluid level in See Section 3 0 Preparation for Use Running unit for long time periods without Cycle landing gear or other components periodically or allow unit to cool operating aircraft components Bypass valve partially See Section 4 2 4 Bypass Valve Operation NOTES 1 Running time under deadhead condition can be increased substantially by selecting the Hydraulic Power Unit position reservoir selector valve 2 When a pressure compensated pump is required to hold pressure without any flow delivery dead headed condition it is normal for the pump case drain flow and temperature to increase By selecting the Hydraulic Power Unit position of the selector valve all of the oil in th
9. 18 2003 Version 5 1 E Solutia Inc Material Safety Data Sheet 1 PRODUCT AND COMPANY IDENTIFICATION Product name Reference Number 000000000183 Company Information United States Solutia Inc 575 Maryville Center Drive P O Box 66760 St Louis MO 63166 6760 Emergency telephone Chemtrec 1 800 424 9300 Non Emergency telephone 1 314 674 6661 Mexico Solutia MEXICO S DE R L DE Blvd Manuel Avila Camacho No 40 Piso 12 Colonia Lomas de Chapultepec Edificio Torre Esmeraldal 1000 Mexico D F Emergency telephone SETIQ in Mexico 01 800 002 1400 Non Emergency telephone in Mexico 555 202 5600 SKYDROL LD4 Fire resistant hydraulic fluid Date 03 18 2003 Canada Solutia Canada Inc 6800 St Patrick Street LaSalle PQ H8N 2H3 Emergency telephone CANUTEC 1 613 996 6666 Non Emergency telephone 1 314 674 6661 Brazil Solutia Brazil Ltd Avenue Jorge Bei Maluf 2105 CEP 08686 000 Suzano SP Emergency telephone 0800 193 190 Non Emergency telephone 5511 4745 8569 2 COMPOSITION INFORMATION ON INGREDIENTS Components CAS No tributyl phosphate 126 73 8 dibutyl phenyl phosphate 2528 36 1 butyl diphenyl phosphate 2752 95 6 2 6 di tert butyl p cresol 128 37 0 2 ethylhexyl 7 oxabicyclo 4 1 0 heptane 62256 00 2 3 carboxylate 3 HAZARDS IDENTIFICATION EMERGENCY OVERVIEW Form oily liquid Colour clear to purple Odour odourless Average Concentration Units co
10. CALIBRATION ADJUSTMENT SCREW ITEM PART NUMBER DESCRIPTION QTY Vitis 1093 aid ja 1 dees vine N 2204 04 S Connector 1 tata AA Nipple Pipe NPT 1 Page 20 05 2004 Rev 01 TRONAIR Model 5030 Hydraulic Power Unit Aviation Phosphate Ester Type IV Fluids Hourmeter Option F Part numbers given for Aviation Phosphate Ester Type IV Fluids Type Units only ITEM PART NUMBER DESCRIPTION QTY en SOM ese tit aaa aah ee da ma Deea aloe Dr oo e a ee 1 Dd ECO ee ee Transformers ce ta ra aaa al ne ta a ao ut EN 1 208V 60Hz 380V 50Hz 575V 60Hz 415V 50Hz PIERRE GERN ECO Ob ae NER Transformers Za 1 230V 60Hz 220V 50Hz 460V 60Hz 440V 50Hz Ds EC 1060 0 coccccconooccccnnccnocononnncnnnnnonononononnnnnononononnnnnononon 1 A E E cica situau data di s EC Oda cca eee an an Fuse 1 amp Glass Tube Slo 1 ECO ina FUSE Holder atrasa rasta 1 Selectone based voltage Page 21 05 2004 Rev 01 TRONAIR Model 509 Hydraulic Power Unit Aviation Phosphate Ester Type IV Fluids Return Back Pressure with Sight Gauge Option T
11. Hazardous Substances Section 313 Toxic Chemical s CERCLA Reportable Quantity Not applicable Product name SKYDROL LD4 Fire resistant hydraulic fluid Solutia Inc Material Safety Data Sheet Reference Number 000000000183 Page 8 8 Date 03 18 2003 Version 5 1 E This product has been classified in accordance with the hazard criteria of the Canadian Controlled Products Regulation and the MSDS contains all the information required by the Canadian Controlled Products Regulation Refer to Section 11 for OSHA HPA Hazardous Chemical s and Section 13 for RCRA classification Safety data sheet also created in accordance with Brazilian law NBR 14725 16 OTHER INFORMATION Product use Hydraulic fluids and additives Reason for revision Significant changes to the following section s Section 2 Section 8 Section 15 Health Fire Reactivity Additional Information Suggested NFPA Rating 2 l 0 Suggested HMIS Rating 2 1 0 G Prepared by the Solutia Hazard Communication Group Please consult Solutia 314 674 6661 if further information is needed TM is a registered trademark of Solutia Inc SOLUTIA is a trademark of Solutia Inc Responsible Care is a registered trademark ofthe American Chemistry Council Although the information and recommendations set forth herein hereinafter Information are presented in good faith and believed to be correct as of the date hereof Solutia Inc makes no representations as to
12. Part numbers given for Aviation Phosphate Ester Type IV Fluids Type Units only z _ MITO ald ZEN 2 ITEM PART NUMBER DESCRIPTION QTY Vegan A ae 1 Dt ida TEF 1041 02 180 ae Assembly Return Hose Aircraft Reservoir 1 to 1425 4 00011 Valve Ball tica a hen es lei 1 Ai ina HTM ai Gauge 1 dos 1041 017180 Assembly Return Hose 1 Doa 1041 09 180 Assembly Pressure 1 A ala 51118 Enns Valve Back 1 05 2004 Rev 01 Page 22 TRONAIR Model 5030 Hydraulic Power Unit Aviation Phosphate Ester Type IV Fluids Return Filter Assembly Option W Part numbers given for Aviation Phosphate Ester Type IV Fluids Type Units only ITEM PART NUMBER Muni a A an E 6 FILTER REPLACEMENT PARTS ARE RE 2006 142 K 3097 scoase ce nein Din HG 185 ui 4 includes corresponding 2 O ring 05 2004 Rev 01 DESCRIPTION QTY Assembly Filter nene nenea aaa 1 Element Filt
13. STEL ACGIH TLV 0 3 ml m3 3 5 mg m3 skin 8 hr TWA skin absorption of this material may add to the overall exposure ACGIH TLV 2 mg m3 8 hr TWA Mexican OEL 10 mg m3 8 hr TWA Mexican OEL 20 mg m3 15 min STEL Components referred to herein may be regulated by specific Canadian provincial legislation Please refer to exposure limits legislated for the province in which the substance will be used 9 PHYSICAL AND CHEMICAL PROPERTIES Specific gravity Viscosity 1 004 1 014 25C 10 8 11 6 mPa s 38 C Product name SKYDROL LD4 Fire resistant hydraulic fluid Solutia Inc Material Safety Data Sheet Reference Number 000000000 183 Page 5 8 Date 03 18 2003 Version 5 1 E NOTE These physical data are typical values based on material tested but may vary from sample to sample Typical values should not be construed as a guaranteed analysis of any specific lot or as specifications for the product 10 STABILITY AND REACTIVITY Conditions to avoid Elevated temperatures Materials to avoid Contact with strong oxidizing agents Hazardous reactions Hazardous polymerization does not occur Hazardous decomposition phosphorus oxides PxOy carbon monoxide CO carbon dioxide products 11 TOXICOLOGICAL INFORMATION This product has been tested for toxicity Results from Solutia sponsored studies or from the available public literature are described below Acute animal toxicity data Oral L
14. hydraulic power unit should be maintained a safe and clean condition at all times e Locate and correct the source of any and all leaks e hoses and electrical cord periodically for damage and wear Replace as required 5 2 FILTER MAINTENANCE Replace the filter element annually to ensure proper cleanliness of the hydraulic system This is a minimum requirement Replace the return filter element at the same time the pressure filter element is being replaced Standard filter changes depend on how frequently the HPU is used and the cleanliness of the fluid along with the environment to which the HPU is exposed Periodic fluid analysis is recommended to properly determine the optimum frequency of filter element changes 5 3 SELECTOR VALVE MAINTENANCE The Reservoir Selector Valve has been assembled with special grease Tronair H 2132 that is compatible with Skydrol It is recommended that this valve be disassembled and re lubed every two 2 years or if there is any sign of external leakage 5 4 LUBRICATION The swivel casters are equipped with grease fittings which should be lubricated annually 5 5 STORAGE In the event that the HPU will not be used for 12 months or longer the reservoir may be drained The unit should then be appropriately covered in order to maintain cleanliness 05 2004 Rev 01 Page 8 TRONA Model 5030 Hydraulic Power Unit Aviation Phosphate Ester Type IV Fluids 6 0 TROUBLESHOOTING 6
15. is provided on the rear of the unit to obtain a fluid sample for analysis or inspection In order to obtain a representative fluid sample it is suggested that American National Standard number B93 minutes and shut off 6 If additional bleeding is required proceed with the following steps a Connect the pressure and return hoses together Kits containing the necessary fitting s are available from Tronair b Ifthe unit is equipped with pressure and return ball valves open the ball valves prior to starting the unit WARNING Failure to open the return ball valves will cause hose or valve rupture Property damage and personal injury can result c Place the reservoir selector valve in the Hydraulic Power Unit position d Open the bypass valve on the instrument panel e Start unit and adjust flow control to maximum position f Close the bypass valve and allow the unit to run for 5 minutes Under some conditions where a large amount of air has entered the system the pump may not be able to draw an initial prime and will not pump If this occurs it may be necessary to fill the pump inlet line with fluid 4 5 ABBREVIATED OPERATING INSTRUCTIONS These instructions may be used for fast reference after a thorough understanding of the HPU operation has been achieved 4 5 1 Initial Adjustments 1 Set flow control See Section 4 2 A 2 Set pressure control See Section 4 1 B 4 5 2 Prior to Starting 1 Select reservoir valve posi
