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HYDRAULIC GROUND POWER UNIT <HGPU60-50-1DSX-AMA>

GENERAL OPERATION INSTRUCTIONS Page D-102.02.2017 MAWN

CHAPTER ”D“

GENERAL OPERATION INSTRUCTIONS

1. ACTIVITIES BEFORE FIRST

STARTUP

2. STARTUP

3. OPERATION

4. SHUT DOWN

5. ERROR MESSAGES

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1. ACTIVITIES BEFORE FIRST

4. SHUT DOWN

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5. ERROR MESSAGES

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1. ACTIVITIES BEFORE FIRST STARTUP

1.1. FILL IN HYDRAULIC MEDIUM

Before startup of the ”HYDRAULIC GROUND POWER UNIT“ it must be filled with appropriate

hydraulic oil.

Note

The type plate indicates which hydraulic medium is to be used.

For example Skydrol PE-5

+ CAUTION +

WRONG MEDIUM CAN CAUSE SERIOUS DAMAGE TO THE

”HYDRAULIC GROUND POWER UNIT“ OR TO THE UNIT UNDER TEST.

- Open the protection cover

- Open the ventilation filter [502]

- Fill until the fill level of inspection glass on the cover indicates a range of approx. 70 %.

- Close the tank [501] with the ventilation filter [502] and close the protection cover



Ventilation filter [502]Inspection glass Protection cover

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The type plate indicates which hydraulic medium i

Skydrol PE-5

+ CAUTION +



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Ventilation filter [502]

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1.2. FLUSHING OF THE HYDRAULIC CIRCUIT

- Fill the appropriate hydraulic oil (see para 1.1. FILL IN HYDRAULIC MEDIUM) in the

tank [501].

- By means of a flushing circuit connect the flow/return hose. Close the throttle valve

completely and then open it for a half revolutions

(please also follow the instructions in chapter “C“).

Note

A throttle valve always must be mounted in the flushing circuit.

An appropriate flushing circuit is offered by the manufacturer (Option “C“)

- Afterwards start the ”HYDRAULIC GROUND POWER UNIT“ (see para 2.1. PREPARING

WORKS AND INITIALIZATION)



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A throttle valve always must be mounted in the flushing circuit.



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- Start the hydraulic pump via control panel as follows:

a.) Switch to ”Reservoir Selection HGPU“ (see para 3.2.)

b.) Start the hydraulic pump (see para 3.1.)

c.) Switch to 3000psi pressure on the output (see para 3.3.)

Limit the Flow Rate to approx. 10US gpm via potentiometer (see para 3.3.)

d.) Keep this operating condition for approx. 10 min. - the ”hydraulic circuit“ will be flushed.

e.) After flushing switch-off the hydraulic pump by the illuminated button ”System Off“ and

remove the flushing circuit.

- Afterwards the flushed hydraulic circuit is ready for operation.

Note

This action needs to be performed before the assigned use.

After flushing the ”HYDRAULIC GROUND POWER UNIT“ fill level of

the tank [501] must be inspected via the inspection glass [503].

If necessary refill hydraulic oil. Instructions on how to fill in/refill

hydraulic oil, see para 1.1. FILL IN HYDRAULIC MEDIUM.



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rmation! d.) Keep this operating condition for approx. 10 min. - the ”hydraulic circuit“ will be flushed.

e.) After flushing switch-off the hydraulic pump by the illuminated button ”System Off“ and


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2. STARTUP

2.1. PREPARING WORKS AND INITIALIZATION

To refill the diesel tank [902], open filler and fill in the diesel (if the tank is empty, approx 170l),

if the tank is full enough, then close the cover.

+CAUTION+

THE UNIT MUST BE SWITCHED OFF DURING THE REFILL PROCEDURE!



Figure D01

“FILLER FOR FUEL TANK [902]“

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THE UNIT MUST BE SWITCHED OFF DURING THE REFILL PROCEDURE!

