(NAVY) NAVAIR 01-1A-17
(AIR FORCE) TO 42B2-1-12
15 August 2006
TECHNICAL MANUAL
ORGANIZATIONAL, INTERMEDIATE AND
DEPOT MAINTENANCE
AVIATION HYDRAULICS MANUAL
N68936-04-D-0008
This publication supersedes NAVAIR 01-1A-17 dated 1 June 2002 and
NAVAIR 17-15E-52 dated 1 April 2000.
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
0801LP1060942
NAVAIR 01-1A-17
TO 42B2-1-12
15 August 2006
Page A
NUMERICAL INDEX OF EFFECTIVE WORK PACKAGES/PAGES
List of Current Changes
Original 15 August 2006, including IRACs/RACs 1 through 9.
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 Dispose of superseded work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 Superseded classified work packages/pages shall be destroyed in accordance with applicable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.
WP
Number
Title
Page A
TPDR-1
HMWS-1
001 00
002 00
003 00
004 00
005 00
WP
Number
Title
Numerical Index of Effective Work
Packages/Pages
List of Technical Publications
Deficiency Reports Incorporated
Warnings Applicable to Hazardous
Materials
Alphabetical Index
Introduction
Description, Hydraulic Systems and
Hydraulic Fluids
Hydraulic Fluid Contamination
Hydraulic Fluid Contamination
Analysis
006 00
007 00
008 00
009 00
010 00
011 00
012 00
013 00
014 00
015 00
016 00
017 00
Title
Aircraft System Decontamination
Hydraulic Contamination Control
Servicing Hydraulic Systems
Hydraulic Support Equipment
Hydraulic Filters
Controlled Environment Work Center
Selection and Use of Cleaning
Materials
Repair, Test, and Maintenance of
Hydraulic Systems and Components
Protective Closures
Hydraulic Seals
Phosphate Ester Hydraulic Fluid
Hydraulic Fluid Contamination
Analysis Kit (P/N 57L414)
Total number of pages in this manual is 194, consisting of the following:
WP/Page Number
Change No.
Title ............................................ 0
A................................................. 0
TPDR-1—TPDR-2...................... 0
HMWS-1 – HMWS-6 .................. 0
001 00
1 ............................................. 0
2 Blank................................... 0
002 00
1 – 26..................................... 0
003 00
1 – 6 ....................................... 0
004 00
1 – 7 ....................................... 0
8 Blank................................... 0
005 00
1-10 ........................................ 0
WP/Page Number
Change No.
006 00
1 – 11..................................... 0
12 Blank................................. 0
007 00
1 – 5....................................... 0
6 Blank................................... 0
008 00
1 – 3....................................... 0
4 Blank................................... 0
009 00
1 – 24..................................... 0
010 00
1 – 8....................................... 0
011 00
1 – 8....................................... 0
WP/Page Number
Change No.
012 00
1 – 7....................................... 0
8 Blank................................... 0
013 00
1 – 12..................................... 0
014 00
1 – 12..................................... 0
015 00
1 – 24..................................... 0
016 00
1 – 5....................................... 0
6 Blank................................... 0
017 00
1-15........................................ 0
16 Blank ................................ 0
NAVAIR 01-1A-17
16 AUGUST 2006
PREVIOUSLY RELEASED TITLE PAGE CONTAINED
INCORRECT SUPERSEDURE NOTICE. REMOVE
TITLE PAGE AND A PAGE DATED 15 AUGUST 2006
AND REPLACE WITH ATTACHED PAGES.
REMOVE PRINTED COPY OF IRAC 9 DISTRIBUTED
WITH THE INITIAL REVISION DATED 15 AUGUST
2006.
NAVAIR 01-1A-17
TO 42B2-1-12
15 August 2006
TPDR-1
ORGANIZATIONAL, INTERMEDIATE AND
DEPOT MAINTENANCE
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
08981-02-0087, VR-52
09209-99-0006, HELANTISUBRON-14
09257-04-0011, VMFA (AW) 121
09432-05-0010, VMGR-252
09465-02-0029, VAW-116
09465-05-0001, VAW-116
09496-01-0001, 0104273 “Lucky Red Lions”
09935-04-0063, VMX-22
09995-04-0030, VAQ-129
21560-04-0003, USS WASP (LHD-1)
30328-03-0309, NATEC Detachment Oceana
30332-04-0031, NATEC Detachment North Island
30332-04-0032, NATEC Detachment North Island
30340-03-1006, NATEC Detachment Jacksonville
30340-03-1007, NATEC Detachment Jacksonville
30340-03-1008, NATEC Detachment Jacksonville
30340-03-1009, NATEC Detachment Jacksonville
39782-97-0073, CO Hanger 301 Suite 202
LOCATION*
WP009 00
HMWS
WP014 00
WP017 00 F14 (Sheet 4)
WP009 00
WP017 00 F14 (Sheet 4)
WP009 00
WP017 00 F14 (Sheet 4)
WP017 00
WP004 00
WP009 00
WP005 00
WP015 00
WP015 00
WP016 00
WP015 00
WP017 00
NAVAIR 01-1A-17
TO 42B2-1-12
TPDR-2
39784-05-0082, HX-21
WP017 00
44314-06-0010, AIMD Brunswick
44329-02-0066, CVWP DET AIMD
57025-98-0061, COMNAVAIRPAC
WP004 00
HMWS, WP017 00
WP017 00 F14 (Sheet 4)
*Location-work package (WP), figure no. (F) shall be indicated as appropriate.
NAVAIR 01-1A-17
TO 42B2-1-12
1 January 2006
HMWS-1
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
TO 42B2-1-12
HMWS-2
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.
NAVAIR 01-1A-17
TO 42B2-1-12
HMWS-3
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.
2
Hydraulic Fluid, MIL-PRF-83282
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
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.
NAVAIR 01-1A-17
TO 42B2-1-12
HMWS-4
HAZARDOUS MATERIALS WARNINGS (Cont)
Index
Material
Warning
4
Hydraulic Fluid, MIL-PRF-87257
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.
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-PRF5606, 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.
NAVAIR 01-1A-17
TO 42B2-1-12
HMWS-5
HAZARDOUS MATERIALS WARNINGS (Cont)
Index
Material
Warning
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.
NAVAIR 01-1A-17
TO 42B2-1-12
HMWS-6
HAZARDOUS MATERIALS WARNINGS (Cont)
Index
Material
Warning
12
General Purpose Aircraft Grease, MIL-PRF32014
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
TO 42B2-1-12
15 August 2006
001 00
Page 1/(2 blank)
ORGANIZATIONAL, INTERMEDIATE AND
DEPOT MAINTENANCE
ALPHABETICAL INDEX
AVIATION HYDRAULICS MANUAL
Title
Aircraft System Decontamination.......................................................................................................
Alphabetical Index..............................................................................................................................
Controlled Environment Work Center (NAVY USE ONLY) ...............................................................
Description, Hydraulic Systems and Hydraulic Fluids .......................................................................
Hydraulic Contamination Control (NAVY USE ONLY) ......................................................................
Hydraulic Filters .................................................................................................................................
Hydraulic Fluid Contamination ...........................................................................................................
Hydraulic Fluid Contamination Analysis.............................................................................................
Hydraulic Fluid Contamination Analysis Kit (P/N 57L414) (NAVY USE ONLY)................................
Hydraulic Seals ..................................................................................................................................
Hydraulic Support Equipment (NAVY USE ONLY) ...........................................................................
Introduction ........................................................................................................................................
Phosphate Ester Hydraulic Fluid........................................................................................................
Protective Closures (NAVY USE ONLY) ...........................................................................................
Repair, Test, and Maintenance of Hydraulic Systems and Components (NAVY USE ONLY) .........
Selection and Use of Cleaning Materials ...........................................................................................
Servicing Hydraulic Systems..............................................................................................................
WP
Number
006 00
001 00
011 00
003 00
007 00
010 00
004 00
005 00
017 00
015 00
009 00
002 00
016 00
014 00
013 00
012 00
008 00
NAVAIR 01-1A-17
TO 42B2-1-12
15 August 2006
002 00
Page 1 of 26
ORGANIZATIONAL, INTERMEDIATE AND
DEPOT MAINTENANCE
INTRODUCTION
AVIATION HYDRAULICS MANUAL
1.
be followed as specified in WP008 00
thru WP010 00.
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.
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
DISTRIBUTION
OF
MANUALS.
AND
NAVAIR
AUTOMATIC
TECHNICAL
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.
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
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
TO 42B2-1-12
002 00
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-CDQARQAR-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
TO 42B2-1-12
002 00
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.
31.
32. Abbreviations used in this manual are listed in
Table 1.
33.
NOTE
Highlights an essential procedure to
ensure correct maintenance.
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.
Indicates a procedure or practice which,
if not strictly observed, will result in
damage or destruction of equipment.
ABBREVIATIONS.
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
TO 42B2-1-12
002 00
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
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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
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Table 2.
Term
Glossary
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.
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Table 2.
Term
Glossary (Cont)
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.
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Table 2.
Term
Glossary (Cont)
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.
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Table 2.
Term
Glossary (Cont)
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.
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Table 2.
Term
Glossary (Cont)
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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Table 2.
Term
Glossary (Cont)
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.
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00200101
Figure 1.
Graphic Symbols for Fluid Power Diagrams (Sheet 1 of 6)
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00200102
Figure 1.
Graphic Symbols for Fluid Power Diagrams (Sheet 2)
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00200103
Figure 1.
Graphic Symbols for Fluid Power Diagrams (Sheet 3)
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00200104
Figure 1.
Graphic Symbols for Fluid Power Diagrams (Sheet 4)
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Figure 1.
Graphic Symbols for Fluid Power Diagrams (Sheet 5)
00200105
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00200106
Figure 1.
Graphic Symbols for Fluid Power Diagrams (Sheet 6)
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Table 3.
Item
No.
Consumable Materials List
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
MIL-PRF-83282
NATO No. H-537
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
MIL-PRF-87257
NATO No. H-538
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
A-A-59601 (PD-680)
Refer to WP012 00
NOT APPLICABLE TO
NAVY
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.
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Table 3.
Item
No.
12
Consumable Materials List (Cont)
Nomenclature
Grease, Aircraft General
Purpose Wide Temp. Range
Specifications
Intended Use
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-A1026)
Blending out nicks and scratches on Oring grooves of filter elements.
Glove, Rubber
MIL-DTL-32066 (formerly
ZZ-G-381)
Protecting hands from cleaning
compounds.
17A
Glove, Poly-D, Disposable
*35-125 (12036)
17B
Glove, Nitrile, Disposable,
Powder-free
Various Laboratory Supply
Distributors
Handling Phosphate Ester fluids.
Bottle, Prescription,
Glass 8 ounce
A-A-50983
Sample bottles for testing solvents.
Bottle, Polyethylene with
24 mm Polypropylene
Screw Closures, 4 ounce
*2002-0004 (05178)
NSN 6640-61-330-4902
19B
Bottle, Polypropylene
*02-893A (1JGK5)
20
Can, Safety, 5 Gallon
UL30 (formerly RR-S-30)
GLOVES
16
CONTAINERS
18
19A
Sample bottles for phosphate ester fluid.
*Manufacturer’s part number and CAGE Code.
Waste container for used hydraulic fluids
and solvents.
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Table 3.
Item
No.
Consumable Materials List (Cont)
Nomenclature
Specifications
Intended Use
21
Bottle Screw Cap, Glass,
8 ounce Square, Colorless
NSN 8125-00-543-7699
Collect hydraulic fluid samples.
22
Bottle Caps, Electronic
Particle Counter
P/N 240-480
NSN 5340-01-470-8709
Sample collection bottle caps for
the HIAC sampling unit.
23
Electronic Particle Counter
Safety Coated Bottle
250 ml capacity
P/N 219-457
NSN 5340-01-470-8720
Sample collection bottle caps for
the HIAC hydraulic sampling unit.
24
120 ml Safety Coated Glass
Sample Bottles for HACH
Ultra Analytics Hydraulic
Particle Counter (PODS)
GLC-09190
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.
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Table 4.
Publication Number
Related Publications
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 HSU1
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
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Page 22
Table 4. Related Publications (Cont)
Publication Number
Title
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
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Table 4. Related Publications (Cont)
Publication Number
Title
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
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Table 4. Related Publications (Cont)
Publication Number
Title
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 20873011 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
TO 42B2-1-12
002 00
Page 25
Table 4. Related Publications (Cont)
Publication Number
Title
NAVAIR 17-600-126-6-1
Preoperational Checklist Hose Burst Test Stand 63A101E1
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 H250-1
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
TO 42B2-1-12
002 00
Page 26
Table 4. Related Publications (Cont)
Publication Number
Title
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
NAVAIR 01-1A-17
TO 42B2-1-12
15 August 2006
003 00
Page 1 of 6
ORGANIZATIONAL, INTERMEDIATE AND
DEPOT MAINTENANCE
DESCRIPTION
HYDRAULIC SYSTEMS AND HYDRAULIC FLUIDS
Reference Material
None
Alphabetical Index
Subject
Page No.
Aircraft Hydraulic Systems .............................................................................................................
Detailed Description...................................................................................................................
General Description ...................................................................................................................
Hydraulic Fluids Used in Military Aircraft .......................................................................................
Hydraulic Fluid, Military Specification MIL-H-81019 ..................................................................
Hydraulic Fluid, Military Specification MIL-PRF-5606 ...............................................................
Hydraulic Fluid, Military Specification MIL-PRF-83282 .............................................................
Hydraulic Fluid, Military Specification MIL-PRF-87257 .............................................................
Hydraulic Fluid, SAE-AS1241, Phosphate Ester .......................................................................
Intended Use..............................................................................................................................
Record of Applicable Technical Directives
None
2
2
2
5
6
5
5
6
6
6
NAVAIR 01-1A-17
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003 00
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-toengine 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
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003 00
Page 3
003001
Figure 1.
Typical Fighter Hydraulic System
NAVAIR 01-1A-17
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003 00
Page 4
003002
Figure 2.
Heavy Aircraft Hydraulic System
NAVAIR 01-1A-17
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003 00
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.
Hydraulic Fluid, MIL-PRF-83282
2
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 fireresistant 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-PRF83282 is miscible with hydraulic fluid MIL-PRF-5606
(WP002 00, Table 3, Item 1) and hydraulic fluid MILPRF-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
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003 00
Page 6
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-PRF83282 (WP002 00, Table 3, Item 2). However, the
addition of MIL-PRF-5606 will reduce the fire resistant
properties of MIL-PRF-87257.
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 MILPRF-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).
Hydraulic Fluid, MIL-PRF-87257
4
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
22. INTENDED USE. Hydraulic fluids MIL-PRF5606, MIL-PRF-87257, MIL-PRF-83282, and MIL-H81019 (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 MILPRF-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.
NAVAIR 01-1A-17
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15 August 2006
004 00
Page 1 of 8
ORGANIZATIONAL, INTERMEDIATE AND
DEPOT MAINTENANCE
HYDRAULIC FLUID CONTAMINATION
HYDRAULIC SYSTEMS
Reference Material
Cleanliness Requirements of Parts Used in Hydraulic Systems ................................
Metrology Requirements List (METRL)........................................................................
Calibration Procedure for TMDE Calibration Notes Maintenance Data Collection
Codes and Calibration Measurement Summaries (CMS) .......................................
Air Force Metrology and Calibration Program..............................................................
Maintenance Program, Naval Aviation ....................................................................
Aerospace Equipment Maintenance Management......................................................
NAS 1638
NAVAIR 17-35MTL-1
TO 33K-1-100-1
TO 00-20-14
COMNAVAIRFORINST
4790.2
AFI 21-101
Alphabetical Index
Subject
Page No.
Introduction ....................................................................................................................................
Measurement of Contamination.....................................................................................................
Electronic Particle Counting.......................................................................................................
Patch Testing .............................................................................................................................
Sources and Effects of Contamination...........................................................................................
Air Contamination ......................................................................................................................
Fluid Contamination...................................................................................................................
Particulate Contamination..........................................................................................................
Record of Applicable Technical Directives
None
2
4
4
4
2
4
3
2
NAVAIR 01-1A-17
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004 00
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
CONTAMINATION.
EFFECTS
OF
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
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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-PRF5606, MIL-PRF-87257 and MIL-PRF83282, 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.
NAVAIR 01-1A-17
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Page 4
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 HIAC 8011-3 or equivalent, are the preferred
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 continue to 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 WP 017 00.
NOTE
Operators shall qualify in accordance
with
Naval
Aviation
Maintenance
Program Standard Operating Procedures
(NAMPSOP) and Commander Naval Air
Forces
Instruction
(COMNAVAIRFORINST)
4790.2,
Chapter 6.
NAVAIR 01-1A-17
TO 42B2-1-12
004 00
Page 5
004001
Figure 1.