16. output of the pump blocked and then check pressure throughout the pump flow range Volume Control Adjust volume at minimum pump pressure or at pump deadhead The volume adjusting screw is directly opposite the pressure adjusting screw see parts page item number 55 The adjusting screw has a right hand thread turning the screw clockwise decreases the maximum volume turning the screw counterclockwise increases the maximum volume Pumps are set at a maximum rated volume at the factory unless otherwise specified Stop adjustment of the volume screw when pressure begins to drop See Sales Catalog for complete pump performance specifications ADJUSTMENT PROCEDURES To adjust the maximum output volume use the following steps 1 Set the pump at minimum pressure 2 Hand tighten the volume screw until it touches the pressure ring NOTE The pump should be at full flow for this step 3 See Pressure and Volume Adjustment Sensitivity chart below 4 Deadhead the pump turn the volume screw the proper number of turns to obtain the flow desired 5 Return pump to flow condition and check flow rate If output flow is incorrect switch pump to deadhead and readjust per above CAUTION Turning the maximum volume A control in too far can force the pressure ring over center and destroy the pump PRESSURE and VOLUME ADJUSTMENT SENSITIVITY PUMP SIZE 4B 6B 8B PRESSURE CODE P
17. temperature of the surrounding air should not exceed 104 F 40 C except for motors with nameplates indicating a higher allowable maximum ambient temperature 44 WARNING MOVING PARTS can injure e BEFORE starting motor be sure shaft key is captive e Consider application and provide guarding to protect personnel 5 1 INSTALLATION MECHANICAL Base Mount the motor on a firm foundation or base sufficiently rigid to prevent excessive vibration On foot mounted motors use appropriately sized bolts through all four mounting holes For frames which have six or eight mounting holes use the two closest the drive shaft and two on the end opposite the drive shaft one on each side of the frame If necessary properly shim the motor to prevent undue stress on the motor frame and to precision align the unit Position Standard motors may be mounted in any position The radial and thrust load capacity of the motor s bearing system provides for this feature Drains All motors have drain holes located in the end brackets As standard drains are in place for the horizontal with feet down mounting position Other positions may require either rotation of the end brackets or drilling additional holes to attain proper drainage Be sure existing drain or vent holes do not permit contaminant entry when motor is mounted in the other positions Additional drain holes exist near the bearing cartridge in both end brackets of 284T thru 44
18. 2 Hose Pressure ci 1 Not 1041 01 180 Hose 0040000 1 05 2004 Rev 01 Page 10 TRONA Model 5030 Power Unit Aviation Phosphate Ester Type IV Fluids Internal Components Part numbers given for Aviation Phosphate Ester Type IV Fluids Type Units only RESERVOIR ASSEMBLY FILTER ASSEMBLY MOTOR SEE SEPARATE PAGE FOR DETAILS ITEM PART NUMBER DESCRIPTION QTY es see 2 1834 2 0 44 1 HG 1059 ne nn Valve en ana 1 05 2004 Rev 01 Page 11 TRONA Model 5030 Power Unit Aviation Phosphate Ester IV Fluids Electrical Components 1 4 Starter 60 Hz Switch Wire EC 1044 EC 1186 01 EC 1202 W51 EC 1252 01 43 0 EC 1170 01 0600 EC 1044 EC 1186 02 EC 1202 W50 EC 1252 01 43 0 EC 1170 01 0600 EC 1044 EC 1186 01 EC 1202 W45 3 EC 1252 01 43 0 EC 1170 01 0600 460 1044 EC 1186 02 EC 1202 w43 3 EC 1252 01 43 0 EC 1170 01 0600 2 2 3 5 Power Cord lt 40 Q Q T T Y Y lt 1044 1186 03 EC 1202 W41 3 1252 01 43 0 EC 1170 01 0600 3 3 T Heater Y Wire 3 3 EI 3 4 Power Cord zoo
19. 449T 2 Yrs CF CN CS CP 182U 449U 2 Yrs Contact C5 C6 Lincoln M504 689 NS MD SE 284 445 1 RC RJ SC 56 145T 2 Yrs RD RF 56 56H 2 Yrs 56 256T 1 REW SEW er 143T 449T 5 Yrs SD SF S H P B 2 Yrs Field Kits and Accessories 5 Yrs Applies to motors with a service factor of 1 15 or higher Motors with a 1 0 service factor have a 1 year warranty on PWM power If the Buyer gives the Seller written notice of any defects in equipment within any period of the warranty and the Seller s inspection confirms the existence of such defects then the Seller shall correct the defect or defects at its option either by repair or replacement F O B its own factory or other place as designated by the Seller The remedy provid ed the Buyer herein for breach of Seller s warranty shall be exclusive No expense liability or responsibility will be assumed by the Seller for repairs made outside of the Seller s factory without written authority from the Seller The Seller shall not be liable for any consequential damages in case of any failure to meet the conditions of any warranty The liability of the Seller arising out of the supplying of said equipment or its use by the Buyer whether on warranties or otherwise shall not in any case exceed the cost of correcting defects in the equipment in accordance with the above guarantee Upon the expiration of any pe
20. 9T steel frame motors The drain holes are closed with a plastic plug When the motor is vertically mounted the plug located in the lower end bracket must be removed To access the plug on blower end simply remove the shroud on some models it is also necessary to take off the blower Drive Power Transmission The pulley sprocket or gear used in the drive should be located on the shaft as close to the shaft shoulder as possible Do not drive the unit on the shaft as this will damage the bearings Coat the shaft lightly with heavy oil before installing pulley Belt Drive Align the pulleys so that the belt s will run true Consult the belt manufacturer s catalog for recommended tension Properly tension the belt excessive tension will cause premature bearing failure If possible the lower side of the belt should be the driving side On multiple belt installations be sure all belts are matched for length Chain Drive Mount the sprocket on the shaft as close to the shaft shoulder as possible Align the sprockets so that the chain will run true Avoid excessive chain tension Gear Drive and Direct Connection Accurate alignment is essential Secure the motor and driven unit rigidly to the base Shims may be needed to achieve proper alignment Excessive motor vibration may result if the full length of the motor shaft key is not completely engaged by the coupling or sheave For these situations adjustment of the key length is requir
21. D50 rat 2 100 mg kg Slightly toxic following oral administration Dermal LDSO rabbit gt 3 160 mg kg Practically nontoxic after skin application in animal studies Inhalation LC50 gt 5 8 mg l No mortality or signs of toxicity at the highest level achievable Eye irritation rabbit Slightly irritating to eyes rabbit 24 h Skin irritation rabbit Moderately irritating to skin 24 h Skin sensitization Human experience Predictive patch testing on human volunteers did not produce dermal sensitization Repeat dose toxicity rat inhalation 28 days Repeated exposure produced eye irritation in animal models Repeated exposure produced respiratory tract irritation in animal models Produced effects on body weight serum enzymes and or organ weights in repeat dose studies Neurotoxicity chicken gavage acute Brain cholinesterase inhibition Mutagenicity No genetic effects were observed in standard tests using bacterial and animal cells Components Data from Solutia studies and or the available scientific literature on the components of this material which have been identified as hazardous chemicals under the criteria of the OSHA Hazard Communication Standard 29 CFR 1910 1200 or the Canadian Hazardous Products Act are discussed below tributyl phosphate Slightly toxic following oral administration Practically nontoxic after skin application in animal studies Product name SKYDROL LD4 Fir
22. ENTS Ha er ne Wel nt aes ie eee 5 4 1 1 O E 5 4 1 2 Use of the HPU Reservo i siirre ee EI E SEI det 5 4 2 PRELIMINARY ADJUSTMENTS AND 5 4 2 1 Flow Control Bee pr ie ai Dia erkenne 5 4 2 2 Pressure Control Adjustment da aa aaa a 5 4 2 3 Reservoir Selector Valve Operation mmm nn nana nana nana nana aaa aaa 5 4 2 4 Bypass Valve Operation ceci ar a san leed a 6 4 3 SAMPEE VALVE a O ga Da a Ea a a Dr a a Dita Ge a aa 6 4 4 BLEEDING AIR EROM SYSTEM isa si ae a ata ea Rn e da a a da i a a 6 4 5 ABBREVIATED OPERATING INSTRUCTIONS enma mana manea nana na 7 4 5 1 Initial Adjustments 4 5 2 Piiorto Starting ecimiento a ee 4 5 3 ta 4 5 4 Shut Offo 4 6 OPTIONS A ai aci 30 lada c p A 5 na 0 pa piata da t Sa ao aa aia da 4 6 1 Dual System Option Operation men nenea nana nana 7 4 6 2 Return Back Pressure with Sight Gauge Option 8 5 0 MAINTENANCE a A ia 8 5 1 GENERAL MAINTENANGE SSEERERTRRERRRTTTEFEFSTEREFPIETEFEFENTTERTHETTFEEFERSPERFERLSTEGEETFEESTRRERTTIRTEEFPRTFRETRFERTTERFERTERRERFRTTTSFETEFGLEFFFRITE
