Instruction manual HT2000-E
CONTENTS
Introduction
1. Safety instructions
1.1 Obligations and adhesion
1.2 Symbols and reference explanation
1.3 General safety references
1.4 Intended use
1.5 Extra unfavourable use
1.6 Protection device
1.7 Informal safety precautions
1.8 Training of personnel
1.9 Safety precautions in normal operation
1.10 Dangers by electricity
1.11 Maintenance, Repair
1.12 Structural change in the hydraulic test stand
1.13 Behaviour in an emergency
1.14 Personal preventive measures
1.15 Dangers for the health by HFD-Fluids
1.16 First assistance measures
2. Commissioning
2.1. Filling
2.2 Electrical connections
2.3 Initial start up
3. Operating instructions step by step
3.1 General
3.2 Explanation functions of the operating panel
3.3 Start procedure
4. Hydraulic connection diagram
4.1 Part list and spare parts
4.2 Components documentation
5. Electrical connection diagram - Part list and spare parts
6. Troubleshooting
6.1 Excessive noise in installation
6.2 No pressure or insufficient pressure
6.3 Pressure and flow fluctuations
6.4 Insufficient or no delivery
6.5 Fluid temperature too high
6.6 Position specific troubleshooting
7. Maintenance and service
7.1 Routine maintenance
7.2 Oil changes
7.3 Spare parts
7.4 Scheduled Maintenance Instruction
8. Certificates
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INTRODUCTION
This manual contains a description for the Hycom Hydraulic Test unit HT2000. This test unit was
designed for functional testing and maintenance of hydraulic aircraft systems. In this manual you will
find instructions for operation, maintenance and troubleshooting.
To ensure that the test unit operates satisfactorily and safely, it is important to read this manual first,
before using the test unit.
Please notice that the maintenance takes place in time. In doubtful cases, please contact our service
department.
We recommend using only original Hycom spare parts.
We hope you will enjoy working with your Hycom test unit.
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1. SAFETY INSTRUCTIONS
This manual contains the most important instructions, to control the Hydraulic Test Stand HT safely.
The working reliability of the HT depends very strongly on maintenance.
Regular maintenance work is described in these operating instructions.
With necessary repairs we support you gladly and supply you with original spare parts.
1.1 Obligations and adhesion
• Basic condition for safe handling and trouble free working of the HT is the knowledge of the
fundamental safety references and the safety regulations.
• This operating instructions, in particular the safety references, are to be considered from all
persons to, who work with the hydraulic test stand.
• Beyond that the rules and regulations valid for the place of work are to be considered for
accident prevention.
• The safety references described herein are only limited to the use of the HT.
The hydraulic test stand is built according to the state of the art and the recognized safety relevant
rules.
Nevertheless dangers for life and health for the user or third and/ or impairments at the equipment or at
other real values can develop with the us.
The hydraulic test stand is to be only used
• For the intended use
• Exclusive in the proven group, category and zone
• In safety relevant perfect condition
Disturbances, which can impair security, are immediately to be eliminated.
In principle our general trading conditions (AGB) apply.
These are only to the operator’s disposal at conclusion of the contract.
Guarantee and liability claims with damages to property and persons are impossible, if they are
accountable on or several following causes:
• Not intended use of the hydraulic test stand
• Inappropriate starting, serving and maintenance of the hydraulic test stand
• Operating the hydraulic test stand with defective safety devices
• Arbitrary structural change in the hydraulic test stand
• Unsatisfactory monitoring of components, which are subject to wear
• Inappropriate accomplished repairs
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1.2 Symbols and reference explanation
1.2.1 Fundamental symbols
1.3 General safety references
Operation and maintenance work are only form adept personnel, who have knowledge of the operating
and maintenance manual, to accomplish.
The working reliability of the unit is ensured only with intended application. In the case of doubt
consultation with the manufacturer is to be held. For damage, which results from inappropriate use of
the unit, the manufacturer does not take over adhesion.
With all work the existing national regulations for the accident prevention and security on the job as
well as internal regulations of the operator are to be kept if necessary, even if these are not designated
in detail in this manual.
Leakages of dangerous promotion goods must be caught and be disposed in such a way that no
endangerment for persons and the environment develops. The respective legal regulations are to be
kept.
With all work on the unit the connecting cables must be made without pressure and the motor
tension-free.
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1.4 Intended use
The Hydraulic Test Stand was developed for functional testing and maintenance of hydraulic aircraft
systems.
Inappropriate use of the test stand, does not result in any liability for the manufacture.
