Cessna

HYDRO TEST
SERVICE/PARTS MANUAL
MODELS SE588, SE588-1
& SE588-2 WHEN MODIFIED
BY SK210-38 AND SK421-68

MODELS SE589, SE589-100

& SE589-200 WHEN MODIFIED
BY SK421-68 , AND MODELS SE589-1000,
SE589-1100 & SE589-1200

3/76
100
CES
05429-13 MARCH 1976
 PREPARATION OF HYDRO TEST FOR SERVICE

PREPARING HYDRO TEST FOR OPERATION (NEW UNITS).

After removing the Hydro Test from the shipping crate, service the Hydro Test for use ,
follows:

a. Remove upper and lower rear panel from Hydro Test and fill reservoir to approx
mately 3/4 full with clean MIL-H-5606 hydraulic fluid. Fluid level in reservo
be checked by observing sight gage through opening in side panel below the hose
connections.
b. Connect suction, pressure and overboard vent return hose to the appropriate fit
side of Hydro Test.
c. Install an appropriate electrical plug at end of electric service cable.

NOTE: The electrical plug has not been included due to the many different type
available. The Hydro Test is equipped with either a single-phase or a
phase 220-volt, 60-cycle, AC electrical motor.

d. Connect service cable to power source and jog the motor by rapid "on-off" oper;
motor switch. If motor does not turn in direction of arrow on motor, rewire e
plug as necessary.

CAUTION: Continued operation of the motor in direction opposite of the arrow ,

will cause damage to the hydraulic pump.

e. Using a reducer of correct size, connect suction hose to pressure hose.

f. Set Hydro Test valves as follows:
1. Priority flow regulator - CLOSED.
2. Bypass valve - OPEN.
3. Lockout Valve - OPEN.
g. Start Hydro Test motor and slowly close bypass valve and open priority flow re
to the desired gallon per minute mark on handle (manual knob) of priority flow
regulator.
h. The flow rate indicator and priority flow regulator are calibrated at the fact
should be adjusted to read the same.
i. If marking on priority flow regulator handle and flow indicator do not agree,
set screw securing handle to shaft of priority flow regulator and adjust handl,
j. Make a\mark on flow placard located directly above priority flow regulator rely
(1) one gallon per minute mark on handle.

NOTE. The gallon per minute hydraulic fluid flow rate may be varied from (0)
(5) five gallon per minute.

k. Stop Hydro Test motor.

1. Set Hydro Test valves as follows.
1. Priority flow regulator - CLOSED.
2. Bypass - OPEN.
3. Lockout valve - OPEN.
m. Disconnect pressure hose from suction hose and cap suction hose.
n. Cap pressure hose with suitable plug for dead-ending flow through the pressure
o. Start Hydro Test motor.
p. Pressure gage should indicate an immediate rise to a value of.1950 +50 PSi.
Hydro Test only long enough to be certain that reading on gage has stabilized.
q. Successful conclusion of preceeding steps completes the preparation check and t
Hydro Test is now ready to be placed in service.
 Hydro
Manual
Test Service/Parts

MAINTENANCE ADJUSTMENTS AND OPERATION

SERVICING SUGGESTIONS.

a. Periodically lubricate pressure Jack adjusting screw threads with a graphite base
grease.
b. Clean reservoir filler cap assembly every 25 hours of operation. A plugged or dirt
reservoir breather will cause the Hydro Test to evacuate all fluid from the aircraft
reservoir.
c. Replace filter element in filter assembly every 100 hours of operation to insure,
proper operation.
d. The Hydro Test electric motor bearings are sealed and requires no lubrication. The
hydraulic pump requires no lubrication other than the fluid it displaces when
operating.
e. Periodic tests should be made on the gages and indicators. If hydraulic checks on
or three aircraft show unusual pressure and the landing gear systems functions
acceptably, calibrate the Hydro Test gages and indicators as outlined in the follow
paragraphs.

RELIEF VALVE.