23. Extreme Severe Service Operating horizontally 24 hours per day vibration dirty dusty high humidity weather exposure or ambient temperatures from 104 130 F 40 55 C Extreme Service Operating vertically heavy vibration or shock heavy duty cycle very dirty or ambient temperatures from 130 150 F 55 65 C Table 2 Bearing Lubrication Intervals Service Conditions Motor Motor Syn Speed Horsepower Severe Extreme BALL BEARINGS 1800 RPM 1 4 to 7 1 2 HP and slower 6 months 2 years 10 to 40 HP 1 year 3 months 50 HP and up 6 months 3 months above 1800 RPM all sizes 3 months 3 months ROLLER BEARINGS all speeds all sizes 3 months 3 months When adding lubricant keep all dirt out of the area Wipe the fitting completely clean and use clean grease dispensing equipment More bearing failures are caused by dirt introduced during greasing than from insufficient grease If the motor is equipped with a relief port or tube make certain it is open and free of caked or hardened grease Before replacing relief plugs allow excess grease or pressure to vent by running the motor for several minutes after lubrication A CAUTION e LUBRICANT SHOULD BE ADDED AT A STEADY MODERATE PRESSURE IF ADDED UNDER HEAVY PRESSURE BEARING SHIELD S MAY COLLAPSE e DO NOT OVER GREASE PARTS All parts should be ordered from Authorized Motor Warranty Stations Call your Lincoln Motors Sales Offi
24. TRONAIR Operation amp Service Manual Model 5030 Hydraulic Power Unit 05 2004 Rev 01 Includes Illustrated Parts Lists 1740 Eber Rd Tronair Inc Phone 419 866 6301 Holland OH 43528 9794 www tronair com 800 426 6301 USA Email sales tronair com Fax 419 867 0634 REVISION DATE TEXT AFFECTED 01 5 2004 Modified Parts ost TRONA Model 5030 Power Unit Aviation Phosphate Ester Type IV Fluids TABLE OF CONTENTS PAGE Figure 1 External Components a iai ca iti iai ii ii ia ia ii 1 Figure 2 Internal Componen s caca aci cca a Eat cate ded a tad a i tas ted 1 Figure Standard Hydraulic Schematic amp Option Hydraulic Schematic nenea nenea emana ana 2 Figure 4 Electrical Schematico cional ria ita a a ia da 3 1 0 GENERAL DESCRIPTION ni 4 2 0 TECHNICAL SPECIFICATIONS ooo occ a ai a iii i i i i i ia i ii di ea 4 2 1 HYDRAULIC sanirane ninaa ea a a ea een lee een oh 4 2 2 ELEGTRICAL css societ poa ca cae tao aaa 4 2 3 2 2 ee ee Dar nenne ade 4 3 0 PREPARATION FOR USE cea za i a i d da i an an an nu ca iai nn nu ann wann ii i iai di iai ii 4 3 1 SERVICING RESERVOIR cocina eiii 4 3 2 CONNECTING ELECTRICAL 5 4 4 0 OPERATION coacaze oa c t ia antet a dieta daia bat a E 5 4 1 GENERALGOMM
25. TTER 8 5 2 FILTER MAINTENANGE 2 loci Rinne ni 8 5 3 SELECTOR VALVE MAINTENANCE ice acte e aa be dr e lett 8 5 4 LUBRICATION Y a reinen at O nat ta le e cl aa Pl ta 8 5 5 sie e Aira 8 6 0 TROUBLESHOOTING iai ca ta i a iai i ii i i i i iii ii ii i i 9 6 1 NO FLOW OR PRESSURE iii ag a e d Di i nee ie ae a 9 6 2 FLUCTUATING PRESSURE OR FLOW aeaii airada a e i a a a i a i a a i n 9 6 3 UNITOVERHEATS Ar ee Reel dat tea da a ai ata beste aaa Eat duce a Oa a ai 9 6 4 LOSSOF FLOW IN CLOSED LOOP ni ae ie leat Ca aia aaa aaa 9 6 5 EXTERNAL LEAKAGE FROM SELECTOR VALVE nana nana nana aaa 9 7 0 PARTS LIST INDEX sete aaa n aa aaa ada atei ada aaa aa 9 APPENDIX Instrument Certification Notice APPENDIX II Lincoln Motor Manual APPENDIX III Continental Hydraulics Service Booklet PVR6 G Design Series Pumps APPENDIX IV MSDS Hydraulic Fluid Aviation Phosphate Ester Type IV 05 2004 Rev 01 TRONAIR Model 5030 Hydraulic Power Unit Aviation Phosphate Ester Type IV Fluids ON OFF STARTER SWITCH BYPASS VALVE PRESSURE GAUGE FLOW CONTROL PUMP ASSEMBLY
26. aceia a oaia Do ata a Da een 13 Reservoir Sub Assembly a senior DA Sree deter da al Aaa a 14 Return Back Pressure with Sight Gauge Option nenea nana nana 22 Return Filter Assembly Option Wisin as ee pt ant a ee 23 Sample VaVe s vias stia ado els a SE eine va as 18 05 2004 Rev 01 Page 9 TRONA Model 5030 Power Unit Aviation Phosphate Ester Type IV Fluids External Components Part numbers given for Aviation Phosphate Ester Type IV Fluid Type Units only ITEM PART NUMBER DESCRIPTION QTY dera a 1S 1482 01 wens lie ae een 1 A A O 1 E E ECT DA iii nenn Switch Starter All 1 See Page diiniita ner Ener 3 Deine 2214S a iv ted Hourmeter Option 1 N21 O56 ute dnd Gaster Rigid re res 2 47 Valve Selector 34 1 Buin ee en een Pyrometer Option 1 Outer HE 1072 01 2 em et PUMP energie 1 Trees HG 1383 2 aaa Gauge 1 A Flowmeter pis sosi ci a boabe 1 pis HC 2153 A1 en Flowmeter Calibrated 1 Not 1041 09 180 22220200
27. acturer to determine the appropriate type glove clothing for a given application See Solutia Glove Facts for permeation data Wear suitable protective clothing Wear full protective clothing if exposed to splashes Consult the glove clothing manufacturer to determine the appropriate type glove clothing for a given application Wash contaminated skin promptly Launder contaminated clothing and clean protective equipment before reuse Have safety shower available at locations where skin contact can occur Wash thoroughly after handling Avoid breathing vapour or mist Use approved respiratory protection equipment full facepiece recommended when airborne exposure limits are exceeded If used full facepiece replaces the need for face shield and or chemical goggles Consult the respirator manufacturer to determine the appropriate type of equipment for a given application See Solutia Respirator Facts Observe respirator use limitations specified by the manufacturer Provide natural or mechanical ventilation to control exposure levels below airborne exposure limits If practical use local mechanical exhaust ventilation at sources of air contamination such as processing equipment ml m3 ppm No specific occupational exposure limit has been established ACGIH TLV 0 2 ml m3 2 2 mg m3 8 hr TWA OSHA PEL 5 mg m3 8 hr TWA Mexican OEL 0 2 ml m3 2 5 mg m3 8 hr TWA Mexican OEL 0 4 ml m3 5 mg m3 15
28. aft 1 25 Buna N 104617 O Ring 1 4 4B 6B 550101 Port Plate Assembly 1 25 Viton 166069 O Ring 1 4 18B 550074 Port Plate Assembly 1 30 309977 Pressure Adj Screw Ass y 1 4 1108 550280 Port Plate Assembly 1 40 Buna N 250058 SAE O Ring Plug 1 5 550351 Thrust Plate 1 40 Viton 254789 SAE O Ring plug 1 6 4B 114592 Pressure Ring 1 41 306466 Spring Retainer 1 6 6 112021 Pressure Ring 124 42 144927 Shim 005 1 6 8B 123175 Pressure Ring 1 43 144928 Shim 0149 1 6 108 251715 Pressure Ring 1 46 15 36 252152 Handwheel 1 7 4 250516 Vane Kit Set of 13 1 47 15 36 261323 Spring Pin 1 7 6B 8B 10B 250517 Vane Kit Set of 13 1 50_ 17 350952 Dual Pressure Control Ass y 1 8 306465 Spring Seat 1 53 8 9 256508 Flow Control Valve 1 8 6B3L 6B5L 350988 Spring Seat 1 55 6 36 450196 Volume Adj Screw Ass y 1 8B3L 8B5L 66 307179 Name Plate 1 8 10B3L 10B5L 166620 Spring Seat 1 67 250597 Self Tapping Screw 4 9 4820 165223 Governor Spring 1 80 002586 Dowel Pin 2 9 16806 149917 Governor Spring 1 81 1221 21 350663 Spline Coupling 1 9 8B06 251193 Governor Spring 1 85 1221 21 147655 Flange Cover Shipping 1 9 6B15 8B15 165225 Governor Spring 1 86 Viton 112222 O Ring 1 9 6B20 8B20 165226 Governor Spring 1 86 1221 21 111298 O Ring 1 9 6B3l 8B3L 257653 Governor Spring 1 92 256708 SAE O Ring Plug 1 9 10B3L 109792 Governor Spring 1 93 166288 Cap
29. be removed they should be pushed out from the inside of the housing at this time Care must be taken not to damage the journal bearing in the housing while the shaft seal is being removed It is recommended that the shaft seal be replaced whenever the pump is disassembled for maintenance The seal cannot be reused once they have been removed 10 The bushings 21 in the pumps are assembled with a press fit If they are to be removed at this time the bushing in the housing should be pressed out from the front The cover bearing should be pulled out using an expanding type puller The bushings should not be reused once they have been removed 11 It is unlikely that further disassembly will be necessary in order to perform routine maintenance on the pump REASSEMBLY PROCEDURE 1 Clean and inspect parts to determine which parts are worn enough to require replacement 2 Assemble the new bushings 21 in the housing and cover The bushing OD s should be lubricated before they are pressed in the bores Care must be taken to orient the split and the oil groove in the bushing as shown in the illustration below Spring Housing Thrust e Screw Oil Groove Positions 21 Bushing Orientation 3 After the bearings are in place check to see that the rotor shaft will fit into the bearings and provide a smooth turning fit If the shaft turns hard the bearings should be removed and the bore checked closely for nicks or b
30. been made to relate to any specific aircraft operation It is suggested that this manual and the be studied thoroughly in order to obtain optimum benefit of the various features By combining an understanding of the HPU and the aircraft hydraulic system many services oned in this manual may be performed Refer to the hydraulic schematic front panel controls and internal nts pages for clarification while reading this manual 4 1 GENERAL COMMENTS Most questions or problems concerning hydraulic power units are usually caused by improper training or understanding of hydraulics The following comments are given to aid in obtaining maximum benefits from the hydraulic power unit 4 1 1 Training Be sure that all personnel that will use the machine read the operating manual and receive training We encourage customers to call Tronair to discuss any operating or testing requirements 4 1 2 Use of the HPU Reservoir It is suggested that the integral reservoir be used whenever possible Use of this reservoir eliminates any possibility of cavitating the pump Most complaints of pump noises are due to fluid restrictions in the aircraft systems when using the aircraft reservoir Also if the integral reservoir is used the HPU will run considerably cooler This occurs because the pump case drain oil is directed to the reservoir instead of the pump return The only compromise in using the HPU reservoir is that the aircraft system reservoir mu