To the intended use also belongs:
• The attention of all references from the operating instructions.
• The adherence of the inspection and maintenance work.
1.5 Extra unfavourable use
• Other uses than specified are forbidden above.
• With extra unfavourable use dangers can develop.
• Such extra unfavourable uses are e.g.:
Running with illegal medium.
1.6 Protection device
• Before each start-up the hydraulic test stand, all protection device must be, properly attached
and fully functional.
• Safety devices may be only removed after stop and security against unintentional power-on of
the machine (e.g. warning or padlock at the main switch).
• In supply of partial components the safety devices are to be attached by the operator correctly.
1.7 Informal safety precautions
• The operating instructions are always to be kept at the hydraulic test stand.
• In addition to the operating instructions the general accepted, as well as the local regulations,
are to be made available to the accident prevention and to environmental protection and to be
considered.
• All safety and danger reference at the hydraulic test stand are to be held in readable condition
and renewed if necessary.
• The opening from parts of the hydraulic test stand may only happen in not loaded normal
• The tightness of the hoses and connecting pieces must be examined daily (visual inspection).
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environment.
Tests with opened housing may only be accomplished by trained hydraulic specialist.
This applies also to repairs and/ or to modifications at hydraulic components, approved by us.
Warning: All liquids, which are at pressure, can cause bodily injuries with death
sequence. Consider therefore all safety regulations, which absolutely apply when
working with liquids under pressure!
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A
1.8 Training of personnel
• Only trained and instructed personnel may work with the hydraulic test stand.
• Specify the competencies of the personnel clearly.
• Personnel who can be trained may work only under supervision of an experienced person on
the hydraulic test stand.
ctivity
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1.9 Safety precautions in normal operation
• Operate the hydraulic test stand only when all protection devices are fully functional.
• Examine the unit at least once per day for outwardly recognizable damage and
operability of the safety devices.
1.10 Dangers by electricity
• Only electrical specialists may work on the electrical supply.
• Check the electrical execution of the unit regularly. Remove lose or burned cables
immediately.
• If work on live parts is necessary, a second person is to be consulted, who can switch off
the main switch, if necessary.
1.11 Maintenance, Repair
• Apply adjust-, maintenance- and inspection work punctually.
• Secure all operating media against unintentional start-up.
• With all maintenance-, inspection and repair work, the hydraulic test stand is to be
switched without tension and secured against unexpected restarting.
• Check lose bolt connections for tightness.
• Check safety devices after completion of the maintenance work for function.
1.12 Structural change in the hydraulic test stand
• Do not make structural changes in to the hydraulic test stand, without permission of the
manufacturer.
• All structural alteration measures require a written permission of the company Hycom
B.V.
• Exchange machine parts in not perfect condition immediately.
• Use only original spare and wearing parts. With bought-in parts it is not ensured that
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they are, on demand and safely, designed and manufactured.
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1.13 Behaviour in an emergency
In an emergency turn the main and emergency stop switch to the left around 90°
to stop the entire plant. Accordingly the entire plant is without tension starting
from this switch.
1.14 Personal preventive measures
If an effect is possible while handling it is necessary to use, eye protection, chemistry protective
clothing and protection hand gloves.
The necessary personal protection equipment are to be made available by the operator.
Examine all existing safety devices regularly.
If the room air concentration should exceed job exposition value despite technical caution
measures, measures must be seized for exhaust i.E., otherwise a suitable respiratory protection
is to be carried.
5 Dangers for the health by HFD-Fluids
Dangerous characteristics of HFD-Fluids:
• Provokes the eyes.
• Injurious to health when swallowing.
• During swallowing or following vomiting liquid can arrive into the lungs.
• Potential environmental effects:
• Appropriate precautionary measures while handling this product are to be obeyed
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accordingly serious lung damages and even death can be caused.
Harmful for water organisms, at longer term, can leave a harmful effect in waters.
strictly.
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1.16 First assistance measures
With inhalation:
At normal customs temperatures generally no endangerment exists by inhalation of steams.
Bring the concerning personnel from the danger zone in case of excessive exposure with steams,
which can develop at high temperatures. If the respiration is irregular of if respiratory arrest
occurred, an artificial respiration is necessary. Further treatment by an emergency doctor is to
be provided.
With skin contact:
Skin portions concerned are to be washed thoroughly with water and soap. Dirty clothes are to
be taken off and cleaned before re-use. If the skin irritation continues, a doctor is to be
consulted.
With eye contact:
Rinse out eyes with plentifully water immediately (min. 15 Minutes). Transfer into a hospital
for investigation by a specialist.
