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TECHNICAL MANUAL
N68936-04-D-0008
/3
NAVAIR 01-1A-17
TO 42B2-1-12
Change 2 – 1 August 2014 Page A
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 Dispose of superseded work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 Superseded classified work packages/pages shall be destroyed in accordance with applicable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 WP
Number Title Number Title
WP/Page Number Change No. WP/Page Number Change No. WP/Page Number Change No.
IDENTIFICATION NUMBER/
QA SEQUENCE NUMBER LOCATION*
01362-09-0141
WP009 00
01362-09-0173
WP012 00
01362-09-0174
WP015 00
09070-13-0022
WP017 00
09229-13-0026
WP008 00
09774-09-0051
WP004 00
09989-11-0002
WP002 00
44328-10-0081
WP017 00
52814-10-0029
WP017 00
52895-08-0003
WP017 00
55215-14-0015
WP017 00
57105-12-0002
WP004 00
65886-09-6133
WP007 00
65923-10-0224
WP017 00
65923-10-0225
WP009 00
65923-10-0226
WP015 00
65923-10-P116
WP009 00
65923-10-P328
WP016 00
NAVAIR 01-1A-17
TO 42B2-1-12
Change 2 – 1 August 2014 TPDR-2
65923-10-P330
WP016 00
65923-11-0714
WP002 00
65923-11-0715
WP002 00
65923-11-0716
WP002 00
65923-11-0717
WP002 00
65923-11-0718
WP002 00
65923-11-0722
WP002 00, WP006 00, WP009 00
65923-11-0724
WP009 00
65923-11-0725
WP009 00
65923-11-0726
WP009 00
65923-11-0727
WP002 00
65923-11-0728
WP002 00
65923-11-0731
WP002 00
65923-11-0732
WP002 00
65923-11-0733
WP014 00
65923-11-0734
WP014 00
65923-11-0735
WP014 00
65923-11-0744
WP009 00
65923-11-0745
WP005 00
65923-11-0746
WP005 00
65923-11-0747
WP017 00
65923-11-0748
WP017 00
65923-11-0749
WP017 00
65923-11-0751
WP017 00
65923-11-0752
WP017 00
65923-11-0753
WP017 00
NAVAIR 01-1A-17
TO 42B2-1-12
Change 2 – 1 August 2014 TPDR-3
65923-11-0754
WP017 00
65923-11-0758
WP005 00
65923-11-0759
WP017 00
65923-11-0760
WP017 00
65923-11-0761
WP017 00
65923-11-0763
WP017 00
65923-11-0764
WP017 00
65923-11-0765
WP017 00
65923-11-0770
WP009 00
65923-11-0781
WP009 00
65923-11-0782
WP009 00
65923-11-0783
WP014 00
65923-11-0785
WP016 00
65923-11-0786
WP017 00
65923-11-0814
WP005 00
65923-11-0815
WP009 00
65923-11-0816
WP009 00
65923-11-0818
WP012 00
65923-11-0898
WP002 00
65923-11-0899
WP005 00
65923-11-0900
WP005 00
65923-11-0904
WP006 00
65923-11-0908
WP009 00
65923-11-0909
WP009 00
65923-11-0914
WP011 00
65923-11-0917
WP008 00
NAVAIR 01-1A-17
TO 42B2-1-12
Change 2 – 1 August 2014 TPDR-4
65923-11-0930
WP016 00
65923-11-0931
WP016 00
65923-11-0933
WP009 00
65923-11-0934
WP017 00
65923-11-0935
WP017 00
65923-11-0936
WP017 00
65923-11-1099
WP002 00
65923-11-1102
WP009 00
65923-11-1103 WP009 00
65923-11-1147
WP014 00
65923-11-1200
WP014 00
65923-11-1479
WP017 00
65923-12-0374
WP002 00
65923-12-0375
WP004 00
65923-12-0376
WP005 00
65923-12-0384
WP002 00
65923-12-0385
WP009 00
65923-12-0392
WP009 00
65923-12-0393
WP009 00
65923-12-0394
WP009 00
65923-12-0619
WP006 00
65923-12-1392
WP005 00
65923-13-2215
WP002 00, WP 004 00, WP 006 00
*Location-work package (WP), figure no. (F) shall be indicated as appropriate.
NAVAIR 01-1A-17 HMWS-1
TO 42B2-1-12
1 January 2006
Warnings 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.
Chemical
The symbol of drops of a liquid burning a hand shows a material that causes burns to human skin or
tissue.
Cryogenic
The symbol of a hand in a block of ice shows a material is so cold it will burn your skin on contact.
Explosion
The rapidly expanding symbol shows that the material may explode if subjected to high temperature,
sources of ignition, or high pressure.
Eye Protection
The symbol of a person wearing goggles shows a material that can injure your eyes.
NAVAIR 01-1A-17 HMWS-2
TO 42B2-1-12
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 HMWS-3
TO 42B2-1-12
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 HMWS-5
TO 42B2-1-12
12 General Purpose Aircraft Grease, MIL-PRF- Grease, MIL-PRF-32014, may cause skin
32014 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 Do not dispose of test filter patch membranes in
and SMWP02500 ashtrays or other receptacles where the
temperature will exceed 121EC (250EF). Flash
fires occur when filters are exposed to flame
temperature.
14 Dry Cleaning Solvent, A-A-59601 Dry Cleaning Solvent, A-A-59601, may cause eye
and skin irritation. Overexposure may cause
dizziness and other central nervous system effects.
Wear nitrile gloves and chemical splash proof
protective goggles. Consult the applicable Material
Safety Data Sheet (MSDS) and local Occupational
Safety and Health (OSH) regulations for
appropriate safety precautions.
NAVAIR 01-1A-17 001 00
TO 42B2-1-12
15 August 2006 Page 1/(2 Blank)
ALPHABETICAL INDEX
WP
Title Number
INTRODUCTION
office, Navy message, or SALTS to DAAS (Defense voltage supply turned on. Under certain conditions,
Automated Address System), or through the DAAS or dangerous potentials may exist when the power
NAVSUP web sites. For assistance with a MILSTRIP control is in the off position, due to charges retained
requisition, contact the Naval Inventory Control Point by capacitors. To avoid casualties, always remove
(NAVICP) Publications and Forms Customer Service power, discharge, and ground a circuit before
at DSN 442-2626 or (215) 697-2626, Monday through touching it.
Friday, 0700 to 1600 Eastern Time.
22. DO NOT SERVICE OR ADJUST ALONE.
13. MANUAL ISSUE DATE. Under no circumstance shall any person reach into or
enter an enclosure for the purpose of servicing or
14. The date on the title page is the copy freeze adjusting the equipment, except in the presence of
date. No additions, deletions, or changes are made someone who is capable of rendering aid.
after the manual issue date except last minute safety
of flight or required maintenance changes. Data 23. RESUSCITATION. Personnel working with or
collected after the manual issue date will be included near high voltages should be familiar with modern
in later changes or revisions of the manual. methods of resuscitation. Such information may be
obtained from the Bureau of Medicine and Surgery.
15. EFFECTIVITIES.
24. ENGINE NOISE. Personnel must observe the
16. Effectivity notes on manual title pages, work following precautions when working within danger
package title pages, and within a work package areas of jet engines.
indicate the equipment model to which the data
applies. If no effectivity note appears on the work a. Wear the proper protection (earplugs and/or
package title page, the work package has the same earmuffs).
effectivity as shown on the manual title page.
b. Do not exceed the time limits of exposure to
17. QUALITY ASSURANCE PROCEDURES. various sound intensities.
18. Improper performance of certain procedures or c. Have periodic checks on hearing ability.
steps in this manual may cause equipment failure or
The wearing of regulation earplugs or earmuffs will
personnel hazards. Procedures or parts of procedures
raise the time limits of exposure. All personnel
which require quality assurance inspection are
working within danger areas should be familiar with
identified by the letters (QA) after the applicable
calculated sound levels (as specified in the general
steps. When (QA) is assigned to a step or a heading
information section of applicable Maintenance
which is immediately followed by substeps, the
Instruction Manual or Technical Order) and should
inspection requirement is applicable to all substeps.
wear the necessary protection equipment.
Proper performance of the step(s) shall be verified by
a Quality Assurance representative (CDI-CDQAR- 25. FLIGHT LINE SAFETY PRECAUTIONS.
QAR-QA) as established within the Naval Aviation Personnel working in or around aircraft on the flight
Maintenance Program (COMNAVAIRFORINST line shall observe flight line safety precautions and
4790.2 Series) prior to proceeding to the next regulations.
operation, unless it can be determined that such an
inspection can be performed after completing the 26. USE SAFETY SHIELDS. Observe applicable
entire procedure. safety regulations and use safety shields on power
tools where provided. Adequate shielding to protect
19. SAFETY SUMMARY. eyes and face shall be used at all times when
operating power tools or performing pressure tests.
20. The following general safety precautions are not
related to any specific procedure and therefore do not 27. HANDLING FLUIDS AND GASES. Observe
appear elsewhere in this publication. These are applicable safety precautions when using fluids or
precautions that personnel must understand and gases which are flammable or toxic. Do not use gases
apply during all phases of operation and or fluids which are not positively identified.
maintenance.
28. SEAT EJECTION MECHANISMS. Safety 34. For a glossary of terms used in this manual,
refer to Table 2.
precautions shall be strictly observed when
working around aircraft equipped with an
ejection seat. These safety precautions cannot 35. GRAPHIC SYMBOLS FOR FLUID POWER
be overemphasized. Each ejection seat has DIAGRAMS.
several ground safety pins. These safety pins
are provided on red-flagged lanyards for use at NOTE
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 symbols may vary with different
aircraft is ready for flight. The following general manufacturers.
precautions should always be kept in mind.
Table 1. Abbreviations
Abbreviation Definition
ml Milliliter
QA Quality Assurance
SE Support Equipment
TO Technical Order
Table 2. Glossary
Term Definition
Aircraft Sustainment Group Air Force engineering group who provides engineering
assistance to resolve discrepancies noted by the fleet
community.
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).
Controlled Environment Work Center An enclosed workspace, room, or facility in which humidity
and filtered inlet air are controlled.
Term Definition
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.
Fleet Readiness Center (FRC) A Navy activity tasked with and having the capability to
provide depot level maintenance.
Fleet Support Team (FST) NAVAIR engineering group who provides engineering
assistance to resolve discrepancies noted by the fleet
community.
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.
Term Definition
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.
Laminar Flow A flow situation in which fluid (or gas) moves in parallel
layers.
Maintenance Instruction Manual (MIM) A manual containing instructions for intermediate and
organizational level servicing and maintenance of a specific
model of aircraft or equipment.
NAVAIR 01-1A-17 002 00
TO 42B2-1-12
Change 2 – 1 August 2014 Page 9
Term Definition
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.
Manifold An assembly which serves as a fluid conductor having multiple
connection ports.
Milliliter (ml) A metric unit used to define fluid volume. One fluid ounce is
equivalent to 29.6 ml.
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 A NAVAIR TEAM entity responsible for the support of Naval
(NAWCAD) 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.
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.
Term Definition
Term Definition
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.
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 Installed equipment intended for use in shop testing of
hydraulic system components at intermediate and depot
AF-Test Stand, Hydraulic Component maintenance activities.
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.
00200101
Figure 1. Graphic Symbols for Fluid Power Diagrams (Sheet 1 of 6)
NAVAIR 01-1A-17 002 00
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Page 13
00200102
Figure 1. Graphic Symbols for Fluid Power Diagrams (Sheet 2)
NAVAIR 01-1A-17 002 00
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Page 14
00200103
Figure 1. Graphic Symbols for Fluid Power Diagrams (Sheet 3)
NAVAIR 01-1A-17 002 00
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Page 15
00200104
Figure 1. Graphic Symbols for Fluid Power Diagrams (Sheet 4)
NAVAIR 01-1A-17 002 00
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Page 16
00200106
Figure 1. Graphic Symbols for Fluid Power Diagrams (Sheet 6)
NAVAIR 01-1A-17 002 00
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Page 18
Item
No. Nomenclature Specifications Intended Use
HYDRAULIC FLUIDS
SOLVENTS
NOT APPLICABLE TO
NAVY
LUBRICANTS
Item
No. Nomenclature Specifications Intended Use
12 Grease, Aircraft General MIL-PRF-32014 O-rings, bushings, ball and roller bearing
Purpose Wide Temp. Range assemblies, certain splines, areas
subject to corrosion (like landing gear),
compatible with MIL-PRF-81322
14 Wiping Cloth, Ultra Clean, CCC-C-46, Type I Class 7 Refer to WP012 00.
Low Lint (Non-woven) NSN 7920-01-180-0556
for 9' x 9' cloth
NSN 7920-01-180-0557
for 17' x 21' cloth
15 Crocus Cloth UAMA B74.18 (formerly Blending out nicks and scratches on O-
ANSI B74.18 / A-A-1206) ring grooves of filter elements.
GLOVES
CONTAINERS
19 Can, Safety, 5 Gallon UL30 (formerly RR-S-30) Waste container for used hydraulic fluids
and solvents.
Item
No. Nomenclature Specifications Intended Use
20 Bottle Screw Cap, Glass, NSN 8125-00-543-7699 Collect hydraulic fluid samples.
8 ounce Square, Colorless
P/N F70508 (7S566)
21 Bottle Caps, Electronic NSN 5340-01-470-8709 Sample collection bottle caps for
Particle Counter the HIAC sampling unit.
P/N 240480 (15887)
22 Electronic Particle Counter NSN 5340-01-470-8720 Sample collection bottle for the
Safety Coated Bottle HIAC hydraulic sampling unit.
250 ml capacity P/N 219457 (15887)
23 120 ml Safety Coated Glass NSN 4920-01-524-5674 Sample collection bottles for the
Sample Bottles for HACH HACH Ultra Analytics, Hydraulic
Ultra Analytics Hydraulic P/N 2088138-01 (53882) Particle Counter
Particle Counter (PODS)
24 Bottle, Screw Cap, NSN 6640-00-500-0276 Sample collection bottles for the
4 ounce capacity Patch Test Kit.
P/N XX65-047-09 (08071)
25 Kit, Bottle Screw Cap, Glass, NSN 9125-01-477-9105 Collect hydraulic fluid samples
Pre-cleaned, 8 oz., 24 ea
NAS 1638 (superseded by SAE AS4059) Cleanliness Requirements of Parts Used in Hydraulic
Systems
SAE AS4059 (formerly NAS 1638) Contamination Classifications for Hydraulic Fluids
DESCRIPTION
Reference Material
None
Alphabetical Index
None
NAVAIR 01-1A-17 003 00
TO 42B2-1-12
Page 2
1. AIRCRAFT HYDRAULIC SYSTEMS. which the fluid displaced by actuating components is
returned for storage. The reservoir shown in Figure 1
2. GENERAL DESCRIPTION. All modern military is liquid pressurized to ensure a supply of fluid to the
aircraft contain hydraulic systems for operation of pumps at all times. Reservoirs may also be air or gas
various mechanisms. The number of hydraulically pressurized, or simply vented to the atmosphere with
operated units depends upon the model of aircraft. A only gravity or boost pumps to sustain flow, as shown
complete aircraft hydraulic system consists of a power in Figure 2.
system and a number of actuating systems
(subsystems), the exact number dependent upon the 7. Variable displacement axial piston pumps provide
aircraft design. The power system is generally the flow of fluid to the system. Each pump has an
considered to include the fluid supply (reservoir), integral compensator that regulates volume delivery in
power supply (pump), and all other components accordance with system flow demands. The flow from
leading up to, but not including, the selector the pump is ported to a manifold from which lines
(directional control) valves. The selector valves direct branch off to the various actuating systems.
the flow of fluid to the various actuating units, and
each selector valve is considered a part of its related 8. Check valves near the pump pressure ports serve
actuating system. to isolate the pump output from system back pressure
or loss of pressure. They also prevent pressure
3. DETAILED DESCRIPTION. To ensure required supplied from an external hydraulic power source
reliability, current aircraft hydraulic system from attempting to motor the pump (rotating it in
specifications require that two separate systems be reverse), possibly shearing or damaging the pump-to-
available for operating the flight controls. All aircraft engine drive spline. Check valves are also installed in
which utilize hydraulically actuated flight controls have the system return lines to direct the return flow back
at least two hydraulic power systems. One hydraulic to the reservoir and to prevent pressure from acting
system may supply fluid power to the utility system as against the return ports of other system components.
well as to the flight controls. The utility systems
actuate the landing gear, wing fold, wheel brakes, 9. An accumulator is installed in the manifold line to
cargo door, and other such sub-systems. In fighter damp the pump pulsations and maintain smoothness
type aircraft, the systems are generally referred to as of operation. In addition, the accumulator assists the
power control system 1 (PC-1), power control system pumps by providing the system with a limited amount
2 (PC-2), and utility system. In heavy aircraft, such as of fluid flow and pressure during peak system power
tankers, bombers, ant transports, the hydraulic demands. Accumulator servicing is accomplished via
systems are usually numbered according to the the connecting air charge valve. The attached
associated engine driving the system pump. Each pressure gage is used to check the accumulator air
system has its own reservoir, power pump, and lines. charge and to determine the degree of system
pressurization.
4. Aircraft hydraulic systems are designed to produce
and maintain a given pressure over the entire range 10. Filters are installed in both the system pressure
of required fluid flow rates. The pressure utilized in lines and the return lines. The filters shown are of the
most military high performance aircraft is 3,000 psi, bypass type and contain a valve which allows fluid to
although some new aircraft hydraulic systems operate flow through the top of the filter, instead of the filter
at 4,000 - 8,000 psi. element, should the element become loaded. Filters
are also installed in various actuating systems.
5. Figure 1 illustrates a typical fighter type aircraft
utility hydraulic system. In addition to the utility system 11. A system relief valve is installed to protect the
shown, there are two other independent hydraulic system from detrimental pressure surges and limit
systems (not shown) for operation of the flight excessive system pressure buildup by dumping the
controls. All three systems operate at 3,000 psi. fluid to return.
Figure 2 illustrates a typical heavy aircraft hydraulic
system. A description of the power system 12. There are two pressure switches installed in the
components shown and their functions follow. hydraulic system. They are installed in the pressure
lines leading from the pumps and are isolated from
6. The reservoir is the source from which the one another by the check valves. When the pressure
hydraulic pumps draw their supply of fluid, and to from either pump drops below a predetermined value,
NAVAIR 01-1A-17 003 00
TO 42B2-1-12
Page 3
003001
Figure 1. Typical Fighter Hydraulic System
NAVAIR 01-1A-17 003 00
TO 42B2-1-12
Page 4
003002
its pressure switch completes an electrical circuit that in Naval aircraft prior to the introduction of hydraulic
illuminates a warning light in the cockpit. fluid MIL-PRF-83282. Hydraulic fluid MIL-PRF-5606
consists of petroleum products with additive materials
13. Heat exchangers are honeycomb radiators similar to improve viscosity temperature characteristics,
to automobile radiators. Hydraulic fluid returning to inhibit oxidation, and act as an antiwear agent. The
the reservoir is routed through heat exchangers oxidation inhibitor has been included to reduce the
where heat energy is dissipated. amount of oxidation which occurs in petroleum-based
fluids when subjected to high pressure and
14. The hydraulic power system provides fluid under temperature, and to minimize corrosion of metal parts
pressure for those actuating systems indicated in due to such oxidation and resulting acids. This
Figure 1 and 2. The other aircraft hydraulic systems hydraulic fluid is intended for use in hydraulic systems
are similar to the system depicted and provide fluid having a temperature range of -65°F to +275°F (-
under pressure for operation of the flight control 54EC to +135EC). This hydraulic fluid is further
systems and other subsystems. identified by NATO Code H-515 and is dyed red so it
can be distinguished from incompatible fluids.
15. HYDRAULIC FLUIDS USED IN MILITARY Hydraulic fluid MIL-PRF-5606 is compatible with
AIRCRAFT. hydraulic fluid MIL-PRF-87257 (WP002 00, Table 3,
Item 4) and hydraulic fluid MIL-PRF-83282 (WP002
16. Hydraulic fluids in aircraft hydraulic systems are 00, Table 3, Item 2). However, mixing MIL-PRF-5606
primarily used to transmit power, but must perform with MIL-PRF-87257 or MIL-PRF-83282 will reduce
several additional vital functions. A hydraulic fluid their fire resistant properties.
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 Hydraulic Fluid, MIL-PRF-83282 2
acceptable limits.