31. ce for location and phone number A Service Directory listing all Authorized Motor Warranty Stations by geographic location is available request Bulletin SD 6 These shops stock GENUINE Lincoln replacement parts and have factory trained personnel to service your motor 8 WHO TO CALL For the location and phone number of the Lincoln Motors District Sales Office nearest you check your local Yellow Pages or call 1 800 MOTOR 4 U 1 800 668 6748 or visit our web site at www lincolnmotors com Lincoln LINCOLN MOTORS Cleveland OH 44117 2525 USA Tel 1 800 MOTOR 4 U 668 6748 Fax 1 888 536 6867 Web www lincolnmotors com E Mail mailbox O lincolnmotors com 566 December 1999 9 WARRANTY Lincoln Motors the Seller warrants all new standard motors and accessories thereof against defects in workmanship and material provided the equipment has been properly cared for and operated under normal conditions All warranty periods begin on the date of shipment to the original purchaser Warranty periods for low voltage lt 600 V motors are defined in the following chart The warranty period for medium voltage gt 600 V motors is one year on sine wave power Contact Lincoln for warranty period on PWM power Warranty Period Sine Wave PWM Power Power Model Number Prefix AA AF AN Efficiency Code s 143T 286T CF SD 143T 215T 143T
32. d HPU Reservoir Position Open Loop In this position the HPU reservoir supplies oil to the pump and accepts return oil from the aircraft It is desirable to operate the HPU in this mode since it eliminates any possibility of cavitation Since the reservoir is vented to atmosphere and the aircraft is at a higher level it is normal for the aircraft reservoir to drain into the HPU reservoir It is therefore necessary to be sure that sufficient room is available in the HPU reservoir to accommodate the additional fluid CAUTION The aircraft system reservoir must be serviced after completion of operational testing In the HPU Reservoir position faster landing gear swings are usually possible since there are no restrictions to flow at the pump inlet On most aircraft the aircraft reservoir may usually be serviced by disconnecting the return hose Normally servo leakage or operation of a hydraulic component will allow some flow to the aircraft reservoir Caution should be observed if this method is used WARNING AN e When using the HPU reservoir it may be possible to overfill the aircraft reservoir if several landing gear swings are done in a short time period e Always wait approximately 15 seconds between gear swings to allow the aircraft reservoir to drain into the HPU Do not change the reservoir selector valve position while the machine is running 4 2 4 Bypass Valve Operation The bypass valve is used for unloading the pum
33. ding Start Connection La 5 La 1 1 2 PART WINDING STARTER E La 1 3 La Ly La La 2 7 9 T6 74 TS 42 740 TH TA Connection Diagram 5 Dual Voltage 12 Leads YA Start Connection LOW VOLTAGE LINE HIGH VOLTAGE LINE L4 Lo La La La Lg L L 1 _1 1 1 YA STARTER YA STARTER Ly La Lg Lo La La Ly La La Lo bg ty 1 2 8 4 5 6 2 8 4 6 6 TA T2 Fo TH TH 0 0 7 8 T9 T10 1 T 12 4 7 5 8 6 79 Space Heater option Leads for space heaters are identified as H1 and H2 Heater voltage and watts are marked on the motor nameplate and should be checked prior to connection to power source Thermostat option Leads for thermostats normally closed automatic reset contacts are identified as P1 and P2 Connect these to a relay or signaling device Motor line current cannot be handled by the thermostat Table 1 Thermostat Contact Ratings Voltage 60 Hz Max Cont Current amps Min Cont Current amps Thermistor option Leads for thermistors are identified as P3 and P4 Thermistors require connection to Texas Instruments Control Module Model 32AA or its equivalent for proper operation This item may be purchased from Lincoln see LC100 catalog Brake option Carefully read and fully understand the instructions supplied by the brake manufacturer see inside of brake housing or separately encl
34. e 11 When replacing pumps the suction screen in the reservoir must be removed and thoroughly cleaned Also the suction line from the reservoir to the pump should be flushed inside and out to remove any contaminants Pieces of metal from a damaged pump can back up into this line If they not removed they will be drawn into the new pump and destroy it Start unit by using proper pump start up procedure items 1 through 10 CAUTION If both pressure and volume A modifications are supplied on the pump the pressure should be adjusted before the volume Volume should be adjusted at minimum pump pressure or at deadhead Stop adjustment at the volume screw when pressure begins to drop 2 Form No 265664 Rev 2 05 OPERATION PRESSURE AND VOLUME ADJUSTMENTS Pressure Control All pumps are adjusted to reduced pressure before shipment and must be readjusted to the required system pressure after installation and start up The pressure adjusting screw is located at the end face of the compensator chamber See parts page item number 30 The adjusting screw has a right hand thread clockwise adjustment increases pressure counterclockwise reduces pressure A pressure gauge located at the pump must be used when making adjustment to insure the pressure settings do not exceed limits specified for the particular pump of maximum system pressure Make all pressure settings with pump operating against a closed circuit that is with the
35. e reservoir is utilized for cooling 6 4 LOSS OF FLOW IN CLOSED LOOP Leaking over Reservoir Selector Valve Valve must be disassembled and thoroughly cleaned with alcohol Re lubricate with grease Tronair part number H 2132 before re assembled 6 5 EXTERNAL LEAKAGE FROM SELECTOR VALVE Leaking out the front of Reservoir Selector Valve Valve must be disassembled and thoroughly cleaned with alcohol Re lube with grease Tronair part number H 2132 before re assembled 7 0 PARTS LIST INDEX When ordering Replacement Parts Kits please specify Model amp Serial Number of your product Reference the following pages for ordering information of Replacement Parts and Kits Description Page Bypass Valve edie a ee 17 Crossover Check Option Dy casita Sa etal i ete aaa 19 D al System Option nr aie il i ren 19 Electrical Components ae zica i iaz sea ie E Aaa E e al dia al d Dat ul 12 External COMPONENTS 222 a die Da lee ae sane 10 Fiter Assembly cit an lis 16 Hourmeter Optio MET it ee Er da tul 21 2 11 15 Pyrometer Option Keita la ide a 20 Reservoir Selector Valve catre
36. e resistant hydraulic fluid Solutia Inc Material Safety Data Sheet Reference Number 000000000183 dibutyl phenyl phosphate 2 6 di tert butyl p cresol 2 ethylhexyl 7 oxabicyclo 4 1 0 heptane 3 carbox ylate Page 6 8 Date 03 18 2003 Version 5 1 Slightly irritating to eyes rabbit Highly irritating to skin rabbit Produced no dermal sensitization guinea pigs Repeated oral administration produced multiple systemic effects No delayed neurotoxicity was observed in animal models This material produced tumours in laboratory animals at dose levels that exceed the maximum tolerated dose The weight of the evidence indicates that this material is not mutagenic in in vitro assays Slightly toxic following oral administration Practically nontoxic after skin application in animal studies Practically non irritating to eyes rabbit Practically non irritating to skin rabbit Produced no dermal sensitization guinea pigs Repeated skin exposure produced irritation in animal studies Produced effects on body weight serum enzymes and or organ weights in repeat dose studies Repeated oral administration produced multiple organ effects No delayed neurotoxicity was observed in animal models No birth defects were noted in rats given the active ingredient orally during pregnancy This material had no effect on reproduction or fertility Produced developmental toxicity The weight of the evidence indicates that th
37. e transmitted from the driven machine Vibration may also be caused by excessive belt or chain tension BEARING SYSTEM Lincoln motors have a high quality premium design bearing system Bearing sizes and enclosures are identified on most motor nameplates The majority are double shielded deep groove ball bearings Double sealed ball bearings are used on some motors in frames 56 and 143T thru 145T A drive end cylindrical roller bearing is standard on Crusher Duty motors frames 405T and larger Lubrication instructions and or grease specifications provided on the motor supersede the following information In general the motor s bearing system has sufficient grease to last indefinitely under normal service conditions For severe or extreme service conditions it is advisable to add one quarter ounce of grease to each bearing per the schedule listed in Table 2 Use a good quality moisture resistant polyurea based grease such as Chevron SRI 2 Lithium based greases are not compatible with polyurea based greases mixing the two types may result in the loss of lubrication Motors designed for low ambient applications have bearings with special low temperature grease Use Beacon 325 lithium based grease or equivalent per the appropriate interval in Table 2 Motors designed for high ambient applications have bearings with special high temperature grease Use Dow Corning DC44 silicone grease or equivalent per the interval in Table 2 under
