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(NAVY) NAVAIR 01-1A-17

(AIR FORCE) TO 42B2-1-12


15 August 2006
Change 2 – 1 August 2014

TECHNICAL MANUAL

ORGANIZATIONAL, INTERMEDIATE AND


DEPOT MAINTENANCE

AVIATION HYDRAULICS MANUAL

Includes IRACs 10, 11, 12, 13, 14, and 15.

N68936-04-D-0008

DISTRIBUTION STATEMENT A. Approved for public release, distribution is


unlimited. PA Case Number AFMC 06-273 for Air Force.

PUBLISHED BY DIRECTION OF THE COMMANDER, NAVAL AIR SYSTEMS COMMAND

/3
NAVAIR 01-1A-17
TO 42B2-1-12
Change 2 – 1 August 2014 Page A

NUMERICAL INDEX OF EFFECTIVE WORK PACKAGES/PAGES

Dates of issue for original and changed pages are:

Original ......................... 0 .......................... 15 August 2006 (Includes IRACs 10 through 15)


Change ......................... 1 ............................ 1 August 2008
Change ......................... 2 ............................ 1 August 2014

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 Dispose of superseded work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 Superseded classified work packages/pages shall be destroyed in accordance with applicable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

Title 006 00 Aircraft System Decontamination


Page A Numerical Index of Effective Work 007 00 Hydraulic Contamination Control
Packages/Pages 008 00 Servicing Hydraulic Systems
TPDR-1 List of Technical Publications 009 00 Hydraulic Support Equipment
Deficiency Reports Incorporated 010 00 Hydraulic Filters
HMWS-1 Warnings Applicable to Hazardous 011 00 Controlled Environment Work Center
Materials 012 00 Selection and Use of Cleaning
001 00 Alphabetical Index Materials
002 00 Introduction 013 00 Repair, Test, and Maintenance of
003 00 Description, Hydraulic Systems and Hydraulic Systems and Components
Hydraulic Fluids 014 00 Protective Closures
004 00 Hydraulic Fluid Contamination 015 00 Hydraulic Seals
005 00 Hydraulic Fluid Contamination 016 00 Phosphate Ester Hydraulic Fluid
Analysis 017 00 Hydraulic Fluid Contamination
Analysis Kit (P/N 57L414)

Total number of pages in this manual is 218, consisting of the following:

WP/Page Number Change No. WP/Page Number Change No. WP/Page Number Change No.

Title ............................................ 2 4 ............................................. 2 5 – 6 ...................................... 0


A ................................................. 2 5 ............................................ 0 7 – 8 ....................................... 2
B ................................................. 2 6 – 11 ..................................... 2 9 – 10 ..................................... 0
C Blank ....................................... 0 12 – 18 .................................. 0 006 00
TPDR-1 ...................................... 2 19 – 28 ................................... 2 1 – 3 ....................................... 0
TPDR-2 ..................................... 2 003 00 4 – 5 ....................................... 2
TPDR-3 ...................................... 2 1 – 6 ....................................... 0 6 ............................................. 0
TPDR-4 ...................................... 2 004 00 7 – 8 ....................................... 2
HMWS-1 – HMWS-6 .................. 0 1 ............................................. 2 9 ............................................. 0
001 00 2 ............................................. 0 10 ........................................... 2
1 ............................................. 0 3 – 8 ....................................... 2 11 ........................................... 0
2 Blank ................................... 0 005 00 12 Blank ................................. 0
002 00 1 ............................................. 2 007 00
1 ............................................ 2 2 ............................................. 0 1 ............................................. 0
2 – 3 ....................................... 0 3 – 4 ....................................... 2 2 ............................................. 1
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3 – 5 ....................................... 0 010 00 015 00


6 Blank ................................... 0 1 – 8 ....................................... 0 1 ............................................. 2
008 00 011 00 2 – 12 ..................................... 0
1 – 4 ....................................... 2 1 – 6 ...................................... 0 13 ........................................... 2
009 00 7 ............................................. 2 14 – 24 ................................... 0
1 – 3 ....................................... 2 8 ............................................. 0 016 00
4 ............................................. 0 012 00 1 ............................................. 2
5 – 9 ....................................... 2 1 – 2 ....................................... 0 2 ............................................. 0
10 ........................................... 1 3 ............................................. 2 3 ............................................. 2
11 ........................................... 2 4 – 6 ....................................... 0 4 ............................................. 0
12 – 13 ................................... 1 7 ............................................. 1 5 – 6 ...................................... 2
14 ........................................... 2 8 Blank ................................... 0 017 00
15 ........................................... 1 013 00 1 ............................................ 0
16 – 17 ................................... 2 1 – 12 .................................... 0 2 – 6 ...................................... 2
18 – 24 ................................... 1 014 00 7 – 8 ....................................... 0
25 ........................................... 2 1 ............................................. 2 9 – 10 ..................................... 2
26 – 27 ................................... 1 2 – 9 ...................................... 1 11 ........................................... 0
28 ........................................... 2 10 – 14 ................................... 2 12 – 16 ................................... 2
29 ........................................... 1 15 – 16 ................................... 1
30 ........................................... 2
THIS PAGE LEFT INTENTIONALLY BLANK
NAVAIR 01-1A-17
TO 42B2-1-12
Change 2 – 1 August 2014 TPDR-1

ORGANIZATIONAL, INTERMEDIATE AND


DEPOT MAINTENANCE

LIST OF TECHNICAL PUBLICATIONS DEFICIENCY


REPORTS INCORPORATED

AVIATION HYDRAULICS MANUAL

NAVY USE ONLY

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

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 APPLICABLE TO HAZARDOUS MATERIALS

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

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

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

EXPLANATION OF HAZARDOUS SYMBOLS


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

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

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

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

Eye Protection
The symbol of a person wearing goggles shows a material that can injure your eyes.
NAVAIR 01-1A-17 HMWS-2
TO 42B2-1-12

EXPLANATION OF HAZARDOUS SYMBOLS (Cont)


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

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

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

Vapor
The symbol of a human figure in a cloud shows that breathing this material can present a health
hazard.
NAVAIR 01-1A-17 HMWS-3
TO 42B2-1-12

HAZARDOUS MATERIALS WARNINGS

Index Material Warning

1 Hydraulic Fluid, MIL-PRF-5606 If hydraulic fluid is decomposed by heat, toxic


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

2 Hydraulic Fluid, MIL-PRF-83282 If hydraulic fluid is decomposed by heat, toxic


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

3 Hydraulic Fluid, MIL-H-81019 If hydraulic fluid is decomposed by heat, toxic


gases are released. Prolonged contact with liquid
or mist can cause dermatitis and irritation to skin
and eyes. If there is any prolonged contact with
skin, wash contacted area with soap and water. If
prolonged contact with mist is likely, wear approved
respirator. Hydraulic fluid is toxic if swallowed.
Wash hands after handling and before eating,
drinking or smoking. PPE: Chemical splash proof
goggles and gloves. Consult the applicable
Material Safety Data Sheet (MSDS) and local
Occupational Safety and Health (OSH) regulations
for appropriate safety precautions.
NAVAIR 01-1A-17 HMWS-4
TO 42B2-1-12

HAZARDOUS MATERIALS WARNINGS (Cont)

Index Material Warning

4 Hydraulic Fluid, MIL-PRF-87257 If hydraulic fluid is decomposed by heat, toxic


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

5 Hydraulic Fluid, SAE AS1241 If hydraulic fluid is decomposed by heat, toxic


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

6 Dry Cleaning Solvent, MIL-PRF-680 Dry Cleaning Solvent, MIL-PRF-680, may cause
eye and skin irritation. Overexposure may cause
dizziness and other central nervous system effects.
Wear nitrile gloves and chemical splash proof
protective goggles. Consult the applicable Material
Safety Data Sheet (MSDS) and local Occupational
Safety and Health (OSH) regulations for
appropriate safety precautions.
NAVAIR 01-1A-17 HMWS-5
TO 42B2-1-12

HAZARDOUS MATERIALS WARNINGS (Cont)

Index Material Warning

7 Aircraft External Cleaning Compound, Aircraft Cleaning Compound, MIL-PRF-85570, is


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

8 Detergent, Non-Ionic, MIL-D-16791 Non-ionic detergent, MIL-D-16791, Type I, may


irritate skin and eyes. Avoid contact. Wear gloves
and chemical splash proof safety glasses. Consult
the applicable Material Safety Data Sheet (MSDS)
and local Occupational Safety and Health (OSH)
regulations for appropriate safety precautions.

9 Isopropyl Alcohol, TT-I-735 Isopropyl Alcohol, TT-I-735, is flammable. Do not


use near open flame or other sources of ignition.
May irritate skin and eyes. Inhalation may cause
dizziness, headaches and irritation to respiratory
tract. Wear chemical splash proof goggles and
gloves. Consult the applicable Material Safety Data
Sheet (MSDS) and local Occupational Safety and
Health (OSH) regulations for appropriate safety
precautions.

10 Molydisulphide Grease, MIL-G-21164 Molydisulphide Grease, MIL-G-21164, may cause


skin irritation. Avoid contact with skin and eyes.
Wear nitrile gloves and safety glasses. Consult the
applicable Material Safety Data Sheet (MSDS) and
local Occupational Safety and Health (OSH)
regulations for appropriate safety precautions.

11 General Purpose Aircraft Grease, General Purpose Aircraft Grease, MIL-PRF-81322,


MIL-PRF-81322 is an eye irritant and, upon prolonged exposure, a
skin irritant. May contain chromates, suspected
carcinogens. Keep away from oxidizing agents.
Wear gloves and safety glasses. Manufacturers’
hazards may vary. Always consult proper MSDS.
NAVAIR 01-1A-17 HMWS-6
TO 42B2-1-12

HAZARDOUS MATERIALS WARNINGS (Cont)

Index Material Warning

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)

ORGANIZATIONAL, INTERMEDIATE AND


DEPOT MAINTENANCE

ALPHABETICAL INDEX

AVIATION HYDRAULICS MANUAL

WP
Title Number

Aircraft System Decontamination....................................................................................................... 006 00


Alphabetical Index.............................................................................................................................. 001 00
Controlled Environment Work Center (NAVY USE ONLY) ............................................................... 011 00
Description, Hydraulic Systems and Hydraulic Fluids ....................................................................... 003 00
Hydraulic Contamination Control (NAVY USE ONLY) ...................................................................... 007 00
Hydraulic Filters ................................................................................................................................. 010 00
Hydraulic Fluid Contamination ........................................................................................................... 004 00
Hydraulic Fluid Contamination Analysis............................................................................................. 005 00
Hydraulic Fluid Contamination Analysis Kit (P/N 57L414) (NAVY USE ONLY)................................ 017 00
Hydraulic Seals .................................................................................................................................. 015 00
Hydraulic Support Equipment (NAVY USE ONLY) ........................................................................... 009 00
Introduction ........................................................................................................................................ 002 00
Phosphate Ester Hydraulic Fluid........................................................................................................ 016 00
Protective Closures (NAVY USE ONLY) ........................................................................................... 014 00
Repair, Test, and Maintenance of Hydraulic Systems and Components (NAVY USE ONLY) ......... 013 00
Selection and Use of Cleaning Materials ........................................................................................... 012 00
Servicing Hydraulic Systems.............................................................................................................. 008 00
THIS PAGE LEFT INTENTIONALLY BLANK
NAVAIR 01-1A-17 002 00
TO 42B2-1-12
Change 2 – 1 August 2014 Page 1 of 28

ORGANIZATIONAL, INTERMEDIATE AND


DEPOT MAINTENANCE

INTRODUCTION

AVIATION HYDRAULICS MANUAL

1. PURPOSE. be followed as specified in WP008 00


thru WP010 00.
2. The purpose of this manual is to provide general
requirements for maintenance of aircraft hydraulic
systems and related support equipment (SE). 8. Maintenance instructions provided in this manual
relate to hydraulic systems utilizing hydraulic fluids
3. SCOPE. MIL-PRF-5606 (Table 3, item 1), MIL-PRF-83282
(Table 3, item 2), MIL-H-81019 (Table 3, item 3), and
4. This manual is applicable to all military aircraft MIL-PRF-87257 (Table 3, Item 4). Some military
hydraulic systems, airborne hydraulic equipment, and aircraft employ phosphate ester hydraulic fluids
related hydraulic servicing and test equipment. It is (Table 3, Item 5). This in some cases, results in
required reading for all military and civilian personnel maintenance procedures and materials peculiar to
at all levels of maintenance, performing any hydraulic these aircraft. Refer to WP016 00 for specific
maintenance function on military aircraft systems, information regarding phosphate ester hydraulic fluid
airborne hydraulic equipment and related SE. and those systems which employ this fluid.

5. APPLICATION. 9. REQUISITION AND AUTOMATIC


DISTRIBUTION OF NAVAIR TECHNICAL
6. This manual is applicable to all military aircraft MANUALS.
hydraulic systems, airborne hydraulic equipment, and
related hydraulic servicing and test equipment, 10. Procedures to be used by Naval activities and
including SE, peculiar support equipment (PSE), other Department of Defense activities requiring
common support equipment (CSE) and facilities or NAVAIR technical manuals are defined in NAVAIR
installed equipment. This manual is not applicable to 00-25-100 and NAVAIRINST 5605.5 Series.
missile systems, propeller systems and their related
SE. It is applicable to all levels of maintenance, 11. To automatically receive future changes and
including contract maintenance performed by other revisions to NAVAIR technical manuals, an activity
Government agencies on military aircraft, and must be established on the Automatic Distribution
associated airborne hydraulic equipment and related Requirements List (ADRL) maintained by the Naval
SE. Engineering personnel and technical data writers Air Technical Data and Engineering Service
shall comply with the general requirement of this Command (NATEC). To become established on the
manual. When a conflict exists, this manual takes ADRL, notify your activity central technical
precedence over other NAVAIR directives, publications librarian. If your activity does not have a
engineering directives, and maintenance instructions. library, you may establish your automatic distribution
Maintenance activities shall contact the applicable by contacting the Commanding Officer, NATEC, Attn:
Fleet Support Team (FST) for immediate resolution of Distribution, NAS North Island, Bldg. 90, P.O. Box
the conflict. 357031, San Diego, CA 92135-7031. Annual
reconfirmation of these requirements is necessary to
7. The Air Force specific systems/components remain on automatic distribution. Please use your
manuals shall take precedence over this manual. NATEC assigned account number whenever referring
to automatic distribution requirements.
NOTE
12. If additional or replacement copies of this
Hydraulic fluids in propeller systems and manual are required with no attendant changes in the
air refueling stores are exempt from the ADRL, they may be ordered by submitting a
cleanliness requirements in WP004 00. MILSTRIP requisition in accordance with NAVSUP
However, hydraulic servicing and 485 to Routing Identifier Code “NFZ”. MILSTRIP
hydraulic filter handling procedures shall requisitions can be submitted through your supply
NAVAIR 01-1A-17 002 00
TO 42B2-1-12
Page 2

office, Navy message, or SALTS to DAAS (Defense 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.

21. KEEP AWAY FROM LIVE CIRCUITS. Operating WARNING


personnel must observe safety precautions at all
times. Do not replace components or make
adjustments inside any equipment with the high Extreme caution shall be taken when
NAVAIR 01-1A-17 002 00
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Page 3

troubleshooting hydraulic systems under 31. ABBREVIATIONS.


pressure to avoid accidental injection of
fluid under the skin. Fluid injection can 32. Abbreviations used in this manual are listed in
result in serious injury and great pain; get Table 1.
immediate medical attention.
33. GLOSSARY.

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.

a. Ejection seats shall be treated with the


same respect as a loaded gun. 36. Types of symbols commonly used in drawing
circuit diagrams for fluid power systems are Pictorial,
b. Always consider an ejection seat system Cutaway and Graphic. Pictorial and Cutaway symbols
as loaded and armed. have been in widespread usage for many years and
should be readily familiar to all hydraulic maintenance
29. WARNINGS, CAUTIONS, AND NOTES. personnel. Graphic symbols, which emphasize the
function and methods of operation of components,
30. Warning, cautions, and notes will be found provide a very effective means of depicting system
throughout the manual in various procedures. It configuration and as a result are being utilized with
is important that the significance of each be increasing frequency. Figure 1 illustrates commonly
thoroughly understood by personnel using this used symbols that may be encountered in hydraulic
manual. Their definitions are: schematic diagrams employing graphic symbols and
is provided as reference data. The symbols shown
have been extracted from SAE AS1290 and USA
Standard Graphic Symbols for Fluid Power Diagrams
(USAS Y32.10-1967) with the permission of the
Indicates a procedure, practice, etc., publisher. The American Society of Mechanical
which will result in personal injury or loss Engineers United Engineering Center, 345 E. 47th
of life if not correctly followed. Street, New York, NY 10017.

37. CONSUMABLE MATERIALS.

38. Table 3 lists the consumable materials used in


Indicates a procedure or practice which, this manual.
if not strictly observed, will result in
damage or destruction of equipment. 39. RELATED PUBLICATIONS.

NOTE 40. In many instances, procedures called out in this


manual can best be performed in conjunction with
Highlights an essential procedure to other system or component manuals and directives,
ensure correct maintenance. as listed in Table 4.
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Table 1. Abbreviations

Abbreviation Definition

ADRL Automatic Distribution Requirements List

AFPA Air Force Petroleum Agency

AMMRL Aircraft Maintenance Material Readiness List

ASG Aircraft Sustainment Group

COMNAVAIRFORINST Commander Naval Air Forces Instruction

CSE Common Support Equipment

FRC Fleet Readiness Center

FST Fleet Support Team

gpm Gallons Per Minute

GSE Ground Support Equipment

IMA Intermediate Maintenance Activity

MIM Maintenance Instruction Manual

ml Milliliter

MRC Maintenance Requirement Cards

MSDS Material Safety Data Sheet

NAMPSOP Naval Aviation Maintenance Program Standard


Operating Procedures

NATEC Naval Air Technical Data and Engineering Service


Command

NAVAIR Naval Air Systems Command

NAWCAD Naval Air Warfare Center, Aircraft Division

NOAP Naval Oil Analysis Program

OMA Organizational Maintenance Activity

OSH Occupational Safety and Health

QA Quality Assurance

PODS Portable Oil Diagnostic System


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Table 1. Abbreviations (Cont)

PSE Peculiar Support Equipment

ppm Parts Per Million

SE Support Equipment

TLV Threshold Limit Values

TO Technical Order

TPDR Technical Publication Deficiency Report


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Table 2. Glossary

Term Definition

Air Bleeding A service operation in which entrapped air is allowed to


escape from the closed hydraulic system.

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

Backup Ring A device used to prevent pressure and friction from


extruding the O-ring packing through the clearance gap of
a seal.

Cavitation A localized gaseous condition within a liquid stream which


occurs where the pressure is reduced to the vapor
pressure.

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

Contaminant Any material or substance which is undesired or capable of


adversely affecting the hydraulic system or its components.

Contaminant, Built-In Initial residual contamination in a component, fluid, or


system. Typical built-in contaminants are buns, chips, flash,
dirt, dust, fiber, sand, moisture, pipe dope, weld spatter,
paints and solvents, incompatible fluids and operating fluid
impurities.

Contamination Level A quantitative term specifying the degree of contamination.

Contamination, Gross A level of contamination which exceeds Class 6 of Navy


Standard or SAE AS4059 (formerly NAS 1638) Class 9 and
is considered abnormally high as a result of either the
amount or size of the contaminants present.

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

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


filled system.

Decontamination The process of removing unwanted material or substances;


the reduction of contamination to an acceptable level.
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Table 2. Glossary (Cont)

Term Definition

Depot Maintenance That maintenance performed on material requiring major


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

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

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

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

Flash Point The temperature to which a liquid must be heated under


specified conditions of the test method to give off sufficient
vapor to form a mixture with air that can be ignited
momentarily (caused to flash) by a specified flame. ASTM D
92 or ASTM D 93

Fleet 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.

Flushing A decontamination process in which original aircraft fluid is


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

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

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

Gasket A type of seal which is formed by crushing the packing


material into the gland such that the cavity formed by the
gland is normally filled with the packing material.
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Table 2. Glossary (Cont)

Term Definition

Gland The component of the seal which forms the cavity or


inclusion which surrounds and supports the packing and
controls the squeeze.
Halogen Any of the five chemical elements; fluorine, chlorine,
bromine, iodine, and astatine.