Graphic Comparison of Particle Sizes
NAVAIR 01-1A-17
TO 42B2-1-12
004 00
Page 6
Table 1.
Navy Standard for Particulate Contamination
PARTICLE CONTAMINATION LEVEL-BY CLASS
MICRON
SIZE
RANGE
Acceptable
Unacceptable
0
1
2
3
4
5
6
2,700
4,600
9,700
24,000
32,000
87,000
128,000
10-25
670
1,340
2,680
5,360
10,700
21,400
42,000
25-50
93
210
380
780
1,510
3,130
6,500
50-100
16
28
56
110
225
430
1,000
1
3
5
11
21
41
92
3,480
6,181
12,821
30,261
44,456
112,001
177,592
5-10
Over 100
Total
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.
NAVAIR 01-1A-17
TO 42B2-1-12
Table 2: NAS 1638 Contamination Standards
Maximum Contamination Limits (Based on a 100 mL Sample Size)
Classes
Micron
Size
Range
00
0
1
2
3
4
5
6
7
8
9
10
11
12
5-15
125
250
500
1000
2000
4000
8000
16000
320000
640000
128000
256000
512000
1024000
15-25
22
44
88
176
352
704
1408
2816
5632
11264
22528
45056
90112
180224
25-50
4
8
16
32
64
128
253
506
1012
2025
4050
8100
16200
32400
50-100
1
2
3
6
11
22
45
90
180
360
720
1440
2800
5600
>100
0
0
1
1
2
4
8
16
32
64
128
256
512
1024
004 00
Page 7/(8Blank)
NAVAIR 01-1A-17
TO 42B2-1-12
15 August 2006
005 00
Page 1 of 10
ORGANIZATIONAL, INTERMEDIATE AND
DEPOT MAINTENANCE
HYDRAULIC FLUID CONTAMINATION ANALYSIS
HYDRAULIC SYSTEMS
Reference Material
Valve Sampling and Bleed Hydraulic, Type II Systems.............................................
Operational and Intermediate Maintenance with Illustrated Parts
Breakdown, Particle Counting System, P/N 8011-3 ..............................................
Particle Counting System HIAC/ROYCO 8011-3.......................................................
Operation Instructions Hydraulic Particle Counter, Type I Hydraulic Particle Counter
Set - P/N2087301-01, Type II Hydraulic Particle Counter Set - P/N 2087301-02.
MIL-V-81940
NAVAIR 17-15-521
NAVAIR 17-20SX-146
NAVAIR 17-15BF-97
Alphabetical Index
Subject
Page No.
Contamination Analysis..................................................................................................................
Visual Analysis for Water Contamination ..................................................................................
Electronic Particle Count Analysis (All Levels of Maintenance) ................................................
Electronic Particle Counter Description.................................................................................
HACH Ultra Analytics Portable Oil Diagnostic System (PODS) .......................................
HIAC/ROYCO Particle Counting System 8011-3 .............................................................
Introduction ....................................................................................................................................
Sampling Hydraulic Fluid ...............................................................................................................
Cleanliness ................................................................................................................................
Sample Requirements ...............................................................................................................
Sampling Points .........................................................................................................................
Sampling Point Requirements ...................................................................................................
Sample Taking ...............................................................................................................................
Filter Bowl Content Sampling ....................................................................................................
Record of Applicable Technical Directives
None
4
4
6
7
7
7
2
2
3
2
2
2
3
4
NAVAIR 01-1A-17
TO 42B2-1-12
005 00
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 aircraft
maintenance manual for specific fluid
sampling 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
sampling point
requirements:
POINT
should
REQUIREMENTS.
A
satisfy the following
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 SEpowered 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
TO 42B2-1-12
005 00
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, MIL-PRF-5606
1
Hydraulic Fluid, MIL-PRF-83282
2
Hydraulic Fluid, MIL-H-81019
3
Hydraulic Fluid, MIL-PRF-87257
4
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
TO 42B2-1-12
005 00
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
cloudiness shall not be tested
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 semitransparent 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).
or
14. VISUAL
ANALYSIS
FOR
WATER
CONTAMINATION. Prior to sample processing, the
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
TO 42B2-1-12
005 00
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 inservice 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
TO 42B2-1-12
005 00
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 a
shadowy effect occurs due to incidence
of light on the petri slide, remove patch
from petri slide for comparison with
Contamination 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
TO 42B2-1-12
005 00
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
NAVAIR 01-1A-17
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005 00
Page 8
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 and Type 2. 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
Table 1.
NOMENCLATURE
at pressures and temperatures up to 13.8 bar (200
psig) and 131EF (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.
Hydraulic Contamination Analysis Equipment (Navy Use Only)
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
Type 1 (petroleum)
2087301-01 (0BVY1)
NAVAIR 17-15BF-97
N/A
Type 2 (phosphate ester)
2087301-02 (0BVY1)
Portable Oil Diagnostic
Systems (HACH Ultra
Analytics)
NAVAIR 01-1A-17
TO 42B2-1-12
005 00
Page 9
005003
Figure 3.
HIAC/ROYCO 8011-3 Particle Counting System (Navy Use Only)
NAVAIR 01-1A-17
TO 42B2-1-12
005 00
Page 10
005004
Figure 4.
Portable Oil Diagnostic System (PODS) Particle Counter (Navy Use Only)
NAVAIR 01-1A-17
TO 42B2-1-12
15 August 2006
006 00
Page 1 of 12
ORGANIZATIONAL, INTERMEDIATE AND
DEPOT MAINTENANCE
AIRCRAFT SYSTEM DECONTAMINATION
HYDRAULIC SYSTEMS
Reference Material
None
Alphabetical Index
Subject
Page No.
Contamination Control Sequence ..................................................................................................
Decontamination Methods .............................................................................................................
Air Bleeding................................................................................................................................
Flushing .....................................................................................................................................
Purging.......................................................................................................................................
Purifying .....................................................................................................................................
Recirculation Cleaning...............................................................................................................
Selection of Decontamination Method.......................................................................................
Decontamination Procedures.........................................................................................................
Flushing Procedures..................................................................................................................
Purging Procedures ...................................................................................................................
Purifying Procedures .................................................................................................................
Recirculation Cleaning Procedures ...........................................................................................
Introduction ....................................................................................................................................
Record of Applicable Technical Directives
None
5
2
2
4
4
4
3
5
5
8
10
7
7
2
NAVAIR 01-1A-17
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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 selfscavenge 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
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006 00
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.
NAVAIR 01-1A-17
TO 42B2-1-12
006 00
Page 4
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.
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 58).
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
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
TO 42B2-1-12
006 00
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
TO 42B2-1-12
006 00
Page 6
Table 1.
Test Method
Visual Inspection
Patch Test
(NAVY USE ONLY)
Particle Count
Chemical
Analysis (Depot)
Reservoir Needle Sink
Aircraft Decontamination Requirements
Abnormal Indication
Decontamination
Method Required
(Note 2)
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
Excessive Particulate - exceeds Class 5
Water Droplets or Stains
Fibers
Gross Particulate Matter - extreme contamination
from component failure or external sources
SE Recirculation
Flush
SE Recirculation
SE Recirculation
Excessive Particulate Matter - exceeds Class 5
SE Recirculation
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)
Failure per limits as identified in applicable MIM
Flush
Flush
Flush
Flush
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
TO 42B2-1-12
006 00
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
TO 42B2-1-12
006 00
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 overfilling, 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.
Hydraulic Fluid, MIL-PRF-5606
1
Hydraulic Fluid, MIL-PRF-83282
2
Hydraulic Fluid, MIL-H-81019
3
Hydraulic Fluid, MIL-PRF-87257
4
Hydraulic Fluid, SAE AS1241
5
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
TO 42B2-1-12
006 00
Page 9
006003
Figure 3.
Fluid Flow During Decontamination
NAVAIR 01-1A-17
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Page 10
(1) Drain SE reservoir into an approved
waste receptacle (WP002 00, Table 3, Item 20) and
service with new filtered fluid.
i. Continuously monitor all filter differential
pressure indicators on the aircraft or SE and in the
external hydraulic power source.
(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.
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.
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.
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-bycase 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.
Hydraulic Fluid, MIL-PRF-5606
1
NAVAIR 01-1A-17
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Page 11/(12 blank)
Hydraulic Fluid, MIL-PRF-83282
2
Hydraulic Fluid, MIL-H-81019
3
Hydraulic Fluid, MIL-PRF-87257
4
Hydraulic Fluid, SAE AS1241
5
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.
NAVAIR 01-1A-17
TO 42B2-1-12
15 August 2006
007 00
Page 1 of 6
ORGANIZATIONAL, INTERMEDIATE AND
DEPOT MAINTENANCE
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 ...............................................................
Clean Work Areas......................................................................................................................
Contamination Measurement.....................................................................................................
Filter Element Cleaning .............................................................................................................
Quality Assurance......................................................................................................................
Procedures.................................................................................................................................
Responsibilities ..........................................................................................................................
Support Equipment ....................................................................................................................
System Decontamination...........................................................................................................
System Filters ............................................................................................................................
Training ......................................................................................................................................
Introduction ....................................................................................................................................
Specific Contamination Control Program Requirements ...............................................................
Maintenance Practices ..............................................................................................................
Maintenance Procedures...........................................................................................................
Record of Applicable Technical Directives
None
2
3
2
3
2
3
2
3
3
3
2
2
3
4
3
NAVAIR 01-1A-17
TO 42B2-1-12
007 00
Page 2
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
PROGRAM REQUIREMENTS.
CONTROL
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 Vol. V, Chapter 6.
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. At all maintenance levels, “Hydraulic Fluid
Contamination Control Parts 1 and 2” (videotape No.
806547) is required viewing. Availability of video can
be found at the website dodimagery.afis.osd.mil
under AFIS Products.
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
crash/battle damage.
maintenance
and/or
b. When a metal-generating component failure
has occurred as directed by applicable MIM, MRC or
rework specifications.
c. When erratic flight control
hydraulic pressure drop is noted.
d. When repeated
malfunction occurs.
e. Any time the
excessive temperature.
or
system
function
extensive
is
or
system
subjected
to
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
TO 42B2-1-12
007 00
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
requirements
maintenance
WORK
AREAS. Shop
facility
have
been
established
and
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
PROGRAM REQUIREMENTS.
CONTROL
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
TO 42B2-1-12
007 00
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.
Hydraulic Fluid, MIL-PRF-83282
2
Hydraulic Fluid, MIL-H-81019
3
Hydraulic Fluid, MIL-PRF-87257
4
Hydraulic Fluid, SAE AS1241
5
a. Exercise extreme care when working on a
hydraulic system in the open, especially under
adverse conditions.
Hydraulic Fluid, MIL-PRF-5606
1
Hydraulic Fluid, MIL-PRF-83282
2
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 MILPRF-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.
Hydraulic Fluid, MIL-PRF-5606
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.
1
Do not use plastic plugs or caps. Plastic
plugs and caps are a possible source of
contamination.
NAVAIR 01-1A-17
TO 42B2-1-12
007 00
Page 5/(6 blank)
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.
t. Do not use
unidentifiable O-rings.
previously
installed
or
u. Seals or backup rings shall be replaced with
new items when disturbed.
k. Store unused caps and plugs in a clean
container.
l. Use approved wiping cloths (see WP012 00)
to remove exterior contaminants. Use approved lintfree 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.
When installing O-rings over threaded
fitting, prevent threads from damaging Oring (WP015 00, Figure 14).
v. Decontaminate tubing, hoses, fittings, and
components if found or received opened.
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
hydraulic fluid.
only
with
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).
clean
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.
x. Perform required periodic checks on
equipment used for servicing hydraulic systems in
accordance with MRC or technical directives.
Hydraulic Fluid, MIL-PRF-83282
2
y. Use hydraulic fluid MIL-PRF-83282 (WP002
00, Table 3, Item 2) in stationary hydraulic test
stands.
NAVAIR 01-1A-17
TO 42B2-1-12
15 August 2006
008 00
Page 1 of 4
ORGANIZATIONAL, INTERMEDIATE AND
DEPOT MAINTENANCE
SERVICING HYDRAULIC SYSTEMS
Reference Material
None
Alphabetical Index
Subject
Page No.
Filter Servicing ...............................................................................................................................
Fluid Servicing................................................................................................................................
Introduction ....................................................................................................................................
Record of Applicable Technical Directives
None
2
2
2
NAVAIR 01-1A-17
TO 42B2-1-12
008 00
Page 2
1. INTRODUCTION.
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.
NOTE
USAF: For specific fluid servicing
requirements, refer to the applicable
aircraft maintenance manual.
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. Sightglass, 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:
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
Maintenance Instruction Manuals (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.
NOTE
USAF: For specific filter servicing
requirements, refer to the applicable
aircraft maintenance manual.
NAVAIR 01-1A-17
TO 42B2-1-12
008 00
Page 3/(4 blank)
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
TO 42B2-1-12
15 August 2006
009 00
Page 1 of 24
ORGANIZATIONAL, INTERMEDIATE AND DEPOT MAINTENANCE
HYDRAULIC SUPPORT EQUIPMENT
HYDRAULIC SYSTEMS
NAVY USE ONLY
Reference Material
Organizational, Intermediate and Depot Maintenance Aviation Hose and Tube
Manual ..................................................................................................................
Maintenance Instructions with Illustrated Parts Breakdown (Organizational,
Intermediate) Hydraulic Fill Unit.............................................................................
Preoperational Checklist Hydraulic Service Unit Model H-250-1...............................
Periodic Maintenance Requirements Manual Hydraulic Service Unit Model H-250-1
Operation and Intermediate Maintenance Instructions with Illustrated Parts
Breakdown Hydraulic Fluid Service Unit Type HSU-1...........................................
Preoperational Checklist Hydraulic Service Unit HSU-1 ...........................................
Periodic Maintenance Requirements Manual Service Unit Model HSU-1 ................
Preoperational Checklist Pump, Dispensing, Hand Driven PMU-55E.......................
Operation and Maintenance Instructions with Illustrated Parts Breakdown Pump
Dispensing Hand Driven PMU-55/E Part Number 4-5280 ....................................
Preoperational Checklist Hydraulic Service Cart Model 310 ....................................
Operation and Intermediate Maintenance Instructions with Illustrated Parts
Breakdown, Pump Hydraulic Fluid Dispensing A/M27M-10..................................
Preoperational Checklist Hydraulic Fluid Dispensing Unit A/M27M-10 .....................
Periodic Maintenance Requirements Manual Hydraulic Fluid Dispensing Unit
A/M27M-10 ............................................................................................................
Operation and Maintenance Instructions with Illustrated Parts Breakdown Air Driven,
Portable, Hydraulic Check and Fill Test Stand Model 74 ......................................
Preoperational Checklist Maintenance Requirements Air Driven, Portable, Hydraulic
Check and Fill Stand Model 74..............................................................................
Calendar Maintenance Requirements Cards Air Driven, Portable, Hydraulic, Check
And Fill Stand Model 74.........................................................................................
Operating and Service Instructions with Parts Breakdown, Air Driven Portable
Hydraulic Check and Fill Stand Model 718............................................................
Operation and Intermediate Maintenance with Illustrated Parts Breakdown Test
Stand Aircraft Hydraulic Systems A/M27T-6 .........................................................
Preoperational Checklist Test Stand, Aircraft Hydraulic System, A/M27T-6 .............
Periodic Maintenance Requirements Manual Test Stand, Aircraft Hydraulic
System, A/M27T-6 .................................................................................................
Organizational and Intermediate Maintenance with Illustrated Parts
Breakdown, Portable Hydraulics Power Supply (Electric Motor Driven) Model
A/M27T-7 and A/M27T-7A ....................................................................................
Preoperational Checklist Portable Hydraulic Power Supply A/M27T-7 and
A/M27T-7A ............................................................................................................
Operation and Intermediate Maintenance Instructions with Illustrated Parts Breakdown,
Portable Hydraulic Power Supply A/M27T-5 and A/M27T-5A...............................
Portable Hydraulic Power Supply (A/M27T-5) Preoperational Checklist...................
Periodic Maintenance Requirements Manual Portable Hydraulic Power
Supply A/M27T-5 ..................................................................................................
NAVAIR 01-1A-20
NAVAIR 17-15BF-57
NAVAIR 17-600-40-6-1
NAVAIR 17-600-40-6-2
AG-140BA-MIB-000
AG-140BA-MRC-100
AG-140BA-MRC-200
AG-720AO-MRC-000
AG-720AO-S15-000
NAVAIR 17-600-67-6-1
NAVAIR 17-15BF-87
NAVAIR 17-600-107-6-1
NAVAIR 17-600-107-6-2
NAVAIR 17-15BF-26
NAVAIR 17-600-35-6-1
NAVAIR 17-600-35-6-2
NAVAIR 17-15BF-35
NAVAIR 17-15BF-90
NAVAIR 17-600-156-6-1
NAVAIR 17-600-156-6-2
NAVAIR 17-15BF-91
NAVAIR 17-600-150-6-1
NAVAIR 17-15BF-89
NAVAIR 17-600-127-6-1
NAVAIR 17-600-127-6-2
NAVAIR 01-1A-17
TO 42B2-1-12
009 00
Page 2
Organizational, Intermediate, and Depot Maintenance Instructions with Illustrated
Parts Breakdown Portable Hydraulic Power Unit A/M27T-3 .................................