38. ed 5 2 INSTALLATION ELECTRICAL 44 WARNING ELECTRIC SHOCK can kill e Disconnect input power supply before installing or servicing motor e Motor lead connections can short and cause damage or injury if not well secured and insulated Use washers lock washers and the largest bolt size which will pass through the motor lead terminals in making connections Insulate the connection equal to or better than the insulation on the supply conductors Properly ground the motor see GROUNDING Check power supply to make certain that voltage frequency and current carrying capacity are in accordance with the motor nameplate Proper branch circuit supply to a motor should include a disconnect switch short circuit current fuse or breaker protection motor starter controller and correctly sized thermal elements or overload relay protection Short circuit current fuses or breakers are for the protection of the branch circuit Starter or motor controller overload relays are for the protection of the motor Each of these should be properly sized and installed per the National Electrical Code and local codes Properly ground the motor See GROUNDING Terminal Box Remove the appropriate knockout For terminal boxes without a knockout either a threaded power conduit entry hole is provided or the installer is responsible for supplying a correctly sized hole The majority of terminal boxes can be rotated in place to a
39. ems 7 6B 21 250817 6B 21 250834 Model Kit Number 8B 250759 8B15 250823 4B 250516 8B 12 250762 8B15 12 250827 6B 8B 10B 250517 8B 21 250816 10B i 254917 254912 10B 12 254918 10B 21 254919 Form No 265664 Rev 2 05 5 PVR6 PUMP REPAIR PROCEDURES DISASSEMBLY PROCEDURE NOTE Disassembling pump to change components or for any other reason may void the warranty Refer to Policy Statement and Discounts Summaries 1 Remove the key 22 in the rotor shaft keyway 2 Asmall amount of oil may remain in the pump Remove the four cover bolts and slide the cover back far enough on the shaft to break the seal between the housing and cover to allow the pump to drain 3 Remove the cover 2 Take care to avoid damage to the bearing with the end of the shaft when the cover is removed 4 The port plate 4 may come out with the cover Do not let it drop off the locating pins 5 Remove the vanes 7 with a long nosed pliers or tweezers There is one vane in each slot 13 vanes total 6 Remove the rotorshaft 3 from the pump Be sure that the key 22 has been removed from the keyway so that it will not damage the shaft seals when the rotorshaft is removed 7 Turn the pressure adjustment screw 30 counterclockwise to release the tension on the governor spring 8 Remove the pressure ring 6 ring shoe 11 governor spring 9 retainer 41 and follower spring 10 9 If the shaft seal 24 are to
40. er aaa ata a a ital dd 1 lehnen 2 Kit Filter 1 Indicator 1 Page 23 TRONAIR APPENDIX Instrument Certification Notice TRONAIR INSTRUMENT CERTIFICATION NOTICE The gauge Certificates of Calibration supplied for the gauge s on this unit contain the calibration data for the actual instrument calibrated along with the calibration date of the STANDARD used to perform the calibration check The due date for re calibration of the instrument should be based upon the date the instrument was placed in service in your facility Re calibration should be done on a periodic basis as dictated by the end user s quality system or other overriding requirements Note that Tronair Inc does not supply certificates of calibration on flow meters or pyrometers unless requested at the time of placed order These instruments are considered reference indicators only and are not critical to the test s being performed on the aircraft 1740 Eber Rd Tronair Inc Phone 419 866 6301 Holland OH 43528 9794 www tronair com 800 426 6301 USA Email sales tronair com Fax 419 867 0634 TRONAIR APPENDIX Il Lincoln Motor Manual Lincoln MOTORS Instruction Manual Standard Motors Carefully read and fully understand this Owner s Manual prior to installation operation and maintenance of your moto
41. g direction interchange any two supply leads Couple the motor to its load and operate it for a minimum of one hour During this period check for any unusual noise or thermal conditions Check the actual operating current to be sure that the nameplate current times service factor is not exceeded for steady continuous loads 7 MAINTENANCE A WARNING ELECTRIC SHOCK can kill e Internal parts of the motor may be at line potential even when it is not rotating Disconnect all input power to the drive and motor before performing any maintenance Lincoln motors have been designed and manufactured with long motor life expectancy and trouble free operation in mind Periodically inspect the motor for excessive dirt friction or vibration Dust may be blown from an inaccessible location using compressed air Keep the ventilation openings clear to allow free passage of air Make sure the drain holes in the motors are kept open and the shaft slinger is positioned against the end bracket Grease or oil can be wiped by using a petroleum solvent Overheating of the bearings caused by excessive friction is usually caused by one of the following factors 1 Bent shaft 2 Excessive belt tension 3 Excessive end or side thrust from the gearing flexible coupling etc 4 Poor alignment Damaging vibrations can be caused by loose motor mountings motor misalignment resulting from the settling or distortion of the foundation or it may b
42. is material is not mutagenic in in vitro assays Slightly irritating to skin eyes and respiratory system in animal models Produced effects on body weight serum enzymes and or organ weights in repeat dose studies Both positive and negative responses observed in standard tests for genetic changes Slightly toxic following oral administration Practically nontoxic after skin application in animal studies Practically non irritating to eyes rabbit Slightly irritating to skin rabbit No mortality or signs of toxicity at the highest level tested Produced dermal sensitization guinea pigs The weight of the evidence indicates that this material is not mutagenic in in vitro assays The weight of the evidence indicates that this material is mutagenic in in vivo assays 12 ECOLOGICAL INFORMATION Environmental Toxicity Invertebrates Fish Algae Environmental fate Biodegradation 48h EC50 Water flea Daphnia magna 5 8 mg l 96h ECSO Rainbow trout Oncorhynchus mykiss 5 2 mg l 96h EC50 Fathead minnow Pimephales promelas 4 8 mg l 96h 50 Algae Selenastrum capricornutum 10 mg l Product name SKYDROL LD4 Fire resistant hydraulic fluid Solutia Inc Material Safety Data Sheet Reference Number 000000000183 Page 7 8 Date 03 18 2003 Version 5 1 E Readily biodegradable 13 DISPOSAL CONSIDERATIONS US EPA RCRA Status This material when discarded is not a hazardous waste as that term is defined b
43. ke the sample shown below _ RF _ 1__ H Basic Pump 6 __ Pump Capacity Pressure Range Rotation Mounting Fluid Type Port Options Mechanical Options Control Options Design Letter INSTALLATION PUMP DRIVE AND MOUNTING When mounting the pump and motor care must be taken to align the pump and motor shafts within 003 0 076 mm direct inline through a jaw type flexible web coupling This is recommended for all pumps Tire type flexing elements and chain type drives are not recommended With belt drives please consult factory To avoid axial and radical end loading of the pump shaft do not couple the pump and motor shafts rigidly Allow freedom at the coupling for the two shafts to ride independently To prevent end loading the space between the pump and motor shaft ends should be 1 2 inch 12 7 mm for PVR6 pumps or as the coupling manufacturer specifies Form 265664 Rev 2 05 1 Installation Continued PIPING AND RESERVOIR The pump should be mounted with a minimum number of elbows or fittings The pump suction should be at least 1 inch 25 4 mm tube pipe for PVR6 pumps For any system and combination of piping except High Water Based Fluids HWBF the vacuum at the pump inlet must not exceed seven inches of Mercury 5 inch Hg for fire resistant fluids HWBF Pumps are to have a positive inlet head in the range of 0 5 inch Hg t
44. llow power lead entry from the 3 6 9 or 12 o clock direction Motor Connection All single speed and two speed Lincoln motors are capable of across the line or autotransformer starting Reference the lead connection diagram located on the nameplate or inside of the terminal box cover Single speed motors have reduced voltage start capability per the following chart Number of Rated Voltages Number of Motor Leads Lead Numbers 1 YDS capability on lower voltage only 2 PWS capability on lower voltage only 1200 RPM 324T 365T steel frame motors with Model Number efficiency letters of S or H Contact Customer Service at 1 800 668 6748 phone 1 888 536 6867 fax or mailbox lincolnmotors com e mail for a copy of across the line and other reduced voltage start connection diagrams oe Connection Diagram 1 Single Voltage 6 Leads Part Winding Start Connection 1 2 PART WINDING STARTER La La iti T2 T3 7 T8 T9 1 bs La 1 Ti Connection Diagram 2 Single Voltage 6 Leads YA Start Connection La La La 1 YA STARTER La La Le ERRE T2 T3 T4 T5 76 E Ly Connection Diagram 3 Single Voltage 12 Leads YA Start Connection Ly Lo La 1 1 YA STARTER La La Ly La La Ly 4 2 08 24 25 26 Ta BEBE T7 78 TAO T 12 Connection Diagram 4 Single Voltage 12 Leads Part Win
