01-1a-17

(NAVY) NAVAIR 01-1A-17 (AIR FORCE) TO 42B2-1-12 15 August 2006 Change 1 – 1 August 2008

TECHNICAL MANUAL

ORGANIZATIONAL, INTERMEDIATE AND DEPOT MAINTENANCE

AVIATION HYDRAULICS MANUAL

N68936-04-D-0008

DISTRIBUTION STATEMENT A. Approved for public release, distribution is unlimited. PA Case Number AFMC 06-273 for Air Force.

PUBLISHED BY DIRECTION OF THE COMMANDER, NAVAL AIR SYSTEMS COMMAND

0801LP1087070

NAVAIR 01-1A-17 TO 42B2-1-12 Change 1 – 1 August 2008 Page A

NUMERICAL INDEX OF EFFECTIVE WORK PACKAGES/PAGES

List of Current Changes

Original 15 August 2006, including IRACs/RACs 1 through 9.

Change 1 – 1 August 2008

Only those work packages/pages assigned to the manual are listed in this index. Dispose of superseded work packages/pages. Superseded classified work packages/pages shall be destroyed in accordance with applicable security regulations. If changed pages are issued to a work package, insert the changed pages in the applicable work package. The portion of text affected in a change or revision is indicated by change bars or the change symbol “R” in the outer margin of each column of text. Changes to illustrations are indicated by pointing hands, change bars, or MAJOR CHANGE symbols. Changes to diagrams may be indicated by shaded borders.

Title Page A Numerical Index of Effective Work

Packages/Pages TPDR-1 List of Technical Publications

Deficiency Reports Incorporated HMWS-1 Warnings Applicable to Hazardous

Materials 001 00 Alphabetical Index 002 00 Introduction 003 00 Description, Hydraulic Systems and

Hydraulic Fluids 004 00 Hydraulic Fluid Contamination 005 00 Hydraulic Fluid Contamination

Analysis

WP Number Title

WP Number Title

006 00 Aircraft System Decontamination 007 00 Hydraulic Contamination Control 008 00 Servicing Hydraulic Systems 009 00 Hydraulic Support Equipment 010 00 Hydraulic Filters 011 00 Controlled Environment Work Center 012 00 Selection and Use of Cleaning

Materials 013 00 Repair, Test, and Maintenance of

Hydraulic Systems and Components 014 00 Protective Closures 015 00 Hydraulic Seals 016 00 Phosphate Ester Hydraulic Fluid 017 00 Hydraulic Fluid Contamination

Analysis Kit (P/N 57L414)

Total number of pages in this manual is 204, consisting of the following:

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NAVAIR 01-1A-17 T.O. 42B2-1-12

2 AUGUST 2008

AUTOMATIC DISTRIBUTION AND WAREHOUSE STOCK COPIES OF NAVAIR 01-1A-17 DATED 15 AUGUST 2006 WITH CHANGE 1 DATED 1 AUGUST 2008 WAS PRINTED IN BLACK AND WHITE. FOUR PHOTOS SHOULD BE PRINTED IN COLOR. REPLACE BLACK AND WHITE PHOTOS WITH ATTACHMENT. PLACE THIS PAGE BEHIND TITLE PAGE AFTER INCORPORATION.

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NAVAIR 01-1A-17 TO 42B2-1-12 Change 1 – 1 August 2008 Page B/(C Blank)

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UNCLASSIFIED// R 102101Z APR 12 IRAC 015 TO 01-1A-17 DTD 15-AUG-2006 WITH NOTICE 1 OF/ COMNAVAIRSYSCOM PATUXENT RIVER MD TO AIG 423 FLTREADCEN EAST CHERRY POINT NC//6.8// INFO COMNAVAIRSYSCOM PATUXENT RIVER MD//DRPO// COMNAVAIRWARCENACDIV PATUXENT RIVER MD FLTREADCEN EAST CHERRY POINT NC//6.8// UNCLAS//N05600// MSGID/GENADMIN/MIL-STD-6040(SERIES)/B.0.01.00 /COMNAVAIRSYSCOM PAX DRPO/-/-/-/-/USA/UNCLASSIFIED// SUBJ/IRAC 015 TO 01-1A-17 DTD 15-AUG-2006 WITH NOTICE 1 OF/ /02-AUG-2008// REF/A/DOC/COMNAVAIRFORINST 4790.2A/10NOV2009// REF/B/PUB/NAVAIR 00-25-100/12DEC2009// REF/C/DOC/N65923-10-0364/09NOV2010// REF/D/PUB/NAVAIR 01-1A-17/15AUG2006// NARR/REF A IS THE NAVAL AVIATION MAINTENANCE PROGRAM REF B IS THE NAVAL AIR SYSTEMS COMMAND TECHNICAL MANUAL PROGRAM REF C IS THE TECHNICAL PUBLICATION DEFICIENCY REPORT REF D IS THE AVIATION HYDRAULICS MANUAL// POC/CRUSE, MARIA/-/FLTREADCEN SOUTHWEST SAN/LOC:6.8.5.1 //TEL:619-545-3646// GENTEXT/REMARKS/THIS MESSAGE WAS AUTO GENERATED FROM THE JDRS WEBSITE FOR NON-WEB SITE CAPABLE ORGANIZATIONS. THE REPORT WAS ORIGINATED BY: ------ FLTREADCEN EAST CHERRY POINT NC/V-22FST. IF RESPONSE VIA WEB SITE IS NOT POSSIBLE, TO: LINE RECIPIENTS SHOULD ADDRESS RESPONSE DIRECTLY TO: ------ FLTREADCEN EAST CHERRY POINT NC/V-22FST WHEN APPROPRIATE. THIS DEFICIENCY REPORT WILL BE PROCESSED VIA THE JDRS WEBSITE. FOR FURTHER DETAILS OR REAL TIME STATUS VISIT THE JDRS WEB SITE AT: JDRS.MIL. 1. IRAC 015 TO 01-1A-17 DTD 15-AUG-2006 WITH NOTICE 1 OF 02-AUG-2008 2. PURPOSE OF CHANGE: ADD INFORMATION TO MANUAL ABOUT HOW MANY RE-SAMPLES CAN BE PULLED IF THE INITIAL EPC RESULTS FAIL BEFORE THE SYSTEM MUST BE DECONTAMINATED. 3. DETAILED INFORMATION: PEN AND INK CHANGES TO THE TECHNICAL CONTENT OF A MANUAL ARE NOT AUTHORIZED. THE FOLLOWING TECHNICAL CONTENT CHANGE INFORMATION APPLIES TO THE FOLLOWING REFERENCED PAGES AND PARAGRAPHS OF THE SUBJECT MANUAL UNTIL THE FORMAL CHANGE IS RELEASED. ADD THE FOLLOWING NOTE TO REFERENCE (D) WP005 00 PAGE 7 UNDER PARAGRAPH 18. NOTE "SHOULD THE SYSTEM UNDER TEST EXHIBIT FREE WATER, THE SYSTEM MUST BE DECONTAMINATED PER THE APPLICABLE MAINTENANCE INSTRUCTION MANUAL (MIM)." "SHOULD THE SYSTEM UNDER TEST FAIL TO MEET THE NAVY STANDARD CLASS 5 (OR CLASS 3 FOR SUPPORT EQUIPMENT) PARTICULATE REQUIREMENT RESAMPLE THE SYSTEM BEING TESTED. THE SYSTEM CAN BE RE-SAMPLED A MAXIMUM OF TWO TIMES AND IF THE SECOND RE-SAMPLE FAILS TO MEET THE NAVY STANDARD PARTICULATE REQUIREMENTS, THE SYSTEM MUST BE DECONTAMINATED PER THE APPLICABLE MIM."

4. VALIDATED BY: M. K. CRUSE, FRCSW, 6.8.5.1, 619-545-3646, 735-3646, [email protected] 5. RELATED INSTRUCTIONS: A. FOR IRACS AFFECTING MANUALS IN PAPER COPY - MAINTAIN THIS IRAC WITH THE APPLICABLE MANUAL BY PLACING OR ATTACHING IT DIRECTLY BEHIND THE TITLE PAGE. MARK THE SPECIFIC AREA AFFECTED AND ANNOTATE THE CHANGED PAGE OR CARD LISTED ON THE A PAGE WITH A VERTICAL LINE IN THE MARGIN NEXT TO THE CHANGED DATA, OPPOSITE THE BINDING. FOR DOUBLE COLUMN MATERIAL, MARK THE CENTER MARGIN WHEN THE INNER PARAGRAPH IS AFFECTED. NOTE THE IRAC NUMBER IN THE MARGIN. THIS IRAC SHALL NOT BE REMOVED UNTIL RECEIPT OF FORMAL CHANGE PAGES.

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B. FOR IRACS AFFECTING MANUALS THAT ARE ON DIGITAL MEDIA - AFFIX AN ADHESIVE LABEL TO THE DIGITAL MEDIA CASE ANNOTATED WITH THE APPLICABLE PUBLICATION NUMBER AND IRAC NUMBER. THE LABEL SHOULD BE POSITIONED TO ALLOW FOR ADDITIONAL IRACS AS THEY OCCUR AND SHOULD NOT COVER THE DATE OR DIGITAL MEDIA TITLE. MAINTAIN THE IRAC ON FILE UNTIL RECEIPT OF THE SUPERSEDING DIGITAL MEDIA. C. SUBJECT IRAC SHALL BE INCORPORATED INTO APPLICABLE MANUAL NLT 12 MONTHS FROM THE DATE OF IRAC ISSUE. D.//

UNCLASSIFIED// R 101933Z APR 12 IRAC 014 TO 01-1A-17 DTD 15-AUG-2006 WITH NOTICE 1 OF/ COMNAVAIRSYSCOM PATUXENT RIVER MD TO AIG 423 FLTREADCEN EAST CHERRY POINT NC//NA// INFO COMNAVAIRSYSCOM PATUXENT RIVER MD//DRPO// COMNAVAIRWARCENACDIV PATUXENT RIVER MD FLTREADCEN EAST CHERRY POINT NC//NA// UNCLAS//N05600// MSGID/GENADMIN/MIL-STD-6040(SERIES)/B.0.01.00 /COMNAVAIRSYSCOM PAX DRPO/-/-/-/-/USA/UNCLASSIFIED// SUBJ/IRAC 014 TO 01-1A-17 DTD 15-AUG-2006 WITH NOTICE 1 OF/ /02-AUG-2008// REF/A/DOC/COMNAVAIRFORINST 4790.2A/10NOV2009// REF/B/PUB/NAVAIR 00-25-100/12DEC2009// REF/C/DOC/N65923-10-0227/14SEP2010// REF/D/PUB/NAVAIR 01-1A-17/15AUG2006// NARR/REF A IS THE NAVAL AVIATION MAINTENANCE PROGRAM REF B IS THE NAVAL AIR SYSTEMS COMMAND TECHNICAL MANUAL PROGRAM REF C IS THE TECHNICAL PUBLICATION DEFICIENCY REPORT REF D IS THE AVIATION HYDRAULICS MANUAL// POC/CRUSE, MARIA/-/FLTREADCEN SOUTHWEST SAN/LOC:6.8.5.1 //TEL:619-545-3646// GENTEXT/REMARKS/THIS MESSAGE WAS AUTO GENERATED FROM THE JDRS WEBSITE FOR NON-WEB SITE CAPABLE ORGANIZATIONS. THE REPORT WAS ORIGINATED BY: ------ FLTREADCEN EAST CHERRY POINT NC/V-22FST. IF RESPONSE VIA WEB SITE IS NOT POSSIBLE, TO: LINE RECIPIENTS SHOULD ADDRESS RESPONSE DIRECTLY TO: ------ FLTREADCEN EAST CHERRY POINT NC/V-22FST WHEN APPROPRIATE. THIS DEFICIENCY REPORT WILL BE PROCESSED VIA THE JDRS WEBSITE. FOR FURTHER DETAILS OR REAL TIME STATUS VISIT THE JDRS WEB SITE AT: JDRS.MIL. 1. IRAC 014 TO 01-1A-17 DTD 15-AUG-2006 WITH NOTICE 1 OF 02-AUG-2008 2. PURPOSE OF CHANGE: WP009 00 CURRENTLY REQUIRES A WATER CONTENT ANALYSIS WHICH IS NO LONGER REQUIRED. THE ONLY REQUIREMENT IS TO VISUALLY INSPECT FOR WATER. 3. DETAILED INFORMATION: PEN AND INK CHANGES TO THE TECHNICAL CONTENT OF A MANUAL ARE NOT AUTHORIZED. THE FOLLOWING TECHNICAL CONTENT CHANGE INFORMATION APPLIES TO THE FOLLOWING REFERENCED PAGES AND PARAGRAPHS OF THE SUBJECT MANUAL UNTIL THE FORMAL CHANGE IS RELEASED.

1. IN REFERENCE (D) WP009 00 PAGE 5 - DELETE PARAGRAPH 11A AND REPLACE WITH "ALL HYDRAULIC SE RESERVOIRS SHALL BE SAMPLED, PREFERABLY AT A LOW POINT DRAIN, AND ANALYZED FOR PARTICULATE CONTENT AND VISUALLY INSPECTED FOR WATER." 2. IN REFERENCE (D) WP009 00 PAGE 6 TABLE 1 - UNDER CHEMICAL ANALYSIS (DEPOT) TEST METHOD, DELETE "WATER-IN EXCESS OF (NOTE 1) PPM" FROM ABNORMAL INDICATION COLUMN AND "FLUSH" FROM DECONTAMINATION METHOD REQUIRED COLUMN.

4. VALIDATED BY: M K CRUSE, FRCSW, 6.8.5.1, 619-545-3646, 735-3646, [email protected] 5. RELATED INSTRUCTIONS: A. FOR IRACS AFFECTING MANUALS IN PAPER COPY - MAINTAIN THIS IRAC WITH THE APPLICABLE MANUAL BY PLACING OR ATTACHING IT DIRECTLY BEHIND THE TITLE PAGE. MARK THE SPECIFIC AREA AFFECTED AND ANNOTATE THE CHANGED PAGE OR CARD LISTED ON THE A PAGE WITH A VERTICAL LINE IN THE MARGIN NEXT TO THE CHANGED DATA, OPPOSITE THE BINDING. FOR DOUBLE COLUMN MATERIAL, MARK THE CENTER MARGIN WHEN THE INNER PARAGRAPH IS AFFECTED. NOTE THE IRAC NUMBER IN THE MARGIN. THIS IRAC SHALL NOT BE REMOVED UNTIL RECEIPT OF FORMAL CHANGE PAGES.


UNCLASSIFIED// R 101840Z APR 12 IRAC 013 TO 01-1A-17 DTD 15-AUG-2006 WITH NOTICE 1 OF/ COMNAVAIRSYSCOM PATUXENT RIVER MD TO AIG 423 FLTREADCEN EAST CHERRY POINT NC//V-22FST// INFO COMNAVAIRSYSCOM PATUXENT RIVER MD//DRPO// COMNAVAIRWARCENACDIV PATUXENT RIVER MD FLTREADCEN EAST CHERRY POINT NC//V-22FST// UNCLAS//N05600// MSGID/GENADMIN/MIL-STD-6040(SERIES)/B.0.01.00 /COMNAVAIRSYSCOM PAX DRPO/-/-/-/-/USA/UNCLASSIFIED// SUBJ/IRAC 013 TO 01-1A-17 DTD 15-AUG-2006 WITH NOTICE 1 OF/ /02-AUG-2008// REF/A/DOC/COMNAVAIRFORINST 4790.2A/10NOV2009// REF/B/PUB/NAVAIR 00-25-100/12DEC2009// REF/C/DOC/N65923-10-0454/23FEB2011// REF/D/PUB/NAVAIR 01-1A-17/15AUG2006// NARR/REF A IS THE NAVAL AVIATION MAINTENANCE PROGRAM REF B IS THE NAVAL AIR SYSTEMS COMMAND TECHNICAL MANUAL PROGRAM REF C IS THE TECHNICAL PUBLICATION DEFICIENCY REPORT REF D IS THE AVIATION HYDRAULICS MANUAL// POC/CRUSE, MARIA/-/FLTREADCEN SOUTHWEST SAN/LOC:6.8.5.1 //TEL:619-545-3646// GENTEXT/REMARKS/THIS MESSAGE WAS AUTO GENERATED FROM THE JDRS WEBSITE FOR NON-WEB SITE CAPABLE ORGANIZATIONS. THE REPORT WAS ORIGINATED BY: ------ FLTREADCEN EAST CHERRY POINT NC/V-22FST. IF RESPONSE VIA WEB SITE IS NOT POSSIBLE, TO: LINE RECIPIENTS SHOULD ADDRESS RESPONSE DIRECTLY TO: ------ FLTREADCEN EAST CHERRY POINT NC/V-22FST WHEN APPROPRIATE. THIS DEFICIENCY REPORT WILL BE PROCESSED VIA THE JDRS WEBSITE. FOR FURTHER DETAILS OR REAL TIME STATUS VISIT THE JDRS WEB SITE AT: JDRS.MIL. 1. IRAC 013 TO 01-1A-17 DTD 15-AUG-2006 WITH NOTICE 1 OF 02-AUG-2008 2. PURPOSE OF CHANGE: TO ADD/CLARIFY 3. DETAILED INFORMATION: PEN AND INK CHANGES TO THE TECHNICAL CONTENT OF A MANUAL ARE NOT AUTHORIZED. THE FOLLOWING TECHNICAL CONTENT CHANGE INFORMATION APPLIES TO THE FOLLOWING REFERENCED PAGES AND PARAGRAPHS OF THE SUBJECT MANUAL UNTIL THE FORMAL CHANGE IS RELEASED. IN WP004 00 PAGE 4 PARAGRAPH 23 OF REFERENCE (D), ADD "OPERATORS OF THE ELECTRONIC PARTICLE COUNTER MUST BE TRAINED BY A NATEC REPRESENTATIVE OR A QUALIFIED OPERATOR." 4. VALIDATED BY: M. K. CRUSE, FRCSW, 6.8.5.1, 619-545-3646, 735-3646, [email protected] 5. RELATED INSTRUCTIONS: A. FOR IRACS AFFECTING MANUALS IN PAPER COPY - MAINTAIN THIS IRAC WITH THE APPLICABLE MANUAL BY PLACING OR ATTACHING IT DIRECTLY BEHIND THE TITLE PAGE. MARK THE SPECIFIC AREA AFFECTED AND ANNOTATE THE CHANGED PAGE OR CARD LISTED ON THE A PAGE WITH A VERTICAL LINE IN THE MARGIN NEXT TO THE CHANGED DATA, OPPOSITE THE BINDING. FOR DOUBLE COLUMN MATERIAL, MARK THE CENTER MARGIN WHEN THE INNER PARAGRAPH IS AFFECTED. NOTE THE IRAC NUMBER IN THE MARGIN. THIS IRAC SHALL NOT BE REMOVED UNTIL RECEIPT OF FORMAL CHANGE PAGES. B. FOR IRACS AFFECTING MANUALS THAT ARE ON DIGITAL MEDIA - AFFIX AN ADHESIVE LABEL TO THE DIGITAL MEDIA CASE ANNOTATED WITH THE APPLICABLE PUBLICATION NUMBER AND IRAC NUMBER. THE LABEL SHOULD BE POSITIONED TO ALLOW FOR ADDITIONAL IRACS AS THEY OCCUR AND SHOULD NOT COVER THE DATE OR DIGITAL MEDIA TITLE. MAINTAIN THE IRAC ON FILE UNTIL RECEIPT OF THE SUPERSEDING DIGITAL MEDIA. C. SUBJECT IRAC SHALL BE INCORPORATED INTO APPLICABLE MANUAL NLT 12 MONTHS FROM THE DATE OF IRAC ISSUE. D.//


UNCLASSIFIED// R 101829Z APR 12 IRAC 012 TO 01-1A-17 DTD 15-AUG-2006 WITH NOTICE OF/ COMNAVAIRSYSCOM PATUXENT RIVER MD TO AIG 423 FLTREADCEN EAST CHERRY POINT NC//4.3// INFO COMNAVAIRSYSCOM PATUXENT RIVER MD//DRPO// COMNAVAIRWARCENACDIV PATUXENT RIVER MD FLTREADCEN EAST CHERRY POINT NC//4.3// UNCLAS//N05600// MSGID/GENADMIN/MIL-STD-6040(SERIES)/B.0.01.00 /COMNAVAIRSYSCOM PAX DRPO/-/-/-/-/USA/UNCLASSIFIED// SUBJ/IRAC 012 TO 01-1A-17 DTD 15-AUG-2006 WITH NOTICE OF/ /02-AUG-2008// REF/A/DOC/COMNAVAIRFORINST 4790.2A/10NOV2009// REF/B/PUB/NAVAIR 00-25-100/12DEC2009// REF/C/DOC/N65923-11-0723/07JUL2011// REF/D/PUB/NAVAIR 01-1A-17/15AUG2006// NARR/REF A IS THE NAVAL AVIATION MAINTENANCE PROGRAM REF B IS THE NAVAL AIR SYSTEMS COMMAND TECHNICAL MANUAL PROGRAM REF C IS THE TECHNICAL PUBLICATION DEFICIENCY REPORT REF D IS THE AVIATION HYDRAULICS MANUAL// POC/CRUSE, MARIA/-/FLTREADCEN SOUTHWEST SAN/LOC:6.8.5.1 //TEL:619-545-3646// GENTEXT/REMARKS/THIS MESSAGE WAS AUTO GENERATED FROM THE JDRS WEBSITE FOR NON-WEB SITE CAPABLE ORGANIZATIONS. THE REPORT WAS ORIGINATED BY: ------ FLTREADCEN EAST CHERRY POINT NC/V-22FST. IF RESPONSE VIA WEB SITE IS NOT POSSIBLE, TO: LINE RECIPIENTS SHOULD ADDRESS RESPONSE DIRECTLY TO: ------ FLTREADCEN EAST CHERRY POINT NC/V-22FST WHEN APPROPRIATE. THIS DEFICIENCY REPORT WILL BE PROCESSED VIA THE JDRS WEBSITE. FOR FURTHER DETAILS OR REAL TIME STATUS VISIT THE JDRS WEB SITE AT: JDRS.MIL. 1. IRAC 012 TO 01-1A-17 DTD 15-AUG-2006 WITH NOTICE OF 02-AUG-2008 2. PURPOSE OF CHANGE: TO CLARIFY INFORMATION. 3. DETAILED INFORMATION: PEN AND INK CHANGES TO THE TECHNICAL CONTENT OF A MANUAL ARE NOT AUTHORIZED. THE FOLLOWING TECHNICAL CONTENT CHANGE INFORMATION APPLIES TO THE FOLLOWING REFERENCED PAGES AND PARAGRAPHS OF THE SUBJECT MANUAL UNTIL THE FORMAL CHANGE IS RELEASED. REVISE THE NOTE IN WP009 00 PAGE 5 PRIOR TO PARAGRAPH 13 IN REFERENCE (D) TO READ AS FOLLOWS: NOTE PRIOR TO SAMPLING, OPERATE THE SE FOR A MINIMUM OF 5 MINUTES IN A MANNER THAT WILL RESULT IN FLUID FLOW THROUGH ITS RESERVOIR TO ENSURE UNIFORM DISTRIBUTION OF CONTAMINANTS. CERTAIN MODEL EQUIPMENT MAY REQUIRE RETURN OF THE PRESSURE OUTLET TO THE RESERVOIR FILL OPENING TO ACHIEVE SUCH FLOW. FOR HYDRAULIC FLUID SERVICING UNITS WITH A CAPACITY OF 3 GALLON OR LESS, A 5 MINUTE RECIRCULATION PERIOD IS NOT REQUIRED. HOWEVER, TO ENSURE A REPRESENTATIVE SAMPLE IS PULLED, PERFORM 5-6 PUMP STROKES ON THE EQUIPMENT PRIOR TO SAMPLING.

4. VALIDATED BY: M K CRUSE, FRCSW, 6.8.5.1, 619-545-3646, 735-3646, [email protected] 5. RELATED INSTRUCTIONS: A. FOR IRACS AFFECTING MANUALS IN PAPER COPY - MAINTAIN THIS IRAC WITH THE APPLICABLE MANUAL BY PLACING OR ATTACHING IT DIRECTLY BEHIND THE TITLE PAGE. MARK THE SPECIFIC AREA AFFECTED AND ANNOTATE THE CHANGED PAGE OR CARD LISTED ON THE A PAGE WITH A VERTICAL LINE IN THE MARGIN NEXT TO THE CHANGED DATA, OPPOSITE THE BINDING. FOR DOUBLE COLUMN MATERIAL, MARK THE CENTER MARGIN WHEN THE INNER PARAGRAPH IS AFFECTED. NOTE THE IRAC NUMBER IN THE MARGIN. THIS IRAC SHALL NOT BE REMOVED UNTIL RECEIPT OF FORMAL CHANGE PAGES.


UNCLASSIFIED// R 101747Z APR 12 IRAC 011 TO 01-1A-17 DTD 15-AUG-2006 WITH NOTICE 1 OF/ COMNAVAIRSYSCOM PATUXENT RIVER MD TO AIG 423 FLTREADCEN EAST CHERRY POINT NC//NA// INFO COMNAVAIRSYSCOM PATUXENT RIVER MD//DRPO// COMNAVAIRWARCENACDIV PATUXENT RIVER MD FLTREADCEN EAST CHERRY POINT NC//NA// UNCLAS//N05600// MSGID/GENADMIN/MIL-STD-6040(SERIES)/B.0.01.00 /COMNAVAIRSYSCOM PAX DRPO/-/-/-/-/USA/UNCLASSIFIED// SUBJ/IRAC 011 TO 01-1A-17 DTD 15-AUG-2006 WITH NOTICE 1 OF/ /02-AUG-2008// REF/A/DOC/COMNAVAIRFORINST 4790.2A/10NOV2009// REF/B/PUB/NAVAIR 00-25-100/12DEC2009// REF/C/DOC/N65923-10-0220/09SEP2010// REF/D/PUB/NAVAIR 01-1A-17/15AUG2006// NARR/REF A IS THE NAVAL AVIATION MAINTENANCE PROGRAM REF B IS THE NAVAL AIR SYSTEMS COMMAND TECHNICAL MANUAL PROGRAM REF C IS THE TECHNICAL PUBLICATION DEFICIENCY REPORT REF D IS THE AVIATION HYDRAULICS MANUAL// POC/CRUSE, MARIA/-/FLTREADCEN SOUTHWEST SAN/LOC:6.8.5.1 //TEL:619-545-3646// GENTEXT/REMARKS/THIS MESSAGE WAS AUTO GENERATED FROM THE JDRS WEBSITE FOR NON-WEB SITE CAPABLE ORGANIZATIONS. THE REPORT WAS ORIGINATED BY: ------ FLTREADCEN EAST CHERRY POINT NC/V-22FST. IF RESPONSE VIA WEB SITE IS NOT POSSIBLE, TO: LINE RECIPIENTS SHOULD ADDRESS RESPONSE DIRECTLY TO: ------ FLTREADCEN EAST CHERRY POINT NC/V-22FST WHEN APPROPRIATE. THIS DEFICIENCY REPORT WILL BE PROCESSED VIA THE JDRS WEBSITE. FOR FURTHER DETAILS OR REAL TIME STATUS VISIT THE JDRS WEB SITE AT: JDRS.MIL. 1. IRAC 011 TO 01-1A-17 DTD 15-AUG-2006 WITH NOTICE 1 OF 02-AUG-2008 2. PURPOSE OF CHANGE: TO CLARIFY. 3. DETAILED INFORMATION: PEN AND INK CHANGES TO THE TECHNICAL CONTENT OF A MANUAL ARE NOT AUTHORIZED. THE FOLLOWING TECHNICAL CONTENT CHANGE INFORMATION APPLIES TO THE FOLLOWING REFERENCED PAGES AND PARAGRAPHS OF THE SUBJECT MANUAL UNTIL THE FORMAL CHANGE IS RELEASED.

1. IN REFERENCE (D) WP004 00 PAGE 7 TABLE 2 REPLACE THE CURRENT CONTAMINATION LIMITS FOR MICRON SIZE RANGE 5-15 CLASSES 7 AND 8 (320000 AND 640000) WITH THE FOLLOWING LIMITS: CLASS 7: 32000 CLASS 8: 64000

4. VALIDATED BY: M K CRUSE, FRCSW, 6.8.5.1, 619-545-3646, 735-3646, [email protected] 5. RELATED INSTRUCTIONS: A. FOR IRACS AFFECTING MANUALS IN PAPER COPY - MAINTAIN THIS IRAC WITH THE APPLICABLE MANUAL BY PLACING OR ATTACHING IT DIRECTLY BEHIND THE TITLE PAGE. MARK THE SPECIFIC AREA AFFECTED AND ANNOTATE THE CHANGED PAGE OR CARD LISTED ON THE A PAGE WITH A VERTICAL LINE IN THE MARGIN NEXT TO THE CHANGED DATA, OPPOSITE THE BINDING. FOR DOUBLE COLUMN MATERIAL, MARK THE CENTER MARGIN WHEN THE INNER PARAGRAPH IS AFFECTED. NOTE THE IRAC NUMBER IN THE MARGIN. THIS IRAC SHALL NOT BE REMOVED UNTIL RECEIPT OF FORMAL CHANGE PAGES. B. FOR IRACS AFFECTING MANUALS THAT ARE ON DIGITAL MEDIA - AFFIX AN ADHESIVE LABEL TO THE DIGITAL MEDIA CASE ANNOTATED WITH THE APPLICABLE PUBLICATION NUMBER AND IRAC NUMBER. THE LABEL SHOULD BE POSITIONED TO ALLOW FOR ADDITIONAL IRACS AS THEY OCCUR AND SHOULD NOT COVER THE DATE OR DIGITAL MEDIA TITLE. MAINTAIN THE IRAC ON FILE UNTIL RECEIPT OF THE SUPERSEDING DIGITAL MEDIA. C. SUBJECT IRAC SHALL BE INCORPORATED INTO APPLICABLE MANUAL NLT 12 MONTHS FROM THE DATE OF IRAC ISSUE. D.//


UNCLASSIFIED// R 101742Z APR 12 IRAC 010 TO 01-1A-17 DTD 15-AUG-2006 WITH NOTICE 1 OF/ COMNAVAIRSYSCOM PATUXENT RIVER MD TO AIG 423 FLELOGSUPPRON FIVE FIVE//MO// COMFLELOGSUPPWING FORT WORTH TX FLTREADCEN EAST CHERRY POINT NC//040// INFO COMNAVAIRSYSCOM PATUXENT RIVER MD//DRPO// COMNAVAIRWARCENACDIV PATUXENT RIVER MD FLELOGSUPPRON FIVE FIVE//MO// UNCLAS//N05600// MSGID/GENADMIN/MIL-STD-6040(SERIES)/B.0.01.00 /COMNAVAIRSYSCOM PAX DRPO/-/-/-/-/USA/UNCLASSIFIED// SUBJ/IRAC 010 TO 01-1A-17 DTD 15-AUG-2006 WITH NOTICE 1 OF/ /02-AUG-2008// REF/A/DOC/COMNAVAIRFORINST 4790.2A/10NOV2009// REF/B/PUB/NAVAIR 00-25-100/12DEC2009// REF/C/DOC/N53855-10-0008/05JAN2011// REF/D/PUB/NAVAIR 01-1A-17/15AUG2006// NARR/REF A IS THE NAVAL AVIATION MAINTENANCE PROGRAM REF B IS THE NAVAL AIR SYSTEMS COMMAND TECHNICAL MANUAL PROGRAM REF C IS THE TECHNICAL PUBLICATION DEFICIENCY REPORT REF D IS THE AVIATION HYDRAULICS MANUAL// POC/CRUSE, MARIA/-/FLTREADCEN SOUTHWEST SAN/LOC:6.8.5.1 //TEL:619-545-3646// GENTEXT/REMARKS/THIS MESSAGE WAS AUTO GENERATED FROM THE JDRS WEBSITE FOR NON-WEB SITE CAPABLE ORGANIZATIONS. THE REPORT WAS ORIGINATED BY: ------ FLTREADCEN EAST CHERRY POINT NC/V-22FST. IF RESPONSE VIA WEB SITE IS NOT POSSIBLE, TO: LINE RECIPIENTS SHOULD ADDRESS RESPONSE DIRECTLY TO: ------ FLTREADCEN EAST CHERRY POINT NC/V-22FST WHEN APPROPRIATE. THIS DEFICIENCY REPORT WILL BE PROCESSED VIA THE JDRS WEBSITE. FOR FURTHER DETAILS OR REAL TIME STATUS VISIT THE JDRS WEB SITE AT: JDRS.MIL. 1. IRAC 010 TO 01-1A-17 DTD 15-AUG-2006 WITH NOTICE 1 OF 02-AUG-2008 2. PURPOSE OF CHANGE: CORRECTING PART NUMBER. 3. DETAILED INFORMATION: PEN AND INK CHANGES TO THE TECHNICAL CONTENT OF A MANUAL ARE NOT AUTHORIZED. THE FOLLOWING TECHNICAL CONTENT CHANGE INFORMATION APPLIES TO THE FOLLOWING REFERENCED PAGES AND PARAGRAPHS OF THE SUBJECT MANUAL UNTIL THE FORMAL CHANGE IS RELEASED. IN WP004 00 PAGE 4 PARAGRAPH 23 OF REFERENCE (D), REPLACE MXU-937E LISTED IN THE SECOND SENTENCE WITH MXU-973E.

4. VALIDATED BY: M. K. CRUSE, FRCSW, 6.8.5.1, 619-545-3646, 735-3646, [email protected] 5. RELATED INSTRUCTIONS: A. FOR IRACS AFFECTING MANUALS IN PAPER COPY - MAINTAIN THIS IRAC WITH THE APPLICABLE MANUAL BY PLACING OR ATTACHING IT DIRECTLY BEHIND THE TITLE PAGE. MARK THE SPECIFIC AREA AFFECTED AND ANNOTATE THE CHANGED PAGE OR CARD LISTED ON THE A PAGE WITH A VERTICAL LINE IN THE MARGIN NEXT TO THE CHANGED DATA, OPPOSITE THE BINDING. FOR DOUBLE COLUMN MATERIAL, MARK THE CENTER MARGIN WHEN THE INNER PARAGRAPH IS AFFECTED. NOTE THE IRAC NUMBER IN THE MARGIN. THIS IRAC SHALL NOT BE REMOVED UNTIL RECEIPT OF FORMAL CHANGE PAGES. B. FOR IRACS AFFECTING MANUALS THAT ARE ON DIGITAL MEDIA - AFFIX AN ADHESIVE LABEL TO THE DIGITAL MEDIA CASE ANNOTATED WITH THE APPLICABLE PUBLICATION NUMBER AND IRAC NUMBER. THE LABEL SHOULD BE POSITIONED TO ALLOW FOR ADDITIONAL IRACS AS THEY OCCUR AND SHOULD NOT COVER THE DATE OR DIGITAL MEDIA TITLE. MAINTAIN THE IRAC ON FILE UNTIL RECEIPT OF THE SUPERSEDING DIGITAL MEDIA. C. SUBJECT IRAC SHALL BE INCORPORATED INTO APPLICABLE MANUAL NLT 12 MONTHS FROM THE DATE OF IRAC ISSUE. D.//


NAVAIR 01-1A-17 TO 42B2-1-12 Change 1 – 1 August 2008 TPDR-1/(TPDR-2 Blank)


LIST OF TECHNICAL PUBLICATIONS DEFICIENCY REPORTS INCORPORATED

AVIATION HYRDRAULICS MANUAL

NAVY USE ONLY

1. The TPDRs listed below have been incorporated in this issue.

IDENTIFICATION NUMBER/ QA SEQUENCE NUMBER LOCATION*

09823-06-0015, HSC-25 Page A

39783-06-0089, VX-23 Title Page and Page A

4143A-07-0079, FRC MA SITE PAXR WP009 00

44487-07-0047, FRC West Fort Worth, TX WP008 00

53998-06-0065, HMH-466 Title Page

55140-06-0092, VAQRON 142 Page A

*Location-work package (WP), figure no. (F) shall be indicated as appropriate.

NAVAIR 01-1A-17 HMWS-1 TO 42B2-1-12 1 January 2006

WARNINGS APPLICABLE TO HAZARDOUS MATERIALS

Warnings for hazardous materials listed in this manual are designed to warn personnel of hazards associated with such items when they come in contact with them by actual use. Additional information related to hazardous materials is provided in OPNAVINST 5100.23, Navy Occupational Safety and Health (NAVOSH) Program Manual, NAVSUPINST 5100.27, Navy Hazardous Material Control Program, and the DOD 6050.5, Hazardous Materials Information System (HMIS) series publications. For each hazardous material used within the Navy, a Material Safety Data Sheet (MSDS) is required to be provided and available for review by users. Consult your local safety and health staff concerning any questions on hazardous chemicals, MSDSs, personal protective equipment requirements and appropriate handling and emergency procedures and disposal guidance.

Complete warnings for hazardous materials referenced in this manual are identified by use of an icon, nomenclature and specification or part number of the material, and a numeric identifier. The numeric identifiers have been assigned to the hazardous materials in the order of their appearance in the manual. Each hazardous material is assigned only one numeric identifier. Repeated use of a specific hazardous material references the numeric identifier assigned at its initial appearance. The approved icons and their applications are shown in the Explanation of Hazardous Materials.

In the text of the manual, the caption “WARNING” will not be used for hazardous materials. Such warnings will be identified by an icon and numeric identifier. The material nomenclature will also be provided. The user is directed to refer to the corresponding numeric identifier listed in this WP under the heading HAZARDOUS MATERIALS WARNINGS for the complete warning applicable to the hazardous material.

EXPLANATION OF HAZARDOUS SYMBOLS

Biological

The abstract symbol shows a material that may contain bacteria or viruses that present a health hazard.

Chemical

The symbol of drops of a liquid burning a hand shows a material that causes burns to human skin or tissue.

Cryogenic

The symbol of a hand in a block of ice shows a material is so cold it will burn your skin on contact.

Explosion

The rapidly expanding symbol shows that the material may explode if subjected to high temperature, sources of ignition, or high pressure.

Eye Protection

The symbol of a person wearing goggles shows a material that can injure your eyes.

NAVAIR 01-1A-17 HMWS-2 TO 42B2-1-12

EXPLANATION OF HAZARDOUS SYMBOLS (Cont)

Fire

The symbol of a fire shows that a material can ignite and burn you.

Poison

The symbol of a skull and crossbones shows a material that is highly toxic and can be a danger to life and health.

Radiation

The symbol of three circular wedges shows that the material emits radioactive energy and can injure human tissue or organs.

Vapor

The symbol of a human figure in a cloud shows that breathing this material can present a health hazard.


HAZARDOUS MATERIALS WARNINGS

Index Material Warning

1 Hydraulic Fluid, MIL-PRF-5606

If hydraulic fluid is decomposed by heat, toxic gases are released. Prolonged contact with liquid or mist can cause dermatitis and irritation to skin and eyes. If there is any prolonged contact with skin, wash contacted area with soap and water. If prolonged contact with mist is likely, wear approved respirator. Hydraulic fluid is toxic if swallowed. Wash hands after handling and before eating, drinking or smoking. PPE: Chemical splash proof goggles and gloves. Consult the applicable Material Safety Data Sheet (MSDS) and local Occupational Safety and Health (OSH) regulations for appropriate safety precautions.



3 Hydraulic Fluid, MIL-H-81019



HAZARDOUS MATERIALS WARNINGS (Cont)




5 Hydraulic Fluid, SAE AS1241

If hydraulic fluid is decomposed by heat, toxic gases are released. Prolonged contact with liquid or mist can cause dermatitis and irritation to skin and eyes. If there is any prolonged contact with skin, wash contacted area with soap and water. If prolonged contact with mist is likely, wear approved respirator. Hydraulic fluid is toxic if swallowed. Wash hands after handling and before eating, drinking or smoking. PPE: Chemical splash proof goggles and gloves. Consult the applicable Material Safety Data Sheet (MSDS) and local Occupational Safety and Health (OSH) regulations for appropriate safety precautions. Many contain a neurotoxin that can be absorbed through the intact skin. Symptoms of overexposure include tingling or numbness in hands or feet. These are fire resistant aircraft hydraulic fluids identified by NATO Code H-580. They have an operating temperature of -65EF (-54EC) to 225EF (106EC). These hydraulic fluids are not mixable with MIL-PRF-5606, MIL-PRF-87257 or MIL-PRF-83282 hydraulic fluids and cannot be used with synthetic (Buna N) rubber seals used in hydraulic systems designed to operate on MIL-PRF-5606.

6 Dry Cleaning Solvent, MIL-PRF-680

Dry Cleaning Solvent, MIL-PRF-680, may cause eye and skin irritation. Overexposure may cause dizziness and other central nervous system effects. Wear nitrile gloves and chemical splash proof protective goggles. Consult the applicable Material Safety Data Sheet (MSDS) and local Occupational Safety and Health (OSH) regulations for appropriate safety precautions.




7 Aircraft External Cleaning Compound, MIL-PRF-85570, Type II

Aircraft Cleaning Compound, MIL-PRF-85570, is irritating to skin and eyes. Prolonged contact may cause dermatitis. Wear chemical splash proof goggles and gloves. Use only with adequate ventilation. Consult the applicable Material Safety Data Sheet (MSDS) and local Occupational Safety and Health (OSH) regulations for appropriate safety precautions.

8 Detergent, Non-Ionic, MIL-D-16791

Non-ionic detergent, MIL-D-16791, Type I, may irritate skin and eyes. Avoid contact. Wear gloves and chemical splash proof safety glasses. Consult the applicable Material Safety Data Sheet (MSDS) and local Occupational Safety and Health (OSH) regulations for appropriate safety precautions.

9 Isopropyl Alcohol, TT-I-735

Isopropyl Alcohol, TT-I-735, is flammable. Do not use near open flame or other sources of ignition. May irritate skin and eyes. Inhalation may cause dizziness, headaches and irritation to respiratory tract. Wear chemical splash proof goggles and gloves. Consult the applicable Material Safety Data Sheet (MSDS) and local Occupational Safety and Health (OSH) regulations for appropriate safety precautions.

10 Molydisulphide Grease, MIL-G-21164

Molydisulphide Grease, MIL-G-21164, may cause skin irritation. Avoid contact with skin and eyes. Wear nitrile gloves and safety glasses. Consult the applicable Material Safety Data Sheet (MSDS) and local Occupational Safety and Health (OSH) regulations for appropriate safety precautions.

11 General Purpose Aircraft Grease, MIL-PRF-81322

General Purpose Aircraft Grease, MIL-PRF-81322, is an eye irritant and, upon prolonged exposure, a skin irritant. May contain chromates, suspected carcinogens. Keep away from oxidizing agents. Wear gloves and safety glasses. Manufacturers’ hazards may vary. Always consult proper MSDS.




12 General Purpose Aircraft Grease, MIL-PRF-32014

Grease, MIL-PRF-32014, may cause skin irritation. Avoid contact with skin and eyes. Wear nitrile gloves and safety glasses. Consult the applicable Material Safety Data Sheet (MSDS) and local Occupational Safety and Health (OSH) regulations for appropriate safety precautions.

13 Test Filter Patch Membrane SMWP04700 and SMWP02500

Do not dispose of test filter patch membranes in ashtrays or other receptacles where the temperature will exceed 121EC (250EF). Flash fires occur when filters are exposed to flame temperature.

14 Dry Cleaning Solvent, A-A-59601

Dry Cleaning Solvent, A-A-59601, may cause eye and skin irritation. Overexposure may cause dizziness and other central nervous system effects. Wear nitrile gloves and chemical splash proof protective goggles. Consult the applicable Material Safety Data Sheet (MSDS) and local Occupational Safety and Health (OSH) regulations for appropriate safety precautions.

NAVAIR 01-1A-17 001 00 TO 42B2-1-12 15 August 2006 Page 1/(2 blank)


ALPHABETICAL INDEX


WP Title Number

Aircraft System Decontamination....................................................................................................... 006 00 Alphabetical Index.............................................................................................................................. 001 00 Controlled Environment Work Center (NAVY USE ONLY) ............................................................... 011 00 Description, Hydraulic Systems and Hydraulic Fluids ....................................................................... 003 00 Hydraulic Contamination Control (NAVY USE ONLY) ...................................................................... 007 00 Hydraulic Filters ................................................................................................................................. 010 00 Hydraulic Fluid Contamination ........................................................................................................... 004 00 Hydraulic Fluid Contamination Analysis............................................................................................. 005 00 Hydraulic Fluid Contamination Analysis Kit (P/N 57L414) (NAVY USE ONLY)................................ 017 00 Hydraulic Seals .................................................................................................................................. 015 00 Hydraulic Support Equipment (NAVY USE ONLY) ........................................................................... 009 00 Introduction ........................................................................................................................................ 002 00 Phosphate Ester Hydraulic Fluid........................................................................................................ 016 00 Protective Closures (NAVY USE ONLY) ........................................................................................... 014 00 Repair, Test, and Maintenance of Hydraulic Systems and Components (NAVY USE ONLY) ......... 013 00 Selection and Use of Cleaning Materials ........................................................................................... 012 00 Servicing Hydraulic Systems.............................................................................................................. 008 00

NAVAIR 01-1A-17 002 00 TO 42B2-1-12 15 August 2006 Page 1 of 26


INTRODUCTION


1. PURPOSE.

2. The purpose of this manual is to provide general requirements for maintenance of aircraft hydraulic systems and related support equipment (SE).

3. SCOPE.

4. This manual is applicable to all military aircraft hydraulic systems, airborne hydraulic equipment, and related hydraulic servicing and test equipment. It is required reading for all military and civilian personnel at all levels of maintenance, performing any hydraulic maintenance function on military aircraft systems, airborne hydraulic equipment and related SE.

5. APPLICATION.

6. This manual is applicable to all military aircraft hydraulic systems, airborne hydraulic equipment, and related hydraulic servicing and test equipment, including SE, peculiar support equipment (PSE), common support equipment (CSE) and facilities or installed equipment. This manual is not applicable to missile systems, propeller systems and their related SE. It is applicable to all levels of maintenance, including contract maintenance performed by other Government agencies on military aircraft, and associated airborne hydraulic equipment and related SE. Engineering personnel and technical data writers shall comply with the general requirement of this manual. When a conflict exists, this manual takes precedence over other NAVAIR directives, engineering directives, and maintenance instructions. Maintenance activities shall contact the applicable Fleet Support Team (FST) for immediate resolution of the conflict.

7. The Air Force specific systems/components manuals shall take precedence over this manual.

NOTE

Hydraulic fluids in propeller systems and air refueling stores are exempt from the cleanliness requirements in WP004 00. However, hydraulic servicing and hydraulic filter handling procedures shall

be followed as specified in WP008 00 thru WP010 00.

8. Maintenance instructions provided in this manual relate to hydraulic systems utilizing hydraulic fluids MIL-PRF-5606 (Table 3, item 1), MIL-PRF-83282 (Table 3, item 2), MIL-H-81019 (Table 3, item 3), and MIL-PRF-87257 (Table 3, Item 4). Some military aircraft employ phosphate ester hydraulic fluids (Table 3, Item 5). This in some cases, results in maintenance procedures and materials peculiar to these aircraft. Refer to WP016 00 for specific information regarding phosphate ester hydraulic fluid and those systems which employ this fluid.

9. REQUISITION AND AUTOMATIC DISTRIBUTION OF NAVAIR TECHNICAL MANUALS.

10. Procedures to be used by Naval activities and other Department of Defense activities requiring NAVAIR technical manuals are defined in NAVAIR 00-25-100 and NAVAIRINST 5605.5 Series.

11. To automatically receive future changes and revisions to NAVAIR technical manuals, an activity must be established on the Automatic Distribution Requirements List (ADRL) maintained by the Naval Air Technical Data and Engineering Service Command (NATEC). To become established on the ADRL, notify your activity central technical publications librarian. If your activity does not have a library, you may establish your automatic distribution by contacting the Commanding Officer, NATEC, Attn: Distribution, NAS North Island, Bldg. 90, P.O. Box 357031, San Diego, CA 92135-7031. Annual reconfirmation of these requirements is necessary to remain on automatic distribution. Please use your NATEC assigned account number whenever referring to automatic distribution requirements.

12. If additional or replacement copies of this manual are required with no attendant changes in the ADRL, they may be ordered by submitting a MILSTRIP requisition in accordance with NAVSUP 485 to Routing Identifier Code “NFZ”. MILSTRIP requisitions can be submitted through your supply

NAVAIR 01-1A-17 002 00 TO 42B2-1-12 Page 2 office, Navy message, or SALTS to DAAS (Defense Automated Address System), or through the DAAS or NAVSUP web sites. For assistance with a MILSTRIP requisition, contact the Naval Inventory Control Point (NAVICP) Publications and Forms Customer Service at DSN 442-2626 or (215) 697-2626, Monday through Friday, 0700 to 1600 Eastern Time.

13. MANUAL ISSUE DATE.

14. The date on the title page is the copy freeze date. No additions, deletions, or changes are made after the manual issue date except last minute safety of flight or required maintenance changes. Data collected after the manual issue date will be included in later changes or revisions of the manual.

15. EFFECTIVITIES.

16. Effectivity notes on manual title pages, work package title pages, and within a work package indicate the equipment model to which the data applies. If no effectivity note appears on the work package title page, the work package has the same effectivity as shown on the manual title page.

17. QUALITY ASSURANCE PROCEDURES.

18. Improper performance of certain procedures or steps in this manual may cause equipment failure or personnel hazards. Procedures or parts of procedures which require quality assurance inspection are identified by the letters (QA) after the applicable steps. When (QA) is assigned to a step or a heading which is immediately followed by substeps, the inspection requirement is applicable to all substeps. Proper performance of the step(s) shall be verified by a Quality Assurance representative (CDI-CDQAR-QAR-QA) as established within the Naval Aviation Maintenance Program (COMNAVAIRFORINST 4790.2 Series) prior to proceeding to the next operation, unless it can be determined that such an inspection can be performed after completing the entire procedure.

19. SAFETY SUMMARY.

20. The following general safety precautions are not related to any specific procedure and therefore do not appear elsewhere in this publication. These are precautions that personnel must understand and apply during all phases of operation and maintenance.

21. KEEP AWAY FROM LIVE CIRCUITS. Operating personnel must observe safety precautions at all times. Do not replace components or make adjustments inside any equipment with the high

voltage supply turned on. Under certain conditions, dangerous potentials may exist when the power control is in the off position, due to charges retained by capacitors. To avoid casualties, always remove power, discharge, and ground a circuit before touching it.

22. DO NOT SERVICE OR ADJUST ALONE. Under no circumstance shall any person reach into or enter an enclosure for the purpose of servicing or adjusting the equipment, except in the presence of someone who is capable of rendering aid.

23. RESUSCITATION. Personnel working with or near high voltages should be familiar with modern methods of resuscitation. Such information may be obtained from the Bureau of Medicine and Surgery.

24. ENGINE NOISE. Personnel must observe the following precautions when working within danger areas of jet engines.

a. Wear the proper protection (earplugs and/or earmuffs).

b. Do not exceed the time limits of exposure to various sound intensities.

c. Have periodic checks on hearing ability.

The wearing of regulation earplugs or earmuffs will raise the time limits of exposure. All personnel working within danger areas should be familiar with calculated sound levels (as specified in the general information section of applicable Maintenance Instruction Manual or Technical Order) and should wear the necessary protection equipment.

25. FLIGHT LINE SAFETY PRECAUTIONS. Personnel working in or around aircraft on the flight line shall observe flight line safety precautions and regulations.

26. USE SAFETY SHIELDS. Observe applicable safety regulations and use safety shields on power tools where provided. Adequate shielding to protect eyes and face shall be used at all times when operating power tools or performing pressure tests.

27. HANDLING FLUIDS AND GASES. Observe applicable safety precautions when using fluids or gases which are flammable or toxic. Do not use gases or fluids which are not positively identified.

WARNING

Extreme caution shall be taken when

NAVAIR 01-1A-17 002 00 TO 42B2-1-12 Page 3

troubleshooting hydraulic systems under pressure to avoid accidental injection of fluid under the skin. Fluid injection can result in serious injury and great pain; get immediate medical attention.

28. SEAT EJECTION MECHANISMS. Safety precautions shall be strictly observed when working around aircraft equipped with an ejection seat. These safety precautions cannot be overemphasized. Each ejection seat has several ground safety pins. These safety pins are provided on red-flagged lanyards for use at every point of potential danger. They shall be installed whenever the aircraft is on the ground or deck, and must never be removed until the aircraft is ready for flight. The following general precautions should always be kept in mind.

a. Ejection seats shall be treated with the same respect as a loaded gun.

b. Always consider an ejection seat system as loaded and armed.

29. WARNINGS, CAUTIONS, AND NOTES.

30. Warning, cautions, and notes will be found throughout the manual in various procedures. It is important that the significance of each be thoroughly understood by personnel using this manual. Their definitions are:

Indicates a procedure, practice, etc., which will result in personal injury or loss of life if not correctly followed.

Indicates a procedure or practice which, if not strictly observed, will result in damage or destruction of equipment.

NOTE

Highlights an essential procedure to ensure correct maintenance.