HEPA Filter High Efficiency Particulate Air Filter. An efficient filter


usually constructed from fine fiber pleated papers, intended
for the removal of particulate matter from air. Widely used
in clean rooms and clean work stations.

Humidity The amount or degree of moisture in the air.

Incompatible Fluids Fluids which, when mixed in a system, will have a


deleterious effect on that system, its components, or its
operation.

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

Intermediate Maintenance Activity (IMA) A Navy/USMC maintenance activity designated to provide


direct maintenance support to using organizations. Its
responsibilities normally consist of calibration, test, repair,
or replacement of damaged or unserviceable parts,
components, or assemblies; emergency manufacture of
non-available parts; and technical assistance to using
organizations.

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

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

Laminar Flow Work Station A contamination controlled workbench used to ensure a


high degree of cleanliness about a component.

Loaded Filter (Clogged) A filter element that has collected a quantity of


contaminants such that it can no longer pass fluid at rated
flow without excessive differential pressure or by-pass.

Maintenance Instruction Manual (MIM) A manual containing instructions for intermediate and
organizational level servicing and maintenance of a specific
model of aircraft or equipment.
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Table 2. Glossary (Cont)

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.

Micron Unit of measurement one millionth of a meter long, or


approximately 0.00003937 inch expressed in English units.

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

Naval Air 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.

Oxidation Inhibitor An additive to the base fluid intended to minimize fluid


oxidation and the generation of oxidation byproducts.

Packing The component of a seal which serves as a sealing medium


by nature of its plastic or elastic properties, or its ability to
deform into the shape of the gland.

Particle Counter Electronic equipment which counts solid particles contained in


fluid and provides a breakdown by size ranges of particles.

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

Particulate Contamination Standards Standard used to quantitatively grade levels of particulate


contamination. The Navy standard defines seven class levels
of particles (0 thru 6) and the SAE AS4059 (formerly NAS
1638) standard defines fourteen class levels of particles (00
and 12). Both are based on the quantity of particles in 100 ml
of sampled fluid.
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Table 2. Glossary (Cont)

Term Definition

Patch Test A method of evaluating fluid contamination wherein the


fluid sample is passed through a standardized laboratory
filter membrane and the change in color or reflectivity of the
filter compared with previously established standards.
Phosphate Ester Clear, light purple, fire-resistant hydraulic fluids conforming
to SAE AS1241.

Polymerization The union of two or more molecules of a compound to form


a more complex compound with a higher molecular weight;
a process which can result in the generation of undesired
substances or contaminants.

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

Pressure, Proof The nondestructive test pressure, in excess of the


maximum rated operating pressure, which causes no
permanent deformation, excessive external leakage, or
other malfunction.

Purging A decontamination process in which the aircraft system is


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

Purifying A decontamination process using equipment capable of


removing particles, air, water, and some solvents from
hydraulic fluid.

Recirculation Cleaning A decontamination process in which the aircraft systems


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

A decontamination process in which SE or PSE supply


hose is coupled to it’s own return hose by a manifold or is
coupled to a fitting on the unit to return fluid to it’s own
reservoir. Decontamination is accomplished by returning
fluid to reservoir and circulating fluid past the unit’s own
filter. Recirculation of SE may allow air trapped in SE lines,
hoses and fluid to vent out in the unit’s reservoir.
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Table 2. Glossary (Cont)

Term Definition

Seal A device to retain fluid within a hydraulic component. The


seal may consist of two or more components, such as a
packing in a gland, and a packing and backup ring in a
gland.
Skydrol and Hyjet Trade names for phosphate ester fluids. Defined by SAE
AS1241.

Squeeze The dimension by which a packing is distorted from its


molded shape when installed in a packing gland.

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

Technical Order A manual containing instructions for intermediate and


organizational level servicing and maintenance of a specific
model of aircraft or equipment.

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

Test Stands, Stationary Hydraulic Installed equipment intended for use in shop testing of
hydraulic system components at intermediate and depot
AF-Test Stand, Hydraulic Component maintenance activities.

TFE A tetrafluoroethylene resin.

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

Ultrasonic Cleaning A cleaning method in which mechanical energy varying at


an ultrasonic rate is coupled through the cleaning medium
to the work to facilitate cleaning action.

Valve, Sampling A valve provided specifically to enable the extraction of


representative fluid samples from an operation system for
purposes of contamination analysis.

Viscosity A measure of the internal friction or the resistance of fluid


to flow.
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00200101
Figure 1. Graphic Symbols for Fluid Power Diagrams (Sheet 1 of 6)
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00200102
Figure 1. Graphic Symbols for Fluid Power Diagrams (Sheet 2)
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00200103
Figure 1. Graphic Symbols for Fluid Power Diagrams (Sheet 3)
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Page 15

00200104
Figure 1. Graphic Symbols for Fluid Power Diagrams (Sheet 4)
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Figure 1. Graphic Symbols for Fluid Power Diagrams (Sheet 5)


00200105
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00200106
Figure 1. Graphic Symbols for Fluid Power Diagrams (Sheet 6)
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Table 3. Consumable Materials List

Item
No. Nomenclature Specifications Intended Use

HYDRAULIC FLUIDS

1 Hydraulic Fluid, Aircraft, MIL-PRF-5606 Refer to WP003 00.


Missile, and Ordnance NATO No. H-515

2 Hydraulic Fluid, MIL-PRF-83282 Refer to WP003 00.


Fire Resistant NATO No. H-537

3 Hydraulic Fluid, MIL-H-81019 Refer to WP003 00.


Ultra-Low-Temperature

4 Hydraulic Fluid, MIL-PRF-87257 Refer to WP003 00.


Low Temperature, NATO No. H-538
Synthetic Hydrocarbon
Aircraft and Missile

5 Hydraulic Fluid, SAE AS1241 Refer to WP016 00.


Phosphate Ester

SOLVENTS

6 Dry Cleaning Solvent MIL-PRF-680 Performing hydraulic fluid


contamination analysis, cleaning
sample bottles and filter elements.

7 Dry Cleaning Solvent A-A-59601 (PD-680) Refer to WP012 00

NOT APPLICABLE TO
NAVY

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

9 Calibration Fluid P/N LSTMP010 Calibration fluid for the HIAC


NSN 6695-01-476-0550 particle counter.

LUBRICANTS

10 Grease, Molybdenum MIL-G-21164 Sliding steel on steel, heavily


Disulfide, For Low and High NATO No. G-353 loaded hinges; rolling element
Temperatures bearings where required.

11 Grease, Aircraft General MIL-PRF-81322 O-rings, certain splines, ball and


Purpose Wide Temp. Range NATO No. G-395 roller bearing assemblies, primarily
wheel brake assemblies and in
applications where compatibility
with rubber is required.

* Manufacturer’s part number and CAGE Code.


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Table 3. Consumable Materials List (Cont)

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

CLOTHS AND CLEANING PADS

13A Wiping Cloth, Disposable, A-A-59323, Type I Refer to WP012 00.


Lint-free, Ultra-Clean

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

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

16 Glove, Rubber MIL-DTL-32066 (formerly Protecting hands from cleaning


ZZ-G-381) compounds.

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


Distributors
Handling Phosphate Ester fluids.
17B Glove, Nitrile, Disposable, Various Laboratory Supply
Powder-free Distributors

CONTAINERS

18A Bottle, Polyethylene with *2002-0004 (05178)


24 mm Polypropylene NSN 6640-01-330-4902
Screw Closures, 4 ounce Sample bottles for phosphate ester fluid.

18B Bottle, Polypropylene *02-893-5A (22527)


NSN 6640-01-468-8092

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

*Manufacturer’s part number and CAGE Code.


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Table 3. Consumable Materials List (Cont)

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

CONTROLLED ENVIRONMENT WORK CENTER CLEANING MATERIALS

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

27 Sponge, Cellulose Commercially available Refer to WP011 00.

28 Squeegee Commercially available Refer to WP011 00.

29 Detergent, general purpose MIL-D-16791, Type 1 Refer to WP011 00.


(liquid, non-ionic)

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

*Manufacturer’s part number and CAGE Code.


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Table 4. Related Publications

Publication Number Title

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

AFI 21-101 Aerospace Equipment Maintenance Management

AG-140BA-MIB-000 Operation and Intermediate Maintenance Instructions


with Illustrated Parts Breakdown Hydraulic Fluid
Service Unit Type HSU-1 Part Number 630AS100-11

AG-140AB-MMB-000 Operations and Intermediate Maintenance with


Illustrated Parts Breakdown Portable Hydraulic Power
Supply Electric (PHPSE) Part Number 98612-100

AG-140AB-MRC-100 Preoperational Checklist Portable Hydraulic Power


Supply Electric (PHPSE) Part Number 98612-100

AG-140AB-MRC-200 Periodic Maintenance Requirement Cards (MRC)


Portable Hydraulic Power Supply Electric (PHPSE)Part
Number 98612-100

AG-140AC-MMB-000 Operations and Intermediate Maintenance with


Illustrated Parts Breakdown Portable Hydraulic Power
Supply Diesel (PHPSD) Part Number 000850-100

AG-140AC-MRC-100 Preoperational Checklist Portable Hydraulic Power


Supply Diesel (PHPSD) P/N 000850-100

AG-140AC-MRC-200 Periodic Maintenance Requirements Manual Portable


Hydraulic Power Supply Diesel (PHPSD) Part Number
000850-100

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

AG-140BA-MRC-200 Periodic Maintenance Requirements Manual Hydraulic


Service Unit Model HSU-1

AG-711BA-MAB-000 Operation and Intermediate Maintenance with


Illustrated Parts Breakdown Fluid Purifier A/M 37M-2
Part Number AD-A352-8Y10

AG-720AO-MRC-000 Preoperational Checklist Pump, Dispensing, Hand


Driven PMU-55/E P/N 4-5280

AG-720AO-S15-000 Operation and Intermediate Maintenance Instructions


with Illustrated Parts Breakdown Pump, Dispensing,
Hand Driven PMU-55/E Part Number 4-5280

AN929 Cap Insert, Assembly, Pressure Seal, Flared Tube


Fitting

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


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Change 2 – 1 August 2014 Page 22

Table 4. Related Publications (Cont)

Publication Number Title

COMNAVAIRFORINST 4790.2 Maintenance Program, Naval Aviation

ISO 14644-1/14644-2 Cleanrooms and Associated Controlled Environments

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

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

MIL-DTL-32066 Gloves, Rubber, Industrial

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


Micronic Type

MIL-F-8815 Filter and Filter Elements, Fluid Pressure, Hydraulic


Line, 15 Micron Absolute and 5 Micron Absolute, Type
II Systems

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


Temperatures, NATO Code Number G-353

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


Requirements for

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


Temperature, Metric

MIL-HDBK-695 Rubber Products: Recommended Shelf Life

MIL-PRF-32014 Grease, Aircraft and Instrument

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


Ordnance

MIL-PRF-680 Degreasing Solvent

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


Range, NATO Code G-395

MIL-PRF-81836 Filter and Disposable Element, Fluid Pressure,


Hydraulic, 3 Micron Absolute

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


Base, Metric, NATO Code Number H-537

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

MIL-PRF-87257 Hydraulic Fluid, Fire Resistant; Low Temperature


Synthetic Hydrocarbon Base, Aircraft and Missle

MIL-STD-1472 Human Engineering Design Criteria For Military


Systems Equipment and Facilities
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Table 4. Related Publications (Cont)

Publication Number Title

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

MS28774 Retainer, Packing Backup, Single Turn


Polytetrafluoroethylene

MS9404 Plug, Machine Thread – AMS5646, Preformed


Packing

NAS 1638 (superseded by SAE AS4059) Cleanliness Requirements of Parts Used in Hydraulic
Systems

NAS817 Cap - Protective, Flared Fitting

NAS818 Plug - Protective, Flared Tube, Hose Assembly

NAS838 Plug - Protective, Flareless Tube End (Plastic)

NAS839 Cap - Beaded Hose Connection, Plastic, Protective

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

NAS842 Plugs, Protective, Flareless Tube End (Metal)

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

NAS847 Caps and Plugs, Protective, Dust and Moisture Seal

NAVAIR 00-25-100 Naval Air Systems Command Technical Publication


Library Management Program

NAVAIR 01-1A-20 Organizational, Intermediate and Depot Maintenance


Aviation Hose and Tube Manual

NAVAIR 17-15-521 Operation and Intermediate Maintenance Instructions


with Illustrated Parts Breakdown, Particle Counting
System Part Number 8011-3

NAVAIR 17-15BF-26 Operation and Maintenance Instructions with


Illustrated Parts Breakdown Air Driven, Portable,
Hydraulic Check and Fill Test Stand Model 74

NAVAIR 17-15BF-35 Operation and Service Instructions with Parts


Breakdown Air Driven, Portable, Hydraulic Check and
Fill Stand Model 718

NAVAIR 17-15BF-37 Operation and Maintenance Instructions with


Illustrated Parts Breakdown Aircraft Hydraulic and
Pneumatic Component Test Stand Model HCT-10
Part No. 66A91J001
NAVAIR 01-1A-17 002 00
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Change 2 – 1 August 2014 Page 24

Table 4. Related Publications (Cont)

Publication Number Title

NAVAIR 17-15BF-41 Operation, Service, and Overhaul Instructions Manual


with Illustrated Parts Breakdown Automatic Flight
Control System Servocylinder Test Stand Assembly
Part Number 65700-65014-041

NAVAIR 17-15BF-504 Handbook Operation and Service Instructions with


Illustrated Parts Breakdown, Aircraft Hydraulic Hose
Check Stand

NAVAIR 17-15BF-57 Maintenance Instructions with Illustrated Parts


Breakdown (Organizational, Intermediate) Hydraulic
Fill Unit

NAVAIR 17-15BF-76 Operation, Intermediate, and Depot Maintenance


Instructions with Illustrated Parts Breakdown Portable
Hydraulic Power Unit A/M27T-3 Part Number
636AS100-1

NAVAIR 17-15BF-87 Operation and Intermediate Maintenance with


Illustrated Parts Breakdown Hydraulic Fluid
Dispensing Unit A/M27M-10 Part Number 995AS300-
1

NAVAIR 17-15BF-89 Operation and Intermediate Maintenance with


Illustrated Parts Breakdown, Portable Hydraulic Power
Supply A/M27T-5 and A/M27T-5A

NAVAIR 17-15BF-90 Operation and Intermediate Maintenance with


Illustrated Parts Breakdown Test Stand Aircraft
Hydraulic Systems A/M27T-6 Part Number
1415AS100-1

NAVAIR 17-15BF-91 Operation and Intermediate Maintenance with


Illustrated Parts Breakdown, Portable Hydraulics
Power Supply (Electric Motor Driven) Model A/M27T-7
and A/M27T-7A

NAVAIR 17-15BF-94 Intermediate and Depot Maintenance with Illustrated


Parts Breakdown, Hydraulic Component Test Stand
Navy Model A/F27T-10 Part Number 2029AS100-10,-
20

NAVAIR 17-15BF-96 Operation and Intermediate Maintenance Instructions


with Illustrated Parts Breakdown for Hydraulic
Purification Unit Model No. HPU-1-5-GH-N-16

NAVAIR 17-15BF-97 Operation Instructions Hydraulic Particle Counter


Type I Hydraulic Particle Counter Set – P/N 2087301-
01 Type II Hydraulic Particle Counter Set – P/N
2087301-02
NAVAIR 01-1A-17 002 00
TO 42B2-1-12
Change 2 – 1 August 2014 Page 25

Table 4. Related Publications (Cont)

Publication Number Title

NAVAIR 17-15BF-110 Operation and Intermediate Maintenance with Illustrated


Parts Breakdown Diesel Hydraulic Power Supply (DHPS)
A/M 27T-15 Part Number 040489-100

NAVAIR 17-15BF-120 Operation and Intermediate Maintenance with Illustrated


Parts Breakdown Electric Hydraulic Power Supply
(EHPS) A/M 27T-14 Part Number 040499-100

NAVAIR 17-15BF-125 Operation and Intermediate Maintenance with Illustrated


Parts Breakdown Hydraulic Fluid Purifier (HFP) A/M
37M-11 Part Number 040505-100

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


Calibration Manual

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

NAVAIR 17-600-101-6-1 Preoperational Maintenance Requirements Portable


Hydraulic Power Supply Model A/M27T-3

NAVAIR 17-600-101-6-2 Periodic Maintenance Requirements Manual Portable


Hydraulic Power Supply A/M27T-3

NAVAIR 17-600-107-6-1 Preoperational Checklist Hydraulic Fluid Dispensing Unit


A/M27M-10

NAVAIR 17-600-107-6-2 Periodic Maintenance Requirements Manual Hydraulic


Fluid Dispensing Unit A/M27M-10

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


E1

NAVAIR 17-600-126-6-2 Periodic Maintenance Requirements Manual Hose Burst


Test Stand P/N 63A101-E1

NAVAIR 17-600-127-6-1 Preoperational Checklist Portable Hydraulic Power


Supply A/M27T-5 and A/M27T-5A

NAVAIR 17-600-127-6-2 Periodic Maintenance Requirements Manual Portable


Hydraulic Power Supply A/M27T-5

NAVAIR 17-600-150-6-1 Preoperational Checklist Portable Hydraulic Power


Supply A/M27T-7 and A/M27T-7A

NAVAIR 17-600-156-6-1 Preoperational Checklist Test Stand, Aircraft Hydraulic


System, A/M27T-6 P/N 1415AS100-1

NAVAIR 17-600-156-6-2 Periodic Maintenance Requirements Manual Test Stand,


Aircraft Hydraulic System, A/M27T-6 P/N 1415AS100-1

NAVAIR 17-600-196-6-1 Preoperational Checklist Hydraulic Purification Unit


(HPU) Model No. HPU-1-5 Part No. 95163-100
NAVAIR 01-1A-17 002 00
TO 42B2-1-12
Change 2 – 1 August 2014 Page 26

Table 4. Related Publications (Cont)

Publication Number Title


NAVAIR 17-600-196-6-2 Periodic Maintenance Requirements Manual Hydraulic
Purification Unit (HPU) Model No. HPU-1-5 Part No.
95163-100
NAVAIR 17-600-32-6-1 Aircraft Hydraulic and Pneumatic Component Test Stand
HCT-10
NAVAIR 17-600-32-6-2 Periodic Maintenance Requirements Manual Aircraft
Hydraulic and Pneumatic Component Test Stand HCT-10
NAVAIR 17-600-35-6-1 Preoperational Checklist Maintenance Requirements Air
Driven, Portable, Hydraulic Check and Fill Stand Model
74

NAVAIR 17-600-35-6-2 Calendar Maintenance Requirements Cards Air Driven,


Portable, Hydraulic, Check and Fill Stand Model 74

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


250-1

NAVAIR 17-600-40-6-2 Periodic Maintenance Requirements Manual Hydraulic


Service Unit Model H-250-1

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


310

NAVAIR 17-600-97PC-6-1 Preoperational Checklist Portable Oil Diagnostic System


Part Numbers 2087301-01 and 2087301-02

NAVAIR 17-600-BF110-6-1 Diesel Hydraulic Power Supply A/M27T-15 P/N 040489-


100

NAVAIR 17-600-BF110-6-2 Periodic Maintenance Requirements Manual Diesel


Hydraulic Power Supply A/M27T-15 Part Number
040489-100

NAVAIR 17-600-BF120-6-1 Electric Hydraulic Power Supply A/M27T-14 Part Number


040499-100

NAVAIR 17-600-BF120-6-2 Periodic Maintenance Requirements Manual Electric


Hydraulic Power Supply A/M27T-14 Part Number
040499-100

NAVAIR 17-600-BF125-6-1 Hydraulic Fluid Purifier A/M37M-11 Part Number 040505-


100

NAVAIR 17-600-BF125-6-2 Periodic Maintenance Requirements Manual Hydraulic


Fluid Purifier A/M 37M-11 Part Number 040505-100

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


Component Test Stand Part Numbers 2029AS100-10,-20

NAVAIR 17-600-T10-6-2 Periodic Maintenance Requirements Manual Hydraulic


Component Test Stand A/F27T-10 Part Numbers
2029AS100-10,-20
NAVAIR 01-1A-17 002 00
TO 42B2-1-12
Change 2 – 1 August 2014 Page 27