18. HYDRAULIC FLUID, MILITARY
SPECIFICATION MIL-PRF-83282 (WP002 00,
TABLE 3, ITEM 2). This is the principal hydraulic fluid
now used in military aircraft. This fluid is a fire-
resistant type developed to replace hydraulic fluid
Utmost care must be taken when it is MIL-PRF-5606 (WP002 00, Table 3, Item 1). The fluid
necessary to replace hydraulic fluids in a consists of a synthetic hydrocarbon base and
system. Compatibility and contains additives to provide the required rubber swell
interchangeability such as that present in and anti-wear characteristics, and to inhibit oxidation
the three hydrocarbon based mil-spec and corrosion. It is intended for use in hydraulic
reds (MIL-PRF-5606, MIL-PRF-83282, systems having a temperature range of -40°F to
and MIL-PRF-87257) must be proven +401°F (-40EC to +205EC). Hydraulic fluid MIL-PRF-
and their suitability for each aircraft 83282 is miscible with hydraulic fluid MIL-PRF-5606
tested. Do not mix dissimilar hydraulic (WP002 00, Table 3, Item 1) and hydraulic fluid MIL-
fluids, such as hydrocarbon based with PRF-87257 (WP002 00, Table 3, Item 4) from -40EF
phosphate ester based, in the same to 400EF (-40EC to 200EC). However, the addition of
system. Damage to equipment and MIL-PRF-5606 will reduce the fire resistant properties
aircraft could result. of MIL-PRF-83282.
HYDRAULIC SYSTEMS
Reference Material
Alphabetical Index
Introduction..................................................................................................................................... 2
Measurement of Contamination ..................................................................................................... 4
Electronic Particle Counting....................................................................................................... 4
Patch Testing ............................................................................................................................. 5
Sources and Effects of Contamination........................................................................................... 2
Air Contamination ...................................................................................................................... 4
Fluid Contamination ................................................................................................................... 3
Particulate Contamination .......................................................................................................... 2
None
NAVAIR 01-1A-17 004 00
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Page 2
11. Oil oxidation products are not abrasive, but they 16. Effects of Foreign Fluid Contamination. The
will result in system degradation because the effect of foreign fluids other than water on a hydraulic
resulting sludge or varnish-like materials will collect at system will depend upon the nature of the
close-fitting moving parts, such as the spool and contaminant, and must be ascertained on a case
sleeve on servovalves, causing sluggish valve basis. When determining possible effects,
response. consideration must be given to such factors as
compatibility with materials of construction,
12. FLUID CONTAMINATION. The following compatibility with the system hydraulic fluid, possible
paragraphs provide a discussion of water, solvent, reactions with water, and changes of flammability and
and other foreign fluid contaminations and their viscosity characteristics. The effects of such
effects. contamination may be relatively mild or quite severe,
depending upon the contaminant, the amount in the
13. Free Water Contamination. Free water is a system and how long it has been present.
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
NAVAIR 01-1A-17 004 00
TO 42B2-1-12
Change 2 – 1 August 2014 Page 4
19. Support Equipment improperly used is another 23. ELECTRONIC PARTICLE COUNTING (NAVY
major source of air. An improperly used fill service USE ONLY). Electronic Particle Counters, such as
unit or portable hydraulic test stand can introduce the HACH Ultra Analytic PODS MXU-973E or MXU-
large amounts of air into a system. It is extremely 976E or equivalent, are the required method for
important that hydraulic SE and their service hoses measuring particle contamination to be utilized at all
be properly deaerated prior to aircraft connection. levels of maintenance. Operation of electronic particle
counters shall be in accordance with applicable
20. Effects of Air Contamination. Free or NAVAIR manuals. Operators of the electronic particle
entrained air affects the system in many ways. If the counter must be trained by a NATEC representative
fluid supplied to a pump has a high air content, or a qualified operator. Calibration of this equipment
resulting cavitation can cause severe mechanical is performed by a calibration technician trained by
damage within the pump, and partial or complete loss Naval Air Technical Data and Engineering Service
of output pressure. A temporary pressure loss, in Command (NATEC) or Naval Oil Analysis Program
many of our present systems, because of the (NOAP) NAVAIR technical personnel. The Portable
resulting loss of “bootstrap” pressure, can prevent the Oil Diagnostic System (PODS) particle counter
pump from repriming itself. Air elsewhere in the calibration is performed by HACH Ultra Analytics.
system generally manifests itself in the form of slow Calibration shall be accomplished after any repairs
or erratic actuator movement. Sometimes this is that could affect calibration; whenever there is any
reason to suspect inaccuracy in test results; or at
NAVAIR 01-1A-17 004 00
TO 42B2-1-12
Change 2 – 1 August 2014 Page 5
004001
Figure 1. Graphic Comparison of Particle Sizes
NAVAIR 01-1A-17 004 00
TO 42B2-1-12
Change 2 – 1 August 2014 Page 7
Over 100 1 3 5 11 21 41 92
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.
Table 2: SAE AS4059 (Formerly NAS 1638) Contamination Standards
TO 42B2-1-12
NAVAIR 01-1A-17
Classes
Change 2 – 1 August 2014
Micron
Size 00 0 1 2 3 4 5 6 7 8 9 10 11 12
Range
5-15 125 250 500 1000 2000 4000 8000 16000 32000 64000 128000 256000 512000 1024000
15-25 22 44 89 178 356 712 1425 2850 5700 11400 22800 45600 91200 182400
25-50 4 8 16 32 63 126 253 506 1012 2025 4050 8100 16200 32400
NOTE: No conversion is required for the contamination classifications. For example, SAE AS4059 Class 6 is the same as NAS 1638 Class 6
Page 8
004 00
NAVAIR 01-1A-17 005 00
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HYDRAULIC SYSTEMS
Reference Material
Alphabetical Index
None
NAVAIR 01-1A-17 005 00
TO 42B2-1-12
Page 2
suitable waste receptacle (WP002 00, Table 3, Item fluid under test should be given a careful visual
19). Repeat this operation two times to remove examination for possible free water. Water can be
residual contaminants. Replace cap on bottle. If flow recognized in hydraulic fluid samples in the form of
to sampling point has been terminated, re-open droplets which usually settle to the bottom of the
sampling port. Without interrupting the fluid flow, sample bottle. Allowing the fluid sample to remain
obtain the required sample by replacing the motionless for 10 minutes or longer may facilitate the
uncovered, rinsed, and clean sample bottle under the formation of visible droplets if water is present. Fluid
fluid stream. Once the bottle is filled to the shoulder or samples that are hazy or pink in appearance indicate
fill line, remove it from the fluid stream and terminate the presence of water. Another identical sample bottle
the flow of sample fluid. Install cap on sample bottle filled with a standard of unused fluid can be used for
and affix a tag or label identifying aircraft or comparison. If water is observed, take another
equipment and the specified sampling point. sample from the system to verify the indication and
initiate corrective maintenance (refer to WP006 00).
10. FILTER BOWL CONTENT SAMPLING (NAVY
USE ONLY). Filter bowl residue samples can be NOTE
taken from a filter bowl. Aircraft filter assemblies are
sampled by removing the filter bowl contents of both Contamination analysis using kit P/N
the bowl and the element and transferring the fluid 57L414 not applicable to USAF.
contents to a clean sample bottle. The amount of fluid
obtained will vary with the type of filter assembly. Early models of Contamination Analysis
Kit 57L414 were equipped with semi-
11. Filter Bowl/Element Hydraulic Fluid Samples. transparent sample bottles. With these
Hydraulic fluid samples obtained from filter bowls kits, the examination for water must be
and/or elements are not suitable for determination of performed after the fluid sample is
system contamination levels and shall not be so transferred from the sample bottle to a
employed. Filter bowl/element samples are rendered clear measuring graduated cylinder.
useless in determining the system class level of
contamination as a result of the following conditions:
15. The Contamination Analysis Kit 57L414 (08071),
a. Sedimentation shown in Figure 1, shall be used for testing only if
electronic particle count testing is not available either
b. Functional location directly or via the appropriate supporting Intermediate
Level (I-level) activity or Navy Oil Analysis Program
c. Inability to obtain the required 100 ml of (NOAP) laboratory. The equipment employs a patch
hydraulic fluid to conduct the testing test method in which a fluid sample of known volume
is filtered through a test filter membrane of known
12. Filter Bowl Residue Samples Filter bowl porosity. All particulate matter in excess of a size
residues should be analyzed, using the determined by the filter characteristics is retained on
Contamination Analysis Kit 57L414 (08071) (Figure the surface of the membrane causing it to discolor an
1), for purposes of monitoring hydraulic system amount proportional to the particulate level of the fluid
degradation, suspected impending component failure, sample. (Refer to WP017 00 for operation instructions
or in isolating a cause for continued contaminant and parts breakdown).
generation.
NOTE
13. CONTAMINATION ANALYSIS
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).
005001
Figure 1. Contamination Analysis Kit P/N 57L414 (NAVY USE ONLY)
comparing the test filter with Contamination Do not dispose of test filter patch
Standards representative of known contamination membrane in ashtrays or other
levels, a judgment can be made as to the receptacles where the temperature will
contaminant level of the system. Free water will exceed 250°F (121°C). Flash fires occur
appear either as droplets during the fluid sample when filters are exposed to flame
processing or as a stain on the test filter. temperatures.
NOTE
17. Analyze Test Filter Membrane (Navy Use
Only). After the fluid sample is processed, the Test patches that show a residual pink
resultant test filter membrane (patch) should be color may be the result of failure to have
visually compared with the Contamination Standards. washed the filter adequately. Some new
Determine the particulate contamination level by hydraulic fluids will also exhibit a residual
comparing the shade and color of the test patch with pink background as shown by example in
the Contamination Standards (Figure 2). If the test the Contamination Standards. Green test
patch displays a rust or tan color, use the tan patches have also been produced by
standard patch. If the test patch is gray in color, use elevated amounts of wear copper and in-
the gray standard patch. Follow operating instructions service fluid breakdown in some
contained in the Contamination Standards. Tan systems.
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 a. The maximum acceptable particulate level for
systems containing normal proportions of common Naval aircraft is Navy Standard Class 5, and for
wear materials and external contaminants. The related SE is Navy Standard Class 3.
following procedures provide test patch analysis.
b. Visible free water present in either the
sample bottle or on the surface of the test patch (at
completion of filtration) is cause for rejection of the
NAVAIR 01-1A-17 005 00
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Page 6
005002
Figure 2. Comparing Test Filter with Contamination Standards (NAVY USE ONLY)
system under test. A stain on the test filter d. Filter bowl patch residues should be
membrane may be an indication of the presence of evaluated qualitatively based upon requirements of
free water. When a stain is seen on the test patch, a applicable manuals and utilizing experience relative
second fluid sample from the system under test to normal contaminants for specific aircraft systems
should be obtained and processed so that water and hours of operation. Considerable experience is
content can be confirmed prior to system rejection. required to adequately perform visual evaluation of
Ensure that observed water is not a result of filter bowl residues. Experience has shown analysis
atmospheric condensation during the sampling of main pressure line and case drain filter bowl
process. residue to be useful in verifying failure of
components upstream in these particular
c. Should the system under test fail to meet the assemblies. Residue in other filter assemblies is
Navy Standard Class 5 (or Class 3 for SE) affected by so many other components and factors
particulate requirement, or should it exhibit free as to render their interpretation difficult. Filter bowl
water, the system must be decontaminated in residue should be analyzed only as a means of
accordance with procedures provided in the identifying or verifying suspected component failure.
applicable Maintenance Instruction Manual (MIM). Such utilization shall be limited to examination of
Refer to WP006 00 of this manual for general residue from those filter assemblies directly
information concerning system decontamination. downstream of the component.
any size range render the fluid unsuitable for use in 22. The contents of the log shall include, at a
Navy aircraft. Electronic particle counters shall be minimum, the following sample identifying information
operated and calibrated in accordance with the (see NAVAIR 17-15-521):
appropriate NAVAIR manuals as specified in Table 1.
When calibration is required for the HIAC 8011-3, Squadron/Activity Name
utilize calibration fluids, (WP002 00, Table 3, Item 9) Aircraft Bureau Number
for the applications shown in WP002 00. Contact Serial Number
HACH Ultra Analytics to obtain a Return Authorization Operator
from the company, then pack and send only the Date
PODS particle counter and its power supply in the Time
black storage case for calibration by manufacturer Class
under the service contract.
23. Log book entries shall be maintained for a
NOTE period of three (3) months.
Should the system under test exhibit free 24. Electronic Particle Counter Description. Two
water, the system must be common particle counters are described below. All
decontaminated per the applicable MIM.
units use the principle of light extinction to determine
particle size. Light shines through sample fluid to a
Should the system under test fail to meet
photodetector. As the fluid from the sample flows past
the Navy Standard Class 5 (or Class 3
the photodetector at a constant rate, a particle in the
for support equipment) particulate fluid would block the light and create a shadow that
requirement, resample the system being reduces intensity of light shining on the photodetector.
tested. The system can be re-sampled a
The bigger the shadow, the larger reduction in
maximum of two times and if the second
intensity. The photodetector converts intensity to an
re-sample fails to meet the Navy
electrical impulse whose amplitude is then converted
standard particulate requirements; the to particle sizes. The fluid from the sample is drawn
system must be decontaminated per the past the sensor at a constant flow rate by use of a
applicable MIM.
motor controlled syringe pump. Follow appropriate
procedure in NAVAIR manuals per Table 1.
19. After collecting fluid sample, sample taker shall 25. HIAC/ROYCO Particle Counting System
attach a label to the sample bottle, showing sample 8011-3 (NAVY USE ONLY). The 8011-3 particle
taker’s name, activity, phone number, the name and counter, (Figure 3) consists of three primary
identifying numbers of the aircraft/SE hydraulic components: Model 8000A particle counter, ABS2
system sample, and the date and the time sample Bottle Sampler, and HRLD 400 Laser Diode Sensor.
was collected. Properly labeled samples shall be It is a non-portable bench top laboratory equipment
delivered to supporting I-level or NOAP laboratory for primarily used at I-Level sites or at NOAP
testing. laboratories. Once a sample in a bottle has been
properly prepared, it is placed and sealed in the ABS2
20. In the Organizational Level (O-Level), I-Level, or sample chamber. The chamber is pressurized and the
NOAP laboratory, fluid samples shall be prepared for fluid flows at a constant rate up and out from the
testing, and the particle counts shall be performed in bottle and past the HRLD sensor. The sensor
accordance with NAVAIR instructions and procedures measures the particles in the fluid by shining light
given during operator training. Only personnel with from a laser diode through the fluid and into a
appropriate training shall operate electronic particle photodetector. Particles in the fluid will block the light;
counters or perform sample preparation. thus, less light registers on the photodetector. The
amount of shadow (i.e. decrease in light intensity) on
21. Results of the particle count testing, in terms of the sensor determines the size of the particle. The
contamination class level determined, shall be intensity of the light is converted to an electrical signal
reported back to the activity that submitted the whose amplitude is converted by the Model 8000A
sample, and results along with all the sample particle counter into particle size. As the fluid and
identifying information shall be entered into a log kept particles flow past the sensor, the size and number of
in the testing shop. particles are recorded in the Model 8000A particle
counter which prints the result when enough sample
NAVAIR 01-1A-17 005 00
TO 42B2-1-12
Change 2 – 1 August 2014 Page 8
has been drawn (typically two runs of 50 milliliter (ml) at pressures and temperatures up to 13.8 bar (200
of sample). The sample exits the sensor and ABS2 to psig) and 131°F (55°C), respectively. In bottle
an external waste container. sampling mode, the PODS require a clean dry steady
pressurized air source. The PODS accessory case
26. HACH Ultra Analytics Portable Oil Diagnostic contains both an electric driven compressor and two
System (PODS) (NAVY USE ONLY). The PODS refillable CO2 bottles. The CO2 bottles are quieter and
(Figure 4) is an intelligent, portable, and durable take less space than the compressor.
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 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 analyzed in on-line mode
may return to SE reservoir if SE had a online sample
return and PODS had hose to connect its waste port
to that fitting. There are two versions of the PODS:
Type 1, MXU-973E and Type 2, MXU-976E. Type 1
can analyze MIL-PRF-83282 and MIL-PRF-5606 and
is compatible with most petroleum based fluids. Type
1 is not compatible with phosphate ester based fluids
(e.g. Skydrol). Type 2 is compatible with phosphate
ester based hydraulic fluids, synthetic and petroleum
based fluids. To prevent fluid cross contamination, the
Type 2 PODS is used only for phosphate ester based
hydraulic fluids. The unit is capable of online sampling
Hydraulic Contamination
Analysis Equipment 57L414 (08071) WP017 00 N/A
(“Patch Test”)
005003
005004
Figure 4. Portable Oil Diagnostic System (PODS) Particle Counter (Navy Use Only)
NAVAIR 01-1A-17 006 00
TO 42B2-1-12
15 August 2006 Page 1 of 12
HYDRAULIC SYSTEMS
Reference Material
None
Alphabetical Index
None
NAVAIR 01-1A-17 006 00
TO 42B2-1-12
Page 2
006002
Figure 2. Fluid Purification System
Decontamination
Method Required
Test Method Abnormal Indication (Note 2)
Reservoir Needle Sink Failure per limits as identified in applicable MIM SE Recirculation
2. Fluid purifiers shall be used instead of flushing when purifying equipment is available except for the
following abnormal indications: Oxidation, Viscosity, Flash Point and Neutralization. Fluid purifiers,
when authorized, are recommended for use during aircraft and SE recirculation cleaning.
3. Less than the minimum flashpoint required by the applicable military or performance specification.
NAVAIR 01-1A-17 006 00
TO 42B2-1-12
Change 2 – 1 August 2014 Page 7
reservoirs), where pressure to cycle aircraft exceed the minimum basic steps cited. In instances
components is not required. The purifier return and where an adequate procedure does not exist, the
supply hoses and adapters are used to pump specified minimum requirements shall be employed
hydraulic fluid to and from the aircraft reservoir as an interim minimum guide.
respectively.
006003
Figure 3. Fluid Flow During Decontamination
NAVAIR 01-1A-17 006 00
TO 42B2-1-12
Change 2 – 1 August 2014 Page 10
(1) Drain SE reservoir into an approved i. Continuously monitor all filter differential
waste receptacle (WP002 00, Table 3, Item 19) and pressure indicators on the aircraft or SE and in the
service with new filtered fluid. external hydraulic power source.
(2) Detail and functional diagrams which j. Sample and analyze the system after cycling
illustrate the required equipment configuration should the components. If contaminant level shows
be provided. Refer to Figure 3, View C, for an improvement but is still unacceptable, continue the
example of a functional flow diagram. flushing operation. If no improvement is observed,
attempt to determine the source of contamination and
c. Test stands used for system flushing must be take appropriate corrective action. Should extensive
equipped with 3-micron (absolute) filtration and shall system flushing fail to decontaminate the affected
have an internal reservoir of 16 gal (minimum). The system adequately or if the cause of contamination
stand itself shall be recirculation cleaned before it is cannot be determined, contact the appropriate FST or
connected to the aircraft. ASG immediately.
d. Drain, flush, and service the reservoirs or k. Upon successful completion of system
other fluid storage devices in the contaminated flushing, subject the decontaminated system to the
system prior to system flushing. If contamination is minimum period of recirculation cleaning to eliminate
known to have originated at an aircraft pump, the possible residual debris and to ensure that the system
hoses and lines directly associated with the pump is in an acceptable condition.
output and case drains should be drained and flushed
separately. l. Sample the system subsequent to
recirculation cleaning to verify that contaminant level
e. Install new filter elements in the aircraft and is satisfactory. Repeat the flushing or recirculation
SE prior to initiation of flushing. cleaning operation in accordance with Paragraphs 27
and 30 if an unsatisfactory contaminant condition is
f. External hydraulic test stands shall be set up again detected.
and operated in accordance with requirements of the
specific aircraft and SE MIM or TO on systems being
m. Upon successful completion of system
flushed. Adjust external hydraulic test stand operating
decontamination, service the system as needed to
parameters in accordance with the aircraft or SE
establish proper reservoir fluid level.
specific MIM or TO.
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
Depletion of the external hydraulic power required must be custom-engineered on a case-by-
source reservoir fluid may result in case basis by the appropriate FST or ASG in
cavitation or failure of the test stand consultation with a supporting materials laboratory.
pump.
33. Minimum Requirements for Purging. Due to
g. Monitor the reservoir level in the external the highly specialized nature of any system purging
hydraulic source continuously during the flushing operation, it is not practical to develop definitive
operation. Replenish the reservoir using approved procedures having broad applicability. The following
fluid dispensing equipment before the level decreases compilation of general guidelines is used by the FST
to the half-full point. or ASG in the development of such procedures.
