chapter “e” inspection and maintenance …...property of american airlines hydraulic ground...
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HYDRAULIC GROUND POWER UNIT <HGPU60-50-1DSX-AMA>
INSPECTION AND MAINTENANCE Page E-102.02.2017 MAWN
CHAPTER “E”
INSPECTION AND MAINTENANCE
- SURVEY - MAINTENANCE INTERVALS
- OPEN THE COVER
- SAFETY INSTRUCTIONS
1. VISUAL INSPECTION
2. CLEANING
3. INSPECTION
4. FILTER
5. TANK [501]
6. MAINTENANCE OF THE SCREW
SYSTEM
7. PUMPS
8. OIL-AIR COOLERS
9. CLEANING / LUBRICATING /
INSPECTING THE CHASSIS
Only
Only
Only
4. FILTER
5. TANK [501]
for
2. CLEANING
3. INSPECTION
info
rmation!
info
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info
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info
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info
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- SURVEY - MAINTENANCE INTERVALS
- SAFETY INSTRUCTIONS
1. VISUAL INSPECTION
No
5. TANK [501]
6. MAINTENANCE OF THE SCREW
revis
ion
3. INSPECTION
4. FILTER
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HYDRAULIC GROUND POWER UNIT <HGPU60-50-1DSX-AMA>
INSPECTION AND MAINTENANCE Page E-202.02.2017 MAWN
CHAPTER “E”
INSPECTION AND MAINTENANCE
10. MAINTENANCE OF THE HOISTING
DEVICE
11. DIESEL ENGINE
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for in
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info
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10. MAINTENANCE OF THE HOISTING
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SURVEY - MAINTENANCE INTERVALS
This list gives a survey of the tasks to be carried out and intervals to be observed in inspection
and maintenance of the ”HYDRAULIC GROUND POWER UNIT“.
HYDRAULIC GROUND POWER UNIT <HGPU60-50-1DSX-AMA>
INSPECTION AND MAINTENANCE Page E-302.02.2017 MAWN
Leakage inspection of the complete unit -- weekly
(inspect for eventual internal or external leakage)
Cleaning and lubricating of all hinges, -- periodically
locks and slideways
Visual inspection (external) 1.1. before each test run
(daily)
Visual inspection (internal, switch cabinet) 1.2. monthly
Cleaning 2. weekly
Inspection of the electrical protection elements 3.1. after failure
Inspection of filters 4.1. indication by led-signal lamp
Inspection of the fill level 5.1. before each test run
(daily)
Maintenance of the screw system 6. 3 times with the interval of
Retightening of the union nut one month after delivery
annually afterwards
Pumps 7. annually
INSPECTION AND MAINTENANCE
TO BE DONEPARA INTERVAL
+ CAUTION +
FAILURE TO CARRY OUT THE FOLLOWING OPERATIONS WITHOUT DUE CARE
CAUSE SERIOUS ACCIDENTS OR DAMAGE TO THE ASSEMBLIES
AND THE TEST BENCH COMPONENTS.
Only
Cleaning 2. weekly
Inspection of the electrical protection elements 3.1. after failure
for (daily)
Visual inspection (internal, switch cabinet) 1.2. monthly
info
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Leakage inspection of the complete unit -- weekly
(inspect for eventual internal or external leakage)
Cleaning and lubricating of all hinges, -- periodically
Visual inspection (external) 1.1. before each test runinfo
rmation!
Leakage inspection of the complete unit -- weekly
info
rmation!
PARA
info
rmation!
FAILURE TO CARRY OUT THE FOLLOWING OPERATIONS WITHOUT DUE CARE
CAUSE SERIOUS ACCIDENTS OR DAMAGE TO THE ASSEMBLIES
AND THE TEST BENCH COMPONENTS.
No
Inspection of the electrical protection elements 3.1. after failure
Inspection of filters 4.1. indication by led-signal lamp
revis
ion
Visual inspection (external) 1.1. before each test run
(daily)
Visual inspection (internal, switch cabinet) 1.2. monthly
Cleaning 2. weekly
revis
ion
Visual inspection (external) 1.1. before each test run
(daily)
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Leakage inspection of the complete unit -- weekly
Cleaning and lubricating of all hinges, -- periodicallyserv
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HYDRAULIC GROUND POWER UNIT <HGPU60-50-1DSX-AMA>
INSPECTION AND MAINTENANCE Page E-402.02.2017 MAWN
(Continuation)
Oil-air coolers 8. annually
Cleaning / lubricating/inspecting the chassis 9. annually
Maintenance of the hoisting device (cover) 10. annually
Diesel engine 11. see manufacturer
documentation
INSPECTION AND MAINTENANCE
TO BE DONEPARA INTERVAL
Note
Test and replacement of hoses must be performed i.a.w.
current norms and customer requirements.
„TEST-FUCHS“ recommends replacement of hoses after 7 years at the latest!
Only
Only
„TEST-FUCHS“ recommends replacement of hoses after 7 years at the latest!for Test and replacement of hoses must be performed i.a.w.
current norms and customer requirements.
„TEST-FUCHS“ recommends replacement of hoses after 7 years at the latest!
info
rmation!
info
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info
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info
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info
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info
rmation!
Cleaning / lubricating/inspecting the chassis 9. annually
Maintenance of the hoisting device (cover) 10. annually
Diesel engine 11. see manufacturer
documentation
info
rmation!
info
rmation!
Diesel engine 11. see manufacturer
documentation
info
rmation!
info
rmation!
No
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Note
Test and replacement of hoses must be performed i.a.w.
current norms and customer requirements.
„TEST-FUCHS“ recommends replacement of hoses after 7 years at the latest!
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Diesel engine 11. see manufacturer
documentationserv
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OPEN THE COVER
Close the retaining screw and lift the cover by moving the towing bar up and down equally.
++ WARNING ++
TO PREVENT AN UNINTENTIONAL OPENING OF THE COVER,
SECURE THE HAND LEVER INSIDE THE SWITCH CABINET.
After the cover is opened completely, secure it against falling by the mechanic locking!
In order to lower the cover, remove the mechanic lock
and lower the cover - by opening the retaining screw -
into closed position.
HYDRAULIC GROUND POWER UNIT <HGPU60-50-1DSX-AMA>
INSPECTION AND MAINTENANCE Page E-502.02.2017 MAWN
Mechanic
locking
Retaining screw Hand leverStorage room in
the switch cabinet
Only
URE THE HAND LEVER INSIDE THE SWITCH CABINET.
After the cover is opened completely, secure it against falling by the mechanic locking!
Only
for
TO PREVENT AN UNINTENTIONAL OPENING OF THE COVER, for in
form
ation!
info
rmation!
Hand leverinfo
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info
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++ WARNING ++
TO PREVENT AN UNINTENTIONAL OPENING OF THE COVER,
URE THE HAND LEVER INSIDE THE SWITCH CABINET.
After the cover is opened completely, secure it against falling by the mechanic locking!revis
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SAFETY INSTRUCTIONS
++ WARNING ++
PLEASE FOLLOW THE SAFETY INSTRUCTIONS GIVEN IN THE CHAPTER “A“!
PLEASE FOLLOW THE INSTRUCTIONS
GIVEN IN THE CHAPTER “LOCKOUT AND TAGOUT“
AT THE BEGINNING OF THIS CHAPTER!
HYDRAULIC GROUND POWER UNIT <HGPU60-50-1DSX-AMA>
INSPECTION AND MAINTENANCE Page E-602.02.2017 MAWN
Only
for in
form
ation!
PLEASE FOLLOW THE INSTRUCTIONS
GIVEN IN THE CHAPTER “LOCKOUT AND TAGOUT“
AT THE BEGINNING OF THIS CHAPTER!
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1. VISUAL INSPECTION
At visual inspection the external and the internal components (after opening the cover) of the
hydraulic supply have to be inspected.
++ WARNING ++
FOR SECURITY REASONS - BEFORE VISUAL INSPECTION -
POWER SUPPLY MUST BE SWITCHED-OFF!
HYDRAULIC SUPPLY CONTAINS DEVICES, WHICH SAVE A LOT OF POWER.
IMPROPER USE CAN CAUSE ELECTRIC SHOCK OR SERIOUS BURNS!