Table 4. Related Publications (Cont)

Publication Number Title


NAVAIR 19-1-96 Operation and Organizational Maintenance with
Illustrated Parts Breakdown Fluid Servicing Unit
Hydraulic Fluid and Bulk Dispensing Unit Model PMU-
71/E Part Number 061481-100 and Part Number 061482-
100

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

NAVAIR 19-600-201-6-2 Periodic Maintenance Requirements Manual Fluid


Purifier A/M 37M-2

NAVAIR 19-600-441-6-1 Preoperational Checklist Fluid Servicing Unit Hydraulic


Fluid Model PMU-71/E Part Number 061481-100

NAVAIR 19-600-441-6-2 Periodic Maintenance Requirements Manual Fluid


Servicing Unit Hydraulic Fluid Model PMU-71/E Part
Number 061481-100

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


Type I Hydraulic (-65 to 160°F)

SAE AS1241 Fire Resistant Phosphate Ester Hydraulic Fluid for


Aircraft

SAE AS1290 Symbols, Graphic, for Aircraft Hydraulic and Pneumatic


Systems

SAE AS21913 Plug, Flareless Tube

SAE AS21914 Cap, Pressure Seal, Flareless Tube Fitting

SAE AS28775 Packing, Preformed, Hydraulic, +275°F

SAE AS28778 Packing, Preformed, Straight Thread Tube Fitting Boss

SAE AMS3819 Cloths, Cleaning, for Aircraft Primary and Secondary


Structural Surfaces

SAE AS4059 (formerly NAS 1638) Contamination Classifications for Hydraulic Fluids

SAE AS4841 Fittings, 37° Internal Flared, Fluid Connection

SAE AS5168 Fitting, Plug, Tube End, Flared

SAE AS5169 Fitting, Port Plug and Bleeder

SAE AS8791 Retainers, Hydraulic and Pneumatic,


Polytetrafluoroethylene, Single Turn

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

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


and Installed)
NAVAIR 01-1A-17 002 00
TO 42B2-1-12
Change 2 – 1 August 2014 Page 28

Table 4. Related Publications (Cont)

Publication Number Title

TO 33K-1-100-1 Calibration Procedure for Maintenance Data Collection


Codes and Calibration Measurement Summaries

TT-I-735 Isopropyl Alcohol

UL 30 UL Standard for Metal Safety Cans


UAMA B74.18 (formerly ANSI B74.18 / A-A-1026) Grading of Certain Abrasive Grain on Coated Abrasive
Products
NAVAIR 01-1A-17 003 00
TO 42B2-1-12
15 August 2006 Page 1 of 6

ORGANIZATIONAL, INTERMEDIATE AND


DEPOT MAINTENANCE

DESCRIPTION

HYDRAULIC SYSTEMS AND HYDRAULIC FLUIDS

Reference Material

None

Alphabetical Index

Subject Page No.

Aircraft Hydraulic Systems ............................................................................................................. 2


Detailed Description................................................................................................................... 2
General Description ................................................................................................................... 2
Hydraulic Fluids Used in Military Aircraft ....................................................................................... 5
Hydraulic Fluid, Military Specification MIL-H-81019 .................................................................. 6
Hydraulic Fluid, Military Specification MIL-PRF-5606 ............................................................... 5
Hydraulic Fluid, Military Specification MIL-PRF-83282 ............................................................. 5
Hydraulic Fluid, Military Specification MIL-PRF-87257 ............................................................. 6
Hydraulic Fluid, SAE-AS1241, Phosphate Ester ....................................................................... 6
Intended Use.............................................................................................................................. 6

Record of Applicable Technical Directives

None
NAVAIR 01-1A-17 003 00
TO 42B2-1-12
Page 2
1. AIRCRAFT HYDRAULIC SYSTEMS. 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

Figure 2. Heavy Aircraft Hydraulic System


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

its pressure switch completes an electrical circuit that 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 Fluid, MIL-PRF-5606 1

17. HYDRAULIC FLUID, MILITARY


SPECIFICATION MIL-PRF-5606 (WP002 00, TABLE
3, ITEM 1). This was the principal hydraulic fluid used
NAVAIR 01-1A-17 003 00
TO 42B2-1-12
Page 6

fluid. It is further identified by NATO Code H-538. It is


designed for use within a temperature range of -65EF
to +392EF (-54°C to +200°C) in aircraft and missile
MIL-PRF-83282 (WP002 00, Table 3, hydraulic systems. Hydraulic fluid MIL-PRF-87257 is
Item 2) shall not be used in some viscous miscible with hydraulic fluid MIL-PRF-5606 (WP002
dampers due to its low temperature 00, Table 3, Item 1) and hydraulic fluid MIL-PRF-
characteristics. Refer to applicable 83282 (WP002 00, Table 3, Item 2). However, the
Maintenance Instruction Manuals (MIM) addition of MIL-PRF-5606 will reduce the fire resistant
or Maintenance Requirement Cards properties of MIL-PRF-87257.
(MRC) for specific Naval aircraft.
22. INTENDED USE. Hydraulic fluids MIL-PRF-
5606, MIL-PRF-87257, MIL-PRF-83282, and MIL-H-
19. Flash point, fire point, and spontaneous ignition 81019 (WP002 00, Table 3, Items 1, 4, 2, and 3,
temperature of MIL-PRF-83282 exceed that of MIL- respectively) are intended for use in automatic pilots,
PRF-5606 by more than 200°F (93EC). The fluid shock absorbers, brakes, control mechanisms,
extinguishes itself when the external source of flame servocontrol systems, and other hydraulic systems
or heat is removed. Hydraulic fluid MIL-PRF-83282 is using seal materials compatible with petroleum based
identified by NATO Code H-537 and is compatible fluids.
with all materials used in systems presently
employing MIL-PRF-5606. Because of its superior
properties, MIL-PRF-83282 is now required in the
main systems of all Naval aircraft previously using
MIL-PRF-5606. Hydraulic Fluid, SAE AS 1241 5

Hydraulic Fluid, MIL-H-81019 3 Under no circumstance should SAE


AS1241 be mixed with MIL-PRF-5606,
20. HYDRAULIC FLUID, MILITARY MIL-H-81019, MIL-PRF-83282 or MIL-
PRF-87257. Mixing these hydraulic
SPECIFICATION MIL-H-81019 (WP002 00, TABLE
3, ITEM 3). This is an ultra-low temperature hydraulic fluids could compromise the safe
fluid designed for use on aircraft where extremely low operation of the aircraft.
surrounding temperatures are expected. The
hydraulic fluid consists of petroleum products with
23. HYDRAULIC FLUID, SAE-AS1241,
additive materials to improve its viscosity temperature
PHOSPHATE ESTER (WP002 00, TABLE 3, ITEM
characteristics, increase its resistance to oxidation,
5). This is a fire resistant aircraft hydraulic fluid. It has
inhibit corrosion, and act as an anti-wear agent. This
an operating temperature range of -65°F (-54°C) to
hydraulic fluid is dyed red so it can be distinguished
from other incompatible hydraulic fluids. This fluid is 225°F (107°C). This hydraulic fluid shall not be mixed
not interchangeable with any other type or grade of with any other hydraulic fluid. This fluid can’t be used
hydraulic fluid other then MIL-PRF-5606 in extreme with synthetic (Buna N) rubber seals used in hydraulic
emergencies. This hydraulic fluid is designed to systems designed to operate on MIL-PRF-5606.
operate in hydraulic systems from -94°F to +212°F (- Phosphate ester hydraulic fluids are described in
detail in WP016 00.
70EC to +100EC).

Hydraulic Fluid, MIL-PRF-87257 4

21. HYDRAULIC FLUID, MILITARY


SPECIFICATION MIL-PRF-87257 (WP002 00,
TABLE 3, ITEM 4). This is a fire resistant, low
temperature, synthetic hydrocarbon base hydraulic
NAVAIR 01-1A-17 004 00
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Change 2 – 1 August 2014 Page 1 of 8

ORGANIZATIONAL, INTERMEDIATE AND


DEPOT MAINTENANCE

HYDRAULIC FLUID CONTAMINATION

HYDRAULIC SYSTEMS

Reference Material

Cleanliness Requirements of Parts Used in Hydraulic Systems ................................ NAS 1638


Contamination Classification for Hydraulic Fluids ........................................................ SAE AS4059
Metrology Requirements List (METRL) ........................................................................ NAVAIR 17-35MTL-1
Calibration Procedure for Maintenance Data Collection Codes and Calibration
Measurement Summaries........................................................................................ TO 33K-1-100-1
Air Force Metrology and Calibration Program.............................................................. TO 00-20-14
Maintenance Program, Naval Aviation .................................................................... COMNAVAIRFORINST
4790.2
Aerospace Equipment Maintenance Management ...................................................... AFI 21-101

Alphabetical Index

Subject Page No.

Introduction..................................................................................................................................... 2
Measurement of Contamination ..................................................................................................... 4
Electronic Particle Counting....................................................................................................... 4
Patch Testing ............................................................................................................................. 5
Sources and Effects of Contamination........................................................................................... 2
Air Contamination ...................................................................................................................... 4
Fluid Contamination ................................................................................................................... 3
Particulate Contamination .......................................................................................................... 2

Record of Applicable Technical Directives

None
NAVAIR 01-1A-17 004 00
TO 42B2-1-12
Page 2

1. INTRODUCTION. temperature, and the presence of system


contaminants (wear particles, water, or dirt).
2. Hydraulic fluid contamination may be described as Oxidation products appear as organic acids,
any foreign material or substance whose presence in asphaltics, gums, and varnishes. These products
the fluid is capable of adversely affecting system combine with particles in the hydraulic fluid to form
performance or reliability. It may assume many sludge. Some oxidation products are oil soluble and
different forms including liquids, gases, and solid cause the hydraulic fluid to increase in viscosity; other
matter of various compositions, sizes, and shapes. oxidation products are not oil soluble and form
Solid matter is the type most often found in aircraft sediment.
hydraulic systems and is generally referred to as
particulate contamination. Contamination is always 7. Metallic Solid Contamination. Metallic
present to some degree, even in new, unused fluid. contaminants are almost always present in a
Contamination must be below a level that will not hydraulic system and will range in size from
adversely affect system operation. Hydraulic microscopic particles to particles readily visible to the
contamination control consists of those requirements, naked eye. These particles are the result of wearing
techniques, and practices for minimizing and and scoring of bare metal parts and plating materials
controlling fluid contamination. such as silver and chromium. These wear products
and other foreign metal particles such as steel,
3. SOURCES AND EFFECTS OF aluminum, and copper may also act as metallic
CONTAMINATION. catalysts in the formation of oxidation products. Fine
metallic particles enter the hydraulic fluid from many
4. Contamination present in an operating hydraulic sources within the hydraulic system. Although
system will have normally originated at several practically all metals commonly used for parts
different sources, with its rate of introduction being fabrication and plating may be found in hydraulic
dependent upon numerous factors. Because several fluids, the major metallic materials found are ferrous,
of these factors are directly related to wear and aluminum, and chromium particles. Because of their
chemical reaction, the amount of contamination in a continuous high-speed internal movement, hydraulic
system will increase with use unless contamination pumps usually contribute most of the metallic
removal reverses the natural trend. Production of particulate contamination present in hydraulic
contaminants in the hydraulic system also increases systems. Metal particles are also produced by other
with the number of system components. The rate of hydraulic system components such as hydraulic
contamination from external sources is not readily valves and actuators, due to body wear and the
predicted, and a hydraulic system can be seriously chipping and wearing away of small pieces of metal
contaminated by maintenance malpractices leading to plating materials.
the introduction of large amounts of external
contaminants. Poorly maintained support equipment 8. Inorganic Solid Contamination. This
(SE) may also be a source of contamination. contaminant group includes dust, paint particles, dirt,
Contaminants in hydraulic fluids may be grouped into and silicates. Glass particles from glass bead peening
several types. The types may be generally classed as and blasting may also be found as contaminants.
organic, metallic solids, nonmetallic (inorganic) solids, Glass particles are very undesirable contaminants
foreign fluids, air, and water. due to their abrasive effect on synthetic rubber seals
and the very fine surfaces of critical moving parts.
5. PARTICULATE CONTAMINATION. The Atmospheric dust, dirt, paint particles, and other
following paragraphs provide a discussion of organic, materials are often drawn into the hydraulic systems
metallic solid and inorganic solid contaminations and from external sources. For example, the wet piston
their effects. shaft of a hydraulic actuator may draw some of these
foreign materials into the cylinder past the wiper and
6. Organic Contamination. Organic solids or semi dynamic seals, and the contaminant materials are
solids found in hydraulic systems are produced by then dispersed in the hydraulic fluid. Contaminants
wear, oxidation, or polymerization. Minute particles of may also enter the hydraulic fluid during maintenance
O-rings, seals, gaskets, and hoses are present, due when tubing, hoses, fittings, and components are
to wear or chemical reactions. Synthetic products, disconnected or replaced. It is important that all
such as neoprene, thiokol, silicones, and hypalon, exposed fluid ports be sealed with approved
though resistant to chemical reaction with hydraulic protective closures to minimize such contamination.
fluids, produce small wear particles. The oxidative
rate of hydraulic fluids increases with pressure,
NAVAIR 01-1A-17 004 00
TO 42B2-1-12
Change 2 – 1 August 2014 Page 3

9. Effects of Particulate Contamination. entering vented systems. When it separates from


Contamination of hydraulic fluid with particulate hydraulic fluids, it collects in filter bowls, and at other
matter is one of the principal causes of wear in more critical locations. Corrective actions shall be
hydraulic pumps, actuators, valves, and servovalves. taken to remove all free or emulsified water from
Due to their ease of control and rapid rate of hydraulic systems.
response, spool-type electrohydraulic valves operated
with both ultra clean and contaminated hydraulic 14. Effects of Free Water Contamination. The
fluids has demonstrated that the amount of wear is presence of free water in hydraulic systems can result
accelerated by even small amounts of contamination. in the formation of undesired oxidation products and
Erosion of the sharp spool edges and general corrosion of metallic surfaces. If water in the system
deterioration of the surfaces of the spools is results in the formation of ice, fluid flow, or operation
increased by contamination. Because of the of valves, actuators or other moving parts will be
extremely close fit of spools in servovalve housings, impeded. This is particularly true of water located in
these valves are particularly susceptible to damage or static circuits or system extremities and subjected to
erratic operation when operated with contaminated high-altitude, low temperature conditions.
hydraulic fluid. Microorganisms may grow and spread in hydraulic
fluid contaminated with water. These may clog filters
10. Hydraulic actuators and valves are affected by and be detrimental to hydraulic system performance.
contamination in several ways. Large metallic or hard
nonmetallic particles will collect at the seal area, and 15. Foreign Fluids Contamination. Hydraulic
the scraping action of the particle may groove the systems can be seriously contaminated by foreign
inside wall of the actuator body. Small particles act as fluids other than water and chlorinated solvents. This
abrasives between seals and actuator body and type of contamination, although rare, is generally a
cause general wear and scoring. The resultant wear result of lube oil, engine fuel, or incorrect hydraulic
and scoring will eventually cause excessive fluid fluid having been introduced inadvertently into the
leakage and possible seal failure due to extrusion of system during servicing. In addition, some models of
the seal into the enlarged gap between the piston aircraft employ hydraulic oil coolers which, when
head and the bore of the actuator body. Once the leaky, can result in fuel intrusion into the hydraulic
abrasive material begins to wear the actuator body, system. Contamination with a foreign fluid, when
the process will continue at an increasing rate suspected, can usually be verified by chemical
because the wear particles add to the available analysis of a fluid sample. Assistance of the Fleet
abrasive material. In a similar manner, metallic or Support Team (FST), Air Force Petroleum Agency
nonmetallic particles may lodge in the poppets and (AFPA) or Aircraft Sustainment Group (ASG) must be
poppet seat portions of valves and thereby cause requested to verify and identify the contaminant and
system malfunction by holding valves open. to direct the required decontamination.

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
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NOTE accompanied by vibrations, which may be felt and/or


Hydrocarbon based fluids, MIL-PRF- heard. Air can also damage a system in less obvious
5606, MIL-PRF-87257 and MIL-PRF- ways. Air entrained in the fluid has been shown to
cause erosion of metering orifices and servovalves,
83282, will hold 12% dissolved air and
as well as high fluid temperatures. High temperatures
phosphate ester fluids, SAE AS1241, will
can result in fluid breakdown, as well as the
hold 18% dissolved air which is not
hardening of seals and attendant leaks.
harmful to aircraft operation unless it
becomes entrained or free air.
21. MEASUREMENT OF CONTAMINATION.
17. AIR CONTAMINATION. Hydraulic fluids are
adversely affected by dissolved, entrained, or free air. 22. The size of particulate matter in hydraulic fluid is
Air may be introduced through improper maintenance measured in “microns,” (millionths of a meter.) A
or as a result of system design. Any maintenance micron is equivalent to 0.0000394 inch, and 25,400
operation that involves breaking into the hydraulic microns equal 1 inch. The largest dimension of the
system, such as disconnecting or removing a line or particle is measured when determining its size. A
component, will invariably result in some air being graphic representation of the relative size of particles
introduced into the system. This source of air can, measured in microns is shown in Figure 1. Refer to
and must be minimized by prefilling replacement Tables 1 and 2 for particulate contamination levels.
components with new, filtered fluid prior to
installation. Failing to prefill a filter element bowl with NOTE
fluid is a good example of how air can be introduced USAF aircraft and aircraft hydraulic
in this manner. systems using phosphate esters classify
contamination levels in accordance with
SAE AS4059 (formerly NAS 1638). Refer
18. Most aircraft hydraulic systems have “built-in”
to WP016 00 or the applicable aircraft
sources of air. Leaky seals in gas-pressurized
accumulators and reservoirs can feed gas into a maintenance manual for determination of
system faster than it can be removed, even with the appropriate particulate contamination
levels.
best of maintenance. Air can also be pulled in past
unpressurized rod seals. This occurs if only one side
of a tandem actuator is powered, the surface is NOTE
moved by hand or the surface droops after shutdown. Operators shall qualify in accordance
Moving a flight control surface while unpressurized with Naval Aviation Maintenance
can produce a vacuum and may cause a significant Program Standard Operating Procedures
amount of air to be pulled in past the actuator rod (NAMPSOP) and COMNAVAIRFORINST
seals. 4790.2, Chapter 10 Par. 10.5.

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
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Change 2 – 1 August 2014 Page 5

regular intervals as specified in NAVAIR 17-35MTL-1.

24. PATCH TESTING (NAVY USE ONLY).


Activities that do not have access to a particle counter
either located in their own area or through a
supporting Intermediate Level (I-Level) unit or NOAP
Lab, shall measure hydraulic fluid contamination by
patch testing with the contamination analysis kit
57L414 (08071) (WP005 00, Figure 1). Operation of
the contamination analysis kit is described in detail in
WP017 00.
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004001
Figure 1. Graphic Comparison of Particle Sizes
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Table 1. Navy Standard for Particulate Contamination

PARTICLE CONTAMINATION LEVEL-BY CLASS


MICRON
SIZE Acceptable Unacceptable
RANGE
0 1 2 3 4 5 6

5-10 2,700 4,600 9,700 24,000 32,000 87,000 128,000

10-25 670 1,340 2,680 5,360 10,700 21,400 42,000

25-50 93 210 380 780 1,510 3,130 6,500

50-100 16 28 56 110 225 430 1,000

Over 100 1 3 5 11 21 41 92

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

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

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

3. The Class 5 level of acceptability shall be met at the inspection interval specified for the
equipment under test.
Table 2: SAE AS4059 (Formerly NAS 1638) Contamination Standards
TO 42B2-1-12
NAVAIR 01-1A-17

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

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

50-100 1 2 3 6 11 22 45 90 180 360 720 1440 2880 5760

>100 0 0 1 1 2 4 8 16 32 64 128 256 512 1024

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
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ORGANIZATIONAL, INTERMEDIATE AND


DEPOT MAINTENANCE

HYDRAULIC FLUID CONTAMINATION ANALYSIS

HYDRAULIC SYSTEMS

Reference Material

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


Operational and Intermediate Maintenance Instructions with Illustrated Parts
Breakdown, Particle Counting System, P/N 8011-3 .............................................. NAVAIR 17-15-521
Particle Counting System HIAC/ROYCO 8011-3 Calibration Manual ....................... NAVAIR 17-20SX-146
Operation Instructions Hydraulic Particle Counter, Type I Hydraulic Particle Counter
Set - P/N2087301-01, Type II Hydraulic Particle Counter Set - P/N 2087301-02 . NAVAIR 17-15BF-97
Preoperational Checklist Hydraulic Particle Counter Part Numbers 2087301-01
and 2087301-02 .................................................................................................... NAVAIR 17-600-97PC-6-1

Alphabetical Index

Subject Page No.

