FOR TRAINING USE ONLY

AW189
Airframe Maintenance
Type Training Course (cat. B1.3)

29 - Hydraulic System
Student Notes

This document contains commercial in confidence information that is AgustaWestland S.p.A. (hereinafter “AW”) proprietary
and it is supplied in collaboration with AgustaWestland Ltd (hereinafter “AW”), on the express condition that it may not be
copied to, used by, disclosed to or re-produced, in whole or in part, for any third party without the AW written consent.
Any unauthorised use, disclosure, reproduction in whole or in part of the information contained in this training publication is
forbidden and prosecuted in accordance with the applicable law.

DOCUMENT NO: AW189-AF001-SN-I-29

ISSUE: 6.0
ISSUE DATE: 30/05/2014

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29 - Hydraulic System
Student Notes - B1.3

Issue Record
The latest issue number shown below wholly defines the standard of this document. Changes to this
document will be made by re-issue of the document in its entirety or by amendment list action that will raise
the issue.

ISSUE DATE REMARKS

6.0 30/05/2014

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29 - Hydraulic System
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29 - Hydraulic System
Student Notes - B1.3

Table of Contents
Issue Record ....................................................................................................................................................... i
Hydraulic System Lesson ...................................................................................................................................1
1 Purpose of the Hydraulic System ............................................................................................................1
1.1 Hydraulic Power General................................................................................................................1
1.1.1 Hydraulic Power Purpose ...........................................................................................................1
2 Architecture of the Hydraulic System ......................................................................................................2
2.1 Architecture of the Hydraulic Power ...............................................................................................2
2.1.1 Hydraulic Power System Interfaces............................................................................................2
2.1.2 Architecture.................................................................................................................................4
3 Components and Location of the Hydraulic System ...............................................................................5
3.1 Hydraulic System ............................................................................................................................5
3.1.1 General Layout ...........................................................................................................................5
3.1.2 Power Control Module 1/2 ..........................................................................................................7
3.1.3 Hydraulic Power Supply 1/2 .......................................................................................................8
3.1.4 Electrical Driven Pump No. 3....................................................................................................10
3.1.5 Electrical Driven Pump No. 3 Circuit ........................................................................................11
3.1.6 Tail Rotor Shutoff Valve ............................................................................................................12
3.1.7 Hydraulic Lines .........................................................................................................................13
3.1.8 By-Pass Restrictors ..................................................................................................................14
3.1.9 Drain Lines................................................................................................................................15
3.2 Power Control Module (1).............................................................................................................17
3.2.1 PCM Reservoir .........................................................................................................................17
3.2.2 PCM Manifold ...........................................................................................................................18
3.2.3 PCM Filters ...............................................................................................................................19
3.2.4 PCM Filters Delta P Indicators .................................................................................................20
3.2.5 PCM Pressure Relief Valve ......................................................................................................21
3.2.6 PCM Pressure Transducer .......................................................................................................22
3.2.7 PCM Shutoff Valves .................................................................................................................23
3.2.8 PCM Pressure Switches ...........................................................................................................24
3.3 Power Control Module (2).............................................................................................................25
3.3.1 PCM Flow Restrictor .................................................................................................................25
3.3.2 PCM Return Line Shuttle Valve ................................................................................................26
3.3.3 PCM Return Bypass Valve .......................................................................................................27
3.3.4 PCM Check Valves ...................................................................................................................28
3.3.5 PCM Case Drain Pressure Indicator ........................................................................................29
3.3.6 PCM Ground Test Connections................................................................................................30
3.3.7 PCM Bleed and Relief Valve ....................................................................................................31
3.4 Power Control Module (3).............................................................................................................32
3.4.1 PCM Temperature Sensor........................................................................................................32
3.4.2 PCM Temperature Switch ........................................................................................................33
3.4.3 PCM Oil Level Indicators ..........................................................................................................34
4 Hydraulic System Controls and Indicators ............................................................................................35
4.1 Hydraulic Systems Indications (1) ................................................................................................35
4.1.1 Primary Flight Display ...............................................................................................................35
4.1.2 Multifunction Display .................................................................................................................36
4.1.3 Hydraulic Synoptic Display .......................................................................................................37
4.1.4 Synoptic Page Symbols ............................................................................................................39
4.2 Hydraulic System Control .............................................................................................................40
4.2.1 Electrical Control Display Unit ..................................................................................................40
4.3 Hydraulic System Indications (2) ..................................................................................................41
4.3.1 Hydraulic System CAS Messages ............................................................................................41
5 Operation of the Hydraulic System ........................................................................................................42
5.1 Hydraulic System Normal Operation ............................................................................................42
5.1.1 Hydraulic Systems Operation ...................................................................................................42

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29 - Hydraulic System
Student Notes - B1.3

5.1.2 Prestart Check ......................................................................................................................... 44

5.1.3 Normal Operations ................................................................................................................... 45
5.2 Hydraulic System Abnormal Operation........................................................................................ 46
5.2.1 Shutoff Valves Interlocks (1) .................................................................................................... 46
5.2.2 Shutoff Valves Interlocks (2) .................................................................................................... 47
5.2.3 Shutoff Valves Interlocks (3) .................................................................................................... 48
5.3 Pump Malfunction Operation ....................................................................................................... 49
5.3.1 Failure No. 1 Pump .................................................................................................................. 49
5.3.2 Failure No. 2 Pump .................................................................................................................. 50
5.4 Malfunction Procedure ................................................................................................................. 51
5.4.1 System 2 Fluid Level At 50% ................................................................................................... 51
5.4.2 System 2 Fluid Level At 28% ................................................................................................... 52
5.4.3 System 2 Fluid Level At 22% ................................................................................................... 53
5.4.4 System 1 Fluid Level At 50% ................................................................................................... 55
5.4.5 System 1 Fluid Level At 28% ................................................................................................... 56
5.4.6 System 1 Fluid Level At 22% ................................................................................................... 57
5.5 Overtemperature Operation ......................................................................................................... 58
5.5.1 Failure No. 2 System Overtemperature ................................................................................... 58
5.5.2 Failure 2 Servo and No. 1 System Overtemperature .............................................................. 59
5.6 Ground Operation ........................................................................................................................ 61
5.6.1 Hydraulic System Pressurisation ............................................................................................. 61
5.6.2 Hydraulic System Refilling ....................................................................................................... 62