The relief valve is calibrated to 1950 ±100. PSI at the factory prior to shipping. Do not
alter.

ACCURACY CHECK OF PRIORITY FLOW REGULATOR.

a. Insure reservoir is properly filled with hydraulic fluid prior to start of test.
b. Set priority low regulator to one gallon per minute with the lockout valve open and
the bypass valve closed.
c. Cap overboard vent hose.
d. With the pressure hose connected to the return hose, leave the control valves set at
let fluid flow approximately one minute until air is out of the lines. Stop Hydro
Test motor. Disconnect pressure and return hose. Cap return hose.
e. Start Hydro Test motor and allow hydraulic fluid to flow into a clean marked (known
gallons) container for one minute. Check and record for later use, the flow rate.

CAUTION: After 90 seconds of flow, refill Hydro Test hydraulic reservoir. Allowing
reservoir to become empty will damage the hydraulic pump..

f. Remove cap from hoses.

HYDRO TEST PROOF PRESSURE CHECK.

a. Set the priority flow regulator closed, the bypass valve slightly open. the lockout
valve slightly open and open the pressure jack until approximately 1-1/2 inches of.
thread on screw is showing above the panel.
b. Plug pressure hose with a suitable plug for dead-ending pressure through the pressur
hose.
c. Start Hydro Test motor, close bypass valve and when pressure reaches 1800 PSI rapid
close the lockout valve completely and stop Hydro Test immediately. This procedure
must be accomplished in rapid succession in order to trap a certain amount of pressu
in the lines.
d. Screw the pressure jack in to obtain 2250 PSI on the pressure gage. Allow this
pressure to remain for five minutes. Maximum allowable drop in pressure during this
timing period is approximately 25 PSI.

NOTE: The pressure drop over a period of several minutes can be affected by either
moving the external pressure line or room temperature Changes during the tim-
ing period. This Is a very sensitive check and changing conditions should be
watched carefully during the checking procedure.
OPERATION

a. Always open bypass valve before starting test stand motor. This will permit motor to
start under a no-load condition and will contribute to the service life of the test
stand unit.
b. Operation of the test stand with bypass and lockout valves closed at the same time
should not be continued for more than one minute.
c. Avoid continuous operation of the test stand under high-pressure - low-flow condition
this will cause rapid heating of the fluid supply. When pressure is no longer needed
open bypass valve to relieve pressure.
d. Cap all hoses and stow on rack when not in use
e. Avoid contamination of test stand fluid by checking condition of fluid in aircraft
system before connecting test stand.
f. Before disconnecting test stand, check that aircraft reservoir is full; fluid may
siphon from aircraft reservoir to test stand if idle for a period of time.

NOTE: The Hydro Test unit is a precision test instrument as well as a hydraulic
power source. The retention of its accuracy and the length of its service lif
depends on good care ahd proper operation.

LOW REGULATION.

he following procedure is used to adjust the test unit flow to any value desired for a
pecific operation with the test unit connected to the aircraft hydraulic system and the
ircraft on jacks.

a. Open bypass valve and lockout valve.

b. Start test unit pump motor.
c. Close bypass valve.
d. Open priority flow regulator valve then slowly close it until flow meter is indicatin
the desired gallon per minute flow.
 Figure 1. Simplified Schematic of Hydro Test
BYPASS VALVE
PRESSURE JACK PRESSURE GAGE / PUMP MOTOR SWITCHES

FLOWRATE
INDICATOR PRIORITY FLOW

TEMPERATURE GAGE
SUCTION
HOSE

PRESSURE

LOCKOUT VALVE

HYDRO-TEST
77

DETAIL A

Figure 3. Hydro Test Stand Assembly (Sheet 2)

 EFFECT
FIG
ITEM PART NUMBER NOMENCLATURE FROM TO
ASSY
1 2 3 4 6 7

SE589-l000 Test Stand Assembly - Portable Hydraulic 5 HP 3-Phase Motor . 1

SE589-1100 Test Stand Assembly - Portable Hydraulic 5 HP Single-Phase Motor 1
SE589-1200 Test Stand Assembly - Portable Less Motor ......... .
-1 SE589-2 Caster - Swivel . .. ... .. . .. . . . . . . . . . .. 2
SE589-3 .Caster - Swivel .. .... ............ 2
ATTACHING PARTS
MS24665-357 . Pin - Cotter . ............. .... 2

-2 SE589-212 Mount Assembly - Motor . .......... .....