Contamination Analysis .................................................................................................................. 4


Visual Analysis for Water Contamination .................................................................................. 4
Electronic Particle Count Analysis (All Levels of Maintenance) ................................................ 6
Electronic Particle Counter Description ................................................................................. 7
HACH Ultra Analytics Portable Oil Diagnostic System (PODS) ....................................... 8
HIAC/ROYCO Particle Counting System 8011-3 ............................................................. 7
Introduction..................................................................................................................................... 2
Sampling Hydraulic Fluid ............................................................................................................... 2
Cleanliness ................................................................................................................................ 3
Sample Requirements ............................................................................................................... 2
Sampling Points ......................................................................................................................... 2
Sampling Point Requirements ................................................................................................... 2
Sample Taking ............................................................................................................................... 3
Filter Bowl Content Sampling .................................................................................................... 4

Record of Applicable Technical Directives

None
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1. INTRODUCTION. a. The fluid sample should be obtained from a


main system return line, pump suction line, or system
2. During normal operation, hydraulic systems may reservoir. Sample fluid from these areas can be
become contaminated with metallic and nonmetallic considered representative because of the high
particles. Particulate contamination may result from circulatory rates and because samples are obtained
internal wear, failure of system components, or from the dirtiest portion of the closed-loop system.
incorrect maintenance and servicing operations. The However, this sampling method may not be valid if
contamination analysis procedures herein allow the system is equipped with a return line filter,
determination of the particulate level of a hydraulic particularly one of the low micron depth-type variety.
system and the presence of free water or other Due to the high single-pass efficiency of such filters,
foreign substances. considerable difference in particulate levels may be
observed between its inlet and outlet ports. Should
3. SAMPLING HYDRAULIC FLUID. return line filtration be present, it is desirable that the
sample be obtained from a main system return line
NOTE upstream of the filter in order to obtain a realistic
indication of contamination level.
USAF: Check the applicable aircraft
maintenance manual for specific fluid b. Reservoir sampling should not be employed
sampling requirements and procedures. in a system using a reservoir of the make-up variety,
or where the reservoir is bypassed during SE-
powered operation. A make-up reservoir is that
4. SAMPLE REQUIREMENTS. To determine
configuration in which all system return line fluid does
contamination level, a single fluid sample is required
not pass through the reservoir. Fluid exchange in the
which represents the working fluid in the system. It
reservoir is limited and results only from the changes
also must provide a worst-case indication of system
in fluid volume that occurs elsewhere in the system.
particulate level, because the particulate level is not
the same throughout an operating system. The
c. The sampling point should be usable
particulate level displays distinct gradients due to the
immediately after flight without requiring the use of
effects of system components (such as filters) on
external ground support equipment (GSE). Sampling
circulating particles.
with the aircraft engines turning is satisfactory,
5. SAMPLING POINTS. The fluid sample is provided no personnel hazards are involved.
obtained from a sampling point. A fluid sampling point
is a physical point in a hydraulic system from which d. The sampling point should be usable when
small amounts of hydraulic fluid can be obtained for the system is being powered by external SE, or
contamination analysis. It may be an air bleed valve, immediately after such operation. To achieve this, it is
a reservoir drain valve, quick-disconnect fittings, generally necessary to ensure that the same flow
removable line connections, or special valves conditions exist at the selected point in either mode of
installed for ease of sampling. Valves conforming to operation.
the requirements of MIL-V-81940 may be used as
sampling points. e. The sampling point should be immediately
adjacent or reasonably close to the main body or
6. Selection of an adequate fluid sampling point stream of fluid being sampled. A minimum amount of
generally requires a thorough investigation of the static fluid should be associated with the sampling
system involved. The task is further complicated if point and whatever is present should be readily
selection is limited to use of existing valves and purged upon initiation of sample flow. This may be
fittings, in which case certain trade-offs may have to accomplished by dumping an initial quantity of the
be accepted. Assistance should be requested from sampled fluid, but problems may be encountered
the Fleet Support Team (FST) or Aircraft Sustainment where a long line is involved, as in certain reservoir
Group (ASG) when it becomes necessary to select drain lines.
hydraulic sampling points in aircraft or Support
Equipment (SE) for which none have been previously f. The sampling point should not be located in
specified. an area of high sedimentation. Ensure that the effects
of such sedimentation can be minimized by always
7. SAMPLING POINT REQUIREMENTS. A discarding an initial quantity of the sample fluid
sampling point should satisfy the following drawn. Sample fluid should ideally be obtained from
requirements: turbulent high-flow areas.
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g. Operation of the sampling point shall not


introduce any significant amount of external
contaminants into the fluid collected. With reasonable
external pre-cleaning and prior self-flush of the valve Hydraulic Fluid, MIL-PRF-83282 2
or fitting, the background level attributable to the
sample point itself should not exceed 10 percent of
the normally observed particulate level.

h. The internal porting of the sampling point Hydraulic Fluid, MIL-H-81019 3


shall be such that it will not impede the passage of
hard particulate matter up to 500 microns in diameter.

i. The sampling point should be readily


Hydraulic Fluid, MIL-PRF-87257 4
accessible and otherwise convenient to use.
Sufficient clearance must exist beneath the valve or
fitting to adequately position the sample collection
bottle. The sampling point should be easy to operate,
and not distort the particulate level of the sampled Hydraulic Fluid, SAE AS1241 5
fluid either by acting as a filter or by introducing NOTE
external or self-generated contaminants. The latter
Sampling points that have not been
point is particularly critical and should be minimized
adequately cleaned prior to use may
prior to sample collection by external cleaning of the
produce erroneous test results and
valve or fitting and by dumping a small amount of the
needless rejection of the system under
initial fluid flow. test.
j. With normal system operating pressures
present, the sample fluid flow rate should be between Check sample bottle clarity prior to taking
100 and 1,000 ml (approximately 3 to 30 fluid oz.) per sample. Discard any bottles that become
minute. The flow rate should be manageable, and the so unclear that the observer can’t visually
time required to collect the required sample should inspect the sample for contamination.
not be excessive.
a. Remove dirt and other external contaminants
k. Repeated use of the sampling valve or fitting from the sampling point by wiping with clean
should not degrade its mechanical integrity. disposable wiping cloths (WP002 00, Table 3, Item
Provisions should exist for mechanically securing it in 14).
the closed position. NOTE
Electronic Particle Counter Bottles shall
8. CLEANLINESS. Accurate determination of be cleaned only with hydraulic fluid. If
hydraulic contaminant levels requires proper sampling using sample kit NSN 9125-01-477-9105
techniques using equipment and materials that are pre-cleaned bottles, no further cleaning is
known to be clean. Any foreign matter which is necessary.
allowed to contaminate the sample fluid or testing
equipment will cause erroneous results. Careful b. Clean the required number of sample bottles,
attention to the detailed procedures herein will assure caps and the threaded area of bottle caps (WP002
that the effects of external contaminants are 00, Table 3, Items 20 thru 24) prior to use by rinsing
minimized. and flushing with the fluid from the system being
analyzed. Initiate the flow of fluid to be sampled by an
9. SAMPLE TAKING. appropriate means; allowing an initial quantity to flow
into a suitable waste receptacle (WP002 00, Table 3,
Item 19). This will serve to flush any contaminants in
the sampling line and any contaminants generated by
mechanical operation. Remove the cap from the
Hydraulic Fluid, MIL-PRF-5606 1 bottle, fill the bottle to be cleaned approximately half
full with the fluid from the sampling point. Shutoff flow
from sampling point, if necessary. Replace cap on
bottle opening, agitate the sample bottle several
times, remove the cap and dump contents into an
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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).

Samples showing visible water or


cloudiness shall not be tested 16. The typical color of contamination in any given
system remains fairly uniform. The degree of filter
membrane discoloration may be correlated with a
14. VISUAL ANALYSIS FOR WATER level of particulate contamination. By visually
CONTAMINATION. Prior to sample processing, the
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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
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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.

NOTE 18. ELECTRONIC PARTICLE COUNT ANALYSIS


(ALL LEVELS OF MAINTENANCE) NAVY USE
If the result is inconclusive or if a ONLY. The electronic particle counters provide
shadowy effect occurs due to incidence counts of the number of particles in various size
of light on the petri slide, remove patch ranges (WP004 00, Table 1). The counts obtained
from petri slide for comparison with are compared with the maximum allowable under
Contamination Standards. Navy Standard Class 5 for aircraft (and Class 3 for
SE). Count exceeding the maximum allowable in
NAVAIR 01-1A-17 005 00
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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
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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

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

NOMENCLATURE MODEL/CAGE MANUAL CALIBRATION MANUAL

Particle Counting System


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

Hydraulic Contamination
Analysis Equipment 57L414 (08071) WP017 00 N/A
(“Patch Test”)

Portable Oil Diagnostic


Systems (HACH Ultra
Analytics)

Type 1 (petroleum) 2087301-01 (53882) NAVAIR 17-15BF-97 N/A

Type 2 (phosphate ester) 2087301-02 (53882) NAVAIR 17-600-97PC-6-1


NAVAIR 01-1A-17 005 00
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005003

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


NAVAIR 01-1A-17 005 00
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005004
Figure 4. Portable Oil Diagnostic System (PODS) Particle Counter (Navy Use Only)
NAVAIR 01-1A-17 006 00
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ORGANIZATIONAL, INTERMEDIATE AND


DEPOT MAINTENANCE

AIRCRAFT SYSTEM DECONTAMINATION

HYDRAULIC SYSTEMS

Reference Material

None

Alphabetical Index

Subject Page No.

Contamination Control Sequence .................................................................................................. 5


Decontamination Methods ............................................................................................................. 2
Air Bleeding................................................................................................................................ 2
Flushing ..................................................................................................................................... 4
Purging ....................................................................................................................................... 4
Purifying ..................................................................................................................................... 4
Recirculation Cleaning ............................................................................................................... 3
Selection of Decontamination Method ....................................................................................... 5
Decontamination Procedures ......................................................................................................... 5
Flushing Procedures .................................................................................................................. 8
Purging Procedures ................................................................................................................... 10
Purifying Procedures ................................................................................................................. 7
Recirculation Cleaning Procedures ........................................................................................... 7
Introduction..................................................................................................................................... 2

Record of Applicable Technical Directives

None
NAVAIR 01-1A-17 006 00
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1. INTRODUCTION. 6. Hydraulic fluid can hold large amounts of air


trapped in solution when a system is pressurized.
2. This section provides a discussion of Fluid, as received, may contain dissolved air or
decontamination methods, contamination sequence gasses equivalent to 10 percent by volume and may
control, and decontamination procedures. rise to as high as 20 percent after pumping. Dissolved
air is readily pulled from the fluid as it travels through
3. DECONTAMINATION METHODS. pumps and actuator servovalves and becomes
entrained air which causes extra flight control activity,
4. System decontamination is an essential elevated temperatures and intermittent stiffness
maintenance operation performed whenever a system problems. Free air is most likely introduced into a
is found to contain fluid unacceptably contaminated system during component installation, filter element
with foreign matter, particulates, liquids, and gases or installation, or opening of the system during repairs.
otherwise considered not acceptable for service. The
purpose of decontamination is to remove foreign
matter from the operating fluid, or to remove the 7. Entrained or free air is harmful to hydraulic
contaminated fluid itself. Five basic methods are system performance. The compressibility of air acts
utilized in decontaminating aircraft hydraulic systems: as a soft spring in series with the stiff spring of the oil
column in actuators or tubing, resulting in degraded
a. Air bleeding response. Also, because free air can enter fluid at a
very high rate, the rapid collapse of bubbles may
b. Recirculation cleaning generate extremely high local fluid velocities. If they
occur near metal parts, these high velocities can be
c. Purifying converted into impact pressures. This is the
phenomenon known as cavitation. Cavitation can
d. Flushing cause rapid wear of pump pistons and slide valve
metering lands, and is a common cause of
e. Purging
component failure.
5. AIR BLEEDING. Air bleeding is a service
operation in which entrapped air is allowed to escape 8. Any maintenance action that involves breaking
from the closed hydraulic system. Specific air bleed into the hydraulic system, such as disconnecting a
procedures for each model aircraft may be found in line or removing a component, will invariably result in
the applicable Maintenance Instruction Manual (MIM) some air being introduced into the system. The
or Technical Order (TO). Excessive amounts of free amount of such air can be minimized by prefilling
or entrained air in an operating hydraulic system can replacement components with new, filtered hydraulic
result in degraded performance, chemical fluid. Because some residual air may still be
deterioration of fluid, elevated operating introduced, it is essential that all maintenance of this
temperatures, and premature failure of components. type be followed by a thorough air bleed of the
Because of the possible consequences it is important compromised system.
that a hydraulic system be bled of air to the maximum
extent possible whenever a component is replaced or
the hydraulic system is opened for repairs which 9. Most hydraulic systems in high performance
could introduce air. aircraft are of the closed type and are designed to
allow free air, provided it is not trapped behind a
NOTE piston rod, check valve, or isolation valve, to self-
scavenge back to the system reservoir when a
Entrapped air in a closed hydraulic system is depressurized. Air bleed valves are
system, pressurized above 50 psi, provided at the reservoir to enable removal of any air
becomes compressed into solution. It will so entrapped when the system is depressurized. After
not be released from the fluid until pressurization, reservoir bleed valves in a closed
pressure is removed and the air is allowed system will not be effective in air bleeding because
to be out-gassed (i.e. actuating a reservoir the air has now been compressed into solution and
bleed valve during engine start or opening must be allowed to depressurize and outgas before
the bleed valve to the atmosphere in the the air can be removed from the system.
jenny reservoir).
NAVAIR 01-1A-17 006 00
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12. All air bleed operations shall be followed by a


check of the system hydraulic fluid level. Fluid
replenishment may be required, depending upon the
Do not adjust hydraulic fittings with amount of air and fluid purged from the system.
system pressure applied. Hydraulic fluid Ensure that fluid servicing is performed with fluid
under pressure is dangerous. If fittings are dispensing equipment that meets requirements of
loosened to bleed air at system high WP008 00 (Paragraph 6).
points, ensure that internal pressure is
relatively low ~100 psi which is sufficient
to force air from the system with minimal 13. RECIRCULATION CLEANING. Recirculation
safety hazard. cleaning is a decontamination process in which the
system to be cleaned is powered from a clean
external power source and cycled so as to produce a
10. Air bleed valves are sometimes provided at high maximum interchange of fluid between the powered
points in the aircraft circulatory system, filter system and the SE used to power it. Decontamination
assemblies, and remote system components such as is accomplished by circulating the contaminated fluid
actuators, to further facilitate removal of free air. through the hydraulic filters in the aircraft system and
Applicable MIM or TO should be consulted regarding in portable hydraulic test stands.
location and use of these additional bleed points. In
systems not so equipped, it may be necessary to
loosen line connections temporarily at strategic points
in the system to permit removal of entrapped air from 14. Recirculation cleaning is a filtration process and
remote or dead-end points. When bleeding systems can remove only that foreign matter which is retained
in this manner, caution must be exercised to avoid by the filter elements normally found in the
excessive loss of hydraulic fluid and to prevent the equipment. A key factor in recirculation cleaning is the
induction of air or contaminants into the system when utilization of high-efficiency 3-micron (absolute) filter
the system is not under pressure. elements. These filters have a large dirt-holding
capacity in the portable test stands used for this
11. Air inspection procedures are, in many cases, purpose. In a single fluid pass, these filters will
inadequate. Support Equipment (SE) specifically remove all particulate matter larger than 3 microns,
designed to detect and measure air is not presently remove a high percentage of the other particles down
available to fleet personnel, and indirect methods to the submicron sizes and reduce the air content of
must be employed to determine the amount of air that system fluid. While recirculation cleaning is effective
might be present in a system. Operating the air bleed in removing hard particulate matter and air
valve on the reservoir insertion while the system is contamination from hydraulic fluid that is otherwise
unpressurized or as the system is beginning to serviceable, it must be recognized that the filters are
pressurize (below 50 psi) will reveal whether or not not capable of removing water, other foreign fluids, or
there is excessive air present in the reservoir. dissolved solids. Recirculation cleaning is limited to
However, large amounts of air might be present decontamination of systems found to have a
elsewhere in the system and go undetected. An particulate level in excess of Navy Standard Class 5
effective means for measuring the air in your system or air contamination, but whose fluid is considered
is the “reservoir sink” check. Using this method, the otherwise acceptable.
fluid level in the aircraft reservoir is checked with the
system both pressurized and non-pressurized. The
presence of air or any compressible gas in the system 15. Recirculation cleaning is an effective way to
will cause the pressurized reading to be lower remove air from the hydraulic fluid if performed in
(reservoir sink), indicating the need for possible accordance with specific aircraft MIM or TO.
maintenance action (Figure 1). This check is Recommend the system be extensively cycled with
particularly effective when performed after a period of full power to transfer air-laden hydraulic fluid from the
depressurization (i.e. overnight). In which case the air aircraft into the SE to outgas.
in solution has had time to outgas and is now in the
form of free air.
NAVAIR 01-1A-17 006 00
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contaminant, layout of the system and the ability to


produce flow in all affected circuits. Certain portions
of operating systems are often “dead ended” in that
the fluid associated with them is static and not
affected by the normal system fluid flow.
Contaminated fluid in these circuits and associated
components must be removed by means of partial
disassembly and localized draining or flushing.
System flushing is generally continued until analysis
of return line fluid from the system being
decontaminated indicates that the fluid is acceptable.
In instances of severe contamination, considerable
quantities of hydraulic fluid may be expended and it is
important that the portable hydraulic test stand
reservoir level be monitored closely and replenished
as needed.
006001
Figure 1. Reservoir Level Changes (Reservoir 19. Flushing is a means to effectively
Sink) Indicate Presence of Air In System decontaminate a system found to contain water, large
amounts of gelatinous type materials, or fluid that is
16. PURIFYING. Purification is the process of chemically unacceptable (containing solvents).
removing particulate, air, water, and volatile Contamination or fluid degradation of chlorinated or
contaminants from the hydraulic fluid without altering other types cannot be remedied by conventional
the physical or chemical properties. A schematic of filtration. Severe cases of particulate contamination,
one typical purifier, P/N AD-A352-8Y10 (A/M37M-2) is such as those resulting from major component
illustrated in Figure 2. Contaminated fluid going to the failures, may be more easily corrected by flushing
purifier tower is first filtered by a 25-micron (absolute) techniques than by recirculation cleaning.
filter. The vacuum applied to the tower removes air,
water, and chlorinated solvents from the 20. PURGING. Purging is a decontamination
contaminated fluid. As the fluid comes out of the process in which the aircraft hydraulic system is
tower, it is filtered through a 3-micron (absolute) filter drained to the maximum extent practicable and the
to remove solid particles. This cycle is repeated until removed fluid discarded. A suitable cleaning agent is
a desired level of cleanliness is attained. For systems then introduced into the hydraulic system and
contaminated with air, water, and chlorinated circulated as effectively as possible so as to dislodge
solvents, the use of a purifier to clean aircraft and SE or dissolve the contaminating substances. The
will reduce the consumption of oil and replace the cleaning operation is followed by complete removal of
need for flushing. Additional information on the cleaning agent and its replacement with new
purification equipment can be found in WP009 00 hydraulic fluid. Upon completion of purging, the
(Paragraph 70). affected system shall be subjected to a period of
flushing and recirculation cleaning to ensure
17. FLUSHING. Flushing is a decontamination adequate decontamination.
method in which contaminated system fluid is
removed to the maximum extent practicable and then 21. Purging of aircraft hydraulic systems shall be
discarded. It is a draining process that is generally performed only upon recommendation from, and
accomplished by powering the aircraft system with a under the direct supervision of the Fleet Support
portable hydraulic test stand and allowing the Team (FST). It shall be the responsibility of the FST
contaminated return line fluid from the aircraft to flow or Aircraft Sustainment Group (ASG) to select the
overboard into a suitable receptacle (WP002 00, required cleaning agents, provide detailed cleaning
Table 3, Item 19) for disposal. In effect, filtered fluid procedures, and perform test upon completion of
from the portable hydraulic test stand is used to purging to ensure satisfactory removal of all cleaning
displace contaminated fluid in the system and to agents. Whenever possible, purging operations shall
replenish it with clean serviceable fluid. be accomplished at a Fleet Readiness Center (FRC).
Organizational and Intermediate Maintenance
18. The amount of fluid removed and replaced Activities (OMA and IMA) are not authorized to
during system flushing can vary greatly and will perform system purging.
depend upon such factors as the nature of the
NAVAIR 01-1A-17 006 00
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Change 2 – 1 August 2014 Page 5