HYRAULIC SYSTEMS
Reference Material
Alphabetical Index
None
NAVAIR 01-1A-17 007 00
TO 42B2-1-12
Change 1 – 1 August 2008 Page 2
i. Seal all hydraulic lines, tubing, hoses, fittings, t. Do not use previously installed or
and components with approved metal closures (refer unidentifiable O-rings.
to WP014 00).
u. Seals or backup rings shall be replaced with
j. Ensure that quick-disconnect dust covers are new items when disturbed.
installed.
Reference Material
None
Alphabetical Index
None
NAVAIR 01-1A-17 008 00
TO 42B2-1-12
Change 2 – 1 August 2014 Page 2
1. INTRODUCTION. NOTE
5. Because of the close tolerance between d. Hydraulic fluid shall not be left in an open
operating parts of equipment used in aircraft hydraulic container any longer than necessary, particularly in
systems and the seriousness of hydraulic fluid dusty environments. Exposed fluid will readily collect
contamination, it is extremely important that contaminants which could jeopardize system
precautions be taken to ensure that foreign matter is performance.
not introduced into the system being serviced. All
servicing must be accomplished by qualified e. With the exception of fluid cans or drums
personnel using authorized fluid dispensing installed in approved dispensing units, open cans of
equipment. hydraulic fluid are prohibited.
6. Hydraulic systems and components shall be fluid f. Hydraulic fluid drained from hydraulic
serviced using equipment and procedures that satisfy equipment or components shall not be reused.
the following requirements. Dispose of drained fluid immediately to prevent
accidental reuse.
NAVAIR 01-1A-17 008 00
TO 42B2-1-12
Change 2 – 1 August 2014 Page 3
g. In the event hydraulic fluid is spilled on other need for investigation. If the filter element is of the
parts of equipment on the aircraft, remove spilled fluid wire mesh type and not available in a timely manner,
using approved wiping materials (see WP012 00). cleaning may be required. Consult applicable MIM,
TO, Fleet Support Team (FST) or Aircraft
7. FILTER SERVICING. Sustainment Group (ASG) for guidance.
8. Replacement of hydraulic filter elements is d. The replacement filter element should not be
normally a maintenance operation performed on a removed from its protective packing until just prior to
periodic basis, but need for prior replacement may be installation. Once removed from packing, the element
indicated during routine inspection. Hydraulic filter must be carefully handled to protect it from
assemblies in some aircraft and Support Equipment contamination and mechanical damage.
(SE) are equipped with indicating devices (“buttons”
or “pins”) which will extend when the differential
pressure across the filter exceeds a predetermined e. The replacement element is installed in
value indicating a loaded element. Upon appearance reverse order of its removal. In most instances the
of this indication, it becomes necessary to verify the element is inserted up into the head, employing a
condition of the filter element and replace it if gentle twisting motion. O-ring seals located in the
required. When checking or changing filter elements, head, or sometimes in the element itself, prevent fluid
check the functioning of any pop-up mechanism (refer from flowing around the element. It is important that
to WP010 00, Paragraph 25). these seals be inspected and replaced in accordance
with the applicable MIM or TO.
9. Loaded filter indicators have protection for both
shock and temperature. Loaded filter indication f. Prior to installation of the cleaned filter bowl,
should result in filter replacement. Additional button the bowl is first filled with new filtered hydraulic fluid to
resets allow continued service with loaded filters. minimize the introduction of air into the hydraulic
Specific aircraft MIM or TO will address button reset, system. It is important that the fluid used for this
as allowed. operation be obtained only from an authorized
hydraulic fill service unit of the type described in
10. It is important that the applicable MIM or TO be Paragraph 6.
consulted for specific filter element replacement
procedures. The following basic principles apply to g. Once filled, the filter bowl is carefully and
most replacement operations: 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.
a. Removal of the filter bowl is the first step in Provisions shall be made to collect or absorb all
replacing the filter element. With most filter spilled fluid.
assemblies, this operation usually consists of
removing a lockwire and unscrewing the bowl from h. The installed filter bowl shall be torqued to
the filter head. In most filter assemblies, an automatic the value specified in the applicable MIM or TO. The
shut-off valve in the head will prevent fluid loss from bowl is then lockwired using standard tools and the
the system when the bowl is removed. lockwire provisions in the filter assembly.
HYDRAULIC SYSTEMS
Reference Material
Breakdown for Hydraulic Purification Unit Model No. HPU-1-5-GH-N-16 ............. NAVAIR 17-15BF-96
Preoperational Checklist Hydraulic Purification Unit (HPU) Model No. HPU-1-5
Part No. 95163-100 ............................................................................................... NAVAIR 17-600-196-6-1
Periodic Maintenance Requirements Manual Hydraulic Purification Unit (HPU)
Model No. HPU-1-5 Part No. 95163-100 ............................................................... NAVAIR 17-600-196-6-2
Operation and Intermediate Maintenance with Illustrated Parts Breakdown,
Hydraulic Fluid Purifier (HFP) A/M 37M-11 Part Number 040505-100 ................. NAVAIR 17-15BF-125
Hydraulic Fluid Purifier A/M37M-11 Part Number 040505-100 ................................. NAVAIR 17-600-BF125-6-1
Periodic Maintenance Requirements Manual Hydraulic Fluid Purifier A/M37M-11
Part Number 040505-100 ...................................................................................... NAVAIR 17-600-BF125-6-2
Alphabetical Index
None
NAVAIR 01-1A-17 009 00
TO 42B2-1-12
Page 4
all times. Surfaces that will come into direct contact a. All hydraulic SE reservoirs shall be sampled,
with working hydraulic fluid shall be cleaned using a preferably at a low point drain, and analyzed for
non-chlorinated cleaning agent and wiping materials particulate content and visually inspected for water.
as specified in WP012 00.
b. Disposable 3-micron pressure line filters,
c. Unused fittings or hose ends shall be because of their large dirt-holding capacity, shall be
protected by suitable metal dust caps or other replaced only upon actuation of their differential
approved closures (WP014 00). Clean polyethylene pressure indicators. Disposable filters not equipped
bags may be used as an interim measure in the with differential pressure indicators shall be replaced
absence of approved metal closures, provided the at the prescribed interval.
bags are adequately secured, protected from physical
damage, and prevent the intrusion of water.
c. Upon completion of periodic maintenance and
d. Equipment not in service shall be stored in repairs that compromised hydraulic system integrity,
clean, dry areas. Exposure of in-service equipment to hydraulic SE shall have a fluid contamination level not
precipitation, wind-driven sand, or other in excess of Navy Standard Class 3.
environmental contaminants shall be minimized to the
greatest extent practicable. 12. FLUID SAMPLING. Sampling points and
procedures will vary with the SE type and model.
10. OPERATIONAL USE. Users of SE shall Specific procedures applicable to the particular
observe the following requirements for operational equipment and consistent with the general
use: requirements of this manual shall be employed
a. Test stands equipped with hydraulic whenever available. In instances where specific
manifolds for self-recirculation cleaning shall be procedures are not available, sampling shall be
operated in this mode prior to any connection to performed in accordance with the sampling
equipment or components under test. The test stand procedures in WP005 00.
shall be recirculation cleaned for a sufficient time to
enable at least one pass of its total reservoir contents NOTE
through the internal filtration.
Decontamination
Method Required
Test Method Abnormal Indication (Note 2)
3. Less than the minimum flashpoint required by the applicable military or performance specification.
NOTE
14. RECIRCULATION CLEANING. Recirculation
Since not all portable hydraulic test stands cleaning is employed when equipment is found to
are designed the same way, see be contaminated beyond acceptable limits (in excess
applicable equipment manual for proper of Navy Standard Class 3) with particulate matter.
recirculation cleaning instructions. With this method, the equipment is self-cleaned using
its internal 3-micron filter elements. The procedures
utilized shall satisfy the following minimum
requirements:
NAVAIR 01-1A-17 009 00
TO 42B2-1-12
Change 2 – 1 August 2014 Page 7
e. Service reservoir.
Hydraulic Fluid, MIL-PRF-5606 1 16. PURGING. Purging of SE hydraulic systems
shall be performed only upon recommendation from,
and under the direct supervision of, the applicable
FST. It shall be the responsibility of the FST to select
the required cleaning agents, provide detailed
Hydraulic Fluid, MIL-PRF-83282 2 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 Fleet
Readiness Center (FRC). Intermediate Maintenance
Hydraulic Fluid, MIL-H-81019 3 Activities (IMA) are not authorized to perform system
purging without direct FRC supervision.
17. FLUID DISPENSING UNIT. and filter. A vent hose is connected between the top
of the reservoir (sight gage) and the upper can
18. Several approved types of fluid dispensing piercer.
equipment are available for use in servicing hydraulic
systems. The equipment, differing primarily in their 22. Fluid is delivered by means of a single-action
fluid-holding capacity, are listed in Table 2. Use of piston type hand pump displacement of 1.5 fluid
fluid servicing equipment other than those listed in ounces per full stroke at 0 to 250 psi. The pump is
Table 2, is not authorized unless specifically approved operated with sliding pump handle which is held in the
for use by the Aircraft Controlling Custodian, the extended or retracted position by a spring-loaded ball
applicable FST, the FRC or the Naval Air Systems detent. A replaceable 3-micron (absolute) disposable
Command (NAVAIR). In all cases ensure that any filter on the pump base removes particulate
equipment so approved is fitted with 3-micron contamination from the hydraulic fluid being delivered
(absolute) filter in the fluid discharge line and that its to the suction side of the pump. The filter unseats a
construction is such that its fluid contents will not be shutoff valve which closes the suction port whenever
exposed to either internally generated or external the filter element is being replaced.
contamination. The use of fluid dispensers that do not
fully satisfy the specific and general contamination 23. The HSU-1 service unit is equipped with a 7-foot
control requirement as stated in this manual is service hose connected to the unit’s fluid output port
prohibited. at the pump assembly. The hose assembly ends with
a short bent-tube assembly for direct connection to fill
19. FLUID SERVICE UNIT, MODEL HSU-1. Fluid fittings on the aircraft or components being serviced.
Service Unit, Model HSU-1 (HSU-1 service unit), A 3-micron inline filter located between the hose end
illustrated in Figure 1, is similar in operation to the and the tube prevents reverse-flow contamination and
Model H-250-1, except that it has a fluid-holding serves as a final filter. When the fluid service unit is
capacity of 3 gallons. Like the H-250-1 servicing unit, not in use, it is stored by wrapping the hose assembly
this unit also accepts a standard 1-gallon container around the can holder assembly and by fastening the
and uses it as a fluid reservoir. In addition, it contains tube end to the hose storage fitting on the base.
an integral 2-gallon reservoir assembly. Three micron
filtration is incorporated to ensure delivery of 24. HYDRAULIC FLUID SERVICING UNIT (HFSU),
contamination-free fluid. MODEL PMU-71/E. The HFSU, P/N 061481-100,
illustrated in Figure 2, is a portable hand carried
20. The integral 2-gallon reservoir assembly is servicing unit for servicing aircraft hydraulic systems
anodized cast aluminum and, along with a hand pump from its nominal 2 gallon capacity reservoir.
assembly, is mounted to a cast aluminum base. The
lower can piercer (Figure 1) is mounted on top of the 25. The HFSU has a black static dissipative
reservoir and allows fluid to flow from the installed 1- polyethylene plastic reservoir housing with red
gallon container into the reservoir, automatically aluminum top plate and red reflective tape both
replenishing it. A sight gage indicates the fluid level of around the base and on the carrying handles of the
the reservoir. It reads from 0 to 2 gallons in 1/4-gallon unit. Reservoir has a clear plastic fluid level sight
increments. An indicated level of 2 gallons or less glass that is marked every half gallon up to 2 gallons.
denotes that the 1-gallon container is empty and can The top mark on the sight glass is 2.25 gallons.
be removed for replacement. A capped deaeration
port is located on top of the reservoir to permit 26. The manual single-acting self-priming piston
bleeding the air from the pump and output hose. pump delivers 3 ounces of fluid per stroke. The
pump has an extendable pump handle that is locked
21. Can holder and handle assemblies are mounted
in operational or storage position by a removable
above the 2-gallon reservoir. The can holder positions
lanyarded pin. Fluid pressure is controlled by both a
the 1-gallon fluid container directly above the
relief and a bleed valve. The relief valve is factory
reservoir and also provides a means of placing the
set to prevent delivery hose pressure from exceeding
handle assembly over the container top. The handle
150 psi in pressure. The manual bleed valve allows
assembly is hinged to a bracket on the can holder
operator to bleed any pressure in the hose back to the
assembly, and is provided with a spring-loaded latch
reservoir. A 0 to160 psi pressure gage monitors fluid
to lock the handle in the closed position. In addition to
pressure in the delivery hose.
the carrying handle itself, the handle assembly
contains an upper can piercer, a vent check valve,
27. The HFSU has a 15 ft wire braided hose encased
within a smooth clear plastic sleeve. A 3-micron
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absolute filter is located near the end of the hose applications where the fluid capacity of the H-250-1
assembly. After filter housing is another 18” of hose servicing unit (1 gallon), PMU-71/E (2 gallons), or
that ends with a -4 flared swivel nut fitting with an HSU-1 (3 gallons) is inadequate. The hand pump is
attached cap. This swivel nut can attach to quick fill used to deliver 3-micron (absolute) filtered fluid.
adapter to lock in hose for storage or for recirculating
fluid in hose back to reservoir to remove air in hose. 32. The mainframe assembly of the fluid service cart
Prongs on the sides of the reservoir housing carrying consists of a two-wheel dolly having a tubular handle
handle hold hose in place during storage or transport. extending outward to enable hand pushing (or pulling)
of the cart. The frame contains an inner bridle which,
28. HFSU is designed to be filled by a Hydraulic Fluid with the cart in its upright position, may be positioned
Bulk Dispensing Unit (HFBDU). The HFBDU is a around and secured to a 10-gallon fluid drum without
specially designed drum pump that fills the HFSU requiring lifting of the drum. Once installed in the
through its quick fill adapter. The HFSU can also be bridle, the drum can be readily moved about using the
filled by cans, by removing the fill cap and pouring in dolly, or tilted back 90 degrees from vertical to the
new fluid with the aid of a funnel. position required for operation.
009001
NAVAIR 17-15BF-90
A/M27T-6 (30003) 5 gal NAVAIR 17-600-156-6-1
NAVAIR 17-600-156-6-2
NAVAIR 17-15BF-89
A/M27T-5 (30003) 20 gal NAVAIR 17-600-127-6-1
A/M27T-5A (30003) (Note 2) NAVAIR 17-600-127-6-2
NAVAIR 17-15BF-110
A/M27T-15 (56529) 25 gal NAVAIR 17-600-BF110-6-1
NAVAIR 17-600-BF110-6-2
NAVAIR 17-15BF-76
A/M27T-3 (30003) 3 gal NAVAIR 17-600-101-6-1
NAVAIR 17-600-101-6-2
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.
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009002
Figure 2. Two Views of Hydraulic Fluid Servicing Unit (HFSU) Model PMU-71E
NOTE
Reservoir Housing color is black with red reflective tape along bottom and sides of
carrying handle. Hydraulic fluid placard has black text on a white background.
009003
Figure 3. Hydraulic Fluid Bulk Dispensing Unit (HFBDU) P/N 061482-101, CAGE 56529
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009004
MODEL POWER
(Note 1) P/N & MFR (CAGE) PUBLICATION MRC TEC FLOW CAPACITY SOURCE
A/M27T-5 68A4-J1000-1 NAVAIR 17-15BF-89 17-600-127-6-1 GGJZ 20 gpm @ 3000 psi Diesel
A/M27T-5A 68A4-J1000-20 17-600-127-6-2 GGJ8 10 gpm @ 5000 psi
Hydraulic International (Note 3)
(30003)
A/M27T-14 Hydraulics International, NAVAIR 17-15BF-120 17-600-BF120-6-1 GGJB 32 gpm @ 3000 psi Electric
040499-100 (56529) 17-600-BF120-6-2 22 gpm @ 5000 psi
A/M27T-15 Hydraulics International, NAVAIR 17-15BF-110 17-600-BF110-6-1 GGJE 32 gpm @ 3000 psi Diesel
040489-100 (56529) 17-600-BF110-6-2 22 gpm @ 5000 psi
PHPSD Hydraulic International AG-140AC-MMB-000 AG-140AC-MRC-100 S7DJ 50 gpm @ 3000 psi Diesel
Diesel P/N: 000850-100 AG-140AC-MRC-200
(56529)
PHPSE Hydraulic International AG-140AB-MMB-000 AG-140AB-MRC-100 S7DJ 32 gpm @ 5000 psi Electric
Electric P/ N: 98612-100 AG-140AB-MRC-200
(56529)
Notes: 1. A/M27T-5/-7 test stands are preferred equipment and shall be used whenever available.
Other equipment may be used if it conforms to configurations as specified in Paragraph 8.
2. All electric motor-driven units operate from 220/440-V, 60-Hz, 3-phase power source except the A/M27T-14 which
operates only on 440-V, 60-Hz, 3-phase power.
3. The A/M27T-5A and A/M27T-7A are upgraded A/M27T-5 and A/M27T-7 for the F/A-18E/F/G
with quick disconnects and flowmeters rated for 5000-PSI operation.
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A/M27T-7
A/M27T- A/M27T-14
7A
A/M27T-5 A/M27T-15
A/M27T-
OPERATING FEATURE A/M27T-3 5A CAPABILITY AFFORDED
Return line back pressure No No Yes Compensates for aircraft reservoir pressurization
regulator effects. Allows test stand reservoir to be used (open
loop) during aircraft test without affecting fluid level
in aircraft reservoir. Backpressure can be used to fill
aircraft reservoir while in one loop mode.
Pressure line shutoff valve Yes No Yes A/M27T-3: Precludes possible reverse flow from
aircraft to stand when closed prior to stand
shutdown.
Reservoir selector valve No Yes Yes Enables use of test stand reservoir when powering
aircraft. Aids in removal of air from aircraft fluid.
De-aeration valve Yes Yes Yes Provides limited fluid air removal during operation
without test stand reservoir. For the A/M27T-14/-15,
this is a manual process vice automatic with the
other test stands.
Oil cooler Yes Yes Yes Enables prolonged closed-loop operation, such as
when recirculation cleaning test stand.
Reservoir fill service No Yes Yes Provides 3-micron (absolute) filtered fluid for system
servicing.
Fluid sampling valves Yes Yes Yes Enables sampling fluid for contamination analysis.
In addition, A/M27T-14/-15 has ports that allow for
online particle counting.
Recirculation Yes Yes Yes Enables recirculation cleaning for test stand and
cleaning/hose storage service hoses and provides hose stowage means.
manifolds
37. PORTABLE HYDRAULIC TEST STAND cannot be operated at the same time
A/M27T-5. Portable Test Hydraulic Stand A/M27T-5 is without depleting the aircraft reservoirs.
a diesel engine driven unit. Figure 5 illustrates a Refer to appropriate manual listed in
typical unit. The test stand is designed to check the Table 3 to obtain detailed operating
performance and operating characteristics of instructions and other information relating
hydraulic systems installed in aircraft. As a portable, to the equipment being operated.
completely self-contained unit, it will perform the
following tests and operations:
39. The A/M27T-5 test stand hydraulic system
(Figure 6) consists of two segments; the fill system
and the high-pressure system. The fill system
provides a capability for servicing the aircraft system
with filtered hydraulic fluid. The high-pressure system
Hydraulic Fluid, MIL-PRF-5606 1
furnishes fluid to the aircraft system for testing
operations under controlled conditions of flow and
pressure.
40. PORTABLE HYDRAULIC TEST STAND
Hydraulic Fluid, MIL-PRF-83282 2 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.
Hydraulic Fluid, MIL-H-81019 3
41. The principles of operation and the operating
procedures for A/M27T-7 test stand are basically the
same as those for the A/M27T-5 test stand, with the
exception of starting and stopping procedures and the
Hydraulic Fluid, MIL-PRF-87257 4 utilization of electrical power to operate this test
stand. Refer to the applicable equipment manual
(Table 3) for operational and maintenance
instructions.