31. ABBREVIATIONS.

32. Abbreviations used in this manual are listed in Table 1.

33. GLOSSARY.

34. For a glossary of terms used in this manual, refer to Table 2.

35. GRAPHIC SYMBOLS FOR FLUID POWER DIAGRAMS.

NOTE

Aircraft symbols may vary with different manufacturers.

36. Types of symbols commonly used in drawing circuit diagrams for fluid power systems are Pictorial, Cutaway and Graphic. Pictorial and Cutaway symbols have been in widespread usage for many years and should be readily familiar to all hydraulic maintenance personnel. Graphic symbols, which emphasize the function and methods of operation of components, provide a very effective means of depicting system configuration and as a result are being utilized with increasing frequency. Figure 1 illustrates commonly used symbols that may be encountered in hydraulic schematic diagrams employing graphic symbols and is provided as reference data. The symbols shown have been extracted from SAE AS1290 and USA Standard Graphic Symbols for Fluid Power Diagrams (USAS Y32.10-1967) with the permission of the publisher. The American Society of Mechanical Engineers United Engineering Center, 345 E. 47th Street, New York, NY 10017.

37. CONSUMABLE MATERIALS.

38. Table 3 lists the consumable materials used in this manual.

39. RELATED PUBLICATIONS.

40. In many instances, procedures called out in this manual can best be performed in conjunction with other system or component manuals and directives, as listed in Table 4.

NAVAIR 01-1A-17 002 00 TO 42B2-1-12 Page 4

Table 1. Abbreviations

Abbreviation Definition

ADRL Automatic Distribution Requirements List

AFPET Air Force Petroleum Office

AMMRL Aircraft Maintenance Material Readiness List

ASG Aircraft Sustainment Group

COMNAVAIRFORINST Commander Naval Air Forces Instruction

CSE Common Support Equipment

FST Fleet Support Team

gpm Gallons Per Minute

GSE Ground Support Equipment

IMA Intermediate Maintenance Activity

MIM Maintenance Instruction Manual

ml Milliliter

MRC Maintenance Requirement Cards

MSDS Material Safety Data Sheet

NADEP Naval Air Depot

NAMPSOP Naval Aviation Maintenance Program Standard Operating Procedures

NATEC Naval Air Technical Data and Engineering Service Command

NAVAIR Naval Air Systems Command

NAWCAD Naval Air Warfare Center, Aircraft Division

NOAP Naval Oil Analysis Program

OMA Organizational Maintenance Activity

OSH Occupational Safety and Health

QA Quality Assurance

PODS Portable Oil Diagnostic System

NAVAIR 01-1A-17 002 00 TO 42B2-1-12 Page 5

Table 1. Abbreviations (Cont)

PSE Peculiar Support Equipment

ppm Parts Per Million

SE Support Equipment

TLV Threshold Limit Values

TO Technical Order

TPDR Technical Publication Deficiency Report

NAVAIR 01-1A-17 002 00 TO 42B2-1-12 Page 6

Table 2. Glossary

Term Definition

Air Bleeding A service operation in which entrapped air is allowed to escape from the closed hydraulic system.

Aircraft Sustainment Group Air Force engineering group who provides engineering assistance to resolve discrepancies noted by the fleet community.

Backup Ring A device used to prevent pressure and friction from extruding the O-ring packing through the clearance gap of a seal.

Cavitation A localized gaseous condition within a liquid stream which occurs where the pressure is reduced to the vapor pressure.

Cognizant Engineering Activity The Navy or Air Force activity which has been assigned the responsibility and delegated the authority to perform specific engineering functions. Such responsibilities may be assumed by Naval Air System Command Headquarters (NAVAIR) or delegated to a Fleet Support Team (FST) or Aircraft Sustainment Group (ASG).

Contaminant Any material or substance which is undesired or capable of adversely affecting the hydraulic system or its components.

Contaminant, Built-In Initial residual contamination in a component, fluid, or system. Typical built-in contaminants are buns, chips, flash, dirt, dust, fiber, sand, moisture, pipe dope, weld spatter, paints and solvents, incompatible fluids and operating fluid impurities.

Contamination Level A quantitative term specifying the degree of contamination.

Contamination, Gross A level of contamination which exceeds Class 6 of Navy Standard or NAS 1638 Class 12 and is considered abnormally high as a result of either the amount or size of the contaminants present.

Controlled Environment Work Center An enclosed workspace, room, or facility in which humidity and filtered inlet air are controlled.

De-aerate To remove free, entrained, or dissolved gas from a fluid filled system.

Decontamination The process of removing unwanted material or substances; the reduction of contamination to an acceptable level.

NAVAIR 01-1A-17 002 00 TO 42B2-1-12 Page 7

Table 2. Glossary (Cont)

Term Definition

Depot Maintenance That maintenance performed on material requiring major overhaul or a complete rebuild of parts, assemblies, subassemblies, and end items. It includes the manufacture of parts, modifications, testing, and reclamation of parts, as required. Depot maintenance serves to support lower levels of maintenance by providing technical assistance and performing that maintenance beyond the responsibility and capability of Organizational and Intermediate maintenance levels.

Disposable Filter (Throw Away) A filter element which is intended to be discarded and replaced after one service cycle.

Dissolved Gas Gas that enters into a fluid that is neither free nor entrained.

Entrained Air (Or Water) A mechanical mixture of air bubbles (or water droplets) having a tendency to separate from a combined phase.

Flash Point The temperature to which a liquid must be heated under specified conditions of the test method to give off sufficient vapor to form a mixture with air that can be ignited momentarily (caused to flash) by a specified flame. ASTM D 92 or ASTM D 93

Fleet Support Team (FST) NAVAIR engineering group who provides engineering assistance to resolve discrepancies noted by the fleet community.

Flushing A decontamination process in which original aircraft fluid is removed to the maximum extent practical, and then discarded. The draining operation is generally, but not necessarily, performed with the system connected to a clean external hydraulic power source and new replacement fluid is added as required.

Free Air Any compressible gas, air or vapor trapped within a hydraulic system that does not condense or dissolve to form a part of the system fluid.

Free Water Water droplets or globules in the system fluid, usually tending to accumulate at system low points.

Gasket A type of seal which is formed by crushing the packing material into the gland such that the cavity formed by the gland is normally filled with the packing material.

Gland The component of the seal which forms the cavity or inclusion which surrounds and supports the packing and controls the squeeze.

NAVAIR 01-1A-17 002 00 TO 42B2-1-12 Page 8


Term Definition

Halogen Any of the five chemical elements; fluorine, chlorine, bromine, iodine, and astatine.

HEPA Filter High Efficiency Particulate Air Filter. An efficient filter usually constructed from fine fiber pleated papers, intended for the removal of particulate matter from air. Widely used in clean rooms and clean work stations.

Humidity The amount or degree of moisture in the air.

Incompatible Fluids Fluids which, when mixed in a system, will have a deleterious effect on that system, its components, or its operation.

Indicator, Differential Pressure An indicator which signals the difference in pressure at two points. A feature often included in filter assemblies to monitor the pressure drop across the filter element and thereby indicate element loading and the need for replacement.

Intermediate Maintenance Activity (IMA) A Navy/USMC maintenance activity designated to provide direct maintenance support to using organizations. Its responsibilities normally consist of calibration, test, repair, or replacement of damaged or unserviceable parts, components, or assemblies; emergency manufacture of non-available parts; and technical assistance to using organizations.

K-B (Kauri-butanol) A test method to measure solvent effectiveness.

Laminar Flow A flow situation in which fluid (or gas) moves in parallel layers.

Laminar Flow Work Station A contamination controlled workbench used to ensure a high degree of cleanliness about a component.

Loaded Filter (Clogged) A filter element that has collected a quantity of contaminants such that it can no longer pass fluid at rated flow without excessive differential pressure or by-pass.

Maintenance Instruction Manual (MIM) A manual containing instructions for intermediate and organizational level servicing and maintenance of a specific model of aircraft or equipment.

Maintenance Requirement Cards (MRC) Sets of cards issued by NAVAIR containing scheduled maintenance requirements applicable to intermediate and organizational level activities for the specific model of aircraft or SE for which they are issued.

NAVAIR 01-1A-17 002 00 TO 42B2-1-12 Page 9


Term Definition

Manifold An assembly which serves as a fluid conductor having multiple connection ports.

Micron Unit of measurement one millionth of a meter long, or approximately 0.00003937 inch expressed in English units.

Milliliter (ml) A metric unit used to define fluid volume. One fluid ounce is equivalent to 29.6 ml.

Naval Air Depot (NADEP) A Navy activity tasked with and having the capability to provide depot level maintenance.

Naval Air Systems Command (NAVAIR) The Navy headquarters activity having overall responsibility for the acquisition and support of aeronautical weapons systems and related material.

Naval Air Warfare Center, Aircraft Division (NAWCAD)

A NAVAIR TEAM entity responsible for the support of Naval aircraft and their associated components.

Organizational Maintenance Activity (OMA) The maintenance capability provided by the using organization itself in support of its assigned equipment. Such maintenance normally includes inspection, servicing, lubrication, adjustment and replacement of parts, minor assemblies, and subassemblies.

Oxidation Inhibitor An additive to the base fluid intended to minimize fluid oxidation and the generation of oxidation byproducts.

Packing The component of a seal which serves as a sealing medium by nature of its plastic or elastic properties, or its ability to deform into the shape of the gland.

Particle Counter Electronic equipment which counts solid particles contained in fluid and provides a breakdown by size ranges of particles.

Particulate Contamination The presence of undesired solid matter in the form of minute discrete particles each having an observable length, width, and thickness; usually measured in microns.

Particulate Contamination Standards Standard used to quantitatively grade levels of particulate contamination. The Navy standard defines seven class levels of particles (0 thru 6) and the NAS 1638 standard defines fourteen class levels of particles (00 and 12). Both are based on the quantity of particles in 100 ml of sampled fluid.

Patch Test A method of evaluating fluid contamination wherein the fluid sample is passed through a standardized laboratory filter membrane and the change in color or reflectivity of the filter compared with previously established standards.

NAVAIR 01-1A-17 002 00 TO 42B2-1-12 Page 10


Term Definition

Phosphate Ester Clear, light purple, fire-resistant hydraulic fluids conforming to SAE AS1241.

Polymerization The union of two or more molecules of a compound to form a more complex compound with a higher molecular weight; a process which can result in the generation of undesired substances or contaminants.

Pressure, Operating The pressure at which the system is operated.

Pressure, Proof The nondestructive test pressure, in excess of the maximum rated operating pressure, which causes no permanent deformation, excessive external leakage, or other malfunction.

Purging A decontamination process in which the aircraft system is drained to the maximum extent practical and the removed fluid discarded. A suitable cleaning agent is then introduced into the system and circulated as effectively as possible so as to remove gross contaminants. The operation is completed by removing the circulated cleaning agent and replacing it with new working fluid. Purging is usually followed by a period of recirculation cleaning to ensure adequate decontamination. System purging is limited to use by depot level maintenance activities.

Purifying A decontamination process using equipment capable of removing particles, air, water, and some solvents from hydraulic fluid.

Recirculation Cleaning A decontamination process in which the aircraft systems are powered from a clean external source and cycled so as to produce maximum displacement of fluids. Decontamination is accomplished by circulating the original aircraft fluid through the aircraft and GSE filters, replacing or cleaning these filters, as required, throughout the cleaning operation.

A decontamination process in which SE or PSE supply hose is coupled to it’s own return hose by a manifold or is coupled to a fitting on the unit to return fluid to it’s own reservoir. Decontamination is accomplished by returning fluid to reservoir and circulating fluid past the unit’s own filter. Recirculation of SE may allow air trapped in SE lines, hoses and fluid to vent out in the unit’s reservoir.

Seal A device to retain fluid within a hydraulic component. The seal may consist of two or more components, such as a packing in a gland, and a packing and backup ring in a gland.

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Term Definition

Skydrol and Hyjet Trade names for phosphate ester fluids. Defined by SAE AS1241.

Squeeze The dimension by which a packing is distorted from its molded shape when installed in a packing gland.

Support Equipment (SE), Hydraulic Equipment intended for use in servicing and testing hydraulic system components. Includes portable hydraulic test stands, stationary hydraulic test stands, hydraulic check and fill stands, hydraulic fluid dispensing units, and purifiers.

Technical Order A manual containing instructions for intermediate and organizational level servicing and maintenance of a specific model of aircraft or equipment.

Test Stand, Portable Hydraulic Mobile equipment intended for use in externally powering, servicing, and decontaminating aircraft hydraulic systems at organizational, intermediate, and depot maintenance activities.

Test Stands, Stationary Hydraulic

AF-Test Stand, Hydraulic Component

Installed equipment intended for use in shop testing of hydraulic system components at intermediate and depot maintenance activities.

TFE A tetrafluoroethylene resin.

Threshold Limit Values (TLV) A guide used to define recommended safety limits for personnel exposed to toxic vapors. Limits are expressed as maximum parts vapor (tolerable) per million parts of air.

Ultrasonic Cleaning A cleaning method in which mechanical energy varying at an ultrasonic rate is coupled through the cleaning medium to the work to facilitate cleaning action.

Valve, Sampling A valve provided specifically to enable the extraction of representative fluid samples from an operation system for purposes of contamination analysis.

Viscosity A measure of the internal friction or the resistance of fluid to flow.

NAVAIR 01-1A-17 002 00 TO 42B2-1-12 Page 12

00200101

Figure 1. Graphic Symbols for Fluid Power Diagrams (Sheet 1 of 6)

NAVAIR 01-1A-17 002 00 TO 42B2-1-12 Page 13

00200102

Figure 1. Graphic Symbols for Fluid Power Diagrams (Sheet 2)

NAVAIR 01-1A-17 002 00 TO 42B2-1-12 Page 14

00200103


NAVAIR 01-1A-17 002 00 TO 42B2-1-12 Page 15

00200104


NAVAIR 01-1A-17 002 00 TO 42B2-1-12 Page 16

Figure 1. Graphic Symbols for Fluid Power Diagrams (Sheet 5) 00200105

NAVAIR 01-1A-17 002 00 TO 42B2-1-12 Page 17

00200106


NAVAIR 01-1A-17 002 00 TO 42B2-1-12 Page 18

Table 3. Consumable Materials List

Item No. Nomenclature Specifications Intended Use

HYDRAULIC FLUIDS

1 Hydraulic Fluid, Aircraft, Missile, and Ordnance

MIL-PRF-5606 NATO No. H-515

Refer to WP003 00.

2 Hydraulic Fluid, Fire Resistant


Refer to WP003 00.

3 Hydraulic Fluid, Ultra-Low-Temperature

MIL-H-81019 Refer to WP003 00.

4 Hydraulic Fluid, Low Temperature, Synthetic Hydrocarbon Aircraft and Missile


Refer to WP003 00.

5 Hydraulic Fluid, Phosphate Ester

SAE AS1241 Refer to WP016 00.

SOLVENTS

6 Dry Cleaning Solvent MIL-PRF-680 Performing hydraulic fluid contamination analysis, cleaning sample bottles and filter elements.

7 Dry Cleaning Solvent

NOT APPLICABLE TO NAVY

A-A-59601 (PD-680) Refer to WP012 00

8 Isopropyl Alcohol TT-I-735A Refer to WP011 00

9 Calibration Fluid P/N LSTMP010 NSN 6695-01-476-0550

Calibration fluid for the HIAC particle counter.

LUBRICANTS

10 Grease, Molybdenum Disulfide, For Low and High Temperatures

MIL-G-21164 NATO No. G-353

Sliding steel on steel, heavily loaded hinges; rolling element bearings where required.

11 Grease, Aircraft General Purpose Wide Temp. Range

MIL-PRF-81322 NATO No. G-395

O-rings, certain splines, ball and roller bearing assemblies, primarily wheel brake assemblies and in applications where compatibility with rubber is required.

* Manufacturer’s part number and CAGE Code.

NAVAIR 01-1A-17 002 00 TO 42B2-1-12 Change 1 – 1 August 2008 Page 19

Table 3. Consumable Materials List (Cont)


12

Grease, Aircraft General Purpose Wide Temp. Range

MIL-PRF-32014 O-rings, bushings, ball and roller bearing assemblies, certain splines, areas subject to corrosion (like landing gear), compatible with MIL-PRF-81322

CLOTHS AND CLEANING PADS

13A Wiping Cloth, Disposable, Lint-free, Ultra-Clean

A-A-59323, Type I Refer to WP012 00.

13B Wiping Cloth, Lint-free A-A-59323, Type II Refer to WP012 00.

14 Wiping Cloth, Ultra Clean, Low Lint (Non-woven)

CCC-C-46, Class 7 NSN 7920-01-180-0556 for 9' x 9' cloth NSN 7920-01-180-0557 for 17' x 21' cloth

Refer to WP012 00.

15 Crocus Cloth ANSI B74.18 (formerly A-A-1026)

Blending out nicks and scratches on O-ring grooves of filter elements.

GLOVES

16 Glove, Rubber MIL-DTL-32066 (formerly ZZ-G-381)

Protecting hands from cleaning compounds.

17A Glove, Poly-D, Disposable Various Laboratory Supply Distributors

17B Glove, Nitrile, Disposable, Powder-free

Various Laboratory Supply Distributors

Handling Phosphate Ester fluids.

CONTAINERS

18 Bottle, Prescription, Glass 8 ounce

A-A-50983 Sample bottles for testing solvents.

19A Bottle, Polyethylene with 24 mm Polypropylene Screw Closures, 4 ounce

*2002-0004 (05178) NSN 6640-01-330-4902

19B Bottle, Polypropylene *02-8935A (22527) NSN 6640-01-468-8092

Sample bottles for phosphate ester fluid.

20 Can, Safety, 5 Gallon UL30 (formerly RR-S-30) Waste container for used hydraulic fluids and solvents.

*Manufacturer’s part number and CAGE Code.


Table 3. Consumable Materials List (Cont)


21 Bottle Screw Cap, Glass, 8 ounce Square, Colorless

NSN 8125-00-543-7699 Collect hydraulic fluid samples.

22 Bottle Caps, Electronic Particle Counter

NSN 5340-01-470-8709 Sample collection bottle caps for the HIAC sampling unit.

23 Electronic Particle Counter Safety Coated Bottle 250 ml capacity

NSN 5340-01-470-8720 Sample collection bottle for the HIAC hydraulic sampling unit.

24 120 ml Safety Coated Glass Sample Bottles for HACH Ultra Analytics Hydraulic Particle Counter (PODS)

NSN 4920-01-524-5674 Sample collection bottles for the HACH Ultra Analytics, Hydraulic Particle Counter

25 Bottle, Screw Cap, 4 ounce capacity

P/N XX65-047-09 NSN 6640-00-500-0276

Sample collection bottles for the Patch Test Kit.

26 Kit, Bottle Screw Cap, Glass, Pre-cleaned, 8 oz., 24 ea

NSN 9125-01-477-9105 Collect hydraulic fluid samples

CONTROLLED ENVIRONMENT WORK CENTER CLEANING MATERIALS

27 Chamois, Leather KK-C-300 Refer to WP011 00.

28 Sponge, Cellulose Commercially available Refer to WP011 00.

29 Squeegee Commercially available Refer to WP011 00.

30 Detergent, general purpose (liquid, non-ionic)

MIL-D-16791, Type 2 Refer to WP011 00.

31 Cleaning Compound MIL-PRF-85570, Type II Refer to WP011 00.

*Manufacturer’s part number and CAGE Code.

NAVAIR 01-1A-17 002 00 TO 42B2-1-12 Page 21

Table 4. Related Publications

Publication Number Title

A-A-50983 Bottle, Safety Cap (Glass, Light-Resistant, Liquid Prescription)

A-A-59323 Cloth, Cleaning, Low-Lint

AFI 21-101 Aerospace Equipment Maintenance Management

AG-140BA-MIB-000 Operation and Intermediate Maintenance Instructions with Illustrated Parts Breakdown Hydraulic Fluid Service Unit Type HSU-1

AG-140BA-MRC-100 Preoperational Checklist Hydraulic Service Unit HSU-1

AG-140BA-MRC-200 Periodic Maintenance Requirements Manual Hydraulic Service Unit Model HSU-1

AG-140V22-MIB-000 Operation and Maintenance with Illustrated Parts Breakdown Portable Hydraulic Power Supply, Diesel and Electric Part Nos. 000850-100 and 98612-100

AG-140V22-MRC-100 Pre-Operation, Checklist Portable Hydraulic Power Supply, Diesel 000850 Electric, 98612

AG-140V22-MRC-200 Periodic Maintenance Requirements Manual Portable Hydraulic Power Supply, Diesel, 000850-100 Portable Hydraulic Power Supply, Electric, 98612-100

AG-711BA-MAB-000 Operation and Intermediate Maintenance with Illustrated Parts Breakdown Fluid Purifier A/M 37M-2

AG-720AO-MRC-000 Preoperational Checklist Pump, Dispensing, Hand Driven PMU-55/E

AG-720AO-S15-000 Operation and Maintenance Instructions with Illustrated Parts Breakdown Pump Dispensing Hand Driven PMU-55/E Part Number 4-5280

AN929 Cap Assembly, Pressure Seal Flared Tube Fitting

ANSI B74.18 Grading of Certain Abrasive Grain on Coated Abrasive Products

CCC-C-46 Cloth, Cleaning, Non-woven Fabric

COMNAVAIRFORINST 4790.2 Maintenance Program, Naval Aviation

ISO 14644-1/14611-2 Clean Room and Work Station Requirements, Controlled Environment

KK-C-300 Chamois Leather, Sheepskin, Oil Tanned

NAVAIR 01-1A-17 002 00 TO 42B2-1-12 Page 22

Table 4. Related Publications (Cont)


MIL-D-16791 Detergents, General Purpose (Liquid, Nonionic)

MIL-DTL-32066 Gloves, Rubber, Industrial

MIL-F-5504 Filter and Filter Elements, Fluid Pressure, Hydraulic Micronic Type

MIL-F-8815 Filter and Filter Elements, Fluid Pressure, Hydraulic Line, 15 Micron Absolute and 5 Micron Absolute Type II Systems

MIL-G-21164 Grease, Molybdenum Disulfide for Low and High Temperature

MIL-G-5514 Gland Design; Packings, Hydraulic, General Requirements for

MIL-H-81019 Hydraulic Fluid, Petroleum Base, Ultra-Low Temperature, Metric

MIL-HDBK-695 Rubber Products: Recommended Shelf Life

MIL-PRF-32014 Grease, Aircraft and Instrument

MIL-PRF-5606 Hydraulic Fluid, Petroleum Base; Aircraft, Missile, and Ordnance

MIL-PRF-680 Dry Cleaning Solvent

MIL-PRF-81322 Grease, Aircraft, General Purpose Wide Temperature Range

MIL-PRF-81836 Filter and Disposable Element, Fluid Pressure, Hydraulic, 3 Micron Absolute

MIL-PRF-83282 Hydraulic Fluid, Fire Resistant, Synthetic Hydrocarbon Base, Metric

MIL-PRF-85570 Type II Cleaning Compound, Aircraft, Exterior

MIL-PRF-87257 Hydraulic Fluid, Fire Resistant; Low Temperature Synthetic Hydrocarbon Base, Aircraft and Missle

MIL-STD-1472 Human Engineering Design Criteria For Military Systems Equipment and Facilities

MIL-V-81940 Valve Sampling and Bleed Hydraulic, Type II Systems

MS28774 Retainer, Packing Backup, Single Turn Tetrafluoroethylene

MS9404 Plug, Machine Thread – AMS5646, Preformed Packing

NAVAIR 01-1A-17 002 00 TO 42B2-1-12 Page 23



NAS 1638 Cleanliness Requirements of Parts Used in Hydraulic Systems

NAS817 Cap - Protective, Flared Fitting

NAS818 Plug-Protective, Flared Tube, Hose Assembly

NAS838 Plug - Protective, Flareless Tube End (Plastic)

NAS839 Cap - Beaded Hose Connection, Plastic, Protective

NAS840 Plug, Pipe Thread, Protective, Dust and Moisture Seal

NAS842 Plugs, Protective, Flareless Tube End (Metal)

NAS846 Cap, Pipe, Thread, Protective, Dust and Moisture Seal

NAS847 Caps and Plugs, Protective, Dust and Moisture Seal

NAVAIR 00-25-100 Naval Air Systems Command Technical Manual Program

NAVAIR 01-1A-20 Organizational, Intermediate and Depot Maintenance Aviation Hose and Tube Manual

NAVAIR 17-15-521 (HIAC) Operational and Intermediate Maintenance with Illustrated Parts Breakdown, Particle Counting System, P/N 8011-3

NAVAIR 17-15BF-26 Operation and Maintenance Instructions with Illustrated Parts Breakdown Air Driven, Portable, Hydraulic Check and Fill Test Stand Model 74

NAVAIR 17-15BF-35 Operation and Service Instructions with Illustrated Parts Breakdown Air Driven, Portable, Hydraulic Check and Fill Stand Model 718

NAVAIR 17-15BF-37 Operation and Maintenance Instructions with Illustrated Parts Breakdown (Intermediate) Aircraft Hydraulic and Pneumatic Component Test Stand Model HCT-10

NAVAIR 17-15BF-41 Operation, Service, and Overhaul Instructions Manual with Illustrated Parts Breakdown Automatic Flight Control System Servocylinder Test Stand Assembly

NAVAIR 17-15BF-504 Handbook Operation and Service Instructions with Illustrated Parts Breakdown, Aircraft Hydraulic Hose Check Stand

NAVAIR 17-15BF-57 Maintenance Instructions with Illustrated Parts Breakdown (Organizational, Intermediate) Hydraulic Fill Unit

NAVAIR 01-1A-17 002 00 TO 42B2-1-12 Page 24



NAVAIR 17-15BF-76 Operation, Intermediate, and Depot Maintenance Instructions with Illustrated Parts Breakdown Portable Hydraulic Power Unit A/M27T-3

NAVIAR 17-15BF-78-1 HCT-12 Hydraulic Test Stand

NAVAIR 17-15BF-78-2 HCT-12 Hydraulic Test Stand

NAVAIR 17-15BF-87 Operation and Intermediate Maintenance with Illustrated Parts Breakdown, Hydraulic Fluid Dispensing Unit A/M27M-10

NAVAIR 17-15BF-89 Operation and Intermediate Maintenance with Illustrated Parts Breakdown, Portable Hydraulic Power Supply A/M27T-5 and A/M27T-5A

NAVAIR 17-15BF-90 Operation and Intermediate Maintenance with Illustrated Parts Breakdown Test Stand Aircraft Hydraulic Systems A/M27T-6

NAVAIR 17-15BF-91 Operation and Intermediate Maintenance with Illustrated Parts Breakdown, Portable Hydraulics Power Supply (Electric Motor Driven) Model A/M27T-7 and A/M27T-7A

NAVAIR 17-15BF-94 Intermediate and Depot Maintenance with Illustrated Parts Breakdown, Hydraulic Component Test Stand Navy Model A/F27T-10

NAVAIR 17-15BF-96 Operation and Intermediate Maintenance Instructions with Illustrated Parts Breakdown for Hydraulic Purification Unit Model No. HPU-1-5-GH-N-16

NAVAIR 17-15BF-97 (PODS) Operation Instructions Hydraulic Particle Counter Type I Hydraulic Particle Counter Set – P/N 2087301-1 Type II Hydraulic Particle Counter Set – P/N 2087301-2

NAVAIR 17-20SX-146 (HIAC) Particle Counting System HIAC/ROYCO 8011-3

NAVAIR 17-35MTL-1 Metrology Requirements List (METRL)

NAVAIR 17-600-101-6-1 Preoperational Maintenance Requirements Portable Hydraulic Supply Model A/M27T-3

NAVAIR 17-600-101-6-2 Periodic Maintenance Requirements Manual Portable Hydraulic Power Supply A/M27T-3

NAVAIR 17-600-107-6-1 Preoperational Checklist Hydraulic Fluid Dispensing Unit A/M27M-10

NAVAIR 17-600-107-6-2 Periodic Maintenance Requirements Manual Hydraulic Fluid Dispensing Unit A/M27M-10

NAVAIR 01-1A-17 002 00 TO 42B2-1-12 Page 25



NAVAIR 17-600-126-6-1 Preoperational Checklist Hose Burst Test Stand 63A101-E1

NAVAIR 17-600-126-6-2 Periodic Maintenance Requirements Manual Hose Burst Test Stand P/N 63A101-E1

NAVAIR 17-600-127-6-1 Portable Hydraulic Power Supply (A/M27T-5) Preoperational Checklist

NAVAIR 17-600-127-6-2 Periodic Maintenance Requirements Manual Portable Hydraulic Power Supply A/M27T-5

NAVAIR 17-600-150-6-1 Preoperational Checklist Portable Hydraulic Power Supply A/M27T-7 and A/M27T-7A

NAVAIR 17-600-156-6-1 Preoperational Checklist Test Stand, Aircraft Hydraulic System, A/M27T-6

NAVAIR 17-600-156-6-2 Periodic Maintenance Requirements Manual Test Stand, Aircraft Hydraulic System, A/M27T-6

NAVAIR 17-600-196-6-1 Preoperational Checklist Hydraulic Purification Unit (HPU) Model No. HPU-1-5 Part No. 95163-100

NAVAIR 17-600-196-6-2 Periodic Maintenance Requirements Manual Hydraulic Purification Unit (HPU) Model No. HPU-1-5 Part No. 95163-100

NAVAIR 17-600-32-6-1 Aircraft Hydraulic and Pneumatic Component Test Stand HCT-10

NAVAIR 17-600-32-6-2 Periodic Maintenance Requirements Manual Aircraft Hydraulic and Pneumatic Component Test Stand HCT-10

NAVAIR 17-600-35-6-1 Preoperational Checklist Maintenance Requirements Air Driven, Portable, Hydraulic Check and Fill Stand Model 74

NAVAIR 17-600-35-6-2 Calendar Maintenance Requirements Cards Air Driven, Portable, Hydraulic, Check and Fill Stand Model 74

NAVAIR 17-600-40-6-1 Preoperational Checklist Hydraulic Service Unit Model H-250-1

NAVAIR 17-600-40-6-2 Periodic Maintenance Requirements Manual Hydraulic Service Unit Model H-250-1

NAVAIR 17-600-67-6-1 Preoperational Checklist Hydraulic Service Cart Model 310

NAVAIR 17-600-T10-6-1 Preoperational Checklist A/F27T-10 Hydraulic Component Test Stand

NAVAIR 01-1A-17 002 00 TO 42B2-1-12 Page 26



NAVAIR 17-600-T10-6-2 Calendar/Hour/Periodic Maintenance Requirements Manual A/F27T-10 Hydraulic Component Test Stand

NAVAIR 19-600-201-6-1 Preoperational Checklist Fluid Purifier A/M 37M-2

NAVAIR 19-600-201-6-2 Periodic Maintenance Requirements Manual Fluid Purifier A/M 37M-2

SAE AMS-P-5510 Packing, Preformed, Straight Thread Tube Fitting Boss, Type I Hydraulic

SAE AS1241 Fire Resistant Phosphate Ester Hydraulic Fluid for Aircraft

SAE AS1290 Graphic Symbols for Aircraft Hydraulic and Pneumatic Systems

SAE AS28775 Packing, Preformed, Hydraulic, +275 Degrees F (“O”-Ring)

SAE AS28778 Packing, Preformed, Straight Thread Tube Fitting

SAE AS21913 Plug, Flareless Tube

SAE AS4841 Fittings, 37 Degree Flared, Fluid Connection

SAE AS5168 Fitting, Plug, Tube End, Flared

SAE AS5169 Fitting, Port Plug and Bleeder

SAE AS8791 Hydraulic and Pneumatic Retainers (Back-Up Rings), Polytetrafluoroethylene (PTFE) Resin

TO 00-20-14 Air Force Metrology and Calibration Program

TO 00-25-223 Integrated Pressure Systems and Components (Portable and Installed)

TO 33K-1-100-1 Calibration Procedure for TMDE Calibration Notes Maintenance Data Collection Codes and Calibration Measurement Summaries (CMS)

TT-I-735 Isopropyl Alcohol

UL 30 UL Standard for Metal Safety Cans



DESCRIPTION

HYDRAULIC SYSTEMS AND HYDRAULIC FLUIDS

Reference Material

None

Alphabetical Index

Subject Page No.

Aircraft Hydraulic Systems............................................................................................................. 2 Detailed Description................................................................................................................... 2 General Description ................................................................................................................... 2

Hydraulic Fluids Used in Military Aircraft ....................................................................................... 5 Hydraulic Fluid, Military Specification MIL-H-81019.................................................................. 6 Hydraulic Fluid, Military Specification MIL-PRF-5606 ............................................................... 5 Hydraulic Fluid, Military Specification MIL-PRF-83282 ............................................................. 5 Hydraulic Fluid, Military Specification MIL-PRF-87257 ............................................................. 6 Hydraulic Fluid, SAE-AS1241, Phosphate Ester ....................................................................... 6 Intended Use.............................................................................................................................. 6

Record of Applicable Technical Directives

None

NAVAIR 01-1A-17 003 00 TO 42B2-1-12 Page 2 1. AIRCRAFT HYDRAULIC SYSTEMS.

2. GENERAL DESCRIPTION. All modern military aircraft contain hydraulic systems for operation of various mechanisms. The number of hydraulically operated units depends upon the model of aircraft. A complete aircraft hydraulic system consists of a power system and a number of actuating systems (subsystems), the exact number dependent upon the aircraft design. The power system is generally considered to include the fluid supply (reservoir), power supply (pump), and all other components leading up to, but not including, the selector (directional control) valves. The selector valves direct the flow of fluid to the various actuating units, and each selector valve is considered a part of its related actuating system.

3. DETAILED DESCRIPTION. To ensure required reliability, current aircraft hydraulic system specifications require that two separate systems be available for operating the flight controls. All aircraft which utilize hydraulically actuated flight controls have at least two hydraulic power systems. One hydraulic system may supply fluid power to the utility system as well as to the flight controls. The utility systems actuate the landing gear, wing fold, wheel brakes, cargo door, and other such sub-systems. In fighter type aircraft, the systems are generally referred to as power control system 1 (PC-1), power control system 2 (PC-2), and utility system. In heavy aircraft, such as tankers, bombers, ant transports, the hydraulic systems are usually numbered according to the associated engine driving the system pump. Each system has its own reservoir, power pump, and lines.

4. Aircraft hydraulic systems are designed to produce and maintain a given pressure over the entire range of required fluid flow rates. The pressure utilized in most military high performance aircraft is 3,000 psi, although some new aircraft hydraulic systems operate at 4,000 - 8,000 psi.

5. Figure 1 illustrates a typical fighter type aircraft utility hydraulic system. In addition to the utility system shown, there are two other independent hydraulic systems (not shown) for operation of the flight controls. All three systems operate at 3,000 psi. Figure 2 illustrates a typical heavy aircraft hydraulic system. A description of the power system components shown and their functions follow.

6. The reservoir is the source from which the hydraulic pumps draw their supply of fluid, and to

which the fluid displaced by actuating components is returned for storage. The reservoir shown in Figure 1 is liquid pressurized to ensure a supply of fluid to the pumps at all times. Reservoirs may also be air or gas pressurized, or simply vented to the atmosphere with only gravity or boost pumps to sustain flow, as shown in Figure 2.

7. Variable displacement axial piston pumps provide the flow of fluid to the system. Each pump has an integral compensator that regulates volume delivery in accordance with system flow demands. The flow from the pump is ported to a manifold from which lines branch off to the various actuating systems.

8. Check valves near the pump pressure ports serve to isolate the pump output from system back pressure or loss of pressure. They also prevent pressure supplied from an external hydraulic power source from attempting to motor the pump (rotating it in reverse), possibly shearing or damaging the pump-to-engine drive spline. Check valves are also installed in the system return lines to direct the return flow back to the reservoir and to prevent pressure from acting against the return ports of other system components.

9. An accumulator is installed in the manifold line to damp the pump pulsations and maintain smoothness of operation. In addition, the accumulator assists the pumps by providing the system with a limited amount of fluid flow and pressure during peak system power demands. Accumulator servicing is accomplished via the connecting air charge valve. The attached pressure gage is used to check the accumulator air charge and to determine the degree of system pressurization.

10. Filters are installed in both the system pressure lines and the return lines. The filters shown are of the bypass type and contain a valve which allows fluid to flow through the top of the filter, instead of the filter element, should the element become loaded. Filters are also installed in various actuating systems.

11. A system relief valve is installed to protect the system from detrimental pressure surges and limit excessive system pressure buildup by dumping the fluid to return.

12. There are two pressure switches installed in the hydraulic system. They are installed in the pressure lines leading from the pumps and are isolated from one another by the check valves. When the pressure from either pump drops below a predetermined value,

NAVAIR 01-1A-17 003 00 TO 42B2-1-12 Page 3

003001

Figure 1. Typical Fighter Hydraulic System

NAVAIR 01-1A-17 003 00 TO 42B2-1-12 Page 4

003002

Figure 2. Heavy Aircraft Hydraulic System

NAVAIR 01-1A-17 003 00 TO 42B2-1-12 Page 5

its pressure switch completes an electrical circuit that illuminates a warning light in the cockpit.

13. Heat exchangers are honeycomb radiators similar to automobile radiators. Hydraulic fluid returning to the reservoir is routed through heat exchangers where heat energy is dissipated.

14. The hydraulic power system provides fluid under pressure for those actuating systems indicated in Figure 1 and 2. The other aircraft hydraulic systems are similar to the system depicted and provide fluid under pressure for operation of the flight control systems and other subsystems.

15. HYDRAULIC FLUIDS USED IN MILITARY AIRCRAFT.

16. Hydraulic fluids in aircraft hydraulic systems are primarily used to transmit power, but must perform several additional vital functions. A hydraulic fluid must also act as a lubricant to reduce friction and wear, serve as a coolant to maintain operating temperatures within limits of critical sealant materials and serve as a corrosion and rust inhibitor. These vital functions may be impaired if the hydraulic system fluid is allowed to become contaminated beyond acceptable limits.

Utmost care must be taken when it is necessary to replace hydraulic fluids in a system. Compatibility and interchangeability such as that present in the three hydrocarbon based mil-spec reds (MIL-PRF-5606, MIL-PRF-83282, and MIL-PRF-87257) must be proven and their suitability for each aircraft tested. Do not mix dissimilar hydraulic fluids, such as hydrocarbon based with phosphate ester based, in the same system. Damage to equipment and aircraft could result.

Hydraulic Fluid, MIL-PRF-5606 1

17. HYDRAULIC FLUID, MILITARY SPECIFICATION MIL-PRF-5606 (WP002 00, TABLE 3, ITEM 1). This was the principal hydraulic fluid used

in Naval aircraft prior to the introduction of hydraulic fluid MIL-PRF-83282. Hydraulic fluid MIL-PRF-5606 consists of petroleum products with additive materials to improve viscosity temperature characteristics, inhibit oxidation, and act as an antiwear agent. The oxidation inhibitor has been included to reduce the amount of oxidation which occurs in petroleum-based fluids when subjected to high pressure and temperature, and to minimize corrosion of metal parts due to such oxidation and resulting acids. This hydraulic fluid is intended for use in hydraulic systems having a temperature range of -65°F to +275°F (-54EC to +135EC). This hydraulic fluid is further identified by NATO Code H-515 and is dyed red so it can be distinguished from incompatible fluids. Hydraulic fluid MIL-PRF-5606 is compatible with hydraulic fluid MIL-PRF-87257 (WP002 00, Table 3, Item 4) and hydraulic fluid MIL-PRF-83282 (WP002 00, Table 3, Item 2). However, mixing MIL-PRF-5606 with MIL-PRF-87257 or MIL-PRF-83282 will reduce their fire resistant properties.


18. HYDRAULIC FLUID, MILITARY SPECIFICATION MIL-PRF-83282 (WP002 00, TABLE 3, ITEM 2). This is the principal hydraulic fluid now used in military aircraft. This fluid is a fire-resistant type developed to replace hydraulic fluid MIL-PRF-5606 (WP002 00, Table 3, Item 1). The fluid consists of a synthetic hydrocarbon base and contains additives to provide the required rubber swell and anti-wear characteristics, and to inhibit oxidation and corrosion. It is intended for use in hydraulic systems having a temperature range of -40°F to +401°F (-40EC to +205EC). Hydraulic fluid MIL-PRF-83282 is miscible with hydraulic fluid MIL-PRF-5606 (WP002 00, Table 3, Item 1) and hydraulic fluid MIL-PRF-87257 (WP002 00, Table 3, Item 4) from -40EF to 400EF (-40EC to 200EC). However, the addition of MIL-PRF-5606 will reduce the fire resistant properties of MIL-PRF-83282.

NAVAIR 01-1A-17 003 00 TO 42B2-1-12 Page 6

MIL-PRF-83282 (WP002 00, Table 3, Item 2) shall not be used in some viscous dampers due to its low temperature characteristics. Refer to applicable Maintenance Instruction Manuals (MIM) or Maintenance Requirement Cards (MRC) for specific Naval aircraft.

19. Flash point, fire point, and spontaneous ignition temperature of MIL-PRF-83282 exceed that of MIL-PRF-5606 by more than 200°F (93EC). The fluid extinguishes itself when the external source of flame or heat is removed. Hydraulic fluid MIL-PRF-83282 is identified by NATO Code H-537 and is compatible with all materials used in systems presently employing MIL-PRF-5606. Because of its superior properties, MIL-PRF-83282 is now required in the main systems of all Naval aircraft previously using MIL-PRF-5606.

Hydraulic Fluid, MIL-H-81019 3

20. HYDRAULIC FLUID, MILITARY SPECIFICATION MIL-H-81019 (WP002 00, TABLE 3, ITEM 3). This is an ultra-low temperature hydraulic fluid designed for use on aircraft where extremely low surrounding temperatures are expected. The hydraulic fluid consists of petroleum products with additive materials to improve its viscosity temperature characteristics, increase its resistance to oxidation, inhibit corrosion, and act as an anti-wear agent. This hydraulic fluid is dyed red so it can be distinguished from other incompatible hydraulic fluids. This fluid is not interchangeable with any other type or grade of hydraulic fluid other then MIL-PRF-5606 in extreme emergencies. This hydraulic fluid is designed to operate in hydraulic systems from -94°F to +212°F (-70EC to +100EC).


21. HYDRAULIC FLUID, MILITARY SPECIFICATION MIL-PRF-87257 (WP002 00, TABLE 3, ITEM 4). This is a fire resistant, low temperature, synthetic hydrocarbon base hydraulic

fluid. It is further identified by NATO Code H-538. It is designed for use within a temperature range of -65EF to +392EF (-54°C to +200°C) in aircraft and missile hydraulic systems. Hydraulic fluid MIL-PRF-87257 is miscible with hydraulic fluid MIL-PRF-5606 (WP002 00, Table 3, Item 1) and hydraulic fluid MIL-PRF-83282 (WP002 00, Table 3, Item 2). However, the addition of MIL-PRF-5606 will reduce the fire resistant properties of MIL-PRF-87257.

22. INTENDED USE. Hydraulic fluids MIL-PRF-5606, MIL-PRF-87257, MIL-PRF-83282, and MIL-H-81019 (WP002 00, Table 3, Items 1, 4, 2, and 3, respectively) are intended for use in automatic pilots, shock absorbers, brakes, control mechanisms, servocontrol systems, and other hydraulic systems using seal materials compatible with petroleum based fluids.

Hydraulic Fluid, SAE AS 1241 5

Under no circumstance should SAE AS1241 be mixed with MIL-PRF-5606, MIL-H-81019, MIL-PRF-83282 or MIL-PRF-87257. Mixing these hydraulic fluids could compromise the safe operation of the aircraft.

23. HYDRAULIC FLUID, SAE-AS1241, PHOSPHATE ESTER (WP002 00, TABLE 3, ITEM 5). This is a fire resistant aircraft hydraulic fluid. It has an operating temperature range of -65°F (-54°C) to 225°F (107°C). This hydraulic fluid shall not be mixed with any other hydraulic fluid. This fluid can’t be used with synthetic (Buna N) rubber seals used in hydraulic systems designed to operate on MIL-PRF-5606. Phosphate ester hydraulic fluids are described in detail in WP016 00.



HYDRAULIC FLUID CONTAMINATION

HYDRAULIC SYSTEMS

Reference Material

Cleanliness Requirements of Parts Used in Hydraulic Systems ................................ NAS 1638 Metrology Requirements List (METRL)........................................................................ NAVAIR 17-35MTL-1 Calibration Procedure for TMDE Calibration Notes Maintenance Data Collection Codes and Calibration Measurement Summaries (CMS) ....................................... TO 33K-1-100-1 Air Force Metrology and Calibration Program.............................................................. TO 00-20-14 Maintenance Program, Naval Aviation .................................................................... COMNAVAIRFORINST 4790.2 Aerospace Equipment Maintenance Management...................................................... AFI 21-101

Alphabetical Index

Subject Page No.

Introduction .................................................................................................................................... 2 Measurement of Contamination..................................................................................................... 4

Electronic Particle Counting....................................................................................................... 4 Patch Testing............................................................................................................................. 4

Sources and Effects of Contamination........................................................................................... 2 Air Contamination ...................................................................................................................... 4 Fluid Contamination................................................................................................................... 3 Particulate Contamination.......................................................................................................... 2


None

NAVAIR 01-1A-17 004 00 TO 42B2-1-12 Page 2

1. INTRODUCTION.

2. Hydraulic fluid contamination may be described as any foreign material or substance whose presence in the fluid is capable of adversely affecting system performance or reliability. It may assume many different forms including liquids, gases, and solid matter of various compositions, sizes, and shapes. Solid matter is the type most often found in aircraft hydraulic systems and is generally referred to as particulate contamination. Contamination is always present to some degree, even in new, unused fluid. Contamination must be below a level that will not adversely affect system operation. Hydraulic contamination control consists of those requirements, techniques, and practices for minimizing and controlling fluid contamination.

3. SOURCES AND EFFECTS OF CONTAMINATION.

4. Contamination present in an operating hydraulic system will have normally originated at several different sources, with its rate of introduction being dependent upon numerous factors. Because several of these factors are directly related to wear and chemical reaction, the amount of contamination in a system will increase with use unless contamination removal reverses the natural trend. Production of contaminants in the hydraulic system also increases with the number of system components. The rate of contamination from external sources is not readily predicted, and a hydraulic system can be seriously contaminated by maintenance malpractices leading to the introduction of large amounts of external contaminants. Poorly maintained support equipment (SE) may also be a source of contamination. Contaminants in hydraulic fluids may be grouped into several types. The types may be generally classed as organic, metallic solids, nonmetallic (inorganic) solids, foreign fluids, air, and water.

5. PARTICULATE CONTAMINATION. The following paragraphs provide a discussion of organic, metallic solid and inorganic solid contaminations and their effects.

6. Organic Contamination. Organic solids or semi solids found in hydraulic systems are produced by wear, oxidation, or polymerization. Minute particles of O-rings, seals, gaskets, and hoses are present, due to wear or chemical reactions. Synthetic products, such as neoprene, thiokol, silicones, and hypalon, though resistant to chemical reaction with hydraulic fluids, produce small wear particles. The oxidative rate of hydraulic fluids increases with pressure,

temperature, and the presence of system contaminants (wear particles, water, or dirt). Oxidation products appear as organic acids, asphaltics, gums, and varnishes. These products combine with particles in the hydraulic fluid to form sludge. Some oxidation products are oil soluble and cause the hydraulic fluid to increase in viscosity; other oxidation products are not oil soluble and form sediment.

7. Metallic Solid Contamination. Metallic contaminants are almost always present in a hydraulic system and will range in size from microscopic particles to particles readily visible to the naked eye. These particles are the result of wearing and scoring of bare metal parts and plating materials such as silver and chromium. These wear products and other foreign metal particles such as steel, aluminum, and copper may also act as metallic catalysts in the formation of oxidation products. Fine metallic particles enter the hydraulic fluid from many sources within the hydraulic system. Although practically all metals commonly used for parts fabrication and plating may be found in hydraulic fluids, the major metallic materials found are ferrous, aluminum, and chromium particles. Because of their continuous high-speed internal movement, hydraulic pumps usually contribute most of the metallic particulate contamination present in hydraulic systems. Metal particles are also produced by other hydraulic system components such as hydraulic valves and actuators, due to body wear and the chipping and wearing away of small pieces of metal plating materials.

8. Inorganic Solid Contamination. This contaminant group includes dust, paint particles, dirt, and silicates. Glass particles from glass bead peening and blasting may also be found as contaminants. Glass particles are very undesirable contaminants due to their abrasive effect on synthetic rubber seals and the very fine surfaces of critical moving parts. Atmospheric dust, dirt, paint particles, and other materials are often drawn into the hydraulic systems from external sources. For example, the wet piston shaft of a hydraulic actuator may draw some of these foreign materials into the cylinder past the wiper and dynamic seals, and the contaminant materials are then dispersed in the hydraulic fluid. Contaminants may also enter the hydraulic fluid during maintenance when tubing, hoses, fittings, and components are disconnected or replaced. It is important that all exposed fluid ports be sealed with approved protective closures to minimize such contamination.

NAVAIR 01-1A-17 004 00 TO 42B2-1-12 Page 3

9. Effects of Particulate Contamination. Contamination of hydraulic fluid with particulate matter is one of the principal causes of wear in hydraulic pumps, actuators, valves, and servovalves. Due to their ease of control and rapid rate of response, spool-type electrohydraulic valves operated with both ultra clean and contaminated hydraulic fluids has demonstrated that the amount of wear is accelerated by even small amounts of contamination. Erosion of the sharp spool edges and general deterioration of the surfaces of the spools is increased by contamination. Because of the extremely close fit of spools in servovalve housings, these valves are particularly susceptible to damage or erratic operation when operated with contaminated hydraulic fluid.

10. Hydraulic actuators and valves are affected by contamination in several ways. Large metallic or hard nonmetallic particles will collect at the seal area, and the scraping action of the particle may groove the inside wall of the actuator body. Small particles act as abrasives between seals and actuator body and cause general wear and scoring. The resultant wear and scoring will eventually cause excessive fluid leakage and possible seal failure due to extrusion of the seal into the enlarged gap between the piston head and the bore of the actuator body. Once the abrasive material begins to wear the actuator body, the process will continue at an increasing rate because the wear particles add to the available abrasive material. In a similar manner, metallic or nonmetallic particles may lodge in the poppets and poppet seat portions of valves and thereby cause system malfunction by holding valves open.

11. Oil oxidation products are not abrasive, but they will result in system degradation because the resulting sludge or varnish-like materials will collect at close-fitting moving parts, such as the spool and sleeve on servovalves, causing sluggish valve response.

12. FLUID CONTAMINATION. The following paragraphs provide a discussion of water, solvent, and other foreign fluid contaminations and their effects.

13. Water Contamination. Free water is a serious contaminant of hydraulic systems. Hydraulic fluids are adversely affected by emulsified or free water. Water may result in the formation of ice or oxidation products, and in the corrosion of metallic surfaces. Water may also be condensed from air entering vented systems. When it separates from hydraulic fluids, it collects in filter bowls, and at other more

critical locations. Corrective actions shall be taken to remove all free or emulsified water from hydraulic systems.

14. Effects of Free Water Contamination. The presence of water in hydraulic systems can result in the formation of undesired oxidation products and corrosion of metallic surfaces. If water in the system results in the formation of ice, fluid flow, or operation of valves, actuators or other moving parts will be impeded. This is particularly true of water located in static circuits or system extremities and subjected to high-altitude, low temperature conditions. Microorganisms may grow and spread in hydraulic fluid contaminated with water. These may clog filters and be detrimental to hydraulic system performance.

15. Foreign Fluids Contamination. Hydraulic systems can be seriously contaminated by foreign fluids other than water and chlorinated solvents. This type of contamination, although rare, is generally a result of lube oil, engine fuel, or incorrect hydraulic fluid having been introduced inadvertently into the system during servicing. In addition, some models of aircraft employ hydraulic oil coolers which, when leaky, can result in fuel intrusion into the hydraulic system. Contamination with a foreign fluid, when suspected, can usually be verified by chemical analysis of a fluid sample. Assistance of the Fleet Support Team (FST), Air Force Petroleum Office (AFPET) or Aircraft Sustainment Group (ASG) must be requested to verify and identify the contaminant and to direct the required decontamination.

16. Effects of Foreign Fluid Contamination. The effect of foreign fluids other than water on a hydraulic system will depend upon the nature of the contaminant, and must be ascertained on a case basis. When determining possible effects, consideration must be given to such factors as compatibility with materials of construction, compatibility with the system hydraulic fluid, possible reactions with water, and changes of flammability and viscosity characteristics. The effects of such contamination may be relatively mild or quite severe, depending upon the contaminant, the amount in the system and how long it has been present.

NOTE Hydrocarbon based fluids, MIL-PRF-

5606, MIL-PRF-87257 and MIL-PRF-83282, will hold 12% dissolved air and phosphate ester fluids, SAE AS1241, will hold 18% dissolved air which is not harmful to aircraft operation unless it becomes entrained or free air.


17. AIR CONTAMINATION. Hydraulic fluids are adversely affected by dissolved, entrained, or free air. Air may be introduced through improper maintenance or as a result of system design. Any maintenance operation that involves breaking into the hydraulic system, such as disconnecting or removing a line or component, will invariably result in some air being introduced into the system. This source of air can, and must be minimized by prefilling replacement components with new, filtered fluid prior to installation. Failing to prefill a filter element bowl with fluid is a good example of how air can be introduced in this manner.