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“FILLER FOR FUEL TANK [902]“

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HGPU60-50-1:

Select operating mode (position 1 - 3000psi; position 2 - 5000psi) before startup by the

security switch with padlock (+1B1-S24). The selected position can be secured by the provi-

ded padlock.

Depending on the selected position of the security switch with padlock (+1B1-S24), the activated

illuminated button (+1B1-SP17) connects either 3000 or 5000psi to the output. As additional

security gate, the button shines when the 5000psi mode was selected. To confirm this selec-

tion, the button needs to be pressed again. Shining of the button should effect the operator to

think about his action before pressing the button again and connecting 5000psi to the output.

Switching ot the security switch during operation does not have any impact on the button -

under this condition the switch is NOT active. Activation of this function is not completed until

shutdown and re-start of the unit. Thus increase of 3000 to 5000 psi by mistake can be

excluded.

HGPU60-50-1 with customized option 03

For further information please look into chapter „C“.

++ WARNING ++

PAY ATTENTION TO PRESSURE RATING OF THE

HYDRAULIC SYSTEM OF THE A/C! MIX-UP CAN CAUSE

DAMAGE TO THE HYDRAULIC SYSTEM OF THE A/C!

Respective couplings need to be mounted for generating operating pressure.

++ WARNING ++

PAY ATTENTION TO MOUNTING OF PROPER COUPLINGS!

MIX-UP CAN CAUSE DAMAGE TO COUPLINGS.

Switch the power switch (+1B-Q1) to ”I / ON“.

The signal lamp (+1B1-P2) ”Power On”, the illuminated buttons (+1B1-SP8) ”System Off” and

(+1B1-SP16) ”Supply Pressure 0 psi” and the leds on the cover (+1C-P1) and (+1C-P2) are il-

luminated. The illuminated button (+1B1-SP12) ”Reservoir Selection A/C” blinks for approx. 30s

and is illuminated afterwards.

Before startup a lamp test needs to be performed.

When pressing the pushbutton (+1B1-S6) ”Lamptest” all the signal lamps and the illuminated

buttons of the control panel have to be illuminated.



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tion, the button needs to be pressed again. Shining of the button should effect the operator to

think about his action before pressing the button again and connecting 5000psi to the output.

Switching ot the security switch during operation does not have any impact on the button -



For further information please look into chapter „C“.

++ WARNING ++



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Switch the power switch (+1B-Q1) to ”I / ON“.

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++


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Remove hydraulic hoses, located at the right hand side of the unit (direction of motion) and

connect them to the A/C.

In order to start the diesel engine, illuminated button (+1B1-SP7) ”System On” needs to be

pressed (keep on pressing the button until the integrated LED is illuminated).

The ”HYDRAULIC GROUND POWER UNIT” can only be switched on after releasing the

EMERGENCY-OFF-pushbutton (+1B1-S1).



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Figure D02

“CONTROL PANEL“



1 Emergency-off pushbutton (+1B1-S1)

2 Signal lamp (+1B1-P2)




6 Pushbutton (+1B1-S6)

7 Illuminated button (+1B1-SP7)








15 Digital display (+1B1-P15)





20 Rotary knob (+1B1-R20)

21 Digital display (+1B1-P21)

22 Rotary knob (+1B1-R22)


24 Pressure gauge [551]

25 Pressure gauge [553]

26 Shut-off valve [556]

27 Minimess coupling [557]

28 Shut-off valve [558]


30 Operating instructions

31 Safety switch with padlock (+1B1-S24)

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5 6

8 794 10

11 12

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30 20 26 2728 2930 21 31

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30 Operating instructions

31 Safety switch with padlock (+1B1-S24)in

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3 Display (+1B2-P4)

Figure D03

“CONTROL PANEL“

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3. OPERATION

+ CAUTION +

PLEASE NOTE THAT A WRONG ORDER OF THE STEPS

SHOWN IN THE „TECHNICAL DOCUMENTATION“ AND

ON THE „OPERATING INSTRUCTIONS“ ON THE OPERATING PANEL

CAN CAUSE DAMAGE ON THE HGPU OR ON THE A/C!