009005
009006
009007
Figure 7. Electrical Hydraulic Power Supply (EHPS), Model A/M 27T-14 (Typical)
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009008
Figure 8. Diesel Hydraulic Power Supply (DHPS), Model A/M 27T-15 (Typical)
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49. PRE-OPERATIONAL INSPECTIONS AND 50. STARTING TEST STAND ENGINE. Start test
PROCEDURES. Perform all required pre-operational stand engine (or motor) in accordance with applicable
inspections and procedures in accordance with operating instructions. Allow engine to warm up to
applicable equipment MRC listed in Table 3. Ensure normal operating temperature.
that the following are included:
51. CLEANING AND DE-AERATING TEST
STAND. Recirculation clean and de-aerate the
hydraulic fluid in the test stand. Perform both
operations concurrently using the following
Hydraulic Fluid, MIL-PRF-5606 1 procedures:
Hydraulic Fluid, SAE AS1241 5 b. If fault indicators light, shut down unit and
return equipment to supporting activity.
a. Check aircraft reservoir level. Aircraft
reservoir should be filled to the level specified in the c. If an emergency arises, e.g. ruptured
applicable MIM or MRC. If necessary, service hydraulic hose in aircraft open the bypass valve to
reservoir using an approved fluid service unit. relieve pressure and stop flow of hydraulic fluid to
aircraft.
b. Set up test stand to provide for either aircraft
or test stand reservoir operation as specified in the d. Stop engine immediately if any engine parts
applicable MIM. Required mode of operation can be fail. Heed warning signs such as a sudden drop in
obtained by use of the reservoir selector valve on engine oil pressure or any unusual engine noise.
stands so equipped (refer to Table 4) or by use of the
reservoir fluid supply valve. Closure of the test stand 54. TEST STAND SHUTDOWN PROCEDURE.
reservoir supply valve will enable aircraft reservoir Upon completion of required aircraft tests, shut down
operation. test stand as follows:
60. GREER HYDRAULIC HOSE TEST STAND. other components. The HCT-10 test stand consists of
Greer Hydraulic Hose Test Stand is shown in Figure a non-portable cabinet assembly containing a
9. This test stand, designed especially for proof- hydraulic system, a pneumatic system, and an
pressure testing of aircraft hose assemblies, is electrical system. Connection is required to externally
capable of developing static pressures up to 30,000 supply electrical power, water, and compressed air.
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.
009010
Figure 10. Hydraulic and Pneumatic Component Test Stand Model HCT-10 (05172)
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63. The cabinet assembly consists of a welded steel 67. HYDRAULIC COMPONENT TEST STAND
enclosure on a rigid base. Hinged doors and A/F27T-10. The A/F27T-10 Hydraulic component test
removable panels provide access to the interior. The stand (HCTS) as show in Figure 11 provides the
test component work area is located below the center hydraulic, electrical and pneumatic power,
instrument and control panel. The bottom surface of instrumentation and controls necessary for bench
the test component work area and the test chamber is testing, diagnostic testing, and functional acceptance
fabricated in the form of a sink with perforated metal of repaired/overhauled components. The HCTS has
trays. The test chamber is fabricated from 1/4-inch two operating modes: automatic (keyboard entry and
steel plate with a hinged door containing a safety measurements with system status displayed on a
window. monitor) and manual (switch panel controls and
measurements with system status read from pressure
64. Most of the hydraulic and pneumatic system gages and flow/temperature display/readouts on
operating controls are located on a sloping panel manual switch panel). The HCTS consists of two non-
along the front of the cabinet. The electrical system portable units: the hydraulic console (HC) and an
controls and indicators are located on a panel on the electrical console (ECC).
right side of the cabinet. A partition separates the
major part of the electrical system components from
68. The HC contains the pneumatic static, hydraulic
the hydraulic system. static and hydraulic test and conditioning circuits. The
65. The hydraulic system is composed of a reservoir hydraulic static provides fluid to the unit under test
supplying fluid through a helical screw-type boost (UUT) for proof pressure testing at pressures up to
pump and a filter to a variable-volume, pressure 16,000 psi. The hydraulic test circuit consists of two
compensated, axial-piston, high-pressure pump. The hydraulic circuits (i.e. Hydraulic Circuit 1 & 2) to
system consists of three circuits as follows: provide UUT under controlled flow (rate and
direction), and temperature conditions. Hydraulic
Circuit 1 is capable of supplying the flows and
a. The dynamic test circuit is used to test
pressures in Table 5 for the A/F27T-10 via test port
double-acting hydraulic cylinders and other
P1 and is capable of developing return (back)
components requiring combined pressure and flow.
pressures of up to 1500 psi in hydraulic fluid leaving
UUT via port P2. Hydraulic Circuit 2 can provide
b. The static test circuit is essentially a same pressures and flows as Hydraulic Circuit 1
compressed-air-operated, low-displacement, high- except that hydraulic fluid flow can be cycled bi-
pressure pump supplying fluid for static pressure directionally via Hydraulic Circuit 2’s ports P3 and P4.
tests. The circuit may be operated independently of The pneumatic static circuit provides the nitrogen gas
the other two test circuits. A safety interlock prevents from the external nitrogen gas bottle for UUT
operation of the circuit when the door of the test pneumatic tests and uses a service air-driven pump
chamber is open. to boost pressure above bottle pressure if required.
c. The pump test circuit is provided to supply The sink area of the HC is where UUTs can be
controlled pressure and flow to a variable- mounted and tested and can be enclosed in the front
displacement, reversible-flow hydraulic motor that, in by four sliding clear removable access panels. Along
turn, supplies power for driving hydraulic pumps the walls of the cabinet area are the ports/connectors
during tests. for hydraulic, pneumatic and electrical panel,
sampling port and pressure gage panel. On front of
66. The pneumatic system is composed of two the HC on the right hand side is a switch panel which
circuits. One circuit provides control, indication, and can be used to operate the stand manually. On the
filtration of externally supplied compressed air for left hand side is a storage cabinet. In addition the HC
operation of the hydraulic fluid temperature control contains the power and control circuits, control circuit
system, operation of the hydraulic static pressure and instrumentation interface.
pump, and the pneumatic static pressure booster.
The second circuit consists of a portable compressed 69. The ECC contains power and control circuits,
nitrogen cylinder supplying gas to a supply port the system central processing unit (CPU), and CPU
through a manually adjusted pressure regulator for peripherals (e.g. computer display monitor, printer,
the purpose of static pneumatic testing. A safety and keyboard). The ECC receives primary input
interlock prevents operation of this circuit when the power from the HC and produces 115 VAC, 60 Hz,
door of the test chamber is open. 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
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and peripheral devices permit the operator to type in cleaning the hydraulic system may not correct the
test parameters to generate and to apply command inability of the SE to filter its own hydraulic fluid.
instructions to various control circuits for Neither of the following purifiers were designed to
implementation vice manually using switches and provide, contain, or receive high pressure fluids. As
buttons to reach test parameters. The Video Display per WP006 00 (Paragraph 29), consult the purifier
Unit (i.e. computer monitor) displays operational operating manual in Table 6 in addition to manuals or
menus, measurements and status information, procedures from the FST for the system requiring
messages and operator’s prompts. decontamination. Table 6 provides a description of
commonly used hydraulic purifiers and references
applicable operating manuals. The following is a brief
description of the equipment for the purpose of
familiarization.
c. Using purifier to decontaminate different 75. HYDRAULIC FLUID PURIFIER (HFP), Model
types of fluid (e.g. MIL-PRF-83282 and MIL-PRF- A/M37M-11. The Hydraulic Fluid Purifier A/M37M-11,
5606) without flushing the purifier between P/N 040505-100, illustrated in Figure 14 can operate
decontamination of different fluid types (fluid cross as either an engine driven or as an electric driven
fluid contamination). (460 VAC) unit to purify contaminated fluid in
A/M27T-14 and A/M27T-15 hydraulic power supplies.
The operator selects whether to run on either diesel
72. Purifiers can clean SE hydraulic fluid in SE or electric power.
contaminated with particulate matter. However,
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009013
009014
Figure 14. Hydraulic Fluid Purifier (HFP), Model A/M37M-11
FLOW
NOMENCLATURE MODEL/CAGE NO. PUBLICATION
CAPACITY
Notes: 1. Flow capacity varies from either 0 or 5 gpm inlet into the purifier and 3 gpm on return.
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HYDRAULIC FILTERS
HYDRAULIC SYSTEMS
Reference Material
Alphabetical Index
Introduction .................................................................................................................................... 2
Types of Filters............................................................................................................................... 2
Differential Pressure Indicators.................................................................................................. 8
Micronic Hydraulic Filter ............................................................................................................ 5
Sintered Bronze Hydraulic Filter ................................................................................................ 5
Support Equipment (SE) Filters ................................................................................................. 5
Woven Wire-Mesh Filter Elements ............................................................................................ 5
5-Micron Noncleanable Filter Elements..................................................................................... 2
None
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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 non-
cleanable, depending upon their construction, and are
marked accordingly.
010003
13. WOVEN WIRE-MESH FILTER ELEMENTS. Figure 3. Cross Section of a Stainless Steel
Hydraulic filter elements employing a stainless steel Hydraulic Filter Element
wire mesh as the filter medium are still used in some
fleet aircraft. Filters of this type are generally rated as 18. SINTERED BRONZE HYDRAULIC FILTER. A
15 or 25 micron (absolute) and can be cleaned and typical sintered bronze hydraulic filter assembly
reused. MIL-F-8815 describes a series of filter consists of three parts: (1) head assembly, (2) filter
assemblies using 15-micron (absolute) elements of bowl, and (3) element. The element is generally rated
this type which, until recently, were specified for use at 25 microns (absolute), but has some removal
in Navy aircraft (Figure 3). capability down to 5 microns. The filter assembly
contains a bypass relief valve and a sintered bronze
14. Wire mesh filter elements should be replaced filter element which can be cleaned. The element
with cleaned and tested elements during required consists of minute bronze balls joined together as one
maintenance inspections. solid piece, but still remaining porous. The joining of
the balls is known as the sintering process.
15. MICRONIC HYDRAULIC FILTER. A typical 19. If the sintered bronze filter element becomes
micronic hydraulic filter is shown in Figure 4. This loaded, the relief valve will open when a
type of filter was designed to remove 99 percent of all predetermined pressure differential exists, allowing
particles 10 to 20 microns in diameter or larger, and the hydraulic fluid to bypass the filter element.
uses a replaceable, non-cleanable element. Micronic
filters were originally procured in the 1950’s in 20. Sintered bronze filter elements should be
accordance with MIL-F-5504 and are no longer replaced with cleaned and tested elements during
specified in new design. required maintenance inspection intervals.
16. The micronic filter assembly contains an integral 21. SUPPORT EQUIPMENT (SE) FILTERS. To
bypass valve to prevent possible element collapse or ensure delivery of contaminant free hydraulic fluid, all
system starvation. If the micronic filter element SE must be provided with 3-micron (absolute) non-
becomes loaded, the bypass valve will open when a bypass filtration in their fluid discharge or output
predetermined pressure differential exists, allowing pressure lines. With many test stands, the filter used
hydraulic fluid to bypass the filter element. for this application, in addition to having a low micron
rating, must be capable of withstanding high collapse
17. The replaceable element is made of specially pressures and holding large amounts of dirt. Filter
treated convolutions (wrinkles) to increase its dirt- assemblies and elements designed specifically for
holding capacity. Micronic hydraulic filter elements this type of service are available from major filter
should be replaced with new filter elements during manufacturers and are presently being used in Navy
specified maintenance inspections. Refer to the SE. Military Specification MIL-PRF-81836 describes
applicable MIM, MRC, or TO for replacement intervals filters of this type which shall be used in future Navy
and procedures. procurement.
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010004
Figure 4. Micronic Hydraulic Filter
22. Those SE filters conforming to MIL-PRF-81836, required number of 10 gal/min elements together, 20
and some older types still in service, utilize only a or 30 gpm cartridges can be locally assembled. All of
single stage consisting of one large non-cleanable the SE filter assemblies discussed are of the non-
filter cartridge (Figure 5). This configuration has been bypass type and are equipped with differential
made possible by improvements in filter elements pressure indicators to warn of a loaded element. The
which permit manufacture of a non-cleanable element differential pressure indicators are, in most cases,
capable of withstanding 5,000 psi differential preset to activate with an element pressure drop of
pressures and displaying negligible shedding of 100 ± 15 psi, which represents approximately 90
media material. Filtration efficiency and dirt-holding percent of the filter’s total dirt-holding capacity.
capacity of the single-stage filter is comparable to that
of the two-stage design and it has the advantage of 24. Unlike most filter elements, 3-micron high-
not requiring second stage element cleaning. pressure SE filters are not normally replaced on a
Noncleanable single-stage elements can be used to prescribed periodic basis. Because of their large dirt-
replace both the primary and secondary elements in holding capacity and nature of service, it has been
most two-stage filter assemblies. Applicable found more effective to replace such elements only
maintenance instructions should be consulted to when indicated as being loaded by their associated
determine filter element requirements and verify differential pressure indicators. Element replacement
interchangeability. procedures vary with the particular type, and
applicable maintenance instructions should be
23. Filter assemblies used in SE vary in physical consulted for specific procedures. In the event that
size according to their maximum flow rating. Common the required procedures are either not available, or
sizes in use are 10, 20, and 30 gpm, with the flow are inadequate, the following basic steps shall be
rating determining the overall length of the elements employed:
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
Hydraulic Fluid, MIL-PRF-5606 1
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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.
Hydraulic Fluid, MIL-PRF-83282 2 Increase system pressure to the maximum normal
operating value and ensure that filter assembly shows
no external leakage.
25. DIFFERENTIAL PRESSURE INDICATORS. lockout prevents the higher differential pressure
The extent to which a filter element is loaded can be generated at cold temperatures by high fluid viscosity,
determined by measuring the drop in hydraulic from causing a false indication of a loaded filter
pressure across the element under rated flow element.
conditions. This drop or “differential pressure”
provides a convenient means of monitoring the 26. Differential pressure indicators are a component
condition of installed filter elements and is the part of the filter assembly in which they are installed
operating principle used in the differential-pressure or and, as such, are normally tested and overhauled as
loaded-filter indicators found on many filter part of the complete assembly. With some model filter
assemblies. Differential pressure indicating devices assemblies, however, it is possible to replace the
have many configurations, including electrical indicator itself, without removal of the filter assembly,
switches, continuous-reading visual indicators if it is suspected of being inoperative or out of
(gages), and visual indicators with memory. Visual calibration. It is important that the external surfaces of
indicators with memory usually take the form of button-type indicators be kept free of dirt or paint to
magnetic or mechanically latched buttons or pins that ensure free movement of the button.
extend when the differential pressure exceeds that
allowed for a serviceable element. The button or pin, 27. Indications of excessive differential pressure,
once extended, remains in that position until manually regardless of the type of indicator employed, shall
reset and provides a permanent (until reset) warning never be disregarded. All such indications must be
of a loaded element. This feature is particularly useful verified and action taken, as required, to replace the
where it is impossible for an operator to continuously loaded filter element. Failure to replace a loaded
monitor the visual indicator, such as in an aircraft. element can result in system starvation, filter element
Some button type indicators have a thermal lockout collapse, or the loss of filtration where bypass type
device incorporated in their design which prevents assemblies are used. Verification of loaded filter
operation of the indicator below a certain indications is particularly important with button-type
temperature. For many newer aircraft, indicators are indicators as they may have been falsely triggered by
designed so that shock vibration and low mechanical shock, vibration, or cold start of the
temperatures do not cause button activation. A system. Verification is usually obtained by manually
loaded filter indication on these aircraft requires resetting the indicator and operating the system to
immediate replacement of the filter element, without create a maximum flow demand, ensuring that the
verification (consult MIM/MRC/TO for guidance). The fluid is at near normal operating temperatures.
NAVAIR 01-1A-17 011 00
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HYDRAULIC SYSTEMS
Reference Material
Alphabetical Index
None
NAVAIR 01-1A-17 011 00
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Page 2
e. The equipment which will be utilized in the a. Walls and ceilings must be rigidly constructed
operation of the center. to reduce generation of contaminants due to
surrounding structure vibration or movement.
f. Ceiling height should not exceed 10 ft.
b. Materials used should have a low coefficient
12. When considering space allocation, include all of expansion.
major items of furnishings, equipment, and
conveniences located in the center. Allow sufficient c. Ceilings should have adequate structural
access space around each item (a minimum of 2 feet rigidity to support the installation of lights.
on each side of a bench which does not butt against a
wall or another bench). Fixed test stands, if housed in d. Walls should contain a vapor barrier.
the controlled environment, should be partitioned off.
A typical controlled environment work center is shown e. Materials used in the walls and ceilings
in Figure 1. should be made of non-chalking, low-shedding
materials.
13. WORK CENTER ENVIRONMENT. The work f. Surfaces facing into the work center must be
center environment should conform to the following: sealed, glossy, and washable. For most applications,
one coat of a good grade chromate primer and two
a. The temperature of the controlled coats of hard gloss enamel or epoxy paint is
environment work center should be 70°F ± 5°F (21°C adequate to allow ease of cleaning. White is the
± 2.9°C). preferred color. Assure that the fire rating of all
materials meets local codes.
b. The relative humidity should be controlled
between 35 to 50 percent. g. All junctures and joints must be sealed. If an
existing room with windows is used, the windows
c. Inlet air to the center should be filtered should be sealed closed. Internal surfaces should be
through an 85 percent efficient 15-micron filter (class made flush with the inside wall so as to minimize
300,000 minimum). Inlets should be of sufficient ledges or offsets.
design to allow for even air distribution.
h. Floors should be capable of supporting
d. The allowable audio noise level should meet anticipated loads without deflection. Masonry or wood
MIL-STD-1472 requirements of 75 dB(A) for general floors should be covered with low-shedding materials
workspaces and maintenance shops and 80 dB(A) for installed in such a manner as to eliminate cracks or
shipboard maintenance shops, openings. Masonry floors sealed with vinyl or plastic
paints are acceptable. Should vinyl tiles be used,
e. Vibration should be limited as much as assure that the adhesive will not lose its bonding after
possible. repeated hydraulic fluid soaks.
f. Uniform, shadowless lighting at intensity i. Entry ways should be sufficiently wide to allow
levels of 1076 to 1625 lux at the work bench level. easy passage of personnel and components. Doors
should be flush to the inner wall surface. Standard
g. A positive pressure differential equivalent to pressure door closers with an enclosed mechanism
0.05 inches of water shall exist between the center are required to assure the doors will be closed. All
and any adjacent area. When entryways are open, door edges, frames, and sills should be equipped with
the blower capacity should be adequate to maintain a continuous seal. Fire emergency exits should be
an outward flow of air. installed as local codes require.
011001
Figure 1. Typical Controlled Environment Control Work Center
NAVAIR 01-1A-17 011 00
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fabrication of a controlled environment work center c. For most uses, plasterboard or lathe and
inside existing facilities: plaster is sufficient. Internal walls and partitions shall
be of a non-flaking material. Stainless steel and
a. Clean the area of furniture and equipment plastic Mylar laminate (formica, marlite) are examples
which do not meet the criteria specified herein. of materials which can be used for this purpose. Dry
wall may be used, but will require adequate sealing
b. Partitions for test stands and administrative by painting.
areas shall be installed.
d. Ceilings shall be of rigid construction. The
c. All public works functions should be ceiling surface shall be washable. Materials used may
performed: be the same as used for internal walls. If drop ceilings
are used, the ceiling panels shall be non-flaking, such
(1) Electrical service wiring as destaticized vinyl plastic and shall be sealed to
reduce air leakage and dust filtration.
(2) Water line installation
e. All public works functions shall be performed.
(3) Air line installation
Refer to Paragraph 16, step c.
(4) Telephone installation
f. Lighting fixtures shall be flush-mounted to the
All services shall be installed directly through the ceiling and sealed to prevent dust filtration. Light
walls of the center or in the subsurface troughs when panels may be either clear or translucent panels.
possible. Electrical outlets shall be provided with stainless steel
faceplates with neoprene gasketing. All electrical
d. Electrical and plumbing fixtures shall be boxes shall be sealed on the inside. Valves and
installed or replaced as required. Lighting fixtures regulators shall be stainless steel and bulkhead fitted
shall be recessed. All electrical boxes shall be sealed on service plates where possible.
on the inside. Electrical outlets shall be sealed using
smooth faceplates and neoprene gasketing. Valves g. Walls, ceiling, door frames, windows, floors,
and regulators shall be bulkhead fitted on smooth and entryways shall be sealed and conform to the
service plates. requirements outlined in Paragraph 14.
e. Walls, ceilings, door frames, and windows h. Air conditioning shall be provided by a
shall be sealed. Mastic compounds in moderate recirculating system. Ventilating air for personnel shall
3
quantities may be used. be provided at a rate not less than 15 ft /person. The
overall air exchange rate shall not be less than 500
3
f. Walls and ceiling shall be washed and painted ft /min/ton of refrigeration. Discharge vents shall be
3
as described in Paragraph 15, step f, to provide a designed for no greater than 500 ft /min air flow. Air
smooth, dust resistant surface. Vinyl covering shall be shall be supplied through a 15-micron 85 percent
installed along the wall base for ease of cleaning. efficient filter. Inlets shall provide even distribution.
