Tronair 5010 Installation and operating instructions

1740 Eber Rd Tronair, Inc. Phone: [phone]
Holland, OH 43528-9794 www.tronair.com 800-426-6301
USA Email: [email protected] Fax: [phone]
Operation & Service Manual
Model: 5010
Hydraulic Power Unit
05/2004 - Rev. 01
Includes Illustrated Parts Lists

REVISION DATE TEXT AFFECTED
01 5/2004 pg. 24 Modified part number on item

Model: 5010
Hydraulic Power Unit - MIL-PRF-5606 Fluid
05/2004 | Rev. 01
TABLE OF CONTENTS PAGE
Figure 1 External Components..................................................................................................................................................1
Figure 2 Internal Components...................................................................................................................................................1
Figure 3 Hydraulic Schematic ...................................................................................................................................................2
Figure 4 Electrical Schematic....................................................................................................................................................3
1.0 GENERAL DESCRIPTION............................................................................................................................................4
2.0 TECHNICAL SPECIFICATIONS ...................................................................................................................................4
2.1 HYDRAULIC ..............................................................................................................................................................4
2.2 ELECTRICAL.............................................................................................................................................................4
2.3 MECHANICAL............................................................................................................................................................4
3.0 PREPARATION FOR USE............................................................................................................................................4
3.1 SERVICING RESERVOIR .........................................................................................................................................4
3.2 CONNECTING ELECTRICAL LEADS .......................................................................................................................4
4.0 OPERATION..................................................................................................................................................................5
4.1 GENERAL COMMENTS............................................................................................................................................5
4.2 PRELIMINARY ADJUSTMENTS AND OPERATIONS...............................................................................................5
4.3 SAMPLE VALVE........................................................................................................................................................6
4.4 BLEEDING AIR FROM SYSTEM...............................................................................................................................6
4.5 ABBREVIATED OPERATING INSTRUCTIONS ........................................................................................................7
4.6 OPTIONS...................................................................................................................................................................7
5.0MAINTENANCE ............................................................................................................................................................8
5.1 GENERAL MAINTENANCE.......................................................................................................................................8
5.2 FILTER MAINTENANCE............................................................................................................................................8
5.3 SELECTOR VALVE MAINTENANCE ........................................................................................................................8
5.4 LUBRICATION...........................................................................................................................................................8
5.5 STORAGE..................................................................................................................................................................8
6.0 TROUBLESHOOTING ..................................................................................................................................................8
6.1 NO FLOW OR PRESSURE .......................................................................................................................................8
6.2 FLUCTUATING PRESSURE OR FLOW....................................................................................................................8
6.3 UNIT OVERHEATS....................................................................................................................................................8
6.4 LOSS OF FLOW IN CLOSED LOOP.........................................................................................................................8
6.5 EXTERNAL LEAKAGE FROM SELECTOR VALVE ..................................................................................................8
7.0 PARTS LIST INDEX......................................................................................................................................................9
APPENDIX I Instrument Certification Notice
APPENDIX II Lincoln Motor Manual
APPENDIX III Continental Hydraulics Service Booklet PVR6-"G" Design Series Pumps
APPENDIX IV MSDS Hydraulic Fluid

Model: 5010
Hydraulic Power Unit - MIL-PRF-5606 Fluid
05/2004 | Rev. 01 Page | 1
FIGURE 1 External Components
FIGURE 2 Internal Components

Model: 5010
Hydraulic Power Unit - MIL-PRF-5606 Fluid
05/2004 | Rev. 01 Page | 2
Hydraulic Schematic
(Standard Models)
FIGURE 3 Hydraulic Schematics

Model: 5010
Hydraulic Power Unit - MIL-PRF-5606 Fluid
05/2004 | Rev. 01 Page | 3
FIGURE 4 Electrical Schematic