Preoperational Maintenance Requirements Portable Hydraulic Power Supply
Model A/M27T-3 ....................................................................................................
Periodic Maintenance Requirements Manual Portable Hydraulic Power Supply
A/M27T-3 ...............................................................................................................
Operation and Maintenance with Illustrated Parts Breakdown Portable Hydraulic
Power Supply, Diesel and Electric Part Nos. 000850-100 and 98612-100 ...........
Pre-Operational, Checklist Portable Hydraulics Power Supply, Diesel 000850 Electric
98612 .....................................................................................................................
Periodic Maintenance Requirements Manual Portable Hydraulic Power Supply,
Diesel, 000850-100 Portable Hydraulic Power Supply, Electric 98612-100..........
Maintenance Program, Naval Aviation ....................................................................
NAVAIR 17-15BF-76
NAVAIR 17-600-101-6-1
NAVAIR 17-600-101-6-2
AG-140V22-MIB-000
AG-140V22-MRC-100
AG-140V22-MRC-200
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
Alphabetical Index
Subject
Contamination Control Requirements............................................................................................
Cleanliness ................................................................................................................................
Contamination Analysis .............................................................................................................
Fluid Sampling ...........................................................................................................................
Flushing .....................................................................................................................................
Operational Use .........................................................................................................................
Periodic Maintenance ................................................................................................................
Page No.
4
4
5
5
6
5
5
NAVAIR 01-1A-17
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009 00
Page 3
Purging.......................................................................................................................................
Recirculation Cleaning...............................................................................................................
Support Equipment (SE) Configuration .....................................................................................
Fluid Dispensing Unit .....................................................................................................................
Fluid Service Unit, Model HSU-1 ...............................................................................................
Fluid Service Cart, Model 310 ...................................................................................................
Hydraulic Purification Equipment ...................................................................................................
Hydraulic International Inc Hydraulic Purification Unit...............................................................
Pall Aeropower Corp Hydraulic Purifier A/M37M-2 ...................................................................
Introduction ....................................................................................................................................
Minimum Requirements for Portable Hydraulic Test Stand Operation
and Aircraft Connection ...............................................................................................................
Applying Hydraulic Power to Aircraft .........................................................................................
Cleaning and De-Aerating Test Stand.......................................................................................
Pre-Operational Inspections and Procedures............................................................................
Starting Test Stand Engine........................................................................................................
Test Stand Operational Checks.................................................................................................
Test Stand Shutdown Procedure...............................................................................................
Portable Hydraulic Test Stands .....................................................................................................
Portable Hydraulic Test Stand A/M27T-5 ..................................................................................
Portable Hydraulic Test Stand A/M27T-7 ..................................................................................
Stationary Hydraulic Test Stands...................................................................................................
CGS Scientific Thermodynamics (24461) Hose Burst Test Stand ............................................
Greer Hydraulic Hose Test Stand..............................................................................................
Hydraulic and Pneumatic Component Test Stand HCT-10.......................................................
Hydraulic Component Test Stand A/F27T-10............................................................................
Use of Manifolds for Multisystem Operation ..................................................................................
Record of Applicable Technical Directives
None
6
5
4
7
7
7
23
23
23
4
14
17
17
14
17
18
18
10
10
14
19
19
19
19
22
18
NAVAIR 01-1A-17
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1. INTRODUCTION.
NOTE
USAF: This WP not applicable
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
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.
b. Hydraulic fluid dispensing equipment
6. CONTAMINATION CONTROL REQUIREMENTS.
c.
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.
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
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 3microns (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
maintained in accordance with
cleanliness requirements:
SE shall be
the following
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
NAVAIR 01-1A-17
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009 00
Page 5
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.
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
for
maintenance of age-controlled hoses
used 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,
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 and for specific
information to assist in the selection of the most
appropriate method.
14. RECIRCULATION CLEANING. Recirculation
cleaning is employed when equipment is found to
be contaminated beyond acceptable limits (in excess
of Navy Standard Class 3) with particulate matter.
With this method, the equipment is self-cleaned using
NAVAIR 01-1A-17
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009 00
Page 6
its internal 3-micron filter elements. The procedures
utilized shall satisfy the following minimum
requirements:
Hydraulic Fluid, MIL-H-81019
3
Hydraulic Fluid, MIL-PRF-87257
4
Hydraulic Fluid, SAE AS1241
5
NOTE
Since not all portable hydraulic test stands
are designed the same way, see
applicable equipment manual for proper
recirculation 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.
Hydraulic Fluid, MIL-PRF-5606
1
Hydraulic Fluid, MIL-PRF-83282
2
Service reservoir.
16. PURGING. Purging of SE hydraulic systems
shall be performed only upon recommendation from,
and under the direct supervision of, the applicable
Fleet Support Team (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).
NAVAIR 01-1A-17
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009 00
Page 7
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 1. Use of
fluid servicing equipment other than those listed in
Table 1, 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 1gallon 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. FLUID SERVICE CART, MODEL 310. Fluid
Service Cart, Model 310 (fluid service cart), illustrated
in Figure 2 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 3micron (absolute) filtered fluid.
25. 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.
NAVAIR 01-1A-17
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009 00
Page 8
Table 1. Fluid Servicing Equipment
NOMENCLATURE
Hydraulic Fluid Servicing Unit
Hydraulic Fluid Servicing Cart
MODEL NO./CAGE NO.
CAPACITY
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-55/E (94861)
10 gal
AG-720AO-S15-000
AG-720AO-MRC-000
310 (28871)
10 gal
NAVAIR 17-600-67-6-1
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
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 17-600-127-6-1
NAVAIR 17-600-127-6-2
NAVAIR 17-15BF-89
A/M27T-3 (30003)
3 gal
NAVAIR 17-600-101-6-1
NAVAIR 17-600-101-6-2
NAVAIR 17-15BF-76
Hydraulic Dispensing Cart
Hydraulic Check and Fill
Stand
Portable Hydraulic Test Stand
(Note 1)
PUBLICATION
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.
NAVAIR 01-1A-17
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009001
Figure 1.
Fluid Service Unit, Model HSU-1
NAVAIR 01-1A-17
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26. 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 singleaction-type pump having a displacement of 2 fluid
ounces per stroke at 0 to 250 psi. A replaceable 3micron (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.
27. 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 3micron in-line filter assembly is located near the
discharge end of the service hose to further ensure
against system contamination.
28. PORTABLE HYDRAULIC TEST STANDS.
29. 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 2 and 3 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 2 should
be consulted for this information. However, several of
the more common test stands are discussed to
provide a general familiarity with the equipment.
30. PORTABLE HYDRAULIC TEST STAND
A/M27T-5. Portable Test Hydraulic Stand A/M27T-5 is
a diesel engine driven unit. Figure 3 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:
Hydraulic Fluid, MIL-PRF-5606
1
Hydraulic Fluid, MIL-PRF-83282
2
Hydraulic Fluid, MIL-H-81019
3
Hydraulic Fluid, MIL-PRF-87257
4
Hydraulic Fluid, SAE AS1241
5
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.
31. 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 2 to obtain detailed operating
instructions and other information relating
to the equipment being operated.
32. The A/M27T-5 test stand hydraulic system
(Figure 4) 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.
NAVAIR 01-1A-17
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009002
Figure 2.
Fluid Service Cart, Model 310
NAVAIR 01-1A-17
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Table 2.
MODEL
(Note 1)
MFR & P/N
(CAGE)
A/M27T-7
68A5-J1000
A/M27T-7A (56529)
Portable Hydraulic Test Stands
PUBLICATION
MRC
NAVAIR 17-15BF-91 17-600-150-6-1
TEC
GGJV
GGJ9
FLOW CAPACITY
POWER
SOURCE
20 gpm @ 3000 psi
10 gpm @ 5000 psi
(Note 3)
Electric
(Note 2)
A/M27T-3
Greer
636AS100-1
(26637)
NAVAIR 17-15BF-76 17-600-101-6-1
GGJU
6 gpm @ 3000 psi
3 gpm @ 4500 psi
A/M27T-5
Hydraulic
NAVAIR 17-15BF-89 17-600-127-6-1
A/M27T-5A International
68A4-J1000-1
(30003)
17-600-127-6-2
GGJZ
GGJ8
20 gpm @ 3000 psi Diesel
10 gpm @ 5000 psi
(Note 3)
PHPS
S7DJ
17-600-101-6-2
Hydraulic
International
Notes: 1.
AG-140V22-MIB-000
Diesel P/N:
(000850-100)
AG-140V22MRC-100
50 gpm @ 3000 psi Diesel
Electric P/N:
(98612-100)
AG-140V22MRC-200
32 gpm @ 5000 psi Electric
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.
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.
NAVAIR 01-1A-17
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Table 3.
Portable Hydraulic Test Stand Operating Features
A/M27T-3
A/M27T-7
A/M27T-7A
A/M27T-5
A/M27T-5A
Return line back pressure
reducing valve
No
No
Compensates for aircraft reservoir pressurization
effects. Allows test stand reservoir to be used
during aircraft test.
Return line shutoff valve
No
No
Same as above but limited to low volume testing.
Pressure line shutoff valve
Yes
No
Precludes possible reverse fluid flow from
aircraft to stand when closed prior to stand
shutdown.
Reservoir selector valve
No
Yes
Enables use of test stand reservoir when
powering aircraft. Aids in removal of air from
aircraft fluid.
Automatic deaeration valve
Yes
Yes
Provides limited fluid air removal during
operation without test stand reservoir.
Oil cooler
Yes
Yes
Enables prolonged closed-loop operation, such
as when recirculation cleaning test stand.
Reservoir fill service panel
No
Yes
Provides 3-micron (absolute) filtered fluid at 100
psi for system servicing.
Fluid sampling valves
Yes
Yes
Enables sampling fluid for contamination
analysis.
Recirculation cleaning/hose
storage manifolds
Yes
Yes
Enables recirculation cleaning for test stand and
service hoses and provides hose stowage
means.
3-micron filtration
Yes
Yes
Enables delivery of particulate-free fluid to
equipment under test. A MANDATORY
REQUIREMENT.
OPERATING FEATURE
CAPABILITY AFFORDED
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33. 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.
34. 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 2) for operational and maintenance
instructions.
37. PRE-OPERATIONAL INSPECTIONS AND
PROCEDURES. Perform all required pre-operational
inspections and procedures in accordance with
applicable equipment MRC listed in Table 2. Ensure
that the following are included:
Hydraulic Fluid, MIL-PRF-5606
1
Hydraulic Fluid, MIL-PRF-83282
2
Hydraulic Fluid, MIL-H-81019
3
Hydraulic Fluid, MIL-PRF-87257
4
35. MINIMUM REQUIREMENTS FOR PORTABLE
HYDRAULIC TEST STAND OPERATION AND
AIRCRAFT CONNECTION.
36. 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:
Hydraulic Fluid, SAE AS1241
a. Make certain the test stand is located so that
adequate room, ventilation, and engine heat
dissipation are available.
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.
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.
5
NAVAIR 01-1A-17
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009003
Figure 3.
Portable Hydraulic Test Stand Model A/M27T-5 (Typical)
NAVAIR 01-1A-17
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009004
Figure 4.
Hydraulic System Schematic (Typical) A/M27T-5 Test Stand
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38. 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.
39. CLEANING AND DEAERATING TEST STAND.
Recirculation clean and deaerate the hydraulic fluid in
the test stand. Perform both operations concurrently
using the following procedures:
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:
Hydraulic Fluid, MIL-PRF-5606
1
Hydraulic Fluid, MIL-PRF-83282
2
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.
Hydraulic Fluid, MIL-H-81019
3
c. Monitor all filter differential pressure
indicators, particularly those associated with the 3micron 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.
Hydraulic Fluid, MIL-PRF-87257
4
Hydraulic Fluid, SAE AS1241
5
d. Upon completion of recirculation cleaning and
deaeration, 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.
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.
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.
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.
40. 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
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 3) 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.
NAVAIR 01-1A-17
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of fluid through aircraft filters may result if
proper shutdown procedures are not
employed.
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.
41. TEST STAND OPERATIONAL CHECKS.
Monitor test operation during aircraft test and check
for the following:
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.
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.
42. TEST STAND SHUTDOWN PROCEDURE.
Upon completion of required aircraft tests, shut down
test stand as follows:
In aircraft equipped with pressurized
reservoirs, hydraulic accumulators, or
surge dampers, detrimental reverse flow
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.
43. USE OF MANIFOLDS FOR MULTISYSTEM
OPERATION.
44. 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.
NAVAIR 01-1A-17
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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, crosscontamination of the other systems will occur.
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.
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.
49. 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.
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.
45. 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.
50. HYDRAULIC AND PNEUMATIC COMPONENT
TEST STAND HCT-10. The Hydraulic and Pneumatic
Component Test Stand HCT-10, shown in Figure 6, is
used to bench-test aircraft hydraulic and pneumatic
components such as engine-driven hydraulic pumps,
electro-hydraulic flight control assemblies, doubleacting 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.
46. STATIONARY HYDRAULIC TEST STANDS.
47. 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 4 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.
48. GREER HYDRAULIC HOSE TEST STAND.
Greer Hydraulic Hose Test Stand is shown in Figure
5. This test stand, designed especially for proofpressure testing of aircraft hose assemblies, is
009005
Figure 5.
Greer Hydraulic Hose Test Stand
NAVAIR 01-1A-17
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Table 4.
NOMENCLATURE
Stationary Shop Hydraulic Test Stands
MODEL/CAGE
MAX CAPACITY
HANDBOOK
NAVAIR 17-15BF-37
Hydraulic and Pneumatic
Component Test Stand
HCT-10 ACL
(05172)
40 gpm @ 3,000 psi
Pneu. to 6,000 psi
NAVAIR 17-600-32-6-1
NAVAIR 17-600-32-6-2
Hydraulic and Pneumatic
Component Test Stand
HCT-12
100 gpm @ 3,500 psi
60 gpm @ 5,000 psi
Hydraulic Hose Test
Stand
RT-6160-100 GREER
(26337)
Hydraulic pressure to
30,000 psi
Hydraulic Component
Test Stand
A/F27T-10, DAYTON T
BROWN, (96362)
60 gpm @ 3000 psi
25 gpm @ 8000 psi
NAVAIR 17-15BF-78-1
NAVAIR 17-15BF-78-2
NAVAIR 17-15BF-504
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
NAVAIR 17-15BF-41
NAVAIR 17-600-126-6-1
NAVAIR 17-600-126-6-2
NAVAIR 01-1A-17
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009006
Figure 6.
Hydraulic and Pneumatic Component Test Stand Model HCT-10 (05172)
NAVAIR 01-1A-17
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51. 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.
52. 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.
53. 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, highpressure 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 variabledisplacement, reversible-flow hydraulic motor that, in
turn, supplies power for driving hydraulic pumps
during tests.
54. 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.
55. HYDRAULIC COMPONENT TEST STAND
A/F27T-10. The A/F27T-10 Hydraulic component test
stand (HCTS) as show in Figure 7 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 nonportable units: the hydraulic console (HC) and an
electrical console (ECC).
56. 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 4 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 bidirectionally 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.
57. 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
NAVAIR 01-1A-17
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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.
58. HYDRAULIC PURIFICATION EQUIPMENT.
59. 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:
009007
Figure 7.
A/F27T-10 Hydraulic Component
Test Stand
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-PRF5606) without flushing the purifier between
decontamination of different fluid types (fluid cross
fluid contamination).
60. 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 5 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.
61. PALL AEROPOWER CORP HYDRAULIC
PURIFIER A/M37M-2. The fluid purifier A/M37M-2
(Figure 8) 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.
62. HYDRAULICS
INTERNATIONAL
INC
HYDRAULIC PURIFICATION UNIT. This portable
electric driven (440 or 220 VAC) unit P/N 95163-100,
(Figure 9), 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.
NAVAIR 01-1A-17
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009009
009008
Figure 8.
A/M37M-2 Hydraulic Purifier
Table 5.
Figure 9.
Hydraulic Fluid Purifier P/N 95163-100
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)
NAVAIR 17-15BF-96
NAVAIR 17-600-196-6-1
NAVAIR 17-600-196-6-2
Notes: 1. Flow capacity varies from either 0 or 5 gpm inlet into the purifier and 3 gpm on return.