18. Most aircraft hydraulic systems have “built-in” sources of air. Leaky seals in gas-pressurized accumulators and reservoirs can feed gas into a system faster than it can be removed, even with the best of maintenance. Air can also be pulled in past unpressurized rod seals. This occurs if only one side of a tandem actuator is powered, the surface is moved by hand or the surface droops after shutdown. Moving a flight control surface while unpressurized can produce a vacuum and may cause a significant amount of air to be pulled in past the actuator rod seals.

19. Support Equipment improperly used is another major source of air. An improperly used fill service unit or portable hydraulic test stand can introduce large amounts of air into a system. It is extremely important that hydraulic SE and their service hoses be properly deaerated prior to aircraft connection.

20. Effects of Air Contamination. Free or entrained air affects the system in many ways. If the fluid supplied to a pump has a high air content, resulting cavitation can cause severe mechanical damage within the pump, and partial or complete loss of output pressure. A temporary pressure loss, in many of our present systems, because of the resulting loss of “bootstrap” pressure, can prevent the pump from repriming itself. Air elsewhere in the system generally manifests itself in the form of slow or erratic actuator movement. Sometimes this is accompanied by vibrations, which may be felt and/or heard. Air can also damage a system in less obvious ways. Air entrained in the fluid has been shown to cause erosion of metering orifices and servovalves, as well as high fluid temperatures. High temperatures can result in fluid breakdown, as well as the hardening of seals and attendant leaks.

21. MEASUREMENT OF CONTAMINATION.

22. The size of particulate matter in hydraulic fluid is measured in “microns,” (millionths of a meter.) A micron is equivalent to 0.0000394 inch, and 25,400 microns equal 1 inch. The largest dimension of the particle is measured when determining its size. A graphic representation of the relative size of particles measured in microns is shown in Figure 1. Refer to Tables 1 and 2 for particulate contamination levels.

NOTE USAF aircraft and aircraft hydraulic

systems using phosphate esters classify contamination levels in accordance with NAS 1638. Refer to WP016 00 or the applicable aircraft maintenance manual for determination of appropriate particulate contamination levels.

23. ELECTRONIC PARTICLE COUNTING (NAVY USE ONLY). Electronic Particle Counters, such as the HACH Ultra Analytic PODS MXU-937E or MXU-976E or equivalent, are the required method for measuring particle contamination to be utilized at all levels of maintenance. Operation of electronic particle counters shall be in accordance with applicable NAVAIR manuals. Calibration of this equipment is performed by a calibration technician trained by Naval Air Technical Data and Engineering Service Command (NATEC) or Naval Oil Analysis Program (NOAP) NAVAIR technical personnel. The Portable Oil Diagnostic System (PODS) particle counter calibration is performed by HACH Ultra Analytics. Calibration shall be accomplished after any repairs that could affect calibration; whenever there is any reason to suspect inaccuracy in test results; or at regular intervals as specified in NAVAIR 17-35MTL-1.

24. PATCH TESTING (NAVY USE ONLY). Activities that do not have access to a particle counter either located in their own area or through a supporting Intermediate Level (I-Level) unit or NOAP Lab, shall measure hydraulic fluid contamination by patch testing with the contamination analysis kit 57L414 (08071) (WP005 00, Figure 1). Operation of the contamination analysis kit is described in detail in WP017 00.

NOTE

Operators shall qualify in accordance with Naval Aviation Maintenance Program Standard Operating Procedures (NAMPSOP) and COMNAVAIRFORINST4790.2, Chapter 10 Par. 10.5.

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NAVAIR 01-1A-17 004 00 TO 42B2-1-12 Page 5

004001

Figure 1. Graphic Comparison of Particle Sizes

NAVAIR 01-1A-17 004 00 TO 42B2-1-12 Page 6

Table 1. Navy Standard for Particulate Contamination

PARTICLE CONTAMINATION LEVEL-BY CLASS

Acceptable Unacceptable MICRON SIZE RANGE

0 1 2 3 4 5 6

5-10

10-25

25-50

50-100

Over 100

2,700

670

93

16

1

4,600

1,340

210

28

3

9,700

2,680

380

56

5

24,000

5,360

780

110

11

32,000

10,700

1,510

225

21

87,000

21,400

3,130

430

41

128,000

42,000

6,500

1,000

92

Total 3,480 6,181 12,821 30,261 44,456 112,001 177,592

Notes: 1. The class of contamination is based upon the total number of particles in any size range per 100 ml of hydraulic fluid. Exceeding the allowable particle count in any one or more size range requires that the next higher class level be assigned.

2. Class 5 is the maximum acceptable contamination level for hydraulic systems in Naval aircraft. Fluid delivered by SE to equipment under test or being serviced must be Class 3, or cleaner.

3. The Class 5 level of acceptability shall be met at the inspection interval specified for the equipment under test.

NA

VAIR

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004 00 TO

42B2-1-12

Page 7/(8B

lank)

12

1024000

180224

32400

5600

1024

11

512000

90112

16200

2800

512

10

256000

45056

8100

1440

256

9

128000

22528

4050

720

128

8

640000

11264

2025

360

64

7

320000

5632

1012

180

32

6

16000

2816

506

90

16

5

8000

1408

253

45

8

4

4000

704

128

22

4

3

2000

352

64

11

2

2

1000

176

32

6

1

1

500

88

16

3

1

0

250

44

8

2

0

00

125

22

4

1

Maximum Contamination Limits (Based on a 100 mL Sample Size)

Classes

Table 2: NAS 1638 Contamination Standards

0

Micron Size

Range

5-15

15-25

25-50

50-100

>100

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HYDRAULIC FLUID CONTAMINATION ANALYSIS

HYDRAULIC SYSTEMS

Reference Material

Valve Sampling and Bleed Hydraulic, Type II Systems............................................. MIL-V-81940 Operational and Intermediate Maintenance with Illustrated Parts

Breakdown, Particle Counting System, P/N 8011-3.............................................. NAVAIR 17-15-521 Particle Counting System HIAC/ROYCO 8011-3....................................................... NAVAIR 17-20SX-146 Operation Instructions Hydraulic Particle Counter, Type I Hydraulic Particle Counter Set - P/N2087301-01, Type II Hydraulic Particle Counter Set - P/N 2087301-02. NAVAIR 17-15BF-97

Alphabetical Index

Subject Page No.

Contamination Analysis.................................................................................................................. 4 Visual Analysis for Water Contamination .................................................................................. 4 Electronic Particle Count Analysis (All Levels of Maintenance) ................................................ 6

Electronic Particle Counter Description................................................................................. 7 HACH Ultra Analytics Portable Oil Diagnostic System (PODS) ....................................... 7 HIAC/ROYCO Particle Counting System 8011-3 ............................................................. 7

Introduction .................................................................................................................................... 2 Sampling Hydraulic Fluid ............................................................................................................... 2

Cleanliness ................................................................................................................................ 3 Sample Requirements ............................................................................................................... 2 Sampling Points......................................................................................................................... 2 Sampling Point Requirements ................................................................................................... 2

Sample Taking ............................................................................................................................... 3 Filter Bowl Content Sampling .................................................................................................... 4


None

NAVAIR 01-1A-17 005 00 TO 42B2-1-12 Page 2

1. INTRODUCTION.

2. During normal operation, hydraulic systems may become contaminated with metallic and nonmetallic particles. Particulate contamination may result from internal wear, failure of system components, or incorrect maintenance and servicing operations. The contamination analysis procedures herein allow determination of the particulate level of a hydraulic system and the presence of free water or other foreign substances.

3. SAMPLING HYDRAULIC FLUID.

NOTE

USAF: Check the applicable aircraftmaintenance manual for specific fluidsampling requirements and procedures.

4. SAMPLE REQUIREMENTS. To determine contamination level, a single fluid sample is required which represents the working fluid in the system. It also must provide a worst-case indication of system particulate level, because the particulate level is not the same throughout an operating system. The particulate level displays distinct gradients due to the effects of system components (such as filters) on circulating particles.

5. SAMPLING POINTS. The fluid sample is obtained from a sampling point. A fluid sampling point is a physical point in a hydraulic system from which small amounts of hydraulic fluid can be obtained for contamination analysis. It may be an air bleed valve, a reservoir drain valve, quick-disconnect fittings, removable line connections, or special valves installed for ease of sampling. Valves conforming to the requirements of MIL-V-81940 may be used as sampling points.

6. Selection of an adequate fluid sampling point generally requires a thorough investigation of the system involved. The task is further complicated if selection is limited to use of existing valves and fittings, in which case certain trade-offs may have to be accepted. Assistance should be requested from the Fleet Support Team (FST) or Aircraft Sustainment Group (ASG) when it becomes necessary to select hydraulic sampling points in aircraft or Support Equipment (SE) for which none have been previously specified.

7. SAMPLING POINT REQUIREMENTS. A sampling point should satisfy the following requirements:

a. The fluid sample should be obtained from a main system return line, pump suction line, or system reservoir. Sample fluid from these areas can be considered representative because of the high circulatory rates and because samples are obtained from the dirtiest portion of the closed-loop system. However, this sampling method may not be valid if the system is equipped with a return line filter, particularly one of the low micron depth-type variety. Due to the high single-pass efficiency of such filters, considerable difference in particulate levels may be observed between its inlet and outlet ports. Should return line filtration be present, it is desirable that the sample be obtained from a main system return line upstream of the filter in order to obtain a realistic indication of contamination level.

b. Reservoir sampling should not be employed in a system using a reservoir of the make-up variety, or where the reservoir is bypassed during SE-powered operation. A make-up reservoir is that configuration in which all system return line fluid does not pass through the reservoir. Fluid exchange in the reservoir is limited and results only from the changes in fluid volume that occurs elsewhere in the system.

c. The sampling point should be usable immediately after flight without requiring the use of external ground support equipment (GSE). Sampling with the aircraft engines turning is satisfactory, provided no personnel hazards are involved.

d. The sampling point should be usable when the system is being powered by external SE, or immediately after such operation. To achieve this, it is generally necessary to ensure that the same flow conditions exist at the selected point in either mode of operation.

e. The sampling point should be immediately adjacent or reasonably close to the main body or stream of fluid being sampled. A minimum amount of static fluid should be associated with the sampling point and whatever is present should be readily purged upon initiation of sample flow. This may be accomplished by dumping an initial quantity of the sampled fluid, but problems may be encountered where a long line is involved, as in certain reservoir drain lines.

f. The sampling point should not be located in an area of high sedimentation. Ensure that the effects of such sedimentation can be minimized by always discarding an initial quantity of the sample fluid drawn. Sample fluid should ideally be obtained from turbulent high-flow areas.

NAVAIR 01-1A-17 005 00 TO 42B2-1-12 Page 3

g. Operation of the sampling point shall not introduce any significant amount of external contaminants into the fluid collected. With reasonable external pre-cleaning and prior self-flush of the valve or fitting, the background level attributable to the sample point itself should not exceed 10 percent of the normally observed particulate level.

h. The internal porting of the sampling point shall be such that it will not impede the passage of hard particulate matter up to 500 microns in diameter.

i. The sampling point should be readily accessible and otherwise convenient to use. Sufficient clearance must exist beneath the valve or fitting to adequately position the sample collection bottle. The sampling point should be easy to operate, and not distort the particulate level of the sampled fluid either by acting as a filter or by introducing external or self-generated contaminants. The latter point is particularly critical and should be minimized prior to sample collection by external cleaning of the valve or fitting and by dumping a small amount of the initial fluid flow.

j. With normal system operating pressures present, the sample fluid flow rate should be between 100 and 1,000 ml (approximately 3 to 30 fluid oz.) per minute. The flow rate should be manageable, and the time required to collect the required sample should not be excessive.

k. Repeated use of the sampling valve or fitting should not degrade its mechanical integrity. Provisions should exist for mechanically securing it in the closed position.

8. CLEANLINESS. Accurate determination of hydraulic contaminant levels requires proper sampling techniques using equipment and materials that are known to be clean. Any foreign matter which is allowed to contaminate the sample fluid or testing equipment will cause erroneous results. Careful attention to the detailed procedures herein will assure that the effects of external contaminants are minimized.

9. SAMPLE TAKING.





Hydraulic Fluid, SAE AS1241 5

NOTE Sampling points that have not been

adequately cleaned prior to use may produce erroneous test results and needless rejection of the system under test.

a. Remove dirt and other external contaminants

from the sampling point by wiping with clean disposable wiping cloths (WP002 00, Table 3, Item 14).

NOTE Electronic Particle Counter Bottles shall

be cleaned only with hydraulic fluid. If using sample kit NSN 9125-01-477-9105 pre-cleaned bottles, no further cleaning is necessary.

b. Clean the required number of sample bottles,

caps and the threaded area of bottle caps (WP002 00, Table 3, Items 21 thru 25) prior to use by rinsing and flushing with the fluid from the system being analyzed. Initiate the flow of fluid to be sampled by an appropriate means; allowing an initial quantity to flow into a suitable waste receptacle (WP002 00, Table 3, Item 20). This will serve to flush any contaminants in the sampling line and any contaminants generated by mechanical operation. Remove the cap from the bottle, fill the bottle to be cleaned approximately half full with the fluid from the sampling point. Shutoff flow from sampling point, if necessary. Replace cap on bottle opening, agitate the sample bottle several times, remove the cap and dump contents into an

NAVAIR 01-1A-17 005 00 TO 42B2-1-12 Page 4

suitable waste receptacle (WP002 00, Table 3, Item 20). Repeat this operation two times to remove residual contaminants. Replace cap on bottle. If flow to sampling point has been terminated, re-open sampling port. Without interrupting the fluid flow, obtain the required sample by replacing the uncovered, rinsed, and clean sample bottle under the fluid stream. Once the bottle is filled to the shoulder or fill line, remove it from the fluid stream and terminate the flow of sample fluid. Install cap on sample bottle and affix a tag or label identifying aircraft or equipment and the specified sampling point.

10. FILTER BOWL CONTENT SAMPLING (NAVY USE ONLY). Filter bowl residue samples can be taken from a filter bowl. Aircraft filter assemblies are sampled by removing the filter bowl contents of both the bowl and the element and transferring the fluid contents to a clean sample bottle. The amount of fluid obtained will vary with the type of filter assembly.

11. Filter Bowl/Element Hydraulic Fluid Samples. Hydraulic fluid samples obtained from filter bowls and/or elements are not suitable for determination of system contamination levels and shall not be so employed. Filter bowl/element samples are rendered useless in determining the system class level of contamination as a result of the following conditions:

a. Sedimentation

b. Functional location

c. Inability to obtain the required 100 ml of hydraulic fluid to conduct the testing

12. Filter Bowl Residue Samples Filter bowl residues should be analyzed, using the Contamination Analysis Kit 57L414 (08071) (Figure 1), for purposes of monitoring hydraulic system degradation, suspected impending component failure, or in isolating a cause for continued contaminant generation.

13. CONTAMINATION ANALYSIS

Samples showing visible water orcloudiness shall not be tested

14. VISUAL ANALYSIS FOR WATER CONTAMINATION. Prior to sample processing, the

fluid under test should be given a careful visual examination for possible free water. Water can be recognized in hydraulic fluid samples in the form of droplets which usually settle to the bottom of the sample bottle. Allowing the fluid sample to remain motionless for 10 minutes or longer may facilitate the formation of visible droplets if water is present. Fluid samples that are hazy or pink in appearance indicate the presence of water. Another identical sample bottle filled with a standard of unused fluid can be used for comparison. If water is observed, take another sample from the system to verify the indication and initiate corrective maintenance (refer to WP006 00).

NOTE

Contamination analysis using kit P/N 57L414 not applicable to USAF. Early models of Contamination Analysis Kit 57L414 were equipped with semi-transparent sample bottles. With these kits, the examination for water must be performed after the fluid sample is transferred from the sample bottle to a clear measuring graduated cylinder.

15. The Contamination Analysis Kit 57L414 (08071), shown in Figure 1, shall be used for testing only if electronic particle count testing is not available either directly or via the appropriate supporting Intermediate Level (I-level) activity or Navy Oil Analysis Program (NOAP) laboratory. The equipment employs a patch test method in which a fluid sample of known volume is filtered through a test filter membrane of known porosity. All particulate matter in excess of a size determined by the filter characteristics is retained on the surface of the membrane causing it to discolor an amount proportional to the particulate level of the fluid sample. (Refer to WP017 00 for operation instructions and parts breakdown).

NOTE

MIL-PRF-680 (WP002 00, Table 3, Item 6) is the only solvent authorized for performing the contamination analysis with kit P/N 57L414 (Patch Test).

16. The typical color of contamination in any given system remains fairly uniform. The degree of filter membrane discoloration may be correlated with a level of particulate contamination. By visually

NAVAIR 01-1A-17 005 00 TO 42B2-1-12 Page 5

005001

Figure 1. Contamination Analysis Kit P/N 57L414 (NAVY USE ONLY)

comparing the test filter with Contamination Standards representative of known contamination levels, a judgment can be made as to the contaminant level of the system. Free water will appear either as droplets during the fluid sample processing or as a stain on the test filter.

17. Analyze Test Filter Membrane (Navy Use Only). After the fluid sample is processed, the resultant test filter membrane (patch) should be visually compared with the Contamination Standards. Determine the particulate contamination level by comparing the shade and color of the test patch with the Contamination Standards (Figure 2). If the test patch displays a rust or tan color, use the tan standard patch. If the test patch is gray in color, use the gray standard patch. Follow operating instructions contained in the Contamination Standards. Tan patches occur when rust or iron chlorides are formed in the system or the system contains abnormal amounts of silica (sand). Gray patches are typical of systems containing normal proportions of common wear materials and external contaminants. The following procedures provide test patch analysis.

Do not dispose of test filter patch membrane in ashtrays or other receptacles where the temperature will exceed 250EF (121°C). Flash fires occur when filters are exposed to flame temperatures.

NOTE

Test patches that show a residual pink color may be the result of failure to have washed the filter adequately. Some new hydraulic fluids will also exhibit a residual pink background as shown by example in the Contamination Standards. Green test patches have also been produced by elevated amounts of wear copper and in-service fluid breakdown in some systems.

a. The maximum acceptable particulate level for Naval aircraft is Navy Standard Class 5, and for related SE is Navy Standard Class 3.

b. Visible free water present in either the sample bottle or on the surface of the test patch (at completion of filtration) is cause for rejection of the

NAVAIR 01-1A-17 005 00 TO 42B2-1-12 Page 6

005002

Figure 2. Comparing Test Filter with Contamination Standards (NAVY USE ONLY)

system under test. A stain on the test filter membrane may be an indication of the presence of free water. When a stain is seen on the test patch, a second fluid sample from the system under test should be obtained and processed so that water content can be confirmed prior to system rejection. Ensure that observed water is not a result of atmospheric condensation during the sampling process.

c. Should the system under test fail to meet the Navy Standard Class 5 (or Class 3 for SE) particulate requirement, or should it exhibit free water, the system must be decontaminated in accordance with procedures provided in the applicable Maintenance Instruction Manual (MIM). Refer to WP006 00 of this manual for general information concerning system decontamination.

NOTE

If the result is inconclusive or if ashadowy effect occurs due to incidenceof light on the petri slide, remove patchfrom petri slide for comparison withContamination Standards.

d. Filter bowl patch residues should be evaluated qualitatively based upon requirements of applicable manuals and utilizing experience relative to normal contaminants for specific aircraft systems and hours of operation. Considerable experience is required to adequately perform visual evaluation of filter bowl residues. Experience has shown analysis of main pressure line and case drain filter bowl residue to be useful in verifying failure of components upstream in these particular assemblies. Residue in other filter assemblies is affected by so many other components and factors as to render their interpretation difficult. Filter bowl residue should be analyzed only as a means of identifying or verifying suspected component failure. Such utilization shall be limited to examination of residue from those filter assemblies directly downstream of the component.

18. ELECTRONIC PARTICLE COUNT ANALYSIS (ALL LEVELS OF MAINTENANCE) NAVY USE ONLY. The electronic particle counters provide counts of the number of particles in various size ranges (WP004 00, Table 1). The counts obtained are compared with the maximum allowable under Navy Standard Class 5 for aircraft (and Class 3 for SE). Count exceeding the maximum allowable in

NAVAIR 01-1A-17 005 00 TO 42B2-1-12 Page 7

any size range render the fluid unsuitable for use in Navy aircraft. Electronic particle counters shall be operated and calibrated in accordance with the appropriate NAVAIR manuals as specified in Table 1. When calibration is required for the HIAC 8011-3, utilize calibration fluids, (WP002 00, Table 3, Item 9) for the applications shown in WP002 00. Contact HACH Ultra Analytics to obtain a Return Authorization from the company, then pack and send only the PODS particle counter and its power supply in the black storage case for calibration by manufacturer under the service contract.

19. After collecting fluid sample, sample taker shall attach a label to the sample bottle, showing sample taker’s name, activity, phone number, the name and identifying numbers of the aircraft/SE hydraulic system sample, and the date and the time sample was collected. Properly labeled samples shall be delivered to supporting I-level or NOAP laboratory for testing.

20. In the Organizational Level (O-Level), I-Level, or NOAP laboratory, fluid samples shall be prepared for testing, and the particle counts shall be performed in accordance with NAVAIR instructions and procedures given during operator training. Only personnel with appropriate training shall operate electronic particle counters or perform sample preparation.

21. Results of the particle count testing, in terms of contamination class level determined, shall be reported back to the activity that submitted the sample, and results along with all the sample identifying information shall be entered into a log kept in the testing shop.

22. The contents of the log shall include, at a minimum, the following sample identifying information (see WP017 00):

Squadron/Activity Name Aircraft Bureau Number Serial Number Operator Date Time Class

23. Log book entries shall be maintained for a period of three (3) months.

24. Electronic Particle Counter Description. Three common particle counters are described below. All units use the principle of light extinction to

determine particle size. Light shines through sample fluid to a photodetector. As the fluid from the sample flows past the photodetector at a constant rate, a particle in the fluid would block the light and create a shadow that reduces intensity of light shining on the photodetector. The bigger the shadow, the larger reduction in intensity. The photodetector converts intensity to an electrical impulse whose amplitude is then converted to particle sizes. The fluid from the sample is drawn past the sensor at a constant flow rate by use of a motor controlled syringe pump. Follow appropriate procedure in NAVAIR manuals per Table 1.

25. HIAC/ROYCO Particle Counting System 8011-3 (NAVY USE ONLY). The 8011-3 particle counter, (Figure 3) consists of three primary components: Model 8000A particle counter, ABS2 Bottle Sampler, and HRLD 400 Laser Diode Sensor. It is a non-portable bench top laboratory equipment primarily used at I-Level sites or at NOAP laboratories. Once a sample in a bottle has been properly prepared, it is placed and sealed in the ABS2 sample chamber. The chamber is pressurized and the fluid flows at a constant rate up and out from the bottle and past the HRLD sensor. The sensor measures the particles in the fluid by shining light from a laser diode through the fluid and into a photodetector. Particles in the fluid will block the light; thus, less light registers on the photodetector. The amount of shadow (i.e. decrease in light intensity) on the sensor determines the size of the particle. The intensity of the light is converted to an electrical signal whose amplitude is converted by the Model 8000A particle counter into particle size. As the fluid and particles flow past the sensor, the size and number of particles are recorded in the Model 8000A particle counter which prints the result when enough sample has been drawn (typically two runs of 50 milliliter (ml) of sample). The sample exits the sensor and ABS2 to an external waste container.

26. HACH Ultra Analytics Portable Oil Diagnostic System (PODS) (NAVY USE ONLY). The PODS (Figure 4) is an intelligent, portable, and durable analysis instrument for measuring, storing, and reporting oil contamination levels important for maintaining reliable hydraulic systems operation. The PODS comes in two cases: one black case that contains the PODS and one gray case that contains accessories to run the PODS. The PODS will eventually replace both the UCC CM20.9090 and the HIAC/ROYCO 8011-3 as the only particle counter for analyzing aviation hydraulic fluid samples at both the I- and O-level. The PODS can analyze fluids either in bottle sampling mode or online sampling mode. Fluid

maria.cruse

Typewritten Text

SEE IRAC #15


analyzed in on-line mode may return to SE reservoir if SE had a online sample return and PODS had hose to connect its waste port to that fitting. There are two versions of the PODS: Type 1, MXU-973E and Type 2, MXU-976E. Type 1 can analyze MIL-PRF-83282 and MIL-PRF-5606 and is compatible with most petroleum based fluids. Type 1 is not compatible with phosphate ester based fluids (e.g. Skydrol). Type 2 is compatible with phosphate ester based hydraulic fluids, synthetic and petroleum based fluids. To prevent fluid cross contamination, the Type 2 PODS is used only for phosphate ester based hydraulic fluids. The unit is capable of online sampling

at pressures and temperatures up to 13.8 bar (200 psig) and 131ΕF (55°C), respectively. In bottle sampling mode, the PODS require a clean dry steady pressurized air source. The PODS accessory case contains both an electric driven compressor and two refillable CO2 bottles. The CO2 bottles are quieter and take less space than the compressor.

Table 1. Hydraulic Contamination Analysis Equipment (Navy Use Only)

NOMENCLATURE MODEL/CAGE MANUAL CALIBRATION MANUAL

Particle Counting System (HIAC/Royco) 8011-3 (15887) NAVAIR 17-15-521 NAVAIR 17-20SX-146

Hydraulic Contamination Analysis Equipment (“Patch Test”)

57L414 (08071) WP017 00 N/A

Portable Oil Diagnostic Systems (HACH Ultra Analytics)

Type 1 (petroleum)

2087301-01 (0BVY1)

Type 2 (phosphate ester) 2087301-02 (0BVY1)

NAVAIR 17-15BF-97

N/A

NAVAIR 01-1A-17 005 00 TO 42B2-1-12 Page 9

005003

Figure 3. HIAC/ROYCO 8011-3 Particle Counting System (Navy Use Only)

NAVAIR 01-1A-17 005 00 TO 42B2-1-12 Page 10

005004

Figure 4. Portable Oil Diagnostic System (PODS) Particle Counter (Navy Use Only)



AIRCRAFT SYSTEM DECONTAMINATION

HYDRAULIC SYSTEMS

Reference Material

None

Alphabetical Index

Subject Page No.

Contamination Control Sequence .................................................................................................. 5 Decontamination Methods ............................................................................................................. 2

Air Bleeding................................................................................................................................ 2 Flushing ..................................................................................................................................... 4 Purging....................................................................................................................................... 4 Purifying ..................................................................................................................................... 4 Recirculation Cleaning............................................................................................................... 3 Selection of Decontamination Method....................................................................................... 5

Decontamination Procedures......................................................................................................... 5 Flushing Procedures.................................................................................................................. 8 Purging Procedures ................................................................................................................... 10 Purifying Procedures ................................................................................................................. 7 Recirculation Cleaning Procedures ........................................................................................... 7

Introduction .................................................................................................................................... 2


None

NAVAIR 01-1A-17 006 00 TO 42B2-1-12 Page 2

1. INTRODUCTION.

2. This section provides a discussion of decontamination methods, contamination sequence control, and decontamination procedures.

3. DECONTAMINATION METHODS.

4. System decontamination is an essential maintenance operation performed whenever a system is found to contain fluid unacceptably contaminated with foreign matter, particulates, liquids, and gases or otherwise considered not acceptable for service. The purpose of decontamination is to remove foreign matter from the operating fluid, or to remove the contaminated fluid itself. Five basic methods are utilized in decontaminating aircraft hydraulic systems:

a. Air bleeding

b. Recirculation cleaning

c. Purifying

d. Flushing

e. Purging

5. AIR BLEEDING. Air bleeding is a service operation in which entrapped air is allowed to escape from the closed hydraulic system. Specific air bleed procedures for each model aircraft may be found in the applicable Maintenance Instruction Manual (MIM) or Technical Order (TO). Excessive amounts of free or entrained air in an operating hydraulic system can result in degraded performance, chemical deterioration of fluid, elevated operating temperatures, and premature failure of components. Because of the possible consequences it is important that a hydraulic system be bled of air to the maximum extent possible whenever a component is replaced or the hydraulic system is opened for repairs which could introduce air.

NOTE

Entrapped air in a closed hydraulic system, pressurized above 50 psi, becomes compressed into solution. It will not be released from the fluid until pressure is removed and the air is allowed to be out-gassed (i.e. actuating a reservoir bleed valve during engine start or opening the bleed valve to the atmosphere in the jenny reservoir).

6. Hydraulic fluid can hold large amounts of air trapped in solution when a system is pressurized. Fluid, as received, may contain dissolved air or gasses equivalent to 10 percent by volume and may rise to as high as 20 percent after pumping. Dissolved air is readily pulled from the fluid as it travels through pumps and actuator servovalves and becomes entrained air which causes extra flight control activity, elevated temperatures and intermittent stiffness problems. Free air is most likely introduced into a system during component installation, filter element installation, or opening of the system during repairs.

7. Entrained or free air is harmful to hydraulic system performance. The compressibility of air acts as a soft spring in series with the stiff spring of the oil column in actuators or tubing, resulting in degraded response. Also, because free air can enter fluid at a very high rate, the rapid collapse of bubbles may generate extremely high local fluid velocities. If they occur near metal parts, these high velocities can be converted into impact pressures. This is the phenomenon known as cavitation. Cavitation can cause rapid wear of pump pistons and slide valve metering lands, and is a common cause of component failure.

8. Any maintenance action that involves breaking into the hydraulic system, such as disconnecting a line or removing a component, will invariably result in some air being introduced into the system. The amount of such air can be minimized by prefilling replacement components with new, filtered hydraulic fluid. Because some residual air may still be introduced, it is essential that all maintenance of this type be followed by a thorough air bleed of the compromised system.

9. Most hydraulic systems in high performance aircraft are of the closed type and are designed to allow free air, provided it is not trapped behind a piston rod, check valve, or isolation valve, to self-scavenge back to the system reservoir when a system is depressurized. Air bleed valves are provided at the reservoir to enable removal of any air so entrapped when the system is depressurized. After pressurization, reservoir bleed valves in a closed system will not be effective in air bleeding because the air has now been compressed into solution and must be allowed to depressurize and outgas before the air can be removed from the system.

NAVAIR 01-1A-17 006 00 TO 42B2-1-12 Page 3

Do not adjust hydraulic fittings with system pressure applied. Hydraulic fluid under pressure is dangerous. If fittings are loosened to bleed air at system high points, ensure that internal pressure is relatively low ~100 psi which is sufficient to force air from the system with minimal safety hazard.

10. Air bleed valves are sometimes provided at high points in the aircraft circulatory system, filter assemblies, and remote system components such as actuators, to further facilitate removal of free air. Applicable MIM or TO should be consulted regarding location and use of these additional bleed points. In systems not so equipped, it may be necessary to loosen line connections temporarily at strategic points in the system to permit removal of entrapped air from remote or dead-end points. When bleeding systems in this manner, caution must be exercised to avoid excessive loss of hydraulic fluid and to prevent the induction of air or contaminants into the system when the system is not under pressure.

11. Air inspection procedures are, in many cases, inadequate. Support Equipment (SE) specifically designed to detect and measure air is not presently available to fleet personnel, and indirect methods must be employed to determine the amount of air that might be present in a system. Operating the air bleed valve on the reservoir insertion while the system is unpressurized or as the system is beginning to pressurize (below 50 psi) will reveal whether or not there is excessive air present in the reservoir. However, large amounts of air might be present elsewhere in the system and go undetected. An effective means for measuring the air in your system is the “reservoir sink” check. Using this method, the fluid level in the aircraft reservoir is checked with the system both pressurized and non-pressurized. The presence of air or any compressible gas in the system will cause the pressurized reading to be lower (reservoir sink), indicating the need for possible maintenance action (Figure 1). This check is particularly effective when performed after a period of depressurization (i.e. overnight). In which case the air in solution has had time to outgas and is now in the form of free air.

12. All air bleed operations shall be followed by a check of the system hydraulic fluid level. Fluid replenishment may be required, depending upon the amount of air and fluid purged from the system. Ensure that fluid servicing is performed with fluid dispensing equipment that meets requirements of WP008 00 (Paragraph 6).

13. RECIRCULATION CLEANING. Recirculation cleaning is a decontamination process in which the system to be cleaned is powered from a clean external power source and cycled so as to produce a maximum interchange of fluid between the powered system and the SE used to power it. Decontamination is accomplished by circulating the contaminated fluid through the hydraulic filters in the aircraft system and in portable hydraulic test stands.

14. Recirculation cleaning is a filtration process and can remove only that foreign matter which is retained by the filter elements normally found in the equipment. A key factor in recirculation cleaning is the utilization of high-efficiency 3-micron (absolute) filter elements. These filters have a large dirt-holding capacity in the portable test stands used for this purpose. In a single fluid pass, these filters will remove all particulate matter larger than 3 microns, remove a high percentage of the other particles down to the submicron sizes and reduce the air content of system fluid. While recirculation cleaning is effective in removing hard particulate matter and air contamination from hydraulic fluid that is otherwise serviceable, it must be recognized that the filters are not capable of removing water, other foreign fluids, or dissolved solids. Recirculation cleaning is limited to decontamination of systems found to have a particulate level in excess of Navy Standard Class 5 or air contamination, but whose fluid is considered otherwise acceptable.

15. Recirculation cleaning is an effective way to remove air from the hydraulic fluid if performed in accordance with specific aircraft MIM or TO. Recommend the system be extensively cycled with full power to transfer air-laden hydraulic fluid from the aircraft into the SE to outgas.


006001

Figure 1. Reservoir Level Changes (Reservoir Sink) Indicate Presence of Air In System

16. PURIFYING. Purification is the process of removing particulate, air, water, and volatile contaminants from the hydraulic fluid without altering the physical or chemical properties. A schematic of one typical purifier, P/N AD-A352-8Y10 (A/M37M-2) is illustrated in Figure 2. Contaminated fluid going to the purifier tower is first filtered by a 25-micron (absolute) filter. The vacuum applied to the tower removes air, water, and chlorinated solvents from the contaminated fluid. As the fluid comes out of the tower, it is filtered through a 3-micron (absolute) filter to remove solid particles. This cycle is repeated until a desired level of cleanliness is attained. For systems contaminated with air, water, and chlorinated solvents, the use of a purifier to clean aircraft and SE will reduce the consumption of oil and replace the need for flushing. Additional information on purification equipment can be found in WP009 00 (Paragraph 70).

17. FLUSHING. Flushing is a decontamination method in which contaminated system fluid is removed to the maximum extent practicable and then discarded. It is a draining process that is generally accomplished by powering the aircraft system with a portable hydraulic test stand and allowing the contaminated return line fluid from the aircraft to flow overboard into a suitable receptacle (WP002 00, Table 3, Item 20) for disposal. In effect, filtered fluid from the portable hydraulic test stand is used to displace contaminated fluid in the system and to replenish it with clean serviceable fluid.

18. The amount of fluid removed and replaced during system flushing can vary greatly and will depend upon such factors as the nature of the

contaminant, layout of the system and the ability to produce flow in all affected circuits. Certain portions of operating systems are often “dead ended” in that the fluid associated with them is static and not affected by the normal system fluid flow. Contaminated fluid in these circuits and associated components must be removed by means of partial disassembly and localized draining or flushing. System flushing is generally continued until analysis of return line fluid from the system being decontaminated indicates that the fluid is acceptable. In instances of severe contamination, considerable quantities of hydraulic fluid may be expended and it is important that the portable hydraulic test stand reservoir level be monitored closely and replenished as needed.

19. Flushing is a means to effectively decontaminate a system found to contain water, large amounts of gelatinous type materials, or fluid that is chemically unacceptable (containing solvents). Contamination or fluid degradation of chlorinated or other types cannot be remedied by conventional filtration. Severe cases of particulate contamination, such as those resulting from major component failures, may be more easily corrected by flushing techniques than by recirculation cleaning.

20. PURGING. Purging is a decontamination process in which the aircraft hydraulic system is drained to the maximum extent practicable and the removed fluid discarded. A suitable cleaning agent is then introduced into the hydraulic system and circulated as effectively as possible so as to dislodge or dissolve the contaminating substances. The cleaning operation is followed by complete removal of the cleaning agent and its replacement with new hydraulic fluid. Upon completion of purging, the affected system shall be subjected to a period of flushing and recirculation cleaning to ensure adequate decontamination.

21. Purging of aircraft hydraulic systems shall be performed only upon recommendation from, and under the direct supervision of the Fleet Support Team (FST). It shall be the responsibility of the FST or Aircraft Sustainment Group (ASG) to select the required cleaning agents, provide detailed cleaning procedures, and perform test upon completion of purging to ensure satisfactory removal of all cleaning agents. Whenever possible, purging operations shall be accomplished at a Naval Air Depot (NADEP). Organizational and Intermediate Maintenance Activities (OMA and IMA) are not authorized to perform system purging.

NAVAIR 01-1A-17 006 00 TO 42B2-1-12 Page 5

006002

Figure 2. Fluid Purification System

22. SELECTION OF DECONTAMINATION METHOD. The method of decontamination must be selected according to the type of contamination observed. Recirculation cleaning is usually the most effective of the available decontamination methods, considering maintenance man-hours and material requirements, and is to be utilized whenever possible. However, if the contaminant is some substance other than readily filterable particles, it may be necessary to purify or flush the system, or in certain very extreme cases, to purge it. Table 1 provides information intended to assist in the selection of an appropriate decontamination method. The table refers to chemical analysis and particle counting, as well as to patch testing and visual tests that are normally performed. Chemical analysis and actual particle counts of fluid samples can be provided by NADEP Materials Division Laboratories or the Air Force Petroleum Office (AFPET) upon request. These test results can be used in the selection of a decontamination

method. Flushing and purging should be avoided to the maximum extent possible to minimize fluid waste streams.

23. CONTAMINATION CONTROL SEQUENCE.

24. System decontamination is one operation in a contamination control sequence that also includes hydraulic fluid sampling and analysis. Decontamination is performed when the results of sampling and analysis indicate an unacceptable level of contamination, and is then followed by additional testing to determine when an acceptable level has been achieved.

25. DECONTAMINATION PROCEDURES.

26. Prior to decontamination of an affected system, any failed or known contamination generating

NAVAIR 01-1A-17 006 00 TO 42B2-1-12 Page 6

Table 1. Aircraft Decontamination Requirements

Test Method Abnormal Indication

Decontamination Method Required

(Note 2)

Visual Inspection Free Water - standing or droplets Dissolved Water - pinkish fluid, not clear Gelatinous Substances Visible Gross Particulate Matter Oxidation - dark fluid, not clear Free Air - air bubbles

Flush Flush Flush

SE Recirculation Flush

SE Recirculation

Patch Test

(NAVY USE ONLY)

Excessive Particulate - exceeds Class 5 Water Droplets or Stains Fibers Gross Particulate Matter - extreme contamination from component failure or external sources


SE Recirculation SE Recirculation

Particle Count Excessive Particulate Matter - exceeds Class 5 SE Recirculation

Chemical Analysis (Depot)

Viscosity - out of limits (Note 1) centistokes @ 100°F Flash Point - (Note 3) Water - in excess of (Note 1) ppm Neutralization - in excess of 0.8 mg KOH/g (acid)

Flush Flush Flush Flush

Reservoir Needle Sink Failure per limits as identified in applicable MIM SE Recirculation

Notes: 1. Acceptable limits to be determined by the FST or ASG.

2. Fluid purifiers shall be used instead of flushing when purifying equipment is available except for the following abnormal indications: Oxidation, Viscosity, Flash Point and Neutralization. Fluid purifiers, when authorized, are recommended for use during aircraft and SE recirculation cleaning.

3. Less than the minimum flashpoint required by the applicable military or performance specification.

NAVAIR 01-1A-17 006 00 TO 42B2-1-12 Page 7 components must be replaced. Other components of the system are not to be disturbed unless required.

27. RECIRCULATION CLEANING PROCEDURES. Detailed cleaning procedures for accomplishing recirculation cleaning are required for all aircraft, SE, MIM, and TO. The specific procedures in the applicable MIM or TO shall be utilized. Should the MIM or TO procedures be found nonexistent, inadequate, or be deemed excessive, the procedures specified herein shall prevail and local action shall be taken to report the deficiencies to the appropriate FST or ASG.

28. Minimum Requirements for Recirculation Cleaning. Recirculation cleaning procedures used for decontamination of aircraft and SE hydraulic systems must satisfy the following requirements. Ensure that all procedures embody the basic steps cited. Where an adequate procedure does not exist, the specific minimum requirements stated herein shall be employed as an interim guideline.

a. Employ recirculation cleaning to remove excessive particulate matter such as that resulting from normal component wear, limited component failure, external sources or excessive quantities of air contamination indicated by reservoir needle sink failure.

b. Clean the system by powering it with an external hydraulic test stand. Operate aircraft systems so as to produce maximum interchange of fluid between the aircraft and the test stand. Detailed and functional diagrams shall be provided in the aircraft MIM or TO illustrate the required equipment connections and settings. See Figure 3, View A for a basic functional block diagram for recirculation cleaning. Refer to appropriate SE MIM or TO for recirculation cleaning utilizing a purifier. If procedures are found to be non-existent, contact the responsible FST or ASG.

c. Test stands used for recirculation cleaning are equipped with 3-micron (absolute) non-bypass filtration. Before connecting the test stand to the aircraft or SE, the test stand itself shall be recirculation cleaned, and its contamination level verified to meet Navy Standard Class 3 or cleanliness level or better.

d. When utilizing an external hydraulic test stand, the test stand reservoir selector valve shall be in the appropriate position to allow the aircraft or SE reservoir to drain into the test stand reservoir.

e. If contamination is severe, or if aircraft and SE filters are suspected of being loaded, or damaged, or if differential pressure indicators have been activated, install new (or, if marked “Cleanable”, cleaned and tested) filter elements in the aircraft and SE prior to initiation of cleaning.

f. Set up and operate the test stand in accordance with the aircraft and SE MIM or TO for the system being powered and recirculation cleaned.

g. Operate all circuits (actuators) on the system under-going decontamination a minimum of 15 complete cycles, or in accordance with the specific MIM, Maintenance Requirement Cards (MRC), or TO. Give particular emphasis to the operation of large displacement actuators such as those associated with landing gear and wingfold, when powered by the affected system.

h. Continuously monitor all filter differential pressure indicators, both on the aircraft or SE and external hydraulic test stand during the cleaning process. Replace any loaded filter elements.

i. Sample and analyze the system after cycling of components. If the contaminant level shows improvement but is still unacceptable, repeat the recirculation cleaning process. If no improvement is observed, attempt to determine the source of contamination. System flushing may be required (refer to Paragraph 30).

j. Upon completion of successful recirculation cleaning, service the system as needed to establish the proper reservoir fluid level and to eliminate entrapped air.

NOTE

USAF: Check applicable aircraft maintenance manuals to determine if purifying the aircraft hydraulic fluid has been authorized.

29. PURIFYING PROCEDURES. When purifiers are available, they may be used to remove air, water, particulate contamination and foreign volatile fluid contamination such as chlorinated solvents, instead of flushing the contaminated system. See Figure 3, View B and note the various ways a purifier may be used to decontaminate an aircraft system.

a. The upper diagram in View B applies to purification of non-pressurized systems (i.e. open-air

NAVAIR 01-1A-17 006 00 TO 42B2-1-12 Page 8 reservoirs), where pressure to cycle aircraft components is not required. The purifier return and supply hoses and adapters are used to pump hydraulic fluid to and from the aircraft reservoir respectively.

b. The center and bottom diagrams in View B apply to systems requiring flow and pressure assist in purifying fluid trapped in lines and components.

(1) In the center diagram of View B, the purifier is in-line with the contaminated hydraulic fluid sent from the aircraft and the purified fluid returning to the portable hydraulic test stand.

(2) In the lower diagram of View B, the purifier pumps the contaminated fluid from the reservoir drain of the portable hydraulic test stand and returns the purified fluid through the return port of the test stand. While the reservoir fluid in the test stand is being purified, the test stand is concurrently providing pressurized fluid to the aircraft. With the reservoir selector valve of the test stand set in the TEST STAND RESERVOIR position, the contaminated fluid from the aircraft returns to the test stand tank. Initially, some of the fluid in the aircraft reservoir may flow into the test stand reservoir, overfill the stand’s reservoir and result in spilled hydraulic fluid. To prevent over-filling, the test stand reservoir may need to be under filled (e.g. half full) prior to connecting it to aircraft and monitored.

c. Follow aircraft MIM or TO or consult the FST or ASG for the system to be decontaminated on the most appropriate method, procedure, and purifier to use on the system. Various adapters may need to be fabricated to make all the connections shown in Figure 3. Adhere to the appropriate NAVAIR manual or Air Force TO for the operation of the purifiers.

30. FLUSHING PROCEDURES. Detailed procedures for accomplishing hydraulic system flushing are required for all aircraft, SE MIM, and TO. The specific procedures in the applicable MIM or TO shall be used. Should the MIM or TO procedures be found to be nonexistent or inadequate, local action shall be taken to contact the responsible FST or ASG.

31. Minimum Requirements for Flushing. Flushing procedures used for decontamination of aircraft or SE hydraulic systems must satisfy the following minimum requirements. The FST and ASG must ensure that all procedures utilized meet or exceed the minimum basic steps cited. In instances where an adequate procedure does not exist, the

specified minimum requirements shall be employed as an interim minimum guide.






NOTE

Fluid purifiers shall be used to recirculate aircraft and SE hydraulic system fluids instead of flushing when purifying equipment is available.

a. Use flushing to decontaminate only those systems not capable of being cleaned by means of recirculation cleaning or purifying. Flushing will normally be required to remove fluids that are found to be chemically or physically unacceptable, or fluids contaminated with water, air, other foreign fluids, or particular matter not readily filterable due to either its nature or the quantity involved.

b. Accomplish flushing by powering the contaminated system with an external portable hydraulic test stand, and allow return fluid from the aircraft to flow overboard into a waste container for disposal. Aircraft subsystems shall be operated so as to produce maximum displacement of aircraft fluids by cleaned, filtered fluid from the portable test stand.

NAVAIR 01-1A-17 006 00 TO 42B2-1-12 Page 9

006003

Figure 3. Fluid Flow During Decontamination

NAVAIR 01-1A-17 006 00 TO 42B2-1-12 Page 10

(1) Drain SE reservoir into an approved waste receptacle (WP002 00, Table 3, Item 20) and service with new filtered fluid.

(2) Detail and functional diagrams which illustrate the required equipment configuration should be provided. Refer to Figure 3, View C, for an example of a functional flow diagram.

c. Test stands used for system flushing must be equipped with 3-micron (absolute) filtration and shall have an internal reservoir of 16 gal (minimum). The stand itself shall be recirculation cleaned before it is connected to the aircraft.

d. Drain, flush, and service the reservoirs or other fluid storage devices in the contaminated system prior to system flushing. If contamination is known to have originated at an aircraft pump, the hoses and lines directly associated with the pump output and case drains should be drained and flushed separately.

e. Install new filter elements in the aircraft and SE prior to initiation of flushing.

f. External hydraulic test stands shall be set up and operated in accordance with requirements of the specific aircraft and SE MIM or TO on systems being flushed. Adjust external hydraulic test stand operating parameters in accordance with the aircraft or SE specific MIM or TO.

Depletion of the external hydraulic power source reservoir fluid may result in cavitation or failure of the test stand pump.

g. Monitor the reservoir level in the external hydraulic source continuously during the flushing operation. Replenish the reservoir using approved fluid dispensing equipment before the level decreases to the half-full point.

h. All circuits shall be operated on the system undergoing decontamination until the amount of fluid collected from the aircraft/SE return line is equivalent to approximately three times the fluid capacity of the affected system. Give particular emphasis to reservoirs, actuators, and integrated servocylinders in the utility and flight control systems during the decontamination process.

i. Continuously monitor all filter differential pressure indicators on the aircraft or SE and in the external hydraulic power source.

j. Sample and analyze the system after cycling the components. If contaminant level shows improvement but is still unacceptable, continue the flushing operation. If no improvement is observed, attempt to determine the source of contamination and take appropriate corrective action. Should extensive system flushing fail to decontaminate the affected system adequately or if the cause of contamination cannot be determined, contact the appropriate FST or ASG immediately.

k. Upon successful completion of system flushing, subject the decontaminated system to the minimum period of recirculation cleaning to eliminate possible residual debris and to ensure that the system is in an acceptable condition.

l. Sample the system subsequent to recirculation cleaning to verify that contaminant level is satisfactory. Repeat the flushing or recirculation cleaning operation in accordance with Paragraphs 27 and 30 if an unsatisfactory contaminant condition is again detected.

m. Upon successful completion of system decontamination, service the system as needed to establish proper reservoir fluid level.

32. PURGING PROCEDURES. System purging is not considered a normal maintenance operation, and required procedures are not provided in the applicable MIM or TO. The specific techniques and material required must be custom-engineered on a case-by-case basis by the appropriate FST or ASG in consultation with a supporting materials laboratory.

33. Minimum Requirements for Purging. Due to the highly specialized nature of any system purging operation, it is not practical to develop definitive procedures having broad applicability. The following compilation of general guidelines is used by the FST or ASG in the development of such procedures.


NAVAIR 01-1A-17 006 00 TO 42B2-1-12 Page 11/(12 blank)





a. Determination should be made as to whether the contamination is widespread or confined to a particular section of the system. If localized, the purging operation should be confined to the affected portion of the system.

b. The affected portions of the system should be drained to the maximum extent practicable prior to initiation of purging.

c. The cleaning agent(s) shall be drained to the maximum extent practicable.

d. The purged areas shall be flushed with hydraulic fluid. Flushing should continue until chemical analysis of the downstream fluid indicates complete removal of the cleaning agent previously used and the contamination level is acceptable.

e. The entire affected system and purifier (if used) shall be flushed and recirculation cleaned using the normal system operating hydraulic fluid. After the system is returned to service, it should be sampled periodically to detect possible recurrence of the original condition.

34. The selected cleaning agent(s) should be introduced and circulated through affected lines and components, using an appropriate method. Selection of cleaning agent(s) is of extreme importance, and it shall be ensured that the chosen material satisfies the following basic requirements:

a. It must be effective in absorbing, releasing, or otherwise facilitating the removal of the contaminating substance.

b. It must be compatible with all materials, both metallic and nonmetallic, with which it will come in contact.

c. It must be capable of being totally removed or neutralized subsequent to use.



HYDRAULIC CONTAMINATION CONTROL

HYRAULIC SYSTEMS

NAVY USE ONLY

Reference Material

Maintenance Program, Naval Aviation .................................................................. COMNAVAIRFORINST 4790.2

Alphabetical Index

Subject Page No.

General Contamination Control Program Requirements ............................................................... 2 Clean Work Areas...................................................................................................................... 3 Contamination Measurement..................................................................................................... 2 Filter Element Cleaning ............................................................................................................. 3 Quality Assurance...................................................................................................................... 2 Procedures................................................................................................................................. 3 Responsibilities.......................................................................................................................... 2 Support Equipment .................................................................................................................... 3 System Decontamination........................................................................................................... 3 System Filters ............................................................................................................................ 3 Training ...................................................................................................................................... 2

Introduction .................................................................................................................................... 2 Specific Contamination Control Program Requirements ............................................................... 3

Maintenance Practices .............................................................................................................. 4 Maintenance Procedures........................................................................................................... 3


None


1. INTRODUCTION.

NOTE

USAF: This WP not applicable

2. Hydraulic contamination in Navy and Marine Corps aircraft and in related support equipment (SE) has been and continues to be a major cause of failure of hydraulic systems and components. The purpose of this section is to outline the Navy Hydraulic Contamination Control Program. This program is applicable to all Navy and Marine Corps activities involved in the support, manufacture, and maintenance of Naval aircraft, SE, and their related equipment. It is also applicable to contractors, commercial activities, or other government agencies engaged in such activities for the Navy and Marine Corps.

3. GENERAL CONTAMINATION CONTROL PROGRAM REQUIREMENTS.

4. The following general requirements are considered essential to the implementation of an effective hydraulic contamination control program and form the basis for detailed instructions presented in the applicable Maintenance Instruction Manuals (MIM) and elsewhere in this manual.

5. RESPONSIBILITIES. All activities responsible for the design, development, support, resource allocation, or maintenance of aeronautical weapons systems and related equipment shall ensure that contamination of hydraulic systems is prevented to the maximum extent practicable. Every technician performing hydraulic maintenance shall be aware of the causes and effects of hydraulic contamination and be cognizant of practices and procedures to prevent contamination. Supervisory and Quality Assurance (QA) personnel shall likewise be informed and shall ensure compliance with accepted standards. Each maintenance level shall accept that area of responsibility applicable to its maintenance level and shall carry out the required indoctrination, training, and implementation of those procedures applicable to that level of maintenance. The Hydraulic Contamination Control Program is defined in COMNAVAIRFORINST 4790.2 Chapter 10 Par. 10.5.

6. TRAINING. Training shall be consistent with the objectives of an effective aircraft hydraulic system contamination control program. Training aids and

materials shall be reviewed for currency and shall be revised as necessary. Personnel at all levels of aircraft maintenance concerned with aircraft hydraulic systems, components, fluids, and portable hydraulic test stands, shall be indoctrinated or trained as required.