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AW189-AF001-SN-I-29
29 - Hydraulic System
Student Notes - B1.3

Hydraulic System Lesson

1 Purpose of the Hydraulic System
1.1 Hydraulic Power General
1.1.1 Hydraulic Power Purpose

The purpose of the system is to supply the hydraulic power necessary:

 To pressurise the flight control circuit (main and tail rotor servo actuators)

 To pressurise the utility circuit (landing gear extension and retraction system)

 To provide continuous monitoring and crew information with regard to the hydraulic
parameters.

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29 - Hydraulic System
Student Notes - B1.3

2 Architecture of the Hydraulic System

2.1 Architecture of the Hydraulic Power
2.1.1 Hydraulic Power System Interfaces

The hydraulic power system interfaces with the following:

 Auxiliary hydraulic power system

 Central fuselage

 Tail unit

 Flight control system

 Utilities system

 Electrical system

 Main Gearbox (MGB)

 Avionic system

 Flight control system (main and tail rotor actuators described in chapter 67)

 Landing gear system (described in chapter 32)

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29 - Hydraulic System
Student Notes - B1.3

 Electrical system (28 Vdc electrical power distribution described in chapter 24)

 MGB (mechanical pumps driving described in chapter 63)

 Electrical Control Display Unit (ECDU) (described in chapter 24)

 Aircraft Mission and Management Computers (AMMC) (described in chapter 46).

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29 - Hydraulic System
Student Notes - B1.3

2.1.2 Architecture

The hydraulic power system is composed of:

 Main hydraulic power system including:

o 2 x Hydraulic Power Supply (HPS1 and 2)

o 2 x Power Control Module (PCM1 and 2)

o Tail Rotor Shutoff Valve (TRSOV)

 Auxiliary power system including:

o 2 x HPS (Elec Pump and 4)

 Flight control system :

o 3 x Main Rotor Actuator (MRA)

o 1 x Tail Rotor Actuator (TRA)

 Utility hydraulic system:

o Nose and Main Landing Gear Retracting Actuators.

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29 - Hydraulic System
Student Notes - B1.3

3 Components and Location of the Hydraulic System

3.1 Hydraulic System
3.1.1 General Layout

Each hydraulic power system circuit is composed of two pumps (one mechanical and one
electrical from the hydraulic power system for circuit 1, two mechanical driven for circuit 2)
providing pressure flow at 207 bar (3000 psi) to the PCM.

The mechanical hydraulic pumps are driven continuously by the MGB, the electrical hydraulic
pump (when operated by the pilot) only for ground preflight checks of the flight controls servo
actuators for a limited period of time.

The PCM houses all the equipment required for the hydraulic operation such as pressurised
reservoir, pressure and return filters, check valves, ground equipment operation components,
flight controls and utilities circuit solenoid SOV valves, bleed/drain valve, inlet and outlet
pressure switches, circuit pressure sensor, oil temperature sensor and switch, and oil level
microswitches.

Two rigid pipelines are routed from each PCM to the tail servo actuator (in circuit 2 to the
TRSOV first) and two rigid pipelines are routed to the utilities system.

Hydraulic pipelines on the structure upper deck are connected with each PCM with flexible hose
used to drain the reservoir and pump seal leak and PCM reservoir leak.

The hydraulic power system is designed to provide the required safety conditions by:

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AW189-AF001-SN-I-29
29 - Hydraulic System
Student Notes - B1.3

 A TRSOV valve used to isolate the circuit 2 supply to the tail rotor servo actuator in case of
excessive leakage in order to provide full flow capabilities to the main rotor servo actuators

 A set of microswitches in the PCM used to isolate the tail rotor servo actuator and/or the
hydraulic utilities as a function of the oil level in the PCM reservoir

 Interlocks in the hydraulic control panel which prevent depressurisation of both circuits at
the same time or a circuit in case of failure of the other

 Equipment and installations positioned on the upper deck will not be adversely affected by
fire and will provide their required functions without failures, external leakages or system
blockage for a duration of at least 15 minutes to allow a safe landing of the helicopter
following the start of a fire

 Fire resistance is improved by using hydraulic fluid with improved fire resistant properties,
titanium skins to cover the PCM reservoir, fire resistant silicon sleeves fitted on connection
hoses, rigid tubes made of titanium, seal leakages routed overboard through titanium drain
lines and installation of the hydraulic equipment to ensure that hydraulic fluid leaks or
sprays will not impinge on high temperature surfaces

 Hydraulic tubing and equipment installation designed to limit the damage caused by a
potential hazard to affect only one circuit obtained by specific routing of the tubing and
separation of the two hydraulic circuits.

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29 - Hydraulic System
Student Notes - B1.3

3.1.2 Power Control Module 1/2

These major parts are bolted together to form the PCM. The reservoir is a cylindrical vessel that
contains a diaphragm to which a spring applies a load. It has a total volume of 4.1 dm³. A sight
glass indicator is installed on the front side of the reservoir.
The manifold is a part machined from aluminium alloy, which is highly resistant to stress
corrosion and fatigue. The manifold is the part on which all the other components are installed
(hydraulic fittings, filters, electrical connectors, and so on).