1.1. DAILY VISUAL INSPECTION
Examine perfect condition, firm mounting and mechanical function of connection hoses
Examine leakage of outputs and screwed connections of all hoses
Examine damages of external covers (damaged lacquering, dent, deformation, blister etc.)
Examine perfect condition, firm mounting and mechanical function of external covers and their
components
Remedy, if corrosion of metallic parts occur
Examine loose fit, burned, bent or broken contacts of free accessible connectors and plugs
Examine cables for insulation faults, loose connectors and burned, bent or broken contacts
1.2. MONTHLY VISUAL INSPECTION
In addition to daily visual inspection do this visual inspection every month resp. after longer
inactivity
Leakage of internal piping and hosing
Examine the components of the switch cabinet
HYDRAULIC GROUND POWER UNIT <HGPU60-50-1DSX-AMA>
INSPECTION AND MAINTENANCE Page E-702.02.2017 MAWN
Only
loose fit, burned, bent or broken contacts of free accessible connectors and plugs
cables for insulation faults, loose connectors and burned, bent or broken contacts
for perfect condition, firm mounting and mechanical function of external covers and their
Remedy, if corrosion of metallic parts occur
info
rmation! FOR SECURITY REASONS - BEFORE VISUAL INSPECTION -
POWER SUPPLY MUST BE SWITCHED-OFF!
HYDRAULIC SUPPLY CONTAINS DEVICES, WHICH SAVE A LOT OF POWER.
IMPROPER USE CAN CAUSE ELECTRIC SHOCK OR SERIOUS BURNS!
mine perfect condition, firm mounting and mechanical function of connection hoses
leakage of outputs and screwed connections of all hoses
mine damages of external covers (damaged lacquering, dent, deformation, blister etc.)
No cables for insulation faults, loose connectors and burned, bent or broken contacts
1.2. MONTHLY VISUAL INSPECTION
revis
ion leakage of outputs and screwed connections of all hoses
mine damages of external covers (damaged lacquering, dent, deformation, blister etc.)
perfect condition, firm mounting and mechanical function of external covers and their
Remedy, if corrosion of metallic parts occur
loose fit, burned, bent or broken contacts of free accessible connectors and plugs
cables for insulation faults, loose connectors and burned, bent or broken contacts
serv
iceHYDRAULIC SUPPLY CONTAINS DEVICES, WHICH SAVE A LOT OF POWER.
IMPROPER USE CAN CAUSE ELECTRIC SHOCK OR SERIOUS BURNS!
mine perfect condition, firm mounting and mechanical function of connection hoses
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HYDRAULIC GROUND POWER UNIT <HGPU60-50-1DSX-AMA>
INSPECTION AND MAINTENANCE Page E-802.02.2017 MAWN
2. CLEANING
++ WARNING ++
CLEANING WITH DETERGENTS IS ONLY ALLOWED IF THE WORKING ROOM
IS WELL VENTILATED!
THE USAGE OF FIRE-HAZARDOUS DETERGENTS CAN CAUSE EXPLOSION!
+ CAUTION +
CLEANING WITH ISOPROPYL ALCOHOL, ETHANOL OR
DILUENTS IS NOT PERMISSIBLE BECAUSE OF THE RISK TO DAMAGE SOME
PLASTIC PARTS.
RECOMMENDED FOR CLEANING ARE PHOSPHATE-FREE, DILUTABLE GENERAL
PURPOSE CLEANERS OR WORKSHOP CLEANERS.
All the exterior covers incl. the frame, the front panels etc. should be checked regularly for dust
or dirt. If required dust and dirt should be removed by means of a vacuum cleaner, by means of
a lintfree cloth or of a brush.
Also the interior of the test equipment should be clean and dust-free.
+ CAUTION +
THE CABLE CHANNELS MUST NOT BE OPENED.
Only
THE CABLE CHANNELS MUST NOT BE OPENED.
for
Also the interior of the test equipment should be clean and dust-free.info
rmation!
THE USAGE OF FIRE-HAZARDOUS DETERGENTS CAN CAUSE EXPLOSION!
CLEANING WITH ISOPROPYL ALCOHOL, ETHANOL OR
DILUENTS IS NOT PERMISSIBLE BECAUSE OF THE RISK TO DAMAGE SOME
PLASTIC PARTS.
RECOMMENDED FOR CLEANING ARE PHOSPHATE-FREE, DILUTABLE GENERAL
PURPOSE CLEANERS OR WORKSHOP CLEANERS.
All the exterior covers incl. the frame, the front panels etc. should be checked regularly for dust
or dirt. If required dust and dirt should be removed by means of a vacuum cleaner, by means of
Also the interior of the test equipment should be clean and dust-free.
No
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ion or dirt. If required dust and dirt should be removed by means of a vacuum cleaner, by means of
Also the interior of the test equipment should be clean and dust-free.
+ CAUTION +
THE CABLE CHANNELS MUST NOT BE OPENED.
serv
iceCLEANING WITH ISOPROPYL ALCOHOL, ETHANOL OR
DILUENTS IS NOT PERMISSIBLE BECAUSE OF THE RISK TO DAMAGE SOME
RECOMMENDED FOR CLEANING ARE PHOSPHATE-FREE, DILUTABLE GENERAL
PURPOSE CLEANERS OR WORKSHOP CLEANERS.
All the exterior covers incl. the frame, the front panels etc. should be checked regularly for dust
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HYDRAULIC GROUND POWER UNIT <HGPU60-50-1DSX-AMA>
INSPECTION AND MAINTENANCE Page E-902.02.2017 MAWN
3. INSPECTION
3.1. INSPECTION OF ELECTRICAL PROTECTION ELEMENTS
If you find a failure (non-function) in an assembly, first examine all fuse links of applicable fuse
protection resp. reset applicable automatic cutout, power switch, circuit breaker etc.
Automatic cutout and power switches are installed in the switch cabinet.
++ WARNING ++
BEFORE OPENING THE DOOR OF THE UNIT, IT IS
ESSENTIAL TO ISOLATE THE ON-SITE POWER SUPPLY!
In order to get to the location of respective electrical protection elements, the cover must be
closed and the switch cabinet door needs to be opened.
Location and function of the individual electrical protection elements you can find in the
list of electrical protection elements sticked in the switch cabinet.
Only
for
Location and function of the individual electrical protection elements you can find in the Location and function of the individual electrical protection elements you can find in the
list of electrical protection elements sticked in the switch cabinet.list of electrical protection elements sticked in the switch cabinet.
info
rmation! Automatic cutout and power switches are installed in the switch cabinet.Automatic cutout and power switches are installed in the switch cabinet.
WARNING ++WARNING ++
BEFORE OPENING THE DOOR OF THE UNIT, IT IS BEFORE OPENING THE DOOR OF THE UNIT, IT IS
TIAL TO ISOLATE THE ON-SITE POWER SUPPLY!TIAL TO ISOLATE THE ON-SITE POWER SUPPLY!
In order to get to the location of respective electrical protection elements, the cover must beIn order to get to the location of respective electrical protection elements, the cover must be
closed and the switch cabinet door needs to be opened.closed and the switch cabinet door needs to be opened.
Location and function of the individual electrical protection elements you can find in the Location and function of the individual electrical protection elements you can find in the
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ion In order to get to the location of respective electrical protection elements, the cover must beIn order to get to the location of respective electrical protection elements, the cover must be
closed and the switch cabinet door needs to be opened.closed and the switch cabinet door needs to be opened.
Location and function of the individual electrical protection elements you can find in the Location and function of the individual electrical protection elements you can find in the
list of electrical protection elements sticked in the switch cabinet.list of electrical protection elements sticked in the switch cabinet.
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BEFORE OPENING THE DOOR OF THE UNIT, IT IS BEFORE OPENING THE DOOR OF THE UNIT, IT IS
TIAL TO ISOLATE THE ON-SITE POWER SUPPLY!TIAL TO ISOLATE THE ON-SITE POWER SUPPLY!
In order to get to the location of respective electrical protection elements, the cover must be
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HYDRAULIC GROUND POWER UNIT <HGPU60-50-1DSX-AMA>
INSPECTION AND MAINTENANCE Page E-1002.02.2017 MAWN
Figure E01
“LOCATION OF ELECTRICAL PROTECTION ELEMENTS“
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INSPECTION AND MAINTENANCE Page E-1102.02.2017 MAWN
4. FILTER
4.1. INSPECTION OF FILTERS
During operation (oil flow must be ensured) the mounted contamination indication (differential
pressure switch) monitors condition of the filter
Contamination of the filter is indicated by the led-signal lamp (+1B1-P5) at the control panel.
