Model AS-10

Operation and
Training Manual
AeroTrain AEROTRAIN CORP.

Hydraulic System Trainer

Contents of this document are the sole intellectual property of

AeroTrain . This information is provided free of cost for reference
only. The contents, partially or totally, cannot be reproduced,
reprinted, or distributed for any commercial use without the written
consent of the copyright owners.
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 ALWAYS OBSERVE SAFETY REGULATIONS
AS ENFORCED BY THE LOCAL CIVIL
AVIATION AUTHORITY, AND FOLLOW
STANDARD AVIATION SAFETY PRACTICES
WHILE OPEARTING, TROUBLESHOOTING,
OR MAINTAINING THE TRAINER
EQUIPMENT.

Copyrights to AeroTrain Corp.

5252 Exchange Drive, Flint, MI 48507
Phone 810-230-8096 • Fax 810-230-8017
sales@aerotraincorp.com
www.aerotraincorp.com

Table of Content

CHAPTER SUBJECT Page NO.

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SECTION
SUBJECT
29-00-00 System Overview 2
29-00-01 Pre-setup Inspection 2
29-00-02 Setup Inspection 3
29-10-00 General 3
29-10-01 Description of Operation 3
29-10-02 System Operation 4
29-10-03 Troubleshooting 5
29-11-00 Servicing 5
29-11-01 Flushing Hydraulic System 5
29-11-02 Filter unit 6
29-11-03 Accumulator 6
29-11-04 Pressure Regulator and relief valve 7
29-11-05 Flow Restrictor 7
29-11-06 Sequence Valve 7
29-11-07 Shuttle valve 7
29-11-08 Control Valve 8
29-17-00 Hydraulic Pump 8
29-29-00 Emergency pump 8
29-30-00 System Diagrams 9
29.1.1 System Overview

29.1.2 Pre-setup Inspection

1- Open the wooden crate from all four sides. Remove all packing materials.

2- Unlock the caster wheels and remove wheel blocks.

3- Roll out the trainer.

4- Inspect for any visible damages. If yes, take pictures and immediately inform AeroTrain.

5- Ensure that all components are securely attached to the panel.

6- Check electrical wiring and plumbing for loose connections or disconnected joints.

7- Check power cables for any signs of abrasion or cuts.

8- If not already installed; install approved end plug on electrical cord.

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29-00-02 Setup Instructions

1- Place the trainer on a level surface and lock the caster wheels.

2- Ensure that Master Power Switch is OFF.

3- Check all plumbing connections for looseness, tighten if needed.

4- Fill the Hydraulic Reservoir with MIL-H5606 hydraulic fluid until fluid level is above half
way on the site gauge.

NOTE

After the first operation, the fluid level might decrease in the reservoir, refill the
reservoir to maintain a half way level on the site gauge.

5- Wipe down the any fluid spills.

29-10-00 General

The hydraulic system components installed on this trainer consists of electrically powered
hydraulic pump, hand operated emergency pump, accumulator, double acting hydraulic
cylinders, sequence valves, shuttle valve, filter, pressure regulator, control valve and the associated
indication system.

29-10-01 Description and Operation

The Trainer simulate a basic closed center hydraulic system, fluid under pressure is supplied form
electrically driven hydraulic pump during normal operation condition and from manually operated
hand pump during emergency operation. Two double acting hydraulic cylinders simulate sequenced
operation as seen in landing gear and gear door operation. The hydraulic fluid in the system is
filtered and pressure regulated by the associated system components. An accumulator; of the
floating piston type; installed in the system to dampen system pressure and acts as a source of
stored pressure. System Pressure in monitored by direct reading pressure indicator.

29-10-02 System Operation

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 1- Plug in the electrical cord to wall outlet.

2- Insure electrical pump CB is pushed in (located on the back of the trainer).

3- Switch on Master Switch. The hydraulic system will become pressurized by the
electrically driven hydraulic pump. System pressure will be displayed on the hydraulic
pressure indicator.

4- Move Selector valve to UP position; Fluid under pressure will be directed to one of the
hydraulic actuator, as the actuator reaches the maximum travel position it will strike the
plunger on the sequence valve. The sequence valve will direct system pressure to the
second actuator to start its movement.

This operation simulates the condition where the first actuator simulates landing gear
door actuator, and the second is the landing gear actuator. The sequence is required to
insure proper operation of landing gear and door.

5- Move Selector switch down position. The operation of the actuators will become
reversed to simulate landing gear extension sequence.

6- To demonstrate emergency operation; Turn master switch to OFF.

7- Insert the red handle in to the hand operated pump. Operate the handle to build
pressure in the system.

8- Operate the selector valve as you operate the hand pump. The operation of the system
components will be in the same manner as when operated under normal system
pressure.

9- Check system for leaks.