On the PCM three quick disconnect couplings are the connections for the external hydraulic
power source. One coupling ID is used for the pressure line, one for the return line and one to
fill the reservoir. The filling line is connected to the line that goes to the return filter.

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AW189-AF001-SN-I-29
29 - Hydraulic System
Student Notes - B1.3

3.1.3 Hydraulic Power Supply 1/2

The hydraulic power supplies HPS 1 and 2 are variable displacement, axial piston type pumps.
They are located on the left and right input shaft of the main gearbox and they are driven at
8753 rpm and deliver an oil flow rate of 34,9 dm3/min.

The HPS4 is positioned on the auxiliary pad of the MGB, adjacent to the forward MRA. It turns
at 7427 rpm and delivers 29.3 dm3/min. Cooling of the HPS is achieved by a connection on the
pump body that allows case drain flow back to the reservoir.

The pumps include a centrifugal boost stage in the inlet port that assures normal operation at
low inlet pressures. Each pump is connected to its PCM by means of three hoses:

 The low pressure oil suction hose from the reservoir

 The oil pressure delivery hose at nominal pressure

 The case drain hose

 An additional hose connects the HPS4 shaft seal drain to the aircraft drain system.

A drain port is provided to vent fluid in the driveshaft cavity from leakage past the shaft seals.
They have hydrostatic bearings requiring a small amount of internal linkage flow called case
drain. The pump internal leakage flow is routed through the pump case drain to the PCM. This is
high enough to ensure the pump cooling and provide the proper pump lubrication. It is low
enough to preserve pump efficiency and avoid overheating of the hydraulic system.

The pumps driveshaft has a shear section that is designed to break if the drive torque exceeds

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AW189-AF001-SN-I-29
29 - Hydraulic System
Student Notes - B1.3

the specified load. This is to prevent any damage to the engine gearbox in the event of pump
seizure.

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29 - Hydraulic System
Student Notes - B1.3

3.1.4 Electrical Driven Pump No. 3

Electrical pump No. 3 is a 28 Vdc electric motor variable delivery axial piston driven pump. It
provides reduced hydraulic power (approximateli 105 bars) to PCM1 for the full and free
movement check of the flight controls prior to running the mechanically driven pumps. It is
therefore designed for ground use only.

It is mounted on the left-hand side of the upper deck adjacent to the PCM1. A timer relay limits
the electrical pump's operation to two minutes maximum.

In flight, the electrical pump is inoperative due to the electrical supply being isolated by the
weight on wheels status.

A pilot operated switch in the cockpit ECDU controls the pump.

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AW189-AF001-SN-I-29
29 - Hydraulic System
Student Notes - B1.3

3.1.5 Electrical Driven Pump No. 3 Circuit

After the input command OFF/ON is given through the ECDU, the command is provided via the
IOM to the Remote Electrical Power Unit (REPU), which provides the signal to EP3.

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29 - Hydraulic System
Student Notes - B1.3

3.1.6 Tail Rotor Shutoff Valve

The TRSOV enables the isolation of the hydraulic circuit 2 TRA hydraulic line in the event of a
leak, to preserve hydraulic power to the MRA.

This valve is a three-way, two-position and spring-loaded open valve. It consists of a 28 DC

solenoid operated pilot valve and a ball type main flow control valve section with a microswitch
mounted on the unit body. The microswitch provides an indication to the cockpit about the
TRSOV closure.

A low level switch, located in the PCM2, energises the TRSOV. It shuts off the pressure to the
TRA connecting the TRA pressure line to the return.

A nonreturn valve is installed beside circuit 2 beside the TRSOV. Its function is to inhibit a
reverse return flow in the event of major leaks from the TRA circuit 2 pressure return line. It
preserves the pressure in the circuit 2 supply lines for the MRA.

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29 - Hydraulic System
Student Notes - B1.3

3.1.7 Hydraulic Lines

The normal circuit 2 is routed in the right side of the fuselage, while the emergency circuit 1 is
routed on the left side for maximum physical segregation of the two systems.

Each HPS is connected to the PCM by means of flexible hoses. Flexible hoses also provide
connection between the PCM to the MRA circuit 1 pipeline, supplying hydraulic power to the
MRA upper body.

Circuit 2 pipeline supplies hydraulic power to the MRA lower body.

Rigid pipelines are routed from each PCM to the TRA.

In the rear fuselage, circuit 1 and circuit 2 tail rotor hydraulic lines are routed inside the tail boom
(left and right side).

In the vertical fin circuit 1 is routed in the front, while circuit 2 is located in the back and both up
to the tail rotor.

Rigid pipelines are routed from each PCM to the landing gear control valve (utility system) that
is situated on the forward right-hand side of the upper deck.

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29 - Hydraulic System
Student Notes - B1.3

3.1.8 By-Pass Restrictors

Two by-pass restrictors are installed between the pressure and the return lines of each
hydraulic system, in order to create a continuous recirculation of fluid in the area close to the
Tail Rotor Actuator, increasing the fluid temperature and as consequence equipment
temperature in this area.

Both restrictors are sized to allow a fluid recirculation of 0,5 dm3/min.

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29 - Hydraulic System
Student Notes - B1.3

3.1.9 Drain Lines

The drain sub-system provides drainage provision for the major components of the hydraulic
system. The hydraulic drains are routed so that they merge into two drain outlets, running from
the top deck, down the left and right sides of the aircraft, and then overboard at the aircraft
underside near STA 3800.