This may be accomplished by using several louvered
g. Flooring shall be cleaned and repaired or ceiling diffusers. Return vents shall be located at or
replaced. Requirements are identified in Paragraph near floor level.
15, step h.
18. Furnishings. Furnishings shall be made of non-
17. NEW FACILITIES. In order to fabricate a new flaking material which is easily cleanable.
controlled environment work center, attention must be
given to the following design requirements: 19. Bench tops may be made of stainless steel or
other non-flaking surface such as plastic Melamar
a. For ease of installation, modular construction laminate. The bench tops shall have a 1/4- to 1/2-inch
shall be used. Panels shall be interlocking. Each bevel along the edges to prevent chipping of squared
panel shall have a vapor barrier and be insulated for edges. Stools or chairs without arms shall be used
close temperature and humidity control. and made of either steel with baked enamel finish or
vinyl plastic covered construction. Stools and
b. External walls may be of any durable material benches shall have plastic glides.
which is compatible with the activities performed in
adjacent areas and the materials available. 20. Desks, storage and file cabinets within the
controlled area should be discouraged as they
NAVAIR 01-1A-17 011 00
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become pockets for contamination collection. j. Lighting: Fluorescent fixture to provide 1076
Manuals, however, are essential to the functions lux at normal bench height.
performed in the center. They may be kept within the
controlled center in closed cabinets. Such cabinets k. Electrical connectors: Three prong, ground
shall be steel or baked enamel finishes or laminated type rubber covered plug and cord for 115-V 60-Hz
materials. Hinged doors, not sliding panels, are operations. Other models may have magnetic motor
preferred. Components, fittings, tools, and starters for operation on 220/440-V 60-Hz 3-phase
accessories essential to the functions performed in power. All lights wired for 115-V 60-Hz power with
the center shall be stored in closed cabinets. separate switches.
21. Equipment. Most contamination-critical l. Casters: heavy duty, wheel type, with safety
component assembly work conducted in intermediate brakes.
maintenance activities can be done using mobile
modules (Figure 1). These mobile modules are 22. Suitable hygienic eye wash facilities shall be
convenient and economical. These provide Vertical supplied. A minimum of two squeeze bottle type
Laminar Flow Clean Air anywhere they are placed. emergency eye wash stations shall be installed. A
Zippered plastic curtains permit mating of units to preferred eye wash station is full-face-drench twin
create large protected areas. Modules are on rubber spray head, eye and face wash with automatic
tired casters for easy moving. Once positioned, wheel pressure and volume control. Emergency eye wash
brakes hold the module in place. They are station squeeze bottles are available.
commercially available and come in sizes ranging
23. A battery operated, automatic switching
from 4 ft by 4 ft to 6 ft by 8 ft. Size selection depends
emergency light system should be provided in the
on criteria outlined in Paragraphs 8 through 11. (Refer
center to eliminate hazards due to power failure.
to Aircraft Maintenance Material Readiness List
(AMMRL) source data.) The following suggested 24. A minimum of two stored-pressure dry-chemical
design requirements shall be applied when procuring extinguishers for Class B and C fires shall be
clean workstation mobile modules: provided in the center.
a. Air Flow: should meet the requirements of 25. Trash receptacles shall be located at strategic
3
ISO 14644-1 and 14644-2 100-ft3/min ± 10 ft /min at spots throughout the work center. Receptacles should
static pressures 0.5W.G. to 1.3W.G. Class 100 air. be made of plastic for ease of cleaning and shall have
self-closing lids (spring loaded or gravity-closure
b. Pre-filter: Washable polyurethane foam. type). Waste oil and oily rags shall be stored in
accordance with local command, base, or state
c. Final filter: HEPA Type 99.97 percent efficient Environmental Protection Agency regulations.
on particulate 0.3 microns and larger.
26. A first aid kit shall be provided even if the center
d. Noise Level: Less than 65 dB(A) at operator’s is located close to a dispensary or medical station.
level with 48 dB(A) ambient.
27. CONTROLLED ENVIRONMENT WORK
e. Blowers: Belt driven statically and CENTER OPERATING PROCEDURES.
dynamically balanced, with adjustable pulley for
controlling the rate of airflow. 28. OPERATING REGULATIONS. Detailed
regulations for operation of the controlled center shall
f. Motor: Continuous duty with sealed-for-life be established by the user activity. To aid in the
bearings and built in thermal overload. establishment of these regulations, the following
suggestions are offered:
g. Color: White.
a. No special garment need be worn. However,
h. Finish: Polyurethane paint. personal clothing which tends to produce a great deal
of lint, such as sweaters and cotton or flannel shirts
i. Curtains: 12-mil clear polyvinyl chloride shall not be worn in the center.
(PVC), zippered at each corner to permit instant
closure or opening. Zippered tracks are usually b. Eating and smoking shall be prohibited in the
interchangeable so curtains on one unit may be center.
mated to another module.
c. Jewelry shall be removed and placed in side
pockets. Personal property normally carried in
NAVAIR 01-1A-17 011 00
TO 42B2-1-12
Change 2 – 1 August 2014 Page 7
a. Data sheets, log books, and manuals may be Detergent, Non-Ionic, MIL-D-16791 8
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.
a. Servo Valves
HYDRAULIC SYSTEMS
Reference Material
None
Alphabetical Index
None
NAVAIR 01-1A-17 012 00
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Page 2
SOLVENT EFFECTIVE CLEANING TOXICITY FLASH POINT K-B ADVANTAGES DISADVANTAGES SAFETY RECOMMENDED
IN REMOVING METHODS VALUE PRECAUTIONS APPLICATIONS
Change 2 – 1 August 2014
Dry Cleaning Oils, fats, Dip, slosh, High TLV = Type II: 140°F 34 Economical, good Flammable Use with full Cleaning of
Solvent greases, waxes, spray, brush, 100 ppm (60°C) chemical stability. Moderately toxic ventilation. Avoid surfaces coming
MIL-PRF-680 heavy dirt flush, or wipe. Effective for gross excessive into direct
Type II / III deposits. cleaning application. inhalation. Do contact with
Not chlorinated. not use near hot system fluid,
surfaces or open such as interior
Type III: 200°F flame. of hydraulic
(93°C) reservoirs,
filters, bowls,
etc. General
cleaning of all
hydraulic
components.
Dry Cleaning Oil, fat, grease, Dip, slosh, High TLV = 140°F (60°C) 29 to 45 Economical, good Flammable Use with full Cleaning of
Solvent PD680 wax, heavy dirt spray, brush, 100ppm chemical stability. Moderately toxic ventilation. surfaces coming
(Procured under deposits flush, or wipe Effective for gross Avoid excessive into direct
Specification A-A- cleaning application. inhalation. Do contact with
59601) Not chlorinated. not use near hot system fluid,
surfaces or open such as interior
AIR FORCE flames. of hydraulic
ONLY reservoirs, filter
bowls, etc.
General
gleaning of all
hydraulic
components.
USAF and Navy: Oils, organic Dip, slosh, Low TLV = MIL-PRF-5606: 180°F Not Readily available. Flammable. Not very Do not use near As a substitute
Hydraulic Fluids matter, light spray, brush, not known (82°C) known Compatible with effective as a hot surfaces or for MIL-PRF-680
MIL-PRF-5606 deposits of flush, or wipe. materials used in cleaning solvent. open flame. or A-A-59601
MIL-PRF-83282 general dust or MIL-PRF-83282: hydraulic components. Avoid excessive (PD680) when
dirt. 400°F (204°C) Not chlorinated. skin contact. cleaning
USAF Only: MIL-PRF-5606 is not surfaces which
MIL-PRF-87257 MIL-PRF-87257: fire resistant. MIL- come into direct
350°F (175°C) PRF-83282 and MIL- contact with
(Not solvents but PRF-87257 are fire system fluid.
sometimes resistant.
employed as
cleaning agents)
Page 3
012 00
NAVAIR 01-1A-17 012 00
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13. In determining flash point, the fluid vapors are surfaces of system components that may come into
kept relatively confined and exposed directly to a contact with the hydraulic fluid. If such cleaning
source of ignition. As a result of this test method, the agents must be employed, ensure that all surfaces
measured flash point actually represents the lowest are dry and free of any traces of residual solvent prior
temperature, in a worst case situation, under which to installation or assembly. Clean, unused hydraulic
combustion can occur momentarily. In order for a fluid fluid, dry cleaning solvent MIL-PRF-680 (WP002 00,
to burn continuously, or to ignite spontaneously Table 3, Item 6) or A-A-59601 (Air Force Only)
without external ignition, it is necessary that the fluid (WP002 00, Table 3, Item 7) is recommended for
be raised to a temperature that is higher than its rated those cleaning applications where solvent
flash point. These temperatures are the fire point and contamination may be a problem.
autoignition point, respectively, and in effect describe
the safe operating temperature limits more 19. SOLVENT SELECTION.
realistically.
20. Numerous solvents suitable for use as cleaning
14. FIRE POINT. The fire point is the lowest agents are available in the supply system. To
temperature at which a volatile combustible determine which solvent is best suited for a particular
substance will burn continuously in air once its vapors task, it is necessary to compare all characteristics of
have been ignited. This value is also indicative of the the solvents with the detail requirements of the
relative flammability of a solvent and is a temperature specific cleaning operation. Important factors to be
higher than that of the flash point. The fire point is considered include materials to be cleaned, nature of
determined by continuing the flash point test until a substances to be removed, cleaning methods to be
temperature that will support continuous combustion used, work environment, and personnel safety
is reached. requirements. Table 1 outlines the important
characteristics of commonly available solvents and
15. AUTOIGNITION POINT. The autoignition point should be referred to when selecting a solvent.
is the lowest temperature at which a combustible
substance, when heated, will self-ignite in air and
21. SAFETY PRECAUTIONS AND FIRST AID.
continue to burn. No external spark or flame is
applied and combustion results solely from the
temperature rise in the substance. The autoignition 22. The following safety rules should be made
point is also indicative of the flammability of a solvent available to and observed by all personnel involved in
and is always a higher temperature than either the the use or storage of cleaning agents:
flash or fire point.
a. Provide adequate ventilation.
16. SOLVENT CONTAMINATION.
b. Always store new or used solvents in clearly
17. When inadvertently introduced into an operating labeled containers.
hydraulic system, certain cleaning agents can
produce severe corrosion of internal metallic
c. Provide eye flooding and shower facilities as
surfaces. The cleaning agent in such instances
needed.
represents an incompatible foreign substance in the
system and as such is considered a contaminant.
d. Keep containers sealed when not in use.
i. Use protective devices such as cover or cup- 29. A-A-59323, Type I (WP002 00, Table 3, Item
type goggles, face shields, solvent resistant gloves, 13A), lint-free synthetic wiping cloths are pre-cleaned
and other protective clothing, as required. to a very low particulate level and supplied in sealed
10 pound bags. Type I wiping cloths are certified
23. Table 2 presents a general first aid treatment ultra-clean and are to be used exclusively in clean
guide for overexposure to cleaning solvents. It is rooms and controlled work areas during component
recommended that more specific first aid procedures rework, repair, and test.
be prepared and that they be posted in the immediate
work area for each type of solvent used.
30. A-A-59323, Type II (WP002 00, Table 3, Item
24. WIPING MATERIALS. 13B) wiping cloths have the same lint-free features as
Type I. However, they are not pre-cleaned to a high
25. Wiping materials are commonly used during cleanliness standard. This material is to be used for
hydraulic system maintenance to wipe down or to dry general wipe down of hydraulic components, such as
exposed surfaces of hydraulic components and struts and actuators, in place of conventional baled
associated airframe assemblies. Several types of rags. Type II wiping cloths are also supplied in 10
wiping materials which differ considerably as to the pound bags.
basic material and characteristics are presently in
common use in the fleet. Improper utilization of wiping 31. The synthetic wiping materials described should
materials can constitute, and has proven to be, a not be used for wiping down large plastic areas, or
source of hydraulic system contamination. It is used with volatile solvents having flash points less
important, therefore, that maintenance personnel be than 100°F (38°C), due to possibility of developing
familiar with the available materials and their proper dangerous static charges. Cotton flannel or
application. cheesecloth should be used for these applications.
The synthetic wiping materials are ideally suited for
26. Wiping materials suitable for use in hydraulic most hydraulic maintenance operations. They should
system maintenance include rags and towels made of be employed, whenever possible, to minimize
natural or synthetic fibers. These materials are contamination.
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 32. RECOMMENDED WIPING CLOTHS. Table 3
determined by the following considerations: (1) provides information on specific disposable wiping
substances being wiped or absorbed, (2) the amount cloths recommended for use in hydraulic system
of absorbency required, and (3) the required degree maintenance. The table should be referred to and
of cleanliness. For purposes of contamination control, utilized as a guide when selecting wiping cloths for
it is convenient to categorize available wiping specific applications.
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.
TYPE OF
CONTACT SYMPTOMS TREATMENT
Inhalation Anesthetic or narcotic effect. Varies from Remove to fresh air and obtain immediate
irritation of nose and throat to dullness, medical attention. Administer artificial
dizziness, headache, stupor, nausea, respiration if breathing has stopped. Keep
vomiting, and unconsciousness. (Death in patient warm and quiet.
severe exposures.)
External contact: Burning sensation, dermatitis. Remove any soaked clothing. Wash
skin 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 Obtain immediate medical attention.
or unconsciousness.
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Change 1 – 1 August 2008 Page 7/(8 Blank)
CCC-C-46 Low Lint Wiping cloth, non- Wipe-down and drying of Very low lint; ultra
Class 7 woven fabric critical surfaces having clean, high wetted
Number 9404 high cleanliness strength, good
Duralace requirements. absorbency.
A-A-59323 Low Lint Bagged cloth wipers, Use for general wipe- Low lint and other
(Type II) See synthetic fiber down of hydraulic particulate. Poor water
Caution components such as absorbency.
struts and actuators.
A-A-59323 Very Low Bagged cloth wipers, For use in clean rooms Very low lint and other
(Type I) See Lint synthetic fiber, certified and controlled work areas particulate. Pre-
Caution clean during component cleaned to a very low
rework, repair, and test. particulate level. Poor
Wipe-down and drying of water absorbency.
critical surfaces having
high cleanliness
requirements.
SAE AMS 3819 Very Low Wiping cloth, woven, For use in cleaning Very low lint and other
Class 1, Grade A Lint and unwoven, operations where particulate. High
chemically pure, 100% exceptionally low residual absorbent. Solvent
cotton fibers. surfaces contamination resistant.
Air Force Only levels are required.
Do not use wiping cloths to wipe plastic or use with volatile solvents
having flash points less than 100°F (38°C).
THIS PAGE LEFT INTENTIONALLY BLANK
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Reference Material
Alphabetical Index
None
NAVAIR 01-1A-17 013 00
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Page 2
3. MAINTENANCE RESPONSIBILITIES.
Maintenance functions applicable to rework, repair, 11. COMPONENT TESTING.
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. Hydraulic Fluid, MIL-PRF-83282 2
16. Nondestructive testing during component repair 20. POST-INSTALLATION CHECKS. After
shall be limited by the extent to which the component component installation, perform the following in
is disassembled and the need to test for critical accordance with existing maintenance procedures:
defects. The following guidelines are provided to
assist in determining the required level of testing: a. Perform required Quality Assurance
Inspection for correct installation.
a. Disassemble component to the extent b. Perform required Quality Assurance
required to accomplish repair. Inspection for leakage.
b. Visually inspect all parts for cracks or other c. Perform functional checkout of the system
evidence of mechanical stress or failure. component which has been replaced or repaired.
c. If no defects are detected or suspected, d. Perform an individual functional checkout of
reassemble component and perform functional tests
affected hydraulic system to ensure its proper
to verify that component meets applicable operation.
performance specifications. Perform inspections in
accordance with applicable Maintenance Instruction e. Perform checkout, in accordance with
Manuals (MIM). applicable MIM/overhaul manual, of other hydraulic
systems functionally related to the system repaired.
d. If defects are observed or suspected, perform
appropriate nondestructive tests, as applicable. 21. COMPONENT LUBRICATION.
e. If no defects are detected, reassemble
22. During hydraulic component repair, overhaul,
component and perform functional tests to verify that and installation, proper lubrication must be applied to
the component meets applicable performance bearings, bushings, wiper rings, spline shafts, and
specifications.
other components to assure proper operation and
f. Corrosion treat and touch-up paint exposed component reliability. Many component malfunctions
bare metal areas as needed in accordance with and failures can be traced to faulty selection of
lubricant. This problem becomes more acute with
existing instructions, prior to returning component to
service. high temperature applications.
17. During component overhaul, all specified 23. A lubricant has four major functions:
nondestructive tests shall be performed in
a. Provides a separating film between sliding
accordance with applicable overhaul manuals or other
contact surfaces thus minimizing wear.
engineering directives.
b. Acts as a coolant to maintain proper metal
18. COMPONENT PROOF PRESSURE TESTING.
temperature.
Repaired components shall be proof pressure tested
as specified in applicable MIM/overhaul manuals to
c. Facilitates assembly of components.
the extent permitted by the local test capability. If an
additional test capability is considered essential but d. Prevents corrosion of bearing surfaces.
not locally available, components shall be forwarded
to the next higher level of maintenance. Should 24. GENERAL LUBRICATION INSTRUCTIONS.
specified test procedures be considered excessive, Prior to lubricating any components or parts, all
submit Technical Publication Deficiency Report foreign matter shall be removed from joints, fittings,
(TPDR) in accordance with existing instructions. and bearing surfaces. An approved wiping material
saturated with an appropriate solvent shall be used
NOTE for this purpose. The lubricant should be applied
sparingly to prevent accumulation of dust, dirt, and
Proof pressure testing of components is not
required when the repair operation has not foreign matter.
disturbed the seal or housing integrity.
General Purpose Aircraft Grease, 11 30. Hydraulic fluid seepage resulting in drop
MIL-PRF-81322 formation shall not be cause for component rejection
and subsequent removal until verified by functional
25. When applying lubricants through pressure type maintenance check. Seepage can be due to:
fittings with a grease gun, make sure the lubricant has
emerged around the bushing. If no grease appears, a. A film of hydraulic fluid being retained by the
check the fitting and grease gun for proper operation. finish of metal surfaces such as piston rods and being
Be certain the grease gun is properly attached to the carried past the seal. Such a film is necessary for
fitting prior to applying pressure. Wipe up all excess lubrication of the seal.
grease when finished. When applying grease to a
flush type fitting, make sure that the grease gun is b. Pressure and temperature variations affecting
fitted with the flush-type adapter. The gun must be seals.
held perpendicular to the surface of the fitting when
greasing. c. Seals having tendency to take a permanent
set after a period of time, particularly if the system
has not been in operation.
35. For tests requiring long periods of time, and c. Under certain circumstances, several
where fluid can drop, wipe the surface clean and dry. individual components may exhibit “allowable”
Do not use a solvent. Place a clean blotter or white leakage so that the combined leakage will be
cloth immediately below the suspected leak. It may be “excessive”. If this is suspected, the fluid level in the
necessary to secure the blotter or cloth to the hydraulic reservoir should be monitored closely and
suspected component. Examine the blotter or cloth the leakage corrected if the total fluid lost from the
after the system has operated or has been idle for the system is excessive.
required time.
d. Hydraulic fluid may run into cavities, threads,
and grooves during testing and flushing of
36. ALLOWABLE AND EXCESSIVE LEAKAGE. components and during connecting and
The following guidelines provide general criteria for disconnecting of lines and fittings. Over a period of
judging whether leakage is allowable or excessive time, this fluid may seep out in sufficient quantity to
when not defined in the applicable MIM. 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.
Hydraulic Fluid, MIL-PRF-5606 1
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
Hydraulic Fluid, MIL-PRF-83282 2 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
Hydraulic Fluid, MIL-H-81019 3 interval, either pressurized or unpressurized.
g. When dynamic or static seals are internal and d. Thoroughly clean splines of drive coupling
vented on one side by a common vent hole, such as and mating female splines in hydraulic pump motor
between chambers in tandem flight control actuators, and mating gearbox to remove all foreign matter. Use
the allowable leakage rate will be cumulative for two dry cleaning solvent MIL-PRF-680 (WP002 00, Table
or more seals. 3, Item 6) with the aid of a bristle brush and dry with
air blast.