006002
Figure 2. Fluid Purification System

22. SELECTION OF DECONTAMINATION Flushing and purging should be avoided to the


METHOD. The method of decontamination must be maximum extent possible to minimize fluid waste
selected according to the type of contamination streams.
observed. Recirculation cleaning is usually the most
effective of the available decontamination methods, 23. CONTAMINATION CONTROL SEQUENCE.
considering maintenance man-hours and material
requirements, and is to be utilized whenever possible. 24. System decontamination is one operation in a
However, if the contaminant is some substance other contamination control sequence that also includes
than readily filterable particles, it may be necessary to hydraulic fluid sampling and analysis.
purify or flush the system, or in certain very extreme Decontamination is performed when the results of
cases, to purge it. Table 1 provides information sampling and analysis indicate an unacceptable level
intended to assist in the selection of an appropriate of contamination, and is then followed by additional
decontamination method. The table refers to chemical testing to determine when an acceptable level has
analysis and particle counting, as well as to patch been achieved.
testing and visual tests that are normally performed.
Chemical analysis and actual particle counts of fluid 25. DECONTAMINATION PROCEDURES.
samples can be provided by FRC Materials Division
Laboratories or the Air Force Petroleum Agency 26. Prior to decontamination of an affected system,
(AFPA) upon request. These test results can be used any failed or known contamination generating
in the selection of a decontamination method.
NAVAIR 01-1A-17 006 00
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Table 1. Aircraft Decontamination Requirements

Decontamination
Method Required
Test Method Abnormal Indication (Note 2)

Visual Inspection Free Water - standing or droplets Flush


Dissolved Water - pinkish fluid, not clear Flush
Gelatinous Substances Flush
Visible Gross Particulate Matter SE Recirculation
Oxidation - dark fluid, not clear Flush
Free Air - air bubbles SE Recirculation

Patch Test Excessive Particulate - exceeds Class 5 SE Recirculation


Water Droplets or Stains Flush
Fibers SE Recirculation
(NAVY USE ONLY) Gross Particulate Matter - extreme contamination SE Recirculation
from component failure or external sources

Particle Count Excessive Particulate Matter - exceeds Class 5 SE Recirculation

Chemical Viscosity - out of limits (Note 1) centistokes @ 100°F Flush


Analysis (Depot) Flash Point - (Note 3) Flush
Water - in excess of (Note 1) ppm Flush
Neutralization - in excess of 0.8 mg KOH/g (acid) Flush

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

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

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

3. Less than the minimum flashpoint required by the applicable military or performance specification.
NAVAIR 01-1A-17 006 00
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Change 2 – 1 August 2014 Page 7

components must be replaced. Other components of e. If contamination is severe, or if aircraft and


the system are not to be disturbed unless required. SE filters are suspected of being loaded, or damaged,
or if differential pressure indicators have been
27. RECIRCULATION CLEANING PROCEDURES. activated, install new (or, if marked “Cleanable”,
Detailed cleaning procedures for accomplishing cleaned and tested) filter elements in the aircraft and
recirculation cleaning are required for all aircraft, SE, SE prior to initiation of cleaning.
MIM, and TO. The specific procedures in the
applicable MIM or TO shall be utilized. Should the f. Set up and operate the test stand in
MIM or TO procedures be found nonexistent, accordance with the aircraft and SE MIM or TO for the
inadequate, or be deemed excessive, the procedures system being powered and recirculation cleaned.
specified herein shall prevail and local action shall be
taken to report the deficiencies to the appropriate FST g. Operate all circuits (actuators) on the system
or ASG. under-going decontamination a minimum of 15
complete cycles, or in accordance with the specific
28. Minimum Requirements for Recirculation MIM, Maintenance Requirement Cards (MRC), or TO.
Cleaning. Recirculation cleaning procedures used for Give particular emphasis to the operation of large
decontamination of aircraft and SE hydraulic systems displacement actuators such as those associated with
must satisfy the following requirements. Ensure that landing gear and wingfold, when powered by the
all procedures embody the basic steps cited. Where affected system.
an adequate procedure does not exist, the specific
minimum requirements stated herein shall be h. Continuously monitor all filter differential
employed as an interim guideline. pressure indicators, both on the aircraft or SE and
external hydraulic test stand during the cleaning
a. Employ recirculation cleaning to remove process. Replace any loaded filter elements.
excessive particulate matter such as that resulting
from normal component wear, limited component i. Sample and analyze the system after cycling
failure, external sources or excessive quantities of air of components. If the contaminant level shows
contamination indicated by reservoir needle sink improvement but is still unacceptable, repeat the
failure. recirculation cleaning process. If no improvement is
observed, attempt to determine the source of
b. Clean the system by powering it with an contamination. System flushing may be required
external hydraulic test stand. Operate aircraft systems (refer to Paragraph 30).
so as to produce maximum interchange of fluid
between the aircraft and the test stand. Detailed and j. Upon completion of successful recirculation
functional diagrams shall be provided in the aircraft cleaning, service the system as needed to establish
MIM or TO illustrate the required equipment the proper reservoir fluid level and to eliminate
connections and settings. See Figure 3, View A for a entrapped air.
basic functional block diagram for recirculation
cleaning. Refer to appropriate SE MIM or TO for NOTE
recirculation cleaning utilizing a purifier. If procedures
are found to be non-existent, contact the responsible USAF: Check applicable aircraft
FST or ASG. maintenance manuals to determine if
purifying the aircraft hydraulic fluid has
c. Test stands used for recirculation cleaning been authorized.
are equipped with 3-micron (absolute) non-bypass
filtration. Before connecting the test stand to the
aircraft or SE, the test stand itself shall be 29. PURIFYING PROCEDURES. When purifiers are
recirculation cleaned, and its contamination level available, they may be used to remove air, water,
verified to meet Navy Standard Class 3 cleanliness particulate contamination and foreign volatile fluid
level or better. contamination such as chlorinated solvents, instead of
flushing the contaminated system. See Figure 3, View
d. When utilizing an external hydraulic test B and note the various ways a purifier may be used to
stand, the test stand reservoir selector valve shall be decontaminate an aircraft system.
in the appropriate position to allow the aircraft or SE
reservoir to drain into the test stand reservoir. a. The upper diagram in View B applies to
purification of non-pressurized systems (i.e. open-air
NAVAIR 01-1A-17 006 00
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Change 2 – 1 August 2014 Page 8

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.

b. The center and bottom diagrams in View B


apply to systems requiring flow and pressure assist in
purifying fluid trapped in lines and components.
Hydraulic Fluid, MIL-PRF-5606 1

(1) In the center diagram of View B, the


purifier is in-line with the contaminated hydraulic fluid
sent from the aircraft and the purified fluid returning to
the portable hydraulic test stand. Hydraulic Fluid, MIL-PRF-83282 2

(2) In the lower diagram of View B, the


purifier pumps the contaminated fluid from the
reservoir drain of the portable hydraulic test stand and
returns the purified fluid through the return port of the Hydraulic Fluid, MIL-H-81019 3
test stand. While the reservoir fluid in the test stand is
being purified, the test stand is concurrently providing
pressurized fluid to the aircraft. With the reservoir
selector valve of the test stand set in the TEST
STAND RESERVOIR position, the contaminated fluid
Hydraulic Fluid, MIL-PRF-87257 4
from the aircraft returns to the test stand tank. Initially,
some of the fluid in the aircraft reservoir may flow into
the test stand reservoir, overfill the stand’s reservoir
and result in spilled hydraulic fluid. To prevent over-
filling, the test stand reservoir may need to be under
filled (e.g. half full) prior to connecting it to aircraft and Hydraulic Fluid, SAE AS1241 5
monitored. This set-up is to be used for aircraft
purification using A/M27T-15 (or A/M27T-14) and NOTE
A/M37M-11.
Fluid purifiers shall be used to recirculate
aircraft and SE hydraulic system fluids
c. Follow aircraft MIM or TO or consult the FST
instead of flushing when purifying
or ASG for the system to be decontaminated on the
most appropriate method, procedure, and purifier to equipment is available.
use on the system. Various adapters may need to be
fabricated to make all the connections shown in a. Use flushing to decontaminate only those
Figure 3. Adhere to the appropriate NAVAIR manual systems not capable of being cleaned by means of
or Air Force TO for the operation of the purifiers. recirculation cleaning or purifying. Flushing will
normally be required to remove fluids that are found
30. FLUSHING PROCEDURES. Detailed to be chemically or physically unacceptable, or fluids
procedures for accomplishing hydraulic system contaminated with water, air, other foreign fluids, or
flushing are required for all aircraft, SE MIM, and TO. particular matter not readily filterable due to either its
The specific procedures in the applicable MIM or TO nature or the quantity involved.
shall be used. Should the MIM or TO procedures be
found to be nonexistent or inadequate, local action b. Accomplish flushing by powering the
shall be taken to contact the responsible FST or ASG. contaminated system with an external portable
hydraulic test stand, and allow return fluid from the
31. Minimum Requirements for Flushing. aircraft to flow overboard into a waste container for
Flushing procedures used for decontamination of disposal. Aircraft subsystems shall be operated so as
aircraft or SE hydraulic systems must satisfy the to produce maximum displacement of aircraft fluids by
following minimum requirements. The FST and ASG cleaned, filtered fluid from the portable test stand.
must ensure that all procedures utilized meet or
NAVAIR 01-1A-17 006 00
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006003
Figure 3. Fluid Flow During Decontamination
NAVAIR 01-1A-17 006 00
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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.

h. All circuits shall be operated on the system


undergoing decontamination until the amount of fluid
collected from the aircraft/SE return line is equivalent
to approximately three times the fluid capacity of the Hydraulic Fluid, MIL-PRF-5606 1
affected system. Give particular emphasis to
reservoirs, actuators, and integrated servocylinders in
the utility and flight control systems during the
decontamination process.
NAVAIR 01-1A-17 006 00
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Page 11/(12 Blank)

d. The purged areas shall be flushed with


hydraulic fluid. Flushing should continue until
chemical analysis of the downstream fluid indicates
Hydraulic Fluid, MIL-PRF-83282 2 complete removal of the cleaning agent previously
used and the contamination level is acceptable.

e. The entire affected system and purifier (if


used) shall be flushed and recirculation cleaned using
the normal system operating hydraulic fluid. After the
Hydraulic Fluid, MIL-H-81019 3 system is returned to service, it should be sampled
periodically to detect possible recurrence of the
original condition.

34. The selected cleaning agent(s) should be


Hydraulic Fluid, MIL-PRF-87257 4
introduced and circulated through affected lines and
components, using an appropriate method. Selection
of cleaning agent(s) is of extreme importance, and it
shall be ensured that the chosen material satisfies the
following basic requirements:
Hydraulic Fluid, SAE AS1241 5

a. Determination should be made as to whether a. It must be effective in absorbing, releasing, or


the contamination is widespread or confined to a otherwise facilitating the removal of the contaminating
particular section of the system. If localized, the substance.
purging operation should be confined to the affected
portion of the system. b. It must be compatible with all materials, both
metallic and nonmetallic, with which it will come in
b. The affected portions of the system should be contact.
drained to the maximum extent practicable prior to
initiation of purging.
c. It must be capable of being totally removed or
c. The cleaning agent(s) shall be drained to the neutralized subsequent to use.
maximum extent practicable.
THIS PAGE LEFT INTENTIONALLY BLANK
NAVAIR 01-1A-17 007 00
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ORGANIZATIONAL, INTERMEDIATE AND


DEPOT MAINTENANCE

HYDRAULIC CONTAMINATION CONTROL

HYRAULIC SYSTEMS

NAVY USE ONLY

Reference Material

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

Alphabetical Index

Subject Page No.

General Contamination Control Program Requirements ............................................................... 2


Clean Work Areas...................................................................................................................... 3
Contamination Measurement..................................................................................................... 2
Filter Element Cleaning ............................................................................................................. 3
Quality Assurance...................................................................................................................... 2
Procedures................................................................................................................................. 3
Responsibilities .......................................................................................................................... 2
Support Equipment .................................................................................................................... 3
System Decontamination........................................................................................................... 3
System Filters ............................................................................................................................ 3
Training ...................................................................................................................................... 2
Introduction .................................................................................................................................... 2
Specific Contamination Control Program Requirements ............................................................... 3
Maintenance Practices .............................................................................................................. 4
Maintenance Procedures........................................................................................................... 3

Record of Applicable Technical Directives

None
NAVAIR 01-1A-17 007 00
TO 42B2-1-12
Change 1 – 1 August 2008 Page 2

1. INTRODUCTION. materials shall be reviewed for currency and shall be


revised as necessary. Personnel at all levels of
NOTE aircraft maintenance concerned with aircraft hydraulic
systems, components, fluids, and portable hydraulic
USAF: This WP not applicable test stands, shall be indoctrinated or trained as
required.

2. Hydraulic contamination in Navy and Marine 7. CONTAMINATION MEASUREMENT.


Corps aircraft and in related support equipment (SE) Contamination measurement standard and
has been and continues to be a major cause of failure acceptability limits have been established to define
of hydraulic systems and components. The purpose and control hydraulic contamination levels. The
of this section is to outline the Navy Hydraulic acceptable hydraulic fluid particulate level is Navy
Contamination Control Program. This program is Standard Class 5, or cleaner, for naval aircraft and
applicable to all Navy and Marine Corps activities Navy Standard Class 3 for related SE. The
involved in the support, manufacture, and contamination level of a particular system shall be
maintenance of Naval aircraft, SE, and their related determined by analysis of a fluid sample drawn from
equipment. It is also applicable to contractors, the system. Analysis shall be accomplished by use of
commercial activities, or other government agencies an Electronic Particle Counter or Contamination
engaged in such activities for the Navy and Marine Analysis Kit 57L414 (WP017 00) at all levels of
Corps. maintenance. Hydraulic system fluid sampling shall
be accomplished on a periodic basis in accordance
3. GENERAL CONTAMINATION CONTROL with the applicable MIM, Maintenance Requirement
PROGRAM REQUIREMENTS. Cards (MRC), and rework specifications. In addition
to the periodic samplings, analysis shall be performed
before the next flight:
4. The following general requirements are
considered essential to the implementation of an
a. Following extensive maintenance and/or
effective hydraulic contamination control program and
crash/battle damage.
form the basis for detailed instructions presented in
the applicable Maintenance Instruction Manuals
(MIM) and elsewhere in this manual. b. When a metal-generating component failure
has occurred as directed by applicable MIM, MRC or
rework specifications.
5. RESPONSIBILITIES. All activities responsible for
the design, development, support, resource
allocation, or maintenance of aeronautical weapons c. When erratic flight control function or
systems and related equipment shall ensure that hydraulic pressure drop is noted.
contamination of hydraulic systems is prevented to
the maximum extent practicable. Every technician d. When repeated or extensive system
performing hydraulic maintenance shall be aware of malfunction occurs.
the causes and effects of hydraulic contamination and
be cognizant of practices and procedures to prevent e. Any time the system is subjected to
contamination. Supervisory and Quality Assurance excessive temperature.
(QA) personnel shall likewise be informed and shall
ensure compliance with accepted standards. Each f. In any other instance when contamination is
maintenance level shall accept that area of suspected.
responsibility applicable to its maintenance level and
shall carry out the required indoctrination, training, 8. QUALITY ASSURANCE. Quality Assurance shall
and implementation of those procedures applicable to reject any system which does not meet the required
that level of maintenance. The Hydraulic contamination acceptance level. Indiscriminate
Contamination Control Program is defined in sampling and analysis shall be avoided. Refer to
COMNAVAIRFORINST 4790.2 Chapter 10 Par. 10.5. WP005 00 of this manual, and to the applicable MIM
for detailed sampling and analysis requirements.
6. TRAINING. Training shall be consistent with the
objectives of an effective aircraft hydraulic system
contamination control program. Training aids and
NAVAIR 01-1A-17 007 00
TO 42B2-1-12
Page 3

9. PROCEDURES. Contamination control components should be accomplished in work areas


procedures shall be developed for each level of conforming to the environmental control criteria
maintenance, and shall be sufficiently detailed and outlined in WP011 00 of this manual. Each
practical for that maintenance level. Procedures found maintenance activity shall assure that the cleanliness
to be acceptable shall be incorporated into the and quality of hydraulic workshop spaces meet or
applicable MIM. Maintenance data shall be complete, exceed the requirements for that level of maintenance
current, and readily accessible to all personnel being performed.
concerned. Maximum effort shall be made to verify
the effectiveness of all contamination control 15. SPECIFIC CONTAMINATION CONTROL
procedures. Hydraulic fluid surveillance in the form of PROGRAM REQUIREMENTS.
periodic fluid sampling and analysis is essential to an
effective contamination control program. These 16. MAINTENANCE PROCEDURES. The following
operations, together with associated system general procedures relative to contamination control
decontamination, constitute the major procedural and testing of hydraulic systems, subsystems,
requirement. components, and fluids are requirements for the
applicable maintenance level.
10. SYSTEM DECONTAMINATION. Systems shall
be decontaminated as required, utilizing recirculation a. Hydraulic fluid contamination controls are
cleaning, purifying, flushing, or purging methods. necessary to ensure the cleanliness and purity of fluid
These methods are defined and described in detail in in the hydraulic system. Fluid sampling and analysis
WP006 00. System purging shall be accomplished shall be performed periodically. Checks should be
only with direction and support of the Fleet Support made in sufficient time before the scheduled aircraft
Team (FST) inspection interval so that if fluid decontamination is
required, it can be accomplished at that time. The
11. SUPPORT EQUIPMENT. It shall be ensured condition of the fluid will depend to a large degree on
that all ground SE used in servicing or maintaining the condition of the components in the system. If a
aircraft hydraulic systems are configured, maintained, system has required frequent component
and operated in a manner consistent with detail replacement and servicing, the condition of the fluid
requirements of the Hydraulic Contamination Control will have deteriorated proportionately.
Program. Refer to WP008 00 and WP009 00 of this
manual for applicable minimum requirements. b. Replacement of aircraft hydraulic system filter
elements shall be accomplished on a scheduled/
12. SYSTEM FILTERS. Hydraulic filter elements conditional basis depending upon the requirements of
shall be replaced on either a periodic or conditional the specific system. The part number of the filter
basis as specified in the applicable MIM and MRC. element shall always be verified before the element is
Periodic replacement intervals, when specified, shall installed in a system or component. Many filter
be consistent with the established service life. elements look identical, but all are not compatible with
Conditional replacement of elements shall be flow requirements of the system.
authorized only when it has been determined that the
filter assembly has been provided with a known c. In the event that hydraulic system fluid is lost
reliable differential pressure indicator. The applicable to the point that the hydraulic pumps run dry or
MIM and MRC shall be reviewed and revised as cavitate, change defective pumps, check filter
necessary to ensure adequacy of related test and elements, and decontaminate as required. Check the
inspection requirements, and procedures. applicable MIM for corrective action to be taken
regarding decontamination of the system. Failure to
13. FILTER ELEMENT CLEANING. Filter element do this may result in contamination of the complete
cleaning equipment and cleaning fluids shall be system.
approved for use and conform to the requirements of
WP010 00 and WP012 00 of this manual. d. Hydraulic systems and components shall be
serviced using only approved fluid dispensing
14. CLEAN WORK AREAS. Shop facility equipment. (Refer to WP009 00.) Under no
requirements have been established and circumstances shall used or unfiltered hydraulic fluid
maintenance of pumps and other hydraulic be introduced into systems or components.
NAVAIR 01-1A-17 007 00
TO 42B2-1-12
Page 4

e. Ensure that all portable hydraulic test stands


receive the required periodic maintenance checks.
Make certain that each unit is approved and that the
applicable MIM is readily accessible and up to date.
When the portable hydraulic test stand is not in use, Hydraulic Fluid, MIL-PRF-83282 2
ensure that it is protected against contaminants such
as dust and water. Ensure that the hoses are of the
correct and approved type for the fluid and that they
are properly capped when not in use. Hoses must be
serialized and must remain with the equipment (Refer Hydraulic Fluid, MIL-H-81019 3
to WP009 00). Make sure the hoses are coiled, kept
free of kinks, and properly stowed. Make sure they
are in satisfactory condition and are checked
periodically. Replace any hose which exhibits
seepage of fluid from the outer cover or separation Hydraulic Fluid, MIL-PRF-87257 4
between the inner tube and the outer cover.

f. Portable hydraulic test stands showing


indications of contamination or loaded filters shall be
removed from service immediately and returned to Hydraulic Fluid, SAE AS1241 5
the supporting activity for maintenance.
a. Exercise extreme care when working on a
hydraulic system in the open, especially under
adverse conditions.