7. CONTAMINATION MEASUREMENT. Contamination measurement standard and acceptability limits have been established to define and control hydraulic contamination levels. The acceptable hydraulic fluid particulate level is Navy Standard Class 5, or cleaner, for naval aircraft and Navy Standard Class 3 for related SE. The contamination level of a particular system shall be determined by analysis of a fluid sample drawn from the system. Analysis shall be accomplished by use of an Electronic Particle Counter or Contamination Analysis Kit 57L414 (WP017 00) at all levels of maintenance. Hydraulic system fluid sampling shall be accomplished on a periodic basis in accordance with the applicable MIM, Maintenance Requirement Cards (MRC), and rework specifications. In addition to the periodic samplings, analysis shall be performed before the next flight:

a. Following extensive maintenance and/or crash/battle damage.

b. When a metal-generating component failure has occurred as directed by applicable MIM, MRC or rework specifications.

c. When erratic flight control function or hydraulic pressure drop is noted.

d. When repeated or extensive system malfunction occurs.

e. Any time the system is subjected to excessive temperature.

f. In any other instance when contamination is suspected.

8. QUALITY ASSURANCE. Quality Assurance shall reject any system which does not meet the required contamination acceptance level. Indiscriminate sampling and analysis shall be avoided. Refer to WP005 00 of this manual, and to the applicable MIM for detailed sampling and analysis requirements.

NAVAIR 01-1A-17 007 00 TO 42B2-1-12 Page 3

9. PROCEDURES. Contamination control procedures shall be developed for each level of maintenance, and shall be sufficiently detailed and practical for that maintenance level. Procedures found to be acceptable shall be incorporated into the applicable MIM. Maintenance data shall be complete, current, and readily accessible to all personnel concerned. Maximum effort shall be made to verify the effectiveness of all contamination control procedures. Hydraulic fluid surveillance in the form of periodic fluid sampling and analysis is essential to an effective contamination control program. These operations, together with associated system decontamination, constitute the major procedural requirement.

10. SYSTEM DECONTAMINATION. Systems shall be decontaminated as required, utilizing recirculation cleaning, purifying, flushing, or purging methods. These methods are defined and described in detail in WP006 00. System purging shall be accomplished only with direction and support of the Fleet Support Team (FST)

11. SUPPORT EQUIPMENT. It shall be ensured that all ground SE used in servicing or maintaining aircraft hydraulic systems are configured, maintained, and operated in a manner consistent with detail requirements of the Hydraulic Contamination Control Program. Refer to WP008 00 and WP009 00 of this manual for applicable minimum requirements.

12. SYSTEM FILTERS. Hydraulic filter elements shall be replaced on either a periodic or conditional basis as specified in the applicable MIM and MRC. Periodic replacement intervals, when specified, shall be consistent with the established service life. Conditional replacement of elements shall be authorized only when it has been determined that the filter assembly has been provided with a known reliable differential pressure indicator. The applicable MIM and MRC shall be reviewed and revised as necessary to ensure adequacy of related test and inspection requirements, and procedures.

13. FILTER ELEMENT CLEANING. Filter element cleaning equipment and cleaning fluids shall be approved for use and conform to the requirements of WP010 00 and WP012 00 of this manual.

14. CLEAN WORK AREAS. Shop facility requirements have been established and maintenance of pumps and other hydraulic

components should be accomplished in work areas conforming to the environmental control criteria outlined in WP011 00 of this manual. Each maintenance activity shall assure that the cleanliness and quality of hydraulic workshop spaces meet or exceed the requirements for that level of maintenance being performed.

15. SPECIFIC CONTAMINATION CONTROL PROGRAM REQUIREMENTS.

16. MAINTENANCE PROCEDURES. The following general procedures relative to contamination control and testing of hydraulic systems, subsystems, components, and fluids are requirements for the applicable maintenance level.

a. Hydraulic fluid contamination controls are necessary to ensure the cleanliness and purity of fluid in the hydraulic system. Fluid sampling and analysis shall be performed periodically. Checks should be made in sufficient time before the scheduled aircraft inspection interval so that if fluid decontamination is required, it can be accomplished at that time. The condition of the fluid will depend to a large degree on the condition of the components in the system. If a system has required frequent component replacement and servicing, the condition of the fluid will have deteriorated proportionately.

b. Replacement of aircraft hydraulic system filter elements shall be accomplished on a scheduled/ conditional basis depending upon the requirements of the specific system. The part number of the filter element shall always be verified before the element is installed in a system or component. Many filter elements look identical, but all are not compatible with flow requirements of the system.

c. In the event that hydraulic system fluid is lost to the point that the hydraulic pumps run dry or cavitate, change defective pumps, check filter elements, and decontaminate as required. Check the applicable MIM for corrective action to be taken regarding decontamination of the system. Failure to do this may result in contamination of the complete system.

d. Hydraulic systems and components shall be serviced using only approved fluid dispensing equipment. (Refer to WP009 00.) Under no circumstances shall used or unfiltered hydraulic fluid be introduced into systems or components.

NAVAIR 01-1A-17 007 00 TO 42B2-1-12 Page 4

e. Ensure that all portable hydraulic test stands receive the required periodic maintenance checks. Make certain that each unit is approved and that the applicable MIM is readily accessible and up to date. When the portable hydraulic test stand is not in use, ensure that it is protected against contaminants such as dust and water. Ensure that the hoses are of the correct and approved type for the fluid and that they are properly capped when not in use. Hoses must be serialized and must remain with the equipment (Refer to WP009 00). Make sure the hoses are coiled, kept free of kinks, and properly stowed. Make sure they are in satisfactory condition and are checked periodically. Replace any hose which exhibits seepage of fluid from the outer cover or separation between the inner tube and the outer cover.

f. Portable hydraulic test stands showing indications of contamination or loaded filters shall be removed from service immediately and returned to the supporting activity for maintenance.



g. Use only approved lubricants for O-ring seals. The use of an incorrect lubricant will contaminate a system. Many lubricants look alike, but few are compatible with hydraulic fluids. The only approved O-ring seal lubricants are hydraulic fluids MIL-PRF-5606 (WP002 00, Table 3, Item 1) and MIL-PRF-83282 (WP002 00, Table 3, Item 2).

17. MAINTENANCE PRACTICES. Certain precautions which fall into the categories of good housekeeping and maintenance practices will assist in the elimination of many problems caused by contamination. The following is provided as practical guidance for all personnel to reduce hydraulic system contamination.






a. Exercise extreme care when working on a hydraulic system in the open, especially under adverse conditions.

b. Exercise extreme caution when working on hydraulic equipment in the vicinity of grinding, blasting, machining, or other contaminant-generating operations. Much of the grit which is harmful cannot be seen with the naked eye.

c. Do not break into hydraulic systems unless absolutely necessary (this includes cannibalization).

d. Use the proper tools for the job.

e. Use only authorized hydraulic fluid, O-rings, lubricants, or filter elements.

f. Use an authorized fluid service unit to dispense hydraulic fluid. Ensure the hydraulic fluid can is clean prior to installation.

g. Keep hydraulic fluid in a closed container at all times.

h. Keep portable hydraulic test stand reservoirs above three-quarters full.

Do not use plastic plugs or caps. Plastic plugs and caps are a possible source of contamination.


i. Seal all hydraulic lines, tubing, hoses, fittings, and components with approved metal closures (refer to WP014 00).

j. Ensure that quick-disconnect dust covers are installed.

k. Store unused caps and plugs in a clean container.

l. Use approved wiping cloths (see WP012 00) to remove exterior contaminants. Use approved lint-free wiping cloths on surfaces along the fluid path.

m. If possible, have the replacement component on hand for immediate installation upon removal of defective component.

n. Replace filters immediately after removal.

o. If possible, fill filter bowl with proper filtered hydraulic fluid before installing. This minimizes induction of air into the system.

p. Do not reset differential pressure indicators if the associated filter element is loaded and in need of replacement (refer to WP008 00).

Clean connectors only with cleanhydraulic fluid.

q. Before connecting a portable hydraulic test stand to an aircraft, clean all connections, interconnect the pressure and return lines of the stand, and circulate the hydraulic fluid through test stand filters.

r. Store O-rings, tubing, hoses, fittings, and components in clean packaging.

s. Do not open or puncture individual packages of O-rings or backup rings until immediately prior to their use.

t. Do not use previously installed or unidentifiable O-rings.

u. Seals or backup rings shall be replaced with new items when disturbed.

When installing O-rings over threaded fitting, prevent threads from damaging O-ring (WP015 00, Figure 14).

v. Decontaminate tubing, hoses, fittings, and components if found or received opened.

w. Decontaminate the system if contamination (including water) is suspected.

NOTE

Ensure that the working area where hydraulic components are repaired, serviced, or stored is clean and free from moisture, metal chips, and other visible contaminants (WP011 00).

x. Perform required periodic checks on equipment used for servicing hydraulic systems in accordance with MRC or technical directives.


y. Use hydraulic fluid MIL-PRF-83282 (WP002 00, Table 3, Item 2) in stationary hydraulic test stands.



SERVICING HYDRAULIC SYSTEMS

Reference Material

None

Alphabetical Index

Subject Page No.

Filter Servicing ............................................................................................................................... 2 Fluid Servicing................................................................................................................................ 2 Introduction .................................................................................................................................... 2


None


1. INTRODUCTION.

NOTE

USAF: For specific fluid servicing and filter servicing requirements, refer to the applicable aircraft maintenance manual.

2. Although aircraft hydraulic systems are capable of reliable unattended operation for long periods of time, some periodic service is generally required. Such service will usually fall into one of the following categories:

a. Fluid servicing

b. Filter servicing

These service operations are performed as required, concurrently with routine tests and inspections of the aircraft. Fluid servicing and system air bleeding must be performed subsequent to any maintenance requiring the opening of fluid connections either in the circulatory system or at hydraulic components.

3. FLUID SERVICING.

4. Fluid servicing consists of adding new filtered hydraulic fluid to the system to replace fluid lost through leakage or as a result of system maintenance or malfunction. Specific procedures exist for checking hydraulic fluid levels in each model aircraft. It is important that the applicable procedures be followed to ensure system operation at the required fluid level. Fluid level is generally determined by means of an indicating device at the system reservoir. The type of indicator used will vary with the aircraft model. Sight-glass, gage type, and piston style indicators are commonly encountered.

5. Because of the close tolerance between operating parts of equipment used in aircraft hydraulic systems and the seriousness of hydraulic fluid contamination, it is extremely important that precautions be taken to ensure that foreign matter is not introduced into the system being serviced. All servicing must be accomplished by qualified personnel using authorized fluid dispensing equipment.

6. Hydraulic systems and components shall be fluid serviced using equipment and procedures that satisfy the following requirements.

NOTE

Use of fluid dispensing equipment is not required for general propeller systems. For specific propeller servicing procedures refer to the applicable Maintenance Instruction Manual (MIM).

a. All servicing shall be performed using approved fluid dispensing equipment equipped with 3-micron (absolute) filtration. Equipment shall be maintained in accordance with applicable MIM, Maintenance Requirement Cards (MRC), and Technical Orders (TO).

b. All hydraulic fluid dispensing equipment shall be maintained in a high degree of cleanliness and stored in a clean, protected environment. This equipment shall be serviced on a periodic basis, including filter servicing (Paragraph 7). When not in use, all fittings or hose ends shall be protected by approved metal closures.

c. Fluid dispensing equipment shall be used only with those specific fluids for which they were intended, and the equipment shall be legibly marked to indicate the type of fluid. Hydraulic systems shall be serviced using only the fluid specified. Precautions shall be taken to avoid accidental use of any other fluid.

d. Hydraulic fluid shall not be left in an open container any longer than necessary, particularly in dusty environments. Exposed fluid will readily collect contaminants which could jeopardize system performance.

e. With the exception of fluid cans or drums installed in approved dispensing units, open cans of hydraulic fluid are prohibited.

f. Hydraulic fluid drained from hydraulic equipment or components shall not be reused. Dispose of drained fluid immediately to prevent accidental reuse.

g. In the event hydraulic fluid is spilled on other parts of equipment on the aircraft, remove spilled fluid using approved wiping materials (see WP012 00).

7. FILTER SERVICING.


8. Replacement of hydraulic filter elements is normally a maintenance operation performed on a periodic basis, but need for prior replacement may be indicated during routine inspection. Hydraulic filter assemblies in some aircraft and Support Equipment (SE) are equipped with indicating devices (“buttons” or “pins”) which will extend when the differential pressure across the filter exceeds a predetermined value indicating a loaded element. Upon appearance of this indication, it becomes necessary to verify the condition of the filter element and replace it if required. When checking or changing filter elements, check the functioning of any pop-up mechanism (refer to WP010 00, Paragraph 25).

9. Loaded filter indicators have protection for both shock and temperature. Loaded filter indication should result in filter replacement. Additional button resets allow continued service with loaded filters. Specific aircraft MIM or TO will address button reset, as allowed.

10. It is important that the applicable MIM or TO be consulted for specific filter element replacement procedures. The following basic principles apply to most replacement operations:

a. Removal of the filter bowl is the first step in replacing the filter element. With most filter assemblies, this operation usually consists of removing a lockwire and unscrewing the bowl from the filter head. In most filter assemblies, an automatic shut-off valve in the head will prevent fluid loss from the system when the bowl is removed.

b. Once the bowl is removed, the fluid is discarded and the bowl is cleaned of sediment by flushing with clean, unused hydraulic fluid.

c. The filter element is, in most instances, removed from the head by a gentle twisting and pulling motion. Once removed, visually inspect the surface of the element. An excessive amount of particulate on the surface of the element may be indicative of upstream component failure and the need for investigation. If the filter element is of the wire mesh type and not available in a timely manner, cleaning may be required. Consult applicable MIM, TO, Fleet Support Team (FST) or Aircraft Sustainment Group (ASG) for guidance.

d. The replacement filter element should not be removed from its protective packing until just prior to installation. Once removed from packing, the element must be carefully handled to protect it from contamination and mechanical damage.

e. The replacement element is installed in reverse order of its removal. In most instances the element is inserted up into the head, employing a gentle twisting motion. O-ring seals located in the head, or sometimes in the element itself, prevent fluid from flowing around the element. It is important that these seals be inspected and replaced in accordance with the applicable MIM or TO.

f. Prior to installation of the cleaned filter bowl, the bowl is first filled with new filtered hydraulic fluid to minimize the introduction of air into the hydraulic system. It is important that the fluid used for this operation be obtained only from an authorized hydraulic fill service unit of the type described in Paragraph 6.

g. Once filled, the filter bowl is carefully and slowly slid up over the installed element and screwed into the head. A quantity of fluid from the bowl will normally be displaced by the element and overflow. Provisions shall be made to collect or absorb all spilled fluid.

h. The installed filter bowl shall be torqued to the value specified in the applicable MIM or TO. The bowl is then lockwired using standard tools and the lockwire provisions in the filter assembly.

i. All filter element installations shall be followed by test and inspection of the system to ensure proper operation. This is generally accomplished by operating the system at its normal pressure and flow rates and inspecting for external leakage at the filter assembly and indications of excessive differential pressure. Any external leakage is unacceptable and shall require that the system be shut down and the problem corrected.

j. Should the filter assembly differential pressure indicator continue to extend after a new element has been installed, the indicator itself is probably defective. Consult the maintenance instructions to determine what corrective action is to be taken.

k. Many filter assemblies encountered may differ in varying degrees from the typical aircraft assembly described. Consult and comply with all applicable procedures.

NAVAIR 01-1A-17 009 00 TO 42B2-1-12 Change 1 – 1 August 2008 Page 1 of 30


HYDRAULIC SUPPORT EQUIPMENT

HYDRAULIC SYSTEMS

NAVY USE ONLY

Reference Material

Organizational, Intermediate and Depot Maintenance Aviation Hose and Tube Manual .................................................................................................................. NAVAIR 01-1A-20 Maintenance Instructions with Illustrated Parts Breakdown (Organizational, Intermediate) Hydraulic Fill Unit............................................................................. NAVAIR 17-15BF-57 Preoperational Checklist Hydraulic Service Unit Model H-250-1............................... NAVAIR 17-600-40-6-1 Periodic Maintenance Requirements Manual Hydraulic Service Unit Model H-250-1 NAVAIR 17-600-40-6-2 Operation and Intermediate Maintenance Instructions with Illustrated Parts Breakdown Hydraulic Fluid Service Unit Type HSU-1........................................... AG-140BA-MIB-000 Preoperational Checklist Hydraulic Service Unit HSU-1 ........................................... AG-140BA-MRC-100 Periodic Maintenance Requirements Manual Service Unit Model HSU-1 ................ AG-140BA-MRC-200 Operation, Organization and Intermediate Maintenance with Illustrated Parts Breakdown, Hydraulic Fluid Servicing Unit Hydraulic Fluid Model PMU-71/E ...... NAVAIR 19-1-96 Fluid Servicing Unit Hydraulic Fluid Model PMU-71/E Part Number 061481-100 GDHB, Preoperational Checklist ........................................................................... NAVAIR 19-600-441-6-1 Periodic Maintenance Requirements Manual Fluid Servicing Unit Hydraulic Fluid Model PMU-71/E Part Number 061481-100 GDHB .............................................. NAVAIR 19-600-441-6-2 Preoperational Checklist Pump, Dispensing, Hand Driven PMU-55E....................... AG-720AO-MRC-000 Operation and Maintenance Instructions with Illustrated Parts Breakdown Pump Dispensing Hand Driven PMU-55/E Part Number 4-5280 .................................... AG-720AO-S15-000 Preoperational Checklist Hydraulic Service Cart Model 310 .................................... NAVAIR 17-600-67-6-1 Operation and Intermediate Maintenance Instructions with Illustrated Parts Breakdown, Pump Hydraulic Fluid Dispensing A/M27M-10.................................. NAVAIR 17-15BF-87 Preoperational Checklist Hydraulic Fluid Dispensing Unit A/M27M-10 ..................... NAVAIR 17-600-107-6-1 Periodic Maintenance Requirements Manual Hydraulic Fluid Dispensing Unit A/M27M-10 ............................................................................................................ NAVAIR 17-600-107-6-2 Operation and Maintenance Instructions with Illustrated Parts Breakdown Air Driven, Portable, Hydraulic Check and Fill Test Stand Model 74 ...................................... NAVAIR 17-15BF-26 Preoperational Checklist Maintenance Requirements Air Driven, Portable, Hydraulic Check and Fill Stand Model 74.............................................................................. NAVAIR 17-600-35-6-1 Calendar Maintenance Requirements Cards Air Driven, Portable, Hydraulic, Check And Fill Stand Model 74......................................................................................... NAVAIR 17-600-35-6-2 Operating and Service Instructions with Parts Breakdown, Air Driven Portable Hydraulic Check and Fill Stand Model 718............................................................ NAVAIR 17-15BF-35 Operation and Intermediate Maintenance with Illustrated Parts Breakdown Test Stand Aircraft Hydraulic Systems A/M27T-6 ......................................................... NAVAIR 17-15BF-90 Preoperational Checklist Test Stand, Aircraft Hydraulic System, A/M27T-6 ............. NAVAIR 17-600-156-6-1 Periodic Maintenance Requirements Manual Test Stand, Aircraft Hydraulic System, A/M27T-6 ................................................................................................. NAVAIR 17-600-156-6-2 Organizational and Intermediate Maintenance with Illustrated Parts

Breakdown, Portable Hydraulics Power Supply (Electric Motor Driven) Model A/M27T-7 and A/M27T-7A .................................................................................... NAVAIR 17-15BF-91 Preoperational Checklist Portable Hydraulic Power Supply A/M27T-7 and A/M27T-7A ............................................................................................................ NAVAIR 17-600-150-6-1


Operation and Intermediate Maintenance Instructions with Illustrated Parts Breakdown,

Portable Hydraulic Power Supply A/M27T-5 and A/M27T-5A............................... NAVAIR 17-15BF-89 Portable Hydraulic Power Supply (A/M27T-5) Preoperational Checklist ................... NAVAIR 17-600-127-6-1 Periodic Maintenance Requirements Manual Portable Hydraulic Power Supply A/M27T-5 .................................................................................................. NAVAIR 17-600-127-6-2 Operation and Intermediate Maintenance with Illustrated Parts Breakdown Electric Hydraulic Power Supply (EHPS) Part Number 040499-100 A/M27T-14 GGJB.... NAVAIR 17-15BF-120 Electric Hydraulic Power Supply A/M27T-14 Part Number 040499-100 GGJB ........ NAVAIR 17-600-BF120-6-1 Periodic Maintenance Requirements Manual, Electric Hydraulic Power Supply A/M27T-14, Part Number 040499-100 TEC GGJB ............................................... NAVAIR 17-600-BF120-6-2 Operation and Intermediate Maintenance with Illustrated Parts Breakdown Hydraulic Power Supply (Diesel) ........................................................................... NAVAIR 17-15BF-110 Diesel Hydraulic Power Supply A/M27T-15 Part Number 040489-100 GGJE .......... NAVAIR 17-600-BF110-6-1 Periodic Maintenance Requirements Manual, A/M27T-15 Diesel Hydraulic Power Supply Part Number 040489-100 TEC GGJE....................................................... NAVAIR 17-600-BF110-6-2 Organizational, Intermediate, and Depot Maintenance Instructions with Illustrated Parts Breakdown Portable Hydraulic Power Unit A/M27T-3 ................................. NAVAIR 17-15BF-76 Preoperational Maintenance Requirements Portable Hydraulic Power Supply Model A/M27T-3 .................................................................................................... NAVAIR 17-600-101-6-1 Periodic Maintenance Requirements Manual Portable Hydraulic Power Supply A/M27T-3 ............................................................................................................... NAVAIR 17-600-101-6-2 Operation and Maintenance with Illustrated Parts Breakdown Portable Hydraulic Power Supply, Diesel and Electric Part Nos. 000850-100 and 98612-100........... AG-140V22-MIB-000 Pre-Operational, Checklist Portable Hydraulics Power Supply, Diesel 000850 Electric 98612 ..................................................................................................................... AG-140V22-MRC-100 Periodic Maintenance Requirements Manual Portable Hydraulic Power Supply, Diesel, 000850-100 Portable Hydraulic Power Supply, Electric 98612-100.......... AG-140V22-MRC-200

Maintenance Program, Naval Aviation .................................................................... COMNAVAIRFORINST 4790.2

Operation and Maintenance Instructions with Illustrated Parts Breakdown (Intermediate) Aircraft Hydraulic and Pneumatic Component Test Stand Model HCT-10 ........... NAVAIR 17-15BF-37 Aircraft Hydraulic and Pneumatic Component Test Stand HCT-10........................... NAVAIR 17-600-32-6-1 Periodic Maintenance Requirements Manual Aircraft Hydraulic and Pneumatic Component Test Stand HCT-10 ............................................................................ NAVAIR 17-600-32-6-2 Hydraulic Test Stand HCT-12 ................................................................................... NAVAIR 17-15BF-78-1 Hydraulic Test Stand HCT-12 .................................................................................... NAVAIR 17-15BF-78-2 Handbook Operation and Service Instructions with Illustrated Parts Breakdown, Aircraft Hydraulic Hose Check Stand .................................................................... NAVAIR 17-15BF-504 Intermediate and Depot Maintenance with Illustrated Parts Breakdown,

Hydraulic Component Test Stand Navy Model A/F27T-10 ................................... NAVAIR 17-15BF-94 Preoperational Checklist A/F27T-10 Hydraulic Component Test Stand.................... NAVAIR 17-600-T10-6-1 Calendar/Hour/Periodic Maintenance Requirements Manual A/F27T-10 Hydraulic Component Test Stand.......................................................................................... NAVAIR 17-600-T10-6-2 Operation, Service, and Overhaul Instructions Manual with Illustrated Parts

Breakdown, Automatic Flight Control System Servocylinder Test Stand Assembly ............................................................................................................... NAVAIR 17-15BF-41 Preoperational Checklist Hose Burst Test Stand 63A101-E1.................................... NAVAIR 17-600-126-6-1 Periodic Maintenance Requirements Manual Hose Burst Stand P/N 63A101-E1..... NAVAIR 17-600-126-6-2 Operation and Intermediate Maintenance with Illustrated Parts Breakdown Fluid Purifier A/M 37M-2................................................................................................. AG-711BA-MAB-000 Preoperational Checklist Fluid Purifier A/M 37M-2 .................................................... NAVAIR 19-600-201-6-1 Periodic Maintenance Requirements Manual Fluid Purifier A/M 37M-2 ................... NAVAIR 19-600-201-6-2 Operation and Intermediate Maintenance Instructions with Illustrated Parts Breakdown for Hydraulic Purification Unit Model No. HPU-1-5-GH-N-16............. NAVAIR 17-15BF-96 Preoperational Checklist Hydraulic Purification Unit (HPU) Model No. HPU-1-5


Part No. 95163-100 ............................................................................................... NAVAIR 17-600-196-6-1 Periodic Maintenance Requirements Manual Hydraulic Purification Unit (HPU) Model No. HPU-1-5 Part No. 95163-100............................................................... NAVAIR 17-600-196-6-2 Operation and Intermediate Maintenance with Illustrated Parts Breakdown, Hydraulic Fluid Purifier (HFP) Part Number 040505-100 A/M37M-11 GGJF........ NAVAIR 17-15BF-125 Hydraulic Fluid Purifier A/M37M-11 Part Number 040505-100 GGJF ...................... NAVAIR 17-600-BF125-6-1 Periodic Maintenance Requirements Manual Hydraulic Fluid Purifier, A/M37M-11 Part Number 040505-100 TEC GGJF ................................................................... NAVAIR 17-600-BF125-6-2

Alphabetical Index

Subject Page No.

Contamination Control Requirements............................................................................................ 4 Cleanliness ................................................................................................................................ 4 Contamination Analysis ............................................................................................................. 5 Fluid Sampling ........................................................................................................................... 5 Flushing ..................................................................................................................................... 7 Operational Use......................................................................................................................... 5 Periodic Maintenance and Repair ............................................................................................. 5 Purging....................................................................................................................................... 7 Recirculation Cleaning............................................................................................................... 5 Support Equipment (SE) Configuration ..................................................................................... 4

Fluid Dispensing Unit ..................................................................................................................... 8 Fluid Service Cart, Model 310................................................................................................... 9 Fluid Service Unit, Model HSU-1............................................................................................... 8

Hydraulic Fluid Servicing Unit (HFSU), Model PMU-71/E ......................................................... 8 Hydraulic Purification Equipment ................................................................................................... 28 Hydraulic Fluid Purifier (HFP) Model A/M37M-11...................................................................... 28

Hydraulics International Inc Hydraulic Purification Unit ............................................................. 28 Pall Aeropower Corp Hydraulic Purifier A/M37M-2 ................................................................... 28

Introduction .................................................................................................................................... 4 Minimum Requirements for Portable Hydraulic Test Stand Operation

and Aircraft Connection ............................................................................................................... 17 Applying Hydraulic Power to Aircraft ......................................................................................... 23 Cleaning and De-Aerating Test Stand....................................................................................... 22 Pre-Operational Inspections and Procedures............................................................................ 22 Starting Test Stand Engine........................................................................................................ 22 Test Stand Operational Checks................................................................................................. 23 Test Stand Shutdown Procedure............................................................................................... 23

Portable Hydraulic Test Stands ..................................................................................................... 9 Diesel Hydraulic Power Supply (DHPS) A/M27T-15 ................................................................. 17 Electric Hydraulic Power Supply (EHPS) A/M27T-14 ............................................................... 16 Portable Hydraulic Test Stand A/M27T-5 .................................................................................. 16 Portable Hydraulic Test Stand A/M27T-7 .................................................................................. 16

Stationary Hydraulic Test Stands................................................................................................... 24 CGS Scientific Thermodynamics (24461) Hose Burst Test Stand ............................................ 25 Greer Hydraulic Hose Test Stand.............................................................................................. 25 Hydraulic and Pneumatic Component Test Stand HCT-10....................................................... 25 Hydraulic Component Test Stand A/F27T-10............................................................................ 27

Use of Manifolds for Multisystem Operation .................................................................................. 24


None

NAVAIR 01-1A-17 009 00 TO 42B2-1-12 Page 4

1. INTRODUCTION.

NOTE


2. Hydraulic Support Equipment (SE) is that equipment intended for use in servicing and testing hydraulic systems and components. The equipment is utilized at all levels of maintenance and consists of the following general types:

a. Portable hydraulic test stands

b. Hydraulic fluid dispensing equipment

c. Stationary hydraulic test stands

A thorough understanding of each hydraulic SE is essential to its proper utilization in the maintenance of aircraft hydraulic systems. All hydraulic SE are under the cognizance of Naval Air Warfare Center Aircraft Division. The maintenance and operation of specific SE units are described in applicable NAVAIR manuals, and (to a lesser extent) in Maintenance Instruction Manuals (MIM) peculiar to the aircraft. It is the intent of this section to provide a general description of the equipment involved, with specific new requirements not presently available in other applicable publications.

3. Portable hydraulic test stands are mobile sources of external hydraulic power that can be connected to an aircraft hydraulic system to provide power normally obtained from the aircraft hydraulic pumps. They provide a means of energizing the aircraft hydraulic systems for purposes of checkout and maintenance. These test stands are employed both on the flight line and in hangar work areas. Portable test stands are important tools in hydraulic contamination control. They provide the primary means of aircraft hydraulic decontamination. Several types of portable stands are available. They differ primarily in their power source (electric motor or engine driven), functional features, and maximum flow capability.

4. Hydraulic fluid dispensing equipment is portable equipment used for replenishing hydraulic fluid lost or otherwise removed from a system. They provide a means of dispensing new filtered fluid under pressure, in a manner that will minimize the introduction of external contaminants. Several different types are available and described in WP008 00 of this manual.

5. Stationary hydraulic test stands are permanently installed equipment intended for shop testing hydraulic system components. With the exception of

specialized equipment such as hose burst test stands, they are general-purpose equipment capable of performing a variety of tests on components such as hydraulic pumps, actuators, motors, valves, accumulators, and gages. Typical component test stands consist of adjustable sources of hydraulic and shaft driven (for pump drive) power, with the associated regulator and indicating devices that enable component performance to be monitored under simulated operating conditions. Stationary hydraulic test stands are employed at the Intermediate Maintenance Level, ashore and afloat, and for Depot Level Maintenance.

6. CONTAMINATION CONTROL REQUIREMENTS.

7. Because of the direct connection of hydraulic SE to systems or components being checked or serviced, strict measures must be observed to minimize the introduction of external contaminants. Testing units that are not properly configured, maintained, or utilized can be responsible for severe contamination of hydraulic systems in operational aircraft. It is the individual responsibility of all maintenance personnel to ensure that hydraulic SE is maintained and used in accordance with existing contamination control requirements.

8. SUPPORT EQUIPMENT CONFIGURATION. All hydraulic SE shall conform to the following requirements:

a. All SE used to service or test aircraft hydraulic systems or components shall be equipped with adequate output filtration having a rating of 3-microns (absolute). The 3-micron filter assembly shall be of a non-bypass variety, preferably equipped with a differential pressure indicator. It shall be installed immediately upstream of the major fluid discharge ports.

b. Portable hydraulic test stands shall be equipped with recirculation cleaning manifolds and fluid sample valves to enable self-cleaning and fluid analysis prior to connection to equipment under test.

9. CLEANLINESS. All hydraulic SE shall be maintained in accordance with the following cleanliness requirements:

a. All hydraulic SE shall be maintained at the highest level of cleanliness practicable, consistent with its construction and utilization.

b. External fluid connections, fittings, and openings shall be kept clean and contaminant-free at


all times. Surfaces that will come into direct contact with working hydraulic fluid shall be cleaned using a non-chlorinated cleaning agent and wiping materials as specified in WP012 00.

c. Unused fittings or hose ends shall be protected by suitable metal dust caps or other approved closures (WP014 00). Clean polyethylene bags may be used as an interim measure in the absence of approved metal closures, provided the bags are adequately secured, protected from physical damage, and prevent the intrusion of water.

d. Equipment not in service shall be stored in clean, dry areas. Exposure of in-service equipment to precipitation, wind-driven sand, or other environmental contaminants shall be minimized to the greatest extent practicable.

10. OPERATIONAL USE. Users of SE shall observe the following requirements for operational use:

a. Test stands equipped with hydraulic manifolds for self-recirculation cleaning shall be operated in this mode prior to any connection to equipment or components under test. The test stand shall be recirculation cleaned for a sufficient time to enable at least one pass of its total reservoir contents through the internal filtration.

b. Differential pressure or “loaded filter” indicators shall be closely monitored during all SE operation subsequent to the fluid reaching normal operating temperature (+ 85°F minimum ). Equipment operation shall be terminated immediately upon appearance of “loaded filter” indications. Replace the loaded element.

c. Use of SE shall be terminated immediately if the reservoir or outlet fluid is determined or suspected to be contaminated beyond acceptable limits. The user shall inform the supporting maintenance activity immediately so that required remedial action can be taken.

11. PERIODIC MAINTENANCE AND REPAIR. Supporting activities for hydraulic SE shall perform periodic maintenance at each 13-week interval unless otherwise directed. Maintenance requirements are as follows:

NOTE

Refer to NAVAIR 01-1A-20 formaintenance of age-controlled hosesused in SE.

a. All hydraulic SE reservoirs shall be sampled, preferably at a low point drain, and analyzed for particulate and water content.

b. Disposable 3-micron pressure line filters, because of their large dirt-holding capacity, shall be replaced only upon actuation of their differential pressure indicators. Disposable filters not equipped with differential pressure indicators shall be replaced at the prescribed interval.

c. Upon completion of periodic maintenance and repairs that compromised hydraulic system integrity, hydraulic SE shall have a fluid contamination level not in excess of Navy Standard Class 3.

12. FLUID SAMPLING. Sampling points and procedures will vary with the SE type and model. Specific procedures applicable to the particular equipment and consistent with the general requirements of this manual shall be employed whenever available. In instances where specific procedures are not available, sampling shall be performed in accordance with the sampling procedures in WP005 00.

NOTE

Prior to sampling, operate the SE for a minimum of 5 minutes in a manner that will result in fluid flow through its reservoir to ensure uniform distribution of contaminants. Certain model equipment may require return of the pressure outlet to the reservoir fill opening to achieve such flow.

13. CONTAMINATION ANALYSIS. Contamination analysis of SE fluid samples shall normally be done using electronic particle count testing. The contamination analysis kit may be employed if electronic particle count testing is unavailable or impractical. Decontamination of unacceptable equipment shall be performed by means of recirculation cleaning, purifying, flushing, or purging. Refer to WP006 00 of this manual for a general discussion of these methods. Refer to Table 1 of this work package to assist in selecting an appropriate decontamination method.

14. RECIRCULATION CLEANING. Recirculation cleaning is employed when equipment is found to be contaminated beyond acceptable limits (in excess

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Typewritten Text

SEE IRAC #14

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SEE IRAC #12


Table 1. Hydraulic Support Equipment Decontamination Requirements

Test Method Abnormal Indication

Decontamination Method Required

(Note 2)

Visual Inspection Free Water - standing or droplets Dissolved Water - pinkish fluid, not clear Gelatinous Substances Visible Gross Particulate Matter Oxidation - dark fluid, not clear Free Air - air bubbles

Purify Purify Flush


SE Recirculation or Purify

Patch Test

Excessive Particulate - exceeds Class 3 Water Droplets or Stains Fibers Gross Particulate Matter - extreme contamination from component failure or external sources

SE Recirculation Purify

SE Recirculation SE Recirculation

Particle Count Excessive Particulate Matter - exceeds Class 3 SE Recirculation

Chemical Analysis (Depot)

Viscosity - out of limits (Note 1) centistokes @ 100°F Flash Point - (Note 3) Water - in excess of (Note 1) ppm Neutralization - in excess of 0.8 mg KOH/g (acid)

Flush Flush Flush Flush

Notes: 1. Acceptable limits to be determined by the Fleet Support Team (FST).

2. If fluid purification or SE recirculation is not possible due to lack of purifying equipment, design of equipment (e.g. 2 or 3 gallon hydraulic servicing unit) or severity of contamination (e.g. > 2% water or solvents), then refer to SE MIMs for further instruction (e.g. filter replacement or flushing).

3. Less than the minimum flashpoint required by the applicable military or performance specification.

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Typewritten Text

SEE IRAC #14


of Navy Standard Class 3) with particulate matter. With this method, the equipment is self-cleaned using its internal 3-micron filter elements. The procedures utilized shall satisfy the following minimum requirements:

NOTE

Since not all portable hydraulic test standsare designed the same way, seeapplicable equipment manual for properrecirculation cleaning instructions.

a. Operate affected SE in a manner that will result in maximum circulation of fluid through the equipment reservoir and internal 3-micron filter(s). Maintain flow long enough to allow a total flow equivalent to at least five times the total fluid capacity of the equipment reservoir. Monitor all filter differential-pressure indicators throughout the operation and check and replace, in accordance with applicable MIM/Maintenance Requirement Cards (MRC), any elements indicated as being loaded.

b. Resample and analyze fluid from the reservoir. If improvement is shown, but contamination level is still excessive, repeat steps a and b.

c. If no improvement is shown, attempt to locate the internal source of the contaminant observed, such as a failed component. Replace any components determined to be contaminating the fluid and continue decontamination by draining, flushing, and refilling the equipment with new filtered fluid. Recirculation clean and resample to determine acceptability.

d. When fluid samples from the reservoir are determined to be within acceptable limits, recirculation cleaning may be terminated.

15. FLUSHING. This method of decontamination is employed when the SE is found to be heavily contaminated with particulate matter or the fluid contains a substance not readily removed by the internal filters. Flushing procedures shall satisfy the following requirements:






a. Drain, flush, and re-service the equipment reservoir using new filtered fluid. If contamination is known to have originated at the pump, the hoses and lines directly associated with the pump output and case drain should be drained and flushed separately.

b. Operate equipment in a manner that will produce flow through all circuits and allow output (or return line) fluid to dump overboard into a waste receptacle. Continue flushing until a quantity of fluid equal to the equipment reservoir capacity has passed through the unit. Closely monitor reservoir level during the operation and add new filtered fluid, as needed, to prevent the reservoir level from dropping below the one-third full point.

c. Sample and analyze output and reservoir fluids. If contamination level shows improvement but is still unacceptable, repeat the flushing operation. Should extensive flushing fail to decontaminate the affected equipment, request assistance from the supporting engineering activity.

d. Upon successful completion of system flushing, subject the equipment to a minimum period of recirculation cleaning. Sample system again subsequent to recirculation cleaning to verify the contamination level as being acceptable.

e. Service reservoir.

16. PURGING. Purging of SE hydraulic systems shall be performed only upon recommendation from, and under the direct supervision of, the applicable FST. It shall be the responsibility of the FST to select the required cleaning agents, provide detailed cleaning procedures, and perform tests upon completion of purging to ensure satisfactory removal of all cleaning agents. Whenever possible, purging operations shall be accomplished at a Naval Air Depot (NADEP).


Intermediate Maintenance Activities (IMA) are not authorized to perform system purging without direct depot supervision.

17. FLUID DISPENSING UNIT.

18. Several approved types of fluid dispensing equipment are available for use in servicing hydraulic systems. The equipment, differing primarily in their fluid-holding capacity, are listed in Table 2. Use of fluid servicing equipment other than those listed in Table 2, is not authorized unless specifically approved for use by the Aircraft Controlling Custodian, the applicable FST, the NADEP or the Naval Air Systems Command (NAVAIR). In all cases ensure that any equipment so approved is fitted with 3-micron (absolute) filter in the fluid discharge line and that its construction is such that its fluid contents will not be exposed to either internally generated or external contamination. The use of fluid dispensers that do not fully satisfy the specific and general contamination control requirement as stated in this manual is prohibited.

19. FLUID SERVICE UNIT, MODEL HSU-1. Fluid Service Unit, Model HSU-1 (HSU-1 service unit), illustrated in Figure 1, is similar in operation to the Model H-250-1, except that it has a fluid-holding capacity of 3 gallons. Like the H-250-1 servicing unit, this unit also accepts a standard 1-gallon container and uses it as a fluid reservoir. In addition, it contains an integral 2-gallon reservoir assembly. Three micron filtration is incorporated to ensure delivery of contamination-free fluid. 20. The integral 2-gallon reservoir assembly is anodized cast aluminum and, along with a hand pump assembly, is mounted to a cast aluminum base. The lower can piercer (Figure 1) is mounted on top of the reservoir and allows fluid to flow from the installed 1-gallon container into the reservoir, automatically replenishing it. A sight gage indicates the fluid level of the reservoir. It reads from 0 to 2 gallons in 1/4-gallon increments. An indicated level of 2 gallons or less denotes that the 1-gallon container is empty and can be removed for replacement. A capped deaeration port is located on top of the reservoir to permit bleeding the air from the pump and output hose.

21. Can holder and handle assemblies are mounted above the 2-gallon reservoir. The can holder positions the 1-gallon fluid container directly above the reservoir and also provides a means of placing the handle assembly over the container top. The handle assembly is hinged to a bracket on the can holder assembly, and is provided with a spring-loaded latch to lock the handle in the closed position. In addition to

the carrying handle itself, the handle assembly contains an upper can piercer, a vent check valve, and filter. A vent hose is connected between the top of the reservoir (sight gage) and the upper can piercer.

22. Fluid is delivered by means of a single-action piston type hand pump displacement of 1.5 fluid ounces per full stroke at 0 to 250 psi. The pump is operated with sliding pump handle which is held in the extended or retracted position by a spring-loaded ball detent. A replaceable 3-micron (absolute) disposable filter on the pump base removes particulate contamination from the hydraulic fluid being delivered to the suction side of the pump. The filter unseats a shutoff valve which closes the suction port whenever the filter element is being replaced.

23. The HSU-1 service unit is equipped with a 7-foot service hose connected to the unit’s fluid output port at the pump assembly. The hose assembly ends with a short bent-tube assembly for direct connection to fill fittings on the aircraft or components being serviced. A 3-micron inline filter located between the hose end and the tube prevents reverse-flow contamination and serves as a final filter. When the fluid service unit is not in use, it is stored by wrapping the hose assembly around the can holder assembly and by fastening the tube end to the hose storage fitting on the base.

24. HYDRAULIC FLUID SERVICING UNIT (HFSU), MODEL PMU-71/E. The HFSU, P/N 061475-100, illustrated in Figure 2, is a portable hand carried servicing unit for servicing aircraft hydraulic systems from its nominal 2 gallon capacity reservoir.

25. The HFSU has a black static dissipative polyethylene plastic reservoir housing with red aluminum top plate and red reflective tape both around the base and on the carrying handles of the unit. Reservoir has a clear plastic fluid level sight glass that is marked every half gallon up to 2 gallons. The top mark on the sight glass is 2.25 gallons.

26. The manual single-acting self-priming piston pump delivers 3 ounces of fluid per stroke. The pump has an extendable pump handle that is locked in operational or storage position by a removable lanyarded pin. Fluid pressure is controlled by both a relief and a bleed valve. The relief valve is factory set to prevent delivery hose pressure from exceeding 150 psi in pressure. The manual bleed valve allows operator to bleed any pressure in the hose back to the reservoir. A 0 to160 psi pressure gage monitors fluid pressure in the delivery hose.


27. The HFSU has a 15 ft wire braided hose encased within a smooth clear plastic sleeve. A 3-micron absolute filter is located near the end of the hose assembly. After filter housing is another 18” of hose that ends with a -4 flared swivel nut fitting with an attached cap. This swivel nut can attach to quick fill adapter to lock in hose for storage or for recirculating fluid in hose back to reservoir to remove air in hose. Prongs on the sides of the reservoir housing carrying handle hold hose in place during storage or transport. 28. HFSU is designed to be filled by a Hydraulic Fluid Bulk Dispensing Unit (HFBDU). The HBDSU is a specially designed drum pump that fills the HFSU through its quick fill adapter. The HFSU can also be filled by cans, by removing the fill cap and pouring in new fluid with the aid of a funnel.

Do not service aircraft directly from HFBDU. HFBDU is designed only to provide clean hydraulic fluid to servicing equipment and not for servicing aircraft directly.

29. The Hydraulic Fluid Bulk Dispensing Unit (HFBDU) P/N 061482-101, CAGE 56529, illustrated in Figure 3, is a modified extendable 55 gallon self-priming manual rotary drum pump which is used for filling Hydraulic Fluid Servicing Units (HFSU). This painted red drum pump has telescoping suction tube for servicing from drums up to 55 gallons in size. In addition it has an adapter for screwing on to 2” drum bung hole, and delivers from 8 to 10 ounces per full clockwise revolution. A spin-on 10 micron filter is mounted off the pump with a filter change pressure gage. The HFBDU has a 6 foot long hose with a -4 flared swivel fitting at the end with a lanyarded cap. When filling an HFSU, the hose is connected to the HFSU quick fill adapter. 30. In addition, the HFBDU has a desiccant vent filter that screws into the smaller ¾” drum bung hole. This filter minimizes the amount of dust and moisture entering the drum. The filter’s desiccant changes from blue to clear or reddish when it needs to be replaced. It is attached by a Velcro strap to above spin-on filter and has caps to seal filter when stored. 31. FLUID SERVICE CART, MODEL 310. Fluid Service Cart, Model 310 (fluid service cart), illustrated in Figure 4 is a hand-propelled mobile unit designed for servicing aircraft hydraulic systems with fluid obtained directly from the 10-gallon container. It can

be operated by one man and is for use in those applications where the fluid capacity of the H-250-1 servicing unit (1 gallon) or HSU-1 (3 gallons) is inadequate. The hand pump is used to deliver 3-micron (absolute) filtered fluid.

32. The mainframe assembly of the fluid service cart consists of a two-wheel dolly having a tubular handle extending outward to enable hand pushing (or pulling) of the cart. The frame contains an inner bridle which, with the cart in its upright position, may be positioned around and secured to a 10-gallon fluid drum without requiring lifting of the drum. Once installed in the bridle, the drum can be readily moved about using the dolly, or tilted back 90 degrees from vertical to the position required for operation.

33. Hydraulic fluid is removed through a swivel fitting installed in a 2-inch bung. The swivel fitting is connected by means of a flexible hose to a single-action-type pump having a displacement of 2 fluid ounces per stroke at 0 to 250 psi. A replaceable 3-micron (absolute) disposable filter installed at the pump assembly base removes particulate contamination from the fluid being delivered to the suction side of the pump. A check valve in the filter assembly prevents operation without a filter element installed.

34. Filtered fluid from the hand pump is routed to an air trap assembly containing a special chamber that functions to remove any free air that may be present in the fluid. The air trap assembly contains a manual bleed valve for venting collected air, and a 0 to 300 psi pressure gage for monitoring output pressure. Fluid is delivered to the system or component being serviced by means of a 15-foot service hose. A 3-micron in-line filter assembly is located near the discharge end of the service hose to further ensure against system contamination.

35. PORTABLE HYDRAULIC TEST STANDS.

36. Several different models of portable hydraulic test stands are currently in fleet use. While the primary function of this equipment is the same, that is, to provide external ground power to aircraft hydraulic systems, the equipment varies as to fluid flow capabilities, source of prime power and manufacturer. Tables 3 and 4 list test stands commonly available and include pertinent descriptive data to assist with the selection of equipment. It is not the intent of this manual to provide detailed description of, or specific operating instructions for, the listed equipment. The applicable handbooks referenced in Table 3 should be consulted for this information. However, several of the more common test stands are discussed to provide a general familiarity with the equipment.


009001

Figure 1. Fluid Service Unit, Model HSU-1


Table 2. Fluid Servicing Equipment

NOMENCLATURE MODEL NO./CAGE NO. CAPACITY PUBLICATION

Hydraulic Fluid Servicing Unit H-250-1 (28871) 1 gal NAVAIR 17-15BF-57 NAVAIR 17-600-40-6-1 NAVAIR 17-600-40-6-2

HSU-1 (91515) 3 gal AG-140BA-MIB-000 AG-140BA-MRC-100 AG-140BA-MRC-200

PMU-71/E 2 gal NAVAIR 19-1-96 NAVAIR 19-600-441-6-1 NAVAIR 19-600-441-6-2

PMU-55/E (94861) 10 gal AG-720AO-S15-000 AG-720AO-MRC-000

Hydraulic Fluid Servicing Cart

310 (28871) 10 gal NAVAIR 17-600-67-6-1

Hydraulic Dispensing Cart A/M27M-10 (51744) 55 gal

NAVAIR 17-600-107-6-1 NAVAIR 17-600-107-6-2 NAVAIR 17-15BF-87

74 (93974) 5 gal NAVAIR 17-600-35-6-1 NAVAIR 17-600-35-6-2 NAVAIR 17-15BF-26

718-0001 (02032) 7.5 gal NAVAIR 17-15BF-35

Hydraulic Check and Fill Stand

A/M27T-6 (2D882) 5 gal NAVAIR 17-15BF-90 NAVAIR 17-600-156-6-1 NAVAIR 17-600-156-6-2

A/M27T-7 (56529) A/M27T-7A (30003)

20 gal (Note 2)

NAVAIR 17-15BF-91 NAVAIR 17-600-150-6-1

A/M27T-5 (30003) A/M27T-5A

20 gal (Note 2)

NAVAIR 17-15BF-89 NAVAIR 17-600-127-6-1 NAVAIR 17-600-127-6-2

A/M27T-14 25 gal NAVAIR 17-15BF-120 NAVAIR 17-600-BF120-6-1 NAVAIR 17-600-BF120-6-2

A/M27T-15 25 gal NAVAIR 17-15BF-110 NAVAIR 17-600-BF110-6-1 NAVAIR 17-600-BF110-6-2

Portable Hydraulic Test Stand (Note 1)

A/M27T-3 (30003) 3 gal NAVAIR 17-600-101-6-1 NAVAIR 17-600-101-6-2 NAVAIR 17-15BF-76

Notes: 1. This equipment is intended primarily for system check and test with approved fluid dispensing capability.

2. These portable hydraulic test stands have 20-gallon reservoirs that should only be filled to 75% of full capacity (15 gallons). The A/M27T-5A and A/M27T-7A operate at 5000 psig to satisfy the F/A-18E/F/G mode aircraft.


009002

Figure 2. Two Views of Hydraulic Fluid Servicing Unit (HFSU) Model PMU-71E NOTE

Reservoir Housing color is black with red reflective tape along bottom and sides of carrying handle. Hydraulic fluid placard has black text on a white background.

009003

Figure 3. Hydraulic Fluid Bulk Dispensing Unit (HFBDU) P/N 061482-101, CAGE 56529


009004

Figure 4. Fluid Service Cart, Model 310


Table 3. Portable Hydraulic Test Stands

MODEL (Note 1)

MFR & P/N (CAGE) PUBLICATION MRC TEC FLOW CAPACITY

POWER SOURCE

A/M27T-7 A/M27T-7A

68A5-J1000 (56529)

NAVAIR 17-15BF-91 17-600-150-6-1 GGJV GGJ9

20 gpm @ 3000 psi 10 gpm @ 5000 psi (Note 3)

A/M27T-3 Greer 636AS100-1 (26637)

NAVAIR 17-15BF-76 17-600-101-6-1

17-600-101-6-2

GGJU 6 gpm @ 3000 psi 3 gpm @ 4500 psi

Electric (Note 2)

A/M27T-5 A/M27T-5A

Hydraulic International 68A4-J1000-1 (30003)

NAVAIR 17-15BF-89 17-600-127-6-1

17-600-127-6-2

GGJZ GGJ8

20 gpm @ 3000 psi 10 gpm @ 5000 psi (Note 3)

Diesel

A/M27T-14 Hydraulics International, 0449-100 (56529)

NAVAIR 17-15BF-120 17-600-BF120-6-1

17-600-BF120-6-2

GGJB 32 gpm @ 3000 psi 22 gpm @ 5000 psi

Electric

A/M27T-15 Hydraulics International, 04489-100 (56529)

NAVAIR 17-15BF-110 17-600-BF110-6-1

17-600-BF110-6-2

GGJE 32 gpm @ 3000 psi 22 gpm @ 5000 psi

Diesel

PHPS Hydraulic International Diesel P/N: (000850-100) Electric P/N: (98612-100)

AG-140V22-MIB-000 AG-140V22-MRC-100 AG-140V22-MRC-200

S7DJ 50 gpm @ 3000 psi 32 gpm @ 5000 psi

Diesel Electric

Notes: 1. A/M27T-5/-7 test stands are preferred equipment and shall be used whenever available. Other equipment may be used if it conforms to configurations as specified in Paragraph 8.

2. All electric motor-driven units operate from 220/440-V, 60-Hz, 3-phase power source except the A/M27T-14 which operates only on 440-V, 60-Hz, 3-phase power.

3. The A/M27T-5A and A/M27T-7A are upgraded A/M27T-5 and A/M27T-7 for the F/A-18E/F/G with quick disconnects and flowmeters rated for 5000-PSI operation.


Table 4. Portable Hydraulic Test Stand Operating Features

OPERATING FEATURE A/M27T-3

A/M27T-7A/M27T-

7A A/M27T-5A/M27T-

5A

A/M27T-14

A/M27T-15

CAPABILITY AFFORDED

Return line back pressure regulator

No No Yes Compensates for aircraft reservoir pressurization effects. Allows test stand reservoir to be used (open loop) during aircraft test without affecting fluid level in aircraft reservoir. Backpressure can be used to fill aircraft reservoir while in one loop mode.

Pressure line shutoff valve Yes No Yes A/M27T-3: Precludes possible reverse flow from aircraft to stand when closed prior to stand shutdown.