(FOR EXAMPLE BECAUSE OF OVERFILLING OF HGPU RESERVOIR)

3.1. SYSTEM ON

Switch on the diesel engine and the hydraulic pump by pressing the illuminated button

(+1B1-SP7) ”System On”.

Note

Items, shown under para ”2.1. PREPARING WORKS AND INITIALIZATION“

must be considered.

When reaching boost pressure, led-signal lamp (+1B1-P10) ”Boost Pressure Failure” expires.

3.2. OPEN / CLOSED HYDRAULIC LOOP

Before switching between “Reservoir Selection HGPU“ and “Reservoir Selection A/C“ always

switch-off the hydraulic pump by pressing illuminated button (+1B1-SP8) ”System Off”, other-

wise the pump is shut down automatically.

Note

Switching between “Reservoir Selection HGPU“ and “Reservoir Selection A/C“

takes approx. 30s.

After pressing the respective illuminated button (+1B1-SP11) ”HGPU”

or (+1B1-SP12) ”A/C”, it blinks for approx. 30s.

Afterwards the respective illuminated button is illuminated, the selected mode is activated.



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Note

Items, shown under para ”2.1. PREPARING WORKS AND INITIALIZATION“

must be considered.

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wise the pump is shut down automatically.

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must be considered.

When reaching boost pressure, led-signal lamp (+1B1-P10) ”Boost Pressure Failure” expires.


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3.3. PRESSURE AND FLOW REGULATION

Pressurization of the A/C tank can be carried out by selecting

- 3000psi (5000psi for HGPU60-50-1)

(with or without ramp control)

- or adjustable (with or without ramp control).

Ramp On - smooth pressure build up (duration approx. 2 seconds)

Ramp Off - pressure increases immediately up to 3000psi / 5000psi

Note

For pressurization without ramp control press illuminated button

(+1B1-SP19) “Supply Pressure Ramp Off“.

Otherwise pressurization is always performed by ramp control.

- Action with 3000/5000psi pressurization (with or without ramp control):

Press illuminated button (+1B1-SP17) ”Supply Pressure 3000/5000psi“

Note

Dependent on the position of the safety switch with padlock (+1B1-S24),

either 3000psi or 5000psi pressure is switched on the output.

For safety reasons in the case of 5000psi the button must be pressed twice.

Max. flow (100%) is available, input potentiometer (+1B1-R22) ”Flow Rate Limit“ is

not activated.



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Max. flow (100%) is available, input potentiometer (+1B1-R22) ”Flow Rate Limit“ is

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Ramp Off - pressure increases immediately up to 3000psi / 5000psi


B1-SP19) “Supply Pressure Ramp Off“.



illuminated button (+1B1-SP17) ”Supply Pressure 3000/5000psi“

No Max. flow (100%) is available, input potentiometer (+1B1-R22) ”Flow Rate Limit“ is

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illuminated button (+1B1-SP17) ”Supply Pressure 3000/5000psi“

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B1-SP19) “Supply Pressure Ramp Off“.



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- Action with adjustable pressurization (with or without ramp control):

Press illuminated button (+1B1-SP18) ”Supply Pressure Adjustable “

Flow will be adjusted by input potentiometer (+1B1-R22) ”Flow Rate Limit“

Pressure is indicated at pressure gauge [551] ”Supply Pressure” and will be adjusted by in-

put potentiometer (+1B1-R20)

Note

Control of flow can only be performed if pressurization of A/C is carried out adjustable.

(Press illuminated button (+1B1-SP18) ”Supply Pressure Adjustable”).

Indication of flow can be read-off at digital display (+1B1-P21) ”Flow Rate [gpm]”

Indication of oil temperature can be read-off at digital display (+1B1-P15) ”Fluid Temperature (°C)”.



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illuminated button (+1B1-SP18) ”Supply Pressure Adjustable”).



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illuminated button (+1B1-SP18) ”Supply Pressure Adjustable”).



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4. SHUT DOWN

Close the output by pressing illuminated button (+1B1-SP16) ”Supply Pressure 0 psi”.

