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~6SEP1986
TB 9-4935251-50 7
DEPARTMENT OF THE ARMY TECHNICAL BULLETIN
CALIBRATION PROCEDURE FOR
HYDRAULIC PUMPING UNIT TEST STAND (M2)
4935-00-646-8385
(NIKE-AJAX AND NIKE-HERCULES
AIR DEFENSE GUIDED MISSILE SYSTEMS)
Headquarters, Deportment of the Army, Washington, D.C.
8 May 1978

REPORTING ERRORS AND RECOMMENDING IMPROVEMENTS

You can help improve this manual. If you find any mistake or if you
know of a way to improve the procedures, please let us know. Mail your
letter, DA Form 2028 (Recommended Changes to Publications and Blank
Forms), direct to Commander, U. S. Army Missile Materiel Readiness
Command, ATIN: DRSMI-NPM, Redstone Arsenal, AL 35809. A reply
will be furnished to you.

Paragraph Page
SECTION I. IDENTIFICATION AND DESCRIPTION
Test instrument identification 1 2
Calibration data card, DA Form 2416 2 2
Calibration description 3 2
II. EQUIPMENT REQUIREMENTS
Equipment required 4 2
Accessories required 5 2
Additional equipment required 6 2
IlL PRELIMINARY OPERATIONS
Preliminary instructions 7 4
Equipment setup 8 4
IV. CALIBRATION PROCESS
HYD PRESSURE gage 9 6
FLOW METER No. 2 10 7
FLOW METER No. I 11 7
Final procedure 12 8

7 ,,
 SECTION I

IDENTIFICATION AND DESCRIPTION

1. Test Instrument Identification. 3. Calibration Description.

This bulletin provides instructions for the TI parameters and performance specifications
calibration of hydraulic pumping unit test stand which pertain to this calibration are listed in table
4935-00-646-8385. TM 9-4935-250-35 was used as 1.
the prime data source in compiling these
instructions. The equipment being calibrated will
be referred to as the TI (test instrument)
throughout this bulletin. Table 1. Calibration Description
a. Model Variations. The hydraulic tube assem-
blies, connecting SELECTOR NO. 3 cock, were Test instrument parameters Performance specIficatton~
changed on TI models 1019 and subsequent to Power requirements
1
meet the point-to-point requirements when Input 120/208 V ac ±10%,400 Hz,
SELECTOR NO. 3 cock was relocated. On TI 3 ph
models 1041 and subsequent, the hydraulic oil
Output 120/208 V ac ±10%,400 Hz,
reservoir was rotated 180 degrees and all associated 3 ph; 28 V dc
hydraulic tube assemblies were changed to meet
the point-to-point requirements. A door was added Hydraulic pressure gage 0 to 5000 psi
to the lower front panel of the TI to provide access
to the hydraulic oil reservoir indicator. Flow meter no. 1
b. Time and Technique. The time required for Rated pressure’ 3000 psi
this calibration is approximately 3 hours using the
Range 0 to 2 gpm
physical technique.
Flow meter no. 2
2. Calibration Data Card, DA Form 2416.
Rated pressure1 3000 psi
Forms, records, and reports required for calibra-
tion personnel in all levels are prescribed by TM Range 0 to 12 gpm
38-750. DA Form 2416 must be annotated in 1 This specification is for -information only and is not
accordance with TM 38-750 for each calibration verified in this bulletin.
performed.

SECTION II

EQUIPMENT REQUIREMENTS

4. Equipment Required. 5. Accessories Required.

Table 2 identifies the specific equipment used in The accessories listed in table 3 are issued as
this calibration procedure. This equipment is issued indicated in paragraph 4 above and are to be used
with secondary transfer standards calibration set, in this calibration procedure. When necessary,
NSN 6695-00-621-7877, and is to be used in these items may be substituted by equivalent items
performing this procedure. Alternate items may be unless specifically prohibited.
used by the calibrating activity when the
equipment listed in table 2 is not available. The
items selected must be verified to perform
satisfactorily prior to use and must bear evidence 6. Additional Equipment Required.
of current calibration. The equipment must meet Equipment required for this calibration but not
or exceed the minimum use specifications listed in available in the secondary transfer standards
table 2. The accuracies listed in table 2 provide a calibration set is listed in table 4. These items must
four-to-one ratio between the standard and TI. be supplied with the TI.