The interval of filter replacement depends on the respective contamination level of filters in the
hydraulic supply.
4.2. LOCATION OF FILTERS
Filters are located inside the hydraulic supply, they can be accessed easily, after opening the
cover.
See next figure for location of respective filters.
4.3. REPLACEMENT OF FILTERS
++ WARNING ++
REPLACEMENT OF FILTERS MUST BE CARRIED OUT AFTER
SHUT DOWN OF THE HYDRAULIC SUPPLY!
IN ORDER TO PERFORM REPLACEMENT OF FILTERS THE COVER
MUST BE OPENED. AFTER THE COVER IS OPENED, IT MUST BE SECURED
AGAINST FALLING BY A MECHANIC LOCK! DANGER OF INJURIES !
Instruction:
- When the unit is shut down, hydraulic supply of the respective filter is unpressurized, the
filter can be dismantled.
- Prepare a suitable drain tray to collect leaking test medium in order to protect the unit against
contamination.
Only
SHUT DOWN OF THE HYDRAULIC SUPPLY!
IN ORDER TO PERFORM REPLACEMENT OF FILTERS THE COVER
MUST BE OPENED. AFTER THE COVER IS OPENED, IT MUST BE SECURED
AGAINST FALLING BY A MECHANIC LOCK! DANGER OF INJURIES !
for
REPLACEMENT OF FILTERS MUST BE CARRIED OUT AFTER
info
rmation! Contamination of the filter is indicated by the led-signal lamp (+1B1-P5) at the control panel.
The interval of filter replacement depends on the respective contamination level of filters in the
Filters are located inside the hydraulic supply, they can be accessed easily, after opening the
See next figure for location of respective filters.
No MUST BE OPENED. AFTER THE COVER IS OPENED, IT MUST BE SECURED
AGAINST FALLING BY A MECHANIC LOCK! DANGER OF INJURIES !
revis
ion
++ WARNING ++
REPLACEMENT OF FILTERS MUST BE CARRIED OUT AFTER
SHUT DOWN OF THE HYDRAULIC SUPPLY!
IN ORDER TO PERFORM REPLACEMENT OF FILTERS THE COVER
MUST BE OPENED. AFTER THE COVER IS OPENED, IT MUST BE SECURED
serv
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Filters are located inside the hydraulic supply, they can be accessed easily, after opening the
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INSPECTION AND MAINTENANCE Page E-1202.02.2017 MAWN
- Unscrew the filter bowl (made of steel) with an appropriate spanner (resp. manually) and turn
it off.
- Remove the filter element by slightly moving it to and fro, dispose it professionally.
- Clean the filter bowl with an appropriate medium (test medium or similar fluid). Examine damages
on the O-ring inside the filter bowl and the filter element attachment, replace them if necessary.
- Make sure that the order number, indicated on the replacement element corresponds to the
order number given in the hydraulic parts list
- Replace the old filter element by a new one, manually screw the cleaned filter bowl into the
filter head.
- Oil the O-ring - filter housing slightly with the test medium.
- Screw in the filter bowl until the mechanical stop is reached. Then screw it out by 1/8 to 1/4
revolutions
- Examine leakage of filters immediately after replacing them. The system needs to be
ventilated (see chapter ”D“ para 1.2. FLUSHING OF HYDRAULIC CIRCUIT)
Note
When replacing the optional filter [820]
the hydraulic system does not need to be ventilated.
- Close the cover
- Used O-rings resp. filter elements need to be disposed professionally
Only
for
- Used O-rings resp. filter elements need to be disposed professionally- Used O-rings resp. filter elements need to be disposed professionally
info
rmation! - Replace the old filter element by a new one, manually screw the cleaned filter bowl into the- Replace the old filter element by a new one, manually screw the cleaned filter bowl into the
- Oil the O-ring - filter housing slightly with the test medium.- Oil the O-ring - filter housing slightly with the test medium.
- Screw in the filter bowl until the mechanical stop is reached. Then screw it out by 1/8 to 1/4- Screw in the filter bowl until the mechanical stop is reached. Then screw it out by 1/8 to 1/4
- Examine leakage of filters immediately after replacing them. The system needs to be - Examine leakage of filters immediately after replacing them. The system needs to be
ventilated (see chapter ”D“ para 1.2. FLUSHING OF HYDRAULIC CIRCUIT)ventilated (see chapter ”D“ para 1.2. FLUSHING OF HYDRAULIC CIRCUIT)
Note Note
When replacing the optional fiWhen replacing the optional fi
the hydraulic system does not need to be ventithe hydraulic system does not need to be venti
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When replacing the optional fiWhen replacing the optional fi
the hydraulic system does not need to be ventithe hydraulic system does not need to be venti
- Used O-rings resp. filter elements need to be disposed professionally- Used O-rings resp. filter elements need to be disposed professionally
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- Screw in the filter bowl until the mechanical stop is reached. Then screw it out by 1/8 to 1/4- Screw in the filter bowl until the mechanical stop is reached. Then screw it out by 1/8 to 1/4
- Examine leakage of filters immediately after replacing them. The system needs to be - Examine leakage of filters immediately after replacing them. The system needs to be
ventilated (see chapter ”D“ para 1.2. FLUSHING OF HYDRAULIC CIRCUIT)ventilated (see chapter ”D“ para 1.2. FLUSHING OF HYDRAULIC CIRCUIT)
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HYDRAULIC GROUND POWER UNIT <HGPU60-50-1DSX-AMA>
INSPECTION AND MAINTENANCE Page E-1302.02.2017 MAWN
Figure E02
“FILTER“
[514] =
LOW
PRESSURE
FILTER
[820]
FILTER
IN RETURN
LINE
[563]
FILL
FILTER
[543]
HIGH
PRESSURE
FILTER
Only
N
o
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HYDRAULIC GROUND POWER UNIT <HGPU60-50-1DSX-AMA>
INSPECTION AND MAINTENANCE Page E-1402.02.2017 MAWN
Contamination indication
Gasket set for
contamination indication
Gasket set for cover
Filter bowl
Filter element
Cover
Figure E03
“HYDRAULIC FILTER, GENERAL DRAWING“
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for in
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INSPECTION AND MAINTENANCE Page E-1502.02.2017 MAWN
Spread sheet E01
“REPLACEMENT OF FILTER ELEMENTS“
[514] electrical (indication
by led-signal lamp
(+1B1-P5))
[543] electrical (indication
by led-signal lamp
(+1B1-P5))
[563] electrical (indication
by led-signal lamp
(+1B1-P5))
[820] electrical (indication
by led-signal lamp
(+1B1-P5))
Item
no /
Filter
Filter contamination
indication
Filter element
Order designation
(Order number)Manufacturer
The corresponding
filter elements
please find in the
Spare parts list
in chapter “G“.
Mahle
Mahle
Mahle
Mahle
Only
Only
for in
form
ation!
info
rmation!
info
rmation!
info
rmation!
The corresponding
filter elements
please find in the
Spare parts l
in chapter “G“.
No
“REPLACEMENT OF FILTER ELEMENTS“
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INSPECTION AND MAINTENANCE Page E-1602.02.2017 MAWN
5. TANK [501]
5.1. INSPECTION OF THE FILL LEVEL
++ CAUTION ++
THE COVER MUST BE OPENED IN ORDER TO PERFORM MAINTENANCE
AT THE TANK [501]. AFTER THE COVER IS OPENED, IT MUST
BE SECURED AGAINST FALLING BY A MECHANIC LOCK!
DANGER OF INJURIES !
Before starting tests (daily) inspect the fill level of tank [501], which is mounted inside the hydraulic
supply of ”HGPU“. The fill level is monitored by float-type switches [505] and
[504] (minimum / shut down, maximum / no consequences).
The exact fill level can be read-off at inspection glass [503]. It is also possible to read-off the fill
level on the inspection glas on the cover.
If the fill level is below minimum, hydraulic medium must be refilled via ventilation filter [502].
Refill until the fill level of inspection glass [503] indicates a range of approx. 70 %.