45. lug C D Poe 9 6BSL 8B5L 255809 Governor Spring 1 94 160259 Caplug In 1 9 10851 113079 Governor Spring 1 95 137020 Caplug Out 1 10 6 06 8 06 165221 Folluwer Spring 1 96 1221 21 130437 Flange 2 10 10810 165220 Follower Spring 1 97 12 21 1221 253841 Spline Warning Tag 1 10 6 15 8 15 165222 Follower Spring 1 98 143391 Grease CAR 11 4B 144926 Ring Shoe Assembly 1 99 132779 LED Plate 250 LAR 11 6B 144913 Ring Shoe Assembly 1 Not Shown 11 8B 162770 Ring Shoe Assembly 1 11 10B 350448 Ring Shoe Assembly 1 11 6B3L 6B5L 112022 Ring Shoe Assembly 1 11 8B3L 8B5L 123174 Ring Shoe Assembly 1 11 10B3L 10B5L 350963 Ring Shoe Assembly 1 4 Form No 265664 Rev 2 05 PVR6 PARTS DRAWING Code 17 86 Codes 12 21 1221 WEAR PLATE KITS Includes Items 4 amp 5 SEAL KITS Includes Items 13 15 16 17 24 28 30 55 99 Includes Items 3 6 amp 21 Includes Items Kits Listed Here Plus item 11 ROTATING KITS COMPLETE REBUILD KITS Model Kit Number Model Kit Number Model Kit Number Model Kit Number 4B 257094 All Buna N HW 257093 4B 250758 4B 257095 6B 250747 All Viton 250457 4B 21 250815 4B 12 257096 8B06 250748 6B 250760 6B 250822 8B15 254700 VANE KITS 6B 12 254763 6B 12 250826 10B10 254911 _ Includes It
46. maintain setting NOTE Once the flow and pressure controls have been adjusted it is not necessary to change these settings after each operation unless desired 4 2 3 Reservoir Selector Valve Operation Operation of the reservoir selector valve allows the operator to select either the aircraft reservoir closed loop of the HPU reservoir open loop CAUTION The reservoir selector valve should only be operated when the HPU is not running The operation of the reservoir selector valve should be done prior to starting the HPU Aircraft Reservoir Position Closed Loop In this position the HPU is dependent on the aircraft reservoir and system for an adequate supply of fluid Cavitation due to an inadequate fluid supply from the aircraft may be indicated by erratic indication of the system pressure gauge or flowmeter Usually the aircraft fluid supply will be restricted due to small return oil lines in the aircraft Sometimes this problem can be minimized or eliminated by pressurizing the aircraft reservoir with air 05 2004 Rev 01 Page 5 TRONA Model 5030 Hydraulic Power Unit Aviation Phosphate Ester Type IV Fluids 4 2 3 Reservoir Selector Valve Operation continued CAUTION If the aircraft reservoir is pressurized do not exceed the aircraft manufacturer s recommendations If the aircraft reservoir cannot be pressurized or the cavitation persists decrease the flow control setting until the cavitation is eliminate
47. mp Drive and Mounting directions above for restrictions 4 Connect the case drain directly to tank or to a heat exchanger if the pump will be deadheading for long periods of time during operation using a full size line corresponding to the case drain in the pump or manifold If connected to a heat exchanger the case drain line should be protected with a 10 psi 0 7 bar maximum relief valve in parallel with the heat exchanger No other return lines should be connected in common with the case drain return 5 Rotate pump and motor by hand to insure free rotation 6 Set the machine controls to open the circuit and allow free flow from the pump back to tank or connect the pump outlet line directly to tank Jog the motor on and off several times on two seconds off three seconds until the pump is primed Check pump for proper direction of rotation during the jogging 7 After the pump has been primed run it for several minutes at lower than normal pressures with an open or intermittently open system which permits oil flow This will purge entrapped air from the pump and system 8 Neither volume adjustment nor pressure adjustment should be adjusted until the pump has been primed and running and air is purged 9 After air has been purged from the system the system can be closed and the pump adjusted to the required operating pressure 10 If necessary the volume adjustment can be adjusted to the required operating pressur
48. ncentration range 58 2 30 0 60 0 5 0 10 0 1 0 5 0 lt 10 0 Product name SKYDROL LD4 Fire resistant hydraulic fluid Solutia Inc Material Safety Data Sheet Reference Number 000000000183 WARNING STATEMENTS WARNING Causes eye irritation Causes skin irritation Page 2 8 Date 03 18 2003 Version 5 1 Causes respiratory tract irritation Contains material which may cause urinary bladder damage based on animal data POTENTIAL HEALTH EFFECTS Likely routes of exposure Eye contact Skin contact Inhalation Ingestion Signs and symptoms of overexposure Target organs systems eye and skin contact inhalation Highly irritating to eyes Highly irritating to skin No more than slightly toxic if absorbed Repeated contact may cause a drying solvent like action on the skin Severely irritating ifinhaled No more than slightly toxic if inhaled Significant adverse health effects are not expected to develop under normal conditions of exposure No more than slightly toxic if swallowed Significant adverse health effects are not expected to develop if only small amounts less than a mouthful are swallowed coughing sneezing headache nausea vomiting Contains material which may cause urinary bladder damage based on animal data Refer to Section 11 for toxicological information 4 FIRST AID MEASURES If in eyes If on skin f inhaled If swallowed Immediately flu
49. o 20 inch Hg Piping should be done with pickled pipe or seamless tubing free of dirt and scale Do not use galvanized or other pipe that tends to flake off A 100 mesh screen 60 mesh for fire resistant and HWEBF should be used on the pump suction line The screen should be located approximately two inches 50 8 mm from the bottom of the tank All lines returning oil to the tank should discharge at least two inches 50 8 mm below the minimum oil level and should be separated from the pump suction area by means of a baffle These lines should also include a 10 micron return line filter with the exception of the case drain line The pump case drain should be connected directly to the tank Pressure in excess of 10 psi 0 7 bar in the case drain line can result in shaft seal leakage It is recommended that the case drain be returned to the tank by a separate 3 8 inch 9 5 mm line STARTUP PROCEDURES The following instructions apply for initial startup of the hydraulic pump After an extended shutdown period start with item 5 CAUTION Never start a new pump installa tion against a blocked system 1 Check the nameplate for model number and rpm The arrow on the pump casting indicates direction of rotation 2 Pump suction line should extend below the lowest point of oil level but not less than two inches 50 8 mm above reservoir bottom 3 The pump and motor shafts must be aligned within 003 inches 0 076 mm See Pu
50. osed sheet Contact the brake manufacturer for additional information GROUNDING A WARNING ELECTRIC SHOCK can kill e Connect the motor frame to a good earth ground per the National Electrical Code and local codes to limit the potential to ground in the event of contact between live electrical parts and the metal exterior Lincoln motors may be electrically connected to earth ground using a terminal box mounting screw or a separate grounding screw when provided Both are accessible inside the mounted terminal box When a bronze mounting screw is supplied always use it as the grounding point In making the ground connection the installer should make certain that there is a good electrical connection between the grounding lead and the motor 6 OPERATION Three phase squirrel cage induction motors will operate successfully but not necessarily in accordance with nameplate ratings at voltages 10 percent above or below nameplated value at the design frequency WARNING MOVING PARTS can injure e Before starting the motor remove all unused shaft keys and loose rotating parts to prevent them from flying off and causing bodily injury e Keep away from moving parts ELECTRIC SHOCK can kill e Do not operate with covers removed e Do not touch electrically live parts After checking that the shaft key is secure operate the motor free of load and check the direction of rotation If the motor rotates in the wron
51. p flow in conjunction with the flowmeter Start Up Operation The bypass valve should be opened prior to starting the HPU in order to allow the motor to start under a no load condition Shut Down Operation Prior to shut down the bypass valve may be opened to bleed off any residual system pressure CAUTION JAN Excessive heat which could damage machine components will be generated if the bypass valve is partially opened or is used for regulating flow or pressure e Use the flow and pressure controls for regulation e Use the bypass valve for unloading the system 4 3 SAMPLE VALVE A sample 19 1972 is followed 4 4 BLEEDING AIR FROM SYSTEM Rapid fluctuations of the pressure gauge and flowmeter are indications of cavitation or entrapped air in the hydraulic lines and or components Air may enter the system when e Operating the unit with insufficient oil in the reservoir e Changing a component on the aircraft e Changing the hose connections and or couplings To Easily Purge the Unit of Air 1 Fill reservoir to recommended level 2 Open bypass valve 3 Place reservoir selector valve in Hydraulic Power Unit position 4 Start unit and adjust flow control to maximum position 4 4 Bleeding air from system continued on following page 05 2004 Rev 01 Page 6 TRONA Model 5030 Hydraulic Power Unit Aviation Phosphate Ester Type IV Fluids 4 4 BLEEDING AIR FROM SYSTEM continued 5 Run unit for five 5 valve