-3 SE589-16 Angle . . . . . . . . . . . . . . 4
ATTACHING PARTS
1/4" x 3/4" Bolt (1/4-20 Thread) . . . . . . .. . . . . . . . . .. . 4
1/4" Nut (1/4-20 Thread) ........ . . ..... .. 2

SE589-213 Channel 1
SE589-214 Angle - Support ......... . 1
-4 SE589-215 . Plate - Pump Mounting (Welded) (Single-Phase Motor) 1
SE589-711 Mounting Assembly - Pump (3-Phase Motor) ...... . . 1
ATTACHING PARTS
1/2" x 1" Bolt (1/2-13 Thread) ..... ......... 2

-5 SE589-601 Motor - Electric 5 HP 3-Phase Dayton 1800 RPM 230V . . . 1

SE589-664 . Motor - Electric 5 HP 1-Phase Dayton 1800 RPM 230/460V 1
ATTACHING PARTS
3/8" x 1" . Bolt (3/8-16 Thread) . ....... ......... . 4

-6 SE589-5 Starter - Magnetic Square D #8536 Type BG-2 220 Volt

(3-Phase) . . . . . . . . . . . 1
SE589-27 . Starter - Magnetic Square D #8536 Type BG-1 220 Volt
(1-Phase) ... . . .. . . . . . . 1
-7 SE589-15 . Coupling - Motor .. ... .. . ...... .... 1
-8 SE589-602 .Pump Assembly - Hydraulic .... ........... . 1
ATTACHING PARTS
3/8" x 1" .Bolt (3/8-16 Thread) ................ ... 2

-9 AN912-8D Reducer (Suction Port) . ...... ..... .... 1

AN816-8D Nipple 1
AN912-4D . Reducer (Pressure Port) ............... 1
MS20822-6-6D Elbow ............ . 1
-10 SE589-701 . Tank Assembly - Hydraulic .... .......... ... . 1
ATTACHING PARTS
MS35207-263 Screw . . . . . . . . . . . . . . . . . . . . . . . . . 3
AN960-10 . Washer . . . . . . . . . . . . . . . . . . . . . . . . . . .
MS21044N3 . Nut . . . . . . . . . . . . . . . . . . . . . . . . . . 3
--- *---

-11 AN912-4D . . Bushing . . . . . .

.. . ... . . . . . . . . . ... 3
AN816-8D . . Nipple .. ................ 3
-12 AN912-2D . Bushing . .................. 1
MS20822-4-4D . Elbow . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
-13 AN912-4D . . Bushing . ...... . .. . .... 2
MS20822-8D Elbow . . .. . . . . . . . . . . 2
-14 SE589-710 .Cap - Filler (Flow Filter) ... .. .. . .. 1
-15 SE589-719 . . Tube . . . . . . . . . . . . . . .. .... .... 1
-16 SE589-717 . . Elbow . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
AN912-1D . Bushing . . . . . . . . . . . . . . . ... 2
-17 SE589-718 Nut - Nylon . . . . . . . . . . . ...
.. . . . .. 2
-18 SE589-311 Jack Assembly - Pressure . ....... ....... 1
ATTACHING PARTS
MS35207-263 .Screw ... ........... ..... . ....... 3
AN960-10 Washer .. . .. ... .. . ...... . . . 3

-19 AN822-4-4D . Elbow . . . . . . . . . . . . . . . . . . . .