Note
If the fill level inside tank [501] falls below minimum, the unit
cannot be switched on. Or - during operation - it will be shut down automatically.
The hydraulic system must be refilled with appropriate medium.
Note
The definite replacement interval can be recorded by ongoing inspections
(on behalf of contamination resp. abrasion) of the hydraulic medium.
By individual inspections (on behalf of use resp. efficiency of the unit) the
replacement interval can be determined and hydraulic medium can be utilized ideally.
Only
The hydraulic system must be refilled with appropriate medium.
The definite replacement interval can be recorded by ongoing inspections
(on behalf of contamination resp. abrasion) of the hydraulic medium.
for If the fill level inside tank [501] falls below minimum, the unit
cannot be switched on. Or - during operation - it will be shut down automatically.
info
rmation!
THE COVER MUST BE OPENED IN ORDER TO PERFORM MAINTENANCE
AT THE TANK [501]. AFTER THE COVER IS OPENED, IT MUST
BE SECURED AGAINST FALLING BY A MECHANIC LOCK!
DANGER OF INJURIES !
Before starting tests (daily) inspect the fill level of tank [501], which is mounted inside the hydraulic
supply of ”HGPU“. The fill level is monitored by float-type switches [505] and
[504] (minimum / shut down, maximum / no consequences).
The exact fill level can be read-off at inspection glass [503]. It is also possible to read-off the fill
If the fill level is below minimum, hydraulic medium must be refilled via ventilation filter [502].
Refill until the fill level of inspection glass [503] indicates a range of approx. 70 %.
No
The definite replacement interval can be recorded by ongoing inspections
(on behalf of contamination resp. abrasion) of the hydraulic medium.
individual inspections (on behalf of use resp. efficiency of the unit) the
revis
ion Refill until the fill level of inspection glass [503] indicates a range of approx. 70 %.
Note
If the fill level inside tank [501] falls below minimum, the unit
cannot be switched on. Or - during operation - it will be shut down automatically.
The hydraulic system must be refilled with appropriate medium.
serv
ice
Before starting tests (daily) inspect the fill level of tank [501], which is mounted inside the hydraulic
supply of ”HGPU“. The fill level is monitored by float-type switches [505] and
[504] (minimum / shut down, maximum / no consequences).
The exact fill level can be read-off at inspection glass [503]. It is also possible to read-off the fill
If the fill level is below minimum, hydraulic medium must be refilled via ventilation filter [502].
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5.2. REPLACEMENT OF MEDIUM
Important for purity of hydraulic medium is fineness of filter elements and (in contrast to regular
filters) frequency of filtration. This means: When filtering medium more often, more particles
remain in the filter element.
Hydraulic medium can be drained into an appropriate container by connecting a drain hose to
cap. Afterwards ball valve needs to be opened.
Used medium needs to be disposed professionally.
After closing ball valve the drain hose needs to be removed.
Appropriate hydraulic medium needs to be filled in at the ventilation filter of tank [501].
Note
The type plate indicates which hydraulic medium is to be used.
For example Skydrol PE-5
+ CAUTION +
WRONG MEDIUM CAN CAUSE SERIOUS DAMAGE TO THE
”HYDRAULIC GROUND POWER UNIT“ OR TO THE UNIT UNDER TEST.
Capacity of tank [501]: approx. 240 L
Inspect leakage of tank [501] periodically (monthly).
HYDRAULIC GROUND POWER UNIT <HGPU60-50-1DSX-AMA>
INSPECTION AND MAINTENANCE Page E-1702.02.2017 MAWN
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Capacity of tank [501]: approx. 240 L
Inspect leakage of tank [501] periodically (monthly).
for WRONG MEDIUM CAN CAUSE SERIOUS DAMAGE TO THE
”HYDRAULIC GROUND POWER UNIT“ OR TO THE UNIT UNDER TEST.
info
rmation!
After closing ball valve the drain hose needs to be removed.
Appropriate hydraulic medium needs to be filled in at the ventilation filter of tank [501].
Note
The type plate indicates which hydrauli
For example Skydrol PE-5
+ CAUTION +
No revis
ion
+ CAUTION +
WRONG MEDIUM CAN CAUSE SERIOUS DAMAGE TO THE
”HYDRAULIC GROUND POWER UNIT“ OR TO THE UNIT UNDER TEST.
Capacity of tank [501]: approx. 240 L
Inspect leakage of tank [501] periodically (monthly).
serv
ice
Appropriate hydraulic medium needs to be filled in at the ventilation filter of tank [501].
The type plate indicates which hydraulic medium i
Skydrol PE-5
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HYDRAULIC GROUND POWER UNIT <HGPU60-50-1DSX-AMA>
INSPECTION AND MAINTENANCE Page E-1802.02.2017 MAWN
Figure E04
“TANK [501]“
Ball valveVentilation filter [502]
Inspection glass [503]
Tank [501]
info
rmation!
info
rmation!
info
rmation!
Inspection glass [503]
info
rmation!
revis
ion s
erv
ice
serv
ice
serv
ice
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6. MAINTENANCE OF THE SCREW-JOINT SYSTEM
In case of screw-joint systems with pipes and hoses the used union nuts must be retightened
3 times with the interval of one month after delivery of power unit.
Afterwards a control once a year is enough.
Test marking on the outside surface of the union nut:
Figure E05
“SKETCH OF THE SCREW-JOINT“
Retightening of union nut is a safety measure, since the screw joints can become loose and
- as a result - leaky due to thermal loads.
The marking on the union nut (number of tests) could be as follows (recommendation of „TEST-
FUCHS“):
X ....................................first test
XX................................second test
XXX ..........................third test
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INSPECTION AND MAINTENANCE Page E-1902.02.2017 MAWN
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“SK
Retightening of union nut is a safety measure, since the screw joints can become loose and
- as a result - leaky due to thermal loads.
for in
form
ation!
No
Retightening of union nut is a safety measure, since the screw joints can become loose and
- as a result - leaky due to thermal loads.
revis
ion
Figure E05
“SKETCH OF THE SCREW-JOINT“
serv
ice
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7. PUMPS
++ WARNING ++
EVEN DURING REGULAR OPERATION HIGH TEMPERATURE
CAN BE REACHED AT THE SURFACE OF PUMPS!
IN ORDER TO PERFORM MAINTENANCE WORKS AT PUMPS THE
COVER MUST BE OPENED. BEFORE OPENING THE COVER IT IS
ESSENTIAL TO ISOLATE THE ON-SITE POWER SUPPLY!
THE OPENED COVER MUST BE SECURED AGAINST FALLING
BY A MECHANIC LOCK! DANGER OF INJURY!
Provided pumps are normally free of maintenance. Depending on operating hours, the operating
cycle and required availability maintenance needs to be planned and performed.
INSPECTION:
- Inspect the fill level of fluid inside the tank
- Inspect cleanliness and condition of fluid
- Inspect temperature during operation
- Pay attention to external leakage
- Inspect the pipe system to loose connections and hoses to chafe marks (damaged tubes and
hoses need to be replaced immediately).
- Inspect the electric supply lines of engine, magnetic valves, sensors, pressure switches etc.
(visual inspection).
HYDRAULIC GROUND POWER UNIT <HGPU60-50-1DSX-AMA>
INSPECTION AND MAINTENANCE Page E-2002.02.2017 MAWN
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- Inspect the pipe system to loose connections and hoses to chafe marks (damaged tubes and
hoses need to be replaced immediately).
- Inspect the electric supply lines of engine, magnetic valves, sensors, pressure switches etc.
sual inspection).
for - Inspect temperature during operation
- Pay attention to external leakage
info
rmation! IN ORDER TO PERFORM MAINTENANCE WORKS AT PUMPS THE
COVER MUST BE OPENED. BEFORE OPENING THE COVER IT IS
TIAL TO ISOLATE THE ON-SITE POWER SUPPLY!
THE OPENED COVER MUST BE SECURED AGAINST FALLING
BY A MECHANIC LOCK! DANGER OF INJURY!
vided pumps are normally free of maintenance. Depending on operating hours, the operating
e and required availability maintenance needs to be planned and performed.
- Inspect the fill level of fluid inside the tank
- Inspect cleanliness and condition of fluid
No - Inspect the electric supply lines of engine, magnetic valves, sensors, pressure switches etc.re
vis
ion
- Inspect the pipe system to loose connections and hoses to chafe marks (damaged tubes and
hoses need to be replaced immediately).