NAVAIR 01-1A-17
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010 00
Page 1 of 8
ORGANIZATIONAL, INTERMEDIATE AND
DEPOT MAINTENANCE
HYDRAULIC FILTERS
HYDRAULIC SYSTEMS
Reference Material
Filter and Filter Elements, Fluid Pressure, Hydraulic Line, 15 Micron
Absolute Type II Systems ......................................................................................
Filter and Filter Elements, Fluid Pressure, Hydraulic Micronic Type .........................
Filter and Disposable Element, Fluid Pressure, Hydraulic 3 Micron Absolute...........
MIL-F-8815
MIL-F-5504
MIL-PRF-81836
Alphabetical Index
Subject
Page No.
Introduction ....................................................................................................................................
Types of Filters...............................................................................................................................
Differential Pressure Indicators..................................................................................................
Micronic Hydraulic Filter ............................................................................................................
Sintered Bronze Hydraulic Filter ................................................................................................
Support Equipment (SE) Filters .................................................................................................
Woven Wire-Mesh Filter Elements ............................................................................................
5-Micron Noncleanable Filter Elements.....................................................................................
Record of Applicable Technical Directives
None
2
2
8
5
5
5
5
2
NAVAIR 01-1A-17
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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.
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 noncleanable, woven mesh, micronic, porous metal, or
magnetic type. The micronic and 5-micron noncleanable 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 noncleanable and are normally discarded.
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
9. 5-MICRON
NON-CLEANABLE
FILTER
ELEMENTS. Non-cleanable filter elements rated at 5microns (absolute) represent the current state of the
art in hydraulic filtration. Elements of this type afford
significantly improved filtration and have greater dirtholding 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-F8815 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.
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010001
Figure 1.
Typical Filter Arrangement in Hydraulic System
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010002
Figure 2.
MIL-F-8815 Hydraulic Filter Assembly, Bypass Type
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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 noncleanable, depending upon their construction, and are
marked accordingly.
010003
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.
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.
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.
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.
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.
21. SUPPORT EQUIPMENT (SE) FILTERS. To
ensure delivery of contaminant free hydraulic fluid, all
SE must be provided with 3-micron (absolute) nonbypass 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.
17. The replaceable element is made of specially
treated convolutions (wrinkles) to increase its dirtholding 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.
20. Sintered bronze filter elements should be
replaced with cleaned and tested elements during
required maintenance inspection intervals.
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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 nonbypass 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 highpressure SE filters are not normally replaced on a
prescribed periodic basis. Because of their large dirtholding 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:
Hydraulic Fluid, MIL-PRF-5606
1
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Hydraulic Fluid, MIL-PRF-83282
2
Hydraulic Fluid, MIL-H-81019
3
Hydraulic Fluid, MIL-PRF-87257
4
Hydraulic Fluid, SAE AS1241
5
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.
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.
010005
Figure 5. Typical High Pressure
SE Filter Assembly
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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.
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Page 1 of 8
ORGANIZATIONAL, INTERMEDIATE AND
DEPOT MAINTENANCE
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..................................................
Existing Facilities .......................................................................................................................
New Facilities.............................................................................................................................
Controlled Environment Work Center Operating Procedures........................................................
Maintenance and Cleaning ........................................................................................................
Operating Regulations ...............................................................................................................
Personnel Regulations...............................................................................................................
Design Guidelines ..........................................................................................................................
Dimensions ................................................................................................................................
Work Center Environment .........................................................................................................
Introduction ....................................................................................................................................
Definitions ..................................................................................................................................
General Description ...................................................................................................................
Typical Aircraft Hydraulic Components Considered Contamination Critical..................................
Record of Applicable Technical Directives
None
3
3
5
6
7
6
7
2
2
3
2
2
2
7
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1. INTRODUCTION.
NOTE
USAF: This WP not applicable
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.
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.
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
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
If unable to meet the requirements of a
Controlled Environmental Work Center,
at a minimum, Laminar Flow Work
Stations 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.
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e. The equipment which will be utilized in the
operation of the center.
a. Walls and ceilings must be rigidly constructed
to reduce generation of contaminants due to
surrounding structure vibration or movement.
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:
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
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011001
Figure 1.
Typical Controlled Environment Control Work Center
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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
performed:
public
works
functions
should
be
(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 nonflaking 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
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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.
j. Lighting: Fluorescent fixture to provide 1076
lux at normal bench height.
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:
l. Casters: heavy duty, wheel type, with safety
brakes.
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.
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.
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.
ENVIRONMENT
27. CONTROLLED
CENTER OPERATING PROCEDURES.
WORK
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:
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.
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
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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.
Aircraft External Cleaning Compound,
MIL-PRF-85570, Type II
7
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.
Detergent, Non-Ionic, MIL-D-16791
8
b. Personnel not regularly employed in the
center should not be allowed in the area.
Isopropyl Alcohol, TT-I-735
9
29. PERSONNEL REGULATIONS. The following
general regulations should be practiced by all
personnel in a controlled environment work center:
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 internal
components 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 chipproof 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:
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
TO 42B2-1-12
011 00
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.
NAVAIR 01-1A-17
TO 42B2-1-12
15 August 2006
012 00
Page 1 of 8
ORGANIZATIONAL, INTERMEDIATE AND
DEPOT MAINTENANCE
SELECTION AND USE OF CLEANING MATERIALS
HYDRAULIC SYSTEMS
Reference Material
None
Alphabetical Index
Subject
Page No.
Cleaning Solvents ..........................................................................................................................
Solvent Cleanliness ...................................................................................................................
Solvent Effectiveness ................................................................................................................
Solvent Toxicity..........................................................................................................................
Flammability ...................................................................................................................................
Autoignition Point.......................................................................................................................
Fire Point....................................................................................................................................
Flash Point .................................................................................................................................
Introduction ....................................................................................................................................
Safety Precautions and First Aid....................................................................................................
Solvent Contamination ...................................................................................................................
Solvent Selection ...........................................................................................................................
Wiping Materials.............................................................................................................................
Recommended Wiping Cloths ...................................................................................................
Record of Applicable Technical Directives
None
2
2
2
2
2
4
4
2
2
4
4
4
5
5
NAVAIR 01-1A-17
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012 00
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 5micron (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 (KB) 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.
SOLVENT
Dry Cleaning
Solvent
MIL-PRF-680
Type II / III
EFFECTIVE
IN REMOVING
CLEANING
METHODS
Oils, fats,
greases, waxes,
heavy dirt
deposits.
Dip, slosh,
spray, brush,
flush, or wipe.
Solvent Selection Chart for Use in Hydraulic Maintenance
TOXICITY
High TLV =
100 ppm
FLASH POINT
Type II: 140°F
(60EC)
K-B
VALUE
ADVANTAGES
DISADVANTAGES
USAF Only:
MIL-PRF-87257
(Not solvents but
sometimes
employed as
cleaning agents)
RECOMMENDED
APPLICATIONS
Economical, good
chemical stability.
Effective for gross
cleaning application.
Not chlorinated.
Flammable
Moderately toxic
Use with full
ventilation. Avoid
excessive
inhalation. Do
not use near hot
surfaces or open
flame.
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.
Oil, fat, grease,
wax, heavy dirt
deposits
Dip, slosh,
spray, brush,
flush, or wipe
High TLV =
100ppm
140EF (60EC)
29 to 45
Economical, good
chemical stability.
Effective for gross
cleaning application.
Not chlorinated.
Flammable
Moderately toxic
Use with full
ventilation.
Avoid excessive
inhalation. Do
not use near hot
surfaces or open
flames.
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.
Oils, organic
matter, light
deposits of
general dust or
dirt.
Dip, slosh,
spray, brush,
flush, or wipe.
Low TLV =
not known
MIL-PRF-5606: 180°F
(82EC)
Not
known
Readily available.
Compatible with
materials used in
hydraulic components.
Not chlorinated.
MIL-PRF-5606, mILPRF-83282, and MILPRF-87257 are fire
resistant.
Flammable. Not very
effective as a
cleaning solvent.
Do not use near
hot surfaces or
open flame.
Avoid excessive
skin contact.
As a substitute
for MIL-PRF-680
or A-A-59601
(PD680) when
cleaning
surfaces which
come into direct
contact with
system fluid.
AIR FORCE
ONLY
USAF and Navy:
Hydraulic Fluids
MIL-PRF-5606
MIL-PRF-83282
SAFETY
PRECAUTIONS
34
Type III: 200°F
(93EC)
Dry Cleaning
Solvent PD680
(Procured under
Specification A-A59601)
NAVAIR 01-1A-17
TO 42B2-1-12
Table 1.
MIL-PRF-83282:
400°F (204EC)
MIL-PRF-87257:
350EF (175EC)
012 00
Page 3
NAVAIR 01-1A-17
TO 42B2-1-12
012 00
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.
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.
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.
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.
Dry Cleaning Solvent, MIL-PRF-680
Dry Cleaning Solvent, A-A-59601
6
14
18. To prevent solvent contamination, it is
imperative that extreme care be exercised when
utilizing these cleaning agents to clean internal
f. Prohibit smoking, welding, or use of open
flame in the vicinity of volatile or flammable solvents.
g. Dispose of contaminated solutions
accordance with local safety regulations.
h. Do not take internally.
in
NAVAIR 01-1A-17
TO 42B2-1-12
012 00
Page 5
i. Use protective devices such as cover or cuptype 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-A59323 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
TO 42B2-1-12
012 00
Page 6
Table 2.
TYPE OF
CONTACT
First Aid Treatment Guide
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
TO 42B2-1-12
012 00
Page 7/(8 Blank)
Table 3: Recommended Wiping Cloths
Specification
Rating
Description
CCC-C-46
Class 7
Number 9404
Duralace
Low Lint
Wiping cloth, nonwoven 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 wipedown 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. Precleaned to a very low
particulate level. Poor
water absorbency.
SAE AMS 3189B
Class 1, Grade A
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.
Air Force Only
Application
Characteristics
Do not use wiping cloths to wipe plastic or use with volatile solvents
having flash points less than 100°F (38EC).
NAVAIR 01-1A-17
TO 42B2-1-12
15 August 2006
013 00
Page 1 of 12
ORGANIZATIONAL, INTERMEDIATE AND
DEPOT MAINTENANCE
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 ..................................................................................................................
General Lubrication Instructions ................................................................................................
Component Spline Maintenance....................................................................................................
Reuse of Splines........................................................................................................................
Spline Cleaning..........................................................................................................................
Spline Inspection Requirements ................................................................................................
Spline Lubrication ......................................................................................................................
Component Testing........................................................................................................................
Component Proof Pressure Testing ..........................................................................................
Nondestructive Testing ..............................................................................................................
Post-Installation Checks ............................................................................................................
Hydraulic Component Leakage......................................................................................................
Allowable and Excessive Leakage ............................................................................................
Measurement of Leakage ..........................................................................................................
Hydraulic Pump Contamination Tests............................................................................................
Analysis of Test Patches ...........................................................................................................
Contamination Testing Procedures ...........................................................................................
Patch Test Technique................................................................................................................
Introduction ....................................................................................................................................
Component Repair and Overhaul ..............................................................................................
Maintenance Responsibilities ....................................................................................................
System Check Requirements ....................................................................................................
Record of Applicable Technical Directives
None
3
3
6
7
6
7
6
2
3
2
3
4
5
4
7
11
9
7
2
2
2
2
NAVAIR 01-1A-17
TO 42B2-1-12
013 00
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.
Hydraulic Fluid, MIL-PRF-83282
2
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.
NAVAIR 01-1A-17
TO 42B2-1-12
013 00
Page 3
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:
20. POST-INSTALLATION
CHECKS.
After
component installation, perform the following in
accordance with existing maintenance procedures:
a. Perform
required
Quality
Inspection for correct installation.
Assurance
a. Disassemble component
required to accomplish repair.
b. Perform
required
Inspection for leakage.
Assurance
to
the
extent
Quality
b. Visually inspect all parts for cracks or other
evidence of mechanical stress or failure.
c. Perform functional checkout of the system
component which has been replaced or repaired.
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. Perform an individual functional checkout of
affected hydraulic system to ensure its proper
operation.
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 not
required when the repair operation has not
disturbed the seal or housing integrity.
19. Overhauled components shall be proof pressure
tested as specified in applicable overhaul manuals or
other engineering directives.
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
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Page 4
the pressure compresses the O-ring and seals the
leak.
General Purpose Aircraft Grease,
MIL-PRF-81322
11
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,
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.
seals.
Pressure and temperature variations affecting
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
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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.
Hydraulic Fluid, MIL-PRF-5606
1
Hydraulic Fluid, MIL-PRF-83282
2
Hydraulic Fluid, MIL-H-81019
3
Hydraulic Fluid, MIL-PRF-87257
4
Hydraulic Fluid, SAE AS1241
5
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.
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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.
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.
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.
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,
MIL-PRF-81322
11
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.
Dry Cleaning Solvent, MIL-PRF-680
6
c. Install hydraulic pump or motor in accordance
with the applicable MIM.
NAVAIR 01-1A-17
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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
TESTS.
PUMP
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:
CONTAMINATION
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
Hydraulic Fluid, MIL-PRF-5606
1
Hydraulic Fluid, MIL-PRF-83282
2
Hydraulic Fluid, MIL-H-81019
3
Hydraulic Fluid, MIL-PRF-87257
4
NAVAIR 01-1A-17
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Page 8
013001
Figure 1.
Patch Test Testing Hydraulic Pump Contamination Using
Contamination Analysis Kit 57L414
NAVAIR 01-1A-17
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equivalent, prepare a test patch from each assembly
employing the following procedure:
Hydraulic Fluid, SAE AS1241
5
a. Clean filter elements installed in pump filter
assemblies.
Hydraulic Fluid, MIL-PRF-5606
1
Hydraulic Fluid, MIL-PRF-83282
2
Hydraulic Fluid, MIL-H-81019
3
Hydraulic Fluid, MIL-PRF-87257
4
Hydraulic Fluid, SAE AS1241
5
Dry Cleaning Solvent, MIL-PRF-680
6
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 reworked
pump. 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
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 filterequipped 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
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and cycling rates are same as for first and second
run-in.
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.
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:
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,
Hydraulic Fluid, MIL-PRF-5606
1
NAVAIR 01-1A-17
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Hydraulic Fluid, MIL-PRF-83282
2
Hydraulic Fluid, MIL-H-81019
3
Hydraulic Fluid, MIL-PRF-87257
4
Hydraulic Fluid, SAE AS1241
5
Dry Cleaning Solvent, MIL-PRF-680
6
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 filterequipped solvent rinse bottle and solvent MIL-PRF680 (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
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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 3micron 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
TO 42B2-1-12
15 August 2006
014 00
Page 1 of 12
ORGANIZATIONAL, INTERMEDIATE AND
DEPOT MAINTENANCE
PROTECTIVE CLOSURES
HYDRAULIC SYSTEMS
NAVY USE ONLY
Reference Material
Caps and Plugs, Protective, Dust and Moisture Seal ................................................
Cap - Protective, Flared Fitting ..................................................................................
Cap - Beaded Hose Connection, Plastic, Protective .................................................
Cap, Pipe, Thread, Protective, Dust and Moisture Seal ............................................
Cap Assembly, Pressure Seal Flared Tube Fitting ...................................................
Plug-Protective, Flared Tube, Hose Assembly .........................................................
Plug - Protective, Flareless Tube End (Plastic) .........................................................
Plugs, Protective, Flareless Tube End (Metal) ..........................................................
Plug, Flareless Tube .................................................................................................
Fitting, Plug, Tube End, Flared .................................................................................
Plug, Pipe Thread, Protective, Dust and Moisture Seal.............................................
Fitting, Port Plug and Bleeder ....................................................................................
Plug, Machine Thread-AMS5646, Preformed Packing .............................................
Fittings, 37 Degree Flared, Fluid Connection ...........................................................
NAS847
NAS817
NAS839
NAS846
AN929
NAS818
NAS838
NAS842
SAE AS21913
SAE AS5168
NAS840
SAE AS5169
MS9404
SAE AS4841
Alphabetical Index
Subject
Page No.
Protective Closure Application .......................................................................................................
Blank-Off Plates .............................................................................................................................
Protective Closure Description.......................................................................................................
Introduction ....................................................................................................................................
Record of Applicable Technical Directives
None
2
2
2
2
NAVAIR 01-1A-17
TO 42B2-1-12
014 00
Page 2
installation, use the external type of
closure. Never blank off openings with
wooden plugs, paper, rags, tape, or other
unauthorized devices.
1. INTRODUCTION.
NOTE
USAF: This WP not applicable
NOTE
d. Use metal protective closures to seal open
ports of all hydraulic lines and accessories.