Select illuminated button (+1B1-SP8) ”System Off” to stop the diesel engine

Select the pushbotton (+1B1-S13) ”A/C Reservoir Fill“ or pushbotton (+1B1-S14) ”A/C Reser-

voir Drain“ to service the A/C reservoir after testing

Disconnect hydraulic hoses and store them at the holders located at the right hand side of the

unit (direction of motion).

Select the illuminated button (+1B1-SP11) ”Reservoir Selection HGPU“ and wait until the pres-

sure at the pressure gauge [553] ”Return Pressure“ indicates 0 psi.

Switch power switch (+1B-Q1) to position ”0 / OFF“.

+ CAUTION +

DO NOT SWITCH OFF MAIN SWITCH EARLIER THAN 30S

AFTER DIESEL ENGINE SHUTDOWN!

EARLIER THAN 30S CAN CAUSE DAMAGE ON SYSTEM PARTS OF THE HGPU.

+ CAUTION +








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Disconnect hydraulic hoses and store them at the holders located at the right hand side of the



Switch power switch (+1B-Q1) to position ”0 / OFF“.

+ CAUTION +


AFTER DIESEL ENGINE SHUTDOWN!


No CAN CAUSE DAMAGE ON THE HGPU OR ON THE A/C!


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+ CAUTION +




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5. ERROR MESSAGES

The following spreadsheet shows all error messages, which can occur, their consequences and

a short instruction on how to remove the error:



- Error: HGPU Reservoir Level Min

Indication: The error is indicated by the signal lamp (+1B1-P3)

Consequence: Automatic shut down of the unit. It will be reset to initial state

Removal: Refill hydraulic medium (see para 1.1. FILL IN HYDRAULIC

MEDIUM)

Cause: Leakage of hydraulic medium or not enough hydraulic medium

inside the hydraulic reservoir

- Error: HGPU Reservoir Level Max


Consequence: None

Removal: Decant the medium from the reservoir by pressing the pushbutton

(+1B1-S13) ”Fill” into A/C tank or drain medium via ball direct at the

reservoir of HGPU

Cause: Too much hydraulic medium inside the hydraulic reservoir

- Error: Filter Contaminated


Consequence: None

Removal: Inspect filter [514], [543], [563], and [820] (red clogging

indicator) and replace contaminated filter

Cause: too high contamination of one (or more) filter element(s)

ERROR

CODEERROR, INDICATION, CONSEQUENCE, REMOVAL

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Consequence: None


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Cause: Leakage of hydraulic medium or not enough hydraulic medium


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No (+1B1-S13) ”Fill” into A/C tank or drain medium via ball direct at the

reservoir of HGPU

Cause: Too much hydraulic medium inside the hydraulic reservoir

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- Error: HGPU Reservoir Level Max



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- Error: High Fluid Temperature



(temperature of the medium > 70°C)

Removal: Wait 10s, then start the pump (system will be cooled),

wait until it reaches 65°C, normal operation can be continued

Cause: Cooling capacity is too low, either caused by: ambient temperature

too high or too much hydraulic capacity used over a long period

- Error: Boost Pressure Failure


Consequence: Automatic shut down of the unit. It will be reset to initial state;

(when Boost Pressure at the pressure switch [521] was not reached

after 5s)

Removal: Adjust the pressure (inside the A/C tank) to normal level, inspect

the unit on leakage, inspect contamination of filte [514], and test

function of pressure switch [521]

Cause: The boost pressure pump does not deliver enough hydraulic

medium to the axial piston pump, either the hydraulic reservoir of

the A/C is unpressurized or the hydraulic reservoir of the A/C has

a low level.

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CODEERROR, INDICATION, CONSEQUENCE, REMOVAL

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(temperature of the medium > 70°C)

Removal: Wait 10s, then start the pump (system will be cooled),

wait until it reaches 65°C, normal operation can be continued



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- Error: Boost Pressure Failure




No the A/C is unpressurized or the hydraulic reservoir of the A/C has

a low level.

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medium to the axial piston pump, either the hydraulic reservoir of

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