-20 SE589-624 .Valve - Bypass ... 1
MS20822-6D Elbow . . .................. ..... 1
AN914-2D Elbow · . . .. . . . . . . . . . . . . . . . . . . . . . .
AN816-7D Nipple . . . . . . . . . . . . . .. . . .. 1
-21 SE589-404 Gage - Pressure . . . . . .. . .. ... . . . . .. . ... 1
ATTACHING PARTS
SE589-205 .Bracket - Pressure Gage ........... .. 1
MS35207-263 Screw .............. ....... 2
AN960D10 Washer . . . . . .. . . . . . . . . . . . . . . . .. 2
MS21044N3 .Nut . ................ . ... 2
---
*--
 EFFECT

FIG
ITEM PART NUMBER NOMENCLATURE FROM
TO

12345678

AN816-6D .. Nipple .. .. .. ..
. . .. . . . . . . . .
.. .. .. .. . .. . . . ..1 . . . 1
US20822-4-4D
AN816-6D N pple .
Elbow
4. . . . . . ... I . . .. . . .. .. .. .. .. .. .. .. .. . . . . 1
AN911-2D ' Nipple . . . . . . . . ... . . . .... . . 1
US20822-6D Elbow . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
·23 SE589-406 . Valve - Lockout ...... , ....... 1
US20822-6D . Elbow ............................ 1
AN816-6D . Nipple . . ................... .... ... . . 1
.24 SE589-427 . Gage - Temperature . . .. .. .. o... . ... 1
AN960-1016 . Washer ......... .......... 1
AN912-2D . Bushing .. ........... . . 1
25 . AN918-3D . Cross . ................... .... ... . . 1
AN816-8D . Nipple . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
MS20822-8D . Elbow ............................ 1
26 US20822-8D . Elbow . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
27 SE589-603 . Priority Flow Regulator .. . . ............ 1
ATTACHING PARTS
SE589-503 . Cap Screw . . . . . . . . . . . ... . . . . . . . . .. 2
NAS75-4-025 . Spacer .. . . .. .. . . . .. . . . .. . .. . 2
SE589-505 . Lockwasher . . . .. . . . .. . . . . .. .......... 2
SE589-506 . Nut . . . . . ... . . .. . . . .......... 2
-_---*___
AN912-5D . Reducer ... . . . . . . . . .. . .......... 2
US20822-6D . Elbow . ... ......... ....... . ....... 1
AN816-6D . Nipple . .. . . . . . . . . . . .. . . . . . . . . . . .. 1
AN912-4D . Reducer ........ . ... ........ . . ... 1
AN816-8D Nipple . .. . . . . . . . . . . . . . . . . . . . . . . . . 1
28 SE589-604 . Indicator - Flow Rate .................... 1
ATTACHING PARTS
SE589-507 . Screw . . . . . . ... . . .. . ... . . . .. .. . . . . 4
SE589-508 . Lockwasher . . . . . .. . . . ......... . 4
SE589-509 . Nut . . . . . . . . . . .. . . . . . . . . . . . . . . 4
--
_*---

AN912-4D . . Reducer . . ....... ............ . 1

hS20822-8U . . Elbow. . ................... ...... . 1
AN911-4D . . Nipple .. . . . . 1
SE589-623 . .Coupling . . . . . . . . . . . . . . .. . . . . . 1
29 SE589-17 . Wire - Electric (Remote starter to magnetic starter) .... 1
30 S1486DGlOU Clamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
ATTACIING PARTS
S1021Z8-8 . Screw . . . . . . . . ..... . . . ...... .... 2
-__-__-