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29 - Hydraulic System
Student Notes - B1.3

The left drain outlet is connected to:

 PCM 1 relief/bleed valve

 PCM 1 reservoir breather drain port

 HPS 1 driveshaft seal drain port

 HPS 3 (EP) driveshaft seal drain port

The right drain outlet is connected to:

 PCM 2 relief/bleed valve

 PCM 2 reservoir breather drain port

 HPS 2 driveshaft seal drain port

 HPS 4 driveshaft seal drain port

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29 - Hydraulic System
Student Notes - B1.3

3.2 Power Control Module (1)

3.2.1 PCM Reservoir

The reservoir is a rolling diaphragm type with a useable volume of 3.2 dm3 and a maximum
volume of 4.1 dm3. The driving piston is shaped to support the diaphragm throughout its stroke.
A helical spring provides the energy to produce a pressure of 0.04 bar (0.7 psi) at MIN level.

Two of the four airframe mounting points are attached to the bottom of the reservoir. This area
has been strengthened to enable load transfer into the main structure. The reservoir consists of
an external housing made in titanium for fire protection and a rubber membrane inside pushed
by the helical spring.

Should an oil leakage occur in the internal rubber part, a dedicated oil drain port collects all the
fluid and drains it overboard.

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29 - Hydraulic System
Student Notes - B1.3

3.2.2 PCM Manifold

The manifold is the basic structure on which all of the components, including the hydraulic
fittings and electrical connectors are mounted. It also provides two of the four mounting
provisions for the PCM onto the airframe. The manifold also serves to hydraulically interconnect
the component parts with one another as well as to the reservoir and the hydraulic system via
the fluid ports.

Passageway sizes, shapes and locations have been selected to minimise pressure drops while
avoiding direct flow impingement on filter elements and the relief valve inlet. Fittings provide
suction, pressure, case drain and overboard drain connections to the helicopter hydraulic
systems.

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29 - Hydraulic System
Student Notes - B1.3

3.2.3 PCM Filters

The pressure and return filter assemblies (items 6a, 6b, 7a and 7b) are identical except for the
filter bowls due to the different impulse fatigue requirements.

A non-bypass line filter is installed in the pressure line. It is located in such a manner that all
fluid coming from the system pumps and the ground test equipment pressure connection is
filtered prior to entering any components of the system. A line filter, bypass type, is installed in
the return line. All fluid entering the return circuit is circulated through the filter prior to entering
the reservoir. No specific pump case drain filter is provided. The system return filters provide
cleaning of case drain flow.

Element filtration rate:

 Not cleanable type, is identical in the pressure and return assemblies

 5 micron particle size.

The filter assemblies incorporate an automatic shutoff feature in both the upstream and
downstream lines to minimise the fluid loss and air introduction into the hydraulic system during
element replacement. Tandem SOV in the inlet and outlet of the filter perform this function.

The element is retained in the bowl by means of a retainer ring to allow easy removal of the
bowl and element.

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29 - Hydraulic System
Student Notes - B1.3

3.2.4 PCM Filters Delta P Indicators

Both filter assemblies incorporate magnetic Delta P indicators. A flow restriction causes the
Delta P indicator to pop out for a visual indication. It actuates simultaneously a switch integrated
into the DPI for a remote electrical indication. The indicators incorporate a magnetically actuated
pop-up button and SPDT switch.

An orifice guard protects the system against any actuation under pressure surges. A filter
screen protects the system against any large contaminants. A thermal lock out operates below
40 °C.

The switch and differential pressure indicator actuate at 5.5 bar (80 psid). The pop-up button is
protected against any external contaminant by a silicon protective cap.

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29 - Hydraulic System
Student Notes - B1.3

3.2.5 PCM Pressure Relief Valve

A pressure relief valve installed in each PCM (item 10) provides protection against pump
overpressurisation.

The operating characteristics at 40 °C are as follows:

 Cracking pressure 232 bar (3364 psid)

 Reset at 227 bar (3292 psid) minimum

 Leakage 2 cc/min maximum at 227 bar (3292 psid).

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29 - Hydraulic System
Student Notes - B1.3

3.2.6 PCM Pressure Transducer

The pressure transducer (item 11) is electromechanical transducer type.

It is installed on the manifold downstream of the pressure relief valve, in order to provide a
signal of the hydraulic pressure in the Multifunction Display (MFD).

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29 - Hydraulic System
Student Notes - B1.3

3.2.7 PCM Shutoff Valves

Two of these valves (item 9a and 9b) are installed in each PCM, one is for isolating the flight
control servo actuators and the other for isolating the landing gear system or the emergency
landing gear system.

These valves are normally open, three-way, two-position solenoid operated. The main valve
spool is driven by pilot pressure from the solenoid valve when it is energised. This
depressurises the hydraulic circuit and connects the upstream fluid lines to return.

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29 - Hydraulic System
Student Notes - B1.3

3.2.8 PCM Pressure Switches

Four pressure switches are installed inside the PCM. Two of them are used to monitor the
pressure pumps delivery (item 12a and 12b) and provide a signal in the MFD about the pump
status.

The other two pressure switches (item 12c and 12d) are installed downstream from the
depressurisation valves and are used to monitor the pressure in the flight control circuits and in
the landing gear normal and emergency circuit.

The switches are set to actuate at 190 bar (2755 psi) and de-actuate at 162 bar (2349 psi).

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Student Notes - B1.3

3.3 Power Control Module (2)

3.3.1 PCM Flow Restrictor

The function of the flow restrictor (item 13) is to relieve trapped pressure between the inlet port
and the pressure line check valve.

A flow restrictor is installed between the ground pressure port and the MRA/TRA return.

The restrictor is sized to flow 1dm3/min at 207 bar (3000 psi) differential pressure.

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29 - Hydraulic System
Student Notes - B1.3

3.3.2 PCM Return Line Shuttle Valve

This is three-way, two-position poppet style valve (item 14). It is pressure actuated and returned
to normal under the action of a helical compression spring.

The valve will actuate when pressure is applied to the ground pressure port and returns to the
deactivated position by spring force when the pressure at the ground pressure port is reduced.