Hydraulic Fluid, MIL-PRF-5606 1 b. Exercise extreme caution when working on


hydraulic equipment in the vicinity of grinding,
blasting, machining, or other contaminant-generating
operations. Much of the grit which is harmful cannot
be seen with the naked eye.
Hydraulic Fluid, MIL-PRF-83282 2
c. Do not break into hydraulic systems unless
g. Use only approved lubricants for O-ring absolutely necessary (this includes cannibalization).
seals. The use of an incorrect lubricant will
contaminate a system. Many lubricants look alike, but d. Use the proper tools for the job.
few are compatible with hydraulic fluids. The only
approved O-ring seal lubricants are hydraulic fluids e. Use only authorized hydraulic fluid, O-rings,
MIL-PRF-5606 (WP002 00, Table 3, Item 1) and MIL- lubricants, or filter elements.
PRF-83282 (WP002 00, Table 3, Item 2).
f. Use an authorized fluid service unit to
17. MAINTENANCE PRACTICES. Certain dispense hydraulic fluid. Ensure the hydraulic fluid
precautions which fall into the categories of good can is clean prior to installation.
housekeeping and maintenance practices will assist
in the elimination of many problems caused by g. Keep hydraulic fluid in a closed container at
contamination. The following is provided as practical all times.
guidance for all personnel to reduce hydraulic system
contamination. h. Keep portable hydraulic test stand reservoirs
above three-quarters full.

Hydraulic Fluid, MIL-PRF-5606 1

Do not use plastic plugs or caps. Plastic


plugs and caps are a possible source of
contamination.
NAVAIR 01-1A-17 007 00
TO 42B2-1-12
Page 5/(6 Blank)

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.

k. Store unused caps and plugs in a clean


container.

l. Use approved wiping cloths (see WP012 00)


to remove exterior contaminants. Use approved lint- When installing O-rings over threaded
free wiping cloths on surfaces along the fluid path. fitting, prevent threads from damaging O-
ring (WP015 00, Figure 14).
m. If possible, have the replacement component
on hand for immediate installation upon removal of
defective component. v. Decontaminate tubing, hoses, fittings, and
components if found or received opened.
n. Replace filters immediately after removal.
w. Decontaminate the system if contamination
o. If possible, fill filter bowl with proper filtered (including water) is suspected.
hydraulic fluid before installing. This minimizes
induction of air into the system.
NOTE
p. Do not reset differential pressure indicators if
the associated filter element is loaded and in need of Ensure that the working area where
replacement (refer to WP008 00). hydraulic components are repaired,
serviced, or stored is clean and free from
moisture, metal chips, and other visible
contaminants (WP011 00).

Clean connectors only with clean


hydraulic fluid. x. Perform required periodic checks on
equipment used for servicing hydraulic systems in
accordance with MRC or technical directives.
q. Before connecting a portable hydraulic test
stand to an aircraft, clean all connections,
interconnect the pressure and return lines of the
stand, and circulate the hydraulic fluid through test
stand filters. Hydraulic Fluid, MIL-PRF-83282 2
r. Store O-rings, tubing, hoses, fittings, and
components in clean packaging. y. Use hydraulic fluid MIL-PRF-83282 (WP002
00, Table 3, Item 2) in stationary hydraulic test
s. Do not open or puncture individual packages stands.
of O-rings or backup rings until immediately prior to
their use.
THIS PAGE LEFT INTENTIONALLY BLANK
NAVAIR 01-1A-17 008 00
TO 42B2-1-12
Change 2 – 1 August 2014 Page 1 of 4

ORGANIZATIONAL, INTERMEDIATE AND


DEPOT MAINTENANCE

SERVICING HYDRAULIC SYSTEMS

Reference Material

None

Alphabetical Index

Subject Page No.

Filter Servicing ............................................................................................................................... 3


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

Record of Applicable Technical Directives

None
NAVAIR 01-1A-17 008 00
TO 42B2-1-12
Change 2 – 1 August 2014 Page 2

1. INTRODUCTION. NOTE

NOTE Use of fluid dispensing equipment is not


required for general propeller systems.
USAF: For specific fluid servicing and For specific propeller servicing
filter servicing requirements, refer to the procedures refer to the applicable
applicable aircraft maintenance manual. Maintenance Instruction Manual (MIM).

2. Although aircraft hydraulic systems are capable NOTE


of reliable unattended operation for long periods of
time, some periodic service is generally required. For hydraulic systems and components
Such service will usually fall into one of the following requiring phosphate ester hydraulic
categories: fluids, refer to the applicable MIM,
Maintenance Requirement Cards (MRC),
a. Fluid servicing or Technical Orders (TO) for specific
servicing procedures.
b. Filter servicing
a. All servicing shall be performed using
These service operations are performed as required, approved fluid dispensing equipment equipped with
concurrently with routine tests and inspections of the 3-micron (absolute) filtration. Equipment shall be
aircraft. Fluid servicing and system air bleeding must maintained in accordance with applicable MIM, MRC,
be performed subsequent to any maintenance and TO.
requiring the opening of fluid connections either in the
circulatory system or at hydraulic components. b. All hydraulic fluid dispensing equipment shall
be maintained in a high degree of cleanliness and
3. FLUID SERVICING. stored in a clean, protected environment. This
equipment shall be serviced on a periodic basis,
4. Fluid servicing consists of adding new filtered including filter servicing (Paragraph 7). When not in
hydraulic fluid to the system to replace fluid lost use, all fittings or hose ends shall be protected by
through leakage or as a result of system maintenance approved metal closures (refer to WP014 00).
or malfunction. Specific procedures exist for checking
hydraulic fluid levels in each model aircraft. It is c. Fluid dispensing equipment shall be used
important that the applicable procedures be followed only with those specific fluids for which they were
to ensure system operation at the required fluid level. intended, and the equipment shall be legibly marked
Fluid level is generally determined by means of an to indicate the type of fluid. Hydraulic systems shall
indicating device at the system reservoir. The type of be serviced using only the fluid specified. Precautions
indicator used will vary with the aircraft model. Sight- shall be taken to avoid accidental use of any other
glass, gage type, and piston style indicators are fluid.
commonly encountered.

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.

i. All filter element installations shall be followed


b. Once the bowl is removed, the fluid is by test and inspection of the system to ensure proper
discarded and the bowl is cleaned of sediment by operation. This is generally accomplished by
flushing with clean, unused hydraulic fluid. operating the system at its normal pressure and flow
rates and inspecting for external leakage at the filter
assembly and indications of excessive differential
pressure. Any external leakage is unacceptable and
c. The filter element is, in most instances,
shall require that the system be shut down and the
removed from the head by a gentle twisting and
pulling motion. Once removed, visually inspect the problem corrected.
surface of the element. An excessive amount of
particulate on the surface of the element may be
indicative of upstream component failure and the
NAVAIR 01-1A-17 008 00
TO 42B2-1-12
Change 2 – 1 August 2014 Page 4

j. Should the filter assembly differential pressure


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

k. Many filter assemblies encountered may


differ in varying degrees from the typical aircraft
assembly described. Consult and comply with all
applicable procedures.
NAVAIR 01-1A-17 009 00
TO 42B2-1-12
Change 2 – 1 August 2014 Page 1 of 30

ORGANIZATIONAL, INTERMEDIATE AND DEPOT MAINTENANCE

HYDRAULIC SUPPORT EQUIPMENT

HYDRAULIC SYSTEMS

NAVY USE ONLY

Reference Material

Organizational, Intermediate and Depot Maintenance Aviation Hose and Tube


Manual .................................................................................................................. NAVAIR 01-1A-20
Maintenance Instructions with Illustrated Parts Breakdown (Organizational,
Intermediate) Hydraulic Fill Unit............................................................................. NAVAIR 17-15BF-57
Preoperational Checklist Hydraulic Service Unit Model H-250-1............................... NAVAIR 17-600-40-6-1
Periodic Maintenance Requirements Manual Hydraulic Service Unit Model H-250-1 NAVAIR 17-600-40-6-2
Operation and Intermediate Maintenance Instructions with Illustrated Parts
Breakdown Hydraulic Fluid Service Unit Type HSU-1 Part Number 630AS100-11 AG-140BA-MIB-000
Preoperational Checklist Hydraulic Service Unit HSU-1 ........................................... AG-140BA-MRC-100
Periodic Maintenance Requirements Manual Service Unit Model HSU-1 ................ AG-140BA-MRC-200
Operation and Organizational Maintenance with Illustrated Parts Breakdown Fluid
Servicing Unit Hydraulic Fluid Model PMU-71/E P/N 061481-100 and 061482-100 NAVAIR 19-1-96
Preoperational Checklist Fluid Servicing Unit Hydraulic Fluid Model PMU-71/E
Part Number 061481-100 ...................................................................................... NAVAIR 19-600-441-6-1
Periodic Maintenance Requirements Manual Fluid Servicing Unit Hydraulic Fluid
Model PMU-71/E Part Number 061481-100.......................................................... NAVAIR 19-600-441-6-2
Operation and Intermediate Maintenance Instructions with Illustrated Parts
Breakdown Pump, Dispensing, Hand Driven PMU-55/E Part Number 4-5280 ..... AG-720AO-S15-000
Preoperational Checklist Pump, Dispensing, Hand Driven PMU-55E P/N 4-5280.... AG-720AO-MRC-000
Preoperational Checklist Hydraulic Service Cart Model 310 .................................... NAVAIR 17-600-67-6-1
Operation and Intermediate Maintenance with Illustrated Parts Breakdown Hydraulic
Fluid Dispensing Unit A/M27M-10 Part Number 995AS300-1 .............................. NAVAIR 17-15BF-87
Preoperational Checklist Hydraulic Fluid Dispensing Unit A/M27M-10 ..................... NAVAIR 17-600-107-6-1
Periodic Maintenance Requirements Manual Hydraulic Fluid Dispensing Unit
A/M27M-10 ............................................................................................................ NAVAIR 17-600-107-6-2
Operation and Maintenance Instructions with Illustrated Parts Breakdown Air Driven,
Portable, Hydraulic Check and Fill Test Stand Model 74 ...................................... NAVAIR 17-15BF-26
Preoperational Checklist Maintenance Requirements Air Driven, Portable, Hydraulic
Check and Fill Stand Model 74 .............................................................................. NAVAIR 17-600-35-6-1
Calendar Maintenance Requirements Cards Air Driven, Portable, Hydraulic, Check
And Fill Stand Model 74 ......................................................................................... NAVAIR 17-600-35-6-2
Operation and Service Instructions with Parts Breakdown, Air Driven, Portable
Hydraulic Check and Fill Stand Model 718 ............................................................ NAVAIR 17-15BF-35
Operation and Intermediate Maintenance with Illustrated Parts Breakdown Test
Stand Aircraft Hydraulic Systems A/M27T-6 Part Number 1415AS100-1............. NAVAIR 17-15BF-90
Preoperational Checklist Test Stand, Aircraft Hydraulic System, A/M27T-6
Part Number 1415AS100-1 ................................................................................... NAVAIR 17-600-156-6-1
Periodic Maintenance Requirements Manual Test Stand, Aircraft Hydraulic
System, A/M27T-6 Part Number 1415AS100-1 .................................................... NAVAIR 17-600-156-6-2
Operation and Intermediate Maintenance with Illustrated Parts Breakdown, Portable
Hydraulics Power Supply (Electric Motor Driven) Model A/M27T-7 and A/M27T-7A NAVAIR 17-15BF-91
Preoperational Checklist Portable Hydraulic Power Supply A/M27T-7 and
A/M27T-7A ............................................................................................................ NAVAIR 17-600-150-6-1
NAVAIR 01-1A-17 009 00
TO 42B2-1-12
Change 2 – 1 August 2014 Page 2

Operation and Intermediate Maintenance with Illustrated Parts Breakdown,


Portable Hydraulic Power Supply A/M27T-5 and A/M27T-5A ............................... NAVAIR 17-15BF-89
Preoperational Checklist Portable Hydraulic Power Supply A/M27T-5 and A/M27T-5A NAVAIR 17-600-127-6-1
Periodic Maintenance Requirements Manual Portable Hydraulic Power
Supply A/M27T-5 .................................................................................................. NAVAIR 17-600-127-6-2
Operation and Intermediate Maintenance with Illustrated Parts Breakdown Electric
Hydraulic Power Supply (EHPS) A/M27T-14 Part Number 040499-100............... NAVAIR 17-15BF-120
Electric Hydraulic Power Supply A/M27T-14 Part Number 040499-100 ................... NAVAIR 17-600-BF120-6-1
Periodic Maintenance Requirements Manual Electric Hydraulic Power Supply
A/M27T-14 Part Number 040499-100 ................................................................... NAVAIR 17-600-BF120-6-2
Operation and Intermediate Maintenance with Illustrated Parts Breakdown Diesel
Hydraulic Power Supply (DHPS) A/M27T-15 Part Number 040489-100 .............. NAVAIR 17-15BF-110
Diesel Hydraulic Power Supply A/M27T-15 Part Number 040489-100 ..................... NAVAIR 17-600-BF110-6-1
Periodic Maintenance Requirements Manual Diesel Hydraulic Power Supply
A/M27T-15 Part Number 040489-100 ................................................................... NAVAIR 17-600-BF110-6-2
Organizational, Intermediate, and Depot Maintenance Instructions with Illustrated
Parts Breakdown Portable Hydraulic Power Unit A/M27T-3 P/N 636AS100-1 ..... NAVAIR 17-15BF-76
Preoperational Maintenance Requirements Portable Hydraulic Power Supply
Model A/M27T-3 .................................................................................................... NAVAIR 17-600-101-6-1
Periodic Maintenance Requirements Manual Portable Hydraulic Power Supply
A/M27T-3 ............................................................................................................... NAVAIR 17-600-101-6-2
Operations and Intermediate Maintenance with Illustrated Parts Breakdown Portable
Hydraulic Power Supply Diesel (PHPSD) Part Number 000850-100 .................... AG-140AC-MMB-000
Pre-Operational Checklist Portable Hydraulic Power Supply Diesel (PHPSD) ......... AG-140AC-MRC-100
Periodic Maintenance Requirements Manual Portable Hydraulic Power Supply
Diesel (PHPSD) Part Number 000850-100 ........................................................... AG-140AC-MRC-200
Operations and Intermediate Maintenance with Illustrated Parts Breakdown Portable
Hydraulic Power Supply Electric (PHPSE) Part Number 98612-100 .................... AG-140AB-MMB-000
Preoperational Checklist Portable Hydraulic Power Supply Electric (PHPSE) Part
Number 98612-100 ................................................................................................ AG-140AB-MRC-100
Periodic Maintenance Requirements Manual Portable Hydraulic Power Supply
Electric (PHPSE) Part Number 98612-100 ............................................................ AG-140AB-MRC-200
Maintenance Program, Naval Aviation .................................................................... COMNAVAIRFORINST
4790.2
Operation and Maintenance Instructions with Illustrated Parts Breakdown Aircraft
Hydraulic and Pneumatic Component Test Stand Model HCT-10 P/N 66A91J001 NAVAIR 17-15BF-37
Aircraft Hydraulic and Pneumatic Component Test Stand HCT-10 ........................... NAVAIR 17-600-32-6-1
Periodic Maintenance Requirements Manual Aircraft Hydraulic and Pneumatic
Component Test Stand HCT-10 ............................................................................ NAVAIR 17-600-32-6-2
Handbook Operation and Service Instructions with Illustrated Parts Breakdown,
Aircraft Hydraulic Hose Check Stand .................................................................... NAVAIR 17-15BF-504
Intermediate and Depot Maintenance with Illustrated Parts Breakdown, Hydraulic
Component Test Stand Navy Model A/F27T-10 P/N’s 2029AS100-10,-20 .......... NAVAIR 17-15BF-94
Preoperational Checklist A/F27T-10 Hydraulic Component Test Stand .................... NAVAIR 17-600-T10-6-1
Periodic Maintenance Requirements Manual A/F27T-10 Hydraulic Component
Test Stand Part Numbers 2029AS100-10,-20 ....................................................... NAVAIR 17-600-T10-6-2
Operation, Service, and Overhaul Instructions Manual with Illustrated Parts
Breakdown, Automatic Flight Control System Servocylinder Test Stand Assembly NAVAIR 17-15BF-41
Preoperational Checklist Hose Burst Test Stand 63A101-E1 .................................... NAVAIR 17-600-126-6-1
Periodic Maintenance Requirements Manual Hose Burst Stand P/N 63A101-E1 ..... NAVAIR 17-600-126-6-2
Operation and Intermediate Maintenance with Illustrated Parts Breakdown Fluid
Purifier A/M 37M-2 Part Number AD-A352-8Y10 .................................................. AG-711BA-MAB-000
Preoperational Checklist Fluid Purifier A/M 37M-2 .................................................... NAVAIR 19-600-201-6-1
Periodic Maintenance Requirements Manual Fluid Purifier A/M 37M-2 ................... NAVAIR 19-600-201-6-2
Operation and Intermediate Maintenance Instructions with Illustrated Parts
NAVAIR 01-1A-17 009 00
TO 42B2-1-12
Change 2 – 1 August 2014 Page 3

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

Subject Page No.