31 SE589-20 .'Wire - Electric (Magnetic starter to power source) ..... 1

SE589-18 . Connector . . . . . . . . . . . . . . . . . .. 1
32 SE589-21 . Wire - Electric (Receptacle to power source) . . ...... 1
SE589-19 . Connector . . . . . . . .. . . .. . . . . . . . . . 1
33 SE589-310 . Hanger Assembly . . . ..... . . . . .. . . ........ 1
ATTACHING PARTS
S1021Z8-8 . Screw . . . . .. . . . .. . . . . . . . . . . . . . . . 2
--- *_---
34 SE589-236 . Panel Assembly - Lower Rear ................. 1
ATTACHING PARTS
1/4" x 1" . Bolt (1/4-20 Thread) . . . . .. . . . . . . .... 2
--- U---
W98292-2-180 . Stud Airlock . . . . . . . . . . . . . . . . . .. . . . 2
99836 . . Pin - Cross Airlock ... ..... . 2
35 SE5SD-203 . Panel Assembly - Upper Rear . . . . . . . . . . . . ... 1
ATTACHING PARTS
S1021Z8-8 . Screw . . . . . .... . . ..... . .... ...... 6
AN960D8 . Washer . . . . . . . . . . . . . . . . . . . . . . . .. . .. 6
36 SE589-3C9 . . an r Assembly . . . . . . . . . .. . . . .. . .. .. . 1
AT ACHING PARTS
S1021Z8-8 . Screw . . . . . .. . . . . . . . . .. . . . .. 3
37 SE589-301 . Holder Astembly - Bottle . . . . . . . . . . . . . . . . . 1
ATTACHING PARTS
AN4-BA . Bolt . .. . . . . . . . . . . . . . . . . . . . . ... . . 2
AN9GO-416 . Wusher . . . . . . . . . . . . . . . . . .. . . . . . . 2
MS21i) 44N4 , Nut . . . . . . . . . . . . .. . . . . . .. . . . ...
5A
AN: 1- llo t . . . . . . . . . .. . . . . . .. . . . .
ANt96IO- 1 J Wa her . . . . . . . . . . . . . . . . . . . . . . .
MU 210 ,14N3 . Nut . . . . . . . . . . . ... . . . . . . .. . .. .
------ +___
 EFFECT
FIG ITEM PART NUMBER NOMENCLATURE FROM TO
12 3 4 5 6 7

-38 SE589-305 Support Assembly - Bottle (Welded) .......... 1

-39 SE589-501 Plate . . . . . . . . . . . . . . . 1
ATTACHING PARTS
S1021Z10- . Screw . . . . . . . . . . . . . . . . . . . . . . . . . ... 6

-40 SE589-347 . Plaque - Bypass ................ 1

-41 SE589-348 .Plaque - Lockout . . . . . . . . . . . . . . . . . . . .. 1
-42 SE589-349 .Plaque - Pressure Jack ............... .... 1
-43 SE589-350 . Plaque - Flow .......... .............. 2
ATTACHING PARTS
US21318-14 .Screw - Drive ............. ... ...... . 8
---
_-_-

-44 AN833-6D Elbow . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

ATTACHING PARTS
AN960-916L . Washer . . . . . . . . . . . . . . 2
AN924-6D . Nut .. 1

-45 MS20822-8D Elbow . . . . . . . . . . . . ...

AN912-4D . Reducer . . .. ... . ...

-46 SE589-436 . Elbow (AN833-6D Altered) . .... . .....

ATTACHING PARTS
AN960PD916 Washer . . . . . . . . . . . .. 2
AN924-6D Nut ................. 1
--- *---
-47 SE589-437 .Tee (AN834-6D Altered) ................... 1
ATTACHING PARTS
AN960PD916 . Washer .................... . 1
AN924-6D Nut ...... . .... . ... ........ .... 2