The function of this valve is to prevent the filling of the reservoir from the return ground
connection when pressure is not available at the ground pressure port.

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AW189-AF001-SN-I-29
29 - Hydraulic System
Student Notes - B1.3

3.3.3 PCM Return Bypass Valve

The function of this valve (item 15) is to provide a redundant return flow path in the event that
the return shuttle valve does not reset properly following removal of the ground pressure
connection.

This valve is similar in design and construction to the high pressure relief valve.

The operating characteristics are as follows:

 Cracking pressure 6.9 bar (100 + 10 psid)

 Reset pressure 4.5 bar (65 psid) minimum

 Full flow of 45 dm3/min 16.5 bar (240 psid) and 40 °C

 Leakage 1.5 cc/min maximum at 4.5 bar (65 psid) and 40 °C.

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AW189-AF001-SN-I-29
29 - Hydraulic System
Student Notes - B1.3

3.3.4 PCM Check Valves

Seven check valves (items 16a, 16b, 17a, 17b, 18, 19a, 19b) are integrated into the PCM for
various flow requirements.

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29 - Hydraulic System
Student Notes - B1.3

3.3.5 PCM Case Drain Pressure Indicator

The function of these indicators is to provide a warning of a deteriorating pump condition by

indicating an increasing flow in the case drain. The differential pressure across a restrictor,
installed in the case drain flow path, actuates these indicators.

The high pressure port of the indicators is connected to the upstream side of the restrictor and
the low pressure port to the downstream side of the restrictor.

The restrictor is sized so that the indicator operates when the flow in the case drain increases to
8 dm3/min. This indicator, once actuated, will remain actuated until manually reset.

The pop-up button is protected against any eventual external contamination by a protective cap.

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AW189-AF001-SN-I-29
29 - Hydraulic System
Student Notes - B1.3

3.3.6 PCM Ground Test Connections

The PCM is provided with three ground test connections.

Two of them allow connecting ground test equipment pressure and return to the hydraulic
system. They are permanently installed on the PCM and allow a quick connection avoiding any
fluid loss and any contamination in the system.

The third connection is dedicated to reservoir fill port.

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29 - Hydraulic System
Student Notes - B1.3

3.3.7 PCM Bleed and Relief Valve

A combination of a bleed and a relief valve provides the air bleeding from the reservoir. It also
protects the reservoir against any overpressure.

The relief valve is set to crack at 0.34 to 0.69 bar (5 to 10 psi), full flow of 10 dm3/min at 1.4 bar
(20 psid) and reset at 0.24 bar (3.5 psid) minimum.

The bleed valve is located at the highest point of the reservoir in order to optimize air bleeding.
Turning the lever mounted on it operates the valve.

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29 - Hydraulic System
Student Notes - B1.3

3.4 Power Control Module (3)

3.4.1 PCM Temperature Sensor

The oil temperature transducer is a resistance temperature device of three wire construction.

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29 - Hydraulic System
Student Notes - B1.3

3.4.2 PCM Temperature Switch

The temperature switch (item 23) is threaded into the manifold. The electrical connector is fitted
to the switch housing. The switch is set to actuate at a temperature of 135 °C (275 °F), and
provide an alarm in the cockpit.

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AW189-AF001-SN-I-29
29 - Hydraulic System
Student Notes - B1.3

3.4.3 PCM Oil Level Indicators

There are three oil level indicator switches inside the reservoir. The switches are
environmentally sealed.

The switches actuate to indicate the oil levels by a mechanical cam. A lever mounted on the
back of the reservoir is used to actuate the switches for maintenance electrical continuity
checks.

An optical oil level indication is achieved by reading the engravings on the oil level indicator
cover at the rear of the reservoir. It indicates the need to add any oil if it is required.

The oil level are set at the following values:

 MIN level at 0.7 dm3 (corresponding to 22%)

 LOW 2 level at 0.9 dm3 (corresponding to 28%)

 LOW 1 level at 1.3 dm3 (corresponding to 50%).

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AW189-AF001-SN-I-29
29 - Hydraulic System
Student Notes - B1.3

4 Hydraulic System Controls and Indicators

4.1 Hydraulic Systems Indications (1)
4.1.1 Primary Flight Display

The values of pressure in the No. 1 and No. 2 systems are represented by digital readouts
beside the labels HYD1 and HYD2.

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29 - Hydraulic System
Student Notes - B1.3

4.1.2 Multifunction Display

The PWR PLANT page displays the values of pressure and temperature in the HYD area.

Pressure
The values of pressure in No. 1 and No. 2 systems are represented by digital readouts under
the label 1 BAR 2 respectively. Graphically these values are represented on a vertical scale by
means of two pointers (triangles) that match the colour of the area on the scale.

Temperature
The fluid temperature values in No. 1 and No. 2 systems are represented by digital readouts
under the label 1 °C 2. Graphically these values are represented on a vertical scale by means of
two pointers (T symbols) that match the colour of the area on the scale.

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AW189-AF001-SN-I-29
29 - Hydraulic System
Student Notes - B1.3

4.1.3 Hydraulic Synoptic Display

The synoptic page provides a diagram showing the interface between the PCM pumps, landing
gears, servo actuators and TRSOV as follows:

 Circuit 1 and 2 operating pressure readout.

 Circuit 1 and 2 operating temperature readout.

 Circuit 1 and 2 oil level percentage indicator - indicates the oil level percentage in the
PCM1 (2) reservoir.

 SOV 1 (2) indicator - indicates the condition of the PCM1 (2) flight control SOV operated by
the 1 (2) CLOSE switch in the ECDU. When the valve is open the SOV 1 (2) indicator is
vertical. When the valve is closed the SOV 1 (2) indicator is horizontal. In this condition the
cautions [1 (2) HYD OIL PRESS], [1 (2) SERVO] are also provided to the MFD and the
amber legend PRESS on the HYD 1 (2) indicator in the ECDU is illuminated.