A/M27T-14/-15: Needed for setting system pressure valve. It also shuts off flow to supply port and hose which is required to operate aircraft reservoir fill system.

Reservoir selector valve No Yes Yes Enables use of test stand reservoir when powering aircraft. Aids in removal of air from aircraft fluid.

De-aeration valve Yes Yes Yes Provides limited fluid air removal during operation without test stand reservoir. For the A/M27T-14/-15, this is a manual process vice automatic with the other test stands.

Oil cooler Yes Yes Yes Enables prolonged closed-loop operation, such as when recirculation cleaning test stand.

Reservoir fill service No Yes Yes Provides 3-micron (absolute) filtered fluid for system servicing.

Fluid sampling valves Yes Yes Yes Enables sampling fluid for contamination analysis. In addition, A/M27T-14/-15 has ports that allow for online particle counting.

Recirculation cleaning/hose storage manifolds

Yes Yes Yes Enables recirculation cleaning for test stand and service hoses and provides hose stowage means.

3-micron filtration Yes Yes Yes Enables delivery of particulate-free fluid to equipment under test. A MANDATORY REQUIREMENT.

Purification Ports No No Yes Allows purifier to directly connect to test stand reservoir.


37. PORTABLE HYDRAULIC TEST STAND A/M27T-5. Portable Test Hydraulic Stand A/M27T-5 is a diesel engine driven unit. Figure 5 illustrates a typical unit. The test stand is designed to check the performance and operating characteristics of hydraulic systems installed in aircraft. As a portable, completely self-contained unit, it will perform the following tests and operations:






a. Provide a source of hydraulic fluid at controlled pressures to operate hydraulic components without the necessity of starting the aircraft engine.

b. Test aircraft hydraulic systems for evidence of component malfunction and flow or pressure leakage.

c. Decontaminate and service aircraft hydraulic systems with filtered fluid.

38. The units are designed to deliver fluid volume up to 20 gpm at pressure of 3,000 psi and 10 gpm at 5,000 psi. Fluid contamination during the test cycle is constantly controlled by 3- and 10-micron replaceable element filters.

The fill system and high-pressure system

cannot be operated at the same time without depleting the aircraft reservoirs. Refer to appropriate manual listed in Table 3 to obtain detailed operating instructions and other information relating to the equipment being operated.

39. The A/M27T-5 test stand hydraulic system (Figure 6) consists of two segments; the fill system and the high-pressure system. The fill system provides a capability for servicing the aircraft system with filtered hydraulic fluid. The high-pressure system furnishes fluid to the aircraft system for testing operations under controlled conditions of flow and pressure.

40. PORTABLE HYDRAULIC TEST STAND A/M27T-7. The Portable Hydraulic Test Stand A/M27T-7 is identical to A/M27T-5 test stand, except that it is powered by an electric motor. The motor is capable of operating on 220/440-V, 3-phase, 60-Hz current.

41. The principles of operation and the operating procedures for A/M27T-7 test stand are basically the same as those for the A/M27T-5 test stand, with the exception of starting and stopping procedures and the utilization of electrical power to operate this test stand. Refer to the applicable equipment manual (Table 3) for operational and maintenance instructions.

42. ELECTRIC HYDRAULIC POWER SUPPLY (EHPS) A/M27T-14. The EHPS, P/N 040499-100, is a portable electric powered, self-contained unit designed to check the performance and operating characteristics of aircraft hydraulic systems. The EHPS Electric motor operates on 440/460 VAC, 3 phase 50/60 Hz electric power and capable of drawing up to 100 amps of current. Figure 7 illustrates a typical unit. The EHPS will perform the following tests and operations:







a. Deliver hydraulic fluid at controlled pressures to operate hydraulic components without the necessity of starting the aircraft engine(s). b. Test aircraft hydraulic systems for evidence of component malfunction and flow or pressure leakage. c. Decontaminate and service aircraft hydraulic systems with filtered hydraulic fluid. 43. The EHPS delivers fluid volumes up to 32 gpm at pressure of 3,000 psi and 22 gpm at 5,000 psi. Back pressure on aircraft return line can be adjusted from 10 to 120 psi. The EHPS 3-micron absolute and 10-micron nominal replaceable filters reduce particulate contamination in hydraulic fluid. The EHPS has dedicated purification ports and fluid sampling ports that allow it to connect to an A/M37M-11 Hydraulic Fluid Purifier (HFP) and a MXU-973/E PODS particle counter respectively. Using the fluid sampling ports to allow online particle counting is the preferred method since results are less likely to fail due to operator error and no hydraulic fluid is wasted.

The fill system and high-pressure system cannot be operated at the same time without depleting the aircraft reservoirs. Refer to appropriate manual listed in Table 3 to obtain detailed operating instructions and other information relating to the equipment being operated.

44. The EHPS (Figure 7) consists of two segments; the fill system and the high-pressure system. The fill system provides a capability for servicing the aircraft system with filtered hydraulic fluid. The high-pressure

system furnishes fluid to the aircraft system for testing operations under controlled conditions of flow and pressure. 45. DIESEL HYDRAULIC POWER SUPPLY (DHPS) A/M27T-15. The DHPS, P/N 040489-100, is identical to the A/M27T-14 Electric Hydraulic Power Supply (EHPS) except it is a diesel engine driven unit. Figure 8 illustrates a typical unit. 46. The principles of operation and the operating procedures for an A/M27T-15 DHPS is basically the same as those for the A/M27T-14 EHPS with exception to starting and stopping procedures and the use of a diesel engine. Refer to the applicable equipment manual (Table 3) for operational and maintenance instructions.

47. MINIMUM REQUIREMENTS FOR PORTABLE HYDRAULIC TEST STAND OPERATION AND AIRCRAFT CONNECTION.

48. Due to differences in equipment, the specific instructions for test stand inspection, turn-up, aircraft connection, and operation must be obtained from the applicable maintenance manuals. It is important to be cognizant of certain minimum general requirements considered essential to the proper utilization of all portable test stands. The following is a step-by-step operating procedure that includes these general requirements which should be followed closely:

The following procedure is for general guidance only and does not in itself constitute sufficient indoctrination for its accomplishment. A valid ground SE operator license in accordance with requirements of COMNAVAIRFORINST 4790.2 is required. If test stand has not been utilized for an appreciable period of time or has been subjected to environmental conditions conducive to water condensation in its reservoir, sample and analyze reservoir fluid for possible water contamination in accordance with procedures of Paragraph 13 prior to use.


009005

Figure 5. Portable Hydraulic Test Stand Model A/M27T-5 (Typical)


009006

Figure 6. Hydraulic System Schematic (Typical) A/M27T-5 Test Stand


009007

Figure 7. Electrical Hydraulic Power Supply (EHPS), Model A/M 27T-14 (Typical)


009008

Figure 8. Diesel Hydraulic Power Supply (DHPS), Model A/M 27T-15 (Typical)


49. PRE-OPERATIONAL INSPECTIONS AND PROCEDURES. Perform all required pre-operational inspections and procedures in accordance with applicable equipment MRC listed in Table 3. Ensure that the following are included:






a. Make certain the test stand is located so that adequate room, ventilation, and engine heat dissipation are available.

b. Set parking brakes securely.

c. Open all necessary access doors.

d. Check that the hydraulic fluid level of the test stand reservoir is three-fourths full as indicated on the gage. Add fluid if needed.

e. Check fuel gage, radiator level, and engine oil level in engine-driven stands. Ensure that levels are adequate for anticipated operating period.

f. Check that the pointers of all other gages rest at or near zero.

g. Clean and connect service ends of the external pressure and return line hoses to the hose storage (recirculation) manifold provided on the equipment. If manifold is equipped with shutoff valves, place valve in open position.

50. STARTING TEST STAND ENGINE. Start test stand engine (or motor) in accordance with applicable operating instructions. Allow engine to warm up to normal operating temperature.

51. CLEANING AND DE-AERATING TEST STAND. Recirculation clean and de-aerate the hydraulic fluid in the test stand. Perform both operations concurrently using the following procedures:

a. Set up test stand to provide fluid flow from the internal reservoir through the external service hoses and interconnecting manifold. Place pump pressure compensator at its lowest setting and ensure that the manifold and service outlet valves (if present) are in the open position. The high-pressure gage should indicate a value less than 600 psi.

b. Allow test stand to recirculate clean for 15 minutes. Monitor fluid temperature throughout the cleaning cycle and ensure that maximum operating limits are not exceeded.

c. Monitor all filter differential pressure indicators, particularly those associated with the 3-micron filter assemblies. If indications of a loaded filter are observed after fluid reaches normal operating temperature (85°F minimum), shut down test stand and have replacement filter elements installed.

d. Upon completion of recirculation cleaning and de-aeration, terminate fluid flow to the external service hoses in preparation for connecting to aircraft. Disconnect service hoses from manifold assembly and reinstall manifold dust covers.

NOTE

Consult applicable maintenance manuals for specific procedures to be used in applying external electric and hydraulic power. As a minimum requirement prior to aircraft connection, set hydraulic test stand controls to the positions and values required to accomplish aircraft tests. Operate test stand to confirm settings, reduce volume adjustment to minimum flow and shut down stand prior to aircraft connection.


52. APPLYING HYDRAULIC POWER TO AIRCRAFT. Connect test stand service hoses to the aircraft ground power quick disconnects, ensuring that all connectors are clean prior to connection. Mate all attached dust caps and plugs to protect against their contamination during test stand operation. If dust plugs are not present at end of test stand service hoses, have required plugs installed in accordance with WP014 00. Apply hydraulic power as follows:






a. Check aircraft reservoir level. Aircraft reservoir should be filled to the level specified in the applicable MIM or MRC. If necessary, service reservoir using an approved fluid service unit.

b. Set up test stand to provide for either aircraft or test stand reservoir operation as specified in the applicable MIM. Required mode of operation can be obtained by use of the reservoir selector valve on stands so equipped (refer to Table 4) or by use of the reservoir fluid supply valve. Closure of the test stand reservoir supply valve will enable aircraft reservoir operation.

c. Start test stand and allow to warm up with controls set for bypass fluid flow.

d. Adjust flow rate and operating pressures to required values by means of the volume and pump compensator controls. Set high-pressure relief valve to the operating pressure plus 10 percent.

NOTE

Bypass control should be fully closed during aircraft operation. Adjust operating pressure using pump compensator control only.

e. Test stand is now ready to provide powered operation of the aircraft hydraulic system. Use specific test procedures as provided in applicable MIM.

53. TEST STAND OPERATIONAL CHECKS. Monitor test operation during aircraft test and check for the following:

In some cases, loaded filter indicators may extend due to cold starting conditions. Reset and continue to monitor the indicator until the equipment reaches the normal operating temperature.

a. Monitor filter differential pressure indicators, particularly those associated with the 3-micron filter assemblies. Should a loaded filter be indicated, shut down and return equipment to supporting activity.

b. If fault indicators light, shut down unit and return equipment to supporting activity.

c. If an emergency arises, e.g. ruptured hydraulic hose in aircraft open the bypass valve to relieve pressure and stop flow of hydraulic fluid to aircraft.

d. Stop engine immediately if any engine parts fail. Heed warning signs such as a sudden drop in engine oil pressure or any unusual engine noise.

54. TEST STAND SHUTDOWN PROCEDURE. Upon completion of required aircraft tests, shut down test stand as follows:


In aircraft equipped with pressurizedreservoirs, hydraulic accumulators, orsurge dampers, detrimental reverse flowof fluid through aircraft filters may result ifproper shutdown procedures are notemployed.

a. Leave bypass valve in closed position. Reduce volume setting to zero and adjust pressure compensator to minimum. Allow several minutes for stored pressure in aircraft to bleed off via normal internal leakage.

b. Slowly open pressure bypass valve.

c. Let engine run at 1,000 rpm for about 5 minutes (engine driven models only).

d. Push throttle down completely.

e. Place panel light switch in OFF position.

Do not drag hose ends on deck or otherwise expose to contamination.

f. Remove external hoses from aircraft hose ports and connect loose ends to hose storage manifold disconnects on test stand. Install all dust caps and plugs, including those at aircraft quick disconnects.

g. Close all access doors to protect instruments and controls.

55. USE OF MANIFOLDS FOR MULTISYSTEM OPERATION.

56. When performing troubleshooting, rigging, and specific tests on dual flight control systems employing tandem actuators, it is often necessary to apply SE hydraulic pressure to two or three systems in an aircraft simultaneously. Simultaneous multi-system operation can be accomplished using separate hydraulic test stands for each system, or by

manifolding two or more systems to a common test stand having sufficient flow capability. The latter method employs a minimum of equipment. The following information provides several basic limitations.

a. Utilization of a single test stand and manifold will result in an exchange of hydraulic fluid between the two or more systems so connected. Should the fluid in one system be contaminated with particulate matter smaller than 3 microns or water, cross-contamination of the other systems will occur.

b. The single test stand may not be able to satisfy differing flow and back pressure requirements of the multiple systems to be powered. Depletion or overfilling of aircraft reservoirs may result.

c. High transient flow demands in one system could adversely affect the performance of the other systems powered by the common hydraulic power source. The resulting lack of total isolation between systems could possibly degrade critical flight control system performance tests.

d. The use of jury-rig manifolds not specifically engineered for the purpose can be a safety hazard to personnel and a possible source of system contamination.

57. Properly designed hydraulic manifolds can be employed in limited, specific applications to power multiple hydraulic systems from a common hydraulic test stand. Such usage must be thoroughly evaluated by the applicable FST to ensure acceptability and be strictly limited to the particular application. All approved manifold utilization must be directed in the applicable aircraft MIM and complete information be provided on the source of required hardware. The use of manifolds not authorized in this manner is prohibited.

58. STATIONARY HYDRAULIC TEST STANDS.

59. Stationary hydraulic test stands, as described in Paragraph 5, are installed as special purpose shop test equipment used primarily for component test and repair. Due to their specialized nature, each model test stand has unique installation, operation, and maintenance requirements. For specific data relative to a particular shop test stand, the NAVAIR series manual applicable to the equipment should be consulted. Table 5 provides a list of commonly used shop hydraulic test stands and references the applicable operating manuals. The following is a brief description of the equipment for purposes of familiarization.


60. GREER HYDRAULIC HOSE TEST STAND. Greer Hydraulic Hose Test Stand is shown in Figure 9. This test stand, designed especially for proof-pressure testing of aircraft hose assemblies, is capable of developing static pressures up to 30,000 psi. Hydraulic fluid compatible with the hose is normally used as the testing medium. The high static pressures required for proof-testing are produced by a booster pump powered by shop air having a pressure of 80 to 120 psi.

61. CGS SCIENTIFIC THERMODYNAMICS (24461) HOSE BURST TEST STAND. The CGS Scientific Thermodynamics (24461) Hose Burst Test Stand is similar in operation to the hose test, but has the additional capability for proof-testing pneumatic hoses. It is similar in general appearance to the hose test stand and also derives its input power from the shop air supply. The CGS test stand is capable of proof-testing hydraulic hoses to 15,000 psi and pneumatic hoses to 1,500 psi.

62. HYDRAULIC AND PNEUMATIC COMPONENT TEST STAND HCT-10. The Hydraulic and Pneumatic Component Test Stand HCT-10, shown in Figure 10, is used to bench-test aircraft hydraulic and pneumatic components such as engine-driven hydraulic pumps, electro-hydraulic flight control assemblies, double-acting hydraulic cylinders, pneumatic and hydraulic relief valves, hydropneumatic accumulators, and

other components. The HCT-10 test stand consists of a non-portable cabinet assembly containing a hydraulic system, a pneumatic system, and an electrical system. Connection is required to externally supply electrical power, water, and compressed air.

009009

Figure 9. Greer Hydraulic Hose Test Stand

Table 5. Stationary Shop Hydraulic Test Stands

NOMENCLATURE MODEL/CAGE MAX CAPACITY HANDBOOK

Hydraulic and Pneumatic Component Test Stand

HCT-10 ACL (05172)

40 gpm @ 3,000 psi Pneu. to 6,000 psi


Hydraulic and Pneumatic Component Test Stand HCT-12 100 gpm @ 3,500 psi

60 gpm @ 5,000 psi NAVAIR 17-15BF-78-1 NAVAIR 17-15BF-78-2

Hydraulic Hose Test Stand

RT-6160-100 GREER (26337)

Hydraulic pressure to 30,000 psi NAVAIR 17-15BF-504

Hydraulic Component Test Stand

A/F27T-10, DAYTON T BROWN, (96362)

60 gpm @ 3000 psi 25 gpm @ 8000 psi

NAVAIR 17-15BF-94 NAVAIR 17-600-T10-6-1 NAVAIR 17-600-T10-6-2

Hose Burst Test Stand (Hydraulic and Pneumatic)

63A101-E1 CGS SCIENTIFIC (30003)

Hydraulic pressure to 15,000 psi Pneu. pressure to 1,500 psi



009010

Figure 10. Hydraulic and Pneumatic Component Test Stand Model HCT-10 (05172)


63. The cabinet assembly consists of a welded steel enclosure on a rigid base. Hinged doors and removable panels provide access to the interior. The test component work area is located below the center instrument and control panel. The bottom surface of the test component work area and the test chamber is fabricated in the form of a sink with perforated metal trays. The test chamber is fabricated from 1/4-inch steel plate with a hinged door containing a safety window.

64. Most of the hydraulic and pneumatic system operating controls are located on a sloping panel along the front of the cabinet. The electrical system controls and indicators are located on a panel on the right side of the cabinet. A partition separates the major part of the electrical system components from the hydraulic system.

65. The hydraulic system is composed of a reservoir supplying fluid through a helical screw-type boost pump and a filter to a variable-volume, pressure compensated, axial-piston, high-pressure pump. The system consists of three circuits as follows:

a. The dynamic test circuit is used to test double-acting hydraulic cylinders and other components requiring combined pressure and flow.

b. The static test circuit is essentially a compressed-air-operated, low-displacement, high-pressure pump supplying fluid for static pressure tests. The circuit may be operated independently of the other two test circuits. A safety interlock prevents operation of the circuit when the door of the test chamber is open.

c. The pump test circuit is provided to supply controlled pressure and flow to a variable-displacement, reversible-flow hydraulic motor that, in turn, supplies power for driving hydraulic pumps during tests.

66. The pneumatic system is composed of two circuits. One circuit provides control, indication, and filtration of externally supplied compressed air for operation of the hydraulic fluid temperature control system, operation of the hydraulic static pressure pump, and the pneumatic static pressure booster. The second circuit consists of a portable compressed nitrogen cylinder supplying gas to a supply port through a manually adjusted pressure regulator for the purpose of static pneumatic testing. A safety interlock prevents operation of this circuit when the door of the test chamber is open.

67. HYDRAULIC COMPONENT TEST STAND A/F27T-10. The A/F27T-10 Hydraulic component test stand (HCTS) as show in Figure 11 provides the hydraulic, electrical and pneumatic power, instrumentation and controls necessary for bench testing, diagnostic testing, and functional acceptance of repaired/overhauled components. The HCTS has two operating modes: automatic (keyboard entry and measurements with system status displayed on a monitor) and manual (switch panel controls and measurements with system status read from pressure gages and flow/temperature display/readouts on manual switch panel). The HCTS consists of two non-portable units: the hydraulic console (HC) and an electrical console (ECC).

68. The HC contains the pneumatic static, hydraulic static and hydraulic test and conditioning circuits. The hydraulic static provides fluid to the unit under test (UUT) for proof pressure testing at pressures up to 16,000 psi. The hydraulic test circuit consists of two hydraulic circuits (i.e. Hydraulic Circuit 1 & 2) to provide UUT under controlled flow (rate and direction), and temperature conditions. Hydraulic Circuit 1 is capable of supplying the flows and pressures in Table 5 for the A/F27T-10 via test port P1 and is capable of developing return (back) pressures of up to 1500 psi in hydraulic fluid leaving UUT via port P2. Hydraulic Circuit 2 can provide same pressures and flows as Hydraulic Circuit 1 except that hydraulic fluid flow can be cycled bi-directionally via Hydraulic Circuit 2’s ports P3 and P4. The pneumatic static circuit provides the nitrogen gas from the external nitrogen gas bottle for UUT pneumatic tests and uses a service air-driven pump to boost pressure above bottle pressure if required. The sink area of the HC is where UUTs can be mounted and tested and can be enclosed in the front by four sliding clear removable access panels. Along the walls of the cabinet area are the ports/connectors for hydraulic, pneumatic and electrical panel, sampling port and pressure gage panel. On front of the HC on the right hand side is a switch panel which can be used to operate the stand manually. On the left hand side is a storage cabinet. In addition the HC contains the power and control circuits, control circuit and instrumentation interface.

69. The ECC contains power and control circuits, the system central processing unit (CPU), and CPU peripherals (e.g. computer display monitor, printer, and keyboard). The ECC receives primary input power from the HC and produces 115 VAC, 60 Hz, single-phase power for the CPU and HCTS peripherals. The ECC power and control circuits also develop AC and DC utility power for UUTs. The CPU


and peripheral devices permit the operator to type in test parameters to generate and to apply command instructions to various control circuits for implementation vice manually using switches and buttons to reach test parameters. The Video Display Unit (i.e. computer monitor) displays operational menus, measurements and status information, messages and operator’s prompts.

009011

Figure 11. A/F27T-10 Hydraulic Component Test Stand

70. HYDRAULIC PURIFICATION EQUIPMENT.

71. Hydraulic purifiers (as described in WP006 00 Paragraph 16) are primarily used to remove air, water, and solvent contaminants from hydraulic fluid in aircraft and SE. In addition, purifiers have 3-micron (absolute) non-bypass filtration required for all hydraulic SE to remove solid contaminants. Purifiers provide an option to avoid flushing a contaminated hydraulic system, which generates waste hydraulic fluid and requires the procurement of new fluid. Do not use purifiers for the following:

a. Purifying heavily solvent contaminated (>0.5% solvent) hydraulic fluid (e.g., patch test waste).

b. Purifying mixed fluids (e.g. MIL-PRF-83282 mixed with MIL-PRF-5606).

c. Using purifier to decontaminate different types of fluid (e.g. MIL-PRF-83282 and MIL-PRF-5606) without flushing the purifier between decontamination of different fluid types (fluid cross fluid contamination).

72. Purifiers can clean SE hydraulic fluid in SE contaminated with particulate matter. However,

cleaning the hydraulic system may not correct the inability of the SE to filter its own hydraulic fluid. Neither of the following purifiers were designed to provide, contain, or receive high pressure fluids. As per WP006 00 (Paragraph 29), consult the purifier operating manual in Table 5 in addition to manuals or procedures from the FST for the system requiring decontamination. Table 6 provides a description of commonly used hydraulic purifiers and references applicable operating manuals. The following is a brief description of the equipment for the purpose of familiarization.

73. PALL AEROPOWER CORP HYDRAULIC PURIFIER A/M37M-2. The fluid purifier A/M37M-2 (Figure 12) is a portable electrical (440 VAC) system. WP006 00 (Paragraph 16) provides a concise description of the unit’s operation. Solvents and water removed by the purifier are vented to the atmosphere. If the oil being purified is possibly contaminated with a solvent or fluid which could be hazardous (e.g. toxic, flammable), ensure vapors will be captured and safely handled prior to operation of the purifier.

74. HYDRAULICS INTERNATIONAL INC HYDRAULIC PURIFICATION UNIT. This portable electric driven (440 or 220 VAC) unit P/N 95163-100, (Figure 13), cleans SE hydraulic systems. The unit uses a similar contamination removal technique as the A/M37M-2 but is smaller and has a lower and varying flow rate. Contaminated fluid is drawn past the inlet filter by the purifier’s supply pump at 5 gpm. The fluid then flows into a manifold to a solenoid valve. If the vacuum chamber is full, the solenoid valve opens and directs the fluid back to the pump; thus the unit does not draw in any contaminated fluid (i.e. 0.0 gpm inlet flow). If the vacuum chamber is not full, the solenoid valve stays closed thus directing the fluid through a 10 micron filter and a heater before being sprayed into the vacuum chamber. Water, solvent, and air are removed in the vacuum chamber and the return pump at the bottom if the chamber picks the decontaminated hydraulic fluid. The return pump at 3 gpm sends the fluid past another water separator and 3 micron absolute filter before the fluid returns to the contaminated hydraulic system.

75. HYDRAULIC FLUID PURIFIER (HFP), Model A/M37M-11. The Hydraulic Fluid Purifier A./M37M-11, P/N 040505-100, illustrated in Figure 14 can operate as either an engine driven or as an electric driven (460 VAC) unit to purify contaminated fluid in A/M27T-14 and A/M27T-15 hydraulic power supplies. The operator selects whether to run on either diesel or electric power.


Do not directly hook this purifier toaircraft. Due to purification method, flowrate of fluid entering fluid purifier willdiffer from flow rate exiting purifier. Thiscan result in draining, overfilling ordamaging aircraft reservoirs.

76. The unit uses the same method as the Hydraulics International Inc. Purification Unit P/N 95163-100 to remove particulate, solvent, and both free and dissolved air and water. Contaminated fluid is drawn through an inlet filter by the purifier’s supply pump at 5 gpm. The fluid then flows into a manifold and past a solenoid valve and is sprayed into a vacuum chamber. The vacuum chamber will fill up since the return pump only discharges at 3 gpm back to the system being purified. When the chamber fills up, a high fluid level switch in the chamber is tripped. This opens the solenoid valve. The open valve allows fluid discharged from the HFP supply pump to loop back to the supply pump’s inlet. Since the supply pump flow loops back on itself, the HFP no longer pulls in more fluid from the contaminated system and essentially fluid is no longer sprayed into the vacuum chamber. Since the return pump will still be discharging fluid from the vacuum chamber at 3 gpm, this pump will keep draining the vacuum chamber, until a low level switch in the chamber is tripped. This causes the solenoid valve to return to its initial closed position. This repeats the process, since the supply pump stops looping its fluid, and fluid again starts spraying to back into the vacuum chamber. After the return pump, the fluid flows past two additional filters to remove any additional water and particulates before purified fluid is returned back to the contaminated system it came from.

009012

Figure 12. A/M37M-2 Hydraulic Purifier

009013

Figure 13. Hydraulic Fluid Purifier P/N 95163-100


009014

Figure 14. Hydraulic Fluid Purifier (HFP), Model A/M37M-11

Table 6. Hydraulic Fluid Purification Equipment

NOMENCLATURE MODEL/CAGE NO. FLOW CAPACITY PUBLICATION

Fluid Purifier A/M37M-2 (18350) 9 gpm AG-711BA-MAB-000 NAVAIR 19-600-201-6-1 NAVAIR 19-600-201-6-2

Hydraulic Fluid Purification Unit 95163-100 (56529) (Note 1)


Hydraulic Fluid Purifier A/M37M-11 (56529) (Note 1)

NAVAIR 17-15BF-125 NAVAIR 17-600-BF125-6-1 NAVAIR 17-600-BF125-6-2

Notes: 1. Flow capacity varies from either 0 or 5 gpm inlet into the purifier and 3 gpm on return.



HYDRAULIC FILTERS

HYDRAULIC SYSTEMS

Reference Material

Filter and Filter Elements, Fluid Pressure, Hydraulic Line, 15 Micron Absolute Type II Systems ...................................................................................... MIL-F-8815

Filter and Filter Elements, Fluid Pressure, Hydraulic Micronic Type ......................... MIL-F-5504 Filter and Disposable Element, Fluid Pressure, Hydraulic 3 Micron Absolute........... MIL-PRF-81836

Alphabetical Index

Subject Page No.

Introduction .................................................................................................................................... 2 Types of Filters............................................................................................................................... 2

Differential Pressure Indicators.................................................................................................. 8 Micronic Hydraulic Filter ............................................................................................................ 5 Sintered Bronze Hydraulic Filter ................................................................................................ 5 Support Equipment (SE) Filters ................................................................................................. 5 Woven Wire-Mesh Filter Elements ............................................................................................ 5 5-Micron Noncleanable Filter Elements..................................................................................... 2


None

NAVAIR 01-1A-17 010 00 TO 42B2-1-12 Page 2

1. INTRODUCTION.

2. Continuous filtration of hydraulic fluid during system operation is necessary to maintain system cleanliness. Filters are employed having fine pores or openings which allow hydraulic fluid to pass, but are small enough to trap contaminant particles. Hydraulic filter elements are rated in several ways. The absolute filtration rating is the diameter in microns of the largest spherical particle that will pass through the filter under a certain test condition. This rating is an indication of the largest opening in the filter element. The mean filtration rating is the measurement of the average size of the openings in the filter element. The nominal filtration rating is usually interpreted to mean the size of the smallest particles of which 90 percent will be trapped in the filter at each pass through the filter.

3. TYPES OF FILTERS.

4. A filter is a screening or straining device which cleans the hydraulic fluid by preventing foreign particles and contamination substances from remaining in continuous circulation. Failure to remove such particulate contamination will result in degraded system performance and possible catastrophic failure. Figure 1 shows a typical filter arrangement in a hydraulic system.

5. Hydraulic fluid will hold in suspension tiny particles generated during normal wear of selector valves, pumps, and other system components. These minute particles may damage or impair the function of the units and parts through which they pass if they are not removed by a filter. Because close tolerances exist within a hydraulic system, the performance and reliability of the entire system depends upon adequate filtration.

6. Filters may be located within the reservoir, the pressure line, the return line, or any other location where they are needed to safeguard the hydraulic system against contaminants. Their location in the system and other design criteria determine their shape and size.

7. There are many types of filters. Most filter assemblies used in modern aircraft are of the T-type. The T-type filter assembly is composed of three basic units: a head assembly, a bowl, and a filter element. The head assembly is that part which is secured to the aircraft structure and connecting lines. Within the

head assembly of some filters, there may be a pressure-operated bypass valve which will route the hydraulic fluid directly from the inlet to the outlet port if the filter element becomes loaded with foreign matter. Some design criteria call for a differential pressure indicator which gives a visual indication when the element should be changed. The bowl is the housing which holds the element to the filter head and is removed when element replacement is required.

8. The filter element may be of the 5-micron non-cleanable, woven mesh, micronic, porous metal, or magnetic type. The micronic and 5-micron non-cleanable elements have nonmetallic filter media and are discarded when removed. Porous metal, woven mesh, and magnetic filter elements are usually designed to be cleaned and reused. Hydraulic filters currently in Naval aviation use are considered non-cleanable and are normally discarded.

9. 5-MICRON NON-CLEANABLE FILTER ELEMENTS. Non-cleanable filter elements rated at 5-microns (absolute) represent the current state of the art in hydraulic filtration. Elements of this type afford significantly improved filtration and have greater dirt-holding capacities than other type elements of the same physical size. They are particularly effective in controlling particles in the 1 to 10 micron size range which are normally passed by other type elements and they are capable of maintaining a hydraulic system at much cleaner levels than could previously be achieved. The use of 5-micron (absolute) filters is presently specified for all new design aircraft, and they are being retrofitted to existing fleet aircraft where practical. Hydraulic filter specification MIL-F-8815 describes elements of this type (Figure 2).

10. The most common 5-micron filter medium is composed of organic and inorganic fibers integrally bonded by epoxy resin and faced with a metallic mesh upstream and downstream for protection and added mechanical strength. Filters of this type are not to be cleaned under any circumstances and will be marked DISPOSABLE or NON-CLEANABLE, usually on bottom end cap.

11. Five-micron non-cleanable hydraulic filter elements should be replaced with new elements during specified maintenance inspection intervals in accordance with the applicable procedures. Refer to the applicable Maintenance Instruction Manual (MIM), Maintenance Requirement Cards (MRC) or Technical Order (TO) for replacement intervals and procedures.

NAVAIR 01-1A-17 010 00 TO 42B2-1-12 Page 3

010001

Figure 1. Typical Filter Arrangement in Hydraulic System

NAVAIR 01-1A-17 010 00 TO 42B2-1-12 Page 4

010002

Figure 2. MIL-F-8815 Hydraulic Filter Assembly, Bypass Type

NAVAIR 01-1A-17 010 00 TO 42B2-1-12 Page 5

12. Another 5-micron filter medium of recent design employs layers of very fine stainless steel fibers drawn into a random but controlled matrix. The matrix is then processed by an exclusive procedure which, in successive steps, compresses and sinters (bonds all wires at their crossing points) the material into a thin layer with controlled filtration characteristics. Filter elements of this material may be cleanable or non-cleanable, depending upon their construction, and are marked accordingly.

13. WOVEN WIRE-MESH FILTER ELEMENTS. Hydraulic filter elements employing a stainless steel wire mesh as the filter medium are still used in some fleet aircraft. Filters of this type are generally rated as 15 or 25 micron (absolute) and can be cleaned and reused. MIL-F-8815 describes a series of filter assemblies using 15-micron (absolute) elements of this type which, until recently, were specified for use in Navy aircraft (Figure 3).

14. Wire mesh filter elements should be replaced with cleaned and tested elements during required maintenance inspections.

15. MICRONIC HYDRAULIC FILTER. A typical micronic hydraulic filter is shown in Figure 4. This type of filter was designed to remove 99 percent of all particles 10 to 20 microns in diameter or larger, and uses a replaceable, non-cleanable element. Micronic filters were originally procured in the 1950’s in accordance with MIL-F-5504 and are no longer specified in new design.

16. The micronic filter assembly contains an integral bypass valve to prevent possible element collapse or system starvation. If the micronic filter element becomes loaded, the bypass valve will open when a predetermined pressure differential exists, allowing hydraulic fluid to bypass the filter element.

17. The replaceable element is made of specially treated convolutions (wrinkles) to increase its dirt-holding capacity. Micronic hydraulic filter elements should be replaced with new filter elements during specified maintenance inspections. Refer to the applicable MIM, MRC, or TO for replacement intervals and procedures.

010003

Figure 3. Cross Section of a Stainless Steel Hydraulic Filter Element

18. SINTERED BRONZE HYDRAULIC FILTER. A typical sintered bronze hydraulic filter assembly consists of three parts: (1) head assembly, (2) filter bowl, and (3) element. The element is generally rated at 25 microns (absolute), but has some removal capability down to 5 microns. The filter assembly contains a bypass relief valve and a sintered bronze filter element which can be cleaned. The element consists of minute bronze balls joined together as one solid piece, but still remaining porous. The joining of the balls is known as the sintering process.

19. If the sintered bronze filter element becomes loaded, the relief valve will open when a predetermined pressure differential exists, allowing the hydraulic fluid to bypass the filter element.

20. Sintered bronze filter elements should be replaced with cleaned and tested elements during required maintenance inspection intervals.

21. SUPPORT EQUIPMENT (SE) FILTERS. To ensure delivery of contaminant free hydraulic fluid, all SE must be provided with 3-micron (absolute) non-bypass filtration in their fluid discharge or output pressure lines. With many test stands, the filter used for this application, in addition to having a low micron rating, must be capable of withstanding high collapse pressures and holding large amounts of dirt. Filter assemblies and elements designed specifically for this type of service are available from major filter manufacturers and are presently being used in Navy SE. Military Specification MIL-PRF-81836 describes filters of this type which shall be used in future Navy procurement.

NAVAIR 01-1A-17 010 00 TO 42B2-1-12 Page 6

010004

Figure 4. Micronic Hydraulic Filter

22. Those SE filters conforming to MIL-PRF-81836, and some older types still in service, utilize only a single stage consisting of one large non-cleanable filter cartridge (Figure 5). This configuration has been made possible by improvements in filter elements which permit manufacture of a non-cleanable element capable of withstanding 5,000 psi differential pressures and displaying negligible shedding of media material. Filtration efficiency and dirt-holding capacity of the single-stage filter is comparable to that of the two-stage design and it has the advantage of not requiring second stage element cleaning. Noncleanable single-stage elements can be used to replace both the primary and secondary elements in most two-stage filter assemblies. Applicable maintenance instructions should be consulted to determine filter element requirements and verify interchangeability.

23. Filter assemblies used in SE vary in physical size according to their maximum flow rating. Common sizes in use are 10, 20, and 30 gpm, with the flow rating determining the overall length of the elements used and the filter bowl. To minimize supply requirements, at least one manufacturer provides noncleanable primary stage elements in the form of 10 gpm cartridges capable of being connected together with a simple coupling device. By joining the

required number of 10 gal/min elements together, 20 or 30 gpm cartridges can be locally assembled. All of the SE filter assemblies discussed are of the non-bypass type and are equipped with differential pressure indicators to warn of a loaded element. The differential pressure indicators are, in most cases, preset to activate with an element pressure drop of 100 ± 15 psi, which represents approximately 90 percent of the filter’s total dirt-holding capacity.

24. Unlike most filter elements, 3-micron high-pressure SE filters are not normally replaced on a prescribed periodic basis. Because of their large dirt- holding capacity and nature of service, it has been found more effective to replace such elements only when indicated as being loaded by their associated differential pressure indicators. Element replacement procedures vary with the particular type, and applicable maintenance instructions should be consulted for specific procedures. In the event that the required procedures are either not available, or are inadequate, the following basic steps shall be employed:


NAVAIR 01-1A-17 010 00 TO 42B2-1-12 Page 7





a. Shut down equipment if required, and relieve any hydraulic pressure present.

b. If filter assembly is equipped with drain and air bleed plugs, remove plugs and allow contents of filter bowl to drain into waste container.

c. Remove filter bowl and clean inside surface by flushing with clean filtered hydraulic fluid. If wiping is required to remove heavy dirt deposits, use approved low-lint wiping materials (refer to WP012 00) and follow with additional flush.

d. Remove and discard non-cleanable filter cartridge. Visually inspect outside surface of secondary filter element, when utilized. If secondary element shows evidence of fine “fuzz” (primary stage media) or other particulate matter, remove element and replace with new or cleaned, and retest unit.

e. Install new non-cleanable filter cartridge. Replace all associated packings with new seals.

f. Install drain plug on filter bowl, if removed. Partially fill filter bowl with new filtered hydraulic fluid to minimize entrapped air, and install bowl on filter head. Tighten as required.

g. Install air bleed plug, if removed. Tighten as required. Operate equipment to produce a low output pressure at the filter assembly. Inspect for leaks. Increase system pressure to the maximum normal operating value and ensure that filter assembly shows no external leakage.

010005

Figure 5. Typical High Pressure SE Filter Assembly

NAVAIR 01-1A-17 010 00 TO 42B2-1-12 Page 8

25. DIFFERENTIAL PRESSURE INDICATORS. The extent to which a filter element is loaded can be determined by measuring the drop in hydraulic pressure across the element under rated flow conditions. This drop or “differential pressure” provides a convenient means of monitoring the condition of installed filter elements and is the operating principle used in the differential-pressure or loaded-filter indicators found on many filter assemblies. Differential pressure indicating devices have many configurations, including electrical switches, continuous-reading visual indicators (gages), and visual indicators with memory. Visual indicators with memory usually take the form of magnetic or mechanically latched buttons or pins that extend when the differential pressure exceeds that allowed for a serviceable element. The button or pin, once extended, remains in that position until manually reset and provides a permanent (until reset) warning of a loaded element. This feature is particularly useful where it is impossible for an operator to continuously monitor the visual indicator, such as in an aircraft. Some button type indicators have a thermal lockout device incorporated in their design which prevents operation of the indicator below a certain temperature. For many newer aircraft, indicators are designed so that shock vibration and low temperatures do not cause button activation. A loaded filter indication on these aircraft requires immediate replacement of the filter element, without verification (consult MIM/MRC/TO for guidance). The

lockout prevents the higher differential pressure generated at cold temperatures by high fluid viscosity, from causing a false indication of a loaded filter element.

26. Differential pressure indicators are a component part of the filter assembly in which they are installed and, as such, are normally tested and overhauled as part of the complete assembly. With some model filter assemblies, however, it is possible to replace the indicator itself, without removal of the filter assembly, if it is suspected of being inoperative or out of calibration. It is important that the external surfaces of button-type indicators be kept free of dirt or paint to ensure free movement of the button.

27. Indications of excessive differential pressure, regardless of the type of indicator employed, shall never be disregarded. All such indications must be verified and action taken, as required, to replace the loaded filter element. Failure to replace a loaded element can result in system starvation, filter element collapse, or the loss of filtration where bypass type assemblies are used. Verification of loaded filter indications is particularly important with button-type indicators as they may have been falsely triggered by mechanical shock, vibration, or cold start of the system. Verification is usually obtained by manually resetting the indicator and operating the system to create a maximum flow demand, ensuring that the fluid is at near normal operating temperatures.



CONTROLLED ENVIRONMENT WORK CENTER

HYDRAULIC SYSTEMS

NAVY USE ONLY

Reference Material

Human Engineering Design Criteria For Military Systems Equipment and Facilities .......................................................................................................... MIL-STD-1472

Alphabetical Index

Subject Page No.

Controlled Environment Work Center Fabrication Requirements.................................................. 3 Existing Facilities ....................................................................................................................... 3 New Facilities............................................................................................................................. 5

Controlled Environment Work Center Operating Procedures........................................................ 6 Maintenance and Cleaning ........................................................................................................ 7 Operating Regulations ............................................................................................................... 6 Personnel Regulations............................................................................................................... 7

Design Guidelines .......................................................................................................................... 2 Dimensions ................................................................................................................................ 2 Work Center Environment ......................................................................................................... 3

Introduction .................................................................................................................................... 2 Definitions .................................................................................................................................. 2 General Description ................................................................................................................... 2

Typical Aircraft Hydraulic Components Considered Contamination Critical.................................. 7


None

NAVAIR 01-1A-17 011 00 TO 42B2-1-12 Page 2

1. INTRODUCTION.

NOTE


2. Aircraft hydraulic system contamination control requires a strong emphasis on controlling the amount of contaminants a component can impart to the aircraft hydraulic system. In order to establish this control, depot and intermediate maintenance activities shall establish programs which ensure that dirty components will not contaminate hydraulic systems.

3. This section provides environmental and cleanliness control recommendations for organizational, intermediate and depot level maintenance activities engaged in the repair, overhaul, assembly, and test of hydraulic and pneumatic components. Local environmental conditions may preclude full compliance with these recommendations. The concept of optimum cleanliness during hydraulic and pneumatic component repair, assembly, and test must, however, remain paramount.

4. GENERAL DESCRIPTION. The ideal facility (Paragraphs 8 thru 31) will provide the required degree of cleanliness at minimum cost. It has been determined that an effective and economical approach to control contamination ingestion into critical components during final assembly, is to establish a controlled environment work center incorporating a laminar flow workstation.

5. Using this concept, contamination control is effected through the separation of critical assembly function from other functions by the use of clean workstations, air conditioning, and room pressurization techniques throughout the entire work center.

6. The guidelines contained in this section are intended to assist in establishing a controlled environment work center housing Class 100 Vertical Laminar Flow Work Stations. Designing, dimensioning, fabricating, furnishing, operating and environment are all addressed. These concepts, while not new or innovative, represent contamination control technology applied in a more practical manner than existing clean-room requirements.

7. In applying these concepts, the user must bear in mind that the effectiveness of a component repair facility is dependent upon the attitude and motivation of the personnel utilizing the facility, as well as the

physical facility itself. Strict adherence to the operating procedures will allow the facility to be easily maintained and contamination goals to be realistically achieved.

8. DEFINITIONS.

a. Controlled Environment Work Center: An enclosed workspace, room, or facility in which humidity and inlet air are controlled.

b. Laminar Flow Work Station: A contamination controlled workbench used to ensure a high degree of cleanliness around a component. The workstation contains an atmosphere of extremely low airborne contamination. Laminar Flow Work Stations are normally installed in controlled environment work centers, and come in fixed or mobile module construction.

9. DESIGN GUIDELINES.

10. The controlled environment work center can be of two types:

a. An existing area which is converted into a controlled work center.

b. A facility which is fabricated expressly as a controlled work center. This approach is preferred, but in the interest of time or for budgetary reasons, the former approach may be used with equal effectiveness.

NOTE

If unable to meet the requirements of a Controlled Environmental Work Center,at a minimum, Laminar Flow WorkStations shall be utilized both ashore and afloat for buildup of contamination-critical components.

11. DIMENSIONS. The overall size of the center will be dependent on the following factors:

a. Existing space available.

b. The volume of work to be handled.

c. The number of people who will be working in the center.

d. The furnishings which will be placed in the center.

NAVAIR 01-1A-17 011 00 TO 42B2-1-12 Page 3

e. The equipment which will be utilized in the operation of the center.

f. Ceiling height should not exceed 10 ft.

12. When considering space allocation, include all major items of furnishings, equipment, and conveniences located in the center. Allow sufficient access space around each item (a minimum of 2 feet on each side of a bench which does not butt against a wall or another bench). Fixed test stands, if housed in the controlled environment, should be partitioned off. A typical controlled environment work center is shown in Figure 1.

13. WORK CENTER ENVIRONMENT. The work center environment should conform to the following:

a. The temperature of the controlled environment work center should be 70°F ± 5°F (21°C ± 2.9°C).

b. The relative humidity should be controlled between 35 to 50 percent.

c. Inlet air to the center should be filtered through an 85 percent efficient 15-micron filter (class 300,000 minimum). Inlets should be of sufficient design to allow for even air distribution.

d. The allowable audio noise level should meet MIL-STD-1472 requirements of 75 dB(A) for general workspaces and maintenance shops and 80 dB(A) for shipboard maintenance shops,

e. Vibration should be limited as much as possible.

f. Uniform, shadowless lighting at intensity levels of 1076 to 1625 lux at the work bench level.

g. A positive pressure differential equivalent to 0.05 inches of water shall exist between the center and any adjacent area. When entryways are open, the blower capacity should be adequate to maintain an outward flow of air.

14. CONTROLLED ENVIRONMENT WORK CENTER FABRICATION REQUIREMENTS.

15. EXISTING FACILITIES. In order to fabricate a controlled environment work center within an existing structure, attention must be given to the following design requirements:

a. Walls and ceilings must be rigidly constructed to reduce generation of contaminants due to surrounding structure vibration or movement.

b. Materials used should have a low coefficient of expansion.

c. Ceilings should have adequate structural rigidity to support the installation of lights.

d. Walls should contain a vapor barrier.

e. Materials used in the walls and ceilings should be made of non-chalking, low-shedding materials.

f. Surfaces facing into the work center must be sealed, glossy, and washable. For most applications, one coat of a good grade chromate primer and two coats of hard gloss enamel or epoxy paint is adequate to allow ease of cleaning. White is the preferred color. Assure that the fire rating of all materials meets local codes.

g. All junctures and joints must be sealed. If an existing room with windows is used, the windows should be sealed closed. Internal surfaces should be made flush with the inside wall so as to minimize ledges or offsets.

h. Floors should be capable of supporting anticipated loads without deflection. Masonry or wood floors should be covered with low-shedding materials installed in such a manner as to eliminate cracks or openings. Masonry floors sealed with vinyl or plastic paints are acceptable. Should vinyl tiles be used, assure that the adhesive will not lose its bonding after repeated hydraulic fluid soaks.

i. Entry ways should be sufficiently wide to allow easy passage of personnel and components. Doors should be flush to the inner wall surface. Standard pressure door closers with an enclosed mechanism are required to assure the doors will be closed. All door edges, frames, and sills should be equipped with a continuous seal. Fire emergency exits should be installed as local codes require.

j. Air conditioning equipment for pre-filtering, cooling, heating, humidification, and dehumidification of the controlled work center should be provided as required (Paragraph 13). The airflow to the work center should be independent of the regular surrounding area airflow system.

16. Preparation and Fabrication. The following general guidelines apply to preparation and

NAVAIR 01-1A-17 011 00 TO 42B2-1-12 Page 4

011001

Figure 1. Typical Controlled Environment Control Work Center

NAVAIR 01-1A-17 011 00 TO 42B2-1-12 Page 5

fabrication of a controlled environment work center inside existing facilities:

a. Clean the area of furniture and equipment which do not meet the criteria specified herein.

b. Partitions for test stands and administrative areas shall be installed.

c. All public works functions should be performed:

(1) Electrical service wiring

(2) Water line installation

(3) Air line installation

(4) Telephone installation

All services shall be installed directly through the walls of the center or in the subsurface troughs when possible.

d. Electrical and plumbing fixtures shall be installed or replaced as required. Lighting fixtures shall be recessed. All electrical boxes shall be sealed on the inside. Electrical outlets shall be sealed using smooth faceplates and neoprene gasketing. Valves and regulators shall be bulkhead fitted on smooth service plates.

e. Walls, ceilings, door frames, and windows shall be sealed. Mastic compounds in moderate quantities may be used.

f. Walls and ceiling shall be washed and painted as described in Paragraph 15, step f, to provide a smooth, dust resistant surface. Vinyl covering shall be installed along the wall base for ease of cleaning.

g. Flooring shall be cleaned and repaired or replaced. Requirements are identified in Paragraph 15, step h.

17. NEW FACILITIES. In order to fabricate a new controlled environment work center, attention must be given to the following design requirements:

a. For ease of installation, modular construction shall be used. Panels shall be interlocking. Each panel shall have a vapor barrier and be insulated for close temperature and humidity control.

b. External walls may be of any durable material which is compatible with the activities performed in adjacent areas and the materials available.

c. For most uses, plasterboard or lathe and plaster is sufficient. Internal walls and partitions shall be of a non-flaking material. Stainless steel and plastic Mylar laminate (formica, marlite) are examples of materials which can be used for this purpose. Dry wall may be used, but will require adequate sealing by painting.

d. Ceilings shall be of rigid construction. The ceiling surface shall be washable. Materials used may be the same as used for internal walls. If drop ceilings are used, the ceiling panels shall be non-flaking, such as destaticized vinyl plastic and shall be sealed to reduce air leakage and dust filtration.

e. All public works functions shall be performed. Refer to Paragraph 16, step c.

f. Lighting fixtures shall be flush-mounted to the ceiling and sealed to prevent dust filtration. Light panels may be either clear or translucent panels. Electrical outlets shall be provided with stainless steel faceplates with neoprene gasketing. All electrical boxes shall be sealed on the inside. Valves and regulators shall be stainless steel and bulkhead fitted on service plates where possible.

g. Walls, ceiling, door frames, windows, floors, and entryways shall be sealed and conform to the requirements outlined in Paragraph 14.

h. Air conditioning shall be provided by a recirculating system. Ventilating air for personnel shall be provided at a rate not less than 15 ft3/person. The overall air exchange rate shall not be less than 500 ft3/min/ton of refrigeration. Discharge vents shall be designed for no greater than 500 ft3/min air flow. Air shall be supplied through a 15-micron 85 percent efficient filter. Inlets shall provide even distribution. This may be accomplished by using several louvered ceiling diffusers. Return vents shall be located at or near floor level.

18. Furnishings. Furnishings shall be made of non-flaking material which is easily cleanable.

19. Bench tops may be made of stainless steel or other non-flaking surface such as plastic Melamar laminate. The bench tops shall have a 1/4- to 1/2-inch bevel along the edges to prevent chipping of squared edges. Stools or chairs without arms shall be used and made of either steel with baked enamel finish or vinyl plastic covered construction. Stools and benches shall have plastic glides.

20. Desks, storage and file cabinets within the controlled area should be discouraged as they

NAVAIR 01-1A-17 011 00 TO 42B2-1-12 Page 6

become pockets for contamination collection. Manuals, however, are essential to the functions performed in the center. They may be kept within the controlled center in closed cabinets. Such cabinets shall be steel or baked enamel finishes or laminated materials. Hinged doors, not sliding panels, are preferred. Components, fittings, tools, and accessories essential to the functions performed in the center shall be stored in closed cabinets.

21. Equipment. Most contamination-critical component assembly work conducted in intermediate maintenance activities can be done using mobile modules (Figure 1). These mobile modules are convenient and economical. These provide Vertical Laminar Flow Clean Air anywhere they are placed. Zippered plastic curtains permit mating of units to create large protected areas. Modules are on rubber tired casters for easy moving. Once positioned, wheel brakes hold the module in place. They are commercially available and come in sizes ranging from 4 ft by 4 ft to 6 ft by 8 ft. Size selection depends on criteria outlined in Paragraphs 8 through 11. (Refer to Aircraft Maintenance Material Readiness List (AMMRL) source data.) The following suggested design requirements shall be applied when procuring clean workstation mobile modules:

a. Air Flow: should meet the requirements of ISO 14644-1 and 14644-2 100-ft3/min ± 10 ft3/min at static pressures 0.5W.G. to 1.3W.G. Class 100 air.

b. Pre-filter: Washable polyurethane foam.

c. Final filter: HEPA Type 99.97 percent efficient on particulate 0.3 microns and larger.

d. Noise Level: Less than 65 dB(A) at operator’s level with 48 dB(A) ambient.

e. Blowers: Belt driven statically and dynamically balanced, with adjustable pulley for controlling the rate of airflow.

f. Motor: Continuous duty with sealed-for-life bearings and built in thermal overload.

g. Color: White.

h. Finish: Polyurethane paint.

i. Curtains: 12-mil clear polyvinyl chloride (PVC), zippered at each corner to permit instant closure or opening. Zippered tracks are usually interchangeable so curtains on one unit may be mated to another module.

j. Lighting: Fluorescent fixture to provide 1076 lux at normal bench height.

k. Electrical connectors: Three prong, ground type rubber covered plug and cord for 115-V 60-Hz operations. Other models may have magnetic motor starters for operation on 220/440-V 60-Hz 3-phase power. All lights wired for 115-V 60-Hz power with separate switches.

l. Casters: heavy duty, wheel type, with safety brakes.