Model: 5010
Hydraulic Power Unit - MIL-PRF-5606 Fluid
05/2004 | Rev. 01 Page | 4
This product can not be modified without the written approval of Tronair, Inc. Any modifications done without written approval
voids all warranties and releases Tronair, Inc., it suppliers, distributors, employees, or financial institutions from any liability
from consequences that may occur. Only Tronair OEM replacement parts shall be used.
1.0 GENERAL DESCRIPTION
The Tronair Hydraulic Power Unit (HPU) provides a source of clean, pressurized hydraulic fluid for performing required aircraft
maintenance.
Important features include:
Pressure compensated pump with integral pressure and flow controls
10 gallon reservoir with selector valve
Bypass valve
Cooler located inside reservoir
Manual starter with overload protection
Non bypass filter with 2 micron filter element
2.0 TECHNICAL SPECIFICATIONS
2.1 HYDRAULIC
Fluid: MIL-PRF-5606
Pressure Range: 300 1,750 psi
Flow Range: 0 6 gpm (60 Hz systems)
0 5 gpm (50 Hz systems)
Filtration: 2 Micron Absolute, Non-Bypass
Reservoir Capacity: 10 gallons (Maximum)
2.2 ELECTRICAL
Power Requirements: 3 Phase, Alternating Current
60 Hz 50 Hz
9.2 amps @ 208 VAC 9.3 amps @ 220 VAC
8.4 amps @ 230 VAC 4.6 amps @ 380, 415, 440 VAC
4.2 amps @ 460 VAC
3.7 amps @ 575 VAC
2.3 MECHANICAL
Dimensions
Length: 35 inches
Width: 30 inches
Height: 24 inches
Weight: 400 lbs
3.0 PREPARATION FOR USE
The HPU is shipped completely assembled and only the following steps are required to make the unit operational.
3.1 SERVICING RESERVOIR
Remove the sheet metal cover and fill the reservoir with the correct fluid until fluid level is slightly above the minimum oil level
mark. Since a case drain cooler is located in the HPU reservoir, it is important that this fluid level be maintained in order to
prevent excessive heat buildup.
3.2 CONNECTING ELECTRICAL LEADS
Install plug onto the electrical cord and check for proper motor rotation by "bumping" the On-Off switch. Correct motor rotation
is indicated by an arrow on pump motor adapter. If rotation is not correct, change any two of the three input leads inside the
on-off switch box or at the plug.
NOTE: Balanced three phase voltage must be available to prevent overheating and damage to the motor.
Voltage unbalanced between phases occurs when the voltages differ from one another. Some reasons for imbalance
are:
1. Unequal loading of each phase.
2. Poor connections in the supply.
3. Single phase condition caused by blown fuses or bad connections.
If these conditions occur in the incoming power system, a protective device, such as a voltage monitor, should be
installed on the machine to prevent motor damage.