37. COMPONENT SPLINE MAINTENANCE.
e. Inspect splines for excessive wear. If
38. Toothed splines are used to transmit power or to damaged, repair or replace in accordance with
drive accessories, where space and weight are of applicable MIM.
paramount importance. Although many alternate
types of drives can be cited and are used in other 41. SPLINE LUBRICATION. Aircraft spline
situations, none can compare with splines in terms of connections are usually lubricated with a grease or
compactness and lightweight. Splines can liquid. Lubricating methods used are divided into
accommodate a small amount of misalignment which three categories: dry pad, mist, and wet pad. The dry
may be the result of design, installation, or dynamic pad spline connection can be operated with or without
operating conditions. If the misalignment is large, the grease. The mist (oil mist) and wet pad are usually
resulting oscillatory, fretting type of wear will be associated with the engine accessory gearbox splines
excessive. In the interest of reduced maintenance, and are oil lubricated. The dry pad is usually the
extended life, and increased reliability, special simplest method since no elaborate lubrication
attention should be directed toward spline alignment system is required.
control at rework and toward proper cleaning and
lubrication at all levels of maintenance.
42. Hydraulic pump and motor spline connections
39. SPLINE CLEANING. In the lubrication process, lubricated with grease shall be lubricated in
it is important to clean the spline connection accordance with the following procedure:
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 Molydisulphide Grease, MIL-G-21164 10
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 General Purpose Aircraft Grease, 11
contaminants should be avoided. MIL-PRF-81322
40. At each removal and installation, hydraulic pump a. Lubricate the male hydraulic pump or motor
and motor spline connections lubricated with grease drive coupling splines and mating female splines in
shall be cleaned in accordance with the following the gear box assembly with a liberal coating of
procedures: grease, specification MIL-G-21164 (WP002 00, Table
3, Item 10) or MIL-PRF-81322 (WP002 00, Table 3,
a. Remove hydraulic pump or motor from Item 11).
aircraft.
NOTE
b. Remove drive coupling retainer by inserting
appropriate tool and gently prying out, if applicable. Use MIL-PRF-81322 grease if applicable
MIM or MRC do not specify a lubricant.
c. Remove drive coupling.
43. Lubrication Interval. Hydraulic pump or motor considered ready for installation. Pump contamination
splines and mating female splines shall be lubricated is generally tested concurrently with test stand
in accordance with the applicable MIM and MRC. In operation of the pump, using patch test techniques.
all cases, the spline connection shall be cleaned and
lubricated at each pump or motor installation. 48. PATCH TEST TECHNIQUE. Pump patch
testing is accomplished by operating the unit under
44. SPLINE INSPECTION REQUIREMENTS. test for a predetermined period of time and collecting
Spline inspection normally consists of visual and gage particulate matter discharged from the outlet and case
measurements for wear and alignment. Specific drain ports using standard aircraft hydraulic filter
methods used will vary with the level of maintenance assemblies. Contaminants, having originated in the
and shall be as specified in applicable overhaul pump, are then retrieved from the filter assemblies
manuals, MIM, or engineering specifications. In all and separated from the fluid medium by use of
cases, visually inspect the spline, gearbox, and analytical-type filter disks and filtration apparatus
component mounting pad for wear, distortion, and such as is provided with Contamination Analysis Kit
cleanliness prior to component installation. 57L414 or equivalent. The discrete particulate matter
retained on the filter disk (“test patch”) is visually
45. REUSE OF SPLINES. The widely used inspected and a determination made whether the
maintenance practice of reusing splines in pump contamination output is within acceptable limits.
combination with new or other used splines has an
adverse effect on the life of both splines involved in a 49. Figure 1 illustrates the basic test setup used and
connection. When worn and new spline surfaces shows the location of the required hydraulic filter
come into contact, the load may be borne initially by a assemblies. In addition to the pump discharge and
relatively small area, thus resulting in excessive case drain filters, a similar filter assembly is also
contact pressures and high rate of wear. During the installed in the suction line of the pump under test.
period of high wear rate, wear debris is formed which This assembly enables a test patch to be produced
in turn may serve as an abrasive to promote that is representative of the pump inlet fluid and which
additional wear. When two new, properly shaped, can serve as a “control” patch against which the
spline surfaces come into contact, the load is more pump output and case drain test patches may be
uniformly distributed and the amount of wear compared.
necessary to provide good conformity is much less
than is the case when an unworn and worn spline 50. The following basic operations are performed
surface are in contact. The reuse of slightly worn when patch testing hydraulic pumps for contamination
splines is dictated by economic considerations, but output:
indiscriminate reuse of worn splines shall be
discouraged.
013001
Figure 1. Patch Test Testing Hydraulic Pump Contamination Using
Contamination Analysis Kit 57L414
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52. Test for Pumps Subjected to Major Rework. b. Prepare separate test patches from each of
Individually test the pump outlet, case drain, and inlet the pump filter samples utilizing contamination
filter assemblies to determine their contamination analysis kit, or equivalent, and detailed instructions
levels. Using Contamination Analysis Kit 57L414 or provided with the equipment. Refer to WP017 00 for
additional information relative to its use.
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resurfaced, requires test stand run-in to allow a final determine whether the discoloration is a result of very
lapping of critical internal surfaces to take place under fine particulate (or oxidized fluid) circulating through
actual operating conditions. Three consecutive run-in the entire test circuit or whether it is originating in the
periods are typically specified in most pump testing pump under test. Any evidence of discrete particles
procedures, with contamination tests performed upon on the inlet filter test patch, at any time, is indicative
the completion of each. The contamination output of of a test stand problem and the condition of its 3-
the pump is greatest during the initial run-in period micron filters should be checked.
and decreases significantly during each subsequent
run-in. When evaluating pump patch test results, the 59. Patch Test Standards for Pumps. Pump patch
rate of “cleanup” (the amount of improvement test standards are specially produced test patches
observed between successive runs) is often more that are representative of those that would be
meaningful than the appearance of any one set of obtained when patch testing a pump having a
test patches. A pump showing significant reductions marginally acceptable contamination output. In effect,
in contamination output with run-in can be expected they provide a go-no-go comparator to which pump
to clean up still further after being placed into actual test patches can be compared to determine
service and is generally considered to be a “clean” acceptability. Any actual patch showing a higher level
pump. In such cases it must still be determined that of contamination is considered unacceptable.
the level of contamination output observed at Because of differences in components and testing
completion of run-in is within acceptable limits in procedures (refer to Paragraphs 52 and 53) it is
order to prevent the overloading of system filters. This required that individual standards be developed for
determination can be made only by comparison of the each model pump and its attendant test procedure.
final test patches with standard patches for the Standard patches, as described, are not presently
particular model pump, if available, or with the being made available to fleet operators. Standard
operator’s past experience and knowledge of what patches can, in many instances, be locally
constitutes an acceptable indication. manufactured by the operator. It is required that all
such standards be approved by a FST prior to their
57. Reworked hydraulic pumps which show utilization.
abnormally large amounts of contamination initially, or
no improvement over successive runs, shall be
considered unacceptable. Such pumps should be 60. Patch standards for a given model shall consist
of three actual test patches, inlet, discharge, and case
disassembled and subjected to internal inspection in
an effort to determine the reason for the high rate of drain, that are produced using the exact test setup
contaminant generation. Careful examination of the and procedures specified for the particular model
pump discharge and case drain test patches will often pump. In order for such patches to serve as a quality
enable identification of the wear materials present control reference, it is necessary that they be
statistically established as being representative of the
and may assist in diagnosing the pump problem.
Modern in-line pump design is such that brass will be “normal” pump. This is currently accomplished by
the most common material observed on the pump collecting the final test patches from a large number
of identical pumps and selecting a set that, based
discharge patches. Contamination originating in the
pump case drain will include bronze, steel, carbon, upon best technical judgment, represents a fair but
fiber, and seal materials. conservative acceptable level. The validity of this
method improves greatly with the number of pumps
58. When examining the pump test patch, particular tested and it is considered necessary that at least ten
emphasis should be given to the amount of discrete pumps be so tested, with no peculiar problems
metallic particles that are observed. Most of the encountered, before any attempt at selecting a
significant wear particles discharged from a pump representative set of patches is made. Intermediate
under test, particularly one that is unacceptably and depot level maintenance activities are authorized
“dirty”, are usually fairly large and can be resolved as to locally produce patch standards, as described.
distinct particles by the unaided eye. In addition to However, all such patches should be submitted to the
these discrete particles, other particles that are too applicable FST for approval prior to their use.
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
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PROTECTIVE CLOSURES
HYDRAULIC SYSTEMS
Reference Material
Organizational, Intermediate, and Depot Maintenance Aviation Hoes and Tube Manual NAVAIR 01-1A-20
Caps and Plugs, Protective, Dust and Moisture Seal ................................................ NAS847
Cap - Protective, Flared Fitting .................................................................................. NAS817
Cap - Beaded Hose Connection, Plastic, Protective ................................................. NAS839
Cap, Pipe, Thread, Protective, Dust and Moisture Seal ............................................ NAS846
Cap Insert, Assembly, Pressure Seal, Flared Tube Fitting ....................................... AN929
Cap, Pressure Seal, Flareless Tube Fitting ............................................................... SAE AS21914
Plug - Protective, Flared Tube, Hose Assembly ....................................................... NAS818
Plug - Protective, Flareless Tube End (Plastic) ......................................................... NAS838
Plugs, Protective, Flareless Tube End (Metal) .......................................................... NAS842
Plug, Flareless Tube ................................................................................................. SAE AS21913
Fitting, Plug, Tube End, Flared ................................................................................. SAE AS5168
Plug, Pipe Thread, Protective, Dust and Moisture Seal ............................................. NAS840
Fitting, Port Plug and Bleeder .................................................................................... SAE AS5169
Plug, Machine Thread - AMS5646, Preformed Packing ........................................... MS9404
Fittings, 37 Degree Internal Flared, Fluid Connection .............................................. SAE AS4841
Alphabetical Index
None
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Change 1 – 1 August 2008 Page 2
8. BLANK-OFF PLATES.
014001
014002
Figure 2. Typical Blank-Off Plates
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014003
014004
Figure 4: AS5168-D High Pressure Aluminum Plugs
014005
Figure 5: NAS817 Light Aluminum Caps for Storage and Shipping
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014006
Figure 6: M5501/1 Light Aluminum Plugs for Storage and Shipping
014007
Figure 7: SAE AS21914 High Pressure Carbon Steel Caps
014008
Figure 8: SAE AS21913 High Pressure Carbon Steel Plugs
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014009
Figure 9: DC - Plastic Caps for Storage and Shipping
0140010
Figure 10: DP - Plastic Plugs for Storage and Shipping
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TYPE APPLICABLE
(Note 1) APPLICATION SPECIFICATION
Notes: 1. When ordering from supply, be sure to specify metal caps or plugs.
Notes: 1. See Figure 3 for examples of AN929D high pressure aluminum caps (blue in color).
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Notes: 1. SAE AS5168, “Fitting, Plug, Tube End, Flared” was adopted for use by the Department of Defense.
It shall be used in lieu of AN806.
2. See Figure 4 for examples of AS5168-D high pressure aluminum plugs (blue in color).
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Table 4. Light Aluminum Caps for Storage and Shipping (silver in color)
Notes: 1. See Figure 5 for examples of NAS817 light aluminum caps for storage and shipping (silver in
color).
2. NAS817 is inactive for design after October 31, 2012, refer to NAS835.
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Table 5. Light Aluminum Plugs for Storage and Shipping (silver in color)
Notes: 1. See Figure 6 for examples of M5501/1 light aluminum plugs for storage and shipping (silver in color).
2. NAS818 is inactive for new design after 11 February 2004, refer to NAS836.
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Units
Part of Cap
Item Number National Stock Issue Thread Tubing
No. (P/N) Nomenclature Number (NSN’s) (U/I) Size Size
Notes: 1. The original military specification, MS21914, “Cap, Pressure Seal, Flareless Tube Fitting”, was
adopted as an SAE Standard. Refer to SAE AS21914 for cancelled and superseded part numbers.
2. See Figure 7 for examples of SAE AS21914 high pressure carbon steel caps (gold in color).
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Units
Part of Cap
Item Number National Stock Issue Thread Tubing
No. (P/N) Nomenclature Number (NSN’s) (U/I) Size Size
Notes: 1. The original military specification, MS21913, “Plug, Flareless Tube”, was adopted as an
SAE Standard. Refer to SAE AS21913. Any part numbers established by the original
specification remain unchanged.
2. See Figure 8 for examples of SAE AS21913 high pressure carbon steel plugs (gold in color).
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Table 8. Plastic Caps for Storage and Shipping (light blue in color)
Units
Part of Cap
Item Number National Stock Issue Thread Tubing
No. (P/N) Nomenclature Number (NSN’s) (U/I) Size Size
Notes: 1. See Figure 9 for examples of plastic caps for storage and shipping (light blue in color).
NAVAIR 01-1A-17 014 00
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Table 9. Plastic Plugs for Storage and Shipping (light blue in color)
Units
Part of Cap
Item Number National Stock Issue Thread Tubing
No. (P/N) Nomenclature Number (NSN’s) (U/I) Size Size
Notes: 1. See Figure 10 for examples of plastic caps for storage and shipping (light blue in color).
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HYDRAULIC SEALS
HYDRAULIC SYSTEMS
Reference Material
Alphabetical Index
None
NAVAIR 01-1A-17 015 00
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NOTE
015005
015003
Figure 5. Typical Double Delta Channel Seal
Figure 3. Typical Cap Seal Installation Installation
015004 015006
Figure 4. Typical Channel Seal Installation Figure 6. Spring Seal Sealing Principle
NAVAIR 01-1A-17 015 00
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015007
Figure 7. Spring Seal and Typical Installations
NAVAIR 01-1A-17 015 00
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12. Hydraulic O-rings were originally specified under Refer to Table 1 for O-ring part number/material
AN (Air Force-Navy) Specification numbers (6227, specification crossovers.
6230, and 6290) for use with hydraulic fluid
conforming to MIL-PRF-5606, MIL-PRF-83282 or 13. The O-ring packing effectively seals in both
MIL-PRF-87257 (WP002 00, Table 3, Item 1, 2 or 4) directions. This sealing is done by distortion of its
at operating temperatures ranging from -65° to 160°F elastic compound. Figure 8, shows an O-ring of the
(-54° to 71°C). Advances in aircraft design, which proper size installed in a grooved seat. Notice that the
raised operating temperatures to a possible 275°F clearance for the O-ring is less than its free outer
(135°C), necessitated the adoption of new packing diameter. The cross section of the O-ring is squeezed
materials. The SAE AS28775 (formerly MS28775) O- out of round prior to the application of pressure. In
ring is a viable substitute for the AN6227 and AN6230 this manner, contact with the inner and outer walls of
O-rings. The SAE AS28778 (formerly MS28778) O- the passage is assured under static (no pressure)
ring is replacing the AN6290 O-ring. These O-rings conditions. Figure 8 also shows the action of the O-
are now standard for systems using hydraulic fluid rings when pressure is applied and the same actions
MIL-PRF-5606, MIL-PRF-83282, or MIL-PRF-87257 when backup rings are installed. In hydraulic systems
(WP002 00, Table 3, Item 1, 2 or 4), where the where components are subjected to 1500 psi
operating temperatures may vary from -65° to 275°F pressure or less, AN6227, AN6230, and SAE
(-54° to 135°C). O-rings made of fluorocarbon rubber AS28775 (formerly MS28775) packings are used.
(FPM) are seals generally used in hydraulic systems Backup rings are not normally required in this
using di-ester or silicate ester based fluids. Their application. In aircraft with hydraulic system
working temperature range is from -15° to 400°F (-26° pressures of 3000 psi, the SAE AS28775 (formerly
to 204°C). O-rings made of FPM are manufactured to MS28775) packings are used in conjunction with
standard O-ring sizes. Compounds used in O-rings backup rings, the latter being employed as anti-
conform to AMS 7276 and AMS7259. extrusion devices. Refer to Table 2 for the O-rings
and backup rings most frequently used.