- Inspect the electric supply lines of engine, magnetic valves, sensors, pressure switches etc.
serv
ice
THE OPENED COVER MUST BE SECURED AGAINST FALLING
BY A MECHANIC LOCK! DANGER OF INJURY!
vided pumps are normally free of maintenance. Depending on operating hours, the operating
e and required availability maintenance needs to be planned and performed.
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MAINTENANCE:
- Maintain system fluid (see para 5. TANK [501]).
- Document the operating temperature
- Inspect pressure/return/ventilation filters (see para 4.3. REPLACEMENT OF FILTERS).
- Inspect the system/control pressure setting
- Search for leakage of pipelines
- Inspect the function of control/monitoring elements
+ CAUTION +
GENERAL OVERHAUL AND REPAIRS CAN BE PERFORMED
ECONOMICALLY AND SAFELY BY THE MANUFACTURER
(TRAINED STAFF, SPECIAL TOOLS, GUARANTEE, ETC.).
HYDRAULIC GROUND POWER UNIT <HGPU60-50-1DSX-AMA>
INSPECTION AND MAINTENANCE Page E-2102.02.2017 MAWN
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for in
form
ation!
+ CAUTION +
GENERAL OVERHAUL AND REPAIRS CAN BE PERFORMED
ECONOMICALLY AND SAFELY BY THE MANUFACTURER
(TRAINED STAFF, SPECIAL TOOLS, GUARANTEE, ETC.).
No revis
ion s
erv
ice
GENERAL OVERHAUL AND REPAIRS CAN BE PERFORMED
ECONOMICALLY AND SAFELY BY THE MANUFACTURER
(TRAINED STAFF, SPECIAL TOOLS, GUARANTEE, ETC.).
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HYDRAULIC GROUND POWER UNIT <HGPU60-50-1DSX-AMA>
INSPECTION AND MAINTENANCE Page E-2202.02.2017 MAWN
Figure E06
“PUMPS [523A], [512] AND [555]“
[555] [512][523a]
No
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8. OIL-AIR COOLERS
++ WARNING ++
IN ORDER TO PERFORM MAINTENANCE WORKS AT OIL-AIR COOLERS
THE COVER MUST BE OPENED. BEFORE OPENING THE COVER IT IS
ESSENTIAL TO ISOLATE THE ON-SITE POWER SUPPLY!
THE OPENED COVER MUST BE SECURED AGAINST FALLING BY A
MECHANIC LOCK! DANGER OF INJURY!
Oil-air coolers do not require special maintenance. During operation with serious contamination
coolers need to be cleaned periodically.
8.1. CLEANING OF AIR COMPONENTS
Cleaning is performed by compressed air and water.The direction of cleaning needs to run
parallel to the plates, to prevent them from damage. Jet of water should be performed against
the direction of air.
Cleaning can be intensified by adding appropriate detergents. Pay attention to aluminum
compatible detergents.
Contamination with oil or fat can be cleaned by steam jet or hot water jet.
Dry the cleaned area, the drive motor needs to be covered during cleaning.
8.2. CLEANING OF OIL COMPONENTS
In order to perform cleaning of this area the oil-air cooler needs to be dismantled.
Light contamination of this area needs to be cleaned in a closed cleaning unit with pump device
and filter. As cleaning medium Perchlorethylene can be used.
++ WARNING ++
IF YOU USE DETERGENTS MAKE SURE THAT ROOMS ARE
VENTILATED SUFFICIENTLY. IF YOU USE INFLAMMABLE
DETERGENTS CONSIDER THE DANGER OF EXPLOSION!
WHEN USING DETERGENTS IT NEEDS TO BE ENSURED THAT
NO HARM TO THE ENVIRONMENT RESULTS OUT OF USED DETERGENTS !
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INSPECTION AND MAINTENANCE Page E-2302.02.2017 MAWN
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In order to perform cleaning of this area the oil-air cooler needs to be dismantled.
Light contamination of this area needs to be cleaned in a closed cleaning unit with pump device
and filter. As cleaning medium Perchlorethylene can be used.
for
Dry the cleaned area, the drive motor needs to be covered during cleaning.
8.2. CLEANING OF OIL COMPONENTS
info
rmation!
THE OPENED COVER MUST BE SECURED AGAINST FALLING BY A
MECHANIC LOCK! DANGER OF INJURY!
Oil-air coolers do not require special maintenance. During operation with serious contamination
Cleaning is performed by compressed air and water.The direction of cleaning needs to run
parallel to the plates, to prevent them from damage. Jet of water should be performed against
Cleaning can be intensified by adding appropriate detergents. Pay attention to aluminum
Contamination with oil or fat can be cleaned by steam jet or hot water jet.
Dry the cleaned area, the drive motor needs to be covered during cleaning.
No revis
ion Cleaning can be intensified by adding appropriate detergents. Pay attention to aluminum
Contamination with oil or fat can be cleaned by steam jet or hot water jet.
Dry the cleaned area, the drive motor needs to be covered during cleaning.
In order to perform cleaning of this area the oil-air cooler needs to be dismantled.
Light contamination of this area needs to be cleaned in a closed cleaning unit with pump device
and filter. As cleaning medium Perchlorethylene can be used.
serv
iceOil-air coolers do not require special maintenance. During operation with serious contamination
Cleaning is performed by compressed air and water.The direction of cleaning needs to run
parallel to the plates, to prevent them from damage. Jet of water should be performed against
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Cleaning medium needs to be operated tempered and should be pumped through the oil cooler
for approx. 10 min.
In case of heavy contamination a detergent for oil-coolers needs to be used. Cleaning should be
continued for approx. 30 min.
Afterwards cleaning medium must be drained completely (e.g. by compressed air), the oil-air cooler
needs to be flushed by means of the operating oil or another compatible oil.
HYDRAULIC GROUND POWER UNIT <HGPU60-50-1DSX-AMA>
INSPECTION AND MAINTENANCE Page E-2402.02.2017 MAWN
Figure E07
“OIL-AIR COOLERS“
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9. CLEANING / LUBRICATING / INSPECTING THE CHASSIS
The chassis of the hydraulic supply needs to be cleaned periodically, movable regions resp.
regions that are exposed to friction need to be lubricated and inspected.
These regions are • the rotating assembly
• the towing bar
• eyes at the towing bar
• all screws at the chassis, if they are pulled tight
Some of these areas that require lubrication are equipped with grease nipples. Lubricate these
areas until grease is leaking. Quality of grease needs to be K3K, i.a.w. DIN 51825.
The cover of the hydraulic supply also needs to be cleaned, lubricated and inspected.
• hinges, locks and slideways with grease quality K3K i.a.w.
DIN 51825
• slideways of hydraulic damper
• inspect gaskets for damage
• inspect the condition of hinges
The wheel bolts must be tested one month after delivery of the test device, thereafter, yearly for
fix mounting. The manufacturer company “PAILLARD“ recommends a torque of 120Nm for the
screws M14 x 1.5.
Inspect the brakes periodically, if they are acting approx. 10 cm before vertical or horizontal
stopping position.
Consider the following advice when adjusting brakes:
• lift the hand lever approx. 10 cm above the towing brake
• pull the screw for horizontal adjustment until the brake cable tightens
• lower the hand lever approx. 10 cm below the vertical stop
• pull the screw for vertical adjustment until the brake cable tightens
HYDRAULIC GROUND POWER UNIT <HGPU60-50-1DSX-AMA>
INSPECTION AND MAINTENANCE Page E-2502.02.2017 MAWN
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be tested
manufacturer
Inspect the brakes periodically, if they are acting approx. 10 cm before vertical or horizontal
for
• inspect gaskets for damage
• inspect the condition of hinges
info
rmation!
• all screws at the chassis, if they are pulled tight
Some of these areas that require lubrication are equipped with grease nipples. Lubricate these
areas until grease is leaking. Quality of grease needs to be K3K, i.a.w. DIN 51825.
The cover of the hydraulic supply also needs to be cleaned, lubricated and inspected.
• hinges, locks and slideways with grease quality K3K i.a.w.