Contamination Control Requirements ............................................................................................ 4


Cleanliness ................................................................................................................................ 4
Contamination Analysis ............................................................................................................. 5
Fluid Sampling ........................................................................................................................... 5
Flushing ..................................................................................................................................... 7
Operational Use ......................................................................................................................... 5
Periodic Maintenance and Repair ............................................................................................. 5
Purging ....................................................................................................................................... 7
Recirculation Cleaning ............................................................................................................... 6
Support Equipment (SE) Configuration ..................................................................................... 4
Fluid Dispensing Unit ..................................................................................................................... 8
Fluid Service Cart, Model 310 ................................................................................................... 9
Fluid Service Unit, Model HSU-1 ............................................................................................... 8
Hydraulic Fluid Servicing Unit (HFSU), Model PMU-71/E ......................................................... 8
Hydraulic Purification Equipment ................................................................................................... 28
Hydraulic Fluid Purifier (HFP) Model A/M37M-11...................................................................... 28
Hydraulics International Inc Hydraulic Purification Unit ............................................................. 28
Pall Aeropower Corp Hydraulic Purifier A/M37M-2 ................................................................... 28
Introduction..................................................................................................................................... 4
Minimum Requirements for Portable Hydraulic Test Stand Operation
and Aircraft Connection ............................................................................................................... 17
Applying Hydraulic Power to Aircraft ......................................................................................... 23
Cleaning and De-Aerating Test Stand ....................................................................................... 22
Pre-Operational Inspections and Procedures ............................................................................ 22
Starting Test Stand Engine ........................................................................................................ 22
Test Stand Operational Checks ................................................................................................. 23
Test Stand Shutdown Procedure ............................................................................................... 23
Portable Hydraulic Test Stands...................................................................................................... 9
Diesel Hydraulic Power Supply (DHPS) A/M27T-15 ................................................................. 17
Electric Hydraulic Power Supply (EHPS) A/M27T-14................................................................ 16
Portable Hydraulic Test Stand A/M27T-5 .................................................................................. 16
Portable Hydraulic Test Stand A/M27T-7 .................................................................................. 16
Stationary Hydraulic Test Stands ................................................................................................... 24
CGS Scientific Thermodynamics (24461) Hose Burst Test Stand ............................................ 25
Greer Hydraulic Hose Test Stand .............................................................................................. 25
Hydraulic and Pneumatic Component Test Stand HCT-10 ....................................................... 25
Hydraulic Component Test Stand A/F27T-10............................................................................ 27
Use of Manifolds for Multisystem Operation .................................................................................. 24

Record of Applicable Technical Directives

None
NAVAIR 01-1A-17 009 00
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1. INTRODUCTION. specialized equipment such as hose burst test stands,


they are general-purpose equipment capable of
NOTE performing a variety of tests on components such as
hydraulic pumps, actuators, motors, valves,
USAF: This WP not applicable accumulators, and gages. Typical component test
stands consist of adjustable sources of hydraulic and
shaft driven (for pump drive) power, with the
2. Hydraulic Support Equipment (SE) is that associated regulator and indicating devices that
equipment intended for use in servicing and testing enable component performance to be monitored
hydraulic systems and components. The equipment is under simulated operating conditions. Stationary
utilized at all levels of maintenance and consists of hydraulic test stands are employed at the
the following general types: Intermediate Maintenance Level, ashore and afloat,
and for Depot Level Maintenance.
a. Portable hydraulic test stands

b. Hydraulic fluid dispensing equipment 6. CONTAMINATION CONTROL REQUIREMENTS.

c. Stationary hydraulic test stands 7. Because of the direct connection of hydraulic SE


to systems or components being checked or serviced,
A thorough understanding of each hydraulic SE is strict measures must be observed to minimize the
essential to its proper utilization in the maintenance of introduction of external contaminants. Testing units
aircraft hydraulic systems. All hydraulic SE are under that are not properly configured, maintained, or
the cognizance of Naval Air Warfare Center Aircraft utilized can be responsible for severe contamination
Division. The maintenance and operation of specific of hydraulic systems in operational aircraft. It is the
SE units are described in applicable NAVAIR individual responsibility of all maintenance personnel
manuals, and (to a lesser extent) in Maintenance to ensure that hydraulic SE is maintained and used in
Instruction Manuals (MIM) peculiar to the aircraft. It is accordance with existing contamination control
the intent of this section to provide a general requirements.
description of the equipment involved, with specific
new requirements not presently available in other 8. SUPPORT EQUIPMENT CONFIGURATION. All
applicable publications. hydraulic SE shall conform to the following
requirements:
3. Portable hydraulic test stands are mobile sources
of external hydraulic power that can be connected to a. All SE used to service or test aircraft
an aircraft hydraulic system to provide power normally hydraulic systems or components shall be equipped
obtained from the aircraft hydraulic pumps. They with adequate output filtration having a rating of 3-
provide a means of energizing the aircraft hydraulic microns (absolute). The 3-micron filter assembly shall
systems for purposes of checkout and maintenance. be of a non-bypass variety, preferably equipped with
These test stands are employed both on the flight line a differential pressure indicator. It shall be installed
and in hangar work areas. Portable test stands are immediately upstream of the major fluid discharge
important tools in hydraulic contamination control. ports.
They provide the primary means of aircraft hydraulic
decontamination. Several types of portable stands are b. Portable hydraulic test stands shall be
available. They differ primarily in their power source equipped with recirculation cleaning manifolds and
(electric motor or engine driven), functional features, fluid sample valves to enable self-cleaning and fluid
and maximum flow capability. analysis prior to connection to equipment under test.
4. Hydraulic fluid dispensing equipment is portable 9. CLEANLINESS. All hydraulic SE shall be
equipment used for replenishing hydraulic fluid lost or maintained in accordance with the following
otherwise removed from a system. They provide a cleanliness requirements:
means of dispensing new filtered fluid under pressure,
in a manner that will minimize the introduction of
a. All hydraulic SE shall be maintained at the
external contaminants. Several different types are
highest level of cleanliness practicable, consistent
available and described in WP008 00 of this manual.
with its construction and utilization.
5. Stationary hydraulic test stands are permanently
installed equipment intended for shop testing b. External fluid connections, fittings, and openings
hydraulic system components. With the exception of shall be kept clean and contaminant-free at
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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.

b. Differential pressure or “loaded filter” Prior to sampling, operate the SE for a


indicators shall be closely monitored during all SE minimum of 5 minutes in a manner that will
operation subsequent to the fluid reaching normal result in fluid flow through its reservoir to
operating temperature (+ 85°F minimum ). Equipment ensure uniform distribution of
operation shall be terminated immediately upon contaminants. Certain model equipment
appearance of “loaded filter” indications. Replace the may require return of the pressure outlet to
loaded element. the reservoir fill opening to achieve such
flow. For hydraulic fluid servicing units with
c. Use of SE shall be terminated immediately if a capacity of 3 gallons or less, a 5 minutes
the reservoir or outlet fluid is determined or suspected recirculation period is not required.
to be contaminated beyond acceptable limits. The However, to ensure a representative
user shall inform the supporting maintenance activity sample is pulled, perform 5-6 pump strokes
immediately so that required remedial action can be on the equipment prior to sampling.
taken.

11. PERIODIC MAINTENANCE AND REPAIR. 13. CONTAMINATION ANALYSIS. Contamination


Supporting activities for hydraulic SE shall perform analysis of SE fluid samples shall normally be done
periodic maintenance at each 13-week interval unless using electronic particle count testing. The
otherwise directed. Maintenance requirements are as contamination analysis kit may be employed if
follows: electronic particle count testing is unavailable or
impractical. Decontamination of unacceptable
NOTE
equipment shall be performed by means of
Refer to NAVAIR 01-1A-20 for recirculation cleaning, purifying, flushing, or purging.
maintenance of age-controlled hoses Refer to WP006 00 of this manual for a general
used in SE. discussion of these methods. Refer to Table 1 of this
work package to assist in selecting an appropriate
decontamination method.
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Table 1. Hydraulic Support Equipment Decontamination Requirements

Decontamination
Method Required
Test Method Abnormal Indication (Note 2)

Visual Inspection Free Water - standing or droplets Purify


Dissolved Water - pinkish fluid, not clear Purify
Gelatinous Substances Flush
Visible Gross Particulate Matter SE Recirculation
Oxidation - dark fluid, not clear Flush
Free Air - air bubbles SE Recirculation or Purify

Patch Test Excessive Particulate - exceeds Class 3 SE Recirculation


Water Droplets or Stains Purify
Fibers SE Recirculation
Gross Particulate Matter - extreme contamination SE Recirculation
from component failure or external sources

Particle Count Excessive Particulate Matter - exceeds Class 3 SE Recirculation

Chemical Viscosity - out of limits (Note 1) centistokes @ 100°F Flush


Analysis (Depot) Flash Point - (Note 3) Flush
Neutralization - in excess of 0.8 mg KOH/g (acid) Flush

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


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

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

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:
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a. Operate affected SE in a manner that will


result in maximum circulation of fluid through the
equipment reservoir and internal 3-micron filter(s).
Maintain flow long enough to allow a total flow Hydraulic Fluid, SAE AS1241 5
equivalent to at least five times the total fluid capacity
of the equipment reservoir. Monitor all filter a. Drain, flush, and re-service the equipment
differential-pressure indicators throughout the reservoir using new filtered fluid. If contamination is
operation and check and replace, in accordance with known to have originated at the pump, the hoses and
applicable MIM/Maintenance Requirement Cards lines directly associated with the pump output and
(MRC), any elements indicated as being loaded. case drain should be drained and flushed separately.
b. Resample and analyze fluid from the
b. Operate equipment in a manner that will
sampling port or point. If improvement is shown, but
produce flow through all circuits and allow output (or
contamination level is still excessive, repeat steps a
return line) fluid to dump overboard into an approved
and b.
waste receptacle (WP002 00, Table 3, Item 19).
c. If no improvement is shown, attempt to locate Continue flushing until a quantity of fluid equal to the
the internal source of the contaminant observed, such equipment reservoir capacity has passed through the
as a failed component. Replace any components unit. Closely monitor reservoir level during the
determined to be contaminating the fluid and continue operation and add new filtered fluid, as needed, to
decontamination by draining, flushing, and refilling the prevent the reservoir level from dropping below the
equipment with new filtered fluid. Recirculation clean one-third full point.
and resample to determine acceptability.
c. Sample and analyze output and reservoir
d. When fluid samples from the sampling port or fluids. If contamination level shows improvement but
point are determined to be within acceptable limits, is still unacceptable, repeat the flushing operation.
recirculation cleaning may be terminated. Should extensive flushing fail to decontaminate the
affected equipment, request assistance from the
15. FLUSHING. This method of decontamination is supporting engineering activity.
employed when the SE is found to be heavily
contaminated with particulate matter or the fluid d. Upon successful completion of system
contains a substance not readily removed by the flushing, subject the equipment to a minimum period
internal filters. Flushing procedures shall satisfy the of recirculation cleaning. Sample system again
following requirements: subsequent to recirculation cleaning to verify the
contamination level as being acceptable.

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.

Hydraulic Fluid, MIL-PRF-87257 4


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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.

33. Hydraulic fluid is removed through a swivel


fitting installed in a 2-inch bung. The swivel fitting is
connected by means of a flexible hose to a single-
action-type pump having a displacement of 2 fluid
Do not service aircraft directly from ounces per stroke at 0 to 250 psi. A replaceable 3-
HFBDU. HFBDU is designed only to micron (absolute) disposable filter installed at the
provide clean hydraulic fluid to servicing pump assembly base removes particulate
equipment and not for servicing aircraft contamination from the fluid being delivered to the
directly. suction side of the pump. A check valve in the filter
assembly prevents operation without a filter element
29. The Hydraulic Fluid Bulk Dispensing Unit installed.
(HFBDU) P/N 061482-101, CAGE 56529, illustrated
in Figure 3, is a modified extendable 55 gallon self- 34. Filtered fluid from the hand pump is routed to an
priming manual rotary drum pump which is used for air trap assembly containing a special chamber that
filling Hydraulic Fluid Servicing Units (HFSU). This functions to remove any free air that may be present
painted red drum pump has telescoping suction tube in the fluid. The air trap assembly contains a manual
for servicing from drums up to 55 gallons in size. In bleed valve for venting collected air, and a 0 to 300
addition it has an adapter for screwing on to 2” drum psi pressure gage for monitoring output pressure.
bung hole, and delivers from 8 to 10 ounces per full Fluid is delivered to the system or component being
clockwise revolution. A spin-on 10 micron filter is serviced by means of a 15-foot service hose. A 3-
mounted off the pump with a filter change pressure micron in-line filter assembly is located near the
gage. The HFBDU has a 6 foot long hose with a -4 discharge end of the service hose to further ensure
flared swivel fitting at the end with a lanyarded cap. against system contamination.
When filling an HFSU, the hose is connected to the
HFSU quick fill adapter. 35. PORTABLE HYDRAULIC TEST STANDS.
36. Several different models of portable hydraulic
30. In addition, the HFBDU has a desiccant vent filter
test stands are currently in fleet use. While the
that screws into the smaller ¾” drum bung hole. This
primary function of this equipment is the same, that is,
filter minimizes the amount of dust and moisture
to provide external ground power to aircraft hydraulic
entering the drum. The filter’s desiccant changes
systems, the equipment varies as to fluid flow
from blue to clear or reddish when it needs to be
capabilities, source of prime power and manufacturer.
replaced. It is attached by a Velcro strap to above
Tables 3 and 4 list test stands commonly available
spin-on filter and has caps to seal filter when stored.
and include pertinent descriptive data to assist with
the selection of equipment. It is not the intent of this
31. FLUID SERVICE CART, MODEL 310. Fluid
manual to provide detailed description of, or specific
Service Cart, Model 310 (fluid service cart), illustrated
operating instructions for, the listed equipment. The
in Figure 4 is a hand-propelled mobile unit designed
applicable handbooks referenced in Table 3 should
for servicing aircraft hydraulic systems with fluid
be consulted for this information. However, several of
obtained directly from the 10-gallon container. It can
the more common test stands are discussed to
be operated by one man and is for use in those
provide a general familiarity with the equipment.
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009001

Figure 1. Fluid Service Unit, Model HSU-1


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Table 2. Fluid Servicing Equipment

NOMENCLATURE MODEL NO./CAGE NO. CAPACITY PUBLICATION

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


NAVAIR 17-600-40-6-1
NAVAIR 17-600-40-6-2

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


AG-140BA-MRC-100
AG-140BA-MRC-200

PMU-71/E (56529) 2 gal NAVAIR 19-1-96


NAVAIR 19-600-441-6-1
NAVAIR 19-600-441-6-2

Hydraulic Fluid Servicing Cart AG-720AO-S15-000


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

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

Hydraulic Dispensing Cart NAVAIR 17-15BF-87


A/M27M-10 (51744) 55 gal NAVAIR 17-600-107-6-1
NAVAIR 17-600-107-6-2

Hydraulic Check and Fill Stand 74 (93974) 5 gal NAVAIR 17-15BF-26


NAVAIR 17-600-35-6-1
NAVAIR 17-600-35-6-2

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

NAVAIR 17-15BF-90
A/M27T-6 (30003) 5 gal NAVAIR 17-600-156-6-1
NAVAIR 17-600-156-6-2

Portable Hydraulic Test Stand A/M27T-7 (30003) 20 gal NAVAIR 17-15BF-91


(Note 1) A/M27T-7A (30003) (Note 2) NAVAIR 17-600-150-6-1

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

A/M27T-14 (56529) 25 gal NAVAIR 17-15BF-120


NAVAIR 17-600-BF120-6-1
NAVAIR 17-600-BF120-6-2

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

Figure 4. Fluid Service Cart, Model 310


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Table 3. Portable Hydraulic Test Stands

MODEL POWER
(Note 1) P/N & MFR (CAGE) PUBLICATION MRC TEC FLOW CAPACITY SOURCE

A/M27T-7 68A5-J1000-1 NAVAIR 17-15BF-91 17-600-150-6-1 GGJ6 20 gpm @ 3000 psi


A/M27T-7A 68A5-J1000-20 GGJ9 10 gpm @ 5000 psi
(56529) (Note 3)
Electric
(Note 2)
A/M27T-3 Greer NAVAIR 17-15BF-76 17-600-101-6-1 GGJU 6 gpm @ 3000 psi
636AS100-1 17-600-101-6-2 3 gpm @ 4500 psi
(30003)

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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Table 4. Portable Hydraulic Test Stand Operating Features

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.

A/M27T-14/-15: Needed for setting system pressure


valve. It also shuts off flow to supply port and hose
which is required to operate aircraft reservoir fill
system.

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

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

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

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

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

Recirculation Yes Yes Yes Enables recirculation cleaning for test stand and
cleaning/hose storage service hoses and provides hose stowage means.
manifolds

3-micron filtration Yes Yes Yes Enables delivery of particulate-free fluid to


equipment under test. A MANDATORY
REQUIREMENT.

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


reservoir.
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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.

42. ELECTRIC HYDRAULIC POWER SUPPLY


Hydraulic Fluid, SAE AS1241 5 (EHPS) A/M27T-14. The EHPS, P/N 040499-100, is
a portable electric powered, self-contained unit
a. Provide a source of hydraulic fluid at designed to check the performance and operating
controlled pressures to operate hydraulic components characteristics of aircraft hydraulic systems. The
without the necessity of starting the aircraft engine. EHPS electric motor operates on 440/460 VAC, 3
phase 50/60 Hz electric power and capable of
b. Test aircraft hydraulic systems for evidence of
drawing up to 100 amps of current. Figure 7
component malfunction and flow or pressure leakage.
illustrates a typical unit. The EHPS will perform the
c. Decontaminate and service aircraft hydraulic following tests and operations:
systems with filtered fluid.
38. The units are designed to deliver fluid volume up
to 20 gpm at pressure of 3,000 psi and 10 gpm at
5,000 psi. Fluid contamination during the test cycle is
constantly controlled by 3- and 10-micron replaceable
element filters. Hydraulic Fluid, MIL-PRF-5606 1

Hydraulic Fluid, MIL-PRF-83282 2


The fill system and high-pressure system
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system furnishes fluid to the aircraft system for testing


operations under controlled conditions of flow and
pressure.
Hydraulic Fluid, MIL-H-81019 3
45. DIESEL HYDRAULIC POWER SUPPLY (DHPS)
A/M27T-15. The DHPS, P/N 040489-100, is identical
to the A/M27T-14 EHPS except it is a diesel engine
driven unit. Figure 8 illustrates a typical unit.
Hydraulic Fluid, MIL-PRF-87257 4
46. The principles of operation and the operating
procedures for an A/M27T-15 DHPS is basically the
same as those for the A/M27T-14 EHPS with
exception to starting and stopping procedures and the
use of a diesel engine. Refer to the applicable
Hydraulic Fluid, SAE AS1241 5 equipment manual (Table 3) for operational and
maintenance instructions.
a. Deliver hydraulic fluid at controlled pressures to
operate hydraulic components without the necessity
of starting the aircraft engine(s). 47. MINIMUM REQUIREMENTS FOR PORTABLE
HYDRAULIC TEST STAND OPERATION AND
b. Test aircraft hydraulic systems for evidence of AIRCRAFT CONNECTION.
component malfunction and flow or pressure leakage.
48. Due to differences in equipment, the specific
c. Decontaminate and service aircraft hydraulic instructions for test stand inspection, turn-up, aircraft
systems with filtered hydraulic fluid. connection, and operation must be obtained from the
applicable maintenance manuals. It is important to be
43. The EHPS delivers fluid volumes up to 32 gpm at cognizant of certain minimum general requirements
pressure of 3,000 psi and 22 gpm at 5,000 psi. Back considered essential to the proper utilization of all
pressure on aircraft return line can be adjusted from portable test stands. The following is a step-by-step
10 to 120 psi. The EHPS 3-micron absolute and 10- operating procedure that includes these general
micron nominal replaceable filters reduce particulate requirements which should be followed closely:
contamination in hydraulic fluid. The EHPS has
dedicated purification ports and fluid sampling ports
that allow it to connect to an A/M37M-11 Hydraulic
Fluid Purifier (HFP) and a MXU-973E PODS particle
counter respectively. Using the fluid sampling ports
to allow online particle counting is the preferred
method since results are less likely to fail due to The following procedure is for general
operator error and no hydraulic fluid is wasted. guidance only and does not in itself
constitute sufficient indoctrination for its
accomplishment. A valid ground SE
operator license in accordance with
requirements of COMNAVAIRFORINST
4790.2 is required.
The fill system and high-pressure system
cannot be operated at the same time If test stand has not been utilized for an
without depleting the aircraft reservoirs. appreciable period of time or has been
Refer to appropriate manual listed in subjected to environmental conditions
Table 3 to obtain detailed operating conducive to water condensation in its
instructions and other information relating reservoir, sample and analyze reservoir
to the equipment being operated. fluid for possible water contamination in
accordance with procedures of
Paragraph 13 prior to use.
44. The EHPS (Figure 7) consists of two segments;
the fill system and the high-pressure system. The fill
system provides a capability for servicing the aircraft
system with filtered hydraulic fluid. The high-pressure
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009005

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


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009006

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


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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:

a. Set up test stand to provide fluid flow from


the internal reservoir through the external service
hoses and interconnecting manifold. Place pump
pressure compensator at its lowest setting and
Hydraulic Fluid, MIL-PRF-83282 2
ensure that the manifold and service outlet valves (if
present) are in the open position. The high-pressure
gage should indicate a value less than 600 psi.

b. Allow test stand to recirculate clean for 15


Hydraulic Fluid, MIL-H-81019 3 minutes. Monitor fluid temperature throughout the
cleaning cycle and ensure that maximum operating
limits are not exceeded.

c. Monitor all filter differential pressure


Hydraulic Fluid, MIL-PRF-87257 4 indicators, particularly those associated with the 3-
micron filter assemblies. If indications of a loaded
filter are observed after fluid reaches normal
operating temperature (85°F minimum), shut down
test stand and have replacement filter elements
Hydraulic Fluid, SAE AS1241 5 installed.

d. Upon completion of recirculation cleaning and


a. Make certain the test stand is located so that de-aeration, terminate fluid flow to the external
adequate room, ventilation, and engine heat service hoses in preparation for connecting to aircraft.
dissipation are available. Disconnect service hoses from manifold assembly
and reinstall manifold dust covers.
b. Set parking brakes securely.
NOTE
c. Open all necessary access doors.
Consult applicable maintenance manuals
d. Check that the hydraulic fluid level of the test
for specific procedures to be used in
stand reservoir is three-fourths full as indicated on the
applying external electric and hydraulic
gage. Add fluid if needed.
power. As a minimum requirement prior
e. Check fuel gage, radiator level, and engine to aircraft connection, set hydraulic test
oil level in engine-driven stands. Ensure that levels stand controls to the positions and values
are adequate for anticipated operating period. required to accomplish aircraft tests.
Operate test stand to confirm settings,
f. Check that the pointers of all other gages rest reduce volume adjustment to minimum
at or near zero. flow and shut down stand prior to aircraft
connection.
g. Clean and connect service ends of the
external pressure and return line hoses to the hose
storage (recirculation) manifold provided on the
equipment. If manifold is equipped with shutoff
valves, place valve in open position.
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52. APPLYING HYDRAULIC POWER TO NOTE


AIRCRAFT. Connect test stand service hoses to the
aircraft ground power quick disconnects, ensuring Bypass control should be fully closed
that all connectors are clean prior to connection. Mate during aircraft operation. Adjust operating
all attached dust caps and plugs to protect against pressure using pump compensator control
their contamination during test stand operation. If dust only.
plugs are not present at end of test stand service
hoses, have required plugs installed in accordance
with WP014 00. Apply hydraulic power as follows: e. Test stand is now ready to provide powered
operation of the aircraft hydraulic system. Use
specific test procedures as provided in applicable
MIM.