52. p out of drains and water courses precautions Methods for cleaning up Contain large spills with dikes and transfer the material to appropriate containers for reclamation or disposal Absorb remaining material or small spills with an inert material and then place in a chemical waste container Flush spill area with water Refer to Section 13 for disposal information and Sections 14 and 15 for reportable quantity information 7 HANDLING AND STORAGE Handling Avoid breathing vapour or mist Avoid contact with eyes skin and clothing Use with adequate ventilation Keep container closed Wash thoroughly after handling Emptied containers retain vapour and product residue Observe all recommended safety precautions until container is cleaned reconditioned or destroyed Do not reuse this container Storage General Stable under normal conditions of handling and storage 8 EXPOSURE CONTROLS PERSONAL PROTECTION Eye protection Wear chemical goggles Have eye flushing equipment available Product name SKYDROL LD4 Fire resistant hydraulic fluid Solutia Inc Material Safety Data Sheet Reference Number 0000000001 83 Hand protection Body protection Respiratory protection Ventilation Airborne exposure limits SKYDROL LD4 tributyl phosphate dibutyl phenyl phosphate 2 6 di tert butyl p cresol Page 4 8 Date 03 18 2003 Version 5 1 E Wear chemical resistant gloves Consult the glove clothing manuf
53. p to operate in an unload condition most of the time therefore extending pump life To Fill Aircraft Reservoir 1 sure that there is sufficient oil in the HPU reservoir 2 With both bypass valves open start machine and adjust flow control for approximately one 1 gpm 3 Close bypass valve and return line ball valve This will force oil returning from the aircraft through the return pressure relief valve causing a back pressure in the aircraft return line 4 sure that the aircraft system has unloaded If not adjust pressure control for 1 500 psi until aircraft does unload indicated by a drop in the panel system pressure gauge 5 Read the back pressure gauge and adjust the back pressure valve for 20 to 25 psi if necessary This action with the one 1 gpm flow rate will fill the aircraft reservoir with an overflow visible through the HPU panel mounted sight glass 6 When little or no air is visible in the sight glass the aircraft reservoir is filled The return line ball valve may now be opened and aircraft testing may start The flow control should be adjusted for a higher desired flow 7 For any tests requiring line back pressure close the return line ball valve and adjust the return line back pressure valve NOTE Since the Citation reservoir is pressurized the return line ball valve may be closed prior to shut down to prevent the aircraft reservoir from draining 5 0 MAINTENANCE 5 1 GENERAL MAINTENANCE e
54. r 1 SAFETY DEPENDS ON YOU Lincoln motors are designed and manufactured with safety in mind However your overall safety can be increased by properly installing operating and maintaining the motor Read and observe all instruc tions warnings and specific safety precautions included in this manual and THINK BEFORE YOU ACT 2 RECEIVING AND INSPECTION Check packing list and inspect motor to make certain no damage has occurred in shipment Claims for any damage done in shipment must be made by the purchaser against the transportation company Turn the motor shaft by hand to be certain that it rotates freely Be careful not to cut yourself on the shaft keyway it is razor sharp Check the nameplate for conformance with power supply and control equipment requirements 3 HANDLING A WARNING FALLING EQUIPMENT can injure e Lift only with equipment of adequate lifting capacity e If so equipped use lift ring s on the motor to lift ONLY the motor and accessories mounted by Lincoln In case of assemblies on a common base the motor lift ring s CANNOT be used to lift the assembly and base but rather the assembly should be lifted by a sling around the base or by other lifting means provided on the base In all cases care should be taken to assure lifting in the direction intended in the design of the lifting means Likewise precautions shouid be taken to prevent hazardous overloads due to deceleration acceleration o
55. r shock forces 4 STORAGE Motor stock areas should be clean dry vibration free and have a relatively constant ambient temperature For added bearing protection while the motor is in storage turn the motor shaft every six months A motor stored on equipment and component equipment prior to installation should be kept dry and protected from the weather If the equipment is exposed to the atmosphere cover the motor with a waterproof cover Motors should be stored in the horizontal position with drains operable and positioned in the lowest point CAUTION Do not completely surround the motor with the protective covering The bottom area should be open at all times Windings should be checked with a megohm meter Megger at the time equipment is put in storage Upon removal from storage the resistance reading must not have dropped more than 50 from the initial reading Any drop below this point necessitates electrical or mechanical drying Note the sensitivity of properly connected megohm meters can deliver erroneous values Be sure to carefully follow the megohm meter s operating instructions when making measurements All external motor parts subject to corrosion such as the shaft and other machined surfaces must be protected by applying a corrosion resistant coating 5 INSTALLATION For maximum motor life locate the motor in a clean dry well ventilated place easily accessible for inspecting cleaning and lubricating The
56. ressure psi 315 220 240 Pressure Change Turn bar 21 7 15 2 i 16 6 Adjustment Maximum ft lbs 8 0 2 7 6 8 27 6 8 Torque 5 0 7 0 94 0 37 0 94 Flow gpm 3 4 4 6 4 6 Change Turn 12 9 17 4 17 4 Volume Approx Min gpm 1 0 1 0 1 0 Adjustment Flow Adjust lpm 3 7 3 7 3 7 Maximum ft lbs 5 5 3 5 3 5 Torque m kg 0 76 0 48 0 48 Form No 265664 Rev 2 05 3 PVR6 PARTS LIST CODE Mo DESCRIPTION Seo PART DESCRIPTION 1 550177 Pump Body 1 13 307257 Teflon Seal Ring 1 1 4 550660 Pump Body 1 15 Buna N 124194 O Ring 1 2 550541 Cover 1 15 Viton 147177 _ O Ring _ 1 2 4 550658 Cover 1 17 Buna N 144929 O Ring 1 2 6B 8B 10B 12 550547 Cover 1 17 _ Viton 144966 __ 1 1221 18 198297 Soc Hd Cap Screw 4 2 4B 21 550659 Cover 1 18 4 21 6B 8B 198301 Soc Hd Cap Screw 4 3 407929 Rotorshaft 1 10B 21 1221 3 4B 407930 Rotorshaft 1 19 252792 Thrust Screw pza 3 4B 12 506066 Rotorshaft 1 20 250371 Thrust Screw Plug_ 1 3 6B 8B i0B 12 506069 Rotorshaft 1 21 __ 163797 Bushing Da 3 6B 8B 10B 550325 Rotorshaft 1 22 126225 Key 1 1221 23 004223 Roll Pin 3 3 4B 21 550326 Rotorshaft 1 24 130795 Lip Seal 1 3 6 8 10 21 550327 Rotorsh
57. riod of warranty all such liability shall terminate The foregoing guarantees and remedies are exclusive and except as above set forth there are no guarantees or warranties with respect to accessories or equipment either expressed or arising by option of law or trade usage or otherwise implied including with limitation the warranty of merchantability all such warranties being waived by the Buyer indicates change since last printing Information subject to change 1999 Lincoln Motors Electrical Group Regal Beloit Corporation Printed in U S A TRONAIR APPENDIX III Continental Hydraulics Service Booklet PVR6 G Design Series Pumps CONTINENTAL HYDRAULICS 2 CAUTION Before performing service operation on any pump be sure that all pressure has been relieved from BOTH SIDES of the system CAUTION Before performing any service operation on any pump disconnect or lock off power supply CAUTION Before starting pump be sure that any resulting machine function will not endanger persons or equipment gt gt gt PRODUCT IDENTIFICATION Each pump has an Ordering Code stamped on its nameplate See Figure 1 above for the location of the Ordering Code ORDERING Seien RF 0 6 H een i Pin Figure 1 This service manual applies to products with Ordering Codes li
58. s This product can not be modified without the written approval of Tronair Inc Any modifications done without written approval voids all warranties and releases Tronair Inc its suppliers distributors employees or financial institutions from any liability from consequences that may occur Only Tronair OEM replacement parts shall be used 1 0 GENERAL DESCRIPTION The Tronair Hydraulic Power Unit HPU provides a source of clean pressurized hydraulic fluid for performing required aircraft maintenance Important features include Pressure compensated pump with integral pressure and flow controls 10 gallon reservoir with selector valve Bypass valve Cooler located inside reservoir Manual starter with overload protection Non bypass filter with 2 micron filter element 2 0 TECHNICAL SPECIFICATIONS 2 1 HYDRAULIC Fluid Aviation Phosphate Ester Type IV Fluids Pressure Range 300 1 750 psi Flow Range 0 6 gpm 60 Hz systems 0 5 gpm 50 Hz systems Filtration 2 Micron Absolute Non Bypass Reservoir Capacity 10 gal 38 1 Maximum 2 2 ELECTRICAL Power Requirements 3 Phase Alternating Current 60 Hz 50 Hz 9 2 amps 208 VAC 9 3 amps 220 VAC 8 4 amps 230 VAC 4 6 amps 380 415 440 VAC 4 2 amps 460 VAC 3 7 amps 575 VAC 2 3 MECHANICAL Dimensions Length 35 in 89 cm Width 30 in 76 cm Height 24 in 61 cm Weight 400 Ibs 181 kg 3 0 PREPARATION FOR USE The HPU is shipped completely assembled and only