• slideways of hydraulic damper
No
Inspect the brakes periodically, if they are acting approx. 10 cm before vertical or horizontal
revis
ion
• slideways of hydraulic damper
• inspect gaskets for damage
• inspect the condition of hinges
one month
company
serv
iceSome of these areas that require lubrication are equipped with grease nipples. Lubricate these
areas until grease is leaking. Quality of grease needs to be K3K, i.a.w. DIN 51825.
The cover of the hydraulic supply also needs to be cleaned, lubricated and inspected.
• hinges, locks and slideways with grease quality K3K i.a.w.
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10. MAINTENANCE OF THE HOISTING DEVICE
Replace hydraulic medium of the hoisting device (cover) periodically/annually.
Instruction:
++WARNING ++
IN ORDER TO PERFORM MAINTENANCE WORK AT THE MEDIUM
RESERVOIR OF THE HOISTING DEVICE, THE COVER MUST BE CLOSED !
- A collecting tray needs to be provided in order to collect leaking medium.
- Unscrew the drain outlet by an appropriate tool.
- Drain medium out of the medium reservoir.
- Close the drain screw and refill medium (hydraulic oil HOP32) through the filling port
(approx. 2.5l).
- Close the filling port and dispose used medium professionally.
HYDRAULIC GROUND POWER UNIT <HGPU60-50-1DSX-AMA>
INSPECTION AND MAINTENANCE Page E-2602.02.2017 MAWN
Figure E08
“MEDIUM RESERVOIR OF
THE HOISTING DEVICE“
Filling port
Drain screw
Only
for
for in
form
ation! IN ORDER TO PERFORM MAINTENANCE WORK AT THE MEDIUM
RESERVOIR OF THE HOISTING DEVICE, THE COVER MUST BE CLOSED !
- A collecting tray needs to be provided in order to collect leaking medium.
- Close the drain screw and refill medium (hydraulic oil HOP32) through the filling port
- Close the filling port and dispose used medium professionally.
No
No revis
ion
revis
ion - Close the filling port and dispose used medium professionally.
revis
ion s
erv
ice- A collecting tray needs to be provided in order to collect leaking medium.
- Close the drain screw and refill medium (hydraulic oil HOP32) through the filling port
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11. DIESEL ENGINE
11.1. SAFETY INSTRUCTIONS
++ WARNING ++
SHUT DOWN THE ENGINE BEFORE EACH MAINTENANCE PROCEDURE!
DO NOT SMOKE OR LIGHT ANY OPEN FIRE DURING MAINTENANCE OF MOTOR!
WHILE DIESEL ENGINE [524] IS ACTIVATED,
IT IS NOT ALLOWED TO TURN THE MAIN SWITCH
TO POSITION “OFF“.
CONTROL THE HOSE BETWEEN AIR FILTER AND TURBOCHARGER REGULARY ON
POSSIBLE DAMAGES. BAD AIR MAY CAUSE DAMAGES ON THE DIESEL ENGINE.
+ CAUTION +
PLACE THE EQUIPMENT HORIZONTAL DURING MAINTENANCE WORK!
Note
The list of the following tasks provides only an overview of the maintenance work to be carried
out at the diesel engine.
The tasks mentioned here do not in any way replace the manufacturer documentation of the
company “DEUTZ” in chapter “H” MANUFACTURER DOCUMENTATION.
The signal lamp (+1B2-P3) indicates any error of the diesel engine.
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The list of the following tasks provides only an overview of the maintenance work to be carried
The tasks mentioned here do not in any way replace the manufacturer documentation of the
company “DEUTZ” in
for in
form
ation!
SHUT DOWN THE ENGINE BEFORE EACH MAINTENANCE PROCEDURE!
DO NOT SMOKE OR LIGHT ANY OPEN FIRE DURING MAINTENANCE OF MOTOR!
WHILE DIESEL ENGINE [524] IS ACTIVATED,
IT IS NOT ALLOWED TO TURN THE MAIN SWITCH
TO POSITION “OFF“.
CONTROL THE HOSE BETWEEN AIR FILTER AND TURBOCHARGER REGULARY ON
POSSIBLE DAMAGES. BAD AIR MAY CAUSE DAMAGES ON THE DIESEL ENGINE.
+ CAUTION +
PLACE THE EQUIPMENT HORIZONTAL DURING MAINTENANCE WORK!
No
The tasks mentioned here do not in any way replace the manufacturer documentation of the
company “DEUTZ” in chapter “H” MANUFACTURER DOCUMENTATION
The signal lamp (+1B2-P3) indicates any error of the diesel engine.
revis
ion + CAUTION +
PLACE THE EQUIPMENT HORIZONTAL DURING MAINTENANCE WORK!
The list of the following tasks provides only an overview of the maintenance work to be carried
out at the diesel engine.
serv
ice
WHILE DIESEL ENGINE [524] IS ACTIVATED,
IT IS NOT ALLOWED TO TURN THE MAIN SWITCH
CONTROL THE HOSE BETWEEN AIR FILTER AND TURBOCHARGER REGULARY ON
POSSIBLE DAMAGES. BAD AIR MAY CAUSE DAMAGES ON THE DIESEL ENGINE.
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INSPECTION AND MAINTENANCE Page E-2802.02.2017 MAWN
Figure E09
“DIESEL ENGINE [524]“
info
rmation!
info
rmation!
revis
ion s
erv
ice
serv
ice
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11.2. MAINTENANCE AND CLEANING
11.2.1. Filter replacement
The replacement interval of the filter depends on the degree of cleanliness of the used
fluid.
- Fuel filter
Please pay attention to the instructions of the manufacturer documentation of the
company “DEUTZ”.
- Fuel prefilter
Please pay attention to the instructions of the manufacturer documentation of the
company “DEUTZ”.
- Lubricating oil filter
Please pay attention to the instructions of the manufacturer documentation of the
company “DEUTZ”.
+ CAUTION +
INSUFFICIENT LUBRICATION CAUSES DAMAGE OF THE DIESEL ENGINE [524]!
- Air filter
Please pay attention to the instructions of the manufacturer documentation of the
company “DEUTZ”.
11.2.2. Change of lubricating oil
Please pay attention to the instructions of the
manufacturer documentation of the
company “DEUTZ”.
Figure E10
“BALL VALVE FOR CHANGE
OF LUBRICATING OIL“
Only
INSUFFICIENT LUBRICATION CAUSES DAMAGE OF THE DIESEL ENGINE [524]!
Please pay attention to the instructions of the manufacturer documentation of the
for
Please pay attention to the instructions of the manufacturer documentation of the info
rmation!
Please pay attention to the instructions of the manufacturer documentation of the
Please pay attention to the instructions of the manufacturer documentation of the
Please pay attention to the instructions of the manufacturer documentation of the
No
Please pay attention to the instructions of the manufacturer documentation of the
revis
ion
Please pay attention to the instructions of the manufacturer documentation of the
+ CAUTION +
INSUFFICIENT LUBRICATION CAUSES DAMAGE OF THE DIESEL ENGINE [524]!
serv
ice
Please pay attention to the instructions of the manufacturer documentation of the
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11.2.3. Changing of the coolant
+ CAUTION +
DO NOT OPERATE THE MOTOR WITHOUT COOLANT!
Draining the cooling system:
To drain, unscrew the grid, and the connecting hose at the cooler.
Drain the coolant and then attach the connecting hose and the grid correctly.
Dispose of the coolant in accordance with the environmental regulations.
Filling the cooling system:
Open the cooling system cover.
Refill the coolant up to the mark “max” and close the cover.
Then, warm up the motor up to the operating temperature, switch it back off, let cool down,
inspect the coolant level again and refill where necessary.
Please pay attention to the instructions of the manufacturer documentation of the company
“DEUTZ”.
for
Please pay attention to the instructions of the manufacturer documentation of the companyinfo
rmation! To drain, unscrew the grid, and the connecting hose at the cooler.
Drain the coolant and then attach the connecting hose and the grid correctly.
Dispose of the coolant in accordance with the environmental regulations.
Refill the coolant up to the mark “max” and close the cover.
Then, warm up the motor up to the operating temperature, switch it back off, let cool down,
inspect the coolant level again and refill where necessary.
Please pay attention to the instructions of the manufacturer documentation of the company
No revis
ion Then, warm up the motor up to the operating temperature, switch it back off, let cool down,
inspect the coolant level again and refill where necessary.