When swallowing:
IN NO CASE vomiting may be caused. There is otherwise the danger that the product will
enter into the lungs (aspiration). Persons concerned are to be immobilized and treated
immediately by a doctor.
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2. COMMISSIONING
Commissioning may only be carried out by qualified personnel. It is necessary to observe
certain special instructions of Hycom B.V.
The hydraulic plan, equipment list and functional plan must also be available. The planned
pressure settings must be specified in the hydraulic plan for all pressure valves.
Attention: After receipt of the test unit, we advise you to tighten the bolts/nuts of the
wheels:
Front wheel : 135 Nm
Rear wheel : 205 Nm
2.1. Filling
Before filling the tank with hydraulic fluid check and, if necessary, clean the inside of the tank.
Always fill the tank through a fine filter to guarantee the desired purity class of the hydraulic
fluid at the start.
Note: Filling up the reservoir should always be done at the greatest possible
cleanliness:
- drained off fluid should not be reused
- fibre free cloths should be used
- only fluid from new, unbroken barrels should be used
- working should be performed, as far as possible, in a dust
free environment
- regularly do take oil samples for oil contamination,
sample valves are provided on the test unit.
2.2 Electrical connections
Are the right currents and voltages available?
Check chapter 5 E-diagram power supply.
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2.3 Initial start up
Before the test unit is started up for the first time or when maintenance has taken place, the
following must be performed.
1) Fill the reservoir (ONLY WITH PHOSPHATE ESTER e.g. SKYDROLL OR HYJET)
to the maximum fluid level (about 3/4 of the tank)
2) Connect electrical cable or cables to the connection plug.
3) Before first start up the pump needs to be filled with oil.
This is done through the drain connection at the top of the pump (see picture).
Picture 1:
Drainconnection
Fil l proce dure main pump
4) Open Ball Valve Pos. 270 to select Testunit Reservoir.
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close
270
open
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5) Switch on the main switch on the right side of the unit, all lights are illuminating.
Press “Reset”.
If red light “Failure” illuminates and message display shows
“power sequence failure”.
you have to change the wiring of the power cord to change the rotation direction.
If the green light “Start Running” illuminates, wiring is done properly.
At the first start of the system switch to low pressure circulation (done automatically)
to realize a fast enough filling and bleeding of the pump and the piping.
A short start and stop (Start running and Stop button) relieves the bleeding and realizes
a fast filling of the displacement chamber of the pump (view times).
Only build up pressure if bleeding is completed (see point 9).
6) Close ball valve (pos. 270) to select “aircraft reservoir” operation.
7) Push “Fill aircraft system” button for at least 5 minutes.
8) Open ball valve (pos.270) to select “test stand reservoir” operation, also open pos. 290
“De-aeration”1 turn.
9) Switch the unit at least 3 times in its “on” and “off” position for the period of approx.
2 sec. with the “Start Running” and “Stop” button.
After approx. 1 min. running, turn the flow up (max.). The working pressure now can
be set to its nominal value (no flow, no pressure). Switch Hydraulic Power ON.
Let unit run for approx. 10 minutes (check unit). Then stop the machine.
10) Set the ball valve pos. 270 to “aircraft reservoir (close)” position and close the
“De-aeration valve” pos. 290 (see picture). Make sure these valves are closed before
testing.
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The HT2000 has two operation modes 1. “aircraft reservoir selected”
2. “test stand reservoir selected”
It is important that the right operation mode is selected for several tests.
1. Operation mode “Aircraft reservoir selected”
The reservoir selector valve (pos 270) must be in closed position (see picture) to set the test
stand in “Aircraft reservoir selected” operation mode.
The text display will give you the following message.
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The hydraulic diagram “Aircraft reservoir selected”
This operation mode is used in all circumstances when the aircraft reservoir is pressurized.
The test stand uses the pressurized aircraft reservoir. The aircraft reservoir can be filled by
pushing “fill button”, or drained with the “drain button” on the operation panel.
NOTE: Before connecting hoses to aircraft:
Check if reservoir selector valve (270) is in “aircraft reservoir (close) “ position.
2. Operation mode “Test stand reservoir selected”
The reservoir selector valve (pos 270) must be in open position (see picture) to set the test stand
in “Test stand reservoir selected” operation mode.
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The text display will give you the following message.
The hydraulic diagram “test stand reservoir selected”
When the test stand is running in operation mode “test stand reservoir selected”, it uses the
internal reservoir. The return oil flow goes into the test stand reservoir.