 LDG GEAR NORM indicator - indicates the condition of the PCM2 utility SOV operated by
the PCM2 oil LOW LEVEL 1, LOW LEVEL 2 and MIN LEVEL microswitches. When the
valve is open the LDG GEAR NORM indicator is horizontal. When the valve is closed the
LDG GEAR NORM indicator is vertical. In this condition the caution [HYD UTIL PRESS]
only, or the cautions [HYD UTIL PRESS] and [2 HYD MIN] are also provided.

 LDG GEAR EMER indicator - indicates the condition of the PCM1 utility SOV operated by
the PCM1 oil MIN LEVEL microswitch. When the valve is open the LDG GEAR EMER
indicator is horizontal. When the valve is closed the LDG GEAR EMER indicator is vertical.
In this condition the cautions [EMERG LDG PRESS] and [1 HYD MIN] are also provided.

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29 - Hydraulic System
Student Notes - B1.3

 TAIL SERVO TRSOV indicator - indicates the condition of the TRSOV operated by the
PCM2 oil LOW LEVEL 2 microswitch. When the valve is open the TAIL SERVO TRSOV
indicator is vertical. In this condition the caution [2 SERVO] is also provided.

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29 - Hydraulic System
Student Notes - B1.3

4.1.4 Synoptic Page Symbols

The table shows the symbols used to represent the major components of the hydraulic system
on the hydraulic synoptic page and the relevant status.

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AW189-AF001-SN-I-29
29 - Hydraulic System
Student Notes - B1.3

4.2 Hydraulic System Control

4.2.1 Electrical Control Display Unit

The ECDU Hydraulic page has the following indications/controls.

HYDRAULIC 1 - SOV - 2
Three lateral soft keys with horizontal lines towards NORM, 1CLSD and 2CLSD options. The
default at power-up is NORM and both SOV open. Hydraulic 1 SOV can be closed only if the oil
pressure in the hydraulic circuit 2 is not low and the TRSOV is not closed. If the Hydraulic 1
SOV is closed and hydraulic circuit 2 oil pressure becomes low or the TRSOV closes then the
Hydraulic 1 SOV automatically reopens.

Hydraulic 2 SOV can be closed only if the oil pressure in the hydraulic circuit 1 is not low. If the
Hydraulic 2 SOV is closed and hydraulic circuit 1 oil pressure becomes low then the Hydraulic 2
SOV automatically re-opens.

The relative closed SOV will re-open in case of electrical power loss.

HYDRAULIC ELEC PUMP

This is an imposed toggle command type with OFF and ON options. The default at power-up is
OFF. The HYDRAULIC ELEC PUMP can be activated only on ground and is automatically
turned off after 2 minutes. If the ELEC PUMP is switched on then it turns off after 2 minutes
from the first start to protect the pump from overheating.

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AW189-AF001-SN-I-29
29 - Hydraulic System
Student Notes - B1.3

4.3 Hydraulic System Indications (2)

4.3.1 Hydraulic System CAS Messages

CAS Message Description

Associated hydraulic system pressure low (lower than 163

1(2) HYD OIL PRESS bar)

Associated hydraulic system overtemp (greater than 134 °C)

1(2) HYD OIL TEMP

Associated hydraulic Servo actuator (MRA or TRA) in

1(2) HYD SERVO bypass

Associated hydraulic pump failed

1(2)(4) HYD PUMP

Emergency landing gear deployment system pressure low

EMER LDG PRESS

Utility hydraulic pressure low (lower than 163 bar)

HYD UTIL PRESS

Associated Hydraulic system fluid level low (22%)

1(2) HYD MIN

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AW189-AF001-SN-I-29
29 - Hydraulic System
Student Notes - B1.3

5 Operation of the Hydraulic System

5.1 Hydraulic System Normal Operation
5.1.1 Hydraulic Systems Operation

No. 1 Hydraulic System Principle of Operations

The No. 1 hydraulic system supplies hydraulic power to the main rotor and tail rotor servo
actuators, and the landing gear for emergency extension.

It is controlled by a combination of automatic and manual controls.

Automatic Controls
Automatic controls are provided by the fluid level microswitches located inside the PCM 1
reservoir. If the fluid in the PCM1 reaches the minimum level (22%), the UTIL SOV 1 of the LDG
GEAR EMER circuit will close to stop further drop in fluid pressure. If the fluid in the PCM2
reservoir reaches the minimum level (22%), SOV 1 will be inhibited from closing to avoid that, if
TRSOV closes, the tail rotor will lose power completely.

Manual Controls
The pilot operates the No. 1 hydraulic system acting on the ELEC PUMP push button switch
and the flight control SOV switch. In flight, the SOV switch is used to close the No. 1 system if a
hydraulic over temperature condition occurs.

No. 2 Hydraulic System Principle of Operations

The No. 2 hydraulic system supplies hydraulic power to the main rotor and tail rotor servo
actuators, and the landing gear extension and retraction system in normal condition.

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AW189-AF001-SN-I-29
29 - Hydraulic System
Student Notes - B1.3

The No. 2 hydraulic system is controlled by a combination of automatic and manual controls.

Automatic Controls
Automatic controls are provided by the fluid level microswitches located inside the PCM2
reservoir. If the fluid in the utility circuit reaches the level of 50%, the UTIL SOV 2 will close to
stop further drop in fluid pressure. If the fluid in the PCM2 reaches the level of 28%, the TRSOV
will close and the UTIL SOV 2 is re-opened. If the fluid in the PCM2 reaches the minimum level
(22%), the UTIL SOV 2 will be closed again (TRSOV still closed).

