CHAPTER “E” INSPECTION AND MAINTENANCE …...Property of American Airlines HYDRAULIC GROUND POWER UNIT 02.02.2017 MAWN INSPECTION AND MAINTENANCE Page

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

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4. FILTER

5. TANK [501]

for

2. CLEANING

3. INSPECTION

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- SURVEY - MAINTENANCE INTERVALS

- SAFETY INSTRUCTIONS


No

5. TANK [501]

6. MAINTENANCE OF THE SCREW

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3. INSPECTION

4. FILTER

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CHAPTER “E”


10. MAINTENANCE OF THE HOISTING

DEVICE

11. DIESEL ENGINE

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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“.



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


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


for (daily)


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(inspect for eventual internal or external leakage)

Cleaning and lubricating of all hinges, -- periodically

Visual inspection (external) 1.1. before each test runinfo

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PARA

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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 filters 4.1. indication by led-signal lamp

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(daily)


Cleaning 2. weekly

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(daily)

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Cleaning and lubricating of all hinges, -- periodicallyserv

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(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


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.



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Cleaning / lubricating/inspecting the chassis 9. annually

Maintenance of the hoisting device (cover) 10. annually


documentation

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documentation

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Note

Test and replacement of hoses must be performed i.a.w.



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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.



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!

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TO PREVENT AN UNINTENTIONAL OPENING OF THE COVER, for in

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Hand leverinfo

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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!



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PLEASE FOLLOW THE INSTRUCTIONS

GIVEN IN THE CHAPTER “LOCKOUT AND TAGOUT“

AT THE BEGINNING OF THIS CHAPTER!

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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



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


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rmation! FOR SECURITY REASONS - BEFORE VISUAL INSPECTION -

POWER SUPPLY MUST BE SWITCHED-OFF!

HYDRAULIC SUPPLY CONTAINS DEVICES, WHICH SAVE A LOT OF POWER.


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


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.


mine perfect condition, firm mounting and mechanical function of connection hoses

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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


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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


PLASTIC PARTS.




or dirt. If required dust and dirt should be removed by means of a vacuum cleaner, by means of


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


+ CAUTION +


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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.

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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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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.


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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.


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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Figure E01

“LOCATION OF ELECTRICAL PROTECTION ELEMENTS“

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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





for


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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


See next figure for location of respective filters.

No MUST BE OPENED. AFTER THE COVER IS OPENED, IT MUST BE SECURED


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++ WARNING ++





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- 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

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- 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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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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Figure E02

“FILTER“

[514] =

LOW

PRESSURE

FILTER

[820]

FILTER

IN RETURN

LINE

[563]

FILL

FILTER

[543]

HIGH

PRESSURE

FILTER

Only

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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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Spread sheet E01

“REPLACEMENT OF FILTER ELEMENTS“

[514] electrical (indication

by led-signal lamp

(+1B1-P5))


by led-signal lamp

(+1B1-P5))


by led-signal lamp

(+1B1-P5))


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

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The corresponding

filter elements

please find in the

Spare parts l

in chapter “G“.

No

“REPLACEMENT OF FILTER ELEMENTS“

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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




for If the fill level inside tank [501] falls below minimum, the unit


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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 !






Refill until the fill level of inspection glass [503] indicates a range of approx. 70 %.

No



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



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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).



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for WRONG MEDIUM CAN CAUSE SERIOUS DAMAGE TO THE


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rmation!

After closing ball valve the drain hose needs to be removed.


Note

The type plate indicates which hydrauli

For example Skydrol PE-5

+ CAUTION +

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+ CAUTION +

WRONG MEDIUM CAN CAUSE SERIOUS DAMAGE TO THE




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The type plate indicates which hydraulic medium i

Skydrol PE-5

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Figure E04

“TANK [501]“

Ball valveVentilation filter [502]

Inspection glass [503]

Tank [501]

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Inspection glass [503]

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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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“SK



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Figure E05

“SKETCH OF THE SCREW-JOINT“

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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


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).



Only




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!



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

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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.).