Please pay attention to the instructions of the manufacturer documentation of the company
serv
iceDispose of the coolant in accordance with the environmental regulations.
Refill the coolant up to the mark “max” and close the cover.
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INSPECTION AND MAINTENANCE Page E-3102.02.2017 MAWN
Figure E11
“DRAINAGE OF THE COOLANT“
Grid Connecting hose
Only
Only
Only
Connecting hosefor
for
Connecting hose
info
rmation!
No revis
ion
revis
ion
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11.3. TABLE OF ERRORS
A detailed table of potential errors and methods for rectification is in the manufacturer docu-
mentation of the company “DEUTZ”.
11.4. MEASURES FOR LONGER STANDSTILL PERIOD
If the engine should be put out of operation for a longer time, preservation measures (inter-
nal and external) must be taken to protect it from corrosion.
A detailled description is in the manufacturer documentation of the company “DEUTZ”.
Please also follow the information in chapter ”A“ para “7. SHUTDOWN / STORAGE /
DISPOSAL”.
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for in
form
ation! If the engine should be put out of operation for a longer time, preservation measures (inter-
nal and external) must be taken to protect it from corrosion.
A detailled description is in the manufacturer documentation of the company “DEUTZ”.
Please also follow the information in chapter ”A“ para “7. SHUTDOWN / STORAGE /
No revis
ion s
erv
ice
A detailled description is in the manufacturer documentation of the company “DEUTZ”.
Please also follow the information in chapter ”A“ para “7. SHUTDOWN / STORAGE /
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11.5. STARTER BATTERIES
Keep the batteries dry and clean.
Clean if the terminals are contaminated.
Clean the battery terminals (+ and -) and clamps, and oil them with neutral and acid resistant
oil.
Pay attention to good contact of the clamp connections. Tighten the clamp screws well.
+ CAUTION +
DO NOT START WITH A BOOSTER IF BATTERIES DISCHARGE COMPLETELY
(CONTROL LAMP DOES NOT FUNCTION). CHARGE THE BATTERIES
SLOWLY WITH MAXIMUM 10A).
IF THE ACCUMULATOR IS OVERCHARGED, THE ELECTROLYTE CAN DECOMPOSE!
++ WARNING ++
THE CONTACTS ARE NOT SECURED!
If the battery charges are too low, charge them. If the starter does not turn easily anymore, the
batteries are too weak, as the voltage monitoring relay is set between 21 and 29V.
If the batteries cannot be charged or they discharge very quickly, then they are broken down
and must be replaced.
+ CAUTION +
USE SAME TYPE OF BATTERIES FOR REPLACEMENT (12V / 50AH)
(SEE ELECTRICAL PARTS LIST)!
Note
Heat the batteries to approx 20°C to improve the start performance.
Concerning storage of batteries please also follow the information
in chapter ”A“ para “7. SHUTDOWN / STORAGE / DISPOSAL”.
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USE SAME TYPE OF BATTERIES FOR REPLACEMENT (12V / 50AH)
for batteries are too weak, as the voltage monitoring relay is set between 21 and 29V.
If the batteries cannot be charged or they discharge very quickly, then they are broken down
info
rmation! Pay attention to good contact of the clamp connections. Tighten the clamp screws well.
DO NOT START WITH A BOOSTER IF BATTERIES DISCHARGE COMPLETELY
(CONTROL LAMP DOES NOT FUNCTION). CHARGE THE BATTERIES
SLOWLY WITH MAXIMUM 10A).
IF THE ACCUMULATOR IS OVERCHARGED, THE ELECTROLYTE CAN DECOMPOSE!
++ WARNING ++
THE CONTACTS ARE NOT SECURED!
If the battery charges are too low, charge them. If the starter does not turn easily anymore, the
No USE SAME TYPE OF BATTERIES FOR REPLACEMENT (12V / 50AH)
(SEE
revis
ion
If the battery charges are too low, charge them. If the starter does not turn easily anymore, the
batteries are too weak, as the voltage monitoring relay is set between 21 and 29V.
If the batteries cannot be charged or they discharge very quickly, then they are broken down
serv
iceDO NOT START WITH A BOOSTER IF BATTERIES DISCHARGE COMPLETELY
(CONTROL LAMP DOES NOT FUNCTION). CHARGE THE BATTERIES
SLOWLY WITH MAXIMUM 10A).
IF THE ACCUMULATOR IS OVERCHARGED, THE ELECTROLYTE CAN DECOMPOSE!
WARNING ++
THE CONTACTS ARE NOT SECURED!
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HYDRAULIC GROUND POWER UNIT <HGPU60-50-1DSX-AMA>
INSPECTION AND MAINTENANCE Page E-3402.02.2017 MAWN
Figure E12
“STARTER BATTERIES“
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Only
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rmation!
No
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HYDRAULIC GROUND POWER UNIT <HGPU60-50-1DSX-AMA>
CALIBRATION INSTRUCTIONS Page F-102.02.2017 MAWN
CHAPTER “F”
CALIBRATION INSTRUCTIONS
1. CALIBRATION, GENERAL
2. LIST OF MEASUREMENTS
3. CALIBRATION OF PRESSURE
MEASUREMENTS
4. INSPECTION AND CALIBRATION OF
5000PSI - REGULATION
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for in
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1. CALIBRATION, GENERAL
2. LIST OF MEASUREMENTS
3. CALIBRATION OF PRESSURE
MEASUREMENTS
4. INSPECTION AND CALIBRATION OF
5000PSI - REGULATION
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4. INSPECTION AND CALIBRATION OF
5000PSI - REGULATION
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3. CALIBRATION OF PRESSURE
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HYDRAULIC GROUND POWER UNIT <HGPU60-50-1DSX-AMA>
CALIBRATION INSTRUCTIONS Page F-202.02.2017 MAWN
1. CALIBRATION, GENERAL
This chapter shows basic information about calibration and adjustment of measuring devices of
the “HYDRAULIC GROUND POWER UNIT“. They are listed in para 2. LIST OF MEASURING
CHANNELS.
The “HYDRAULIC GROUND POWER UNIT“ is designed as hydraulic supply. From the manufacturers
point of view, calibration of meters mounted in this unit is only required in case of relevant
(quality/safety) measurements.
Possible superior calibration requirements (based on national instructions and / or instructions
given by aeronautical authorities or the customer) must be considered.
If necessary, calibration needs to be performed periodically.
These intervals need to be defined according to customers or other, superior instructions.
“TEST-FUCHS“ recommends a calibration intervall of 24 months.
Action during calibration (for measurements shown under para 2.), see calibration instruction on
the following pages.
+ CAUTION +
ONLY TRAINED STAFF MAY CARRY OUT CALIBRATION.
USE ONLY REFERENCE INSTRUMENTS AND TEST EQUIPMENT
FOR CALIBRATION THAT IS APPLICABLE FOR TEST MEDIUM.
Only
USE ONLY REFERENCE INSTRUMENTS AND TEST EQUIPMENT
FOR CALIBRATION THAT IS APPLICABLE FOR TEST MEDIUM.
for
ONLY TRAINED STAFF MAY CARRY OUT CALIBRATION.
info
rmation!
point of view, calibration of meters mounted in this unit is only required in case of relevant
Possible superior calibration requirements (based on national instructions and / or instructions
given by aeronautical authorities or the customer) must be considered.
If necessary, calibration needs to be performed periodically.
These intervals need to be defined according to customers or other, superior instructions.
“TEST-FUCHS“ recommends a calibration intervall of 24 months.
measurements shown
No revis
ion
+ CAUTION +
ONLY TRAINED STAFF MAY CARRY OUT CALIBRATION.
USE ONLY REFERENCE INSTRUMENTS AND TEST EQUIPMENT
FOR CALIBRATION THAT IS APPLICABLE FOR TEST MEDIUM.
serv
ice
given by aeronautical authorities or the customer) must be considered.
These intervals need to be defined according to customers or other, superior instructions.