Manual Controls
The pilot operates on the No. 2 hydraulic system acting on the flight control SOV switch. In flight
the SOV switch is used to close the No. 2 system if a hydraulic over temperature condition
occurs. On the ground, the SOV switch is used to isolate the No. 2 hydraulic system.

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AW189-AF001-SN-I-29
29 - Hydraulic System
Student Notes - B1.3

5.1.2 Prestart Check

The No. 1 system permits the testing of the flight controls on ground only.

By selecting ELEC PUMP ON on the ECDU HYD page the pilot can carry out full and free
checks of the cyclic, collective and yaw pedals. The full and free check should be carried out
with slow displacement of the controls and one control at a time in order not to overload the
electric pump. The electrical pump disengages automatically after 2 minutes.

HYDRAULIC Synoptic Page

The ELEC PUMP pressurises the hydraulic No. 1 system at 105 bars. This value of pressure
results in a fail condition for the main rotor, tail rotor and emergency landing gear servo
actuators.

SOV 1 and SOV 2 are displayed in an undetermined status.

Cautions are displayed in the CAS window as follows:

 1-2-4 HYD PUMP

 1-2 SERVO

 1-2 HYD OIL PRESS

 HYD UTIL PRESS

 EMER LDG PRESS.

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29 - Hydraulic System
Student Notes - B1.3

5.1.3 Normal Operations

When the engines are running and the MGB is driven at its nominal speed, HPS1, 2 and 4 are
driven and provide hydraulic pressure to both PCM. Pressurised oil passes through the filter to
the pressure transducer and then to both SOV. Oil passes to the aircraft circuits and feeds the
flight control actuators and the landing gear circuit.

Hydraulic synoptic page:

 PUMP1 pressurises No. 1 system

 PUMP2 and PUMP4 pressurise No. 2 system

 UTIL SOV 1 and UTIL SOV 2 are opened and the landing gear is pressurised at 207 bar

 SOV 1, SOV 2 and TRSOV are opened and flight controls are pressurised at 207 bar by
both hydraulic systems.

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AW189-AF001-SN-I-29
29 - Hydraulic System
Student Notes - B1.3

5.2 Hydraulic System Abnormal Operation

5.2.1 Shutoff Valves Interlocks (1)

This function inhibits the isolation of both flight control SOV at the same time.

An interlock function is embedded in the system so that the pilot can close the hydraulic system
SOV by means of the ECDU.

The command is sent from the ECDU to the IOM (1 and 2) and then to the REPU1 and/or 2,
and then finally to the affected SOV.

The SOV of No. 1 system or No. 2 system can be closed only if nominal hydraulic pressure is
detected in the other system.

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AW189-AF001-SN-I-29
29 - Hydraulic System
Student Notes - B1.3

5.2.2 Shutoff Valves Interlocks (2)

If one of the hydraulic circuits' SOV has been shut off, in case of a pressure drop in the other
hydraulic system below 162 bar, the hydraulic system control logic will override the initial pilot’s
SOV selection and provide pressure to the servos.

This function provides an improving availability of pressure to the flight control actuators under a
multiple failures condition.

Note: In these conditions the SOV switch on the ECDU is not reset.

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AW189-AF001-SN-I-29
29 - Hydraulic System
Student Notes - B1.3

5.2.3 Shutoff Valves Interlocks (3)

The interlock function is applicable to both No. 1 and No. 2 systems.

Selection of system SOV is permitted only if normal hydraulic pressure in the opposite system is
verified by the pressure switch.

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AW189-AF001-SN-I-29
29 - Hydraulic System
Student Notes - B1.3

5.3 Pump Malfunction Operation

5.3.1 Failure No. 1 Pump

PUMP1 failure implies the total loss of No. 1 system operations. In this case hydraulic power is
supplied by the No. 2 system.

Hydraulic synoptic page:

 PUMP1 fails.

 SOV1 and UTIL SOV1 are in an undetermined status. The flight controls are considered
failed for No. 1 system. 1SERVO shown as failed. The landing gear emergency operation is
not available.

 1 HYD PUMP, 1 HYD OIL PRESS, 1 SERVO, EMER LDG PRESS cautions are displayed
in the CAS list and the pilot has to follow the emergency procedure.

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AW189-AF001-SN-I-29
29 - Hydraulic System
Student Notes - B1.3

5.3.2 Failure No. 2 Pump

In case of failure of either HPS2 or 4, the remaining pump (in this example HPS4) is able to
supply the operating pressure to the No. 2 system.

Hydraulic synoptic page:

 HPS2 fails. HPS4 continues to pressurisethe No. 2 system.

 [2 HYD PUMP] caution is displayed in the CAS windows.

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29 - Hydraulic System
Student Notes - B1.3

5.4 Malfunction Procedure

5.4.1 System 2 Fluid Level At 50%

A loss of hydraulic fluid from the circuit 2 reservoir to the LOW 1 level (approx 1.3 litres or 50%)
will result in the automatic closure of the utility SOV installed on the PCM2. The [HYD UTIL
PRESS] caution will be displayed on the CAS and the LDG GEAR NORM in amber and 50%
level advisories will be shown on the synoptic. The flight control and TRSOV remain opened.

In this case, the three level microswitches installed inside the reservoir control the utility SOV
and the TRSOV to contain the leakage.

Hydraulic Synoptic Page

UTIL SOV2 is automatically closed by the level microswitch and the landing gear normal
operation is not available. The landing gear free falls due to lack of pressure.

The [HYD UTIL PRESS] caution is displayed in the CAS window and the pilot has to follow the
relevant malfunction procedure.

The LDG NORM is displayed in amber at the synopthic.

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AW189-AF001-SN-I-29
29 - Hydraulic System
Student Notes - B1.3

5.4.2 System 2 Fluid Level At 28%

The LOW 2 LEVEL microswitch (28%) is used in PCM2 as a safety threshold closing the
TRSOV and reopening the utility SOV.