59. sh the area with plenty of water Remove contaminated clothing Wash skin gently with soap as soon as it is available Get medical attention Wash clothing before reuse Remove patient to fresh air If not breathing give artificial respiration If breathing is difficult give oxygen Remove material from eyes skin and clothing Immediate first aid is not likely to be required A physician or Poison Control Center can be contacted for advice Wash heavily contaminated clothing before reuse Product name SKYDROL LD4 Fire resistant hydraulic fluid Solutia Inc Material Safety Data Sheet Reference Number 000000000183 Page 3 8 Date 03 18 2003 Version 5 1 E Notes to physicians After flushing eyes for at least 15 minutes opthalmic preparations of sterile mineral or castor oil may be instilled one time in the exposed eye for relief of pain 5 FIRE FIGHTING MEASURES Flash point 160 C Cleveland Open Cup Fire point 176 C ASTM D 2155 Autoignition temperature 398 C ASTM D 2155 Hazardous products of combustion None known Extinguishing media Water spray foam dry chemical or carbon dioxide Unusual fire and explosion hazards None known Fire fighting equipment Firefighters and others exposed wear self contained breathing apparatus Equipment should be thoroughly decontaminated after use 6 ACCIDENTAL RELEASE MEASURES Personal precautions Use personal protection recommended in section 8 Environmental Kee
60. st be serviced after testing which is standard procedure 4 2 PRELIMINARY ADJUSTMENTS AND OPERATIONS The following are basic to the operation of the HPU and should be thoroughly understood The pressure and flow controls have lock nuts to prevent rotation of the control shafts during operation These nuts should be moved away from the pump during adjustments of flow or pressure in order to eliminate binding of the control shafts The following are basic to the operation of the HPU and should be thoroughly understood The pressure and flow controls have lock nuts to prevent rotation of the control shafts during operation These nuts should be moved away from the pump during adjustments of flow or pressure in order to eliminate binding of the control shafts 4 2 1 Flow Control Adjustment a Open bypass valve b Select Hydraulic Power Unit position with reservoir selector valve c Start HPU d Adjust flow control for maximum desired flow Observing the flowmeter read flow gallons per minute directly from flowmeter scale Be sure the control shaft lock nut is loose during adjustment Tighten after adjustment to maintain setting 4 2 2 Pressure Control Adjustment a Open bypass valve b Select Hydraulic Power Unit position with reservoir selector valve c Start HPU d Close bypass valve e Adjust pressure control for desired pressure Be sure the control shaft lock nut is loose during adjustment Tighten after adjustment to
61. the completeness or accuracy thereof Information is supplied upon the condition that the persons receiving same will make their own determination as to its suitability for their purposes prior to use In no event will Solutia Inc be responsible for damages of any nature whatsoever resulting from the use reliance upon Information NO REPRESENTATIONS OR WARRANTIES EITHER EXPRESS OR IMPLIED OF MERCHANTABILITY FITNESS FOR A PARTICULAR PURPOSE OR OF ANY OTHER NATURE ARE MADE HEREUNDER WITH RESPECT TO INFORMATION OR THE PRODUCT TO WHICH INFORMATION REFERS
62. the following steps are required to make the unit operational 3 1 SERVICING RESERVOIR Remove the sheet metal cover and fill the reservoir with the correct fluid until fluid level is slightly above the minimum oil level mark Since a case drain cooler is located in the HPU reservoir it is important that this fluid level be maintained in order to prevent excessive heat buildup 3 2 CONNECTING ELECTRICAL LEADS Install plug onto the electrical cord and check for proper motor rotation by bumping the On Off switch Correct motor rotation is indicated by an arrow on pump motor adapter If rotation is not correct change any two of the three input leads inside the on off switch box or at the plug NOTE Balanced three phase voltage must be available to prevent overheating and damage to the motor Voltage unbalanced between phases occurs when the voltages differ from one another Some reasons for imbalance are 1 Unequal loading of each phase 2 Poor connections in the supply 1 Single phase condition caused by blown fuses or bad connections If these conditions occur in the incoming power system a protective device such as a voltage monitor should be installed on the machine to prevent motor damage 05 2004 Rev 01 Page 4 TRONA Model 5030 Hydraulic Power Unit Aviation Phosphate Ester Type IV Fluids 4 0 OPERATION Due to the complexity differences and ongoing changes in aircraft hydraulic systems no attempt has
63. tion 2 Open bypass valve 4 5 3 Operation 1 Start HPU 2 Close bypass valve 4 5 4 Shut Off 1 Open bypass valve 2 Stop HPU 4 6 OPTIONS The following options are available on some models of hydraulic power units Refer to the appropriate option description for operation information 4 6 1 Dual System Option C Operation The dual system option allows control of fluid flow to aircraft with two hydraulic systems The systems consist of two sets of hoses and valves located in the pressure and return systems The valves are mounted on the rear of the hydraulic power unit and are of the 90 ball type The valves are open when the operating handle is in line with the valve Although both systems may be operated simultaneously usually only one system is required at any one time If both valve sets are open simultaneously the pump output will be divided between the two systems Also cross flow between the reservoirs may occur if a reservoir level or pressure differential exists Select valve positions prior to starting machine To Operate the Dual System 1 Before starting machine open pressure and return valves of the same system WARNING Ensure pressure and return hoses of the same system are paired and used together 2 After completing tests on one system shut the machine OFF before selecting the second system WARNING AN Never open or close dual system valves without shutting off the hydraulic power unit Damage to the
64. urrs before pressing in the new bearings 4 Check all of the replacement parts for nicks or burrs and then lubricate them with clean oil before reassembly 5 Worn port and thrust plates should not be reground to clean up the wear surface if the plates are ground the assembly clearance will become excessive and the seal rings in the thrust plate may rupture Replace worn port and thrust plates if necessary 6 Assemble the springs 9 10 and ring shoe 11 pressure ring 6 and rotorshaft 3 7 To assure proper vane assembly place the vanes 7 with the beveled edge out against the pressure ring 8 Assemble the square seal rings into the cavity in the back of the thrust plate The soft rubber seal ring 15 should be assembled first and the hard seat ring 13 should be assembled on top of them Stretch the larger soft seal ring slightly so it clings to the ID at the cavity Apply clean oil or STP to the back of the thrust plate before it is placed in the locating pins in the body to help hold the parts together while they are assembled 9 Before fitting the cover into the housing check to assure that the bore in the port plate is concentric to the bearing bore in the cover If the bores are not concentric the port place must be relocated 180 on the locating pins 6 Form No 265664 Rev 2 05 PVR6 PUMP REPAIR PROCEDURES Continued 10 Assemble the cover 2 and port plate 4 onto the 14 Turn pump upside down
65. y the Resource Conservation and Recovery Act RCRA 40 CFR 261 Disposal considerations Incineration Recycle Miscellaneous advice This product meets the criteria for a synthetic used oil under the U S EPA Standards for the Management of Used Oil 40 CFR 279 Those standards govern recycling and disposal in lieu of 40 CFR 260 272 of the Federal hazardous waste program in states that have adopted these used oil regulations Consult your attorney or appropriate regulatory official to be sure these standards have been adopted in your state Recycle or burn in accordance with the applicable standards Local state provincial and national disposal regulations may be more or less stringent This product should not be dumped spilled rinsed or washed into sewers or public waterways 14 TRANSPORT INFORMATION The data provided in this section is for information only Please apply the appropriate regulations to properly classify your shipment for transportation US DOT Other Not regulated for transport Canadian TDG Other Not regulated for transport 15 REGULATORY INFORMATION All components are in compliance with U S TSCA EU EINECS Canadian DSL Australian AICS Korean the following inventories Japanese ENCS Chinese Canadian WHMIS classification D2 B Materials Causing Other Toxic Effects SARA Hazard Notification Hazard Categories Under Title IH Immediate Rules 40 CFR 370 Delayed Section 302 Extremely

Operation & Service Manual Model: 5030 Hydraulic Power

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Operation &amp; Service Manual Model: 5030 Hydraulic Power

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Operation & Service Manual Model: 5030 Hydraulic Power