015008
Figure 8. Relative Positions of O-Ring Packings in Different Grooves at Increasing Pressures
NAVAIR 01-1A-17 015 00
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Part Number Part Number Specification Previous Part Number Material Specification
AA55549-XX A-A-55549 MA90064-XX ZZ-R-765, AMS3302
AS3084-XX AS3084 AS3804-XX AMS 7280
AS3085-XXX AS3085 AS3085-XXX AMS 7280
AS3208-XX AS3208 AS3208-XX AMS 7276
AS3209-XXX AS3209 AS3209-XXX AMS 7276
AS3551-XXX AS3551 MS9241-XXX AMS 7272
AS3551-XXX AS3551 MS9355-XX AMS 7272
AS3569-XXX AS3569 AN123951 THRU AN124050 AMS 7270
AS3570-XXX AS3570 AN123851 THRU AN123950 AMS 7274
AS3578-XXX AS3578 MS9020-XX AMS 7271
AS3578-XXX AS3578 MS9021-XXX AMS 7271
AS3581-XXX AS3581 MS9970-XXX AMS 7259
AS3582-XXX AS3582 MS9068-XXX AMS 3304
M83248/1-XXX MIL-R-83248 MS17413-XXX MIL-R-83248, AMS-R-83248
M83248/1-XXX MIL-R-83248/1 M83248/1-XXX MIL-R-83248, AMS-R-83248
M83248/2-XXX MIL-R-83248/2 M83248/2-XXX MIL-R-83248, AMS-R-83248
M83461/1-XXX MIL-P-83461/1 M83461/1-XXX MIL-P-83461, AMS-P-83461
M259888-XXX NSA8200 NSA8200-XXX MIL-R-25988, AMS-R-25988
M259888-XXX NSA8203 NSA8203-XXX MIL-R-25988, AMS-R-25988
M25988/1-XXX MIL-R-25988 M25988/1-XXX MIL-R-25988, AMS-R-25988
M25988/2-XXX MIL-R-25988 M25988/2-XXX MIL-R-25988, AMS-R-25988
M25988/3-XXX MIL-R-25988 M25988/3-XXX MIL-R-25988, AMS-R-25988
M25988/4-XXX MIL-R-25988 M25988/4-XXX MIL-R-25988, AMS-R-25988
M83248/1-XXX MIL-R-83248/1 MS9387-XX MIL-R-83248, AMS-R-83248
M83248/1-XXX MIL-R-83248/1 MS9388-XXX MIL-R-83248, AMS-R-83248
M83248/1-XXX NAS1593 NAS1593-XXX MIL-R-83248, AMS-R-83248
M83248/2-XXX NAS1594 NAS1594-XXX MIL-R-83248, AMS-R-83248
M83248/1-XXX NAS1595 NAS1595-XXX MIL-R-83248, AMS-R-83248
M83248/2-XXX NAS1596 NAS1596-XX MIL-R-83248, AMS-R-83248
MA3362XXXXX MA3362 MA3362XXXX AMS7276
MA3434XXXXX MA3434 MA3434XXXX AMS7273
MA3442XXXXX MA3442 MA3442XXXX AMS7267
MA3445XXXXX MA3445 MA3445XXXX MIL-R-83485, AMS-R-83485
MS28772-XXX AS28772 MS28772-XXX MIL-P-5516, AMS-P-5516
MS28775-XXX AS28775 AN6227-XXX MIL-P-25732, AMS-P-25732
MS28775-XXX AS28775 AN6230-XXX MIL-P-25732, AMS-P-25732
MS28775-XXX AS28775 MS28775-XXX MIL-P-25732, AMS-P-25732
MS28778-XX AS28778 AN6290-XX MIL-P-5510, AMS-P-5510
MS28778-XX AS28778 MS28778-XX MIL-P-5510, AMS-P-5510
MS29512-XX AS29512 MS29512-XX MIL-P-5315, AMS-P-5315
MS29513-XXX AS29513 MS29513-XXX MIL-P-5315, AMS-P-5315
MS29561-XXX AS29561 MS29561 MIL-R-7362, AMS-R-7362
MS3393-XX AS33931 MS3393-XX MIL-P-81716
MS90064-XX MS90064 MS90064-XX ZZ-R-765, AMS3304
MS9385-XX AS9385 MS9385-XX AMS 7267
MS9386-XXX AS9386 MS9386-XXX AMS 7267
MS9966-XX AS9966 MS9966-XX AMS 7273
MS9967-XXX AS9967 MS9967-XXX AMS 7273
NAS617-XXX NAS617 NAS617-XXX MIL-R-7362, AMS-R-7362
NAS1611-XXXA NAS1611 NAS1611-XXX NAS1613
NAS1612-XXA NAS1612 NAS1612-XX NAS1613
NSA8201-X NSA8201 NSA8201-X NAS1613
NSA8204-XXX NSA8204 NSA8204-XXX NAS1613
NSA8205-XXX NSA8205 NSA8205-XXX AMS 3242
NSA8206-XXX NSA8206 NSA8206-XXX AMS 7267
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1/8 1/16 SAE AS28775-006 9/64 3/64 3/64 SAE AS8791-6 1/8 3/64 3/64 MS28782-1
5/32 1/16 SAE AS28775-007 11/64 3/64 3/64 SAE AS8791-7 5/32 3/64 3/64 MS28782-2
3/16 1/16 SAE AS28775-008 13/64 3/64 3/64 SAE AS8791-8 3/16 3/64 3/64 MS28782-3
7/32 1/16 SAE AS28775-009 15/64 3/64 3/64 SAE AS8791-9 7/32 3/64 3/64 MS28782-4
1/4 1/16 SAE AS28775-010 17/64 3/64 3/64 SAE AS8791-10 1/4 3/64 3/64 MS28782-5
5/16 1/16 SAE AS28775-011 21/64 3/64 3/64 SAE AS8791-11 5/16 3/64 3/64 MS28782-6
3/8 1/16 SAE AS28775-012 25/64 3/64 3/64 SAE AS8791-12 3/8 3/64 3/64 MS28782-7
3/8 3/32 SAE AS28775-110 25/64 3/64 3/32 SAE AS8791-110 3/8 3/64 3/32 MS28782-8
7/16 3/32 SAE AS28775-111 29/64 3/64 3/32 SAE AS8791-111 7/16 3/64 3/32 MS28782-9
15/32 1/16 SAE AS28775-013* 29/64 3/64 3/64 SAE AS8791-13
1/2 1/16 SAE AS28775-014* 33/64 3/64 3/64 SAE AS8791-14
1/2 3/32 SAE AS28775-112 33/64 3/64 3/32 SAE AS8791-112 1/2 3/64 3/32 MS28782-10
9/16 1/16 SAE AS28775-015* 37/64 3/64 3/64 SAE AS8791-15
9/16 3/32 SAE AS28775-113 37/64 3/64 3/32 SAE AS8791-113 9/16 3/64 3/32 MS28782-11
5/8 1/16 SAE AS28775-016* 41/64 3/64 3/64 SAE AS8791-16
5/8 3/32 SAE AS28775-114 41/64 3/64 3/32 SAE AS8791-114 5/8 3/64 3/32 MS28782/12
11/16 1/16 SAE AS28775-017* 45/64 3/64 3/64 SAE AS8791-17
11/16 3/32 SAE AS28775-115 45/64 3/64 3/32 SAE AS8791-115 11/16 3/64 3/32 MS28782-13
3/4 1/16 SAE AS28775-018* 49/64 3/64 3/64 SAE AS8791-18
3/4 3/32 SAE AS28775-116 49/64 3/64 3/32 SAE AS8791-116 3/4 3/64 3/32 MS28782-14
3/4 1/8 SAE AS28775-210 49/64 3/64 1/8 SAE AS8791-210 3/4 3/64 1/8 MS28782-15
13/16 1/16 SAE AS28775-019* 53/64 3/64 3/64 SAE AS8791-19
13/16 3/32 SAE AS28775-117* 53/64 3/64 3/32 SAE AS8791-117
13/16 1/8 SAE AS28775-211 53/64 3/64 1/8 SAE AS8791-211 13/16 3/64 1/8 MS28782-16
7/8 1/16 SAE AS28775-020* 57/64 3/64 3/64 SAE AS8791-20
7/8 3/32 SAE AS28775-118* 57/64 3/64 3/32 SAE AS8791-118
7/8 1/8 SAE AS28775-212 57/64 3/64 1/8 SAE AS8791-212 7/8 3/64 1/8 MS28782-17
15/16 1/16 SAE AS28775-021* 61/64 3/64 3/64 SAE AS8791-21
15/16 3/32 SAE AS28775-119* 61/64 3/64 3/32 SAE AS8791-119
15/16 1/8 SAE AS28775-213 61/64 3/64 1/8 SAE AS8791-213 15/16 3/64 1/8 MS28782-18
1 1/16 SAE AS28775-022* 1-1/64 3/64 3/64 SAE AS8791-22
1 3/32 SAE AS28775-120* 1-1/64 3/64 3/32 SAE AS8791-120
1 1/8 SAE AS28775-214 1-1/64 3/64 1/8 SAE AS8791-214 1 3/64 1/8 MS28782-19
1-3/64 1/16 SAE AS28775-023* 1-5/64 3/64 3/64 SAE AS8791-23
1-1/16 3/32 SAE AS28775-121* 1-5/64 3/64 3/32 SAE AS8791-121
1-1/16 1/8 SAE AS28775-215 1-5/64 3/64 1/8 SAE AS8791-215 1-1/16 3/64 1/8 MS28782-20
1-1/8 1/16 SAE AS28775-024* 1-9/64 3/64 3/64 SAE AS8791-24
1-1/8 3/32 SAE AS28775-122* 1-9/64 3/64 3/32 SAE AS8791-122
1-1/8 1/8 SAE AS28775-216 1-9/64 3/64 1/8 SAE AS8791-216 1-1/8 3/64 1/8 MS28782-21
1-3/16 1/16 SAE AS28775-025* 1-13/64 3/64 3/64 SAE AS8791-25
1-3/16 3/32 SAE AS28775-123* 1-13/64 3/64 3/32 SAE AS8791-123
1-3/16 1/8 SAE AS28775-217 1-13/64 3/64 1/8 SAE AS8791-217 1-3/16 3/64 1/8 MS28782-22
1-1/4 1/16 SAE AS28775-026* 1-17/64 3/64 3/64 SAE AS8791-26
1-1/4 3/32 SAE AS28775-124* 1-17/64 3/64 3/32 SAE AS8791-124
1-1/4 1/8 SAE AS28775-218 1-17/64 3/64 1/8 SAE AS8791-218 1-1/4 3/64 1/8 MS28782-23
1-5/16 1/16 SAE AS28775-027* 1-21/64 3/64 3/64 SAE AS8791-27
1-5/16 3/32 SAE AS28775-125* 1-21/64 3/64 3/32 SAE AS8791-125
1-5/16 1/8 SAE AS28775-219 1-21/64 3/64 1/8 SAE AS8791-219 1-5/16 3/64 1/8 MS28782-24
1-3/8 1/16 SAE AS28775-028* 1-25/64 3/64 3/64 SAE AS8791-28
1-3/8 3/32 SAE AS28775-126* 1-25/64 3/64 3/32 SAE AS8791-126
1-3/8 1/8 SAE AS28775-220 1-25/64 3/64 1/8 SAE AS8791-220 1-3/8 3/64 1/8 MS28782-25
1-7/16 3/32 SAE AS28775-127* 1-29/64 3/64 3/32 SAE AS8791-27
1-7/16 1/8 SAE AS28775-221 1-29/64 3/64 1/8 SAE AS8791-221 1-7/16 3/64 1/8 MS28782-26
1-1/2 3/32 SAE AS28775-128* 1-33/64 3/64 3/32 SAE AS8791-128
1-1/2 1/8 SAE AS28775-222 1-33/64 3/64 1/8 SAE AS8791-222 1-1/2 3/64 1/8 MS28782-27
1-1/2 3/16 SAE AS28775-325 1-33/64 5/64 3/16 SAE AS8791-325 1-1/2 1/16 3/16 MS28782-28
1-9/16 3/32 SAE AS28775-129* 1-37/64 3/64 3/32 SAE AS8791-129
1-5/8 3/32 SAE AS28775-130* 1-41/64 3/64 3/32 SAE AS8791-130
1-5/8 1/8 SAE AS28775-223* 1-41/64 3/64 1/8 SAE AS8791-223 1-5/8 3/64 1/8 MS28783-1
1-5/8 3/16 SAE AS28775-326 1-41/64 5/64 3/16 SAE AS8791-326 1-5/8 1/16 3/16 MS28782-29
1-11/16 3/32 SAE AS28775-131* 1-45/64 3/64 3/32 SAE AS8791-131
1-3/4 3/32 SAE AS28775-132* 1-49/64 3/64 3/32 SAE AS8791-132
1-3/4 1/8 SAE AS28775-224* 1-49/64 3/64 1/8 SAE AS8791-224 1-3/4 3/64 1/8 MS28783-2
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1-3/4 3/16 SAE AS28775-327 1-49/64 5/64 3/16 SAE AS8791-327 1-3/4 1/16 3/16 MS28782-30
1-13/16 3/32 SAE AS28775-133* 1-53/64 3/64 3/32 SAE AS8791-133
1-7/8 3/32 SAE AS28775-134* 1-57/64 3/64 3/32 SAE AS8791-134
1-7/8 1/8 SAE AS28775-225* 1-57/64 3/64 1/8 SAE AS8791-225 1-7/8 3/64 1/8 MS28783-3
1-7/8 3/16 SAE AS28775-328 1-57/64 5/64 3/16 SAE AS8791-328 1-7/8 1/16 3/16 MS28782-31
1-15/16 3/32 SAE AS28775-135* 1-61/64 3/64 3/32 SAE AS8791-135
2 3/32 SAE AS28775-136* 2-1/64 3/64 3/32 SAE AS8791-136
2 1/8 SAE AS28775-226* 2-1/64 3/64 1/8 SAE AS8791-226 2 3/64 1/8 MS28783-4
2 3/16 SAE AS28775-329 2-1/64 5/64 3/16 SAE AS8791-329 2 1/16 3/16 MS28783-32
2-3/16 3-32 SAE AS28775-137* 2-5/64 3/64 3/32 SAE AS8791-137
2-1/8 3/32 SAE AS28775-138 2-9/64 3/64 3/32 SAE AS8791-138
2-1/8 1/8 SAE AS28775-227* 2-9/64 3/64 1/8 SAE AS8791-227 2-1/8 3/64 1/8 MS28783-5
2-1/8 3/16 SAE AS28775-330 2-9/64 5/64 3/16 SAE AS8791-330 2-1/8 1/16 3/16 MS28782-33
2-3/16 3/32 SAE AS28775-139* 2-13/64 3/64 3/32 SAE AS8791-139
2-1/4 3/32 SAE AS28775-140* 2-17/64 3/64 3/32 SAE AS8791-140
2-1/4 1/8 SAE AS28775-228* 2-17/64 3/64 1/8 SAE AS8791-228 2-1/4 3/64 1/8 MS28783-6
2-1/4 3/16 SAE AS28775-331 2-17/64 5/64 3/16 SAE AS8791-331 2-1/4 1/16 3/16 MS28782-34
2-5/16 3/32 SAE AS28775-141* 2-21/64 3/64 3/32 SAE AS8791-141
2-3/8 3/32 SAE AS28775-142* 2-25/64 3/64 3/32 SAE AS8791-142
2-3/8 1/8 SAE AS28775-229* 2-25/64 3/64 1/8 SAE AS8791-229 2-3/8 3/64 1/8 MS28783-7
2-3/8 3/16 SAE AS28775-332 2-25/64 5/64 3/16 SAE AS8791-332 2-3/8 1/16 3/16 MS28782-35
2-7/16 3/32 SAE AS28775-143* 2-29/64 3/64 3/32 SAE AS8791-143
2-1/2 3/32 SAE AS28775-144* 2-33/64 3/64 3/32 SAE AS8791-144
2-1/2 1/8 SAE AS28775-230* 2-33/64 3/64 1/8 SAE AS8791-230 2-1/2 3/64 1/8 MS28783-8
2-1/2 3/16 SAE AS28775-333 2-33/64 5/64 3/16 SAE AS8791-333 2-1/2 1/16 3/16 MS28782-36
2-9/16 3/32 SAE AS28775-145* 2-37/64 3/64 3/32 SAE AS8791-145
2-5/8 3/32 SAE AS28775-146* 2-41/64 3/64 3/32 SAE AS8791-146
2-5/8 1/8 SAE AS28775-231* 2-41/64 3/64 1/8 SAE AS8791-231 6-5/8 3/64 1/8 MS28783-9
2-5/8 3/16 SAE AS28775-334 2-41/64 5/64 3/16 SAE AS8791-334 2-5/8 1/16 3/16 MS28782-37
2-11/16 3/32 SAE AS28775-147* 2-45/64 3/64 3/32 SAE AS8791-147
2-3/4 3/32 SAE AS28775-148* 2-49/64 3/64 3/32 SAE AS8791-148
2-3/4 1/8 SAE AS28775-232 2-49/64 3/64 1/8 SAE AS8791-232 2-3/4 3/64 1/8 MS28783-10
2-3/4 3/16 SAE AS28775-335 2-49/64 5/64 3/16 SAE AS8791-335 2-3/4 1/16 3/16 MS28782-38
2-3/16 3/32 SAE AS28775-149* 2-53/64 3/64 3/32 SAE AS8791-149
2-7/8 1/8 SAE AS28775-233* 2-57/64 3/64 1/8 SAE AS8791-233 2-7/8 3/64 1/8 MS28783-11
2-7/8 3/16 SAE AS28775-336 2-57/64 5/64 3/16 SAE AS8791-336 2-7/8 1/16 3/16 MS28782-39
3 1/8 SAE AS28775-234* 3 3/64 1/8 SAE AS8791-234 3 3/64 1/8 MS28783-12
3 3/16 SAE AS28775-337 3-1/64 5/64 3/16 SAE AS8791-337 3 1/16 3/16 MS28782-40
3-1/8 1/8 SAE AS28775-235* 3-1/8 3/64 1/8 SAE AS8791-235 3-1/8 3/64 1/8 MS28783-13
3-1/8 3/16 SAE AS28775-338 3-9/64 5/64 3/16 SAE AS8791-338 3-1/8 1/16 3/16 MS28782-41
3-1/4 1/8 SAE AS28775-236* 3-1/4 3/64 1/8 SAE AS8791-236 3-1/4 3/64 1/8 MS28783-14
3-1/4 3/16 SAE AS28775-339 3-17/64 5/64 3/16 SAE AS8791-339 3-1/4 1/16 3/16 MS28782-42
3-3/8 1/8 SAE AS28775-237* 3-3/8 3/64 1/8 SAE AS8791-237 3-3/8 3/64 1/8 MS28783-15
3-3/8 3/16 SAE AS28775-340 3-25/64 5/64 3/16 SAE AS8791-340 3-3/8 1/16 3/16 MS28782-43
3-1/2 1/8 SAE AS28775-238* 3-1/2 3/64 1/8 SAE AS8791-238 3-1/2 3/64 1/8 MS28783-16
3-1/2 3/16 SAE AS28775-341 3-33/64 5/64 3/16 SAE AS8791-341 3-1/2 1/16 3/16 MS28782-44
3-5/8 1/8 SAE AS28775-239* 3-5/8 3/64 1/8 SAE AS8791-239 3-5/8 3/64 1/8 MS28783-17
3-5/8 3/16 SAE AS28775-342 3-41/8 5/64 3/64 SAE AS8791-342 3-5/8 1/16 3/16 MS28782-45
3-3/4 1/8 SAE AS28775-240* 3-3/4 3/64 1/8 SAE AS8791-240 3-3/4 3/64 1/8 MS28783-18
3-3/4 3/16 SAE AS28775-343 3-49/64 5/64 3/16 SAE AS8791-343 3-3/4 1/16 3/16 MS28783-46
3-7/8 1/8 SAE AS28775-241 3-7/8 3/64 1/8 SAE AS8791-241 3-7/8 3/64 1/8 MS28782-19
3-7/8 3/16 SAE AS28775-344 3-57/64 5/64 3/16 SAE AS8791-344 3-7/8 1/16 3/16 MS28782-47
4 1/8 SAE AS28775-242* 4 3/64 1/8 SAE AS8791-242 4 3/64 1/8 MS28783-20
4 3/16 SAE AS28775-345 4-1/32 5/64 3/16 SAE AS8791-345 4 1/16 3/16 MS28782-48
4-1/8 1/8 SAE AS28775-243* 4-1/8 3/64 1/8 SAE AS8791-243 4-1/8 3/64 1/8 MS28783-21
4-1/8 3/16 SAE AS28775-346 4-5/32 5/64 3/16 SAE AS8791-346 4-1/8 1/16 3/16 MS28782-49
4-1/4 1/8 SAE AS28775-244* 4-1/4 3/64 1/8 SAE AS8791-244 4-1/4 3/64 1/8 MS28783-22
4-1/4 3/16 SAE AS28775-347 4-9/32 5/64 3/16 SAE AS8791-347 4-1/4 1/16 3/16 MS28782-50
4-3/8 1/8 SAE AS28775-245* 4-3/8 3/64 1/8 SAE AS8791-245 4-3/8 3/64 1/8 MS28783-23
4-3/8 3/16 SAE AS28775-348 4-13/32 5/64 3/16 SAE AS8791-348 4-3/8 1/16 3/16 MS28782-51
4-1/2 1/8 SAE AS28775-246* 4-1/2 3/64 1/8 SAE AS8791-246 4-1/2 3/64 1/8 MS28783-24
4-1/2 3/16 SAE AS28775-349 4-17/64 5/64 3/16 SAE AS8791-349 4-1/2 1/16 3/16 MS28782-52
4-1/2 1/4 SAE AS28775-425 4-35/64 7/64 15/64 SAE AS8791-425 4-1/2 3/32 15/64
4-5/8 1/8 SAE AS28775-247* 4-5/6 3/64 1/8 SAE AS8791-247 4-5/8 3/64 1/8 MS28783-25
4-5/8 1/4 SAE AS28775-426 4-43/64 7/64 15/64 SAE AS8791-426 4-5/8 3/32 15/64 MS28782-53
4-3/4 1/4 SAE AS28775-427 4-51/64 7/64 15/64 SAE AS8791-427 4-3/4 3/32 15/64 MS28782-54
4-7/8 1/4 SAE AS28775-428 4-59/64 7/64 15/64 SAE AS8791-428 4-7/8 3/32 15/64 MS28782-55
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5 1/4 SAE AS28775-429 5-3/64 7/64 15/64 SAE AS8791-429 5 3/32 15/64 MS28782-56
5-1/8 1/4 SAE AS28775-430 5-11/64 7/64 15/64 SAE AS8791-430 5-1/8 3/32 15/64 MS28782-57
5-1/4 1/4 SAE AS28775-431 5-19/64 7/64 15/64 SAE AS8791-431 5-1/4 3/32 15/64 MS28782-58
5-3/8 1/4 SAE AS28775-432 5-27/64 7/64 15/64 SAE AS8791-432 5-3/8 3/32 15/64 MS28782-59
5-1/4 1/4 SAE AS28775-433 5-39/64 7/64 15/64 SAE AS8791-433 5-1/2 3/32 15/64 MS28782-60
5-5/8 1/4 SAE AS28775-434 5-43/64 7/64 15/64 SAE AS8791-434 5-5/8 3/32 15/64 MS28782-61
5-3/4 1/4 SAE AS28775-435 5-51/64 7/16 15/64 SAE AS8791-435 5-3/4 3/32 15/64 MS28782-62
5-7/8 1/4 SAE AS28775-436 5-59/64 7/16 15/64 SAE AS8791-436 5-7/8 3/32 15/64 MS28782-63
6 1/4 SAE AS28775-437 6-3/64 7/16 15/64 SAE AS8791-437 6 3/32 15/64 MS28782-64
6-1/4 1/4 SAE AS28775-438 6-9/32 7/16 15/64 SAE AS8791-438 6-1/4 3/32 15/64 MS28782-65
6-1/2 1/4 SAE AS28775-439 6-17/32 7/16 15/64 SAE AS8791-439 6-1/2 8/32 15/64 MS28782-66
Notes: 1. O-rings and backup rings which fall on the same horizontal line in this chart may be substituted
for each other.
2. Industry standard, SAE AS28775 (formerly identified as military specification, MS28775) O-rings
are for hydraulic systems with temperature limits from -65° to +275°F (-50° to +135°C). 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 () do not have the
same scarf cut.
14. In Type I hydraulic systems (operating g. Screw nut toward body until O-ring gently
temperature range from -65° to +160°F (-54° to contacts first threaded area of fitting.