22. Suitable hygienic eye wash facilities shall be supplied. A minimum of two squeeze bottle type emergency eye wash stations shall be installed. A preferred eye wash station is full-face-drench twin spray head, eye and face wash with automatic pressure and volume control. Emergency eye wash station squeeze bottles are available.

23. A battery operated, automatic switching emergency light system should be provided in the center to eliminate hazards due to power failure.

24. A minimum of two stored-pressure dry-chemical extinguishers for Class B and C fires shall be provided in the center.

25. Trash receptacles shall be located at strategic spots throughout the work center. Receptacles should be made of plastic for ease of cleaning and shall have self-closing lids (spring loaded or gravity-closure type). Waste oil and oily rags shall be stored in accordance with local command, base, or state Environmental Protection Agency regulations.

26. A first aid kit shall be provided even if the center is located close to a dispensary or medical station.

27. CONTROLLED ENVIRONMENT WORK CENTER OPERATING PROCEDURES.

28. OPERATING REGULATIONS. Detailed regulations for operation of the controlled center shall be established by the user activity. To aid in the establishment of these regulations, the following suggestions are offered:

a. No special garment need be worn. However, personal clothing which tends to produce a great deal of lint, such as sweaters and cotton or flannel shirts shall not be worn in the center.

b. Eating and smoking shall be prohibited in the center.

c. Jewelry shall be removed and placed in side pockets. Personal property normally carried in

NAVAIR 01-1A-17 011 00 TO 42B2-1-12 Page 7

pockets (keys, handkerchiefs, billfolds) is permitted, but should not be taken out or be used. Combs, paper tissue, cosmetics, pocketbooks, and outerwear are considered high potential sources of contamination and should be restricted to one area in the center.

29. PERSONNEL REGULATIONS. The following general regulations should be practiced by all personnel in a controlled environment work center:

a. Data sheets, log books, and manuals may be used in the center, but newspapers and personal books should remain outside. Ball point pens shall be used instead of lead pencils. Manicuring is prohibited.

b. Personnel not regularly employed in the center should not be allowed in the area.

c. Each worker should be held accountable for the cleanliness of his/her workspace, equipment, and tools. Cleaning shall be done with approved wipes and solvents.

NOTE

Tools that are used in repairing internalcomponents shall not be painted.

d. Personnel with persistent coughing, sneezing, peeling sunburn, or other similar conditions should be assigned duties outside the center.

e. Mobile module workstations shall not be used as storage facilities. Only those objects being used in assembly of the component shall be placed in the Laminar Flow area.

f. Parts of components in process at the end of a shift should be covered with plastic or molded chip-proof plastic trays or covers prior to turning off power to the workstation.

g. No abrasives, such as files and crocus cloth, shall be permitted in the center. Repairs that require grinding, filing or polishing using abrasives shall be performed outside the work center.

30. MAINTENANCE AND CLEANING. Detailed regulations for maintenance and cleaning shall be established by the user activity. To aid in the establishment of these regulations, the following suggestions are offered:

Aircraft External Cleaning Compound, 7 MIL-PRF-85570, Type II

Detergent, Non-Ionic, MIL-D-16791 8

Isopropyl Alcohol, TT-I-735 9

a. Doors, walls, and windows should be spot cleaned with a sponge, detergent, and lukewarm water.

b. All waste receptacles should be removed from the center before disposing of contents.

c. Work center cleaning equipment should be stored in a cabinet within the center. Scrub rags, rag mops, and scouring powder should never be used. Use only cellulose sponges (WP002 00, Table 3, Item 28), leather chamois skin mops (WP002 00, Table 3, Item 27), and rubber (or elastro-meric synthetic) squeegees (WP002 00, Table 3, Item 29) for wet cleaning of large areas. Sponges should be discarded before they begin to deteriorate.

d. Extra heavy duty swabbing such as for gross oil spills may require MIL-PRF-85570, Type II (WP002 00, Table 3, Item 31) in a 10 percent solution or MIL-D-16791 non-ionic detergent, Type I (WP002 00, Table 3, Item 30). Wear rubber gloves (WP002 00, Table 3, Item 16). Such compounds should be free of pine oil. One ounce of isopropyl alcohol (WP002 00, Table 3, Item 8) per gallon of water will disperse the non-ionic detergent into solution and reduce suds.

31. The monthly cleaning routine is as follows: Walls, floors and ceiling should be washed with a solution of detergent and lukewarm water. This cleaning should be accomplished at a time when the center is not being used for normal operations.

32. TYPICAL AIRCRAFT HYDRAULIC COMPONENTS CONSIDERED CONTAMINATION CRITICAL.

NAVAIR 01-1A-17 011 00 TO 42B2-1-12 Page 8

33. The following is a list of types of aircraft hydraulic components that require environment/ cleanliness controls. Final assembly of those components shall be performed within the Laminar Flow Work Station or in a Controlled Environmental Work Center (Paragraph 13). Components that require Cleanliness controls include:

a. Servo Valves

b. Spool and Sleeve Assemblies

c. Hydraulic Pumps and Motors

34. As a rule, all safety of flight hydraulic components shall be considered contamination critical. When in doubt as to where a hydraulic component should be disassembled, repaired, overhauled, reassembled, or tested, perform the operation in a controlled environment.



SELECTION AND USE OF CLEANING MATERIALS

HYDRAULIC SYSTEMS

Reference Material

None

Alphabetical Index

Subject Page No.

Cleaning Solvents .......................................................................................................................... 2 Solvent Cleanliness ................................................................................................................... 2 Solvent Effectiveness ................................................................................................................ 2 Solvent Toxicity.......................................................................................................................... 2

Flammability ................................................................................................................................... 2 Autoignition Point ....................................................................................................................... 4 Fire Point.................................................................................................................................... 4 Flash Point ................................................................................................................................. 2

Introduction .................................................................................................................................... 2 Safety Precautions and First Aid.................................................................................................... 4 Solvent Contamination ................................................................................................................... 4 Solvent Selection ........................................................................................................................... 4 Wiping Materials............................................................................................................................. 5

Recommended Wiping Cloths ................................................................................................... 5


None

NAVAIR 01-1A-17 012 00 TO 42B2-1-12 Page 2

1. INTRODUCTION.

2. This section provides information for guidance in the selection and use of cleaning solvents and wiping materials. Consult the Material Safety Data Sheet (MSDS) for proper use and handling of cleaning agents.

3. CLEANING SOLVENTS.

4. Since cleaning agents (solvents) are frequently used in performing hydraulic system maintenance, the selection of an appropriate agent is often an important consideration. The cleaning agent selected must be compatible with the cleaning method used and with the materials used in construction of the system. It must be capable of removing unwanted substances to the desired degree. For critical cleaning application, filter solvent through a 5-micron (absolute) filter prior to use. Many solvents, in addition, present characteristic safety hazards. It is of the utmost importance that the user be aware of the hazards and exercise the required safety precautions. Disregard for any of these factors can result in incomplete cleaning, damage to equipment, or injury to personnel.

5. SOLVENT CLEANLINESS. Most cleaning compound specifications do not impose stringent requirements on the cleanliness of the fluid supplied. For critical cleaning applications, it is therefore required that the solvent be passed through a 5-micron (absolute) filter prior to use.

6. SOLVENT EFFECTIVENESS. Solvent power, or effectiveness as a dissolving agent, can be measured in many ways. In order to be comparative, however, a known or established standard must be used. For purposes of standardization, the solvent industry has adopted a test method known as the kauri-butanol (K-B) system. Solvent power as expressed by K-B values is the amount of solvent which, when added to a standard kauri gum-butanol solution, will produce a specified degree of turbidity or cloudiness. Since in most cases, 100 ml of benzene will produce the specified level, the K-B number for benzene is 100.0, and it serves as an arbitrarily accepted reference.

7. K-B values serve as a guide or index of relative solvency power. The higher the K-B number the more effective a solvent may be generally considered to be. It must be emphasized, however, that K-B values may not always be indicative of the most effective solvent for a particular cleaning situation. Other factors such

as temperature, time, cleaning method, and materials must also be considered, with the result that a solvent having a relatively low K-B value may often be best suited for a particular task. K-B values for some representative and commonly used solvents are listed in Table 1.

8. SOLVENT TOXICITY. A guide to the toxicity of solvents and other substances is published by the American Conference of Government Industrial Hygienists. The guide provides recommended Threshold Limit Values (TLV) which represents maximum concentrations in the air of substances to which it is believed personnel may be repeatedly exposed, day after day, without adverse effect. These limits are usually stated as parts of the solvent vapor per million parts of air, compared on a volume basis. The highest recommended TLV for any solvent is 1,000 parts per million (ppm) with some commonly used solvents having a TLV as low as 100. To ensure personnel safety, it is imperative that exposure to solvent vapors are limited to values less than the recommended TLV. Table 1 provides a reference source for the TLV of solvents commonly used in aircraft maintenance.

9. Exposure to high temperature may dangerously increase the volatility of many solvents and should be avoided. In addition to producing high levels of concentration, elevated temperatures may result in the formation of toxic or acidic fumes, or possibly explosive mixtures. Ensure adequate ventilation at all times and avoid solvent vapor contact with hot surfaces or open flame.

10. FLAMMABILITY.

11. Flash point, fire point, and autoignition point are the three temperature values used to determine the flammability of a solvent.

12. FLASH POINT. The flammability of a solvent is usually described by a value called its flash point. Several different test methods are employed to determine flash point, all of which involve raising the temperature of the liquid under test, under specified conditions until sufficient vapor is given off to produce momentary ignition when exposed to a specified flame. The flash point rating provides an indication of the ease with which a solvent can be ignited and indicates its relative flammability. Table 1 lists the minimum required flash points for solvent materials commonly used in aircraft hydraulic maintenance.

NA

VAIR

01-1A-17

012 00 TO

42B2-1-12

Page 3

RECOMMENDED APPLICATIONS

Cleaning of surfaces coming into direct contact with system fluid, such as interior of hydraulic reservoirs, filters, bowls, etc. General cleaning of all hydraulic components.

Cleaning of surfaces coming into direct contact with system fluid, such as interior of hydraulic reservoirs, filter bowls, etc. General gleaning of all hydraulic components.

As a substitute for MIL-PRF-680 or A-A-59601 (PD680) when cleaning surfaces which come into direct contact with system fluid.

SAFETY PRECAUTIONS

Use with full ventilation. Avoid excessive inhalation. Do not use near hot surfaces or open flame.

Use with full ventilation. Avoid excessive inhalation. Do not use near hot surfaces or open flames.

Do not use near hot surfaces or open flame. Avoid excessive skin contact.

DISADVANTAGES

Flammable Moderately toxic

Flammable Moderately toxic

Flammable. Not very effective as a cleaning solvent.

ADVANTAGES

Economical, good chemical stability. Effective for gross cleaning application. Not chlorinated.

Economical, good chemical stability. Effective for gross cleaning application. Not chlorinated.

Readily available. Compatible with materials used in hydraulic components. Not chlorinated. MIL-PRF-5606, mIL-PRF-83282, and MIL-PRF-87257 are fire resistant.

K-B VALUE

34

29 to 45

Not known

FLASH POINT

Type II: 140°F (60EC)

Type III: 200°F (93EC)

140EF (60EC)

MIL-PRF-5606: 180°F (82EC) MIL-PRF-83282: 400°F (204EC) MIL-PRF-87257: 350EF (175EC)

TOXICITY

High TLV = 100 ppm

High TLV = 100ppm

Low TLV = not known

CLEANING METHODS

Dip, slosh, spray, brush, flush, or wipe.

Dip, slosh, spray, brush, flush, or wipe

Dip, slosh, spray, brush, flush, or wipe.

EFFECTIVE IN REMOVING

Oils, fats, greases, waxes, heavy dirt deposits.

Oil, fat, grease, wax, heavy dirt deposits

Oils, organic matter, light deposits of general dust or dirt.

Table 1. Solvent Selection Chart for Use in Hydraulic Maintenance

SOLVENT

Dry Cleaning Solvent MIL-PRF-680 Type II / III

Dry Cleaning Solvent PD680 (Procured under Specification A-A-59601) AIR FORCE ONLY

USAF and Navy: Hydraulic Fluids MIL-PRF-5606 MIL-PRF-83282 USAF Only: MIL-PRF-87257 (Not solvents but sometimes employed as cleaning agents)

NAVAIR 01-1A-17 012 00 TO 42B2-1-12 Page 4

13. In determining flash point, the fluid vapors are kept relatively confined and exposed directly to a source of ignition. As a result of this test method, the measured flash point actually represents the lowest temperature, in a worst case situation, under which combustion can occur momentarily. In order for a fluid to burn continuously, or to ignite spontaneously without external ignition, it is necessary that the fluid be raised to a temperature that is higher than its rated flash point. These temperatures are the fire point and autoignition point, respectively, and in effect describe the safe operating temperature limits more realistically.

14. FIRE POINT. The fire point is the lowest temperature at which a volatile combustible substance will burn continuously in air once its vapors have been ignited. This value is also indicative of the relative flammability of a solvent and is a temperature higher than that of the flash point. The fire point is determined by continuing the flash point test until a temperature that will support continuous combustion is reached.

15. AUTOIGNITION POINT. The autoignition point is the lowest temperature at which a combustible substance, when heated, will self-ignite in air and continue to burn. No external spark or flame is applied and combustion results solely from the temperature rise in the substance. The autoignition point is also indicative of the flammability of a solvent and is always a higher temperature than either the flash or fire point.

16. SOLVENT CONTAMINATION.

17. When inadvertently introduced into an operating hydraulic system, certain cleaning agents can produce severe corrosion of internal metallic surfaces. The cleaning agent in such instances represents an incompatible foreign substance in the system and as such is considered a contaminant.

Dry Cleaning Solvent, MIL-PRF-680 6

Dry Cleaning Solvent, A-A-59601 14

18. To prevent solvent contamination, it is imperative that extreme care be exercised when utilizing these cleaning agents to clean internal

surfaces of system components that may come into contact with the hydraulic fluid. If such cleaning agents must be employed, ensure that all surfaces are dry and free of any traces of residual solvent prior to installation or assembly. Clean, unused hydraulic fluid, dry cleaning solvent MIL-PRF-680 (WP002 00, Table 3, Item 6) or A-A-59601 (Air Force Only) (WP002 00, Table 3, Item 7) is recommended for those cleaning applications where solvent contamination may be a problem.

19. SOLVENT SELECTION.

20. Numerous solvents suitable for use as cleaning agents are available in the supply system. To determine which solvent is best suited for a particular task, it is necessary to compare all characteristics of the solvents with the detail requirements of the specific cleaning operation. Important factors to be considered include materials to be cleaned, nature of substances to be removed, cleaning methods to be used, work environment, and personnel safety requirements. Table 1 outlines the important characteristics of commonly available solvents and should be referred to when selecting a solvent.

21. SAFETY PRECAUTIONS AND FIRST AID.

22. The following safety rules should be made available to and observed by all personnel involved in the use or storage of cleaning agents:

a. Provide adequate ventilation.

b. Always store new or used solvents in clearly labeled containers.

c. Provide eye flooding and shower facilities as needed.

d. Keep containers sealed when not in use.

e. Avoid prolonged or repeated contact with the skin or breathing of vapors.

f. Prohibit smoking, welding, or use of open flame in the vicinity of volatile or flammable solvents.

g. Dispose of contaminated solutions in accordance with local safety regulations.

h. Do not take internally.

NAVAIR 01-1A-17 012 00 TO 42B2-1-12 Page 5

i. Use protective devices such as cover or cup-type goggles, face shields, solvent resistant gloves, and other protective clothing, as required.

23. Table 2 presents a general first aid treatment guide for overexposure to cleaning solvents. It is recommended that more specific first aid procedures be prepared and that they be posted in the immediate work area for each type of solvent used. 24. WIPING MATERIALS. 25. Wiping materials are commonly used during hydraulic system maintenance to wipe down or to dry exposed surfaces of hydraulic components and associated airframe assemblies. Several types of wiping materials which differ considerably as to the basic material and characteristics are presently in common use in the fleet. Improper utilization of wiping materials can constitute, and has proven to be, a source of hydraulic system contamination. It is important, therefore, that maintenance personnel be familiar with the available materials and their proper application. 26. Wiping materials suitable for use in hydraulic system maintenance include rags and towels made of natural or synthetic fibers. These materials are referred to as “disposable wiping cloths”. However, some types can be laundered and reused. The type of wiping cloth selected for a given application will be determined by the following considerations: (1) substances being wiped or absorbed, (2) the amount of absorbency required, and (3) the required degree of cleanliness. For purposes of contamination control, it is convenient to categorize available wiping materials by the degree of lint or built-in debris that they may deposit during use. In critical cleaning applications, such as those encountered during hydraulic component overhaul, this factor itself will often determine the choice of wiping cloth. 27. Low lint non-woven wiping cloth, CCC-C-46, Class 7, Number 9404 Duralace (WP002 00, Table 3, Item 14) and lint-free synthetic wiping cloth, A-A-59323 Types I and II (WP002 00, Table 3, Item 13) are descriptively identified in Table 3. They are specified for use in hydraulic maintenance and are presently available in the supply system. 28. CCC-C-46, Class 7, Number 9404 Duralace (WP002 00, Table 3, Item 14) is a non-woven, binder free, non-snag material. It is primarily intended as a washing, polishing, and wiping cloth for critical dry/solvent wiping use in aircraft maintenance.

29. A-A-59323, Type I (WP002 00, Table 3, Item 13A), lint-free synthetic wiping cloths are pre-cleaned to a very low particulate level and supplied in sealed 10 pound bags. Type I wiping cloths are certified ultra-clean and are to be used exclusively in clean rooms and controlled work areas during component rework, repair, and test.

30. A-A-59323, Type II (WP002 00, Table 3, Item 13B) wiping cloths have the same lint-free features as Type I. However, they are not pre-cleaned to a high cleanliness standard. This material is to be used for general wipe down of hydraulic components, such as struts and actuators, in place of conventional baled rags. Type II wiping cloths are also supplied in 10 pound bags.

31. The synthetic wiping materials described should not be used for wiping down large plastic areas, or used with volatile solvents having flash points less than 100°F (38EC), due to possibility of developing dangerous static charges. Cotton flannel or cheesecloth should be used for these applications. The synthetic wiping materials are ideally suited for most hydraulic maintenance operations. They should be employed, whenever possible, to minimize contamination.

32. RECOMMENDED WIPING CLOTHS. Table 3 provides information on specific disposable wiping cloths recommended for use in hydraulic system maintenance. The table should be referred to and utilized as a guide when selecting wiping cloths for specific applications.

NAVAIR 01-1A-17 012 00 TO 42B2-1-12 Page 6

Table 2. First Aid Treatment Guide

TYPE OF CONTACT

SYMPTOMS

TREATMENT

Inhalation Anesthetic or narcotic effect. Varies from irritation of nose and throat to dullness, dizziness, headache, stupor, nausea, vomiting, and unconsciousness. (Death in severe exposures.)

Remove to fresh air and obtain immediate medical attention. Administer artificial respiration if breathing has stopped. Keep patient warm and quiet.

External contact: skin

Burning sensation, dermatitis. Remove any soaked clothing. Wash affected area and apply lanolin ointment, olive oil, or cold cream. Obtain immediate medical attention.

Eyes Pain, inflammation, tearing. Flush eyes with large amounts of water. Obtain immediate medical attention.

Oral intake Nausea, vomiting, diarrhea, and drowsiness or unconsciousness.

Obtain immediate medical attention.

NAVAIR 01-1A-17 012 00 TO 42B2-1-12 Change 1 – 1 August 2008 Page 7/(8 Blank)

Table 3: Recommended Wiping Cloths

Specification Rating Description Application Characteristics

CCC-C-46 Class 7 Number 9404 Duralace

Low Lint Wiping cloth, non-woven fabric

Wipe-down and drying of critical surfaces having high cleanliness requirements.

Very low lint; ultra clean, high wetted strength, good absorbency.

A-A-59323 (Type II) See Caution

Low Lint Bagged cloth wipers, synthetic fiber

Use for general wipe-down of hydraulic components such as struts and actuators.

Low lint and other particulate. Poor water absorbency.

A-A-59323 (Type I) See Caution

Very Low Lint

Bagged cloth wipers, synthetic fiber, certified clean

For use in clean rooms and controlled work areas during component rework, repair, and test. Wipe-down and drying of critical surfaces having high cleanliness requirements.

Very low lint and other particulate. Pre-cleaned to a very low particulate level. Poor water absorbency.

SAE AMS 3819 Class 1, Grade A

Air Force Only

Very Low Lint

Wiping cloth, woven, and unwoven, chemically pure, 100% cotton fibers.

For use in cleaning operations where exceptionally low residual surfaces contamination levels are required.

Very low lint and other particulate. High absorbent. Solvent resistant.

Do not use wiping cloths to wipe plastic or use with volatile solvents having flash points less than 100°F (38°C).



REPAIR, TEST, AND MAINTENANCE

HYDRAULIC SYSTEMS AND COMPONENTS

NAVY USE ONLY

Reference Material

Maintenance Program, Naval Aviation..................................................................... COMNAVAIRFORINST 4790.2

Alphabetical Index

Subject Page No.

Component Lubrication.................................................................................................................. 3 General Lubrication Instructions................................................................................................ 3

Component Spline Maintenance.................................................................................................... 6 Reuse of Splines........................................................................................................................ 7 Spline Cleaning.......................................................................................................................... 6 Spline Inspection Requirements................................................................................................ 7 Spline Lubrication ...................................................................................................................... 6

Component Testing........................................................................................................................ 2 Component Proof Pressure Testing .......................................................................................... 3 Nondestructive Testing .............................................................................................................. 2 Post-Installation Checks ............................................................................................................ 3

Hydraulic Component Leakage...................................................................................................... 4 Allowable and Excessive Leakage ............................................................................................ 5 Measurement of Leakage .......................................................................................................... 4

Hydraulic Pump Contamination Tests............................................................................................ 7 Analysis of Test Patches ........................................................................................................... 11 Contamination Testing Procedures ........................................................................................... 9 Patch Test Technique................................................................................................................ 7

Introduction .................................................................................................................................... 2 Component Repair and Overhaul .............................................................................................. 2 Maintenance Responsibilities .................................................................................................... 2 System Check Requirements .................................................................................................... 2


None

NAVAIR 01-1A-17 013 00 TO 42B2-1-12 Page 2

1. INTRODUCTION.

NOTE USAF: This WP not applicable

2. This section provides general instructions and information for repairing, overhauling, testing, and performing maintenance on hydraulic systems and hydraulic system components. Hydraulic systems and components include pumps, pressure transducers, motors, actuators, indicating devices, valves, sensors, filters, reservoirs, manifolds, associated lines and fittings, and working fluids, accumulators, linear and rotary control devices, modular and integrated equipment. 3. MAINTENANCE RESPONSIBILITIES. Maintenance functions applicable to rework, repair, test, removal, and installation of hydraulic systems, equipment, and components are defined in COMNAVAIRFORINST 4790.2. Specific responsibilities for repair, rework, test, removal, and installation of aeronautical material are assigned by COMNAVAIRFORINST 4790.2.

4. Hydraulic system component removal, repair, installation, and test shall normally be performed in accordance with detailed procedures provided in applicable maintenance, overhaul, and repair publications. However, because many publications and directives relating to hydraulic system and component maintenance require revisions to reflect current requirements, the following additional guidance is provided.

5. SYSTEM CHECK REQUIREMENTS. To ensure safety of personnel and aircraft, it is directed that when any hydraulic system component has been installed, replaced, disconnected, or partially disassembled on the aircraft, the specific hydraulic system affected be pressurized and the installed or repaired component given a complete and thorough functional test. When the affected component is an actuator, a sequencing valve, or a part or assembly of any hydraulically operated subsystem, the test shall include a complete cycling of the subsystem. A thorough system check shall be accomplished to determine that all performance requirements are satisfied.

6. When operational tests require hoisting or jacking an aircraft to cycle the landing gear, care should be exercised to ensure that jacks or hoisting slings are properly positioned and secured, and that all applicable safety precautions are observed.

7. COMPONENT REPAIR AND OVERHAUL.

8. Component repairs shall normally be performed only to the extent necessary to correct malfunctions. However, when a C, D, or F repair kit is utilized, the complete kit shall be installed.

9. Component overhaul shall be performed in accordance with the applicable overhaul manual and/or other engineering directives.

10. Inspection of components disassembled for repair or overhaul includes checking for visible damage to internal parts, contamination, thread damage, misalignment, condition of plating, excessive wear, spring distortion and return to specified free length, and in some cases, nondestructive inspection.

11. COMPONENT TESTING.


12. Components shall be tested following repair to verify their ability to perform intended functions. Test will generally involve proof pressure, static leak, and performance measurements. Stationary test benches utilized for testing shall be filled with hydraulic fluid MIL-PRF-83282 (WP002 00, Table 3, Item 2). Repaired components that are not to be installed immediately shall be filled with MIL-PRF-83282 unless otherwise specified, and all openings capped or plugged with approved metal closures. Components which have been repaired and are to be installed immediately subsequent to bench testing shall be drip-drained, capped and plugged as necessary, and made ready for installation.

13. Tests shall be limited, where practicable, to those that relate to the specific repair action or component malfunction. In all cases, it shall be determined that the component undergoing tests meets all applicable performance specifications for the intended end use.

14. Subsequent to overhaul, complete testing shall be performed in accordance with procedures in the applicable overhaul manual or other applicable engineering directives.

15. NONDESTRUCTIVE TESTING. When nondestructive testing is required, all inspections shall be performed by qualified/certified personnel.

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16. Nondestructive testing during component repair shall be limited by the extent to which the component is disassembled and the need to test for critical defects. The following guidelines are provided to assist in determining the required level of testing:

a. Disassemble component to the extent required to accomplish repair.

b. Visually inspect all parts for cracks or other evidence of mechanical stress or failure.

c. If no defects are detected or suspected, reassemble component and perform functional tests to verify that component meets applicable performance specifications. Perform inspections in accordance with applicable Maintenance Instruction Manuals (MIM).

d. If defects are observed or suspected, perform appropriate nondestructive tests, as applicable.

e. If no defects are detected, reassemble component and perform functional tests to verify that the component meets applicable performance specifications.

f. Corrosion treat and touch-up paint exposed bare metal areas as needed in accordance with existing instructions, prior to returning component to service.

17. During component overhaul, all specified nondestructive tests shall be performed in accordance with applicable overhaul manuals or other engineering directives.

18. COMPONENT PROOF PRESSURE TESTING. Repaired components shall be proof pressure tested as specified in applicable MIM/overhaul manuals to the extent permitted by the local test capability. If an additional test capability is considered essential but not locally available, components shall be forwarded to the next higher level of maintenance. Should specified test procedures be considered excessive, submit Technical Publication Deficiency Report (TPDR) in accordance with existing instructions.

NOTE

Proof pressure testing of components is notrequired when the repair operation has notdisturbed the seal or housing integrity.

19. Overhauled components shall be proof pressure tested as specified in applicable overhaul manuals or other engineering directives.

20. POST-INSTALLATION CHECKS. After component installation, perform the following in accordance with existing maintenance procedures:

a. Perform required Quality Assurance Inspection for correct installation.

b. Perform required Quality Assurance Inspection for leakage.

c. Perform functional checkout of the system component which has been replaced or repaired.

d. Perform an individual functional checkout of affected hydraulic system to ensure its proper operation.

e. Perform checkout, in accordance with applicable MIM/overhaul manual, of other hydraulic systems functionally related to the system repaired.

21. COMPONENT LUBRICATION.

22. During hydraulic component repair, overhaul, and installation, proper lubrication must be applied to bearings, bushings, wiper rings, spline shafts, and other components to assure proper operation and component reliability. Many component malfunctions and failures can be traced to faulty selection of lubricant. This problem becomes more acute with high temperature applications.

23. A lubricant has four major functions:

a. Provides a separating film between sliding contact surfaces thus minimizing wear.

b. Acts as a coolant to maintain proper metal temperature.

c. Facilitates assembly of components.

d. Prevents corrosion of bearing surfaces.

24. GENERAL LUBRICATION INSTRUCTIONS. Prior to lubricating any components or parts, all foreign matter shall be removed from joints, fittings, and bearing surfaces. An approved wiping material saturated with an appropriate solvent shall be used for this purpose. The lubricant should be applied sparingly to prevent accumulation of dust, dirt, and foreign matter.

Molydisulphide Grease, MIL-G-21164 10

NAVAIR 01-1A-17 013 00 TO 42B2-1-12 Page 4

General Purpose Aircraft Grease, 11 MIL-PRF-81322

25. When applying lubricants through pressure type fittings with a grease gun, make sure the lubricant has emerged around the bushing. If no grease appears, check the fitting and grease gun for proper operation. Be certain the grease gun is properly attached to the fitting prior to applying pressure. Wipe up all excess grease when finished. When applying grease to a flush type fitting, make sure that the grease gun is fitted with the flush-type adapter. The gun must be held perpendicular to the surface of the fitting when greasing.

Never allow oil or grease to come in

contact with oxygen equipment. An explosion and fire can result.

26. Clean up all spilled excess oil or grease. Some types of synthetic compounds are harmful to rubber, neoprene, and electrical material. They will also soften paint, and should be removed as soon as possible. 27. The lubrication requirements for each model of aircraft are given in the General Information and Servicing section of the applicable MIM and Maintenance Requirement Cards (MRC). These instructions appear in the form of tables and charts. When replacing or lubricating installed components, refer to these tables and charts for the specified grease, methods of application, and frequency. For exact locations of grease fittings and other lubricated components, refer to applicable MIM/MRC.

28. HYDRAULIC COMPONENT LEAKAGE.

29. An O-ring seal, in design, is the most effective hydraulic sealing device for hydraulic systems and components. It allows very low friction for linear movement. Its design provides positive seal as pressure is exerted against it. Therefore, it is possible for an actuator shaft to show a slight leak or seepage such as a drop of fluid collecting on the sealing surface or piston shaft. In a static or no-pressure condition there may be seepage. Because of this, actuating components are sometimes removed prematurely because personnel are unaware of this fact. When the slightest hydraulic pressure is applied,

the pressure compresses the O-ring and seals the leak.

30. Hydraulic fluid seepage resulting in drop formation shall not be cause for component rejection and subsequent removal until verified by functional maintenance check. Seepage can be due to:

a. A film of hydraulic fluid being retained by the finish of metal surfaces such as piston rods and being carried past the seal. Such a film is necessary for lubrication of the seal.

b. Pressure and temperature variations affecting seals.

c. Seals having tendency to take a permanent set after a period of time, particularly if the system has not been in operation.

d. Detail parts such as felt and leather wiping rings, and cavities retaining fluid.

31. Allowable leakage, which exists on new or overhauled components, will usually show as a seepage, stain, or wet area. On many component overhaul tests, no leakage is allowable after 2 minutes of operation or pressurization of the unit. However, these same units may show a measurable amount of acceptable leakage after longer periods of time. It is possible for seepage or allowable leakage to collect in a cavity of a unit or in a depression of an adjacent structure over a period of time and falsely indicate excessive leakage. This is particularly true for cylinders having felt wiper rings at the output shafts. Allowable leakage accumulation on a flat area or a white painted surface often has the appearance of being excessive. During test of constant volume and variable displacement rotating piston-type hydraulic pumps, if all requirements are met, except the case drain leakage, it shall be authorized to allow a one hundred percent increase of the leakage above the design allowance. Rotating piston groups meeting this increased leakage allowance need not be replaced during repair or overhaul if routine processing inspection indicates parts are not physically damaged other than normal bore wear.

32. MEASUREMENT OF LEAKAGE. Hydraulic systems and components may remain in a static unpressurized condition for lengthy periods of time. Leakage should not be checked immediately after dormant periods. Systems should be activated, brought to operating temperature, and components operated a number of times, after which any hydraulic fluid should be wiped off before making leakage checks or measurements.

NAVAIR 01-1A-17 013 00 TO 42B2-1-12 Page 5

33. In many cases, leakage measurement is a problem because of the location of the component. If observation of the unit is not possible, one method of checking for leakage is to wipe the surface clean below the component and place a drop of hydraulic fluid on the area. When this drip stabilizes, note its size by outlining with a felt marker. Blot the drop, do not wipe because the mark will be removed. Pressurize and cycle the suspected component, correlating the area of wetted surface with area previously occupied by the drop.

34. Where fluid dropping may be observed directly, do not wipe surface but pressurize and cycle the component until a drop falls free. Continue operating component until another drop falls and compare results with leakage criteria outlined herein.

35. For tests requiring long periods of time, and where fluid can drop, wipe the surface clean and dry. Do not use a solvent. Place a clean blotter or white cloth immediately below the suspected leak. It may be necessary to secure the blotter or cloth to the suspected component. Examine the blotter or cloth after the system has operated or has been idle for the required time.

36. ALLOWABLE AND EXCESSIVE LEAKAGE. The following guidelines provide general criteria for judging whether leakage is allowable or excessive when not defined in the applicable MIM.






a. When the fluid escaping is of an insignificant quantity and will have no detrimental effect on aircraft operation, and when correction of this slight leakage does not warrant the maintenance time involved, the leakage is then termed “allowable”.

b. If the fluid leakage rate is such that the hydraulic reservoir level may be depleted or dangerously lowered during normal operation, or a fire hazard created, or the safety of flight of the aircraft otherwise compromised, the leakage is termed “excessive”.

c. Under certain circumstances, several individual components may exhibit “allowable” leakage so that the combined leakage will be “excessive”. If this is suspected, the fluid level in the hydraulic reservoir should be monitored closely and the leakage corrected if the total fluid lost from the system is excessive.

d. Hydraulic fluid may run into cavities, threads, and grooves during testing and flushing of components and during connecting and disconnecting of lines and fittings. Over a period of time, this fluid may seep out in sufficient quantity to be visible. Wipe away any visible fluid, and actually measure and record any additional leakage. The fluid must leak a measurable amount (one drop) and must continue to repeat itself at regular intervals, to be cause for rejection of the component. A trace or wetting of the surface is not considered measurable.

e. Static pulsating packings are static seals that “breathe” or “pump” as pressure is applied and released with the seal moving within the groove. Fluid will often accumulate after a number of cycles (for example, the static seals between piston rod glands or end caps and cylinder barrels). This is characteristic of such seals and is not considered excessive leakage if no more than one drop has formed in five complete cycles. Following cycling, no more than one drop shall form during a 15-minute interval, either pressurized or unpressurized.

f. Dynamic seals in motion, such as rod seals, are considered acceptable if leakage does not exceed one drop after five complete cycles. For dynamic seals in a static condition, no more than one drop shall form in succeeding 15 minute intervals, with the component pressurized or unpressurized.

NAVAIR 01-1A-17 013 00 TO 42B2-1-12 Page 6

g. When dynamic or static seals are internal and vented on one side by a common vent hole, such as between chambers in tandem flight control actuators, the allowable leakage rate will be cumulative for two or more seals.

37. COMPONENT SPLINE MAINTENANCE.

38. Toothed splines are used to transmit power or to drive accessories, where space and weight are of paramount importance. Although many alternate types of drives can be cited and are used in other situations, none can compare with splines in terms of compactness and lightweight. Splines can accommodate a small amount of misalignment which may be the result of design, installation, or dynamic operating conditions. If the misalignment is large, the resulting oscillatory, fretting type of wear will be excessive. In the interest of reduced maintenance, extended life, and increased reliability, special attention should be directed toward spline alignment control at rework and toward proper cleaning and lubrication at all levels of maintenance.

39. SPLINE CLEANING. In the lubrication process, it is important to clean the spline connection thoroughly to prevent carryover of contaminants and used grease. Contamination carryover can adversely affect the life of the spline. In greased splines especially, the wear debris generated from the wearing of mating spline teeth will usually remain within the spline connections. Such debris will be in the form of metallic particles and iron oxides which will accelerate wear. Other contaminants may include dust, salt water, and fuel, depending upon the application. Excessive exposure to such contaminants should be avoided.

40. At each removal and installation, hydraulic pump and motor spline connections lubricated with grease shall be cleaned in accordance with the following procedures:

a. Remove hydraulic pump or motor from aircraft.

b. Remove drive coupling retainer by inserting appropriate tool and gently prying out, if applicable.

c. Remove drive coupling.


d. Thoroughly clean splines of drive coupling and mating female splines in hydraulic pump motor and mating gearbox to remove all foreign matter. Use dry cleaning solvent MIL-PRF-680 (WP002 00, Table 3, Item 6) with the aid of a bristle brush and dry with air blast.

e. Inspect splines for excessive wear. If damaged, repair or replace in accordance with applicable MIM.

41. SPLINE LUBRICATION. Aircraft spline connections are usually lubricated with a grease or liquid. Lubricating methods used are divided into three categories: dry pad, mist, and wet pad. The dry pad spline connection can be operated with or without grease. The mist (oil mist) and wet pad are usually associated with the engine accessory gearbox splines and are oil lubricated. The dry pad is usually the simplest method since no elaborate lubrication system is required.

42. Hydraulic pump and motor spline connections lubricated with grease shall be lubricated in accordance with the following procedure:

Molydisulphide Grease, MIL-G-21164 10

General Purpose Aircraft Grease, 11 MIL-PRF-81322

a. Lubricate the male hydraulic pump or motor drive coupling splines and mating female splines in the gear box assembly with a liberal coating of grease, specification MIL-G-21164 (WP002 00, Table 3, Item 10) or MIL-PRF-81322 (WP002 00, Table 3, Item 11).

NOTE

Use MIL-PRF-81322 grease if applicable MIM or MRC do not specify a lubricant.

b. Install drive coupling and drive coupling retainer in hydraulic pump or motor, if applicable.

c. Install hydraulic pump or motor in accordance with the applicable MIM.

NAVAIR 01-1A-17 013 00 TO 42B2-1-12 Page 7

43. Lubrication Interval. Hydraulic pump or motor splines and mating female splines shall be lubricated in accordance with the applicable MIM and MRC. In all cases, the spline connection shall be cleaned and lubricated at each pump or motor installation.

44. SPLINE INSPECTION REQUIREMENTS. Spline inspection normally consists of visual and gage measurements for wear and alignment. Specific methods used will vary with the level of maintenance and shall be as specified in applicable overhaul manuals, MIM, or engineering specifications. In all cases, visually inspect the spline, gearbox, and component mounting pad for wear, distortion, and cleanliness prior to component installation.

45. REUSE OF SPLINES. The widely used maintenance practice of reusing splines in combination with new or other used splines has an adverse effect on the life of both splines involved in a connection. When worn and new spline surfaces come into contact, the load may be borne initially by a relatively small area, thus resulting in excessive contact pressures and high rate of wear. During the period of high wear rate, wear debris is formed which in turn may serve as an abrasive to promote additional wear. When two new, properly shaped, spline surfaces come into contact, the load is more uniformly distributed and the amount of wear necessary to provide good conformity is much less than is the case when an unworn and worn spline surface are in contact. The reuse of slightly worn splines is dictated by economic considerations, but indiscriminate reuse of worn splines shall be discouraged.

46. HYDRAULIC PUMP CONTAMINATION TESTS.

47. Hydraulic pumps can represent a serious source of contamination in an operating hydraulic system, when not functioning properly. The typical aircraft hydraulic pump contains many highly stressed internal parts that move at high velocities and are directly exposed to the operating fluid. The failure or excessive wear rate of any of these parts will produce metallic debris that will enter the fluid and serve to contaminate the entire system. As a result of its internal design, a variable displacement piston-type pump will normally generate minute amounts of contaminant through normal wear processes. These contaminants are effectively controlled by the system’s hydraulic filters, which are designed to remove the normally generated pump contaminants as they are produced. In order to ensure that a hydraulic pump is not producing excessive amounts of contamination, it is required that contamination tests be performed on the unit prior to its being

considered ready for installation. Pump contamination is generally tested concurrently with test stand operation of the pump, using patch test techniques.

48. PATCH TEST TECHNIQUE. Pump patch testing is accomplished by operating the unit under test for a predetermined period of time and collecting particulate matter discharged from the outlet and case drain ports using standard aircraft hydraulic filter assemblies. Contaminants, having originated in the pump, are then retrieved from the filter assemblies and separated from the fluid medium by use of analytical-type filter disks and filtration apparatus such as is provided with Contamination Analysis Kit 57L414 or equivalent. The discrete particulate matter retained on the filter disk (“test patch”) is visually inspected and a determination made whether the pump contamination output is within acceptable limits.

49. Figure 1 illustrates the basic test setup used and shows the location of the required hydraulic filter assemblies. In addition to the pump discharge and case drain filters, a similar filter assembly is also installed in the suction line of the pump under test. This assembly enables a test patch to be produced that is representative of the pump inlet fluid and which can serve as a “control” patch against which the pump output and case drain test patches may be compared.

50. The following basic operations are performed when patch testing hydraulic pumps for contamination output:





NAVAIR 01-1A-17 013 00 TO 42B2-1-12 Page 8

013001

Figure 1. Patch Test Testing Hydraulic Pump Contamination Using Contamination Analysis Kit 57L414

NAVAIR 01-1A-17 013 00 TO 42B2-1-12 Page 9


a. Clean filter elements installed in pump filter assemblies.

b. Operate pump in accordance with applicable testing procedures for the period of time specified.

c. Retrieve contaminants from pump filter assemblies by collecting fluid from bowl and flushing particulate off surface of the element utilizing filtered solvent.

d. Collect fluids from each filter assembly and individually analyze the fluids using contamination analysis kit or equivalent.

e. Evaluate resulting test patches to determine pump acceptability. Compare patches to Contamination Standards, if available, or test patches from preceding tests to determine rate of pump cleanup.

51. CONTAMINATION TESTING PROCEDURES. It is important the required procedures be closely adhered to when patch testing pumps for contamination output. Any deviations from the techniques specified may result in test indications that are either non-repeatable or not capable of proper interpretation. Procedural requirements differ, depending upon whether the test pump has been subjected to major rework in which internal parts have been replaced, or to limited repair operations such as seal replacement or external adjustments. Paragraphs 52 and 53 provide detailed procedures for both applications and shall be considered as minimum requirements for all such testing.

NOTE

The following test shall be initially performed subsequent to completion of the first run-in period of the reworkedpump. Known clean elements will be installed in the pump filter assemblies prior to initiation of the run-in period. Pump run-in will be accomplished in accordance with existing procedures.

52. Test for Pumps Subjected to Major Rework. Individually test the pump outlet, case drain, and inlet filter assemblies to determine their contamination levels. Using Contamination Analysis Kit 57L414 or

equivalent, prepare a test patch from each assembly employing the following procedure:







a. Remove filter bowl and element from the filter assembly being tested and pour contents of the bowl into a known clean sample container. Using filter-equipped solvent, rinse bottle (such as provided with contamination analysis kit) with solvent MIL-PRF-680 (WP002 00, Table 3, Item 6). Flush as much residual particulate matter as possible from both the inside surface of the filter bowl and the outside surface of the filter element, carefully collecting all flushing fluid in the same sample container. Identify sample container to indicate filter assembly from which fluid was obtained. If contamination analysis kit is available for use in pump test area, the contamination test procedure may be simplified by collecting filter bowl and flushing fluids directly in the stainless steel funnel.

b. Prepare separate test patches from each of the pump filter samples utilizing contamination analysis kit, or equivalent, and detailed instructions provided with the equipment. Refer to WP017 00 for additional information relative to its use.

NAVAIR 01-1A-17 013 00 TO 42B2-1-12 Page 10

Contamination Standards furnished with contamination analysis kit are not intended for use in this application and shall not be so employed.

c. Determine acceptability of pump contamination level by comparing resulting test patches to applicable patch test standards, if available. If applicable standards are not available, the resulting test patches shall be visually inspected for metallic contamination. A substantial quantity of discrete particles may be considered acceptable, subsequent to the first run only, provided that they are detected in either pump outlet or case drain fluid samples. Very large amounts of metallic contamination may be indicative of internal failure, and the pump under test should be disassembled and subjected to internal inspection prior to continued operation. Evidence of any discrete particles on, or abnormal discoloration of, the inlet filter test patch shall be regarded as an indication that the hydraulic test stand being used is unacceptably contaminated. Required corrective action should be initiated. Refer to Paragraph 54 for additional information regarding interpretation of test results.

d. Replace previously removed filter elements with new elements. Ensure that filter bowls are thoroughly cleaned prior to reassembly using filtered hydraulic fluid. Prefill bowls with filtered hydraulic fluid to minimize air inclusion.

e. Perform second pump run-in as specified in applicable procedure. Ensure that total run-in time, flow and cycling rates are the same as for first run-in.

f. Repeat contamination tests of the pump filter assemblies in accordance with preceding steps a, b, and c. Pump outlet and case drain filter test patches should show less general discoloration and fewer metal particles than that observed subsequent to the first run-in period. If test patches indicated increased contamination compared to that previously observed, testing shall be terminated and the pump disassembled and subjected to internal inspection.

g. Replace filter elements in accordance with step d above.

h. Perform final pump run-in as specified in applicable procedure. Ensure that total run time, flow,

and cycling rates are same as for first and second run-in.

i. Repeat contamination tests of the pump filter assemblies in accordance with preceding steps a, b, and c. Pump outlet and case drain test patches must show no degradation from those obtained subsequent to the second run-in period. Any evidence of an increase in contamination output shall be cause for rejection of the pump under test and the unit disassembled and subjected to internal inspection.

j. If test patches show continued improvement but are still considered unacceptable, the pump may be subjected to additional run-in operation in an attempt to attain a satisfactory contamination level. In such situations it is advisable that the pump be disassembled and inspected prior to continued run-in to ensure that all internal clearance and surface finish requirements are within acceptable limits. Determination of final acceptability shall be accomplished by comparison of the pump test patches to standard patches applicable to the model pump tested, when available. Standard patches may be locally produced with Fleet Support Team (FST) approval. Refer to Paragraph 54 for additional information regarding evaluation of test results and the development of standard patches.

NOTE

The following test shall be performed subsequent to completion of the other functional checks prescribed for the component. Known clean elements will be installed in the pump filter assemblies prior to initiation of functional testing. Functional testing will be accomplished in accordance with existing applicable procedures.

53. Testing for Pumps Subjected to Minor Repair and Functional Test. Individually test the pump outlet, case drain, and inlet filter assemblies to determine their contamination levels. Using contamination analysis kit or equivalent, prepare a test patch from each assembly employing the following procedure:


NAVAIR 01-1A-17 013 00 TO 42B2-1-12 Page 11






a. Remove filter bowl and element from the filter assembly being tested and pour contents of the bowl into a known clean sample container. Using filter-equipped solvent rinse bottle and solvent MIL-PRF-680 (WP002 00, Table 3, Item 6), flush as much residual particulate matter as possible from both the inside surface of the filter bowl and the outside surface of the filter element, carefully collecting all flushing fluid in the same sample container. Identify sample container to indicate filter assembly from which fluid was obtained. If the contamination analysis kit is available for use in pump test area, the contamination test procedure may be simplified by collecting filter bowl and flushing directly in the stainless steel funnel.

b. Prepare separate test patches from each of the pump filter samples utilizing contamination analysis kit and detailed instructions provided with the equipment. Refer to WP017 00 for additional information relative to its use.

Contamination Standards furnished with contamination analysis kit are not intended for use in this application and shall not be so employed.

c. Determine acceptability of pump contamination level by comparing resulting test patches to applicable patch test standards, if available. If applicable standards are not available, the resulting test patches shall be visually inspected for contamination and a determination of acceptability made based upon prior experience with the same model pump and testing procedure. Very large amounts of metallic contamination may be indicative of internal failure and the pump under test should be disassembled and subjected to internal inspection prior to continued operation. Evidence of any discrete particles on, or abnormal discoloration of, the inlet filter test patch shall be regarded as an indication that the hydraulic test stand being used is unacceptably contaminated. Required corrective action should be initiated. Refer to Paragraph 54 for additional information regarding interpretation of test results.

54. ANALYSIS OF TEST PATCHES. Standard patches to which pump test patches can be compared may or may not be available for a specific model pump. In the absence of an applicable standard, it becomes necessary that the operator have prior experience in performing the same test on identical model pumps and a thorough understanding of the test technique involved, if accurate judgments on pump acceptability are to be made. Several factors determine the total amount of particulate matter normally discharged from a hydraulic pump during test stand operation. The most significant are:

a. Cleanliness level of the inlet fluid.

b. Rate of internal wear.

c. Total volume of fluid pumped during the test period.

55. By supplying the pump under test with fluid filtered to 3 microns (absolute), the effect of inlet fluid cleanliness upon the test result is eliminated. For all practical purposes, the pump inlet fluid may be considered to be free of particulate matter, with this condition verified by the inlet filter test patch. The amount of contaminants present on the pump discharge and case drain test patches becomes a function of the pump’s wear rate and the total volume of fluid transferred by it. Since the total amount of fluid pumped remains fairly constant when testing in accordance with a specific test procedure, the amount of discharge and case drain contaminants observed corresponds to the rate at which the pump is “wearing”, or producing contamination.

56. A hydraulic pump reworked to the extent that internal moving parts have been replaced or

NAVAIR 01-1A-17 013 00 TO 42B2-1-12 Page 12

resurfaced, requires test stand run-in to allow a final lapping of critical internal surfaces to take place under actual operating conditions. Three consecutive run-in periods are typically specified in most pump testing procedures, with contamination tests performed upon the completion of each. The contamination output of the pump is greatest during the initial run-in period and decreases significantly during each subsequent run-in. When evaluating pump patch test results, the rate of “cleanup” (the amount of improvement observed between successive runs) is often more meaningful than the appearance of any one set of test patches. A pump showing significant reductions in contamination output with run-in can be expected to clean up still further after being placed into actual service and is generally considered to be a “clean” pump. In such cases it must still be determined that the level of contamination output observed at completion of run-in is within acceptable limits in order to prevent the overloading of system filters. This determination can be made only by comparison of the final test patches with standard patches for the particular model pump, if available, or with the operator’s past experience and knowledge of what constitutes an acceptable indication.

57. Reworked hydraulic pumps which show abnormally large amounts of contamination initially, or no improvement over successive runs, shall be considered unacceptable. Such pumps should be disassembled and subjected to internal inspection in an effort to determine the reason for the high rate of contaminant generation. Careful examination of the pump discharge and case drain test patches will often enable identification of the wear materials present and may assist in diagnosing the pump problem. Modern in-line pump design is such that brass will be the most common material observed on the pump discharge patches. Contamination originating in the pump case drain will include bronze, steel, carbon, fiber, and seal materials.

58. When examining the pump test patch, particular emphasis should be given to the amount of discrete metallic particles that are observed. Most of the significant wear particles discharged from a pump under test, particularly one that is unacceptably “dirty”, are usually fairly large and can be resolved as distinct particles by the unaided eye. In addition to these discrete particles, other particles that are too small to be individually seen will also be deposited on the test patch. These particles produce an overall discoloration of the test patch and may be indicative of the condition of the test stand as well as the pump under test. Comparing the discoloration of the pump discharge and case drain test patches to that of the inlet filter test patch will enable the operator to

determine whether the discoloration is a result of very fine particulate (or oxidized fluid) circulating through the entire test circuit or whether it is originating in the pump under test. Any evidence of discrete particles on the inlet filter test patch, at any time, is indicative of a test stand problem and the condition of its 3-micron filters should be checked.

59. Patch Test Standards for Pumps. Pump patch test standards are specially produced test patches that are representative of those that would be obtained when patch testing a pump having a marginally acceptable contamination output. In effect, they provide a go-no-go comparator to which pump test patches can be compared to determine acceptability. Any actual patch showing a higher level of contamination is considered unacceptable. Because of differences in components and testing procedures (refer to Paragraphs 52 and 53) it is required that individual standards be developed for each model pump and its attendant test procedure. Standard patches, as described, are not presently being made available to fleet operators. Standard patches can, in many instances, be locally manufactured by the operator. It is required that all such standards be approved by a FST prior to their utilization.

60. Patch standards for a given model shall consist of three actual test patches, inlet, discharge, and case drain, that are produced using the exact test setup and procedures specified for the particular model pump. In order for such patches to serve as a quality control reference, it is necessary that they be statistically established as being representative of the “normal” pump. This is currently accomplished by collecting the final test patches from a large number of identical pumps and selecting a set that, based upon best technical judgment, represents a fair but conservative acceptable level. The validity of this method improves greatly with the number of pumps tested and it is considered necessary that at least ten pumps be so tested, with no peculiar problems encountered, before any attempt at selecting a representative set of patches is made. Intermediate and depot level maintenance activities are authorized to locally produce patch standards, as described. However, all such patches should be submitted to the applicable FST for approval prior to their use.