Plastic covers shall only be used for
Dyna Tubes ONLY. Plastic covers are
not recommended for fluid fittings.
e. Use metal protective closures to seal new
and reusable hydraulic tubing and hose assemblies.
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 metal closures are identified in Tables 2
through 7.
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. 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.
c. 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.
f. Keep all protective closures clean, sorted by
size, properly identified, and stored in readily
accessible bins.
g. Check protective closure visually for
cleanliness, thread damage, or sealing deformation
before using.
h. 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.
i. 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. BLANK-OFF PLATES.
8.
Blank-off plates (Figure 1) 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.
In all cases where there is a choice
between an internal or external
c. If plastic blank-off plates are used, plastic
material shall conform to NAS847, “Caps and Plugs,
Protective, Dust and Moisture Seal”.
NAVAIR 01-1A-17
TO 42B2-1-12
014 00
Page 3
014001
Figure 1.
Typical Blank-Off Plates
NAVAIR 01-1A-17
TO 42B2-1-12
014 00
Page 4
Table 1.
TYPE
(Note 1)
Protective Caps and Plugs
APPLICABLE
SPECIFICATION
APPLICATION
Cap
Protective, Flared Fitting
NAS817
Cap
Beaded Hose Connection, Plastic,
Protective
NAS839
Cap
Pipe Thread
NAS846
Cap
Assembly, Pressure Seal Flared Tube
Fitting
AN929
Plug
Flared Tube End and Straight Threaded
Boss
NAS-818
or SAE AS5168 (Note 3)
Plug
Protective, Flareless Tube End (Plastic)
NAS838
Plug
Protective, Flareless Tube End (Metal)
NAS842
Plug
Flareless Tube
SAE AS21913 (Note 2)
Plug
Flared Tube Precision Type
SAE AS5168 (Note 3)
Plug
Pipe Thread
NAS840
Plug
Bleeder, Screw Thread
SAE AS5169
Plug
Machine Thread AMS 5646 Preformed
Packing
MS9404
Plug
Bleeder, Screw Thread Precision Type
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.
NAVAIR 01-1A-17
TO 42B2-1-12
014 00
Page 5
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"
2
AN929-D3
Cap, Threaded, 7075 Anodized
Aluminum
4730-00-221-2126
EA
3/8"
3/16"
3
AN929-D4
Cap, Threaded, 7075 Anodized
Aluminum
4730-00-278-5006
EA
7/16"
1/4"
4
AN929-D5
Cap, Threaded, 7075 Anodized
Aluminum
4730-01-061-4150
EA
1/2"
5/16"
5
AN929-D6
Cap, Threaded, 7075 Anodized
Aluminum
4730-00-585-8769
EA
9/16"
3/8"
6
AN929-D8
Cap, Threaded, 7075 Anodized
Aluminum
4730-00-541-8296
EA
3/4"
1/2"
7
AN929-D10
Cap, Threaded, 7075 Anodized
Aluminum
4730-00-221-2127
EA
7/8"
5/8"
8
AN929-D12
Cap, Threaded, 7075 Anodized
Aluminum
4730-00-221-2128
EA
1-1/16"
3/4"
9
AN929-D16
Cap, Threaded, 7075 Anodized
Aluminum
4730-00-221-2129
EA
1-3/8"
1"
10
AN929-D20
Cap, Threaded, 7075 Anodized
Aluminum
4730-00-221-2130
EA
1-5/8"
1-1/4"
11
AN929-D24
Cap, Threaded, 7075 Anodized
Aluminum
4730-00-826-6462
EA
1-7/8"
1-1/2"
12
AN929-D28
Cap, Threaded, 7075 Anodized
Aluminum
4730-00-221-2116
EA
2-1/4"
1-3/4"
13
AN929-D32
Cap, Threaded, 7075 Anodized
Aluminum
4730-00-221-2117
EA
2-1/2"
2"
NAVAIR 01-1A-17
TO 42B2-1-12
014 00
Page 6
Table 3.
High Pressure Aluminum Plugs (blue in color)
{Meets SAE-AS4841 specification (supersedes MIL-F-5509)}
Part
Number
(P/N)
Item
No.
Nomenclature
National Stock
Number (NSNs)
Units of
Issue
(U/I)
Cap
Thread
Size
Tubing
Size
1
AS5168-D02
Plug, Threaded, 7075 Anodized
Aluminum
4730-00-287-0109
EA
5/16"
1/8"
2
AS5168-D03
Plug, Threaded, 7075 Anodized
Aluminum
4730-00-287-0100
EA
3/8"
3/16"
3
AS5168-D04
Plug, Threaded, 7075 Anodized
Aluminum
4730-00-287-0110
EA
7/16"
1/4"
4
AS5168-D05
Plug, Threaded, 7075 Anodized
Aluminum
4730-00-287-0111
EA
1/2"
5/16"
5
AS5168-D06
Plug, Threaded, 7075 Anodized
Aluminum
4730-00-287-0112
EA
9/16"
3/8"
6
AS5168-D08
Plug, Threaded, 7075 Anodized
Aluminum
4730-00-287-0113
EA
3/4"
1/2"
7
AS5168-D10
Plug, Threaded, 7075 Anodized
Aluminum
4730-00-287-0116
EA
7/8"
5/8"
8
AS5168-D12
Plug, Threaded, 7075 Anodized
Aluminum
4730-00-287-0117
EA
1-1/16"
3/4"
9
AS5168-D16
Plug, Threaded, 7075 Anodized
Aluminum
4730-00-287-0118
EA
1-3/8"
1"
10
AS5168-D20
Plug, Threaded, 7075 Anodized
Aluminum
4730-00-640-5104
EA
1-5/8"
1-1/4"
11
AS5168-D24
Plug, Threaded, 7075 Anodized
Aluminum
4730-00-287-0115
EA
1-7/8"
1-1/2"
12
AS5168-D28
Plug, Threaded, 7075 Anodized
Aluminum
4730-00-640-0633
EA
2-1/4"
1-3/4"
13
AS5168-D32
Plug, Threaded, 7075 Anodized
Aluminum
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.
NAVAIR 01-1A-17
TO 42B2-1-12
014 00
Page 7
Table 4.
Light Aluminum Caps for Storage and Shipping (silver in color)
{Meets NAS 817 specification}
Item
No.
Part
Number
(P/N)
Nomenclature
National Stock
Number (NSN’s)
Units of
Issue
(U/I)
Cap
Thread
Size
Tubing
Size
1
NAS817-2
Cap, Threaded, 3003 Anodized
Aluminum
5340-00-682-2112
EA
5/16"
1/8"
2
NAS817-3
Cap, Threaded, 3003 Anodized
Aluminum
5340-00-158-1313
EA
3/8"
3/16"
3
NAS817-4
Cap, Threaded, 3003 Anodized
Aluminum
5340-00-682-2113
EA
7/16"
1/4"
4
NAS817-5
Cap, Threaded, 3003 Anodized
Aluminum
5340-00-682-2114
EA
1/2"
5/16"
5
NAS817-6
Cap, Threaded, 3003 Anodized
Aluminum
5340-00-682-2115
EA
9/16"
3/8"
6
NAS817-8
Cap, Threaded, 3003 Anodized
Aluminum
5340-00-682-2116
EA
3/4"
1/2"
7
NAS817-10
Cap, Threaded, 3003 Anodized
Aluminum
5340-00-682-2117
EA
7/8"
5/8"
8
NAS817-12
Cap, Threaded, 3003 Anodized
Aluminum
5340-00-682-2118
EA
1-1/16"
3/4"
9
NAS817-16
Cap, Threaded, 3003 Anodized
Aluminum
5340-00-682-2119
EA
1-3/8"
1"
10
NAS817-20
Cap, Threaded, 3003 Anodized
Aluminum
5340-00-804-0788
EA
1-5/8"
1-1/4"
11
NAS817-24
Cap, Threaded, 3003 Anodized
Aluminum
5340-01-004-0107
EA
1-7/8"
1-1/2"
NAVAIR 01-1A-17
TO 42B2-1-12
014 00
Page 8
Table 5.
Light Aluminum Plugs for Storage and Shipping (silver in color)
{Meets NAS 818 specification}
Item
No.
Part
Number
(P/N)
Nomenclature
National Stock
Number (NSN’s)
Units of
Issue
(U/I)
Cap
Thread
Size
Tubing
Size
1
M5501/1-2
Plug, Threaded, 3003 Anodized
Aluminum
5340-00-804-1229
EA
5/16"
1/8"
2
M5501/1-3
Plug, Threaded, 3003 Anodized
Aluminum
5340-00-804-1224
EA
3/8"
3/16"
3
M5501/1-4
Plug, Threaded, 3003 Anodized
Aluminum
5340-00-433-3253
EA
7/16"
1/4"
4
M5501/1-5
Plug, Threaded, 3003 Anodized
Aluminum
5340-00-804-1228
EA
1/2"
5/16"
5
M5501/1-6
Plug, Threaded, 3003 Anodized
Aluminum
5340-00-292-3292
EA
9/16"
3/8"
6
M5501/1-8
Plug, Threaded, 3003 Anodized
Aluminum
5340-00-828-8802
EA
3/4"
1/2"
7
M5501/1-10
Plug, Threaded, 3003 Anodized
Aluminum
5340-00-804-1230
EA
7/8"
5/8"
8
M5501/1-12
Plug, Threaded, 3003 Anodized
Aluminum
5340-01-186-6879
EA
1-1/16"
3/4"
9
M5501/1-16
Plug, Threaded, 3003 Anodized
Aluminum
5340-00-804-1245
EA
1-3/8"
1"
10
M5501/1-20
Plug, Threaded, 3003 Anodized
Aluminum
5340-00-804-1248
EA
1-5/8"
1-1/4"
11
M5501/1-24
Plug, Threaded, 3003 Anodized
Aluminum
5340-01-217-1791
EA
1-7/8"
1-1/2"
12
M5501/1-32
Plug, Threaded, 3003 Anodized
Aluminum
5340-00-804-1254
EA
2-1/2"
2"
NAVAIR 01-1A-17
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014 00
Page 9
Table 6.
Part
Number
(P/N)
Item
No.
High Pressure Carbon Steel Caps (gold in color)
Nomenclature
National Stock
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
Cap, Threaded, Steel Tube Fitting,
Cadmium Plated w/ Supplementary
Chromate Treatment
4730-00-289-8633
EA
3/8"
3/16"
3
SAE
AS21914-4
Cap, Threaded, Steel Tube Fitting,
Cadmium Plated w/ Supplementary
Chromate Treatment
4730-00-640-0632
EA
7/16"
1/4"
4
SAE
AS21914-5
Cap, Threaded, Steel Tube Fitting,
Cadmium Plated w/ Supplementary
Chromate Treatment
4730-00-618-9069
EA
1/2"
5/16"
5
SAE
AS21914-6
Cap, Threaded, Steel Tube Fitting,
Cadmium Plated w/ Supplementary
Chromate Treatment
4730-00-618-3572
EA
9/16"
3/8"
6
SAE
AS21914-8
Cap, Threaded, Steel Tube Fitting,
Cadmium Plated w/ Supplementary
Chromate Treatment
4730-00-289-8634
EA
3/4"
1/2"
7
SAE
AS21914-10
Cap, Threaded, Steel Tube Fitting,
Cadmium Plated w/ Supplementary
Chromate Treatment
4730-00-618-4227
EA
7/8"
5/8"
8
SAE
AS21914-12
Cap, Threaded, Steel Tube Fitting,
Cadmium Plated w/ Supplementary
Chromate Treatment
4730-00-202-8792
EA
1-1/16"
3/4"
9
SAE
AS21914-16
Cap, Threaded, Steel Tube Fitting,
Cadmium Plated w/ Supplementary
Chromate Treatment
4730-00-274-7120
EA
1-3/8"
1"
10
SAE
AS21914-20
Cap, Threaded, Steel Tube Fitting,
Cadmium Plated w/ Supplementary
Chromate Treatment
4730-00-554-8917
EA
1-5/8"
1-1/4"
11
SAE
AS21914-24
Cap, Threaded, Steel Tube Fitting,
Cadmium Plated w/ Supplementary
Chromate Treatment
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.
NAVAIR 01-1A-17
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Page 10
Table 7.
Part
Number
(P/N)
Item
No.
High Pressure Carbon Steel Plugs (gold in color)
Nomenclature
National Stock
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
Plug, Threaded, Steel Tube Fitting,
Cadmium Plated w/ Supplementary
Chromate Treatment
4730-00-289-8632
EA
3/8"
3/16"
3
SAE
AS21913-4
Plug, Threaded, Steel Tube Fitting,
Cadmium Plated w/ Supplementary
Chromate Treatment
4730-00-595-2612
EA
7/16"
1/4"
4
SAE
AS21913-5
Plug, Threaded, Steel Tube Fitting,
Cadmium Plated w/ Supplementary
Chromate Treatment
4730-00-541-1465
EA
1/2"
5/16"
5
SAE
AS21913-6
Plug, Threaded, Steel Tube Fitting,
Cadmium Plated w/ Supplementary
Chromate Treatment
4730-00-203-3709
EA
9/16"
3/8"
6
SAE
AS21913-8
Plug, Threaded, Steel Tube Fitting,
Cadmium Plated w/ Supplementary
Chromate Treatment
4730-00-202-8341
EA
3/4"
1/2"
7
SAE
AS21913-10
Plug, Threaded, Steel Tube Fitting,
Cadmium Plated w/ Supplementary
Chromate Treatment
4730-00-966-5695
EA
7/8"
5/8"
8
SAE
AS21913-12
Plug, Threaded, Steel Tube Fitting,
Cadmium Plated w/ Supplementary
Chromate Treatment
4730-00-289-8627
EA
1-1/16"
3/4"
9
SAE
AS21913-16
Plug, Threaded, Steel Tube Fitting,
Cadmium Plated w/ Supplementary
Chromate Treatment
4730-00-289-8626
EA
1-3/8"
1"
10
SAE
AS21913-20
Plug, Threaded, Steel Tube Fitting,
Cadmium Plated w/ Supplementary
Chromate Treatment
4730-00-289-8625
EA
1-5/8"
1-1/4"
11
SAE
AS21913-24
Plug, Threaded, Steel Tube Fitting,
Cadmium Plated w/ Supplementary
Chromate Treatment
4730-01-067-3944
EA
1-7/8"
1-1/2"
adopted
by the
as an
original
Notes:
1.
The original military specification, MS21913, “Plug, Flareless Tube”, was
SAE Standard. Refer to SAE AS21913. Any part numbers established
specification remain unchanged.
NAVAIR 01-1A-17
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Table 8.
Plastic Caps for Storage and Shipping (light blue in color)
National Stock
Number (NSN’s)
Units
of
Issue
(U/I)
Cap
Thread
Size
Tubing
Size
Item
No.
Part
Number
(P/N)
1
DC-3
Cap, Threaded, High-Density
Polyethylene, seals out contaminants
while protecting threads
5340-01-178-7855
EA
3/8"-28
3/16"
2
DC-4
Cap, Threaded, High-Density
Polyethylene, seals out contaminants
while protecting threads
5340-00-435-9188
EA
7/16"-24
1/4"
3
DC-5
Cap, Threaded, High-Density
Polyethylene, seals out contaminants
while protecting threads
5340-01-114-0773
EA
1/2"-24
5/16"
4
DC-6
Cap, Threaded, High-Density
Polyethylene, seals out contaminants
while protecting threads
5340-00-364-9560
EA
9/16"-20
3/8"
5
DC-8
Cap, Threaded, High-Density
Polyethylene, seals out contaminants
while protecting threads
5340-00-376-8953
EA
3/4"-20
1/2"
6
DC-10
Cap, Threaded, High-Density
Polyethylene, seals out contaminants
while protecting threads
5340-00-620-4901
EA
7/8"-18
5/8"
7
DC-12
Cap, Threaded, High-Density
Polyethylene, seals out contaminants
while protecting threads
5340-00-435-9187
EA
1-1/16"-16
3/4"
8
DC-14
Cap, Threaded, High-Density
Polyethylene, seals out contaminants
while protecting threads
5340-01-114-0774
EA
1-1/8"-16
7/8"
9
DC-16
Cap, Threaded, High-Density
Polyethylene, seals out contaminants
while protecting threads
5340-01-114-0775
EA
1-3/8"-14
1"
10
DC-20
Cap, Threaded, High-Density
Polyethylene, seals out contaminants
while protecting threads
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"
12
DC-24
Cap, Threaded, High-Density
Polyethylene, seals out contaminants
while protecting threads
------------------------
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"
Nomenclature
NAVAIR 01-1A-17
TO 42B2-1-12
014 00
Page 12
Table 9.
Plastic Plugs for Storage and Shipping (light blue in color)
National Stock
Number (NSN’s)
Units
of
Issue
(U/I)
Cap
Thread
Size
Tubin
g
Size
Item
No.