Model: 5010
Hydraulic Power Unit - MIL-PRF-5606 Fluid
05/2004 | Rev. 01 Page | 5
4.0 OPERATION
Due to the complexity, differences, and ongoing changes in aircraft hydraulic systems, no attempt has been made to relate to
any specific aircraft operation. It is suggested that this manual and the HPU be studied thoroughly in order to obtain optimum
benefit of the various features. By combining an understanding of the HPU and the aircraft hydraulic system, many services
not mentioned in this manual may be performed. Refer to the hydraulic schematic, front panel controls, and internal
components pages for clarification while reading this manual.
4.1 GENERAL COMMENTS
Most questions or problems concerning hydraulic power units are usually caused by improper training or understanding of
hydraulics. The following comments are given to aid in obtaining maximum benefits from the hydraulic power unit.
4.1.1 Training
Be sure that all personnel that will use the machine read the operating manual and receive training. We encourage customers
to call Tronair to discuss any operating or testing requirements.
4.1.2 Use of the HPU Reservoir
It is suggested that the integral reservoir be used whenever possible. Use of this reservoir eliminates any possibility of
cavitating the pump. Most complaints of pump noises are due to fluid restrictions in the aircraft systems when using the aircraft
reservoir. Also, if the integral reservoir is used, the HPU will run considerably cooler. This occurs because the pump case drain
oil is directed to the reservoir instead of the pump return. The only compromise in using the HPU reservoir is that the aircraft
system reservoir must be serviced after testing, which is standard procedure.
4.2 PRELIMINARY ADJUSTMENTS AND OPERATIONS
The following are basic to the operation of the HPU and should be thoroughly understood. The pressure and flow controls
have lock nuts to prevent rotation of the control shafts during operation. These nuts should be moved away from the pump
during adjustments of flow or pressure in order to eliminate binding of the control shafts.
4.2.1 Flow Control Adjustment
a. Open bypass valve.
b. Select "Hydraulic Power Unit" position with reservoir selector valve.
c. Start HPU.
d. Adjust flow control for maximum desired flow. Observing the flowmeter, read flow (gallons per minute) directly from
flowmeter scale. Be sure the control shaft lock nut is loose during adjustment. Tighten after adjustment to maintain setting.
4.2.2 Pressure Control Adjustment
a. Open bypass valve.
b. Select "Hydraulic Power Unit" position with reservoir selector valve.
c. Start HPU.
d. Close bypass valve.
e. Adjust pressure control for desired pressure. Be sure the control shaft lock nut is loose during adjustment. Tighten after
adjustment to maintain setting.
NOTE: Once the flow and pressure controls have been adjusted, it is not necessary to change these settings after
each operation unless desired.
4.2.3 Reservoir Selector Valve Operation
Operation of the reservoir selector valve allows the operator to select either the aircraft reservoir (closed loop) of the HPU
reservoir (open loop). CAUTION!
The reservoir selector valve should only be operated when the HPU is not running. The operation of the
reservoir selector valve should be done prior to starting the HPU.
4.2.3.a Aircraft Reservoir Position (Closed Loop)
In this position, the HPU is dependent on the aircraft reservoir and system for an adequate supply of fluid. Cavitation, due to
an inadequate fluid supply from the aircraft, may be indicated by erratic indication of the system pressure gauge or flowmeter.
Usually, the aircraft fluid supply will be restricted due to small return oil lines in the aircraft. Sometimes this problem can be
minimized or eliminated by pressurizing the aircraft reservoir with air.
CAUTION!
If the aircraft reservoir is pressurized, do not exceed the aircraft manufacturer's recommendations.
If the aircraft reservoir cannot be pressurized or the cavitation persists, decrease the flow control setting until the cavitation is
eliminated.

Model: 5010
Hydraulic Power Unit - MIL-PRF-5606 Fluid
05/2004 | Rev. 01 Page | 6
4.2.3 Reservoir Selector Valve Operation (continued)
4.2.3.b HPU Reservoir Position (Open Loop)
In this position, the HPU reservoir supplies oil to the pump and accepts return oil from the aircraft. It is desirable to operate the
HPU in this mode since it eliminates any possibility of cavitation.
Since the HPU reservoir is vented to atmosphere and the aircraft is at a higher level, it is normal for the aircraft reservoir to
drain into the HPU reservoir. It is, therefore, necessary to be sure that sufficient room is available in the HPU reservoir to
accommodate the additional fluid. CAUTION!
The aircraft system reservoir must be serviced after completion of operational testing.
In the "HPU Reservoir" position, faster landing gear swings are usually possible since there is no restrictions to flow at the
pump inlet.
On most aircraft, the aircraft reservoir may usually be serviced by disconnecting the return hose. Normally servo leakage or
operation of a hydraulic component will allow some flow to the aircraft reservoir. Caution should be observed if this method is
used.
WARNING!
When using the HPU reservoir, it may be possible to overfill the aircraft reservoir if several landing gear
swings are done in a short time period.
Always wait approximately 15 seconds between gear swings to allow the aircraft reservoir to drain into
the HPU.
Do not change the reservoir selector valve position while the machine is running
4.2.4 Bypass Valve Operation
The bypass valve is used for unloading the pump flow in conjunction with the flowmeter.
4.2.4.a Start Up Operation
The bypass valve should be opened prior to starting the HPU in order to allow the motor to start under a no load condition.
4.2.4.b Shut down Operation
Prior to shutdown, the bypass valve may be opened to bleed off any residual system pressure.
CAUTION!
Excessive heat, which could damage machine components, will be generated if the bypass valve is
partially opened or is used for regulating flow or pressure.
Use the flow and pressure controls for regulation.
Use the bypass valve for unloading the system.
4.3 SAMPLE VALVE
A sample valve is provided on the rear of the unit to obtain a fluid sample for analysis or inspection. In order to obtain a
representative fluid sample, it is suggested that American National Standard number B93.19-1972 be followed.
4.4 BLEEDING AIR FROM SYSTEM
Rapid fluctuations of the pressure gauge and flowmeter are indications of cavitation or entrapped air in the hydraulic lines
and/or components. Air may enter the system when:
Operating the unit with insufficient oil in the reservoir.
Changing a component on the aircraft.
Changing the hose connections and/or couplings.
To Easily Purge the Unit of Air:
1. Fill reservoir to recommended level.
2. Open bypass valve.
3. Place reservoir selector valve in "Hydraulic Power Unit" position.
4. Start unit and adjust flow control to maximum position.
5. Run unit for five (5) minutes and shut off.
6. If additional bleeding is required, proceed with the following steps:
a. Connect the pressure and return hoses together. (Kits containing the necessary fitting(s) are available from Tronair)
b. If the unit is equipped with pressure and return ball valves, open the ball valves prior to starting the unit.
4.4 Bleeding air from system continued on following page.