+71°C)), the designated sizes of AN6230B-1 through
-25, SAE AS28775 (formerly MS28775) -013 through 17. Fitting Installation. Install fitting as follows
-028, -117 through -149, and -223 through -247 O- (Figure 10):
rings are intended for use as static seals and must
not be used in dynamic seal applications which
involve reciprocating or rotary movement. In Type II
hydraulic systems (temperatures range from -65° to
+275°F (-54° to +135°C)) the designated sizes of Hydraulic Fluid, MIL-PRF-5606 1
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 Hydraulic Fluid, MIL-PRF-83282 2
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 Hydraulic Fluid, MIL-H-81019 3
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 Hydraulic Fluid, MIL-PRF-87257 4
and nut as follows (Figure 9):
b. Screw nut passing seal area to second d. System tubing or hose may now be loosely
threaded area of fitting. attached to aid in maintaining alignment.
c. Install Teflon backup ring onto seal area of e. Torque nut SAE AS5179 (formerly AN6289)
fitting. 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. f. Torque assembly tubing or hose B nut with an
open tubular-type crowfoot torque adapter and
e. If necessary, unscrew nut outward to prevent standard torque wrench while holding fitting with a
thread interference. second wrench.
015009
Figure 9. Assembly of O-Ring, Teflon Backup Ring, Nut, and Fitting
015010
Figure 10. Installation of Fitting Assembly
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Change 2 – 1 August 2014 Page 13
Notes: 1. MS28778 replaces AN6290. Use corresponding dash number to obtain part number.
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.
18. SERVICE LIFE OF PREFORMED PACKINGS. on the package. Figure 11 shows the information
The service life (estimated time of trouble-free printed on packages which is essential to determine
service) of preformed packing depends upon several the intended use and qualification.
factors. These include its age, use, exposure to
certain elements, both natural and imposed, and
subjection to physical stress. Operational conditions 20. Color-coding is no longer required by
imposed upon preformed packings in one component specifications and no longer used for most O-rings.
may necessitate replacement more frequently than an Ethylene propylene O-rings, used in systems
identical preformed packing in other components. operated with phosphate ester fluid, are usually
marked with yellow and white markings which vary
19. PREFORMED PACKING IDENTIFICATION. according to the manufacturer. Colored dots, dashes
Hydraulic preformed packings are manufactured in and stripes, or combinations of dots, dashes, and
accordance with military or industry specifications and stripes are used for markings.
can be identified by the technical information printed
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extreme weather conditions. When hydraulic packings extractor tool is inserted beneath the O-ring; the hook
are chosen for installation, they must not be handled type removal tool hooks the O-ring. A slight pull on
with sharp instruments, and the preservative should the latter tool removes the O-ring from its cavity.
not be removed until they are ready for installation.
29. After the removal of all O-rings, cleaning of the
affected parts which will receive new O-rings is
NOTE
mandatory. Ensure that the area used for such
installations is clean and free from all contamination.
Over time, O-rings take a permanent set. Each O-ring to be installed shall be removed from its
Therefore, any time an O-ring is unsealed sealed package and inspected for defects; such as
resulting in excessive leakage, it must be blemishes, abrasions, cuts, or punctures. Although an
replaced with a new O-ring. Unidentified O-ring may appear perfect at first glance, slight
O-rings shall not be used. surface flaws may exist. These are often capable of
preventing satisfactory O-ring performance under the
various operating pressures of aircraft systems. O-
rings shall be rejected for flaws that will affect their
24. Use the correct tool during the installation or performance.
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 Hydraulic Fluid, MIL-PRF-5606 1
phenolic rod or plastics may also be used.
015012
Figure 12. Typical O-Ring Installation and Removal Tools
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015013
Figure 13. O-Ring Removal
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30. PREFORMED PACKING LUBRICATION. After backup rings are installed, the split scarfed ends must
inspection and prior to installation, lubricate the O-ring be staggered as shown in Figure 17, View A.
with system fluid when required. During installation,
avoid rolling or twisting the O-ring to maneuver it into 36. Backup rings for use on hydraulic systems shall
place. Keep the position of the O-ring mold line conform to AS8791 and AS5861, which specifies that
constant. When the O-ring installation requires backup rings be manufactured of a
spanning or inserting through sharp-threaded areas, tetrafluoroethylene resin, also called TFE or Teflon.
ridges, slots, and edges, use protective measures The rings may be used in hydraulic systems with
such as paper sleeves and covers which may be fluids conforming to MIL-PRF-83282 (WP002 00,
fabricated using the seal package (glossy side out) of Table 3, Item 2) and in temperature ranges from -65°
lint-free bond paper (See Figure 14, View A and View to +275°F (-54° to +135°C), at operating pressures
B). from 0 to 3000 psi. The shape and dimensions of
these backup rings conform to MS28774, MS28782,
31. After the O-ring is placed in the cavity provided,
and MS28783.
gently roll the O-ring with the fingers to remove any
twist that might have occurred during installation.
37. Precautions similar to those applicable to O-
32. BACKUP RINGS. rings must be taken to avert contamination of backup
rings and damage to hydraulic components.
33. Backup rings, also referred to as retainer rings,
anti-extrusion devices and non-extrusion rings, are 38. Teflon backup rings may be stocked in
washer-like devices which are installed on the low- individually sealed packages similar to those in which
pressure side of a packing to prevent extrusion of the O-rings are packaged. Several may be installed on a
packing material into the minute clearances between cardboard mandrel, provided a non-tapered mandrel
moving parts in dynamic seals. Backup rings is employed for this purpose. If unpackaged rings are
minimize erosion or wearing away of the packing stored for a long time without the use of mandrels, a
materials and failure of the seal. They are also condition of overlap may develop. In order to
employed in static seals and with gaskets to prevent eliminate this condition, stack Teflon rings on a
extrusion failure due to increasing force (pressure) mandrel of the correct diameter. Stack and clamp the
when the surface tension of the packing compound is rings with their coils flat and parallel. Then place the
no longer sufficient to resist the flow, causing the rings in an oven at a maximum temperature of 350°F
packing material to extrude out of the passage it is
(177°C) for approximately 10 minutes. The rings are
attempting to seal.
then removed and water quenched.
34. At lower pressure, non-extrusion devices will NOTE
prolong the normal wear life of the packing and, at
higher pressure, non-extrusion devices permit greater
After this treatment, rings should be stored
diametrical clearances between mating parts.
at room temperature for 48 hours prior to
use.
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 39. BACKUP RING IDENTIFICATION. Backup
pressure which will cause extrusion of the packing on rings are not color coded or otherwise marked and
either side of the gland. The two-backup ring must be identified from package labels. Backup rings
configuration has also been used to facilitate made of Teflon do not deteriorate with age, are
standardization of groove dimension and service unaffected by any other system fluid or vapor, and
procedures even when the pressure is applied from tolerate temperature extremes in excess of those
one direction only. In single backup ring configuration encountered in high pressure hydraulic systems. The
it is mandatory that the ring be installed on the low- dash number, which is found on the package
pressure side of the gland. See Figure 16 for correct following the specification number, indicates the size
placement of backup rings. When a backup ring is and, in some cases, relates directly to the dash
placed on the high-pressure side of the packing, the number of the O-rings for which the backup ring is
pressure against the relatively hard surface of the dimensionally suited. For example, the single spiral
backup ring acts to force the softer packing against Teflon ring MS28774-6 is used with O-rings
the low-pressure side of the gland and precipitates MS28775-006; the double spiral Teflon ring
extrusion failures at a rapid rate. Whenever dual MS28782-1 is used with the O-ring AN6227B-1.
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40. BACKUP RING INSTALLATION. Care must be spiral. Figure 19, View A, B, and C show the method
taken in handling and installing backup rings. See used to change directions of the spiral. The Teflon
Figure 18. Backup rings shall be inserted without the ring is then stretched slightly, as shown in View D
use of sharp tools. Teflon backup rings must be prior to installation into the groove. While the Teflon
inspected prior to use for evidence of compression ring is being inserted into the groove, rotate the
damage, scratches, cuts, nicks, or frayed conditions, component in a clockwise direction (View E). This
as illustrated in Figure 18. action will tend to expand the ring diameter and
reduce the possibility of damage to the ring.
015014
Figure 14. O-Ring Installation
NAVAIR 01-1A-17 015 00
TO 42B2-1-12
Page 21
015015
Figure 15. Backup Ring Configuration
RIGHT WRONG
015016
Figure 16. Location of Single Backup Ring
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Page 22
015017
Figure 17. Teflon Backup Ring Installation - External
NAVAIR 01-1A-17 015 00
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Page 23
015018
Figure 18. Teflon Backup Ring - Damages Caused by Improper Handling
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Page 24
015019
Figure 19. Installing Internal Teflon Backup Ring
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Change 2 – 1 August 2014 Page 1 of 6
HYDRAULIC SYSTEMS
Reference Material
Alphabetical Index
Introduction..................................................................................................................................... 2
Phosphate Ester Fluids and Component Storage.......................................................................... 3
Component Storage ................................................................................................................... 3
Phosphate Ester Fluid Storage .................................................................................................. 3
Using Phosphate Ester Fluid.......................................................................................................... 2
Handling ..................................................................................................................................... 2
Safety Precautions ..................................................................................................................... 2
Phosphate Ester Fluid System Surveillance .................................................................................. 3
Hydraulic Contamination Analysis ............................................................................................. 3
None
NAVAIR 01-1A-17 016 00
TO 42B2-1-12
Page 2
If hydraulic fluid is decomposed by heat, 9. Gloves (WP002 00, Table 3, Item 17) shall be
toxic gases are released. Prolonged worn when hands are exposed to phosphate ester
contact with liquid or mist can cause fluids. Gloves and aprons of nitrile or polyethylene
dermatitis and irritation to skin and eyes. material are resistant to phosphate ester fluids.
If there is any prolonged contact with
skin, wash contacted area with soap and
water. If prolonged contact with mist is 10. In mist or fog form, phosphate ester fluids are
likely, wear approved respirator. irritating to nasal and respiratory passages and
Hydraulic fluid is toxic if swallowed. generally produce coughing and breathing difficulties.
Wash hands after handling and before These irritations pass as soon as the individual
eating, drinking or smoking. breathes fresh air.
MATERIALS EFFECT
Polystyrene dissolves
12. PHOSPHATE ESTER FLUIDS AND 15. PHOSPHATE ESTER FLUID SYSTEM
COMPONENT STORAGE. SURVEILLANCE.
NOTE
Fluorisant Excellent
Formvar Excellent
Polyamide Excellent
Polyethylene Excellent
Polyisobutylene Excellent
Teflon Excellent
Filter P/N LSWP04700 (08071), support e. Handle completed test filter membranes with
screen gasket P/N XX4004714 (08071), care. Phosphate ester fluids tend to remove some of
and O-rings P/N 2-233 EP and P/N 2-210 the membrane elasticity.
EP (59871) are recommended for patch
testing phosphate ester fluids. The Teflon f. Store completed test filters in a petri slide
filters should be verified by the customer after assuring that the filter membrane is thoroughly
to ensure the correct pore size is being dry.
utilized. These Teflon filters will not show
free water. Check for free water by visual 19. Electronic Particle Counters (NAVY USE
observation of fluid in the sample bottle. ONLY). The Type 2 Portable Oil Diagnostic System
Test filters furnished with Contamination (PODS), P/N MXU-976E, is compatible with
Analysis Kit 57L414 may be softened by phosphate ester based hydraulic fluids, synthetic and
phosphate ester fluids. The Teflon petroleum based fluids. To prevent fluid cross
gaskets are positioned over the thinner contamination, the Type 2 PODS is used only for
Teflon filter to provide a better seal. phosphate ester based hydraulic fluids. See WP005
00 for further information.
NOTE
HYDRAULIC SYSTEMS
Reference Material
None
Alphabetical Index
Cleanliness ..................................................................................................................................... 9
Contamination Analysis Procedures .............................................................................................. 5
Analysis of Test Filter ................................................................................................................ 8
Prepare Filter Holder Assembly ................................................................................................. 5
Sample Processing .................................................................................................................... 5
Description .................................................................................................................................... 2
Filters ......................................................................................................................................... 2
Filter Holder ............................................................................................................................... 2
Filter Mounts .............................................................................................................................. 2
Graduated Cylinder .................................................................................................................... 2
Sample Bottles ........................................................................................................................... 2
Standard .................................................................................................................................... 2
Syringe and Valve ...................................................................................................................... 2
Wash Bottles ............................................................................................................................. 2
Illustrated Parts Breakdown ........................................................................................................... 9
Introduction ................................................................................................................................... 2
Kit Component Maintenance .......................................................................................................... 9
Operational Procedures ................................................................................................................. 4
Sample Collection ...................................................................................................................... 4
Preparation for Use ........................................................................................................................ 3
Filter Holder ............................................................................................................................... 3
Flush Bottle ................................................................................................................................ 3
Sample Bottles ........................................................................................................................... 3
Wash Bottles .............................................................................................................................. 3
None
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Change 2 – 1 August 2014 Page 2
17. WASH BOTTLES. The two wash bottles are Figure 2: Attaching Filter to Flush Bottle
identical except that one has a shorter spout in order
to accommodate the Swinnex filter holder. This
bottle is used to dispense filtered solvent when 20. FLUSH BOTTLE.
making an analysis or when cleaning samples
bottles. The non-filtered wash bottle is employed
when cleaning fittings used at sample taking points.
NOTE
21. WASH BOTTLE. To prepare wash bottle, fill with
When using Swinnex filter, follow placard dry cleaning solvent, MIL-PRF-680 (WP002 00,
instructions. Table 3, Item 6) to wash sampling points.
b. Clean the required number of sample bottles, 31. PREPARE FILTER HOLDER ASSEMBLY.
caps and the threaded area of bottle caps (WP002
00, Table 3, Items 20 thru 24) 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 an approved waste receptacle (WP002 00, Dry Cleaning Solvent, MIL-PRF-680 6
Table 3, Item 19). This will serve to flush any
contaminants generated by mechanical operation. a. Remove filter holder assembly from the
Remove the cap from the bottle, fill the bottle to be storage position in the kit. The stainless steel funnel
cleaned approximately half full with the fluid from the and holder and support assembly is stored in an
sampling point. Shutoff flow from sampling point, if inverted position in the stainless steel vacuum flask.
necessary. Replace cap on bottle opening, agitate The funnel assembly and holder support assembly
the sample bottle several times, remove the cap and must be removed from the flask, inverted and
dump contents into an approved waste receptacle. reinstalled in the flask assembly. If difficulty is
Repeat this operation two times to remove residual encountered in removing the filter holder assembly
contaminants. Replace cap on bottle. If flow to from flask, insert back end of forceps (Figure 14,
sampling point has been terminated, re-open Index No. 15) or an equivalent tool into slot (present
sampling port. Without interrupting the fluid flow, of some assemblies) and pry holder from flask
obtain the required sample by replacing the (Figure 3). A thin film of hydraulic fluid applied to the
uncovered, rinsed, and clean sample bottle under external O-ring seals on the filter holder will aid in
the fluid stream. Once the bottle is filled to the insertion and removal.
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.
017004
017005
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 j. Operate the syringe in a slow pumping manner
pour exactly 100 ml of fluid into the graduated (Figure 10) drawing a vacuum until sustained
cylinder (Figure 14, Index No. 14) (Figure 8). filtration of the fluid is indicated by a steady drop of
Discard any remaining fluid. Pour contents of the fluid level in the funnel. As soon as the fluid level in
graduated cylinder into the stainless steel funnel on the funnel has dropped enough to allow the addition
top of the previously introduced filtered solvent. of approximately 50 ml solvent, pour half the
Allow contents of the graduated cylinder to drain contents of the graduated cylinder into the funnel as
completely into the funnel. filtration continues. If necessary, operate the
syringe again to maintain sufficient vacuum for
filtration.
017008
017010
NOTE
m. After filtration stops, disassemble the filter (5) Let filter membrane dry thoroughly in
holder. still air.
(1) Remove funnel from base. (6) Cover Petri slide.
(2) Remove support screen gasket and
inspect for damage. If damaged,
32. ANALYSIS OF TEST FILTER. After the fluid
remove and replace.
sample is processed, the resultant test filter
(3) Lift off test filter membrane with forceps membrane (patch) should be visually compared with
(Figure 11). 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.
017011
41. GENERAL. The Illustrated Parts Breakdown bulk items. The abbreviation REF indicates
(lPB) contains information applicable to the Reference and indicates the part has been listed
Hydraulic Fluid Contamination Analysis Kit, Part No. and illustrated elsewhere in the IPB and is included
57L414. It lists and describes the parts necessary in the present listing for reference only.
for requisitioning, identifying parts, and for illustrating
disassembly and assembly relationships. 49. USABLE ON CODE. This column indicates the
usability of parts on different models or series of the
42. GROUP ASSEMBLY PARTS LIST (GAPL). end item of equipment. If no letter appears in this
The GAPL consists of a breakdown of the complete column, the part may be used on all models/series
unit into subassemblies and detail parts. Attaching of the end item of equipment. An asterisk (*) in this
parts are identified immediately following the item column opposite two or more part numbers under
they attach. All symbols and abbreviations used in the same index number indicates equivalent parts.
the GAPL are in accordance with ASME Y14.38
Abbreviations and Acronyms. 50.SOURCE MAINTENANCE AND
RECOVERABILITY (SM&R). This column contains
43. INDEX NUMBER. In this column, the index the SM&R codes as assigned by the government.
numbers are assigned in numerical sequence and See Table 1 for a brief description of these codes.
are essentially in disassembly sequence. For a complete description of SM&R codes, refer to
NAVAlRlNST 4423.12 (series).
44. PART NUMBER. This column lists the prime
contractor part number, government standard part
number, or vendor part number.
SOURCE MAINTENANCE
USE REPAIR
1ST POSITION 2nd POSITION 3rd POSITION 4th POSITION
A REPLENISH REPLACE OR
B INSURANCE NO REPAIR
O USE AT Z
(CONSUMABLE)
C CURE-DATED ORG. LEVEL
D INITIAL
P PROCURE END ITEM
E REPLACE RECONDITION
GSE/STOCKED F AFLOAT OR BY ADJUSTMENT,
H ASHORE USE B CALIBRATION,
F GSE/NOT STOCKED G BOTH AT LUBRICATION PLATING,
IMA LEVEL ETC.
REPAIR F ORG/IMA
K KIT REPLACE OR
REPAIR
COMPONENT D DEPOT L USE AT 0
ORG. LEVEL
B BOTH KITS SPECIALIZED IMA
M MANUFACTURE
O REPLACE REPAIR
ORG F AFLOAT
F OR AT
AFLOAT H ASHORE
H USE IMA
ASHORE IMA D G BOTH
G AT LEVEL
BOTH
D DEPOT DEPOT
S REPAIR AT
A ASSEMBLY (L) SPECIALIZED IMA
A REQUEST NHA
OBTAIN FROM
B SALVAGE OR ONE REPAIR AT
TIME BUY NOT REQD.
X MISC. Z D DEPOT OR
THIS APPLIC.
COMMER.
DIAGRAMS-
SCHEMATICS
C
INSTALL
DWGS
RECOVERABILITY
5TH POSITION
NON-REPAIRABLE, CONDEMN AT LEVEL
Z
INDICATED IN POS. 3
017014
017014
017014
USABLE ON
ASSEMBLY
UNITS PER
INDEX NO. PART NUMBER DESCRIPTION SM&R
CODE
CODE
1234567
57L414 HYDRAULIC FLUID CONTAMINATION ANALYSIS REF PAOGG
XX6504700 KIT XX6504700/08071/REPAIR KITS AVAILABLE,
INDEX 26 AND 27
1 XX6300120 . HOLDER, FILTER ASSEMBLY /08071/ 1 AGOGG
2 XX6300121 . . FUNNEL, STAINLESS STEEL /08071 1 PAOZZ
3 XX2004707 . . LOCK, WHEEL /08071/ 2 PAOZZ
4 XX6504708 . . SUPPORT, BASE ASSEMBLY /08071/ 1 PAOZZ
5 XX6300123 . . BASE O-RINGS, BUNA-N /08071/ 2 PAOZZ
6 YY4014267 . . SUPPORT O-RING, BUNA-N /08071/ 1 PAOZZ
7 XX2004703 . . SUPPORT SCREEN GASKET TEFLON /08071/ 1 PAOZZ
8 XX2004708 . . SUPPORT SCREEN STAINLESS STEEL /08071/ 1 PAOZZ