NAVAIR 01-1A-17 014 00 TO 42B2-1-12 Change 1 – 1 August 2008 Page 1 of 16


PROTECTIVE CLOSURES

HYDRAULIC SYSTEMS

NAVY USE ONLY

Reference Material

Caps and Plugs, Protective, Dust and Moisture Seal ................................................ NAS847 Cap - Protective, Flared Fitting .................................................................................. NAS817 Cap - Beaded Hose Connection, Plastic, Protective ................................................. NAS839 Cap, Pipe, Thread, Protective, Dust and Moisture Seal ............................................ NAS846 Cap Assembly, Pressure Seal Flared Tube Fitting ................................................... AN929 Cap, Pressure Seal, Flareless Tube Fitting ............................................................... SAE AS21914 Plug - Protective, Flared Tube, Hose Assembly ....................................................... NAS818 Plug - Protective, Flareless Tube End (Plastic) ......................................................... NAS838 Plugs, Protective, Flareless Tube End (Metal) .......................................................... NAS842 Plug, Flareless Tube ................................................................................................. SAE AS21913 Fitting, Plug, Tube End, Flared ................................................................................. SAE AS5168 Plug, Pipe Thread, Protective, Dust and Moisture Seal............................................. NAS840 Fitting, Port Plug and Bleeder .................................................................................... SAE AS5169 Plug, Machine Thread - AMS5646, Preformed Packing ........................................... MS9404 Fittings, 37 Degree Flared, Fluid Connection ........................................................... SAE AS4841

Alphabetical Index

Subject Page No.

Protective Closure Application ....................................................................................................... 2 Blank-Off Plates ............................................................................................................................. 3 Protective Closure Description....................................................................................................... 2 Introduction .................................................................................................................................... 2


None


1. INTRODUCTION.

NOTE


NOTE

Plastic covers shall only be used for Dyna Tubes ONLY (See Figure 1 for examples of Dyna Tubes). Refer to NAVAIR 01-1A-20 for further Dyna Tube information. Plastic covers are not recommended for fluid fittings.

2. Contamination caused by entry of foreign matter into open lines and parts of hydraulic system equipment is hazardous and expensive. To protect hydraulic systems from contaminants, use protective closures.

3. PROTECTIVE CLOSURE DESCRIPTION.

4. Two types of protective metal closures are approved for sealing hydraulic equipment. These caps and plugs conform to the appropriate military and industry specifications (Table 1). Additional protective closures are identified in Tables 2 through 9.

5. PROTECTIVE CLOSURE APPLICATION.

6. Guidelines for selection and use of protective closures for hydraulic equipment are as follows:

a. Use caps and plugs of the proper size and material.

b. Only use approved metal and plastic caps and plugs to protect hydraulic systems.

c. Every effort shall be made to protect spare or removed components, lines, hoses and open aircraft hydraulic lines and hoses from external contamination.

d. High pressure closures are required for any disconnected lines on components being tested on the test benches and stands.

e. Use closures of metal construction conforming to specifications listed in Table 1 for sealing hydraulic system equipment, lines, tubes,

accessories, and components except as external closures for shipping and storage.

NOTE

f. Plastic closures (Tables 8 and 9) may be used to seal electrical fittings and receptacles or other non-fluid openings where contamination is not considered a problem. Polyethylene plastic closures may also be used for shipping purposes as long as all hydraulic fluid has been drained from the system equipment and components prior to shipping.

In all cases where there is a choice

between an internal or external installation, use the external type of closure. Never blank-off openings with wooden plugs, paper, rags, tape, or other unauthorized devices.

Plastic and light aluminum closures are NOT to be used on aircraft under any circumstance. Doing so could result in personal injury and equipment damage.

g. Only use high pressure approved metal protective closures to seal open ports of all hydraulic lines and accessories on the aircraft. See Tables 2, 3, 6 and 7 for list of approved protective closures.

h. Use metal protective closures to seal new and reusable hydraulic tubing and hose assemblies.

i. Keep all protective closures clean, sorted by size, properly identified, and stored in readily accessible bins.

Polyethylene plastic closures may be used when shipping hydraulic equipment and components if and only if they have been drained of all hydraulic fluid prior to shipping.


j. Check protective closure visually for cleanliness, thread damage, or sealing deformation before using.

k. Rubber, plastic or unthreaded type protective closures designed to fit over open ends of bulk hose and tubing shall be used in accordance with design function only. Do not use this type of protective closure as a plug for insertion into open lines, hoses, or ports of hydraulic equipment.

l. Remove protective closures before installing equipment. If an opening normally requiring protection is found uncovered, the part or assembly shall be cleaned and checked before installation or assembly.

7. POLYETHYLENE PROTECTIVE CLOSURES. High density polyethylene protective caps and plugs (Tables 8 and 9 Figures 9 and 10) may only be used for shipping purposes if all hydraulic fluid has been drained from the system equipment and components prior to shipping. They may also be used to seal electrical fittings and receptacle or other non-fluid openings where contamination is not considered a problem.

8. BLANK-OFF PLATES.

9. Blank-off plates (Figure 2) are used as follows:

Do not use fiber, plastic, or masonite

blank-off plates where pressure or retention of hydraulic fluid is required.

a. Use blank-off plates to seal and protect flange-type connections.

b. Use a gasket and metal plate where retention of hydraulic fluid is required.

c. If plastic blank-off plates are used, plastic material shall conform to NAS847, “Caps and Plugs, Protective, Dust and Moisture Seal”.


014001

Figure 1: Dyna Tube Examples

014002

Figure 2. Typical Blank-Off Plates


014003

Figure 3: AN929-D High Pressure Aluminum Caps

014004

Figure 4: AS5168-D High Pressure Aluminum Plugs

014005

Figure 5: NAS817 Light Aluminum Caps for Storage and Shipping


014006

Figure 6: M5501/1 Light Aluminum Plugs for Storage and Shipping

014007

Figure 7: SAE AS21914 High Pressure Carbon Steel Caps

014008

Figure 8: SAE AS21913 High Pressure Carbon Steel Plugs


014009

Figure 9: DC - Plastic Caps for Storage and Shipping

0140010

Figure 10: DP - Plastic Plugs for Storage and Shipping


Table 1. Protective Caps and Plugs

TYPE (Note 1) APPLICATION

APPLICABLE SPECIFICATION

Cap

Cap

Cap

Cap

Cap

Protective, Flared Fitting

Beaded Hose Connection, Plastic, Protective

Pipe Thread

Assembly, Pressure Seal Flared Tube Fitting

Pressure Seal, Flareless Tube Fitting

NAS817

NAS839

NAS846

AN929

SAE AS21914

Plug

Plug

Plug

Plug

Plug

Plug

Plug

Plug

Plug

Flared Tube End and Straight Threaded Boss

Protective, Flareless Tube End (Plastic)

Protective, Flareless Tube End (Metal)

Flareless Tube

Flared Tube Precision Type

Pipe Thread

Bleeder, Screw Thread

Machine Thread AMS 5646 Preformed Packing

Bleeder, Screw Thread Precision Type

NAS818 or SAE AS5168 (Note 3)

NAS838

NAS842

SAE AS21913 (Note 2)

SAE AS5168 (Note 3)

NAS840

SAE AS5169

MS9404

SAE AS5169

Notes: 1. When ordering from supply, be sure to specify metal caps or plugs.

2. Industry specification, SAE AS21913, shall be used in lieu of MS21913.

3. Industry specification, SAE AS5168, shall be used in lieu of AN806.


Table 2. High Pressure Aluminum Caps (blue in color)

{Meets SAE AS4841 specification (supersedes MIL-F-5509)}

Item No.

Part Number

(P/N) Nomenclature National Stock

Number (NSN’s)

Units of Issue (U/I)

Cap Thread

Size Tubing

Size

1 AN929-D2 Cap, Threaded, 7075 Anodized Aluminum

4730-00-633-4398 EA 5/16" 1/8"


4730-00-221-2126 EA 3/8" 3/16"


4730-00-278-5006 EA 7/16" 1/4"


4730-01-061-4150 EA 1/2" 5/16"


4730-00-585-8769 EA 9/16" 3/8"


4730-00-541-8296 EA 3/4" 1/2"


4730-00-221-2127 EA 7/8" 5/8"


4730-00-221-2128 EA 1-1/16" 3/4"


4730-00-221-2129 EA 1-3/8" 1"


4730-00-221-2130 EA 1-5/8" 1-1/4"


4730-00-826-6462 EA 1-7/8" 1-1/2"


4730-00-221-2116 EA 2-1/4" 1-3/4"


4730-00-221-2117 EA 2-1/2" 2"

Notes: 1. See Figure 3 for examples of AN929D high pressure aluminum caps (blue in color).


Table 3. High Pressure Aluminum Plugs (blue in color)

{Meets SAE AS4841 specification (supersedes MIL-F-5509)}

Item No.

Part Number

(P/N) Nomenclature National Stock Number (NSNs)


Cap Thread

Size Tubing

Size

1 AS5168-D02 Plug, Threaded, 7075 Anodized Aluminum

4730-00-287-0109 EA 5/16" 1/8"


4730-00-287-0100 EA 3/8" 3/16"


4730-00-287-0110 EA 7/16" 1/4"


4730-00-287-0111 EA 1/2" 5/16"


4730-00-287-0112 EA 9/16" 3/8"


4730-00-287-0113 EA 3/4" 1/2"


4730-00-287-0116 EA 7/8" 5/8"


4730-00-287-0117 EA 1-1/16" 3/4"


4730-00-287-0118 EA 1-3/8" 1"


4730-00-640-5104 EA 1-5/8" 1-1/4"


4730-00-287-0115 EA 1-7/8" 1-1/2"


4730-00-640-0633 EA 2-1/4" 1-3/4"


4730-00-287-0120 EA 2-1/2" 2"

Notes: 1. SAE AS5168, “Fitting, Plug, Tube End, Flared” was adopted for use by the Department of Defense. It shall be used in lieu of AN806.

2. See Figure 4 for examples of AS5168-D high pressure aluminum plugs (blue in color).


Table 4. Light Aluminum Caps for Storage and Shipping (silver in color)

{Meets NAS817 specification}

Item No.

Part Number


Number (NSN’s)


Cap Thread

Size Tubing

Size

1 NAS817-2 Cap, Threaded, 3003 Anodized Aluminum

5340-00-682-2112 EA 5/16" 1/8"


5340-00-158-1313 EA 3/8" 3/16"


5340-00-682-2113 EA 7/16" 1/4"


5340-00-682-2114 EA 1/2" 5/16"


5340-00-682-2115 EA 9/16" 3/8"


5340-00-682-2116 EA 3/4" 1/2"


5340-00-682-2117 EA 7/8" 5/8"


5340-00-682-2118 EA 1-1/16" 3/4"


5340-00-682-2119 EA 1-3/8" 1"


5340-00-804-0788 EA 1-5/8" 1-1/4"


5340-01-004-0107 EA 1-7/8" 1-1/2"

Notes: 1. See Figure 5 for examples of NAS817 light aluminum caps for storage and shipping (silver in color).


Table 5. Light Aluminum Plugs for Storage and Shipping (silver in color)

{Meets NAS818 specification}

Item No.

Part Number


Number (NSN’s)


Cap Thread

Size Tubing

Size

1 M5501/1-2 Plug, Threaded, 3003 Anodized Aluminum

5340-00-804-1229 EA 5/16" 1/8"


5340-00-804-1224 EA 3/8" 3/16"


5340-00-433-3253 EA 7/16" 1/4"


5340-00-804-1228 EA 1/2" 5/16"


5340-00-292-3292 EA 9/16" 3/8"


5340-00-828-8802 EA 3/4" 1/2"


5340-00-804-1230 EA 7/8" 5/8"


5340-01-186-6879 EA 1-1/16" 3/4"


5340-00-804-1245 EA 1-3/8" 1"


5340-00-804-1248 EA 1-5/8" 1-1/4"


5340-01-217-1791 EA 1-7/8" 1-1/2"


5340-00-804-1254 EA 2-1/2" 2"

Notes: 1. See Figure 6 for examples of M5501/1 light aluminum plugs for storage and shipping (silver in color).


Table 6. High Pressure Carbon Steel Caps (gold in color)

Item No.

Part Number


Number (NSN’s)

Units of

Issue (U/I)

Cap Thread

Size Tubing

Size

1 SAE AS21914-2

Cap, Threaded, Steel Tube Fitting, Cadmium Plated w/ Supplementary Chromate Treatment

4730-00-541-0677 EA 5/16" 1/8"

2 SAE AS21914-3


4730-00-289-8633 EA 3/8" 3/16"

3 SAE AS21914-4


4730-00-640-0632 EA 7/16" 1/4"

4 SAE AS21914-5


4730-00-618-9069 EA 1/2" 5/16"

5 SAE AS21914-6


4730-00-618-3572 EA 9/16" 3/8"

6 SAE AS21914-8


4730-00-289-8634 EA 3/4" 1/2"

7 SAE AS21914-10


4730-00-618-4227 EA 7/8" 5/8"

8 SAE AS21914-12


4730-00-202-8792 EA 1-1/16" 3/4"

9 SAE AS21914-16


4730-00-274-7120 EA 1-3/8" 1"

10 SAE AS21914-20


4730-00-554-8917 EA 1-5/8" 1-1/4"

11 SAE AS21914-24


4730-00-834-4358 EA 1-7/8" 1-1/2"

Notes: 1. The original military specification, MS21914, “Cap, Pressure Seal, Flareless Tube Fitting”, was adopted as an SAE Standard. Refer to SAE AS21914. Any part numbers established by the original specification shall remain unchanged.

2. See Figure 7 for examples of SAE AS21914 high pressure carbon steel caps (gold in color).


Table 7. High Pressure Carbon Steel Plugs (gold in color)

Item No.

Part Number


Number (NSN’s)

Units of

Issue (U/I)

Cap Thread

Size Tubing

Size

1 SAE AS21913-2

Plug, Threaded, Steel Tube Fitting, Cadmium Plated w/ Supplementary Chromate Treatment

4730-01-068-3245 EA 5/16" 1/8"

2 SAE AS21913-3


4730-00-289-8632 EA 3/8" 3/16"

3 SAE AS21913-4


4730-00-595-2612 EA 7/16" 1/4"

4 SAE AS21913-5


4730-00-541-1465 EA 1/2" 5/16"

5 SAE AS21913-6


4730-00-203-3709 EA 9/16" 3/8"

6 SAE AS21913-8


4730-00-202-8341 EA 3/4" 1/2"

7 SAE AS21913-10


4730-00-966-5695 EA 7/8" 5/8"

8 SAE AS21913-12


4730-00-289-8627 EA 1-1/16" 3/4"

9 SAE AS21913-16


4730-00-289-8626 EA 1-3/8" 1"

10 SAE AS21913-20


4730-00-289-8625 EA 1-5/8" 1-1/4"

11 SAE AS21913-24


4730-01-067-3944 EA 1-7/8" 1-1/2"

Notes: 1. The original military specification, MS21913, “Plug, Flareless Tube”, was adopted as an SAE Standard. Refer to SAE AS21913. Any part numbers established by the original specification remain unchanged.

2. See Figure 8 for examples of SAE AS21913 high pressure carbon steel plugs (gold in color).


Table 8. Plastic Caps for Storage and Shipping (light blue in color)

Part Number


Number (NSN’s)

Units of

Issue (U/I)

Cap Thread

Size Tubing

Size Item No.

1 DC-3 Cap, Threaded, High-Density Polyethylene, seals out contaminants while protecting threads

5340-01-178-7855 EA 3/8"-28 3/16"


5340-00-435-9188 EA 7/16"-24 1/4"


5340-01-114-0773 EA 1/2"-24 5/16"


5340-00-364-9560 EA 9/16"-20 3/8"


5340-00-376-8953 EA 3/4"-20 1/2"


5340-00-620-4901 EA 7/8"-18 5/8"


5340-00-435-9187 EA 1-1/16"-16 3/4"


5340-01-114-0774 EA 1-1/8"-16 7/8"


5340-01-114-0775 EA 1-3/8"-14 1"


5340-01-114-0201 EA 1-5/8"-14 1-1/4"

11 DC-21S Cap, Threaded, High-Density Polyethylene, seals out contaminants while protecting threads

5340-01-184-6883 EA 1-37/64"-14 1-1/4"


------------------------ EA 1-7/8"-14 1-1/2"

13 DC-25S Cap, Threaded, High-Density Polyethylene, seals out contaminants while protecting threads

5340-01-114-0202 EA 1-27/32"-14 1-1/2"

Notes: 1. See Figure 9 for examples of plastic caps for storage and shipping (light blue in color).


Table 9. Plastic Plugs for Storage and Shipping (light blue in color)

Item No.

Part Number


Number (NSN’s)

Units of

Issue (U/I)

Cap Thread

Size Tubing

Size

1 DP-3 Plug, Threaded, High-Density Polyethylene, seals out contaminants while protecting threads

5340-01-114-0205 EA 3/8"-28 3/16"


5340-01-084-5529 EA 7/16"-24 1/4"


5340-01-115-1097 EA 1/2"-24 5/16"


5340-01-089-9029 EA 9/16"-20 3/8"


5340-01-080-9472 EA 3/4"-20 1/2"


5340-01-104-6066 EA 7/8"-18 5/8"


5340-01-085-4233 EA 1-1/16"-16 3/4"


------------------------ EA 1-1/8"-16 7/8"


5340-01-113-3830 EA 1-3/8"-14 1"


5340-01-201-5562 EA 1-5/8"-14 1-1/4"

11 DP-21S Plug, Threaded, High-Density Polyethylene, seals out contaminants while protecting threads

------------------------ EA 1-37/64"-14 1-1/4"


5340-01-201-5563 EA 1-7/8"-14 1-1/2"

13 DP-25S Plug, Threaded, High-Density Polyethylene, seals out contaminants while protecting threads

------------------------ EA 1-27/32"-14 1-1/2"

Notes: 1. See Figure 10 for examples of plastic caps for storage and shipping (light blue in color).



HYDRAULIC SEALS

HYDRAULIC SYSTEMS

Reference Material

Gland Design; Packings, Hydraulic, General Requirements for ................................ MIL-G-5514 Packing, Preformed, Hydraulic, +275 Degrees F (O-Ring)........................................ SAE AS28775 Packing, Preformed, Straight Thread Tube Fitting ................................................... SAE AS28778 Hydraulic and Pneumatic Retainers (Back-Up Rings), Polytetrafluoroethylene (PTFE) Resin ........................................................................................................ SAE AS8791 Retainer, Packing Backup, Single Turn Tetrafluoroethylene ................................... MS28774 Packing, Preformed, Straight Thread Tube Fitting Boss, Type I Hydraulic ............... SAE AMS-P-5510 Rubber Products: Recommended Shelf Life ............................................................. MIL-HDBK-695

Alphabetical Index

Subject Page No.

Backup Rings ................................................................................................................................. 17 Backup Ring Identification ......................................................................................................... 17 Backup Ring Installation ............................................................................................................ 18

Introduction .................................................................................................................................... 2 Definitions .................................................................................................................................. 2

Packings......................................................................................................................................... 2 Gaskets...................................................................................................................................... 11 Preformed Packing Identification............................................................................................... 13 Preformed Packing Lubrication.................................................................................................. 18 Preformed Packing Removal and Installation............................................................................ 14 Preformed Packing Storage....................................................................................................... 14 Service Life of Preformed Packings .......................................................................................... 13 Spring Seals............................................................................................................................... 3 T-Rings ...................................................................................................................................... 2


None

NAVAIR 01-1A-17 015 00 TO 42B2-1-12 Page 2

1. INTRODUCTION.

2. Hydraulic seals are used in the hydraulic systems of aircraft and related support equipment (SE) to minimize internal and external leakage of hydraulic fluids. By minimizing or preventing such leakage, the seals are vital to maintaining the operating pressure of a hydraulic system.

3. DEFINITIONS. Military Specification MIL-G-5514 defines the following:

a. Seal: A device to retain fluid within a hydraulic component. A seal may consist of two or more components, such as a packing in a gland, or a packing and backup ring in a gland.

b. Packing: The component of a seal which serves as a sealing medium by nature of its plastic or elastic properties, or its ability to deform into the shape of the gland.

c. Gland: The component of the seal which forms the cavity or inclusion which surrounds and supports the packing and controls the squeeze.

d. Squeeze: The dimension by which a packing is distorted from its molded shape when installed in a packing gland.

e. Dynamic seal: A type of seal where there is relative motion between some part of the gland and the packing, such as piston or shaft seal.

f. Static seal: A type of seal where there is no relative motion between the packing and any part of the gland, although limited freedom may be provided to permit the packing to change its shape within the gland when under pressure.

g. Gasket: A type of seal which is formed by crushing packing material into the gland such that the cavity formed by the gland is normally filled with the packing material.

h. Backup ring: A device used to prevent pressure and friction from extruding the O-ring packing through the clearance gap of a seal.

i. TFE: A tetrafluoroethylene resin.

4. For further clarification of the above terminology, and for additional information, read paragraphs 5 and 6.

5. PACKINGS.

6. As defined by MIL-G-5514, the term “packing” refers to the synthetic rubber component of either a dynamic seal, a static seal, or a gasket. Although a gasket is one form of static seal and is often called a static seal due to the fact that there are no moving parts associated with it, the two terms must not be interchanged indiscriminately. A gasket is often used in exterior applications where exposure to air is a life factor. A packing compound designed for use in such circumstances may be unsuitable for use as part of a static seal designed only for contact with hydraulic fluid. Packing materials are designed to have particular properties under certain conditions and for contact with certain media. A packing compound designed to have excellent sealing characteristics with one medium may have hazardous characteristics with another medium. An example of this is the difference between a packing designed for a fuel system and one designed for a hydraulic system. By the nature of its compound, a fuel system packing has a greater volume increase than a hydraulic packing which requires precision dimensional stability. Substitution of a fuel packing for a hydraulic packing is prohibited.

7. Preformed packings used in Naval and Air Force aircraft hydraulic installations are normally manufactured of synthetic rubber and are made in various forms. The O-ring is the type most extensively employed. Circular in shape, its cross section is small in relation to its diameter. It is molded and trimmed to extremely close tolerances.

8. Packings other than O-rings are also used, to a lesser extent, to seal aircraft and hydraulic SE. These packings are usually employed in specific sealing applications such as landing gear shock struts, rotary actuators, and in areas of extreme temperature buildup. The following provides a brief description of the more commonly used special application seals.

9. T-RINGS. The T-ring shown in Figure 1 resists spiraling and rolling in glands because of its inverted tee design. It is sometimes used in applications where spiraling or rolling causes O-ring failure. T-rings are also used in applications where large clearances could occur due to expansion of thin wall hydraulic cylinders. The T-sealing ring is installed under radial compression and provides a positive seal at zero or low pressure. Backup rings, normally one on each side, ride free of T-ring flanges and rod or cylinder wall. These clearances keep seal friction to a minimum at low pressure. When pressure is applied, the T-sealing ring acts to provide positive sealing action as fluid pressure increases.

NAVAIR 01-1A-17 015 00 TO 42B2-1-12 Page 3

a. Glyd Ring. Figure 2 depicts a ring designed to prevent O-ring extrusion. No backup rings are required.

b. Cap Seal. The seal shown in Figure 3 is less frequently used and is not recommended for new design applications. The Cap Seal is a ring designed to prevent O-ring extrusion and is usually used in grooves designed for O-rings with no backup rings. Because of crowding in the groove, Cap Seals often present installation difficulties.

c. Channel Seal. Figure 4 shows a ring designed as a replacement for conventional sealing methods (O-ring and backup rings in combination) and is directly interchangeable with a dual backup and O-ring combination. Channel Seals are manufactured to the gland and groove dimensions of MIL-G-5514. Channel Seals are used primarily in dynamic hydraulic and pneumatic sealing applications.

d. Double Channel Seal. Figure 5 shows a type of seal particularly effective in sealing excessive clearances and high pressures. It is used in combination, as are all Channel Seals, with O-rings. The Double Delta Channel Seal is manufactured to gland and groove dimensions of MIL-G-5514.

10. SPRING SEALS. The Spring Seal consists of a flat helical spring inside a modified “C” section Teflon ring. Figure 6 shows the spring sealing action principle in which the action of the spring exerts equal pressure and provides permanent resiliency to assure a reliable seal. Spring seals are manufactured in various sizes and shapes conforming to the groove and gland dimensions of MIL-G-5514. Figure 7 shows spring seal styles and typical installations.

NOTE

Spring seals should always be installed sothat the open side of the cover facestoward system pressure.

11. The spring seal is not as flexible as conventional O-rings, therefore extreme care shall be exercised when installing the seal. Special tooling is required to install spring seals. Refer to applicable Maintenance Instruction Manual (MIM) or Technical Order (TO) for specific installation techniques, procedures, and tooling requirements.

015001

Figure 1. T-Sealing Ring

015002

Figure 2. Typical Glyd Ring Installation

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015003

Figure 3. Typical Cap Seal Installation

015004

Figure 4. Typical Channel Seal Installation

015005

Figure 5. Typical Double Delta Channel Seal Installation

015006

Figure 6. Spring Seal Sealing Principle

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015007

Figure 7. Spring Seal and Typical Installations

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12. Hydraulic O-rings were originally specified under AN (Air Force-Navy) Specification numbers (6227, 6230, and 6290) for use with hydraulic fluid conforming to MIL-PRF-5606, MIL-PRF-83282 or MIL-PRF-87257 (WP002 00, Table 3, Item 1, 2 or 4) at operating temperatures ranging from -65° to 160°F (-54E to 71EC). Advances in aircraft design, which raised operating temperatures to a possible 275°F (135EC), necessitated the adoption of new packing materials. The SAE AS28775 (formerly MS28775) O-ring is a viable substitute for the AN6227 and AN6230 O-rings. The SAE AS28778 (formerly MS28778) O-ring is replacing the AN6290 O-ring. These O-rings are now standard for systems using hydraulic fluid MIL-PRF-5606, MIL-PRF-83282, or MIL-PRF-87257 (WP002 00, Table 3, Item 1, 2 or 4), where the operating temperatures may vary from -65° to 275°F (-54E to 135EC). O-rings made of fluorocarbon rubber (FPM) are seals generally used in hydraulic systems using di-ester or silicate ester based fluids. Their working temperature range is from -15° to 400°F (-26E to 204EC). O-rings made of FPM are manufactured to standard O-ring sizes. Compounds used in O-rings conform to AMS 7276 and AMS7259.

Refer to Table 1 for O-ring part number/material specification crossovers.

13. The O-ring packing effectively seals in both directions. This sealing is done by distortion of its elastic compound. Figure 8, shows an O-ring of the proper size installed in a grooved seat. Notice that the clearance for the O-ring is less than its free outer diameter. The cross section of the O-ring is squeezed out of round prior to the application of pressure. In this manner, contact with the inner and outer walls of the passage is assured under static (no pressure) conditions. Figure 8 also shows the action of the O-rings when pressure is applied and the same actions when backup rings are installed. In hydraulic systems where components are subjected to 1500 psi pressure or less, AN6227, AN6230, and SAE AS28775 (formerly MS28775) packings are used. Backup rings are not normally required in this application. In aircraft with hydraulic system pressures of 3000 psi, the SAE AS28775 (formerly MS28775) packings are used in conjunction with backup rings, the latter being employed as anti-extrusion devices. Refer to Table 2 for the O-rings and backup rings most frequently used.

015008

Figure 8. Relative Positions of O-Ring Packings in Different Grooves at Increasing Pressures

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Table 1. O-Ring Part Numbers Cross Over to Material Specification

Part Number Part Number Specification Previous Part Number Material Specification AA55549-XX A-A-55549 MA90064-XX ZZ-R-765, AMS3302 AS3084-XX AS3084 AS3804-XX AMS 7280

AS3085-XXX AS3085 AS3085-XXX AMS 7280 AS3208-XX AS3208 AS3208-XX AMS 7276

AS3209-XXX AS3209 AS3209-XXX AMS 7276 AS3551-XXX AS3551 MS9241-XXX AMS 7272 AS3551-XXX AS3551 MS9355-XX AMS 7272 AS3569-XXX AS3569 AN123951 THRU AN124050 AMS 7270 AS3570-XXX AS3570 AN123851 THRU AN123950 AMS 7274 AS3578-XXX AS3578 MS9020-XX AMS 7271 AS3578-XXX AS3578 MS9021-XXX AMS 7271 AS3581-XXX AS3581 MS9970-XXX AMS 7259 AS3582-XXX AS3582 MS9068-XXX AMS 3304

M83248/1-XXX MIL-R-83248 MS17413-XXX MIL-R-83248, AMS-R-83248 M83248/1-XXX MIL-R-83248/1 M83248/1-XXX MIL-R-83248, AMS-R-83248 M83248/2-XXX MIL-R-83248/2 M83248/2-XXX MIL-R-83248, AMS-R-83248 M83461/1-XXX MIL-P-83461/1 M83461/1-XXX MIL-P-83461, AMS-P-83461 M259888-XXX NSA8200 NSA8200-XXX MIL-R-25988, AMS-R-25988 M259888-XXX NSA8203 NSA8203-XXX MIL-R-25988, AMS-R-25988 M25988/1-XXX MIL-R-25988 M25988/1-XXX MIL-R-25988, AMS-R-25988 M25988/2-XXX MIL-R-25988 M25988/2-XXX MIL-R-25988, AMS-R-25988 M25988/3-XXX MIL-R-25988 M25988/3-XXX MIL-R-25988, AMS-R-25988 M25988/4-XXX MIL-R-25988 M25988/4-XXX MIL-R-25988, AMS-R-25988 M83248/1-XXX MIL-R-83248/1 MS9387-XX MIL-R-83248, AMS-R-83248 M83248/1-XXX MIL-R-83248/1 MS9388-XXX MIL-R-83248, AMS-R-83248 M83248/1-XXX NAS1593 NAS1593-XXX MIL-R-83248, AMS-R-83248 M83248/2-XXX NAS1594 NAS1594-XXX MIL-R-83248, AMS-R-83248 M83248/1-XXX NAS1595 NAS1595-XXX MIL-R-83248, AMS-R-83248 M83248/2-XXX NAS1596 NAS1596-XX MIL-R-83248, AMS-R-83248 MA3362XXXXX MA3362 MA3362XXXX AMS7276 MA3434XXXXX MA3434 MA3434XXXX AMS7273 MA3442XXXXX MA3442 MA3442XXXX AMS7267 MA3445XXXXX MA3445 MA3445XXXX MIL-R-83485, AMS-R-83485 MS28772-XXX AS28772 MS28772-XXX MIL-P-5516, AMS-P-5516 MS28775-XXX AS28775 AN6227-XXX MIL-P-25732, AMS-P-25732 MS28775-XXX AS28775 AN6230-XXX MIL-P-25732, AMS-P-25732 MS28775-XXX AS28775 MS28775-XXX MIL-P-25732, AMS-P-25732 MS28778-XX AS28778 AN6290-XX MIL-P-5510, AMS-P-5510 MS28778-XX AS28778 MS28778-XX MIL-P-5510, AMS-P-5510 MS29512-XX AS29512 MS29512-XX MIL-P-5315, AMS-P-5315

MS29513-XXX AS29513 MS29513-XXX MIL-P-5315, AMS-P-5315 MS29561-XXX AS29561 MS29561 MIL-R-7362, AMS-R-7362

MS3393-XX AS33931 MS3393-XX MIL-P-81716 MS90064-XX MS90064 MS90064-XX ZZ-R-765, AMS3304 MS9385-XX AS9385 MS9385-XX AMS 7267

MS9386-XXX AS9386 MS9386-XXX AMS 7267 MS9966-XX AS9966 MS9966-XX AMS 7273

MS9967-XXX AS9967 MS9967-XXX AMS 7273 NAS617-XXX NAS617 NAS617-XXX MIL-R-7362, AMS-R-7362

NAS1611-XXXA NAS1611 NAS1611-XXX NAS1613 NAS1612-XXA NAS1612 NAS1612-XX NAS1613

NSA8201-X NSA8201 NSA8201-X NAS1613 NSA8204-XXX NSA8204 NSA8204-XXX NAS1613 NSA8205-XXX NSA8205 NSA8205-XXX AMS 3242 NSA8206-XXX NSA8206 NSA8206-XXX AMS 7267

NAVAIR 01-1A-17 015 00 TO 42B2-1-12 Page 8

Table 2. O-Rings and Backup Rings for Equipment Applications

O-RINGS BACKUP RINGS

SAE AS28775 (Formerly AN6227 and AN6230)

SINGLE SPIRAL, SINGLE SCARF CUT (EXCEPT FOR THOSE MARKED WITH A (Y), MADE FROM TEFLON

DOUBLE SPIRAL, SINGLE SCARF CUT, MADE FROM TEFLON

NOM DIM. NOM DIM. NOM DIM. ID T

SPEC NO.

ID T W

SPEC NO. ID T W

SPEC NO.

1/8 1/16 SAE AS28775-006 9/64 3/64 3/64 SAE AS8791-6 1/8 3/64 3/64 MS28782-1 5/32 1/16 SAE AS28775-007 11/64 3/64 3/64 SAE AS8791-7 5/32 3/64 3/64 MS28782-2 3/16 1/16 SAE AS28775-008 13/64 3/64 3/64 SAE AS8791-8 3/16 3/64 3/64 MS28782-3 7/32 1/16 SAE AS28775-009 15/64 3/64 3/64 SAE AS8791-9 7/32 3/64 3/64 MS28782-4 1/4 1/16 SAE AS28775-010 17/64 3/64 3/64 SAE AS8791-10 1/4 3/64 3/64 MS28782-5 5/16 1/16 SAE AS28775-011 21/64 3/64 3/64 SAE AS8791-11 5/16 3/64 3/64 MS28782-6 3/8 1/16 SAE AS28775-012 25/64 3/64 3/64 SAE AS8791-12 3/8 3/64 3/64 MS28782-7 3/8 3/32 SAE AS28775-110 25/64 3/64 3/32 SAE AS8791-110 3/8 3/64 3/32 MS28782-8 7/16 3/32 SAE AS28775-111 29/64 3/64 3/32 SAE AS8791-111 7/16 3/64 3/32 MS28782-9 15/32 1/16 SAE AS28775-013* 29/64 3/64 3/64 SAE AS8791-13 1/2 1/16 SAE AS28775-014* 33/64 3/64 3/64 SAE AS8791-14 1/2 3/32 SAE AS28775-112 33/64 3/64 3/32 SAE AS8791-112 1/2 3/64 3/32 MS28782-10 9/16 1/16 SAE AS28775-015* 37/64 3/64 3/64 SAE AS8791-15 9/16 3/32 SAE AS28775-113 37/64 3/64 3/32 SAE AS8791-113 9/16 3/64 3/32 MS28782-11 5/8 1/16 SAE AS28775-016* 41/64 3/64 3/64 SAE AS8791-16 5/8 3/32 SAE AS28775-114 41/64 3/64 3/32 SAE AS8791-114 5/8 3/64 3/32 MS28782/12 11/16 1/16 SAE AS28775-017* 45/64 3/64 3/64 SAE AS8791-17 11/16 3/32 SAE AS28775-115 45/64 3/64 3/32 SAE AS8791-115 11/16 3/64 3/32 MS28782-13 3/4 1/16 SAE AS28775-018* 49/64 3/64 3/64 SAE AS8791-18 3/4 3/32 SAE AS28775-116 49/64 3/64 3/32 SAE AS8791-116 3/4 3/64 3/32 MS28782-14 3/4 1/8 SAE AS28775-210

49/64 3/64 1/8 SAE AS8791-210 3/4 3/64 1/8 MS28782-15 13/16 1/16 SAE AS28775-019* 53/64 3/64 3/64 SAE AS8791-19 13/16 3/32 SAE AS28775-117* 53/64 3/64 3/32 SAE AS8791-117 13/16 1/8 SAE AS28775-211 53/64 3/64 1/8 SAE AS8791-211 13/16 3/64 1/8 MS28782-16 7/8 1/16 SAE AS28775-020* 57/64 3/64 3/64 SAE AS8791-20 7/8 3/32 SAE AS28775-118* 57/64 3/64 3/32 SAE AS8791-118 7/8 1/8 SAE AS28775-212 57/64 3/64 1/8 SAE AS8791-212 7/8 3/64 1/8 MS28782-17 15/16 1/16 SAE AS28775-021* 61/64 3/64 3/64 SAE AS8791-21 15/16 3/32 SAE AS28775-119* 61/64 3/64 3/32 SAE AS8791-119 15/16 1/8 SAE AS28775-213 61/64 3/64 1/8 SAE AS8791-213 15/16 3/64 1/8 MS28782-18 1 1/16 SAE AS28775-022* 1-1/64 3/64 3/64 SAE AS8791-22 1 3/32 SAE AS28775-120* 1-1/64 3/64 3/32 SAE AS8791-120 1 1/8 SAE AS28775-214 1-1/64 3/64 1/8 SAE AS8791-214 1 3/64 1/8 MS28782-19 1-3/64 1/16 SAE AS28775-023* 1-5/64 3/64 3/64 SAE AS8791-23 1-1/16 3/32 SAE AS28775-121* 1-5/64 3/64 3/32 SAE AS8791-121 1-1/16 1/8 SAE AS28775-215 1-5/64 3/64 1/8 SAE AS8791-215 1-1/16 3/64 1/8 MS28782-20 1-1/8 1/16 SAE AS28775-024* 1-9/64 3/64 3/64 SAE AS8791-24 1-1/8 3/32 SAE AS28775-122* 1-9/64 3/64 3/32 SAE AS8791-122 1-1/8 1/8 SAE AS28775-216 1-9/64 3/64 1/8 SAE AS8791-216 1-1/8 3/64 1/8 MS28782-21 1-3/16 1/16 SAE AS28775-025* 1-13/64 3/64 3/64 SAE AS8791-25 1-3/16 3/32 SAE AS28775-123* 1-13/64 3/64 3/32 SAE AS8791-123 1-3/16 1/8 SAE AS28775-217 1-13/64 3/64 1/8 SAE AS8791-217 1-3/16 3/64 1/8 MS28782-22 1-1/4 1/16 SAE AS28775-026* 1-17/64 3/64 3/64 SAE AS8791-26 1-1/4 3/32 SAE AS28775-124* 1-17/64 3/64 3/32 SAE AS8791-124 1-1/4 1/8 SAE AS28775-218 1-17/64 3/64 1/8 SAE AS8791-218 1-1/4 3/64 1/8 MS28782-23 1-5/16 1/16 SAE AS28775-027* 1-21/64 3/64 3/64 SAE AS8791-27 1-5/16 3/32 SAE AS28775-125* 1-21/64 3/64 3/32 SAE AS8791-125 1-5/16 1/8 SAE AS28775-219 1-21/64 3/64 1/8 SAE AS8791-219 1-5/16 3/64 1/8 MS28782-24 1-3/8 1/16 SAE AS28775-028* 1-25/64 3/64 3/64 SAE AS8791-28 1-3/8 3/32 SAE AS28775-126* 1-25/64 3/64 3/32 SAE AS8791-126 1-3/8 1/8 SAE AS28775-220 1-25/64 3/64 1/8 SAE AS8791-220 1-3/8 3/64 1/8 MS28782-25 1-7/16 3/32 SAE AS28775-127* 1-29/64 3/64 3/32 SAE AS8791-27 1-7/16 1/8 SAE AS28775-221 1-29/64 3/64 1/8 SAE AS8791-221 1-7/16 3/64 1/8 MS28782-26 1-1/2 3/32 SAE AS28775-128* 1-33/64 3/64 3/32 SAE AS8791-128 1-1/2 1/8 SAE AS28775-222 1-33/64 3/64 1/8 SAE AS8791-222 1-1/2 3/64 1/8 MS28782-27 1-1/2 3/16 SAE AS28775-325 1-33/64 5/64 3/16 SAE AS8791-325 1-1/2 1/16 3/16 MS28782-28 1-9/16 3/32 SAE AS28775-129* 1-37/64 3/64 3/32 SAE AS8791-129 1-5/8 3/32 SAE AS28775-130* 1-41/64 3/64 3/32 SAE AS8791-130 1-5/8 1/8 SAE AS28775-223* 1-41/64 3/64 1/8 SAE AS8791-223 1-5/8 3/64 1/8 MS28783-1 1-5/8 3/16 SAE AS28775-326 1-41/64 5/64 3/16 SAE AS8791-326 1-5/8 1/16 3/16 MS28782-29 1-11/16 3/32 SAE AS28775-131* 1-45/64 3/64 3/32 SAE AS8791-131 1-3/4 3/32 SAE AS28775-132* 1-49/64 3/64 3/32 SAE AS8791-132 1-3/4 1/8 SAE AS28775-224*

1-49/64 3/64 1/8 SAE AS8791-224 1-3/4 3/64 1/8 MS28783-2

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Table 2. O-Rings and Backup Rings for Equipment Applications (Cont)






SPEC NO. ID T W

SPEC NO. ID T W

SPEC NO.

1-3/4 3/16 SAE AS28775-327 1-49/64 5/64 3/16 SAE AS8791-327 1-3/4 1/16 3/16 MS28782-30 1-13/16 3/32 SAE AS28775-133* 1-53/64 3/64 3/32 SAE AS8791-133 1-7/8 3/32 SAE AS28775-134* 1-57/64 3/64 3/32 SAE AS8791-134 1-7/8 1/8 SAE AS28775-225* 1-57/64 3/64 1/8 SAE AS8791-225 1-7/8 3/64 1/8 MS28783-3 1-7/8 3/16 SAE AS28775-328 1-57/64 5/64 3/16 SAE AS8791-328 1-7/8 1/16 3/16 MS28782-31 1-15/16 3/32 SAE AS28775-135* 1-61/64 3/64 3/32 SAE AS8791-135 2 3/32 SAE AS28775-136* 2-1/64 3/64 3/32 SAE AS8791-136 2 1/8 SAE AS28775-226* 2-1/64 3/64 1/8 SAE AS8791-226 2 3/64 1/8 MS28783-4 2 3/16 SAE AS28775-329 2-1/64 5/64 3/16 SAE AS8791-329 2 1/16 3/16 MS28783-32 2-3/16 3-32 SAE AS28775-137* 2-5/64 3/64 3/32 SAE AS8791-137 2-1/8 3/32 SAE AS28775-138 2-9/64 3/64 3/32 SAE AS8791-138 2-1/8 1/8 SAE AS28775-227* 2-9/64 3/64 1/8 SAE AS8791-227 2-1/8 3/64 1/8 MS28783-5 2-1/8 3/16 SAE AS28775-330 2-9/64 5/64 3/16 SAE AS8791-330 2-1/8 1/16 3/16 MS28782-33 2-3/16 3/32 SAE AS28775-139* 2-13/64 3/64 3/32 SAE AS8791-139 2-1/4 3/32 SAE AS28775-140* 2-17/64 3/64 3/32 SAE AS8791-140b 2-1/4 1/8 SAE AS28775-228* 2-17/64 3/64 1/8 SAE AS8791-228 2-1/4 3/64 1/8 MS28783-6 2-1/4 3/16 SAE AS28775-331 2-17/64 5/64 3/16 SAE AS8791-331 2-1/4 1/16 3/16 MS28782-34 2-5/16 3/32 SAE AS28775-141* 2-21/64 3/64 3/32 SAE AS8791-141b 2-3/8 3/32 SAE AS28775-142* 2-25/64 3/64 3/32 SAE AS8791-142b 2-3/8 1/8 SAE AS28775-229* 2-25/64 3/64 1/8 SAE AS8791-229 2-3/8 3/64 1/8 MS28783-7 2-3/8 3/16 SAE AS28775-332 2-25/64 5/64 3/16 SAE AS8791-332 2-3/8 1/16 3/16 MS28782-35 2-7/16 3/32 SAE AS28775-143* 2-29/64 3/64 3/32 SAE AS8791-143b 2-1/2 3/32 SAE AS28775-144*

2-33/64 3/64 3/32 SAE AS8791-144b 2-1/2 1/8 SAE AS28775-230* 2-33/64 3/64 1/8 SAE AS8791-230 2-1/2 3/64 1/8 MS28783-8 2-1/2 3/16 SAE AS28775-333 2-33/64 5/64 3/16 SAE AS8791-333 2-1/2 1/16 3/16 MS28782-36 2-9/16 3/32 SAE AS28775-145* 2-37/64 3/64 3/32 SAE AS8791-145b 2-5/8 3/32 SAE AS28775-146* 2-41/64 3/64 3/32 SAE AS8791-146b 2-5/8 1/8 SAE AS28775-231* 2-41/64 3/64 1/8 SAE AS8791-231b 6-5/8 3/64 1/8 MS28783-9 2-5/8 3/16 SAE AS28775-334 2-41/64 5/64 3/16 SAE AS8791-334 2-5/8 1/16 3/16 MS28782-37 2-11/16 3/32 SAE AS28775-147* 2-45/64 3/64 3/32 SAE AS8791-147 2-3/4 3/32 SAE AS28775-148* 2-49/64 3/64 3/32 SAE AS8791-148b 2-3/4 1/8 SAE AS28775-232 2-49/64 3/64 1/8 SAE AS8791-232b 2-3/4 3/64 1/8 MS28783-10 2-3/4 3/16 SAE AS28775-335 2-49/64 5/64 3/16 SAE AS8791-335 2-3/4 1/16 3/16 MS28782-38 2-3/16 3/32 SAE AS28775-149* 2-53/64 3/64 3/32 SAE AS8791-149b 2-7/8 1/8 SAE AS28775-233* 2-57/64 3/64 1/8 SAE AS8791-233 2-7/8 3/64 1/8 MS28783-11 2-7/8 3/16 SAE AS28775-336 2-57/64 5/64 3/16 SAE AS8791-336 2-7/8 1/16 3/16 MS28782-39 3 1/8 SAE AS28775-234* 3 3/64 1/8 SAE AS8791-234b 3 3/64 1/8 MS28783-12 3 3/16 SAE AS28775-337 3-1/64 5/64 3/16 SAE AS8791-337 3 1/16 3/16 MS28782-40 3-1/8 1/8 SAE AS28775-235* 3-1/8 3/64 1/8 SAE AS8791-235b 3-1/8 3/64 1/8 MS28783-13 3-1/8 3/16 SAE AS28775-338 3-9/64 5/64 3/16 SAE AS8791-338 3-1/8 1/16 3/16 MS28782-41 3-1/4 1/8 SAE AS28775-236* 3-1/4 3/64 1/8 SAE AS8791-236b 3-1/4 3/64 1/8 MS28783-14 3-1/4 3/16 SAE AS28775-339 3-17/64 5/64 3/16 SAE AS8791-339b 3-1/4 1/16 3/16 MS28782-42 3-3/8 1/8 SAE AS28775-237* 3-3/8 3/64 1/8 SAE AS8791-237b 3-3/8 3/64 1/8 MS28783-15 3-3/8 3/16 SAE AS28775-340 3-25/64 5/64 3/16 SAE AS8791-340 3-3/8 1/16 3/16 MS28782-43 3-1/2 1/8 SAE AS28775-238* 3-1/2 3/64 1/8 SAE AS8791-238b 3-1/2 3/64 1/8 MS28783-16 3-1/2 3/16 SAE AS28775-341 3-33/64 5/64 3/16 SAE AS8791-341 3-1/2 1/16 3/16 MS28782-44 3-5/8 1/8 SAE AS28775-239* 3-5/8 3/64 1/8 SAE AS8791-239b 3-5/8 3/64 1/8 MS28783-17 3-5/8 3/16 SAE AS28775-342 3-41/8 5/64 3/64 SAE AS8791-342 3-5/8 1/16 3/16 MS28782-45 3-3/4 1/8 SAE AS28775-240* 3-3/4 3/64 1/8 SAE AS8791-240b 3-3/4 3/64 1/8 MS28783-18 3-3/4 3/16 SAE AS28775-343 3-49/64 5/64 3/16 SAE AS8791-343 3-3/4 1/16 3/16 MS28783-46 3-7/8 1/8 SAE AS28775-241 3-7/8 3/64 1/8 SAE AS8791-241b 3-7/8 3/64 1/8 MS28782-19 3-7/8 3/16 SAE AS28775-344 3-57/64 5/64 3/16 SAE AS8791-344 3-7/8 1/16 3/16 MS28782-47 4 1/8 SAE AS28775-242* 4 3/64 1/8 SAE AS8791-242b 4 3/64 1/8 MS28783-20 4 3/16 SAE AS28775-345 4-1/32 5/64 3/16 SAE AS8791-345 4 1/16 3/16 MS28782-48 4-1/8 1/8 SAE AS28775-243* 4-1/8 3/64 1/8 SAE AS8791-243b 4-1/8 3/64 1/8 MS28783-21 4-1/8 3/16 SAE AS28775-346 4-5/32 5/64 3/16 SAE AS8791-346 4-1/8 1/16 3/16 MS28782-49 4-1/4 1/8 SAE AS28775-244* 4-1/4 3/64 1/8 SAE AS8791-244b 4-1/4 3/64 1/8 MS28783-22 4-1/4 3/16 SAE AS28775-347 4-9/32 5/64 3/16 SAE AS8791-347 4-1/4 1/16 3/16 MS28782-50 4-3/8 1/8 SAE AS28775-245* 4-3/8 3/64 1/8 SAE AS8791-245b 4-3/8 3/64 1/8 MS28783-23 4-3/8 3/16 SAE AS28775-348 4-13/32 5/64 3/16 SAE AS8791-348 4-3/8 1/16 3/16 MS28782-51 4-1/2 1/8 SAE AS28775-246* 4-1/2 3/64 1/8 SAE AS8791-246b 4-1/2 3/64 1/8 MS28783-24 4-1/2 3/16 SAE AS28775-349 4-17/64 5/64 3/16 SAE AS8791-349 4-1/2 1/16 3/16 MS28782-52 4-1/2 1/4 SAE AS28775-425 4-35/64 7/64 15/64 SAE AS8791-425 4-1/2 3/32 15/64 4-5/8 1/8 SAE AS28775-247* 4-5/6 3/64 1/8 SAE AS8791-247b 4-5/8 3/64 1/8 MS28783-25 4-5/8 1/4 SAE AS28775-426 4-43/64 7/64 15/64 SAE AS8791-426 4-5/8 3/32 15/64 MS28782-53 4-3/4 1/4 SAE AS28775-427 4-51/64 7/64 15/64 SAE AS8791-427 4-3/4 3/32 15/64 MS28782-54 4-7/8 1/4 SAE AS28775-428

4-59/64 7/64 15/64 SAE AS8791-428 4-7/8 3/32 15/64 MS28782-55

NAVAIR 01-1A-17 015 00 TO 42B2-1-12 Page 10

Table 2. O-Rings and Backup Rings for Equipment Applications (Cont)






SPEC NO. ID T W

SPEC NO. ID T W

SPEC NO.

5 1/4 SAE AS28775-429 5-3/64 7/64 15/64 SAE AS8791-429 5 3/32 15/64 MS28782-56 5-1/8 1/4 SAE AS28775-430 5-11/64 7/64 15/64 SAE AS8791-430 5-1/8 3/32 15/64 MS28782-57 5-1/4 1/4 SAE AS28775-431 5-19/64 7/64 15/64 SAE AS8791-431 5-1/4 3/32 15/64 MS28782-58 5-3/8 1/4 SAE AS28775-432 5-27/64 7/64 15/64 SAE AS8791-432 5-3/8 3/32 15/64 MS28782-59 5-1/4 1/4 SAE AS28775-433 5-39/64 7/64 15/64 SAE AS8791-433 5-1/2 3/32 15/64 MS28782-60 5-5/8 1/4 SAE AS28775-434 5-43/64 7/64 15/64 SAE AS8791-434 5-5/8 3/32 15/64 MS28782-61 5-3/4 1/4 SAE AS28775-435 5-51/64 7/16 15/64 SAE AS8791-435 5-3/4 3/32 15/64 MS28782-62 5-7/8 1/4 SAE AS28775-436 5-59/64 7/16 15/64 SAE AS8791-436 5-7/8 3/32 15/64 MS28782-63 6 1/4 SAE AS28775-437 6-3/64 7/16 15/64 SAE AS8791-437 6 3/32 15/64 MS28782-64 6-1/4 1/4 SAE AS28775-438 6-9/32 7/16 15/64 SAE AS8791-438b 6-1/4 3/32 15/64 MS28782-65 6-1/2 1/4 SAE AS28775-439

6-17/32 7/16 15/64 SAE AS8791-439b 6-1/2 8/32 15/64 MS28782-66

Notes: 1. O-rings and backup rings which fall on the same horizontal line in this chart may be substituted for each other.

2. Industry standard, SAE AS28775 (formerly identified as military specification, MS28775) O-rings are for hydraulic systems with temperature limits from -65° to +275°F (-50E to +135EC). Part numbers which are asterisked (*) are to be used as static seals only, and are not for application involving rotary or reciprocating motion.

3. SAE AS8791, formerly MS28774, backup rings which are check-marked (b) do not have the same scarf cut.

4. ALL measurements are expressed in inches.

NAVAIR 01-1A-17 015 00 TO 42B2-1-12 Page 11

14. In Type I hydraulic systems (operating temperature range from -65° to +160°F (-54E to +71EC)), the designated sizes of AN6230B-1 through -25, SAE AS28775 (formerly MS28775) -013 through -028, -117 through -149, and -223 through -247 O-rings are intended for use as static seals and must not be used in dynamic seal applications which involve reciprocating or rotary movement. In Type II hydraulic systems (temperatures range from -65° to +275°F (-54E to +135EC)) the designated sizes of SAE AS28775 (formerly MS28775) O-rings are intended as static seals and must not be used as dynamic seals. Refer to Table 2.

15. GASKETS. The O-ring packing defined by SAE AMS-P-5510 (formerly MIL-P-5510) and SAE AS28778 (formerly MS28778) shall be used only with straight thread tube fitting installations. The SAE AS28778 (formerly MS28778) packing is replacing AN6290 gasket for this use. Figure 9 shows that the SAE AS28778 (formerly MS28778) O-rings must be used with an MS28773 backup ring. Refer to Table 3. Figure 10 shows installation of fitting assembly.