The caution [2 SERVO] is provided while the caution [HYD UTIL PRESS] clears.

The hydraulic synoptic page will also display this condition (valve closed and reservoir oil
quantity).

The microswitch is also used to prevent to set OFF No. 1 system.

Hydraulic Synoptic Page

UTIL SOV2 is automatically reopened by the 28% level microswitch.

TRSOV is automatically closed by the level microswitch. No. 2 tail rotor servo is depressurised.
Closure of SOV1 is inhibited.

The caution [2 SERVO] is displayed in the CAS window. All four n°2 actuators are displayed in
amber and the pilot has to follow the relevant malfunction procedure.

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AW189-AF001-SN-I-29
29 - Hydraulic System
Student Notes - B1.3

5.4.3 System 2 Fluid Level At 22%

The MIN LEVEL microswitch (22%) used in PCM2 recloses the utility SOV while in the PCM1 it
closes the utility SOV.

At this stage the quantity of fluid remaining into the reservoirs is sufficient to cover the main
rotor actuators volumetric requirements.

The hydraulic synoptic page will also display these conditions (valve closed and reservoir oil
quantity).

The microswitches can be manually operated for electrical continuity check through a test lever
on the back side of the visual oil level indicator.

Hydraulic Synoptic Page

TRSOV remains closed and N° 2 Tail rotor servo remains depressurised, and closure of SOV 1
remains inhibited.

UTIL SOV2 is automatically closed by the minimum (22%) level microswitch. The landing gear
normal operation is not available and the landing gear free falls due to a lack of pressure.

The following cautions are displayed in the CAS window and the pilot has to follow the
emergency procedures:

 2 SERVO

 HYD UTIL PRESS

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AW189-AF001-SN-I-29
29 - Hydraulic System
Student Notes - B1.3

 2 HYD MIN.

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AW189-AF001-SN-I-29
29 - Hydraulic System
Student Notes - B1.3

5.4.4 System 1 Fluid Level At 50%

When the level of the fluid inside the PCM1 reservoir reaches 50%, there is no effect on the
system operations. Only the indications in the synoptic page (50% reservoir fluid level and
readout indications) are provided.

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AW189-AF001-SN-I-29
29 - Hydraulic System
Student Notes - B1.3

5.4.5 System 1 Fluid Level At 28%

When the level of the fluid inside the PCM1 reservoir reaches the 28%, there is no effect on the
system operations. Only the indications in the synoptic page (28% reservoir fluid level and
readout indications) are provided.

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AW189-AF001-SN-I-29
29 - Hydraulic System
Student Notes - B1.3

5.4.6 System 1 Fluid Level At 22%

Hydraulic Synoptic Page

UTIL SOV1 is automatically closed by the minimum (22%) level microswitch. The landing gear
emergency operation is not available.

The [1 HYD MIN] and [EMER LDG PRESS] cautions are displayed in the CAS window and the
pilot has to follow the emergency procedure.

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AW189-AF001-SN-I-29
29 - Hydraulic System
Student Notes - B1.3

5.5 Overtemperature Operation

5.5.1 Failure No. 2 System Overtemperature

When the hydraulic fluid reaches an overheating condition (the temperature is greater than 135
°C), the system (for example No. 2) must be isolated.

Hydraulic synoptic page:

 Check to confirm No. 2 system over temperature.

 Lower the LDG GEAR following the normal procedure.

 On the ECDU, on the hydraulic page select 2 CLOSE.

 Cautions are displayed in the CAS window and the pilot has to follow the emergency
procedure:

o 2 HYD OIL TEMP

o 2 HYD OIL PRESS

o 2 SERVO.

Note: With one hydraulic system SOV shut off, a subsequent drop of pressure in the other
system will override the SOV selection and reinstate pressure to the servos. In these conditions
the SOV switch will not be automatically reset.

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AW189-AF001-SN-I-29
29 - Hydraulic System
Student Notes - B1.3

5.5.2 Failure 2 Servo and No. 1 System Overtemperature

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Student Notes - B1.3

Moving to 1 CLOSE would cause loss of control in No. 1 servoactuator.

Hydraulic synoptic page:

 Check to confirm the No.1 system over temperature.

Note: The SOV selection on the ECDU is only ineffective when [1 (2) HYD OIL PRESS] caution
is active.

When [2 SERVO] and [1 HYD OIL TEMP] cautions are both illuminated, the SOV selection on
the HYD page is not inhibited.

Cautions are displayed in the CAS windows and the pilot has to follow the relevant malfunction
procedure:

 2 SERVO

 1 HYD OIL TEMP.

Issue No 6.0 30/05/2014

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AW189-AF001-SN-I-29
29 - Hydraulic System
Student Notes - B1.3

5.6 Ground Operation

5.6.1 Hydraulic System Pressurisation

A connection is provided on the PCM in order to pressurise the hydraulic system from a ground
hydraulic test bench.

Two self-sealing couplings are provided on the ground test connections servicing area of the
PCM.

A dust cover, secured with a safety strap, is provided for each connection in order to protect
them when they are not in use.

Any fluid that enters into the system is filtered prior to it entering the aircraft system.

Issue No 6.0 30/05/2014

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Use and disclosure of this document is controlled; see Title/Cover page.

FOR TRAINING USE ONLY

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AW189-AF001-SN-I-29
29 - Hydraulic System
Student Notes - B1.3

5.6.2 Hydraulic System Refilling

Both PCM are equipped with a third quick disconnect port through which reservoir refilling can
be performed.

Oil refilling is carried out at low pressure with AGE and the oil level must be read through a sight
glass positioned on the reservoir.

Issue No 6.0 30/05/2014

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Use and disclosure of this document is controlled; see Title/Cover page.

FOR TRAINING USE ONLY