2
 Table 2. Minimum Specifications of Equipment Required

Common name and/or

Item official nomenclature Minimum use specifications Manufacturer, model, and part number

Al FLOW RATE METER Range: 0-2 gpm Schute and Koerting, Model 18200
Accuracy: ±2%FS (7907273)

A2 0-600 PSI Range: 0-300 psi Mansfield and Green Model T417-2
PRESSURE GAGE Accuracy: 0.25% FS (P/O 8598963)

A3 0-5000 PSI Range: 0-3000 ‘psi Mansfield and Green Model T417-3
PRESSURE GAGE Accuracy: 0.25% FS (P/) 8598963)

A4 THERMOMETER Range: 70 to 115°F Fisher Scientific Co., Model 43850Y

Accuracy: ±1°F

A5 VISCOMETER SET Range: ASTM 50 to 200 (7913076)

Table 3. Accessories Required

Common name and/or

Item official nomenclature Description and part number

Bi ADAPTER Pipe, male 9/16-18 to male 3/4-14 NPT (7921037)

B2 ADAPTER External thread 9/16-18 to 7/8-14, 15 inch length (7921026)

(ADAPTER, TEST GAGE)

Table 4. Additional Equipment Required

Item Common name and/or official nomenclature Description and part number

1/2-3/8 in. NPT (144051)

Cl BUSHING, SHOULDER PIPE
1 2 8168948
C2 COUPLING HALF, QUICK DISCONNECT
HYDRAULIC HOSE ASSEMBLY3 AN6292-6-120 (P/O TI)
C3
NIPPLE, TUBE AN815-6 (8022040)
C4
PREFORMED PACKING1 2 8034459
C5
TEST STAND, HYDRAULIC, MISSILE COMPONENT Douglas Aircraft Co. (8523711)
C6
1 Accessory supplied in hydraulic test equipment kit 8163378.
~ required.
3Four required.

3
 SECTION III

PRELIMINARY OPERATIONS

7. Preliminary Instructions.
a. The instructions outlined in this section are
preparatory to the calibration process. Personnel
should become familiar with the entire bulletin
before beginning the calibration.
b. Items of equipment used in this procedure are
referenced within the text by common name and
item identification number as listed in tables 2, 3,
and 4. For the identification of equipment
referenced by item numbers prefixed with A, see
table 2; for prefix B, see table 3; and for prefix C,
see table 4.
NOTE
Unless otherwise specified, all controls and
control settings refer to.the TI.

8. Equipment Setup.
a. Inspect all gages, meters, and connections on
the TI for tightness of connections, insuring that
there is no evidence of leakage. Refer to figure 1
for location of TI components.
b. Disconnect the TI power cable from electrical 1. Selector valve No. 3
connector receptacle J1 (23, fig. 1). 2. Selector valve No. 4
c. Depressurize the hydraulic system by opening 3. Selector valve No. 2
SHUTOFF NO. 1 valve and BLEED valve, allowing 4. Air pressure gage
the hydraulic oil to return to the hydraulic oil 5. Selector valve No. 1
reservoir. 6. Flow meter No. 2
7. Flow meter No. 1
d. Insure that the HYD PRESSURE gage, FLOW 8. Shutoff valve No. 2
METER NO. 1 gage, and FLOW METER NO. 2 9. Hydraulic pressure gage
gage on the TI indicate 0 (zero). 10. Electrical installations
11. Relief valve
12. Bleed valve
NOTE
13. Shutoff valve No. 1
14. Overflow relief valve
If necessary to zero the flow meters or 15. Air filler valve
hydraulic pressure gage, remove the retaining
16. Pressure ports
ring (or bezel) and glass from the meter face.
17. Louse equipment compartment
Turn zero-adjusting screw on meter face while 18. Reservoir assembly
tapping lightly on the panel. 19. Sight gage
20. Hand pump
e. Insure that the oil level of the oil reservoir is 21. Shutoff valve No. 4
above the refill mark. 22. Shutoff valve No. 3
23. Receptacle Ji
f. Turn BLEED, SHUTOFF NO. 1, SHUTOFF
NO. 2, SHUTOFF NO. 3, and SHUTOFF NO. 4 Figure 1. Hydraulic pumping unit test stand—rear view.
valves fully clockwise.
g. Turn SELECTOR NO. 1, SELECTOR NO. 2, h. Install cap assemblies on ports A, B, C, D, and
SELECTOR NO. 3, and SELECTOR NO. 4 valves F (fig. 2) on the TI.
to position 1 (fig. 1). i. Connect equipment as shown in figure 3.