16. Fitting and Nut Assembly. Assemble fitting and nut as follows (Figure 9):

Use only SAE AS5179 (formerly AN6289)nut which has an external identificationnotch. The SAE AS5179 (formerlyAN6289) nut has a flat surface on oneside and a retaining groove on the otherside. The retaining groove is designed toaccept Teflon backup ring MS28773.

a. Position nut with retaining groove side facing mating body.

b. Screw nut passing seal area to second threaded area of fitting.

c. Install Teflon backup ring onto seal area of fitting.

d. Gently position Teflon backup ring into retaining groove of nut.

e. If necessary, unscrew nut outward to prevent thread interference.

f. Install O-ring onto seal area of fitting.

g. Screw nut toward body until O-ring gently contacts first threaded area of fitting.

17. Fitting Installation. Install fitting as follows (Figure 10):






a. Lubricate fitting threads and O-ring with system fluid.

b. Nut shall not move from its original assembled position while screwing fitting assembly into port finger-tight.

c. Maintain nut in position with one wrench; use second wrench to rotate fitting inward not more than one turn to achieve proper positioning.

d. System tubing or hose may now be loosely attached to aid in maintaining alignment.

e. Torque nut SAE AS5179 (formerly AN6289) with an open crowfoot adapter and standard torque wrench, while holding fitting with a second wrench.

f. Torque assembly tubing or hose B nut with an open tubular-type crowfoot torque adapter and standard torque wrench while holding fitting with a second wrench.

NAVAIR 01-1A-17 015 00 TO 42B2-1-12 Page 12

015009

Figure 9. Assembly of O-Ring, Teflon Backup Ring, Nut, and Fitting

015010

Figure 10. Installation of Fitting Assembly

NAVAIR 01-1A-17 015 00 TO 42B2-1-12 Page 13

Table 3. O-Rings for Straight Thread Tube Fitting Installations

NOMINAL DIMENSIONS OF O-RINGS TUBING

OD ID W O-RING

SPEC NO. TEFLON

BACKUP RING

1/8

3/16

1/4

5/16

3/8

1/2

5/8

3/4

1-1/4

1-1/2

15/64

5/16

11/32

13/32

15/32

21/32

3/4

15/16

1-15/32

1-23/32

1/16

1/16

5/64

5/64

5/64

3/32

3/32

1/8

1/8

1/8

SAE AS28778-2

SAE AS28778-3

SAE AS28778-4

SAE AS28778-5

SAE AS28778-6

SAE AS28778-8

SAE AS28778-10

SAE AS28778-12

SAE AS28778-20

SAE AS28778-24

MS28773-02

MS28773-03

MS28773-04

MS28773-05

MS28773-06

MS28773-08

MS28773-10

MS28773-12

MS28773-20

MS28773-24

Notes: 1. MS28778 replaces AN6290. Use corresponding dash number to obtain part number.

2. Industry specification, SAE AS28778, replaces military specification, MS28778.

3. MS28773 Teflon backup ring used with SAE AS28778 (formerly MS28778) preformed packings have corresponding dash numbers. EXAMPLE: Use MS28773-05 Teflon ring with MS28778-5 packing and AN6289-5 nut.

4. MS28773 replaces M9058 and MS9484.

5. All dimensions are measured in inches.

18. SERVICE LIFE OF PREFORMED PACKINGS. The service life (estimated time of trouble-free service) of preformed packing depends upon several factors. These include its age, use, exposure to certain elements, both natural and imposed, and subjection to physical stress. Operational conditions imposed upon preformed packings in one component may necessitate replacement more frequently than an identical preformed packing in other components.

19. PREFORMED PACKING IDENTIFICATION. Hydraulic preformed packings are manufactured in accordance with military or industry specifications and can be identified by the technical information printed

on the package. Figure 11 shows the information printed on packages which is essential to determine the intended use and qualification.

20. Color-coding is no longer required by specifications and no longer used for most O-rings. Ethylene propylene O-rings, used in systems operated with phosphate ester fluid, are usually marked with yellow and white markings which vary according to the manufacturer. Colored dots, dashes and stripes, or combinations of dots, dashes, and stripes are used for markings.

NAVAIR 01-1A-17 015 00 TO 42B2-1-12 Page 14

015011

Figure 11. O-Ring Package Identification

21. PREFORMED PACKING STORAGE. Proper storage practices must be observed to prevent deformation and deterioration of rubber preformed packings. Most synthetic rubbers are not damaged by several years of storage when kept in the original unopened package and out of direct sunlight. However, most synthetic rubbers deteriorate when exposed to heat, light, oil, grease, fuels, solvents, thinners, moisture, strong drafts, or ozone (form of oxygen formed by an electrical discharge). Damage by exposure is magnified when rubber is under tension, compression, or stress. There are several conditions to be avoided:

a. Deformation as a result of improper stacking of parts and storage containers.

b. Creasing caused by force applied to corners and edges, and by squeezing between boxes and storage containers.

c. Compression and flattening, as a result of storage under heavy parts.

d. Punctures caused by staples used to attach identification.

e. Deformation and contamination due to hanging the preformed packings from nails or pegs. Preformed packings shall be kept in their original envelopes, which provide preservation, protection,

identification, and cure date. There are no exceptions to this requirement.

f. Contamination by fluids leaking from parts stored above and adjacent to preformed packing surfaces.

g. Contamination caused by adhesive tapes applied directly to preformed packings surfaces. A torn package shall be secured with a pressure-sensitive, moisture-proof tape, but the tape must not contact the preformed packing surfaces.

h. Retention of overage parts caused by improper storage or illegible identification. Preformed packings shall be arranged so the older seals are used first. Overage or nonidentifiable packings shall be discarded.

22. The manufacturer’s cure date is one of the most important printed items listed on the package shown in Figure 11. This cure date is denoted in quarters. For example, the cure date 2Q77 indicates that the preformed packing was manufactured during the second quarter of 1977. Synthetic rubber parts manufactured during any given quarter are not considered one quarter old until the end of the succeeding quarter. Preformed packing shelf life is computed from the cure date. The term cure date is used in conjunction with the replacement kits which contain preformed packings, parts, and hardware for repair of components. The age of preformed packings in a spare part is determined from the assembly date recorded on the service or identification plate and/or on the exterior of the assembly. Refer to MIL-HDBK-695 for shelf life of preformed packings.

NOTE

Be sure to always check the shelf life andnever install an O-ring that is past its shel

f

life.

23. PREFORMED PACKING REMOVAL AND INSTALLATION. Successful operation of a hydraulic system and the units within depends greatly upon the methods and procedures used in handling and installing hydraulic packings. These packings are comparatively soft and must not be subjected to nicks, scratches, or dents. They must be kept free of dirt and foreign matter and should not be exposed to

NAVAIR 01-1A-17 015 00 TO 42B2-1-12 Page 15 extreme weather conditions. When hydraulic packings are chosen for installation, they must not be handled with sharp instruments, and the preservative should not be removed until they are ready for installation.

NOTE

Over time, O-rings take a permanent set.Therefore, any time an O-ring is unsealedresulting in excessive leakage, it must bereplaced with a new O-ring. UnidentifiedO-rings shall not be used.

24. Use the correct tool during the installation or removal of hydraulic packings. A variety of these tools may be used on any given job. Suggestions for fabricating typical tools for use in replacing and installing O-rings and backup rings are shown in Figure 12. These tools should be fabricated from soft metal such as brass or aluminum. Tools made from phenolic rod or plastics may also be used.

25. When removing or installing O-rings, avoid using pointed or sharp-edged tools which might scratch or mar hydraulic component surfaces or cause damage to the O-rings. Contact of the seal removal and installation tools with cylinder walls, piston heads, and related precision components is not desirable.

26. Figure 13, View A shows how the hook type removal tool is positioned under the O-ring and then lifted to allow the extractor tool, as well as the removal tool, to pull the O-ring from its cavity. View B shows the use of another type of extractor tool in the removal of internally installed O-rings.

27. Figure 13, View C illustrates how the extractor tool is positioned under both O-rings at the same time. This method of manipulating the tool positions both O-rings, with minimum effort. View D shows practically the same removal as View C except for the use of a different type of extractor tool.

28. Removal of external O-rings is less difficult than removal of internally installed O-rings. Figure 13, View E and F illustrate two accepted removal methods. View E shows the use of a spoon type extractor, which is positioned under the seal. After the O-ring is dislodged from its cavity, the spoon is held stationary while simultaneously rotating and withdrawing the piston. View F installation is similar to View E, except only one O-ring is installed and a different type extractor tool is used. The wedge type

extractor tool is inserted beneath the O-ring; the hook type removal tool hooks the O-ring. A slight pull on the latter tool removes the O-ring from its cavity.

29. After the removal of all O-rings, cleaning of the affected parts which will receive new O-rings is mandatory. Ensure that the area used for such installations is clean and free from all contamination. Each O-ring to be installed shall be removed from its sealed package and inspected for defects; such as blemishes, abrasions, cuts, or punctures. Although an O-ring may appear perfect at first glance, slight surface flaws may exist. These are often capable of preventing satisfactory O-ring performance under the various operating pressures of aircraft systems. O-rings shall be rejected for flaws that will affect their performance.






Do not use petrolatum to lubricate O-ringsor the insides of hydraulic components.

Do not use adhesive tape as an aid to installation of O-rings. Gummy substances left by adhesives are extremely detrimental to hydraulic systems.

NAVAIR 01-1A-17 015 00 TO 42B2-1-12 Page 16

015012

Figure 12. Typical O-Ring Installation and Removal Tools

NAVAIR 01-1A-17 015 00 TO 42B2-1-12 Page 17

015013

Figure 13. O-Ring Removal

NAVAIR 01-1A-17 015 00 TO 42B2-1-12 Page 18

30. PREFORMED PACKING LUBRICATION. After inspection and prior to installation, lubricate the O-ring with system fluid when required. During installation, avoid rolling or twisting the O-ring to maneuver it into place. Keep the position of the O-ring mold line constant. When the O-ring installation requires spanning or inserting through sharp-threaded areas, ridges, slots, and edges, use protective measures such as paper sleeves and covers which may be fabricated using the seal package (glossy side out) of lint-free bond paper (See Figure 14, View A and View B).

31. After the O-ring is placed in the cavity provided, gently roll the O-ring with the fingers to remove any twist that might have occurred during installation.

32. BACKUP RINGS.

33. Backup rings, also referred to as retainer rings, anti-extrusion devices and non-extrusion rings, are washer-like devices which are installed on the low-pressure side of a packing to prevent extrusion of the packing material into the minute clearances between moving parts in dynamic seals. Backup rings minimize erosion or wearing away of the packing materials and failure of the seal. They are also employed in static seals and with gaskets to prevent extrusion failure due to increasing force (pressure) when the surface tension of the packing compound is no longer sufficient to resist the flow, causing the packing material to extrude out of the passage it is attempting to seal.

34. At lower pressure, non-extrusion devices will prolong the normal wear life of the packing and, at higher pressure, non-extrusion devices permit greater diametrical clearances between mating parts.

35. Many seals use two backup rings, one on either side of the packing (Figure 15). The primary reason for this configuration is the alternating direction of pressure which will cause extrusion of the packing on either side of the gland. The two-backup ring configuration has also been used to facilitate standardization of groove dimension and service procedures even when the pressure is applied from one direction only. In single backup ring configuration it is mandatory that the ring be installed on the low-pressure side of the gland. See Figure 16 for correct placement of backup rings. When a backup ring is placed on the high-pressure side of the packing, the pressure against the relatively hard surface of the backup ring acts to force the softer packing against the low-pressure side of the gland and precipitates extrusion failures at a rapid rate. Whenever dual

backup rings are installed, the split scarfed ends must be staggered as shown in Figure 17, View A.

36. Backup rings for use on hydraulic systems shall conform to AS8791 and AS5861, which specifies that backup rings be manufactured of a tetrafluoroethylene resin, also called TFE or Teflon. The rings may be used in hydraulic systems with fluids conforming to MIL-PRF-83282 (WP002 00, Table 3, Item 2) and in temperature ranges from -65° to +275°F (-54E to +135EC), at operating pressures from 0 to 3000 psi. The shape and dimensions of these backup rings conform to MS28774, MS28782, and MS28783.

37. Precautions similar to those applicable to O-rings must be taken to avert contamination of backup rings and damage to hydraulic components.

38. Teflon backup rings may be stocked in individually sealed packages similar to those in which O-rings are packaged. Several may be installed on a cardboard mandrel, provided a non-tapered mandrel is employed for this purpose. If unpackaged rings are stored for a long time without the use of mandrels, a condition of overlap may develop. In order to eliminate this condition, stack Teflon rings on a mandrel of the correct diameter. Stack and clamp the rings with their coils flat and parallel. Then place the rings in an oven at a maximum temperature of 350°F (177EC) for approximately 10 minutes. The rings are then removed and water quenched.

NOTE

After this treatment, rings should be storedat room temperature for 48 hours prior to use.

39. BACKUP RING IDENTIFICATION. Backup rings are not color coded or otherwise marked and must be identified from package labels. Backup rings made of Teflon do not deteriorate with age, are unaffected by any other system fluid or vapor, and tolerate temperature extremes in excess of those encountered in high pressure hydraulic systems. The dash number, which is found on the package following the specification number, indicates the size and, in some cases, relates directly to the dash number of the O-rings for which the backup ring is dimensionally suited. For example, the single spiral Teflon ring MS28774-6 is used with O-rings MS28775-006; the double spiral Teflon ring MS28782-1 is used with the O-ring AN6227B-1.

NAVAIR 01-1A-17 015 00 TO 42B2-1-12 Page 19

40. BACKUP RING INSTALLATION. Care must be taken in handling and installing backup rings. See Figure 18. Backup rings shall be inserted without the use of sharp tools. Teflon backup rings must be inspected prior to use for evidence of compression damage, scratches, cuts, nicks, or frayed conditions, as illustrated in Figure 18.

During installation of scarf backup rings,ensure gap overlap conforms to MS28774.

41. When Teflon spiral rings are being installed in internal grooves, the ring must have a right-hand

spiral. Figure 19, View A, B, and C show the method used to change directions of the spiral. The Teflon ring is then stretched slightly, as shown in View D prior to installation into the groove. While the Teflon ring is being inserted into the groove, rotate the component in a clockwise direction (View E). This action will tend to expand the ring diameter and reduce the possibility of damage to the ring.

42. When Teflon spiral rings are being installed in external grooves, the ring should have a left-hand spiral. As the ring is inserted into the groove, rotate the component in a clockwise direction. This action will tend to contract the ring diameter and reduce the possibility of damage to the ring.

NAVAIR 01-1A-17 015 00 TO 42B2-1-12 Page 20

015014

Figure 14. O-Ring Installation

NAVAIR 01-1A-17 015 00 TO 42B2-1-12 Page 21

015015

Figure 15. Backup Ring Configuration

RIGHT WRONG

015016

Figure 16. Location of Single Backup Ring

NAVAIR 01-1A-17 015 00 TO 42B2-1-12 Page 22

015017

Figure 17. Teflon Backup Ring Installation - External

NAVAIR 01-1A-17 015 00 TO 42B2-1-12 Page 23

015018

Figure 18. Teflon Backup Ring - Damages Caused by Improper Handling

NAVAIR 01-1A-17 015 00 TO 42B2-1-12 Page 24

015019

Figure 19. Installing Internal Teflon Backup Ring



PHOSPHATE ESTER HYDRAULIC FLUID

HYDRAULIC SYSTEMS

Reference Material

Cleanliness Requirements of Parts Used in Hydraulic Systems ................................ NAS 1638

Alphabetical Index

Subject Page No.

Introduction .................................................................................................................................... 2 Phosphate Ester Fluids and Component Storage ......................................................................... 3

Component Storage................................................................................................................... 3 Phosphate Ester Fluid Storage.................................................................................................. 3

Using Phosphate Ester Fluid.......................................................................................................... 2 Handling..................................................................................................................................... 2 Safety Precautions..................................................................................................................... 2

Phosphate Ester Fluid System Surveillance .................................................................................. 3 Hydraulic Contamination Analysis ............................................................................................. 3


None

NAVAIR 01-1A-17 016 00 TO 42B2-1-12 Page 2

1. INTRODUCTION.

2. Skydrol LD-4, Skydrol 500B-4 and Hyjet IV-A are trade names for phosphate ester fluids SAE AS 1241 (WP002 00, Table 3, Item 5) that are qualified for use in military aircraft. Phosphate ester fluids are clear, light purple, fire-resistant hydraulic fluids having a viscosity of approximately 500 centistokes at -40°F (-40EC).

Do not store phosphate ester fluid near hydraulic fluids MIL-PRF-5606, MIL-PRF-87257 or MIL-PRF-83282. Do not use packings, seals, or gaskets designed for use in MIL-PRF-5606, MIL-PRF-87257 or MIL-PRF-83282 hydraulic systems in phosphate ester fluid systems. Do not mix phosphate ester fluids with any other type of hydraulic fluid.

3. USING PHOSPHATE ESTER FLUID.

Hydraulic Fluid SAE AS1241 5

If hydraulic fluid is decomposed by heat, toxic gases are released. Prolonged contact with liquid or mist can cause dermatitis and irritation to skin and eyes. If there is any prolonged contact with skin, wash contacted area with soap and water. If prolonged contact with mist is likely, wear approved respirator. Hydraulic fluid is toxic if swallowed. Wash hands after handling and before eating, drinking or smoking.

4. HANDLING. Phosphate ester fluids should be handled with extreme care. However, care should be taken to avoid spilling phosphate ester fluids on certain paints and plastic materials, since this fluid may cause them to soften. Refer to Tables 1 and 2 for a list of materials which phosphate ester fluids affect, and those which are resistant to it. If a small amount of phosphate ester fluid is spilled during handling, it should be wiped up immediately with a dry cloth, disposable paper towel, or an oil absorbent pad.

5. Tools having painted areas or vinyl chloride plastic handles should not be allowed to soak in phosphate ester fluids. Many nonmetallic materials are resistant to phosphate ester fluids and will not be adversely affected; others are not resistant and will soften slowly. Since it is difficult to distinguish visually between materials that are resistant and those that are not, all materials wetted with phosphate ester fluids must be wiped clean as soon as possible after coming in contact with the fluid.

6. SAFETY PRECAUTIONS. Phosphate ester fluids are slightly toxic. Applicable Material Safety Data Sheets (MSDS) shall be reviewed prior to usage.

7. Phosphate ester fluids (WP002 00, Table 3, Item 5) cause pain when in contact with eye tissue. First aid treatment includes flushing the eye with clear water, and shall be followed by prompt medical attention.

8. Phosphate ester fluids are severely irritating to the skin and should be washed off immediately upon contact.

9. Gloves (WP002 00, Table 3, Item 17) shall be worn when hands are exposed to phosphate ester fluids. Gloves and aprons of nitrile or polyethylene material are resistant to phosphate ester fluids.

10. In mist or fog form, phosphate ester fluids are irritating to nasal and respiratory passages and generally produce coughing and breathing difficulties. These irritations pass as soon as the individual breathes fresh air.

11. Phosphate ester fluids can remove protective paint or lacquer finishes.

NAVAIR 01-1A-17 016 00 TO 42B2-1-12 Page 3

Table 1. Materials Affected by Phosphate Ester Fluid

MATERIALS EFFECT

Acrylics

Cellulose Butyrate

Cellulose Nitrate

Hypalon

Polystyrene

Polyvinyl Chloride (PVC)

Viton

Vulcaprene

Vulcollan

swells and softens

plasticizes

plasticizes

swells and softens

dissolves

plasticizes

swells and softens

swells and softens

swells and softens

12. PHOSPHATE ESTER FLUIDS AND COMPONENT STORAGE.

Do not store phosphate ester fluids near petroleum based hydraulic fluids due to the possibility of inadvertent mixing.

13. PHOSPHATE ESTER FLUID STORAGE. Store phosphate ester fluids (WP002 00, Table 3, Item 5) fluids in a dry, clean, indoor area if possible. These fluids must be stored, handled, and serviced with great care to ensure maximum cleanliness at all stages from container to aircraft hydraulic system. Phosphate ester fluids shall be stored in the original containers. These fluids will not freeze and generally may be handled like any high-grade petroleum fluids. Shelf life is five years.

14. COMPONENT STORAGE. Components in storage that are used in phosphate ester fluid systems shall be issued and installed within six months, if possible. Components filled with phosphate ester fluid and placed in storage should be drained and refilled after one year. Components shall be capped with metal closures at all times and stored in polyethylene bags.

15. PHOSPHATE ESTER FLUID SYSTEM SURVEILLANCE.

NOTE

Navy aircraft (TC-4C and C-20D) utilizing phosphate ester fluids are contractor maintained in accordance with FAA requirements. Therefore, those affected aircraft are exempt from NAVAIR fluid surveillance requirements. The following information is provided to enable use of Contamination Analysis Kit 57L414 for diagnostic purposes only.

16. The methods and procedures used to process and analyze phosphate ester fluid samples are the same as for hydraulic fluids MIL-PRF-83282 (WP002 00, Table 3, Item 2) except as outlined below.

17. HYDRAULIC CONTAMINATION ANALYSIS.

18. Patch Testing (NAVY USE ONLY). A modified or reconfigured contamination analysis kit is not available for processing phosphate ester fluid samples. The parts required for processing phosphate ester fluid samples are procured separately and from various companies. These parts may or may not have national stock numbers. Therefore, direct procurement of parts from the company is necessary.

NAVAIR 01-1A-17 016 00 TO 42B2-1-12 Page 4

Table 2. Materials Resistant to Phosphate Ester Fluid

MATERIALS DEGREE OF RESISTANCE

Acetal (Delrin or Celcon)

Cellulose Triacetate

Chlorinated Polyether

Ethylene Propylene

Fluorisant

Fluorinated Ethylene

Formvar

Polyamide

Polyethylene

Polyvinyl Alcohol (PVA)

Polyisobutylene

Teflon

Teflon FEP

Phenolic Laminates

Alkyds (Dialkyl Phthalate only)

Melamine Formaldehyde

Phenol Formaldehyde (phenolics, Micarta, Formica, etc.)

Polyester (Mylar, Dacroneta)

Excellent

Good

Excellent

Excellent

Excellent

Excellent

Excellent

Excellent

Excellent

Excellent

Excellent

Excellent

Excellent

Generally unaffected

Good

Excellent

Excellent

Excellent


Hydraulic Fluid SAE AS1241 5


Use polyethylene, sample bottles with polypropylene screw closures (WP002 00, Table 3, Item 19A), polypropylene sample bottles (WP002 00, Table 3, Item 19B) or glass sample bottles (refer to WP002 00) for phosphate ester fluid samples. The polyvinyl chloride sample bottles furnished with the Contamination Analysis Kit 57L414 are not compatible with phosphate ester fluid.

NOTE

Filter P/N LSWP04700 (08071), supportscreen gasket P/N XX4004714 (08071),and O-rings P/N 2-233 EP and P/N 2-210 EP (59871) are recommended for patchtesting phosphate ester fluids. The Teflon filters should be verified by the customerto ensure the correct pore size is beingutilized. These Teflon filters will not showfree water. Check for free water by visualobservation of fluid in the sample bottle.Test filters furnished with Contamination Analysis Kit 57L414 may be softened byphosphate ester fluids. The Teflongaskets are positioned over the thinnerTeflon filter to provide a better seal.

a. Thoroughly rinse all components used for processing fluid samples with cleaning solvent MIL-PRF-680 (WP002 00, Table 3, Item 6). Refer to WP017 00 for Contamination Analysis Kit 57L414 parts breakdown. Ensure all traces of previously processed fluid samples are removed from all components which have come into contact with the fluid.

b. Process phosphate ester samples by following the procedures in accordance with WP017 00, except that washing the filter membrane with an additional 50 to 70 milliliters of cleaning solvent MIL-PRF-680 (WP002 00, Table 3, Item 6) is required after all fluid has passed through it.

Do not place a wet filter membrane in a petri slide. Do not allow phosphate ester fluids to come into contact with the petri slides, they will turn milky white and will have to be discarded.

c. Allow the filter membrane to dry completely before performing contamination analysis.

d. Immediately after processing phosphate ester fluid samples, rinse all components contacting phosphate ester fluid with a generous amount of cleaning solvent, MIL-PRF-680, (WP002 00, Table 3, Item 6) and wipe dry with an ultra-clean, lint-free, disposable wiping cloth (WP002 00, Table 3, Item 13A).

e. Handle completed test filter membranes with care. Phosphate ester fluids tend to remove some of the membrane elasticity.

f. Store completed test filters in a petri slide after assuring that the filter membrane is thoroughly dry.

19. Electronic Particle Counters (NAVY USE ONLY). The Type 2 Portable Oil Diagnostic System (PODS) is compatible with phosphate ester based hydraulic fluids, synthetic and petroleum based fluids. To prevent fluid cross contamination, the Type 2 PODS is used only for phosphate ester based hydraulic fluids. See WP005 00 for further information.

20. NAS 1638 Cleanliness Standard. Some aircraft systems use NAS 1638 as the fluid cleanliness standard for determining the degree of particulate contamination class of hydraulic fluid, i.e. C-40, C-9, etc. These aircraft systems should be operated at NAS 1638 Class 8 or better. The support equipment for these Navy systems should deliver fluid at NAS 1638 Class 6 or better. For USAF cleanliness standards refer to the applicable aircraft maintenance manuals.



HYDRAULIC FLUID CONTAMINATION ANALYSIS KIT (P/N 57L414)

HYDRAULIC SYSTEMS

NAVY USE ONLY

Reference Material

None

Alphabetical Index

Subject Page No.

Cleanliness..................................................................................................................................... 9 Contamination Analysis Procedures .............................................................................................. 5

Analysis of Test Filter ................................................................................................................ 8 Prepare Filter Holder Assembly................................................................................................. 5 Sample Processing.................................................................................................................... 5

Description .................................................................................................................................... 2 Filters ......................................................................................................................................... 2 Filter Holder ............................................................................................................................... 2 Filter Mounts .............................................................................................................................. 2 Graduated Cylinder.................................................................................................................... 2 Sample Bottles........................................................................................................................... 2 Standard .................................................................................................................................... 2 Syringe and Valve...................................................................................................................... 2 Wash Bottles ............................................................................................................................. 2

Illustrated Parts Breakdown ........................................................................................................... 9 Introduction ................................................................................................................................... 2 Kit Component Maintenance.......................................................................................................... 9 Operational Procedures ................................................................................................................. 4

Sample Collection...................................................................................................................... 4 Preparation for Use ........................................................................................................................ 3

Filter Holder ............................................................................................................................... 3 Flush Bottle ................................................................................................................................ 3 Sample Bottles........................................................................................................................... 3 Wash Bottles.............................................................................................................................. 3


None

NAVAIR 01-1A-17 017 00 TO 42B2-1-12 Page 2

1. INTRODUCTION.

2. During normal operation, hydraulic systems become contaminated with metallic and nonmetallic particles. Particulate contamination may result from internal wear or failure of system components, or incorrect maintenance and servicing operations. The procedures herein provide a method of determining the particulate level in a hydraulic system and the presence of free water or other foreign substances.

3. This work package describes the fluid contamination analysis kit and how it is used to evaluate contamination levels in Naval aircraft hydraulic systems and support equipment (SE). The equipment employs a patch test method in which a fluid sample of known volume is filtered through a test filter membrane of known porosity. All particulate matter in excess of a size determined by the filter characteristics is retained on the surface of the membrane, causing it to discolor an amount proportional to the particulate level of the fluid sample.

4. The typical color of contamination in any given system remains fairly uniform and the degree of filter membrane discoloration may be correlated with a level of particulate contamination. By visually comparing the test filter with Contamination Standards representative of known contamination levels, a judgment can be made as to the contaminant level of the system sampled. Free water will be seen either as droplets during the fluid sample processing or as a stain on the test filter.

5. DESCRIPTION

6. The kit contains components for collecting, processing and analyzing fluid samples. Descriptions of kit parts are as follows (Figure 1).

7. FILTER HOLDER. To effect vacuum filtration of a test sample; a filter assembly (Figure 14, Index No. 1) is used consisting of a 100-ml funnel, with highly polished inner walls; a filter support; a locking ring; and a 500-ml flask. The funnel and base attach to the flask in a way that allows a vacuum to be drawn in the chamber beneath the filter.

8. WASH BOTTLES. Two polyethylene 500-ml bottles (Figure 14, Index No. 12), each fitted with a dispensing tube and a spout, are used to dispense solvent required in the sampling and analysis procedures. One of the bottles is fitted for a filter holder that attaches to the spout and accepts a 25-mm filter.

9. SAMPLES BOTTLES. Twenty-four, 120-ml capacity, bottles (Figure 14, Index No. 13), are used to collect fluid samples.

017001

10. GRADUATED CYLINDER. The graduated cylinder (Figure 14, Index No. 14), having a capacity of 100-ml marked in increments, is used to measure the volume of sample fluid to be filtered.

Figure 1: Hydraulic Fluid Contamination Analysis Kit

11. FILTER MOUNTS. Transparent Petri slides (Figure 14, Index No. 16), with covers hold the 47-mm test filters flat for examination and protect them from additional contamination.

12. FILTERS. Filters are of the cellulose ester membrane type with a mean-pore size of 5-microns. Discs of 47-mm diameter (Figure 14, Index No. 17), are used to filter fluid samples; Discs of 25-mm diameter (Figure 14, Index No. 18), are used to filter solvent.

13. SYRINGE AND VALVE. The pump action of the syringe and valve (Figure 14, Index No. 19) is used to evacuate the 47-mm filter holder. On the down stroke, air is drawn through the side port into the barrel of the syringe. On the expel stroke, air is forced out through the end port.

14. STANDARD. The processed fluid samples are compared to the standard to determine the level of contamination in the system or component being analyzed.

NAVAIR 01-1A-17 017 00 TO 42B2-1-12 Page 3


15. In addition to the analysis kit components, a cleaning compound/solvent, lint-free wiping cloths, and waste containers are needed to obtain and analyze fluid samples. Dry cleaning solvent, MIL-PRF-680 (WP002 00, Table 3, Item 6), is the only chemical currently authorized for use in conducting Hydraulic Fluid Contamination Analysis Test (patch test).

16. PREPARATION FOR USE.

17. WASH BOTTLES. The two wash bottles are identical except that one has a shorter spout in order to accommodate the Swinnex filter holder or Millex Point-of-Use (disposable) filter unit. This bottle is used to dispense filtered solvent when making an analysis or when cleaning samples bottles. The non-filtered wash bottle is employed when cleaning fittings used at sample taking points.

18. If the flush bottle is damaged, the wash bottle may be modified by carefully cutting off the tip with a sharp knife or razor blade so that the filter unit will fit. The damaged bottle may be used for flushing of fittings and sampling points.

19. FILTER HOLDER. There are two types of filter holders in use:

a. The Swinnex filter holder (Figure 2) consists of two threaded halves and an internal support screen. With it disassembled, use forceps (Figure 14, Index No. 15) to place a 25-mm filter membrane (Figure 14, Index No. 18) onto the exposed aided flat surface. Place the metal perforated disc on top of the filter membrane to provide support for both sides of the membrane. Reassemble the parts, finger tight, and gently press the filter holder assembly on the spout of the flush bottle having the shorter spout.

NOTE

When using Swinnex filter, follow placard instructions.

b. Prepare Millex Point-of-Use (disposable) filter unit. Remove disposable filter from its carton. Twist filter unit securely onto the outlet spout of the wash bottle which is used as a flush bottle (Figure 2).

NOTE

Disposable filters are normally used 10 to 50 times. Replace a used disposable filter when the fluid flow is reduced to drips instead of a steady flow.

20. FLUSH BOTTLE.


a. Remove cap from flush bottle and fill with dry cleaning solvent, MIL-PRF-680 (WP002 00, Table 3, Item 6).

b. Replace cap and ensure filter unit is in place, close hole in cap with finger, and squeeze bottle to dispense filtered solvent.

NOTE

When using Swinnex filters, if air becomes trapped between filter and inside nozzle of flush bottle, flow will stop. To eliminate airlock, remove filter from outlet spout and purge air before filtering. If clogging persist, replace filter.

21. WASH BOTTLE. To prepare wash bottle, fill with dry cleaning solvent, MIL-PRF-680 (WP002 00, Table 3, Item 6) to wash sampling points.

22. SAMPLE BOTTLES. Clean the required number of sample bottles prior to use by rinsing and flushing with filtered solvent using the filtered solvent dispenser.

a. Fill the bottle to be cleaned approximately half full. Replace cap on opening, agitate the sample bottle several times, remove cap, and dump contents. Repeat three or more times to remove residual hydraulic fluid.

b. When the bottle is considered clean, flush external threads of the sample bottle and internal threads of the bottle cap with filtered solvent from dispenser. Replace cap on bottle.

NAVAIR 01-1A-17 017 00 TO 42B2-1-12 Page 4

NOTE

Bottles that are not absolutely clean may cause a hydraulic system to be rejected needlessly.

017002

23. OPERATIONAL PROCEDURES.

24. SAMPLE COLLECTION. It is essential that samples taken from aircraft hydraulic systems and SE be representative of the fluid in the system under test. Aircraft samples should be taken immediately after aircraft flight. If post flight samples cannot be obtained the system shall be cycled in accordance with the applicable Maintenance Instruction Manual (MIM) or Maintenance Requirement Cards (MRC), before drawing a sample. Before sampling SE hydraulic systems, circulate the fluid for a minimum of 5 minutes at full flow rate or for a proportionately longer time at a lower flow rate.

25. Naval Aviation Hydraulics Fluids Contamination Standards applies to the following fluids:

MIL-PRF-5606

MIL-H-81019

MIL-PRF-83282

MIL-PRF-87257

26. Accurate determination of hydraulic contaminant levels requires proper sampling techniques using equipment and materials that are known to be clean. Any foreign matter contaminants in the sample fluid or testing equipment will cause erroneous results.

Careful attention to the detailed procedures given below will assure that the effects of external contaminants are minimized.




Figure 2: Attaching Filter to Flush Bottle



NOTE

Hydraulic fluid sampling points for most Naval aircraft are designated in the applicable MIM. Refer to WP005 00 for general infomration concerning selection of sampling points in those instances where none are specified.

a. Remove dirt and other external contaminants from the sampling point by wiping with clean disposable wiping cloths (WP002 00, Table 3, Item 14).

NOTE

Sampling points that have not been adequately cleaned prior to use may produce erroneous test results and needless rejection of the system under test.

NAVAIR 01-1A-17 017 00 TO 42B2-1-12 Page 5

b. Clean the required number of sample bottles, caps and the threaded area of bottle caps (WP002 00, Table 3, Items 21 thru 25) prior to use by rinsing and flushing with the fluid from the system being analyzed. Initiate the flow of fluid to be sampled by an appropriate means; allowing an initial quantity to flow into a waste receptacle. This will serve to flush any contaminants generated by mechanical operation. Remove the cap from the bottle, fill the bottle to be cleaned approximately half full with the fluid from the sampling point. Shutoff flow from sampling point, if necessary. Replace cap on bottle opening, agitate the sample bottle several times, remove the cap and dump contents into an approved waste receptacle. Repeat this operation two times to remove residual contaminants. Replace cap on bottle. If flow to sampling point has been terminated, re-open sampling port. Without interrupting the fluid flow, obtain the required sample by replacing the uncovered, rinsed, and clean sample bottle under the fluid stream. Once the bottle is filled to the shoulder, remove it from the fluid stream and terminate the flow of sample fluid. Install cap on sample bottle and affix a tag or label identifying aircraft or equipment and the specified sampling point.

27. Aircraft filter assemblies are sampled by removing the filter bowl and transferring the fluid contents of both the bowl and the element to a clean sample bottle. The contents of fluid obtained will vary with the type of filter assembly. Do not use filter bowl samples for patch testing. Filter bowl samples are used to determine types of contaminants.

28. CONTAMINATION ANALYSIS PROCEDURES

29. SAMPLE PROCESSING. Prior to sample processing, the fluid under test should be carefully examined for possible free water. Water can be recognized in hydraulic fluid sample from the formation of droplets usually settling at the bottom of the fluid sample bottle. Allow the fluid sample to remain motionless for 10 minutes or longer to facilitate the formation of visible water droplets.

30. Fluid samples that are hazy or pink in appearance indicate the presence of water. Another identical sample bottle filled with a standard of unused fluid can be used for comparison. If water is observed, take another sample from the system to verify the indication and initiate corrective maintenance.

31. PREPARE FILTER HOLDER ASSEMBLY.


a. Remove filter holder assembly from the storage position in the kit. The stainless steel funnel and holder and support assembly is stored in an inverted position in the stainless steel vacuum flask. The funnel assembly and holder support assembly must be removed from the flask, inverted and reinstalled in the flask assembly. IF difficulty is encountered in removing the filter holder assembly from flask, insert back end of forceps (Figure 14, Index No. 15) or an equivalent tool into slot (present of some assemblies) and pry holder from flask (Figure 3). A thin film of hydraulic fluid applied to the external O-ring seals on the filter holder will aid in insertion and removal.

017003

b. Connect tube and adapter to the vacuum port on syringe to the filter holder assembly base (Figure 4). Note that the tube and adapter are normally left connected to the syringe but may be removed for cleaning or replacement.

Figure 3: Disengaging Filter Holder from Flask

NAVAIR 01-1A-17 017 00 TO 42B2-1-12 Page 6

017004

NOTE

Rapid evaporation of the filtered solvent may result in the condensation of atmospheric moisture on the funnel surface. This can cause inaccurate indications of free water in the sample under test. Carefully inspect for condensation on the funnel surface. If condensation is present, move equipment to an air-conditioned workspace.

c. Using the filtered solvent dispenser, wash down the inside wall of the stainless steel funnel (Figure 5) to flush away any surface contamination present. Ensure funnel screen is also clean with filtered solvent.

017005

d. Remove funnel from the filter holder assembly by rotating the outer knurled ring counterclockwise until disengaged and lift upward. Using forceps, carefully remove a single 47-mm filter membrane (Figure 14, Index No. 17) from its package and place it on top of the wire mesh filter support screen on the filter holder assembly (Figure 6). Insure that the blue separator discs are not installed with the filter membrane.

e. Place support screen gasket (Figure 14, Index No. 7) between the test filter membrane and the stainless steel funnel. Figure 4: Attaching Syringe to Filter Holder

017006

Figure 6: Installing Test Filter and Support Screen Gasket

NOTE

Packaged filter membranes are

separated by blue discs. Remove separators before installing filter membrane in equipment.

f. Install funnel on the filter holder assembly and secure by rotating the outer knurled ring clockwise until fully seated (Figure 7). g. Using filtered solvent, repeatedly rinse the inside of the graduated cylinder to remove all possible contaminants. Pour our residual solvent. Measure out approximately 15 ml of filtered solvent, using the cleaned graduated cylinder, and pour into the stainless steel funnel to pre-wet the filter membrane.

Figure 5: Rinsing Inside Wall of Funnel

NAVAIR 01-1A-17 017 00 TO 42B2-1-12 Page 7

017007

h. Shake the bottle of sample fluid to be processed to distribute uniformly its particulate content. Remove cap from the sample bottle and pour exactly 100 ml of fluid into the graduated cylinder (Figure 14, Index No. 14) (Figure 8). Discard any remaining fluid. Pour contents of the graduated cylinder into the stainless steel funnel on top of the previously introduced filtered solvent. Allow contents of the graduated cylinder to drain completely into the funnel. 017008

i. Using the filtered solvent dispenser, wash down the inside of the graduated cylinder with clean solvent until it contains approximately 100 ml of fluid (Figure 9).

017009 Figure 7: Reinstalling Filter Holder

Figure 9: Rinsing Out Graduated Cylinder

j. Operate the syringe in a slow pumping manner (Figure 10) drawing a vacuum until sustained filtration of the fluid is indicated by a steady drop of fluid level in the funnel. As soon as the fluid level in the funnel has dropped enough to allow the addition of approximately 50 ml solvent, pour half the contents of the graduated cylinder into the funnel as filtration continues. If necessary, operate the syringe again to maintain sufficient vacuum for filtration.

017010

Figure 8: Measuring Test Sample Figure 10: Filtering Sample Fluid

NAVAIR 01-1A-17 017 00 TO 42B2-1-12 Page 8

k. Carefully observe the filtration process in the funnel and note the decreasing fluid level. When the fluid level drops to the narrow neck of the funnel, pour the remaining contents of the graduated cylinder into the funnel. Pour contents to wash down the inside of the funnel, insuring that solvent is not poured directly onto the filter membrane.

l. When filtration is complete, remove the funnel only and inspect the filter surface. If the central area shows a pinkish color, indicating that the filter membrane still has a residue of hydraulic fluid, replace the funnel, and direct a stream of clean solvent from the filtered solvent dispenser against the walls of the funnel until fluid reaches to the top of the tapered portion. Operate the syringe again to initiate filtration, and allow all of this fluid to pass through the filter.

NOTE

Free water, when presenting the fluid sample, may be seen as droplets on the surface of the test filter membrane immediately after completion of filtration. If these droplets do not remain on the filter for an extended period of time, immediate observation is essential.

m. After filtration stops, disassemble the filter holder.

(1) Remove funnel from base.

(2) Remove support screen gasket and inspect for damage. If damaged, remove and replace.

(3) Lift off test filter membrane with forceps (Figure 11).

017011

When dry cleaning solvent is used as the filtered solvent, the test filter membrane must be dried thoroughly prior to placing in Petri slide. Solvents fumes will craze and cloud the Polystyrene Petri slides.

(4) Place test filter on an uncovered Petri

slide (Figure 12). 017012

Figure 12: Placing Filter in Petri Slide

(5) Let filter membrane dry thoroughly in still air.

(6) Cover Petri slide.

32. ANALYSIS OF TEST FILTER. After the fluid sample is processed, the resultant test filter membrane (patch) should be visually compared with the Contamination Standards (Figure 13). Determine the particulate contamination level by comparing the shade and color of the test patch with the Contamination Standards (Figure 14, Index No. 22) If the test patch displays a rust or tan color, use the tan standard patch. If the test patch is gray in color, use the gray standard patch. Follow operating instructions contained in the Contamination Standards.

Figure 11: Remove Test Filter and Support Screen Gasket

NAVAIR 01-1A-17 017 00 TO 42B2-1-12 Page 9

017013

NOTE Test Patches that show a residual pink

color may be the result of failure to have washed the filter adequately. Some new hydraulic fluids will also exhibit a residual pink background as shown by example in the contamination methods.

33. The maximum acceptable particulate level for Naval aircraft is Navy Standard Class 5, and for related SE is Navy Standard Class 3. 34. Visible free water present in either the sample bottle or on the surface of the test patch (at completion of filtration) is cause for rejection of the system under test. A stain on the test filter membrane may be an indication of the presence of free water. When a stain is seen on the test patch, a second fluid sample from the system under test should be obtained and processed so that water content can be confirmed prior to system rejection. Ensure that observed water is not a result of atmospheric condensation during the sampling process. 35. Should the system under test fail to meet the Navy Standard, Class 5 particulate requirement or should it exhibit free water, the system must be decontaminated in accordance with procedures provided in the applicable MIM.

NOTE

If the result is inconclusive or if a shadowy effect occurs due to incidence of light on the Petri slide, remove patch from Petri slide for comparison with Contamination Standards.

36. Filter bowl patch residues should be evaluated qualitatively based upon requirements of applicable manuals and utilizing experience relative to normal contaminates for specific aircraft systems and hours of operation. Considerable experience is required to adequately perform visual evaluation of filter bowl residues. Experience has shown analysis of main pressure line and case drain filter bowl residue to be useful in verifying failure of the upstream in these particular assemblies. Residue in other filter assemblies is affected by so many other components and factors as to render their interpretation difficult. Filter bowl residue should be analyzed only as a means of identifying or verifying suspected component failure. Such utilization shall be limited to examination of residue from those filter assemblies directly downstream of the component.

Figure 13: Comparing Test Filter Contamination Standards

37. CLEANLINESS 38. The accurate determination of hydraulic contaminant levels requires proper sampling techniques and the use of equipment and materials that are known to be clean. Any foreign matter which is allowed to contaminate the sample fluid or testing equipment will cause erroneous results. Careful attention to the detailed procedures herein will assure that the effects of external contaminants are minimized. 39. KIT COMPONENT MAINTENANCE a. The filter holder has two Teflon lock wheels which help provide the sealing action required to maintain a vacuum. After extensive use flats occur on the bottom side of the lock wheels, which may result in poor sealing. b. The syringe and valve assembly should be cleaned at regular intervals by flushing with cleaning solvent. The O-ring seal on the syringe plunger should be lubricated with a thin film of hydraulic fluid. 40. ILLUSTRATED PARTS BREAKDOWN. 41. GENERAL. The Illustrated Parts Breakdown (lPB) contains information applicable to the Hydraulic Fluid Contamination Analysis Kit, Part No. 57L414. It lists and describes the parts necessary for requisitioning, identifying parts, and for illustrating disassembly and assembly relationships. 42. GROUP ASSEMBLY PARTS LIST (GAPL).

NAVAIR 01-1A-17 017 00 TO 42B2-1-12 Page 10

The GAPL consists of a breakdown of the complete unit into subassemblies and detail parts. Attaching parts are identified immediately following the item they attach. All symbols and abbreviations used in the GAPL are in accordance with ASME Y14.38 Abbreviations and Acronyms. 43. INDEX NUMBER. In this column, the index numbers are assigned in numerical sequence and are essentially in disassembly sequence. 44. PART NUMBER. This column lists the prime contractor part number, government standard part number, or vendor part number. 45. DESCRIPTION. This column lists the item nomenclature plus those modifiers necessary to identify the item. The assemblies, subassemblies, detail parts and attaching parts are properly identified (named or indented) to show their relationship to the assembly. Attaching parts are listed immediately after the part they are attached to and preceding any details of the assembly. The caption/ATTACHING PARTS/ appears in the description column preceding the attaching parts and the symbol -*- is used to indicate the end of the attaching parts for that part or assembly. 46. VENDOR CODES. Vendor code numbers are listed in // following the nomenclature of the part. This code is in accordance with cataloging handbook H4/H8, Commercial and Government Entity (CAGE) codes. If a code has not been assigned, the vendors complete name and address will appear. Manufacturer's codes are not listed for government standard parts. 47. MAKE FROM. From for those simple items (i.e., hoses, lines, tubes, brackets, cables, etc.) coded for local manufacture, the material from which the item is manufactured will be included in // after the item nomenclature or vendor code number. 48. UNITS PER ASSEMBLY. This column will list the total number of each part required per assembly or subassembly and are not necessarily the total number used in the end item of equipment. The abbreviation AR (As Required) is used to identify bulk items. The abbreviation REF indicates Reference and indicates the part has been listed and illustrated elsewhere in the IPB and is included in the present listing for reference only. 49. USABLE ON CODE. This column indicates the usability of parts on different models or series of the end item of equipment. If no letter appears in this

column, the part may be used on all models/series of the end item of equipment. An asterisk (*) in this column opposite two or more part numbers under the same index number indicates equivalent parts. 50.SOURCE MAINTENANCE AND RECOVERABILITY (SM&R). This column contains the SM&R codes as assigned by the government. See Table 1 for a brief description of these codes. For a complete description of SM&R codes, refer to NAVAlRlNST 4423.3 (series).

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Table 1: Source, Maintenance, and Recoverability Codes

MAINTENANCE SOURCE USE REPAIR

1ST POSITION 2nd POSITION 3rd POSITION 4th POSITION A REPLENISH B INSURANCE C CURE-DATED

OREPLACE OR USE AT

ORG. LEVEL Z NO REPAIR

(CONSUMABLE)

D INITIAL

E END ITEM GSE/STOCKED

P PROCURE

F GSE/NOT STOCKED

F H G

AFLOAT ASHORE BOTH

REPLACE OR USE AT IMA LEVEL

B

RECONDITION BY ADJUSTMENT, CALIBRATION, LUBRICATION PLATING, ETC.

F ORG/IMA

D DEPOT K

REPAIR KIT COMPONENT

B BOTH KITS L

REPLACE OR USE AT SPECIALIZED IMA

0 REPAIR ORG. LEVEL

F H G

AFLOAT ASHORE BOTH

REPAIR AT IMA LEVEL

M

A

MANUFACTURE ASSEMBLY

O F H G D

ORG AFLOAT ASHORE BOTH DEPOT

IMA D

REPLACE OR USE AT DEPOT S

(L)REPAIR AT SPECIALIZED IMA

A REQUEST NHA

B OBTAIN FROM SALVAGE OR ONE TIME BUY X MISC.

C

DIAGRAMS- SCHEMATICS INSTALL DWGS

Z NOT REQD. THIS APPLIC. D

REPAIR AT DEPOT OR COMMER.

RECOVERABILITY

5TH POSITION

NON-REPAIRABLE, CONDEMN AT LEVEL Z INDICATED IN POS. 3

SPECIAL HANDLING FOR DISPOSAL A (CONSUMABLE APPLICATION)

REPAIRABLE ITEM. CONDEMN AT ORG. LEVEL O

H

F G

AFLOAT ASHORE BOTH

REPAIRABLE ITEM, CONDEMN AT IMA LEVEL

S (L) REPAIRABLE ITEM, CONDEMN AT SPECIALIZED IMA

D REPAIR AT DEPOT OR COMMERCIAL

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017014

Figure 14: Hydraulic Fluid Contamination Kit (Sheet 1 of 4)

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017014


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INDEX NO.

PART NUMBER

USA

BLE

ON

C

OD

E

SM&R CODE

UN

ITS

PER

A

SSEM

BLY

DESCRIPTION

1 2 3 4 5 6 7

57L414 HYDRAULIC FLUID CONTAMINATION ANALYSIS KIT XX6504700/08071/REPAIR KITS AVAILABLE, INDEX 26 AND 27

REF PAOGG

1 XX6300120 . HOLDER, FILTER ASSEMBLY /08071/ 1 AGOGG 2 XX6300121 . . FUNNEL, STAINLESS STEEL /08071 1 PAOZZ 3 XX2004707 . . LOCK, WHEEL /08071/ 2 PAOZZ 4 XX6504708 . . SUPPORT, BASE ASSEMBLY /08071/ 1 PAOZZ 5 XX6300123 . . BASE O-RINGS, BUNA-N /08071/ 2 PAOZZ 6 YY4014267 . . SUPPORT O-RING, BUNA-N /08071/ 1 PAOZZ 7 XX2004703 . . SUPPORT SCREEN GASKET TEFLON

/08071/ 1 PAOZZ

8 XX2004708 . . SUPPORT SCREEN STAINLESS STEEL /08071/

1 PAOZZ

9 XX6300129 . . FLASK, VACUUM, STAINLESS STEEL /08071/ 1 PAOZZ 10 XX2004707 . . RING, FUNNEL, LOCKING/08071/ 1 XBOZZ 11 XX6504707 . HOLDER, SWINNEX FILTER /08071/ 1 PAOZZ 11A SLLS025NS . MILLEX POINT-OF-USE FILTER /08071/ 1 PAOZZ 12 XX6504704 . BOTTLE, WASH (500-ml) /08071/ 2 PAOZZ 13 XX6504709 . BOTTLE, SAMPLE, PLASTIC /08071/ 24 PAOZZ 14 08-572D . CYLINDER, GRADUATED (100-ml) /22527/ 1 22527 15 XX6200006 . FORCEPS, STAINLESS STEEL /08071/ 1 PAOZZ 16 PD1504700 . SLIDES, PETRI /08071/ 1 PAOZZ 17 SMWP04700 . FILTER, TEST MEMBRANES (47-mm) /08071/ 4 PAOZZ 18 SMWP02500 . FILTER, SOLVENT MEMBRANES (25-mm)

/08071) 1 PAOZZ

19 XX6200035 . SYRINGE AND VALVE /08071 KIT AVAIL 1 PAOZZ 20 XX6504710 . . TUBE AND ADAPTER WITH CLAMPS /08071/ 1 PAOZZ 21 2-006 . . VALVE O-RING, BUNA-N /02697/ 1 PAOZZ 22 XX6504713 . STANDARDS, CONTAMINATION /08071/ 1 PAOZZ 23 3074 . TOP INSERT /08071/ 1 PAOZZ 24 3075 . BOTTOM INSERT /08071/ 1 PAOZZ 25 3076 . SYRINGE HOLDER /08071/ 1 PAOZZ 26 XX6504712 . KIT, PARTS CONTAMINATION /08071/ 1 PAOZZ XX6300123 . . BASE O-RING BUNA-N /08071/ 2 PAOZZ XX6504704 . . BOTTLE, WASH (500-ml) /08071/ 2 PAOZZ XX6504709 . . BOTTLE, SAMPLE PLASTIC /08071/ 24 PAOZZ 08-572D . . CYLINDER, GRADUATED /22527/ 1 PAOZZ 27 XX6200036 . . KIT, PARTS VACUUM SYRINGE /08071/ 1 PAOZZ 2-116 . . . PLUNGER O-RING, BUNA-N /02697/ 1 PAOZZ 2-006 . . . VALVE O-RING, BUNA-N /02697/ 2 PAOZZ . . . BALL, VALVE STAINLESS STEEL 2 . . . SPRING, BARREL COMPRESSION VALVE 2 . . . SEAL, VALVE, TEFLON 2 . . . SPRING COMPRESSION VALVE 2

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