29-10-03 Trouble shooting

TROUBLESHOOTING

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 Trouble Cause Remedy
No pressure on the indicator, Defective Indicator Replace
system operates normal
Pressure too low pressure regulator out of Adjust pressure regulator
adjustment
Pressure too high pressure regulator out of Adjust pressure regulator
adjustment
Pressure surges Low accumulator charge Charge accumulator
System pressure normal , no Defective valve Replace
function from selector valve
Only one actuator is functioning Actuator not striking plunger on Adjust actuator to fully engage
sequence valve sequence valve plunger on full
travel
Emergency hand pump not Internal leak Replace seals or replace pump.
functioning
Selector valve operates one way Internal blockage Remove valve, clean and bench
only test

29-11-00 Servicing

29-11-01 Flushing hydraulic system

When contamination of the hydraulic system is suspected, the complete system should
be drained and flushed to remove the contaminated fluid. The cause and type of
contamination should be determined and corrected. Flush the system as follow:

1- Drain the Hydraulic fluid from the reservoir.

2- Disconnect the lines form all system components and drain all fluid from lines and
components.

3- Remove filter element, flush out the filter bowl and install new filter element (clean
element if cleanable).

4- Reinstall all removed items.

5- Flush the hydraulic system with clean fluid (MIL-H5606). Examine seals and cylinder
bores for damage.

29-11-02 Filter Unit

The filter element on the trainer can be cleaned and reinstalled as follow:

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 1- Remove filter bowl.

2- Pull filter element out and clean with mineral spirit and dry with compressed air.

3- Inspect the packing for condition and replace if needed.

4- Install the filter in the housing.

5- Fill the filter bowl with clean hydraulic fluid and reinstall.

6- Torque filter bowl to 100 inch-pounds.

29-11-03 Accumulator
The accumulator on the trainer is a cylindrical accumulator with a floating piston. The piston
separates the fluid and air chambers. The fluid end of the cylinder is fitted with a hydraulic port
connected to the system pressure. The air end of the accumulator is fitted with a service valve to
allow for charging the accumulator with nitrogen or compressed air. To charge the accumulator:

1- Remove protective cap from charging valve.

NOTE

CHARGE WITH NITROGEN OR DRY COMPRESSED AIR ONLY

2- Attach the service hose to the fitting.

3- Open the accumulator service valve by rotating the lock nut CCW.

4- Slowly charge the accumulator to approximately 70% of operating hydraulic system

pressure.

5- Close service valve on the accumulator and remove charging hose.

6- Reinstall protective cap.

29-11-04 Pressure regulator and relief valve

The regulator unit is responsible for maintain a constant pressure in the system and protect the
system components form over pressure by releasing excess pressure back to the reservoir. The unit
is preset and no adjustment is typically required. On the trainer the pressure regulator is set lower
for safety reasons.

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29-11-06 Sequence valves
A sequence valve is a controllable check valve. It will hold system pressure internally until external
mechanical force signals it to allow free flow. In the trainer, the strike bolt on the end of the actuator
shaft strikes the valve plunger and opens the internal passage for the flow of hydraulic fluid. No
service is required to this unit

29-11-07 Shuttle valve

The shuttle valve is a safety device used to separate two system inputs, basically acting as a double
ended check valve. Having 2 separate sources for hydraulic pressure (electric pump and hand pump)
plumbed to the same system will cause pressure build up on one side when the opposite side is
operating. The shuttle valve blocks pressure from passing thru to the side that is not operating.

If both pumps are operating, the high pressure side will take over and blocks the opposite side from
the system. No service is required to this unit

29-11-08 Control Valve

Four way valve with closed center position. The ports are marked on the back of the valve as , P
(pressure), R (return), G1 (gear position), and G2 (gear position).

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29-17-00 Hydraulic pump
The main system pump is a gear type powered by 24vdc motor, capable of supplying up 1500 psi.
Power to the pump is supplied by DC power supply thru a pump relay and circuit breaker.

No maintenance is required for the pump. General inspection of the electrical motor condition and
inspection of motor brushes can be carried out during any routine maintenance.

29-29-00 Emergency Pump

The installed hand operated hydraulic pump provides for emergency source of hydraulic pressure
should the main pump fails. A double action type pump draws fluid in to the pump from the inlet
port in one stroke and pumps that fluid out in the same stroke. No servicing is required.

29-30-00 System Diagrams

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Parts listing

Item P/N QTY

1 Accumulator A70511-200 1

2 Reservoir AT1GAL 1

3 Hydraulic cylinder 849-1 2

4 Sequence valve 492-096 2

5 Pressure relief valve A-5750-6 1

6 Shuttle valve AN6277-6 1

7 Filter assembly AN6234-3 1

8 Manual Pump 316525 1

9 Electric Pump MP500 1

10 Pressure indicator AN5771-4 1

11 Control Valve 8441E-4D3P 1

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