Part
Number
(P/N)
1
DP-3
Plug, Threaded, High-Density
Polyethylene, seals out contaminants
while protecting threads
5340-01-114-0205
EA
3/8"-28
3/16"
2
DP-4
Plug, Threaded, High-Density
Polyethylene, seals out contaminants
while protecting threads
5340-01-084-5529
EA
7/16"-24
1/4"
3
DP-5
Plug, Threaded, High-Density
Polyethylene, seals out contaminants
while protecting threads
5340-01-115-1097
EA
1/2"-24
5/16"
4
DP-6
Plug, Threaded, High-Density
Polyethylene, seals out contaminants
while protecting threads
5340-01-089-9029
EA
9/16"-20
3/8"
5
DP-8
Plug, Threaded, High-Density
Polyethylene, seals out contaminants
while protecting threads
5340-01-080-9472
EA
3/4"-20
1/2"
6
DP-10
Plug, Threaded, High-Density
Polyethylene, seals out contaminants
while protecting threads
5340-01-104-6066
EA
7/8"-18
5/8"
7
DP-12
Plug, Threaded, High-Density
Polyethylene, seals out contaminants
while protecting threads
5340-01-085-4233
EA
1-1/16"-16
3/4"
8
DP-14
Plug, Threaded, High-Density
Polyethylene, seals out contaminants
while protecting threads
------------------------
EA
1-1/8"-16
7/8"
9
DP-16
Plug, Threaded, High-Density
Polyethylene, seals out contaminants
while protecting threads
5340-01-113-3830
EA
1-3/8"-14
1"
10
DP-20
Plug, Threaded, High-Density
Polyethylene, seals out contaminants
while protecting threads
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"
12
DP-24
Plug, Threaded, High-Density
Polyethylene, seals out contaminants
while protecting threads
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"
Nomenclature
NAVAIR 01-1A-17
TO 42B2-1-12
15 August 2006
015 00
Page 1 of 24
ORGANIZATIONAL, INTERMEDIATE AND
DEPOT MAINTENANCE
HYDRAULIC SEALS
HYDRAULIC SYSTEMS
Reference Material
Gland Design; Packings, Hydraulic, General Requirements for ................................
Packing, Preformed, Hydraulic, +275 Degrees F (O-Ring)........................................
Packing, Preformed, Straight Thread Tube Fitting ...................................................
Hydraulic and Pneumatic Retainers (Back-Up Rings), Polytetrafluoroethylene
(PTFE) Resin ........................................................................................................
Retainer, Packing Backup, Single Turn Tetrafluoroethylene ...................................
Packing, Preformed, Straight Thread Tube Fitting Boss, Type I Hydraulic ...............
Rubber Products: Recommended Shelf Life .............................................................
MIL-G-5514
SAE AS28775
SAE AS28778
SAE AS8791
MS28774
SAE AMS-P-5510
MIL-HDBK-695
Alphabetical Index
Subject
Page No.
Backup Rings .................................................................................................................................
Backup Ring Identification .........................................................................................................
Backup Ring Installation ............................................................................................................
Introduction ....................................................................................................................................
Definitions ..................................................................................................................................
Packings.........................................................................................................................................
Gaskets......................................................................................................................................
Preformed Packing Identification ...............................................................................................
Preformed Packing Lubrication..................................................................................................
Preformed Packing Removal and Installation............................................................................
Preformed Packing Storage.......................................................................................................
Service Life of Preformed Packings ..........................................................................................
Spring Seals...............................................................................................................................
T-Rings ......................................................................................................................................
Record of Applicable Technical Directives
None
17
17
18
2
2
2
11
13
18
14
14
13
3
2
NAVAIR 01-1A-17
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015 00
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
TO 42B2-1-12
015 00
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.
015001
Figure 1.
T-Sealing Ring
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 so
that the open side of the cover faces
toward 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.
015002
Figure 2.
Typical Glyd Ring Installation
NAVAIR 01-1A-17
TO 42B2-1-12
015 00
Page 4
015005
015003
Figure 3.
Typical Cap Seal Installation
Figure 5.
Typical Double Delta Channel Seal
Installation
015004
Figure 4.
Typical Channel Seal Installation
015006
Figure 6. Spring Seal Sealing Principle
NAVAIR 01-1A-17
TO 42B2-1-12
015 00
Page 5
015007
Figure 7.
Spring Seal and Typical Installations
NAVAIR 01-1A-17
TO 42B2-1-12
015 00
Page 6
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) Oring is a viable substitute for the AN6227 and AN6230
O-rings. The SAE AS28778 (formerly MS28778) Oring 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 Orings 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 antiextrusion 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
NAVAIR 01-1A-17
TO 42B2-1-12
015 00
Page 7
Table 1. O-Ring Part Numbers Cross Over to Material Specification
Part Number
AA55549-XX
AS3084-XX
AS3085-XXX
AS3208-XX
AS3209-XXX
AS3551-XXX
AS3551-XXX
AS3569-XXX
AS3570-XXX
AS3578-XXX
AS3578-XXX
AS3581-XXX
AS3582-XXX
M83248/1-XXX
M83248/1-XXX
M83248/2-XXX
M83461/1-XXX
M259888-XXX
M259888-XXX
M25988/1-XXX
M25988/2-XXX
M25988/3-XXX
M25988/4-XXX
M83248/1-XXX
M83248/1-XXX
M83248/1-XXX
M83248/2-XXX
M83248/1-XXX
M83248/2-XXX
MA3362XXXXX
MA3434XXXXX
MA3442XXXXX
MA3445XXXXX
MS28772-XXX
MS28775-XXX
MS28775-XXX
MS28775-XXX
MS28778-XX
MS28778-XX
MS29512-XX
MS29513-XXX
MS29561-XXX
MS3393-XX
MS90064-XX
MS9385-XX
MS9386-XXX
MS9966-XX
MS9967-XXX
NAS617-XXX
NAS1611-XXXA
NAS1612-XXA
NSA8201-X
NSA8204-XXX
NSA8205-XXX
NSA8206-XXX
Part Number Specification
A-A-55549
AS3084
AS3085
AS3208
AS3209
AS3551
AS3551
AS3569
AS3570
AS3578
AS3578
AS3581
AS3582
MIL-R-83248
MIL-R-83248/1
MIL-R-83248/2
MIL-P-83461/1
NSA8200
NSA8203
MIL-R-25988
MIL-R-25988
MIL-R-25988
MIL-R-25988
MIL-R-83248/1
MIL-R-83248/1
NAS1593
NAS1594
NAS1595
NAS1596
MA3362
MA3434
MA3442
MA3445
AS28772
AS28775
AS28775
AS28775
AS28778
AS28778
AS29512
AS29513
AS29561
AS33931
MS90064
AS9385
AS9386
AS9966
AS9967
NAS617
NAS1611
NAS1612
NSA8201
NSA8204
NSA8205
NSA8206
Previous Part Number
MA90064-XX
AS3804-XX
AS3085-XXX
AS3208-XX
AS3209-XXX
MS9241-XXX
MS9355-XX
AN123951 THRU AN124050
AN123851 THRU AN123950
MS9020-XX
MS9021-XXX
MS9970-XXX
MS9068-XXX
MS17413-XXX
M83248/1-XXX
M83248/2-XXX
M83461/1-XXX
NSA8200-XXX
NSA8203-XXX
M25988/1-XXX
M25988/2-XXX
M25988/3-XXX
M25988/4-XXX
MS9387-XX
MS9388-XXX
NAS1593-XXX
NAS1594-XXX
NAS1595-XXX
NAS1596-XX
MA3362XXXX
MA3434XXXX
MA3442XXXX
MA3445XXXX
MS28772-XXX
AN6227-XXX
AN6230-XXX
MS28775-XXX
AN6290-XX
MS28778-XX
MS29512-XX
MS29513-XXX
MS29561
MS3393-XX
MS90064-XX
MS9385-XX
MS9386-XXX
MS9966-XX
MS9967-XXX
NAS617-XXX
NAS1611-XXX
NAS1612-XX
NSA8201-X
NSA8204-XXX
NSA8205-XXX
NSA8206-XXX
Material Specification
ZZ-R-765, AMS3302
AMS 7280
AMS 7280
AMS 7276
AMS 7276
AMS 7272
AMS 7272
AMS 7270
AMS 7274
AMS 7271
AMS 7271
AMS 7259
AMS 3304
MIL-R-83248, AMS-R-83248
MIL-R-83248, AMS-R-83248
MIL-R-83248, AMS-R-83248
MIL-P-83461, AMS-P-83461
MIL-R-25988, AMS-R-25988
MIL-R-25988, AMS-R-25988
MIL-R-25988, AMS-R-25988
MIL-R-25988, AMS-R-25988
MIL-R-25988, AMS-R-25988
MIL-R-25988, AMS-R-25988
MIL-R-83248, AMS-R-83248
MIL-R-83248, AMS-R-83248
MIL-R-83248, AMS-R-83248
MIL-R-83248, AMS-R-83248
MIL-R-83248, AMS-R-83248
MIL-R-83248, AMS-R-83248
AMS7276
AMS7273
AMS7267
MIL-R-83485, AMS-R-83485
MIL-P-5516, AMS-P-5516
MIL-P-25732, AMS-P-25732
MIL-P-25732, AMS-P-25732
MIL-P-25732, AMS-P-25732
MIL-P-5510, AMS-P-5510
MIL-P-5510, AMS-P-5510
MIL-P-5315, AMS-P-5315
MIL-P-5315, AMS-P-5315
MIL-R-7362, AMS-R-7362
MIL-P-81716
ZZ-R-765, AMS3304
AMS 7267
AMS 7267
AMS 7273
AMS 7273
MIL-R-7362, AMS-R-7362
NAS1613
NAS1613
NAS1613
NAS1613
AMS 3242
AMS 7267
NAVAIR 01-1A-17
TO 42B2-1-12
015 00
Page 8
Table 2.
O-Rings and Backup Rings for Equipment Applications
O-RINGS
BACKUP RINGS
SAE AS28775
(Formerly AN6227
and AN6230)
NOM
ID
DIM.
T
SPEC
NO.
1/8
5/32
3/16
7/32
1/4
5/16
3/8
3/8
7/16
15/32
1/2
1/2
9/16
9/16
5/8
5/8
11/16
11/16
3/4
3/4
3/4
13/16
13/16
13/16
7/8
7/8
7/8
15/16
15/16
15/16
1
1
1
1-3/64
1-1/16
1-1/16
1-1/8
1-1/8
1-1/8
1-3/16
1-3/16
1-3/16
1-1/4
1-1/4
1-1/4
1-5/16
1-5/16
1-5/16
1-3/8
1-3/8
1-3/8
1-7/16
1-7/16
1-1/2
1-1/2
1-1/2
1-9/16
1-5/8
1-5/8
1-5/8
1-11/16
1-3/4
1-3/4
1/16
1/16
1/16
1/16
1/16
1/16
1/16
3/32
3/32
1/16
1/16
3/32
1/16
3/32
1/16
3/32
1/16
3/32
1/16
3/32
1/8
1/16
3/32
1/8
1/16
3/32
1/8
1/16
3/32
1/8
1/16
3/32
1/8
1/16
3/32
1/8
1/16
3/32
1/8
1/16
3/32
1/8
1/16
3/32
1/8
1/16
3/32
1/8
1/16
3/32
1/8
3/32
1/8
3/32
1/8
3/16
3/32
3/32
1/8
3/16
3/32
3/32
1/8
SAE AS28775-006
SAE AS28775-007
SAE AS28775-008
SAE AS28775-009
SAE AS28775-010
SAE AS28775-011
SAE AS28775-012
SAE AS28775-110
SAE AS28775-111
SAE AS28775-013*
SAE AS28775-014*
SAE AS28775-112
SAE AS28775-015*
SAE AS28775-113
SAE AS28775-016*
SAE AS28775-114
SAE AS28775-017*
SAE AS28775-115
SAE AS28775-018*
SAE AS28775-116
SAE AS28775-210
SAE AS28775-019*
SAE AS28775-117*
SAE AS28775-211
SAE AS28775-020*
SAE AS28775-118*
SAE AS28775-212
SAE AS28775-021*
SAE AS28775-119*
SAE AS28775-213
SAE AS28775-022*
SAE AS28775-120*
SAE AS28775-214
SAE AS28775-023*
SAE AS28775-121*
SAE AS28775-215
SAE AS28775-024*
SAE AS28775-122*
SAE AS28775-216
SAE AS28775-025*
SAE AS28775-123*
SAE AS28775-217
SAE AS28775-026*
SAE AS28775-124*
SAE AS28775-218
SAE AS28775-027*
SAE AS28775-125*
SAE AS28775-219
SAE AS28775-028*
SAE AS28775-126*
SAE AS28775-220
SAE AS28775-127*
SAE AS28775-221
SAE AS28775-128*
SAE AS28775-222
SAE AS28775-325
SAE AS28775-129*
SAE AS28775-130*
SAE AS28775-223*
SAE AS28775-326
SAE AS28775-131*
SAE AS28775-132*
SAE AS28775-224*
SINGLE SPIRAL, SINGLE
SCARF CUT (EXCEPT FOR
THOSE MARKED WITH A (Y),
MADE FROM TEFLON
NOM
ID
DIM.
T
W
9/64
11/64
13/64
15/64
17/64
21/64
25/64
25/64
29/64
29/64
33/64
33/64
37/64
37/64
41/64
41/64
45/64
45/64
49/64
49/64
49/64
53/64
53/64
53/64
57/64
57/64
57/64
61/64
61/64
61/64
1-1/64
1-1/64
1-1/64
1-5/64
1-5/64
1-5/64
1-9/64
1-9/64
1-9/64
1-13/64
1-13/64
1-13/64
1-17/64
1-17/64
1-17/64
1-21/64
1-21/64
1-21/64
1-25/64
1-25/64
1-25/64
1-29/64
1-29/64
1-33/64
1-33/64
1-33/64
1-37/64
1-41/64
1-41/64
1-41/64
1-45/64
1-49/64
1-49/64
3/64
3/64
3/64
3/64
3/64
3/64
3/64
3/64
3/64
3/64
3/64
3/64
3/64
3/64
3/64
3/64
3/64
3/64
3/64
3/64
3/64
3/64
3/64
3/64
3/64
3/64
3/64
3/64
3/64
3/64
3/64
3/64
3/64
3/64
3/64
3/64
3/64
3/64
3/64
3/64
3/64
3/64
3/64
3/64
3/64
3/64
3/64
3/64
3/64
3/64
3/64
3/64
3/64
3/64
3/64
5/64
3/64
3/64
3/64
5/64
3/64
3/64
3/64
3/64
3/64
3/64
3/64
3/64
3/64
3/64
3/32
3/32
3/64
3/64
3/32
3/64
3/32
3/64
3/32
3/64
3/32
3/64
3/32
1/8
3/64
3/32
1/8
3/64
3/32
1/8
3/64
3/32
1/8
3/64
3/32
1/8
3/64
3/32
1/8
3/64
3/32
1/8
3/64
3/32
1/8
3/64
3/32
1/8
3/64
3/32
1/8
3/64
3/32
1/8
3/32
1/8
3/32
1/8
3/16
3/32
3/32
1/8
3/16
3/32
3/32
1/8
DOUBLE SPIRAL,
SINGLE SCARF
CUT, MADE
FROM TEFLON
SPEC
NO.
SAE AS8791-6
SAE AS8791-7
SAE AS8791-8
SAE AS8791-9
SAE AS8791-10
SAE AS8791-11
SAE AS8791-12
SAE AS8791-110
SAE AS8791-111
SAE AS8791-13
SAE AS8791-14
SAE AS8791-112
SAE AS8791-15
SAE AS8791-113
SAE AS8791-16
SAE AS8791-114
SAE AS8791-17
SAE AS8791-115
SAE AS8791-18
SAE AS8791-116
SAE AS8791-210
SAE AS8791-19
SAE AS8791-117
SAE AS8791-211
SAE AS8791-20
SAE AS8791-118
SAE AS8791-212
SAE AS8791-21
SAE AS8791-119
SAE AS8791-213
SAE AS8791-22
SAE AS8791-120
SAE AS8791-214
SAE AS8791-23
SAE AS8791-121
SAE AS8791-215
SAE AS8791-24
SAE AS8791-122
SAE AS8791-216
SAE AS8791-25
SAE AS8791-123
SAE AS8791-217
SAE AS8791-26
SAE AS8791-124
SAE AS8791-218
SAE AS8791-27
SAE AS8791-125
SAE AS8791-219
SAE AS8791-28
SAE AS8791-126
SAE AS8791-220
SAE AS8791-27
SAE AS8791-221
SAE AS8791-128
SAE AS8791-222
SAE AS8791-325
SAE AS8791-129
SAE AS8791-130
SAE AS8791-223
SAE AS8791-326
SAE AS8791-131
SAE AS8791-132
SAE AS8791-224
NOM
ID
DIM.