Model: 5010
Hydraulic Power Unit - MIL-PRF-5606 Fluid
05/2004 | Rev. 01 Page | 7
4.4 BLEEDING AIR FROM SYSTEM WARNING!
Failure to open the return ball valves will cause hose or valve rupture. Property damage and personal
injury can result.
c. Place the reservoir selector valve in the “Hydraulic Power Unit” position.
d. Open the bypass valve on the instrument panel
e. Start unit and adjust flow control to maximum position.
f. Close the bypass valve and allow the unit to run for 5 minutes.
Under some conditions where a large amount of air has entered the system, the pump may not be able to draw an initial prime
and will not pump. If this occurs, it may be necessary to fill the pump inlet line with fluid.
4.5 ABBREVIATED OPERATING INSTRUCTIONS
These instructions may be used for fast reference after a thorough understanding of the HPU operation has been achieved.
4.5.1 Initial Adjustments
1. Set flow control (See Section 4.2-A).
2. Set pressure control (See Section 4.1-B).
4.5.2 Prior to Starting
1. Select reservoir valve position.
2. Open bypass valve.
4.5.3 Operation
1. Start HPU.
2. Close bypass valve.
4.5.4 Shut Off
1. Open bypass valve.
2. Stop HPU.
4.6 OPTIONS
The following options are available on some models of hydraulic power units. Refer to the appropriate option description for
operation information.
4.6.1 Dual System (Option C) Operation
The dual system option allows control of fluid flow to aircraft with two hydraulic systems. The systems consist of two sets of
hoses and valves located in the pressure and return systems. The valves are mounted on the rear of the hydraulic power unit
and are of the 90° ball type. The valves are open when the operating handle is in line with the valve.
Although both systems may be operated simultaneously, usually only one system is required at any one time. If both valve
sets are open simultaneously, the pump output will be divided between the two systems. Also, cross flow between the
reservoirs may occur if a reservoir level or pressure differential exists. Select valve positions prior to starting machine.
To Operate the Dual System
1. Before starting machine, open pressure and return valves of the same system.
WARNING!
Ensure pressure and return hoses of the same system are paired and used together.
2. 2. After completing tests on one system, shut the machine OFF before selecting the second system.
WARNING!
Never open or close dual system valves without shutting off the hydraulic power unit. Damage to the
aircraft system or reservoir may result if either return line valve is closed while the machine is running.
3. If equipped with the Dual System Crossover Check Option, separate pressure gauges are located after each system
pressure shut off valve. This allows bleed down pressures to be read when the pressure valves are closed. Follow aircraft
manufacturer's instructions.