4
 RELIEF VALVE
POPS AT
3500 PSI
PORT H

PORT G

PORT F

PORT E
RETURN TO
TEST STAND SHUTOFF NO. I
VALVE
RESERVOIR

CHECK VALVE
CHECK
PORT D SHUTOFF NO. 3
VALVE

PORT C

RERVOIR RELIEF VALVE

PORT B

PORT A

I -‘ RETURN
~ AIR
PRESSURE
NSO OTT 06
Figure 2. Pressure rate and flow diagram of hydraulic pumping unit test stand.

5
 PRESSURE GAGE
A3

TEST
INSTRUMEN1

I
C6 REOD)

PRaSSORE
PORT PORT S

PORT £

MS007701
Figure 3. Hydraulic pressure gage performance check—equipment hookup.

j. Insure the the oil reservoir on hydraulic (2) RELIEF VALVE fully counterclock-
missile component test stand (C6) is filled. To refill wise.
the reservoir, refer to TM 9-4935-254-15. (3) BLEED VALVE fully clockwise.
(4) PRESSURE SHUTOFF valve fully
clockwise.
k. Position controls on the hydraulic missile (5) GAGE A SHUTOFF valve fully
component test stand as follows: clockwise.
(1) Selector valve to PRESSURE TO MANI- (6) GAGE B SHUTOFF valve fully
FOLD. clockwise.

SECTION IV

CALIBRATION PROCESS

NOTE WARNING
Unless otherwise specified, verify the results of Raise or lower pressure slowly to avoid
each test and, whenever the test requirement is
not met, take corrective action before con- damage to equipment and injury to
tinuing with the calibration. Since out-of- personnel.
tolerance conditions require corrective mainte-
nance, adjustments are not provided in this NOTE
procedure. Refer to TM 9-4935-250-35 for
maintenance instructions. In the procedure which follows do not open the
TI BLEED valve unless instructed to do so.

(2) Regulate pressure from the hydraulic

9. HYD PRESSURE Gage. missile component test stand to the TI by turning
a. Performance Check. RELIEF VALVE on the hydraulic missile compo-
(1) Start hydraulic missile component test nent test stand clockwise until TI HYD PRES-
stand (C6) by turning OFF-ON switch key to ON SURE gage indicates 3000 psi. Observe for fluid
and pressing the START button. leakage.