T
W
1/8
5/32
3/16
7/32
1/4
5/16
3/8
3/8
7/16
3/64
3/64
3/64
3/64
3/64
3/64
3/64
3/64
3/64
3/64
3/64
3/64
3/64
3/64
3/64
3/64
3/32
3/32
SPEC
NO.
MS28782-1
MS28782-2
MS28782-3
MS28782-4
MS28782-5
MS28782-6
MS28782-7
MS28782-8
MS28782-9
1/2
3/64
3/32
MS28782-10
9/16
3/64
3/32
MS28782-11
5/8
3/64
3/32
MS28782/12
11/16
3/64
3/32
MS28782-13
3/4
3/4
3/64
3/64
3/32
1/8
MS28782-14
MS28782-15
13/16
3/64
1/8
MS28782-16
7/8
3/64
1/8
MS28782-17
15/16
3/64
1/8
MS28782-18
1
3/64
1/8
MS28782-19
1-1/16
3/64
1/8
MS28782-20
1-1/8
3/64
1/8
MS28782-21
1-3/16
3/64
1/8
MS28782-22
1-1/4
3/64
1/8
MS28782-23
1-5/16
3/64
1/8
MS28782-24
1-3/8
3/64
1/8
MS28782-25
1-7/16
3/64
1/8
MS28782-26
1-1/2
1-1/2
3/64
1/16
1/8
3/16
MS28782-27
MS28782-28
1-5/8
1-5/8
3/64
1/16
1/8
3/16
MS28783-1
MS28782-29
1-3/4
3/64
1/8
MS28783-2
NAVAIR 01-1A-17
TO 42B2-1-12
015 00
Page 9
Table 2.
O-Rings and Backup Rings for Equipment Applications (Cont)
O-RINGS
BACKUP RINGS
SAE AS28775
(Formerly AN6227
and AN6230)
NOM
ID
DIM.
T
SPEC
NO.
1-3/4
1-13/16
1-7/8
1-7/8
1-7/8
1-15/16
2
2
2
2-3/16
2-1/8
2-1/8
2-1/8
2-3/16
2-1/4
2-1/4
2-1/4
2-5/16
2-3/8
2-3/8
2-3/8
2-7/16
2-1/2
2-1/2
2-1/2
2-9/16
2-5/8
2-5/8
2-5/8
2-11/16
2-3/4
2-3/4
2-3/4
2-3/16
2-7/8
2-7/8
3
3
3-1/8
3-1/8
3-1/4
3-1/4
3-3/8
3-3/8
3-1/2
3-1/2
3-5/8
3-5/8
3-3/4
3-3/4
3-7/8
3-7/8
4
4
4-1/8
4-1/8
4-1/4
4-1/4
4-3/8
4-3/8
4-1/2
4-1/2
4-1/2
4-5/8
4-5/8
4-3/4
4-7/8
3/16
3/32
3/32
1/8
3/16
3/32
3/32
1/8
3/16
3-32
3/32
1/8
3/16
3/32
3/32
1/8
3/16
3/32
3/32
1/8
3/16
3/32
3/32
1/8
3/16
3/32
3/32
1/8
3/16
3/32
3/32
1/8
3/16
3/32
1/8
3/16
1/8
3/16
1/8
3/16
1/8
3/16
1/8
3/16
1/8
3/16
1/8
3/16
1/8
3/16
1/8
3/16
1/8
3/16
1/8
3/16
1/8
3/16
1/8
3/16
1/8
3/16
1/4
1/8
1/4
1/4
1/4
SAE AS28775-327
SAE AS28775-133*
SAE AS28775-134*
SAE AS28775-225*
SAE AS28775-328
SAE AS28775-135*
SAE AS28775-136*
SAE AS28775-226*
SAE AS28775-329
SAE AS28775-137*
SAE AS28775-138
SAE AS28775-227*
SAE AS28775-330
SAE AS28775-139*
SAE AS28775-140*
SAE AS28775-228*
SAE AS28775-331
SAE AS28775-141*
SAE AS28775-142*
SAE AS28775-229*
SAE AS28775-332
SAE AS28775-143*
SAE AS28775-144*
SAE AS28775-230*
SAE AS28775-333
SAE AS28775-145*
SAE AS28775-146*
SAE AS28775-231*
SAE AS28775-334
SAE AS28775-147*
SAE AS28775-148*
SAE AS28775-232
SAE AS28775-335
SAE AS28775-149*
SAE AS28775-233*
SAE AS28775-336
SAE AS28775-234*
SAE AS28775-337
SAE AS28775-235*
SAE AS28775-338
SAE AS28775-236*
SAE AS28775-339
SAE AS28775-237*
SAE AS28775-340
SAE AS28775-238*
SAE AS28775-341
SAE AS28775-239*
SAE AS28775-342
SAE AS28775-240*
SAE AS28775-343
SAE AS28775-241
SAE AS28775-344
SAE AS28775-242*
SAE AS28775-345
SAE AS28775-243*
SAE AS28775-346
SAE AS28775-244*
SAE AS28775-347
SAE AS28775-245*
SAE AS28775-348
SAE AS28775-246*
SAE AS28775-349
SAE AS28775-425
SAE AS28775-247*
SAE AS28775-426
SAE AS28775-427
SAE AS28775-428
SINGLE SPIRAL, SINGLE
SCARF CUT (EXCEPT FOR
THOSE MARKED WITH A (Y),
MADE FROM TEFLON
DOUBLE SPIRAL,
SINGLE SCARF
CUT, MADE
FROM TEFLON
NOM
ID
DIM.
T
W
SPEC
NO.
NOM
ID
DIM.
T
W
SPEC
NO.
1-49/64
1-53/64
1-57/64
1-57/64
1-57/64
1-61/64
2-1/64
2-1/64
2-1/64
2-5/64
2-9/64
2-9/64
2-9/64
2-13/64
2-17/64
2-17/64
2-17/64
2-21/64
2-25/64
2-25/64
2-25/64
2-29/64
2-33/64
2-33/64
2-33/64
2-37/64
2-41/64
2-41/64
2-41/64
2-45/64
2-49/64
2-49/64
2-49/64
2-53/64
2-57/64
2-57/64
3
3-1/64
3-1/8
3-9/64
3-1/4
3-17/64
3-3/8
3-25/64
3-1/2
3-33/64
3-5/8
3-41/8
3-3/4
3-49/64
3-7/8
3-57/64
4
4-1/32
4-1/8
4-5/32
4-1/4
4-9/32
4-3/8
4-13/32
4-1/2
4-17/64
4-35/64
4-5/6
4-43/64
4-51/64
4-59/64
5/64
3/64
3/64
3/64
5/64
3/64
3/64
3/64
5/64
3/64
3/64
3/64
5/64
3/64
3/64
3/64
5/64
3/64
3/64
3/64
5/64
3/64
3/64
3/64
5/64
3/64
3/64
3/64
5/64
3/64
3/64
3/64
5/64
3/64
3/64
5/64
3/64
5/64
3/64
5/64
3/64
5/64
3/64
5/64
3/64
5/64
3/64
5/64
3/64
5/64
3/64
5/64
3/64
5/64
3/64
5/64
3/64
5/64
3/64
5/64
3/64
5/64
7/64
3/64
7/64
7/64
7/64
3/16
3/32
3/32
1/8
3/16
3/32
3/32
1/8
3/16
3/32
3/32
1/8
3/16
3/32
3/32
1/8
3/16
3/32
3/32
1/8
3/16
3/32
3/32
1/8
3/16
3/32
3/32
1/8
3/16
3/32
3/32
1/8
3/16
3/32
1/8
3/16
1/8
3/16
1/8
3/16
1/8
3/16
1/8
3/16
1/8
3/16
1/8
3/64
1/8
3/16
1/8
3/16
1/8
3/16
1/8
3/16
1/8
3/16
1/8
3/16
1/8
3/16
15/64
1/8
15/64
15/64
15/64
SAE AS8791-327
SAE AS8791-133
SAE AS8791-134
SAE AS8791-225
SAE AS8791-328
SAE AS8791-135
SAE AS8791-136
SAE AS8791-226
SAE AS8791-329
SAE AS8791-137
SAE AS8791-138
SAE AS8791-227
SAE AS8791-330
SAE AS8791-139
SAE AS8791-140b
SAE AS8791-228
SAE AS8791-331
SAE AS8791-141b
SAE AS8791-142b
SAE AS8791-229
SAE AS8791-332
SAE AS8791-143b
SAE AS8791-144b
SAE AS8791-230
SAE AS8791-333
SAE AS8791-145b
SAE AS8791-146b
SAE AS8791-231b
SAE AS8791-334
SAE AS8791-147
SAE AS8791-148b
SAE AS8791-232b
SAE AS8791-335
SAE AS8791-149b
SAE AS8791-233
SAE AS8791-336
SAE AS8791-234b
SAE AS8791-337
SAE AS8791-235b
SAE AS8791-338
SAE AS8791-236b
SAE AS8791-339b
SAE AS8791-237b
SAE AS8791-340
SAE AS8791-238b
SAE AS8791-341
SAE AS8791-239b
SAE AS8791-342
SAE AS8791-240b
SAE AS8791-343
SAE AS8791-241b
SAE AS8791-344
SAE AS8791-242b
SAE AS8791-345
SAE AS8791-243b
SAE AS8791-346
SAE AS8791-244b
SAE AS8791-347
SAE AS8791-245b
SAE AS8791-348
SAE AS8791-246b
SAE AS8791-349
SAE AS8791-425
SAE AS8791-247b
SAE AS8791-426
SAE AS8791-427
SAE AS8791-428
1-3/4
1/16
3/16
MS28782-30
1-7/8
1-7/8
3/64
1/16
1/8
3/16
MS28783-3
MS28782-31
2
2
3/64
1/16
1/8
3/16
MS28783-4
MS28783-32
2-1/8
2-1/8
3/64
1/16
1/8
3/16
MS28783-5
MS28782-33
2-1/4
2-1/4
3/64
1/16
1/8
3/16
MS28783-6
MS28782-34
2-3/8
2-3/8
3/64
1/16
1/8
3/16
MS28783-7
MS28782-35
2-1/2
2-1/2
3/64
1/16
1/8
3/16
MS28783-8
MS28782-36
6-5/8
2-5/8
3/64
1/16
1/8
3/16
MS28783-9
MS28782-37
2-3/4
2-3/4
3/64
1/16
1/8
3/16
MS28783-10
MS28782-38
2-7/8
2-7/8
3
3
3-1/8
3-1/8
3-1/4
3-1/4
3-3/8
3-3/8
3-1/2
3-1/2
3-5/8
3-5/8
3-3/4
3-3/4
3-7/8
3-7/8
4
4
4-1/8
4-1/8
4-1/4
4-1/4
4-3/8
4-3/8
4-1/2
4-1/2
4-1/2
4-5/8
4-5/8
4-3/4
4-7/8
3/64
1/16
3/64
1/16
3/64
1/16
3/64
1/16
3/64
1/16
3/64
1/16
3/64
1/16
3/64
1/16
3/64
1/16
3/64
1/16
3/64
1/16
3/64
1/16
3/64
1/16
3/64
1/16
3/32
3/64
3/32
3/32
3/32
1/8
3/16
1/8
3/16
1/8
3/16
1/8
3/16
1/8
3/16
1/8
3/16
1/8
3/16
1/8
3/16
1/8
3/16
1/8
3/16
1/8
3/16
1/8
3/16
1/8
3/16
1/8
3/16
15/64
1/8
15/64
15/64
15/64
MS28783-11
MS28782-39
MS28783-12
MS28782-40
MS28783-13
MS28782-41
MS28783-14
MS28782-42
MS28783-15
MS28782-43
MS28783-16
MS28782-44
MS28783-17
MS28782-45
MS28783-18
MS28783-46
MS28782-19
MS28782-47
MS28783-20
MS28782-48
MS28783-21
MS28782-49
MS28783-22
MS28782-50
MS28783-23
MS28782-51
MS28783-24
MS28782-52
MS28783-25
MS28782-53
MS28782-54
MS28782-55
NAVAIR 01-1A-17
TO 42B2-1-12
015 00
Page 10
Table 2.
O-Rings and Backup Rings for Equipment Applications (Cont)
O-RINGS
BACKUP RINGS
SAE AS28775
(Formerly AN6227
and AN6230)
NOM
ID
DIM.
T
5
5-1/8
5-1/4
5-3/8
5-1/4
5-5/8
5-3/4
5-7/8
6
6-1/4
6-1/2
1/4
1/4
1/4
1/4
1/4
1/4
1/4
1/4
1/4
1/4
1/4
SPEC
NO.
SAE AS28775-429
SAE AS28775-430
SAE AS28775-431
SAE AS28775-432
SAE AS28775-433
SAE AS28775-434
SAE AS28775-435
SAE AS28775-436
SAE AS28775-437
SAE AS28775-438
SAE AS28775-439
SINGLE SPIRAL, SINGLE
SCARF CUT (EXCEPT FOR
THOSE MARKED WITH A (Y),
MADE FROM TEFLON
DOUBLE SPIRAL,
SINGLE SCARF
CUT, MADE
FROM TEFLON
NOM
ID
DIM.
T
W
SPEC
NO.
NOM
ID
DIM.
T
W
5-3/64
5-11/64
5-19/64
5-27/64
5-39/64
5-43/64
5-51/64
5-59/64
6-3/64
6-9/32
6-17/32
7/64
7/64
7/64
7/64
7/64
7/64
7/16
7/16
7/16
7/16
7/16
15/64
15/64
15/64
15/64
15/64
15/64
15/64
15/64
15/64
15/64
15/64
SAE AS8791-429
SAE AS8791-430
SAE AS8791-431
SAE AS8791-432
SAE AS8791-433
SAE AS8791-434
SAE AS8791-435
SAE AS8791-436
SAE AS8791-437
SAE AS8791-438b
SAE AS8791-439b
5
5-1/8
5-1/4
5-3/8
5-1/2
5-5/8
5-3/4
5-7/8
6
6-1/4
6-1/2
3/32
3/32
3/32
3/32
3/32
3/32
3/32
3/32
3/32
3/32
8/32
15/64
15/64
15/64
15/64
15/64
15/64
15/64
15/64
15/64
15/64
15/64
SPEC
NO.
MS28782-56
MS28782-57
MS28782-58
MS28782-59
MS28782-60
MS28782-61
MS28782-62
MS28782-63
MS28782-64
MS28782-65
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
TO 42B2-1-12
015 00
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 Orings 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 identification
notch. The SAE AS5179 (formerly
AN6289) nut has a flat surface on one
side and a retaining groove on the other
side. The retaining groove is designed to
accept Teflon backup ring MS28773.
g. Screw nut toward body until O-ring gently
contacts first threaded area of fitting.
17. Fitting Installation. Install fitting as follows
(Figure 10):
Hydraulic Fluid, MIL-PRF-5606
1
Hydraulic Fluid, MIL-PRF-83282
2
Hydraulic Fluid, MIL-H-81019
3
Hydraulic Fluid, MIL-PRF-87257
4
Hydraulic Fluid, SAE AS1241
5
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.
a. Position nut with retaining groove side facing
mating body.
c. Maintain nut in position with one wrench; use
second wrench to rotate fitting inward not more than
one turn to achieve proper positioning.
b. Screw nut passing seal area to second
threaded area of fitting.
d. System tubing or hose may now be loosely
attached to aid in maintaining alignment.
c. Install Teflon backup ring onto seal area of
fitting.
e. Torque nut SAE AS5179 (formerly AN6289)
with an open crowfoot adapter and standard torque
wrench, while holding fitting with a second wrench.
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.
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
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015009
Figure 9.
Assembly of O-Ring, Teflon Backup Ring, Nut, and Fitting
015010
Figure 10.
Installation of Fitting Assembly
NAVAIR 01-1A-17
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Table 3.
TUBING
O-Rings for Straight Thread Tube Fitting Installations
NOMINAL
DIMENSIONS OF O-RINGS
OD
ID
W
O-RING
SPEC NO.
TEFLON
BACKUP RING
1/8
15/64
1/16
SAE AS28778-2
MS28773-02
3/16
5/16
1/16
SAE AS28778-3
MS28773-03
1/4
11/32
5/64
SAE AS28778-4
MS28773-04
5/16
13/32
5/64
SAE AS28778-5
MS28773-05
3/8
15/32
5/64
SAE AS28778-6
MS28773-06
1/2
21/32
3/32
SAE AS28778-8
MS28773-08
5/8
3/4
3/32
SAE AS28778-10
MS28773-10
3/4
15/16
1/8
SAE AS28778-12
MS28773-12
1-1/4
1-15/32
1/8
SAE AS28778-20
MS28773-20
1-1/2
1-23/32
1/8
SAE AS28778-24
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
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Page 14
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 pressuresensitive, 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.