The operation mode “test stand reservoir selected” is used for the following procedures:
1. When the aircraft reservoir is not pressurized.
2. Filling of the aircraft hydraulic system after removal of components.
3. For all Airbus Ram Air Turbine test (RAT).
4. Service and maintenance of the test stand. It should run in this operation mode to fill and
bleed the test stand. (See initial start up chapter 2.3)
Filling of the aircraft reservoir is not possible by pushing the “fill button”.
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3. OPERATING INSTRUCTIONS STEP BY STEP
3.1 General
This test unit is designed for functional testing and maintenance of hydraulic aircraft systems
with following conditions:
Max. working pressure : 3000 psi (adjusted continuously)
Max. Flow:
Single system: HT2000- … -E/1-S
Dual system: HT2000- … -E/1-S2
The test unit consists of a four-wheeled trailer with an electric motor, a hydraulic system, and
an electrical control system. The test unit components are mounted on the trailer and protected
by a metal cover with access panels and doors. The test unit can be moved by hand or towed by
a motor vehicle with the aid of the tow bar.
3.2 Explanation functions of the operating panel
The test unit has an operating panel. The layout of this panel is according the hydraulic diagram
of the test unit. The components mounted on the operating panel allow the operator full control
and setting of all test stand characteristics.
Mounted items:
[15P4] Electric Fill level indicator. This indicator shows how much Skydroll is in the
reservoir indicated in litres.
[12H03] Warning light “WARNING” indicates a warning.
The text display will indicate what is happening and what should be done.
[12H05] Warning light “FAILURE” indicates a failure.
The text display will indicate the problem.
Possible warnings/ failures:
Warning “max. level reservoir”. Indicates a too high reservoir level. In this case,
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the unit cannot drain the aircraft. Starting of the main pump and filling of the
aircraft is permitted. Warning light is on till “RESET” button is pressed and the
level is below max. level.
Warning “low oil level”. Indicates low reservoir level. In this case, the unit
cannot fill the aircraft. Starting of the main pump is not possible. Draining the
aircraft is possible. Warning light is on till “RESET” button is pressed and the
level is correct.
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Failure “low oil level, refill to continue” indicates too low reservoir level.
The unit stops immediately, filling and draining is not possible. Failure light is
on. Refill the reservoir up till working level. Push reset.
Note: For filling instructions see 2.1
Warning “oil temp. high”. Warning light for too high temperature of the
hydraulic oil, exceeding 70 ˚C. From 70 ˚C the pressure is shut off and the test
unit remains running without giving pressure. After cooling down the fluid to
approx. 50 ˚C press the “RESET” button and adjust the pressure. The light
blinks from 65 ˚C as warning.
Failure “low boost pressure, main pump”. Indicates too low pressure at the
suction side of the main pump. The test unit shuts down automatically.
Check for:
- empty reservoir
- broken hoses
- no return hose connected from aircraft
If no reason can be found for the low boost pressure, push “RESET” and restart
the test unit. If same alarm comes on again, stop testing and inform the
maintenance department “Ground Support Equipment”.
Warning “high pressure filter clogged”. Indicates a too high pressure drop over
the high pressure filter. At low temperature the warning lamp can illuminate as a
result of changing of the viscosity. Let the test unit come up to working
temperature and press the “RESET” button. If the warning light still illuminates,
replace the high pressure filter element immediately.
Warning “boost filter clogged”. Indicates a too high pressure drop over the
Boost filter. At low temperature the warning lamp can illuminate as a result of
changing of the viscosity. Let the test unit come up to working temperature and
press the “RESET” button. If the warning light still illuminates, replace the
boostfilter element as soon as possible.
[17R13] Potentiometer “FLOW” commands the setting of the system flow control in
such a way, that the flow is limited to the maximum flow set. At the scale on the
panel the operator can read the maximal to be expected flow.
[18U02] Digital display “ACTUAL FLOW” indicates actual flow to A/C.
[9S15] Push button “SET PRESSURE” “UP(+)” commands the setting of the system
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pressure up in such a way, that the pressure is limited to the maximum pressure
set. Every time the hydraulic pressure is switched from “OFF” to “ON” the
pressure has to be adjusted to the desired value. This means that the pressure
starts at min. each time that hydro power is switched on.
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[9S17] Push button “SET PRESSURE” “DOWN(-)” commands the setting of
the system pressure down. Every time the hydraulic pressure is switched from
“OFF” to “ON” the pressure has to be adjusted to the desired value.
This means that the pressure starts at min. each time that hydro power is
switched on.
