Scott, unfortunately I did not take this system out before sending to
Colorado Composites to fix. (another mistake)  All of these parts are long
since gone. I did forget to mention that my CB does remove power from all of
this system. For a time I pulled this breaker, during a flight, until I needed
to move the gear.
 
  What would have caused the bubbles? If we have the press. switches in this
circuit and I close the HP switch wont it open the low pressure switch since
the press will be higher that the lo press switch setting?

Don,

 

Do you mean the 50 amp motor CB?  Was the relay power circuit (power to the gear switch) source wired after the motor breaker?  I.E. Pulling the Motor power breaker also removes power from the relay coil circuit?  If so, what other changes from the Lancair wiring diagram existed?

 

BTW, I am asking these questions so that if we can find the cause, we can hopefully prevent an event like this from ever occurring again.

 

You asked about the bubbles - my test system is open and when it stops running, air enters the clear tubing. when the pump starts I can see which way the bubbles start going.  After running a bit, the tube representing the selected direction is completely full of flowing fluid.

 

You must re-think the pressure switches again.  If the pressure is less than the desired end system pressure (up or down), then the switch is closed to allow current,if present, to pass to the associated relay coil.  The only time any pressure switch is open is when the final desired pressure is reached thus ensuring that relay coil power is removed so that the pump stops running when the relay opens.  Of course there is a pressure band of perhaps 100-200 psi below the target that the pressure switch remains open.  So, once again, if the pump is running, both pressure switches are CLOSED because neither has reached the desired pressure. When the desired pressure is reached, then the correct switch can OPEN to then open the proper relay (remove coil power) and stop the motor from running.