6
 (3) Turn RELIEF VALVE on hydraulic 10. FLOW METER No. 2.
missile component test stand counterclockwise a. Performance Check.
gradually until the valve closes. (1) Connect equipment as shown in figure 4
(4) Turn TI SELECTOR NO. 2 valve to 3 using 0-250 mm tube no. 4HCFB and float S-41J
until pressure on the HYD PRESSURE gage from flow rate meter (Al).
decreases to 0 (zero). (2) Turn TI SELECTOR NO. 2 valve to
(5) Turn TI SELECTOR NO. 2 valve to 2 position 1 and turn SHUTOFF NO. 1 valve fully
and repeat steps (2) through (4) above until TI has counterclockwise.
been exercised through three complete cycles of
pressurizing/depressurizing. CAUTION
(6) Turn TI SELECTOR NO. 2 valve to 2.
(7) Regulate pressure from the hydraulic Do not permit pressure gage (A2) to
missile component test stand to the TI by turning exceed 200 psi.
RELIEF VALVE on the hydraulic missile compo-
nent test stand clockwise until TI HYD PRES- (3) Insert thermometer (A4) in the hydrau-
SURE gage indicates 500 psi. TI HYD PRESSURE lic missile component test stand (C6) reservoir.
gage will indicate within ±75psi of pressure gage (4) Turn the switch key to ON and press the
(A3) indication. START button. Allow the hydraulic missile
(8) Gradually increase pressure until TI component test stand to warm up and the
HYD PRESSURE gage indicates 1500 psi. TI HYD temperature 6f the oil in the reservoir to stabilize.
PRESSURE gage will indicate within ±75 psi of (The ambient temperature determines the point at
pressure gage (A3) indication. which oil temperature stabilizes.)
(5) Determine viscosity of the oil using
NOTE viscometer set (A5).
(6) Refer to the calibration curve furnished
Although gages and flow meters located on the with flow rate meter (Al) and convert flow rate
front panel of the r~ are zero calibrated, the
approxim ate readings at one-third, one-half, meter indications in mm to equivalent flow in gpm
and three-quarters scale may be erratic and (gallons per minute).
out-of-tolerance. If readings are not within (7) Turn the hydraulic missile component
tolerance, every effort should be made to test stand selector valve to PRESSURE TO
restore the gage or flow meter to within MANIFOLD and gradually turn RELIEF VALVE
tolerance by cleaning it or by tapping.
clockwise for an indication of 2 gpm on TI FLOW
(9) Gradually increase pressure until TI METER NO. 2. The flow rate meter should
HYD PRESSURE gage indicates 3000 psi. TI HYD indicate as shown in the calibration curve ±7mm.
PRESSURE gage will indicate within ±75psi of (8) Reduce pressure by turning hydraulic
pressure gage (A3) indication. missile component test stand RELIEF VALVE
(10) Turn RELIEF VALVE on hydraulic fully counterclockwise. Turn selector valve to
missile component test stand counterclockwise MANIFOLD TO RESERVOIR.
gradually decreasing pressure until pressure gage (9) Position TI controls as indicated in (a)
(A3) indicates 0 (zero). through (d) below:
(11) Turn TI SELECTOR NO. 2 valve to 3 to (a) Turn BLEED valve fully counterclock-
decrease pressure on HYD PRESSURE gage. wise and allow TI to bleed.
(12) Turn TI SELECTOR NO. 2 valve to 1. (b) Turn BLEED valve fully clockwise.
(13) Very slowly turn TI SHUTOFF NO. 1 (c) Turn SELECTOR NO. 2 valve to 2.
valve counterclockwise to bleed the system. (d) Turn SHUTOFF NO. 1 valve fully
(14) Press the STOP button on the hydraulic clockwise.
missile component test stand and turn the, switch b. Adjustments. No adjustments can be made.
key to OFF. Turn the selector valve to
MANIFOLD TO RESERVOIR. 11. FLOW METER NO.1.
(15) Disconnect all equipment and a. Performance Check.
accessories. (1) Position TI controls as indicated in (a)
b. Adjustments. No adjustments can be made. through (c) below:

7
 OUTLET

PRESSURE GAGE
A2

FLOW RATE
METER Al TEST

I NSTRUMEP4T

I
E

REQ’0)

MS007702

Figure 4. Flow meter No. 1 and No. 2 performance check—equipment hookup.

(a) SELECTOR NO. 2 valve to 1. (5) Reduce pressure by turning hydraulic

(b) SHUTOFF NO. 2 valve fully counter- missile component test stand RELIEF VALVE
clockwise. fully counterclockwise. Turn selector valve to
(c) SELECTOR NO. 1 valve to 3. MANIFOLD TO RESERVOIR.
(2) Turn hydraulic missile component test (6) Position TI controls as indicated in (a)
stand selector valve to PRESSURE TO MANI- through (d) below:
FOLD. -. (a) Turn BLEED valve fully counterclock-
wise and allow TI to bleed.
CAUTION (b) Turn BLEED valve fully clockwise.
(c) Turn SELECTOR NO. 2 valve to 2.
Do not permit pressure gage (A3) to (d) Turn SELECTOR NO. 1 valve to 2.
exceed 300 psi. b. Adjustments. No adjustments can be made.

(3) Gradually turn the hydraulic missile

component test stand RELIEF VALVE clockwise
for an indication of 1 gpm on TI FLOW METER
NO. 1. Flow rate meter (Al) should indicate as 12. Final Procedure.
shown on the calibration curve ±8mm. a. Deenergize and disconnect all equipment.
(4) Gradually turn the hydraulic missile b. In accordance with TM 38-750, annotate and
component test stand RELIEF VALVE clockwise affix DA Label 80 (U.S. Army Calibration
for an indication of 2 gpm on TI FLOW METER System). When the TI cannot be adjusted within
NO. 1. The flow rate meter should indicate as tolerance, annotate and affix DA Form 2417
shown on the calibration curve ±7mm. (Unserviceable or Limited Use) tag.

8
By Order of the Secretary of the Army:

BERNARD W. ROGERS
General, United States Army
Chief of Staff

Official:
J. C. PENNINGTON
Brigadier General, United States Army
The Adjutant General

Distribution:

To be distributed in accordance with BA Form 12—32, Section I, requirements for

Calibration Procedures Publications.

*LJS mERNM~T PRINTING OFFICE: 1978 — 740157/248