[10S11] Pushbutton “FILL AIRCRAFT SYSTEM” energizes the fill pump to fill the
aircraft system with approx. 6 l/min. This function is not available when “oil
temp. high” or “Min. Level reservoir” alarm is given. Warning light
“WARNING” or “FAILURE” is on. Hold button to activate.
[9S11] Pushbutton “BULB TEST”. To be pushed to check function of the warning
lights on the operating panel.
[9S09] Pushbutton “RESET” commands the start stop circuit in its fail position.
“RESET” always has to be pushed before each start and to check if a signalised
alarm still exists. The warning light remains illuminated until pushbutton
“RESET” is pushed.
[10SH05] Push button “ START RUNNING” commands the motor switchgear to start the
motor. Actual running of the motor is monitored by a green signal light inside
the pushbutton. When motor is running the light goes out.
Start commands will only be accepted if:
- “RESET” is pushed first
- no “EMERGENCY STOP” is pushed
- reservoir level is in-between maximum and minimum level
- hydraulic power is off
- “MAINS FAULT” is not on
[10SH03] Pushbutton “STOP” commands the motor to stop and de-energizes the
hydraulic unit.
Note: Before stopping the test unit:
1 Set selector switch ”HYDR. POWER” in off position.
2 Press the “STOP” button
[10S07] Selector switch “HYDR. POWER ON/OFF” activates valves and electric
check circuit in such way that pressure is delivered.
“HYDRAULIC POWER ON” is only activated when:
-- test unit is running
-- no “oil temp. high” alarm is given
[6S04] Pushbutton “EMERGENCY STOP”. Activating this pushbutton shuts down the
[10S13] Pushbutton “DRAIN A/C SYSTEM” energizes a valve for 25 seconds to
drain the aircraft with approx. 5 Liter/min. When the button is pressed for
and when aircraft reservoir is connected. When draining, this is indicated
in the text display. This function is for closed loop only.
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electric motor immediately and disarms the hydraulic circuit. Regular use of this
button is not allowed due to security reasons.
another time, draining of the aircraft will be stopped. Function is only possible
when no “oil temp. high” or “max. Level reservoir” alarm is given
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[9S13] Pushbutton “3000 PSI” energizes the pressure regulator in such way that the
pressure is ramped up till 3000 psi in 3 seconds.
[7U01] Text display. This display gives instructions for the operator. The DOWN arrow
decrements data and scrolls the cursor to the next message.
When one of the warning lights illuminates this display gives also the
possible failure. (For messages see next page)
[420] Manometer “HIGH PRESSURE” indicates the actual pressure at the pressure
outlet of the test unit.
[430] Manometer “RETURN PRESSURE” indicates the actual pressure at the return
inlet of the test unit. This depends on the pressure of the aircraft reservoir.
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Messages in text display
Failure messages
- Live zero failure, tank level sensor
- E-Motor failure
- Main relais failure E-Motor
- Live zero failure, temperature sensor
- Live zero failure, boost pressure sensor
- High oil temperature error
- Low boost pressure, main pump
- Power sequence fault switch 2 main wires
- Thermistor failure main E-Motor
- Low oil level, refill to continue
- Analogue module failure, check fuses
- Ball valve reservoir selector failure
- Emergency stop active
- Thermic failure EM 3 check 3F14
- Oil temperature reached max >79˚C
Warning messages
- Warning low oil level
- System draining for ... seconds
- High oil temperature warning temp......˚C
- High pressure filter clogged PDA1
- Boost filter clogged PDA2
- Press reset to start
- High oil level, draining not possible
- Hydr. power switch in “ON” position
- System cooling down actual temp......<50˚C
Notes
- System draining for ......... seconds
- Test stand reservoir selected temp...... ˚C
- Actual boost pressure ......Bar or PSI (PA1)
- Aircraft reservoir selected temp...... ˚C
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3.3 Start procedure
Warning:
Please note that by starting and/or testing no danger will occur for persons or goods.
1 Connect test unit to the electric mains.
2 Switch on main power switch.
Signal lights are checked, when the unit is connected to the electric mains.
3 Activate the check circuit by pressing “RESET”. Check if “FLOW” potentiometer is fully
turned C.C.W., and if “HYDR. POWER” is off. Only green lamp “START RUNNING”
illuminates, if not, see [10SH05].
4 Check oil level
5 Check the reservoir selector switch pos.270 (open/closed loop)
6 Connect hoses to AC
7 Start the unit by pressing “START RUNNING”.
8 Switch “HYDR. POWER “ on.
9 Select requested flow.
10 Select requested pressure.
Start testing!
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