“TEST-FUCHS“ recommends a calibration intervall of 24 months.
under para
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2. LIST OF MEASUREMENTS
*) measurements to calibrate
HYDRAULIC GROUND POWER UNIT <HGPU60-50-1DSX-AMA>
CALIBRATION INSTRUCTIONS Page F-302.02.2017 MAWN
MEASUREMENTS RANGECLASS/
TOLERANCE
OIL TEMPERATURE (°C) 0 to 100°C
[515]
SUPPLY PRESSURE *) 0 to 400bar Kl. 1,0
[551] (Pressure gauge) (0 to 5800psi) (EN 837)
RETURN PRESSURE *) 0 to 10bar Kl. 1,6
[553] (Pressure gauge) (0 to 145psi) (EN 837)
FLOWRATE (OPTION AB) 10 to 250lpm ± 1% of full scale
[542] (2 to 66USgpm)
Only
*) measurements to calibrate
for
for
for
for
for
for
for
for in
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ation!
FLOWRATE (OPTION AB) 10 to 250lpm ± 1% of full scale
[542] (2 to 66USgpm)
info
rmation! OIL TEMPERATURE (°C) 0 to 100°C
SUPPLY PRESSURE *) 0 to 400bar Kl. 1,0
(0 to 5800psi) (EN 837)
RETURN PRESSURE *) 0 to 10bar Kl. 1,6
)
FLOWRATE (OPTION AB) 10 to 250lpm ± 1% of full scale
info
rmation!
FLOWRATE (OPTION AB) 10 to 250lpm ± 1% of full scale
[542] (2 to 66USgpm)
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ion FLOWRATE (OPTION AB) 10 to 250lpm ± 1% of full scale
[542] (2 to 66USgpm)
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SUPPLY PRESSURE *) 0 to 400bar Kl. 1,0
(0 to 5800psi) (EN 837)
RETURN PRESSURE *) 0 to 10bar Kl. 1,6
(0 to 145psi) (EN 837)
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3. CALIBRATION OF PRESSURE MEASUREMENTS
Pressure gauge ”Supply Pressure” [551] measuring range: 0 to 5800psi Cl. 1.0 (EN 837)
Pressure gauge ”Return Pressure” [553] measuring range: 0 to 145psi Cl. 1.6 (EN 837)
The shut-off valve [556] is used to disconnect the pressure gauge [551] and the minimess cou-
pling [557] from the hydraulic system for measure and calibration works
The minimess coupling [557] is used as connection for these works.
The shut-off valve [558] is used to disconnect the pressure gauge [553] and the minimess cou-
pling [559] from the hydraulic system for measure and calibration works
The minimess coupling [559] is used as connection for these works.
Note
Before starting tests of measuring precision a room
temperature of +23°C (± 5°C) must be ensured.
Calibration must be carried out i.a.w. EN ISO 837 or i.a.w. customer instructions.
HYDRAULIC GROUND POWER UNIT <HGPU60-50-1DSX-AMA>
CALIBRATION INSTRUCTIONS Page F-402.02.2017 MAWN
Only
for
temperature of +23°C (± 5°C) must be ensured.
Calibration must be carried out i.a.w. EN ISO 837 or i.a.w. customer instructions.
info
rmation!
The shut-off valve [556] is used to disconnect the pressure gauge [551] and the minimess cou-
pling [557] from the hydraulic system for measure and calibration works
The minimess coupling [557] is used as connection for these works.
The shut-off valve [558] is used to disconnect the pressure gauge [553] and the minimess cou-
pling [559] from the hydraulic system for measure and calibration works
The minimess coupling [559] is used as connection for these works.
Before starting tests of measuring precision a room
temperature of +23°C (± 5°C) must be ensured.
No revis
ion
Before starting tests of measuring precision a room
temperature of +23°C (± 5°C) must be ensured.
Calibration must be carried out i.a.w. EN ISO 837 or i.a.w. customer instructions.
serv
ice
The shut-off valve [558] is used to disconnect the pressure gauge [553] and the minimess cou-
pling [559] from the hydraulic system for measure and calibration works
The minimess coupling [559] is used as connection for these works.
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HYDRAULIC GROUND POWER UNIT <HGPU60-50-1DSX-AMA>
CALIBRATION INSTRUCTIONS Page F-502.02.2017 MAWN
Figure F01
“PRESSURE GAUGES AND CALIBRATION PORTS“
[551]
[553]
[556] [557]
[558] [559]Only
Only
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4. INSPECTION AND CALIBRATION OF 5000PSI - REGULATION
++WARNING++
IT IS FORBIDDEN TO TOUCH LIVE PARTS - DANGER OF LIFE!
WORKS MUST BE CARRIED OUT BY TRAINED STAFF.
Disconnect hoses from the A/C and roll them out straight
(in order to prevent shoot up during pressurization)
Close all hose ends pressure-resistant.
By means of the security switch (+1B1-S24) select the operating mode position 2 - 5000 psi.
Open the switch cabinet by means of the switch cabinet key
(as a consequence the switch cabinet won’t be interlocked when switching on the main switch)
Now, turn the lenghtening spindle of the main switch a quarter rotation to the right in order to turn
on the main switch.
Note
This can only be done that way
due to the fact the the switch cabinet doors are locked and cannot be opened
if the main switch is switched on.
Switch the “Reservoir Selection” to “HGPU” (press the illuminated button “HGPU”) and wait until
the illuminated button “HGPU” is illuminated.
Press the illuminated button ”System On”.
Press the illuminated button ”3000 / 5000 psi” for two times.
If the indicated pressure at the pressure gauge ”Supply Pressure” is ”5000psi (± 100psi)”,
no further action needs to be taken. The unit can be switched-off.
In case the indicated value is outside the tolerance (± 100psi), the following steps need to be per-
formed:
Adjust the regulator ”Pressure End” at the module ”PUMP CONTROL“ (+1B-A1) by means of a
screw driver. Perform the adjustment until the pressure gauge ”Supply Pressure” indicates ”5000psi
(± 100psi)”.
+ CAUTION +
PRESSURE THAT IS ADJUSTED INCORRECTLY CAN CAUSE DAMAGES!
HYDRAULIC GROUND POWER UNIT <HGPU60-50-1DSX-AMA>
CALIBRATION INSTRUCTIONS Page F-602.02.2017 MAWN
Only
Switch the “Reservoir Selection” to “HGPU” (press the illuminated button “HGPU”) and wait until
the illuminated button “HGPU” is illuminated.
the illuminated button ”System On”.
the illuminated button ”3000 / 5000 psi” for two times.
for
This can only be done that way
due to the fact the the switch cabinet doors are locked and cannot be opened
if the main switch is switched on.
info
rmation!
means of the security switch (+1B1-S24) select the operating mode position 2 - 5000 psi.
Open the switch cabinet by means of the switch cabinet key
(as a consequence the switch cabinet won’t be interlocked when switching on the main switch)
Now, turn the lenghtening spindle of the main switch a quarter rotation to the right in order to turn
This can only be done that way
No the illuminated button ”System On”.
the illuminated button ”3000 / 5000 psi” for two times.
If the indicated pressure at the pressure gauge ”Supply Pressure” is ”5000psi (± 100psi)”,
revis
ion
Note
This can only be done that way
due to the fact the the switch cabinet doors are locked and cannot be opened
if the main switch is switched on.
Switch the “Reservoir Selection” to “HGPU” (press the illuminated button “HGPU”) and wait until
the illuminated button “HGPU” is illuminated.
the illuminated button ”System On”.
serv
ice
means of the security switch (+1B1-S24) select the operating mode position 2 - 5000 psi.
Open the switch cabinet by means of the switch cabinet key
(as a consequence the switch cabinet won’t be interlocked when switching on the main switch)
Now, turn the lenghtening spindle of the main switch a quarter rotation to the right in order to turn
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Press the illuminated button ”0 psi”.
Press the illuminated button ”System Off”.
Now, turn the lenghtening spindle of the main switch a quarter rotation to the left in order to turn
off the main switch.
Close the switch cabinet by means of the switch cabinet key
HYDRAULIC GROUND POWER UNIT <HGPU60-50-1DSX-AMA>
CALIBRATION INSTRUCTIONS Page F-702.02.2017 MAWN
Only
for in
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ation!
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HYDRAULIC GROUND POWER UNIT <HGPU60-50-1DSX-AMA>
CALIBRATION INSTRUCTIONS Page F-802.02.2017 MAWN
Figure F02
“PUMP CONTROL“
Regulador de ajuste
„Pressure End”
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ation!
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Figure F02
“PUMP CONTROL“
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