-48 SE589-438 Tube (From Elbow to Tube) .. ............... 1 ,

ATTACHING PARTS
-49 AN819-6D Sleeve ... ................ . 2
AN818-6D .Nut............................. 2
. .
-50 SE589-464 . Valve - Check ... ........ .. 1
ATTACHING PARTS
AN939-6D .Elbow . ..... 1
AN6290B6 O-Ring . ............. 1
AN894D6-4 . Bushing - Screw Thread Expander . 1
-51 S1499-6-LL-96.00 . Hose Assembly (To Reservoir Vent Adapter) .. ... ... 1
-52 SE589-479 .Adapter Assembly (Aircraft Overboard Vent Line) ....... ..
SE589-480 End - Hose . . . ... . . . . . . . . . . . . ... 1
SE589-481 . . Hose . . . . . . . . . . . . . . . . . . . . . . . . . .. 1
NAS397-12 . . Clamp - Hose ............... ..... . 1
AN737R22 . . Clamp - Hose ....................... 1
-53 SE589-606 . Hose Assembly (Service hose to aircraft) .......... 1
AN916-6D . Nipple . . . . . . . . . . . . . 1
SE589-608 . Adapter Hose (Model 210 aircraft) ....... 1
-51 SE589-605 Hose Assembly (Service hose from aircraft) .. .... . .. 1
-55 30017 . lter Assembly Purolator ............. 1
ATTACHING PARTS
SE589-511 . Bolt .. . . ... . 2
NAS75-4-025 .Spacer . . .. . . . . . . .. . . . . . . . . .. .. . . 2
SE589-505 .Lockwasher . . . . . . . ....... .. . . .2
SE589-506 Nut ............... . ..... . ... 2
-56 AN6235-2A Element - Filter . ............ .... . 1
-57 AN6230B2 . . O-Ring . . . . . . . . . . . . . ... . . . .... 1
-58 AN833-6D . Elbow . . . .. ..... . 1
MS28778-6 . O-Ring . . . . . . . . . . . . . . . . . ... . . 1
AN924-6D .Nut ........................... 1
-59 AN81-6-6D .Nipple .... ..... . ......... 1
MS2877 -6 . O-RIng . . . . . . .. . . . . . . .. . .
-60 AN917-3D Tee 1
-61 AN912-2D . Reducer ............ ... . 1
-62 AN911-2D Nipple . . . . . . 1
-63 AN917-2D Tee .. ..... 1. . . .
-64 MS20822-6D . Elbow .. ., . . . . . . . . 1
-65 AN81O-6D Nipple . ........ . . . . .. 1
 EFFECT
FIG
ITEM PART NUMBER NOMENCLATURE
1 2 3 45 6 7

-66 SE580- 618 . Valve

Relief . . . . . . . . . . . . . . . . . . . . . 1
AN911-3D Nipple . . . . . . . . . . . . . .. . . . . . .... . 1
MS20622-8D . Elbow . . . . . . . . . . . . . . . . . . . .. 1
-67 SE589-6 .Starter Box - Remote (Square D - OO1 Type 830) ...
-68 SE589-610 . Hose Assembly (Reservoir to pump) . . ... . . . . 1
-69 SE589-641 Tube Assembly (Reservoir to bypass valve) ..... .. ....
-70 SE589-650 . Tube Assembly (Check valve to reservoir) . . . ... . 1
-71 SE589-644 . Tube Assembly (Cross to flow indicator) .. .. .. . .... 1
-72 SE589-665 . Tube Assembly (Preseure Gage to Sight Gage). . . ... ... .
-73 SE589-667 . Tube Assembly (Cross to overflow) . . . .. . . .. . 1
-74 SE589-658 .Tube Assembly (Tee on pressure gage to pressure Jack) .... 1
-75 SE589-638 . Tube Assembly (Lockout valve to pressure gage) ....... 1
-76 SE589-635. . Tube Assembly (Bypass valve to relief valve) . . . .... 1
-77 SE589-636 . Tube Assembly (Flow regulator to relief valve) .. . . ... 1
-78 SE589-637 Tube Assembly (Flow regulator to lockout valve) .. . . . .1
-79 SE589-642 . Tube Assembly (Flow regulator to reservoir) . . . ...... 1
-80 SE589-643 Tube Assembly (Cross to reservoir) .. .. . . . . . . . . .1
-81 SE589-611 . Hose Assembly (Reservoir to filter) .. . . ...... . 1
-82 SE589-640 . Tube Assembly (Relief valve to reservoir) . . . . . . .. .
-83 5180000-11 . Placard . . ...... .. . . . ... . ..