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.
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-HDBK695 for shelf life of preformed packings.
NOTE
b. Creasing caused by force applied to corners
and edges, and by squeezing between boxes and
storage containers.
Be sure to always check the shelf life and
never install an O-ring that is past its shelf
life.
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,
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
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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 unsealed
resulting in excessive leakage, it must be
replaced with a new O-ring. Unidentified
O-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. Orings shall be rejected for flaws that will affect their
performance.
Hydraulic Fluid, MIL-PRF-5606
1
Hydraulic Fluid, MIL-PRF-83282
2
Hydraulic Fluid, MIL-H-81019
3
Hydraulic Fluid, MIL-PRF-87257
4
Hydraulic Fluid, SAE AS1241
Do not use petrolatum to lubricate O-rings
or 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.
5
NAVAIR 01-1A-17
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Page 16
015012
Figure 12. Typical O-Ring Installation and Removal Tools
NAVAIR 01-1A-17
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Page 17
015013
Figure 13. O-Ring Removal
NAVAIR 01-1A-17
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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 lowpressure 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 lowpressure 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 Orings 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 stored
at 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.
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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
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Page 20
015014
Figure 14. O-Ring Installation
NAVAIR 01-1A-17
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015 00
Page 21
015015
Figure 15. Backup Ring Configuration
RIGHT
WRONG
015016
Figure 16. Location of Single Backup Ring
NAVAIR 01-1A-17
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Page 22
015017
Figure 17. Teflon Backup Ring Installation - External
NAVAIR 01-1A-17
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015 00
Page 23
015018
Figure 18. Teflon Backup Ring - Damages Caused by Improper Handling
NAVAIR 01-1A-17
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Page 24
015019
Figure 19.
Installing Internal Teflon Backup Ring
NAVAIR 01-1A-17
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15 August 2006
016 00
Page 1 of 6
ORGANIZATIONAL, INTERMEDIATE AND
DEPOT MAINTENANCE
PHOSPHATE ESTER HYDRAULIC FLUID
HYDRAULIC SYSTEMS
Reference Material
Cleanliness Requirements of Parts Used in Hydraulic Systems ................................
NAS 1638
Alphabetical Index
Subject
Page No.
Introduction ....................................................................................................................................
Phosphate Ester Fluids and Component Storage .........................................................................
Component Storage...................................................................................................................
Phosphate Ester Fluid Storage..................................................................................................
Using Phosphate Ester Fluid..........................................................................................................
Handling.....................................................................................................................................
Safety Precautions.....................................................................................................................
Phosphate Ester Fluid System Surveillance ..................................................................................
Hydraulic Contamination Analysis .............................................................................................
Record of Applicable Technical Directives
None
2
3
3
3
2
2
2
3
3
NAVAIR 01-1A-17
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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).
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.
Do not store phosphate ester fluid near
hydraulic fluids MIL-PRF-5606, MIL-PRF87257 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.
6. SAFETY PRECAUTIONS. Phosphate ester fluids
are slightly toxic. Applicable Material Safety Data
Sheets (MSDS) shall be reviewed prior to usage.
3. USING PHOSPHATE ESTER FLUID.
Hydraulic Fluid SAE AS1241
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
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.
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.
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
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Page 3
Table 1.
Materials Affected by Phosphate Ester Fluid
MATERIALS
EFFECT
Acrylics
swells and softens
Cellulose Butyrate
plasticizes
Cellulose Nitrate
plasticizes
Hypalon
swells and softens
Polystyrene
dissolves
Polyvinyl Chloride (PVC)
plasticizes
Viton
swells and softens
Vulcaprene
swells and softens
Vulcollan
swells and softens
12. PHOSPHATE
ESTER
COMPONENT STORAGE.
FLUIDS
AND
15. PHOSPHATE
SURVEILLANCE.
ESTER
FLUID
SYSTEM
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.
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.
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
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016 00
Page 4
Table 2.
Materials Resistant to Phosphate Ester Fluid
MATERIALS
DEGREE OF RESISTANCE
Acetal (Delrin or Celcon)
Excellent
Cellulose Triacetate
Good
Chlorinated Polyether
Excellent
Ethylene Propylene
Excellent
Fluorisant
Excellent
Fluorinated Ethylene
Excellent
Formvar
Excellent
Polyamide
Excellent
Polyethylene
Excellent
Polyvinyl Alcohol (PVA)
Excellent
Polyisobutylene
Excellent
Teflon
Excellent
Teflon FEP
Excellent
Phenolic Laminates
Generally unaffected
Alkyds (Dialkyl Phthalate only)
Good
Melamine Formaldehyde
Excellent
Phenol Formaldehyde (phenolics, Micarta,
Formica, etc.)
Excellent
Polyester (Mylar, Dacroneta)
Excellent
NAVAIR 01-1A-17
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Page 5/(6 blank)
Hydraulic Fluid SAE AS1241
5
Dry Cleaning Solvent, MIL-PRF-680
6
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), support
screen gasket P/N XX4004714 (08071),
and O-rings P/N 2-233 EP and P/N 2-210
EP (59871) are recommended for patch
testing phosphate ester fluids. The Teflon
filters should be verified by the customer
to ensure the correct pore size is being
utilized. These Teflon filters will not show
free water. Check for free water by visual
observation of fluid in the sample bottle.
Test filters furnished with Contamination
Analysis Kit 57L414 may be softened by
phosphate ester fluids. The Teflon
gaskets are positioned over the thinner
Teflon filter to provide a better seal.
a. Thoroughly rinse all components used for
processing fluid samples with cleaning solvent MILPRF-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 MILPRF-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.
NAVAIR 01-1A-17
TO 42B2-1-12
15 August 2006
017 00
Page 1 of 16
ORGANIZATIONAL, INTERMEDIATE AND
DEPOT MAINTENANCE
HYDRAULIC FLUID CONTAMINATION ANALYSIS KIT (P/N 57L414)
HYDRAULIC SYSTEMS
NAVY USE ONLY
Reference Material
None
Alphabetical Index
Subject
Page No.
Cleanliness.....................................................................................................................................
Contamination Analysis Procedures ..............................................................................................
Analysis of Test Filter ................................................................................................................
Prepare Filter Holder Assembly.................................................................................................
Sample Processing....................................................................................................................
Description ....................................................................................................................................
Filters .........................................................................................................................................
Filter Holder ...............................................................................................................................
Filter Mounts ..............................................................................................................................
Graduated Cylinder....................................................................................................................
Sample Bottles...........................................................................................................................
Standard ....................................................................................................................................
Syringe and Valve......................................................................................................................
Wash Bottles .............................................................................................................................
Illustrated Parts Breakdown ...........................................................................................................
Introduction ...................................................................................................................................
Kit Component Maintenance..........................................................................................................
Operational Procedures .................................................................................................................
Sample Collection......................................................................................................................
Preparation for Use ........................................................................................................................
Filter Holder ...............................................................................................................................
Flush Bottle ................................................................................................................................
Sample Bottles...........................................................................................................................
Wash Bottles..............................................................................................................................
Record of Applicable Technical Directives
None
9
5
8
5
5
2
2
2
2
2
2
2
2
2
9
2
9
4
4
3
3
3
3
3
NAVAIR 01-1A-17
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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.
9. SAMPLES BOTTLES. Twenty-four, 120-ml
capacity, bottles (Figure 14, Index No. 13), are used
to collect fluid samples.
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.
017001
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 25mm filter.
Figure 1: Hydraulic Fluid Contamination Analysis Kit
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.
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
TO 42B2-1-12
017 00
Page 3
NOTE
Dry Cleaning Solvent, MIL-PRF-680
6
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, MILPRF-680 (WP002 00, Table 3, Item 6), is the only
chemical currently authorized for use in conducting
Hydraulic Fluid Contamination Analysis Test (patch
test).
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.
Dry Cleaning Solvent, MIL-PRF-680
6
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 nonfiltered 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.
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.
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).
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
TO 42B2-1-12
017 00
Page 4
NOTE
Bottles that are not absolutely clean may
cause a hydraulic system to be rejected
needlessly.
017002
Careful attention to the detailed procedures given
below will assure that the effects of external
contaminants are minimized.
Hydraulic Fluid, MIL-PRF-5606
1
Hydraulic Fluid, MIL-PRF-83282
2
Hydraulic Fluid, MIL-H-81019
3
Hydraulic Fluid, MIL-PRF-87257
4
Dry Cleaning Solvent, MIL-PRF-680
6
Figure 2: Attaching Filter to Flush Bottle
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
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).
MIL-PRF-83282
NOTE
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.
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
TO 42B2-1-12
017 00
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.
Dry Cleaning Solvent, MIL-PRF-680
6
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.
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.
017003
Figure 3: Disengaging Filter Holder from Flask
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.
NAVAIR 01-1A-17
TO 42B2-1-12
017 00
Page 6
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.
017004
Figure 4: Attaching Syringe to Filter Holder
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.
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.
017005
Figure 5: Rinsing Inside Wall of Funnel
NAVAIR 01-1A-17
TO 42B2-1-12
017 00
Page 7
017007
017009
Figure 7: Reinstalling Filter Holder
Figure 9: Rinsing Out Graduated Cylinder
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.
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.
017008
017010
Figure 8: Measuring Test Sample
Figure 10: Filtering Sample Fluid
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).
NAVAIR 01-1A-17
TO 42B2-1-12
017 00
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.
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).
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.
017012
Figure 12: Placing Filter in Petri Slide
(5) Let filter membrane dry thoroughly in
still air.
(6) Cover Petri slide.
(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
Figure 11: Remove Test Filter and Support
Screen Gasket
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.
NAVAIR 01-1A-17
TO 42B2-1-12
017 00
Page 9
017013
Figure 13: Comparing Test Filter Contamination
Standards
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.
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
TO 42B2-1-12
017 00
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).
NAVAIR 01-1A-17
TO 42B2-1-12
017 00
Page 11
Table 1: Source, Maintenance, and Recoverability Codes
MAINTENANCE
SOURCE
USE
1
ST
POSITION
A
B
P
K
M
A
X
REPAIR
3rd POSITION
C
CURE-DATED
D
INITIAL
E
END ITEM
GSE/STOCKED
F
GSE/NOT STOCKED
F
ORG/IMA
D
B
DEPOT
BOTH KITS
O
F
H
G
D
ORG
AFLOAT
ASHORE
BOTH
DEPOT
PROCURE
REPAIR
KIT
COMPONENT
2nd POSITION
REPLENISH
INSURANCE
O
REPLACE OR
USE AT
ORG. LEVEL
F
H
G
AFLOAT
ASHORE
BOTH
L
REPLACE OR
USE AT
SPECIALIZED IMA
REPLACE
OR
USE
AT
IMA LEVEL
4th POSITION
Z
NO REPAIR
(CONSUMABLE)
B
RECONDITION
BY ADJUSTMENT,
CALIBRATION,
LUBRICATION PLATING,
ETC.
0
REPAIR
ORG. LEVEL
F
H
G
AFLOAT
ASHORE
BOTH
MANUFACTURE
IMA
D
REPLACE
OR
USE
AT
DEPOT
REPAIR
AT
IMA
LEVEL
S REPAIR AT
(L) SPECIALIZED IMA
ASSEMBLY
A
REQUEST NHA
B
OBTAIN FROM
SALVAGE OR ONE
TIME BUY
MISC.
C
Z
NOT REQD.
THIS APPLIC.
D
REPAIR AT
DEPOT OR
COMMER.
DIAGRAMSSCHEMATICS
INSTALL
DWGS
RECOVERABILITY
5TH POSITION
Z
A
O
H
F
G
S (L)
D
NON-REPAIRABLE, CONDEMN AT LEVEL
INDICATED IN POS. 3
SPECIAL HANDLING FOR DISPOSAL
(CONSUMABLE APPLICATION)
REPAIRABLE ITEM. CONDEMN AT ORG. LEVEL
AFLOAT
ASHORE
BOTH
REPAIRABLE ITEM,
CONDEMN AT IMA LEVEL
REPAIRABLE ITEM,
CONDEMN AT SPECIALIZED IMA
REPAIR AT DEPOT OR COMMERCIAL
NAVAIR 01-1A-17
TO 42B2-1-12
017 00
Page 12
017014
Figure 14: Hydraulic Fluid Contamination Kit (Sheet 1 of 4)
NAVAIR 01-1A-17
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017 00
Page 13
017014
Figure 14: Hydraulic Fluid Contamination Kit (Sheet 2 of 4)
NAVAIR 01-1A-17
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017 00
Page 14
017014
Figure 14: Hydraulic Fluid Contamination Kit (Sheet 3 of 4)
NAVAIR 01-1A-17
TO 42B2-1-12
017 00
PART NUMBER
57L414
1
2
3
4
5
6
7
XX6300120
XX6300121
XX2004707
XX6504708
XX6300123
YY4014267
XX2004703
8
XX2004708
9
10
11
11A
12
13
14
15
16
17
18
XX6300129
XX2004707
XX6504707
SLLS025NS
XX6504704
XX6504709
08-572D
XX6200006
PD1504700
SMWP04700
SMWP02500
19
20
21
22
23
24
25
26
XX6200035
XX6504710
2-006
XX6504713
3074
3075
3076
XX6504712
XX6300123
XX6504704
XX6504709
08-572D
XX6200036
2-116
2-006
27
DESCRIPTION
1234567
HYDRAULIC FLUID CONTAMINATION
ANALYSIS KIT XX6504700/08071/REPAIR KITS
AVAILABLE, INDEX 26 AND 27
. HOLDER, FILTER ASSEMBLY /08071/
. . FUNNEL, STAINLESS STEEL /08071
. . LOCK, WHEEL /08071/
. . SUPPORT, BASE ASSEMBLY /08071/
. . BASE O-RINGS, BUNA-N /08071/
. . SUPPORT O-RING, BUNA-N /08071/
. . SUPPORT SCREEN GASKET TEFLON
/08071/
. . SUPPORT SCREEN STAINLESS STEEL
/08071/
. . FLASK, VACUUM, STAINLESS STEEL /08071/
. . RING, FUNNEL, LOCKING/08071/
. HOLDER, SWINNEX FILTER /08071/
. MILLEX POINT-OF-USE FILTER /08071/
. BOTTLE, WASH (500-ml) /08071/
. BOTTLE, SAMPLE, PLASTIC /08071/
. CYLINDER, GRADUATED (100-ml) /22527/
. FORCEPS, STAINLESS STEEL /08071/
. SLIDES, PETRI /08071/
. FILTER, TEST MEMBRANES (47-mm) /08071/
. FILTER, SOLVENT MEMBRANES (25-mm)
/08071)
. SYRINGE AND VALVE /08071 KIT AVAIL
. . TUBE AND ADAPTER WITH CLAMPS /08071/
. . VALVE O-RING, BUNA-N /02697/
. STANDARDS, CONTAMINATION /08071/
. TOP INSERT /08071/
. BOTTOM INSERT /08071/
. SYRINGE HOLDER /08071/
. KIT, PARTS CONTAMINATION /08071/
. . BASE O-RING BUNA-N /08071/
. . BOTTLE, WASH (500-ml) /08071/
. . BOTTLE, SAMPLE PLASTIC /08071/
. . CYLINDER, GRADUATED /22527/
. . KIT, PARTS VACUUM SYRINGE /08071/
. . . PLUNGER O-RING, BUNA-N /02697/
. . . VALVE O-RING, BUNA-N /02697/
. . . BALL, VALVE STAINLESS STEEL
. . . SPRING, BARREL COMPRESSION VALVE
. . . SEAL, VALVE, TEFLON
. . . SPRING COMPRESSION VALVE
USABLE ON
CODE
INDEX NO.
UNITS PER
ASSEMBLY
Page 15/(16 blank)
SM&R
CODE
REF
PAOGG
1
1
2
1
2
1
1
AGOGG
PAOZZ
PAOZZ
PAOZZ
PAOZZ
PAOZZ
PAOZZ
1
PAOZZ
1
1
1
1
2
24
1
1
1
4
1
PAOZZ
XBOZZ
PAOZZ
PAOZZ
PAOZZ
PAOZZ
22527
PAOZZ
PAOZZ
PAOZZ
PAOZZ
1
1
1
1
1
1
1
1
2
2
24
1
1
1
2
2
2
2
2
PAOZZ
PAOZZ
PAOZZ
PAOZZ
PAOZZ
PAOZZ
PAOZZ
PAOZZ
PAOZZ
PAOZZ
PAOZZ
PAOZZ
PAOZZ
PAOZZ
PAOZZ
017014
Figure 14: Hydraulic Fluid Contamination Kit (Sheet 4 of 4)