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+ CAUTION +




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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


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 !



Only




for


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 can be intensified by adding appropriate detergents. Pay attention to aluminum



No revis

ion Cleaning can be intensified by adding appropriate detergents. Pay attention to aluminum






serv

iceOil-air coolers do not require special maintenance. During operation with serious contamination



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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.



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



Only

be tested

manufacturer


for



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





No


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one month

company

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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.



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 filling port and dispose used medium professionally.

No

No revis

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ion - Close the filling port and dispose used medium professionally.

revis

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ice- A collecting tray needs to be provided in order to collect leaking medium.


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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.



Only



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!



TO POSITION “OFF“.



+ CAUTION +


No


company “DEUTZ” in chapter “H” MANUFACTURER DOCUMENTATION

The signal lamp (+1B2-P3) indicates any error of the diesel engine.

revis

ion + CAUTION +



out at the diesel engine.

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Figure E09

“DIESEL ENGINE [524]“

info

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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



- Lubricating oil filter



+ CAUTION +

INSUFFICIENT LUBRICATION CAUSES DAMAGE OF THE DIESEL ENGINE [524]!

- Air filter



11.2.2. Change of lubricating oil

Please pay attention to the instructions of the

manufacturer documentation of the


Figure E10

“BALL VALVE FOR CHANGE

OF LUBRICATING OIL“

Only



for

Please pay attention to the instructions of the manufacturer documentation of the info

rmation!




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+ CAUTION +


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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.


Then, warm up the motor up to the operating temperature, switch it back off, let cool down,



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ion Then, warm up the motor up to the operating temperature, switch it back off, let cool down,



serv

iceDispose of the coolant in accordance with the environmental regulations.


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Figure E11

“DRAINAGE OF THE COOLANT“

Grid Connecting hose

Only

Only

Only

Connecting hosefor

for

Connecting hose

info

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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”.



Only

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.



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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”.



Only

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.


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




++ WARNING ++



No USE SAME TYPE OF BATTERIES FOR REPLACEMENT (12V / 50AH)

(SEE

revis

ion


batteries are too weak, as the voltage monitoring relay is set between 21 and 29V.


serv

iceDO NOT START WITH A BOOSTER IF BATTERIES DISCHARGE COMPLETELY




WARNING ++


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Figure E12

“STARTER BATTERIES“

Only

Only

info

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No

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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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info

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info

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info

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MEASUREMENTS



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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



for


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


If necessary, calibration needs to be performed periodically.



measurements shown

No revis

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+ CAUTION +




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under para

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*) measurements to calibrate



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

form

ation!


[542] (2 to 66USgpm)

info

rmation! OIL TEMPERATURE (°C) 0 to 100°C


(0 to 5800psi) (EN 837)


)


info

rmation!


[542] (2 to 66USgpm)

No revis

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revis

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revis

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revis

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revis

ion FLOWRATE (OPTION AB) 10 to 250lpm ± 1% of full scale

[542] (2 to 66USgpm)

revis

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(0 to 5800psi) (EN 837)


(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.




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.



Only

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Figure F01

“PRESSURE GAUGES AND CALIBRATION PORTS“

[551]

[553]

[556] [557]

[558] [559]Only

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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!



Only



the illuminated button ”System On”.

the illuminated button ”3000 / 5000 psi” for two times.

for




info

rmation!

means of the security switch (+1B1-S24) select the operating mode position 2 - 5000 psi.





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






the illuminated button ”System On”.

serv

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means of the security switch (+1B1-S24) select the operating mode position 2 - 5000 psi.




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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



Only

for in

form

ation!

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Figure F02

“PUMP CONTROL“

Regulador de ajuste

„Pressure End”

Only

Only

for in

form

ation!

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info

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info

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info

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Figure F02

“PUMP CONTROL“

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Documents

CHAPTER “E” INSPECTION AND MAINTENANCE …...Property of American Airlines HYDRAULIC GROUND POWER UNIT 02.02.2017 MAWN INSPECTION AND MAINTENANCE Page