Hydraulic Fluid, MIL-PRF-5606 1 53. TEST STAND OPERATIONAL CHECKS.


Monitor test operation during aircraft test and check
for the following:

Hydraulic Fluid, MIL-PRF-83282 2

In some cases, loaded filter indicators


may extend due to cold starting
conditions. Reset and continue to
Hydraulic Fluid, MIL-H-81019 3 monitor the indicator until the equipment
reaches the normal operating
temperature.

Hydraulic Fluid, MIL-PRF-87257 4 a. Monitor filter differential pressure indicators,


particularly those associated with the 3-micron filter
assemblies. Should a loaded filter be indicated, shut
down and return equipment to supporting activity.

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:

c. Start test stand and allow to warm up with


controls set for bypass fluid flow.

d. Adjust flow rate and operating pressures to


required values by means of the volume and pump
compensator controls. Set high-pressure relief valve
to the operating pressure plus 10 percent.
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manifolding two or more systems to a common test


stand having sufficient flow capability. The latter
method employs a minimum of equipment. The
following information provides several basic
In aircraft equipped with pressurized limitations.
reservoirs, hydraulic accumulators, or
surge dampers, detrimental reverse flow a. Utilization of a single test stand and manifold
of fluid through aircraft filters may result if will result in an exchange of hydraulic fluid between
proper shutdown procedures are not the two or more systems so connected. Should the
employed. fluid in one system be contaminated with particulate
matter smaller than 3 microns or water, cross-
contamination of the other systems will occur.
a. Leave bypass valve in closed position.
Reduce volume setting to zero and adjust pressure b. The single test stand may not be able to
compensator to minimum. Allow several minutes for satisfy differing flow and back pressure requirements
stored pressure in aircraft to bleed off via normal of the multiple systems to be powered. Depletion or
internal leakage. overfilling of aircraft reservoirs may result.

c. High transient flow demands in one system


b. Slowly open pressure bypass valve. could adversely affect the performance of the other
systems powered by the common hydraulic power
c. Let engine run at 1,000 rpm for about 5 source. The resulting lack of total isolation between
minutes (engine driven models only). systems could possibly degrade critical flight control
system performance tests.
d. Push throttle down completely.
d. The use of jury-rig manifolds not specifically
engineered for the purpose can be a safety hazard to
e. Place panel light switch in OFF position. personnel and a possible source of system
contamination.

57. Properly designed hydraulic manifolds can be


employed in limited, specific applications to power
multiple hydraulic systems from a common hydraulic
Do not drag hose ends on deck or test stand. Such usage must be thoroughly evaluated
otherwise expose to contamination. by the applicable FST to ensure acceptability and be
strictly limited to the particular application. All
approved manifold utilization must be directed in the
f. Remove external hoses from aircraft hose applicable aircraft MIM and complete information be
ports and connect loose ends to hose storage provided on the source of required hardware. The use
manifold disconnects on test stand. Install all dust of manifolds not authorized in this manner is
caps and plugs, including those at aircraft quick prohibited.
disconnects.
58. STATIONARY HYDRAULIC TEST STANDS.
g. Close all access doors to protect instruments
and controls. 59. Stationary hydraulic test stands, as described in
Paragraph 5, are installed as special purpose shop
test equipment used primarily for component test and
55. USE OF MANIFOLDS FOR MULTISYSTEM
repair. Due to their specialized nature, each model
OPERATION.
test stand has unique installation, operation, and
56. When performing troubleshooting, rigging, and maintenance requirements. For specific data relative
specific tests on dual flight control systems employing to a particular shop test stand, the NAVAIR series
tandem actuators, it is often necessary to apply SE manual applicable to the equipment should be
hydraulic pressure to two or three systems in an consulted. Table 5 provides a list of commonly used
aircraft simultaneously. Simultaneous multi-system shop hydraulic test stands and references the
operation can be accomplished using separate applicable operating manuals. The following is a brief
hydraulic test stands for each system, or by description of the equipment for purposes of
familiarization.
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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.

61. CGS SCIENTIFIC THERMODYNAMICS


(24461) HOSE BURST TEST STAND. The CGS
Scientific Thermodynamics (24461) Hose Burst Test
Stand is similar in operation to the hose test, but has
the additional capability for proof-testing pneumatic
hoses. It is similar in general appearance to the hose
test stand and also derives its input power from the
shop air supply. The CGS test stand is capable of
proof-testing hydraulic hoses to 15,000 psi and
pneumatic hoses to 1,500 psi.

62. HYDRAULIC AND PNEUMATIC COMPONENT


TEST STAND HCT-10. The Hydraulic and Pneumatic
Component Test Stand HCT-10, shown in Figure 10,
is used to bench-test aircraft hydraulic and pneumatic
components such as engine-driven hydraulic pumps,
electro-hydraulic flight control assemblies, double- 009009
acting hydraulic cylinders, pneumatic and hydraulic Figure 9. Greer Hydraulic Hose Test Stand
relief valves, hydropneumatic accumulators, and

Table 5. Stationary Shop Hydraulic Test Stands


NOMENCLATURE MODEL/CAGE MAX CAPACITY HANDBOOK

HCT-10 ACL NAVAIR 17-15BF-37


Hydraulic and Pneumatic (05172) 40 gpm @ 3,000 psi
NAVAIR 17-600-32-6-1
Component Test Stand Pneu. to 6,000 psi
P/N 66A91J001 NAVAIR 17-600-32-6-2
Hydraulic Hose Test RT-6160-100 GREER Hydraulic pressure to
NAVAIR 17-15BF-504
Stand (26337) 30,000 psi

A/F27T-10, DAYTON T NAVAIR 17-15BF-94


Hydraulic Component BROWN, (30003) 60 gpm @ 3000 psi
NAVAIR 17-600-T10-6-1
Test Stand 25 gpm @ 8000 psi
P/N 2029AS100-10, -20 NAVAIR 17-600-T10-6-2

63A101-E1 CGS Hydraulic pressure to NAVAIR 17-15BF-41


Hose Burst Test Stand
SCIENTIFIC (30003) 15,000 psi
(Hydraulic and NAVAIR 17-600-126-6-1
Pneumatic pressure to
Pneumatic) P/N 65700-65014-041 NAVAIR 17-600-126-6-2
1,500 psi
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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.

73. PALL AEROPOWER CORP HYDRAULIC


PURIFIER A/M37M-2. The fluid purifier A/M37M-2
(Figure 12) is a portable electrical (440 VAC) system.
WP006 00 (Paragraph 16) provides a concise
description of the unit’s operation. Solvents and water
removed by the purifier are vented to the atmosphere.
If the oil being purified is possibly contaminated with a
solvent or fluid which could be hazardous (e.g. toxic,
flammable), ensure vapors will be captured and safely
009011 handled prior to operation of the purifier.
Figure 11. A/F27T-10 Hydraulic Component
Test Stand 74. HYDRAULICS INTERNATIONAL INC
HYDRAULIC PURIFICATION UNIT. This portable
electric driven (440 or 220 VAC) unit P/N 95163-100,
70. HYDRAULIC PURIFICATION EQUIPMENT. (Figure 13), cleans SE hydraulic systems. The unit
uses a similar contamination removal technique as
71. Hydraulic purifiers (as described in WP006 00 the A/M37M-2 but is smaller and has a lower and
Paragraph 16) are primarily used to remove air, varying flow rate. Contaminated fluid is drawn past
water, and solvent contaminants from hydraulic fluid the inlet filter by the purifier’s supply pump at 5 gpm.
in aircraft and SE. In addition, purifiers have 3-micron The fluid then flows into a manifold to a solenoid
(absolute) non-bypass filtration required for all valve. If the vacuum chamber is full, the solenoid
hydraulic SE to remove solid contaminants. Purifiers valve opens and directs the fluid back to the pump;
provide an option to avoid flushing a contaminated thus the unit does not draw in any contaminated fluid
hydraulic system, which generates waste hydraulic (i.e. 0.0 gpm inlet flow). If the vacuum chamber is not
fluid and requires the procurement of new fluid. Do full, the solenoid valve stays closed thus directing the
not use purifiers for the following: fluid through a 10 micron filter and a heater before
being sprayed into the vacuum chamber. Water,
a. Purifying heavily solvent contaminated solvent, and air are removed in the vacuum chamber
(>0.5% solvent) hydraulic fluid (e.g., patch test and the return pump at the bottom if the chamber
waste). picks the decontaminated hydraulic fluid. The return
pump at 3 gpm sends the fluid past another water
b. Purifying mixed fluids (e.g. MIL-PRF-83282 separator and 3 micron absolute filter before the fluid
mixed with MIL-PRF-5606). returns to the contaminated hydraulic system.

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,
NAVAIR 01-1A-17 009 00
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Change 1 – 1 August 2008 Page 29

Do not directly hook this purifier to


aircraft. Due to purification method, flow
rate of fluid entering fluid purifier will
differ from flow rate exiting purifier. This
can result in draining, overfilling or
damaging aircraft reservoirs.

76. The unit uses the same method as the Hydraulics


International Inc. Purification Unit P/N 95163-100 to
remove particulate, solvent, and both free and
dissolved air and water. Contaminated fluid is drawn
through an inlet filter by the purifier’s supply pump at
5 gpm. The fluid then flows into a manifold and past
a solenoid valve and is sprayed into a vacuum
chamber. The vacuum chamber will fill up since the
return pump only discharges at 3 gpm back to the
system being purified. When the chamber fills up, a
high fluid level switch in the chamber is tripped. This
opens the solenoid valve. The open valve allows 009012
fluid discharged from the HFP supply pump to loop Figure 12. A/M37M-2 Hydraulic Purifier
back to the supply pump’s inlet. Since the supply
pump flow loops back on itself, the HFP no longer
pulls in more fluid from the contaminated system and
essentially fluid is no longer sprayed into the vacuum
chamber. Since the return pump will still be
discharging fluid from the vacuum chamber at 3 gpm,
this pump will keep draining the vacuum chamber,
until a low level switch in the chamber is tripped. This
causes the solenoid valve to return to its initial closed
position. This repeats the process, since the supply
pump stops looping its fluid, and fluid again starts
spraying to back into the vacuum chamber. After the
return pump, the fluid flows past two additional filters
to remove any additional water and particulates
before purified fluid is returned back to the
contaminated system it came from.

009013

Figure 13. Hydraulic Fluid Purifier P/N 95163-100


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009014
Figure 14. Hydraulic Fluid Purifier (HFP), Model A/M37M-11

Table 6. Hydraulic Fluid Purification Equipment

FLOW
NOMENCLATURE MODEL/CAGE NO. PUBLICATION
CAPACITY

Fluid Purifier A/M37M-2 (18350) AG-711BA-MAB-000


9 gpm NAVAIR 19-600-201-6-1
P/N AD-A352-8Y10 NAVAIR 19-600-201-6-2

HPU-1-5-GH-N-16 (56529) NAVAIR 17-15BF-96


Hydraulic Fluid Purification
(Note 1) NAVAIR 17-600-196-6-1
Unit
P/N 95163-100 NAVAIR 17-600-196-6-2

A/M37M-11 (56529) NAVAIR 17-15BF-125


Hydraulic Fluid Purifier (Note 1) NAVAIR 17-600-BF125-6-1
P/N 040505-100 NAVAIR 17-600-BF125-6-2

Notes: 1. Flow capacity varies from either 0 or 5 gpm inlet into the purifier and 3 gpm on return.
NAVAIR 01-1A-17 010 00
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ORGANIZATIONAL, INTERMEDIATE AND


DEPOT MAINTENANCE

HYDRAULIC FILTERS

HYDRAULIC SYSTEMS

Reference Material

Filter and Filter Elements, Fluid Pressure, Hydraulic Line, 15 Micron


Absolute Type II Systems ...................................................................................... MIL-F-8815
Filter and Filter Elements, Fluid Pressure, Hydraulic Micronic Type ......................... MIL-F-5504
Filter and Disposable Element, Fluid Pressure, Hydraulic 3 Micron Absolute........... MIL-PRF-81836

Alphabetical Index

Subject Page No.

Introduction .................................................................................................................................... 2
Types of Filters............................................................................................................................... 2
Differential Pressure Indicators.................................................................................................. 8
Micronic Hydraulic Filter ............................................................................................................ 5
Sintered Bronze Hydraulic Filter ................................................................................................ 5
Support Equipment (SE) Filters ................................................................................................. 5
Woven Wire-Mesh Filter Elements ............................................................................................ 5
5-Micron Noncleanable Filter Elements..................................................................................... 2

Record of Applicable Technical Directives

None
NAVAIR 01-1A-17 010 00
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Page 2

1. INTRODUCTION. head assembly of some filters, there may be a


pressure-operated bypass valve which will route the
2. Continuous filtration of hydraulic fluid during hydraulic fluid directly from the inlet to the outlet port if
system operation is necessary to maintain system the filter element becomes loaded with foreign matter.
cleanliness. Filters are employed having fine pores or Some design criteria call for a differential pressure
openings which allow hydraulic fluid to pass, but are indicator which gives a visual indication when the
small enough to trap contaminant particles. Hydraulic element should be changed. The bowl is the housing
filter elements are rated in several ways. The which holds the element to the filter head and is
absolute filtration rating is the diameter in microns of removed when element replacement is required.
the largest spherical particle that will pass through the
filter under a certain test condition. This rating is an 8. The filter element may be of the 5-micron non-
indication of the largest opening in the filter element. cleanable, woven mesh, micronic, porous metal, or
The mean filtration rating is the measurement of the magnetic type. The micronic and 5-micron non-
average size of the openings in the filter element. The cleanable elements have nonmetallic filter media and
nominal filtration rating is usually interpreted to mean are discarded when removed. Porous metal, woven
the size of the smallest particles of which 90 percent mesh, and magnetic filter elements are usually
will be trapped in the filter at each pass through the designed to be cleaned and reused. Hydraulic filters
filter. currently in Naval aviation use are considered non-
cleanable and are normally discarded.
3. TYPES OF FILTERS.
9. 5-MICRON NON-CLEANABLE FILTER
4. A filter is a screening or straining device which ELEMENTS. Non-cleanable filter elements rated at 5-
cleans the hydraulic fluid by preventing foreign microns (absolute) represent the current state of the
particles and contamination substances from art in hydraulic filtration. Elements of this type afford
remaining in continuous circulation. Failure to remove significantly improved filtration and have greater dirt-
such particulate contamination will result in degraded holding capacities than other type elements of the
system performance and possible catastrophic failure. same physical size. They are particularly effective in
Figure 1 shows a typical filter arrangement in a controlling particles in the 1 to 10 micron size range
hydraulic system. which are normally passed by other type elements
and they are capable of maintaining a hydraulic
5. Hydraulic fluid will hold in suspension tiny system at much cleaner levels than could previously
particles generated during normal wear of selector be achieved. The use of 5-micron (absolute) filters is
valves, pumps, and other system components. These presently specified for all new design aircraft, and
minute particles may damage or impair the function of they are being retrofitted to existing fleet aircraft
the units and parts through which they pass if they where practical. Hydraulic filter specification MIL-F-
are not removed by a filter. Because close tolerances 8815 describes elements of this type (Figure 2).
exist within a hydraulic system, the performance and
reliability of the entire system depends upon 10. The most common 5-micron filter medium is
adequate filtration. composed of organic and inorganic fibers integrally
bonded by epoxy resin and faced with a metallic
6. Filters may be located within the reservoir, the mesh upstream and downstream for protection and
pressure line, the return line, or any other location added mechanical strength. Filters of this type are not
where they are needed to safeguard the hydraulic to be cleaned under any circumstances and will be
system against contaminants. Their location in the marked DISPOSABLE or NON-CLEANABLE, usually
system and other design criteria determine their on bottom end cap.
shape and size.
11. Five-micron non-cleanable hydraulic filter
7. There are many types of filters. Most filter elements should be replaced with new elements
assemblies used in modern aircraft are of the T-type. during specified maintenance inspection intervals in
The T-type filter assembly is composed of three basic accordance with the applicable procedures. Refer to
units: a head assembly, a bowl, and a filter element. the applicable Maintenance Instruction Manual (MIM),
The head assembly is that part which is secured to Maintenance Requirement Cards (MRC) or Technical
the aircraft structure and connecting lines. Within the Order (TO) for replacement intervals and procedures.
NAVAIR 01-1A-17 010 00
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Page 3

010001
Figure 1. Typical Filter Arrangement in Hydraulic System
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010002
Figure 2. MIL-F-8815 Hydraulic Filter Assembly, Bypass Type
NAVAIR 01-1A-17 010 00
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Page 5
12. Another 5-micron filter medium of recent design
employs layers of very fine stainless steel fibers
drawn into a random but controlled matrix. The matrix
is then processed by an exclusive procedure which, in
successive steps, compresses and sinters (bonds all
wires at their crossing points) the material into a thin
layer with controlled filtration characteristics. Filter
elements of this material may be cleanable or non-
cleanable, depending upon their construction, and are
marked accordingly.
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
NAVAIR 01-1A-17 010 00
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Page 7
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.

Hydraulic Fluid, MIL-H-81019 3

Hydraulic Fluid, MIL-PRF-87257 4

Hydraulic Fluid, SAE AS1241 5

a. Shut down equipment if required, and relieve


any hydraulic pressure present.

b. If filter assembly is equipped with drain and


air bleed plugs, remove plugs and allow contents of
filter bowl to drain into waste container.

c. Remove filter bowl and clean inside surface


by flushing with clean filtered hydraulic fluid. If wiping
is required to remove heavy dirt deposits, use
approved low-lint wiping materials (refer to WP012
00) and follow with additional flush.

d. Remove and discard non-cleanable filter


cartridge. Visually inspect outside surface of
secondary filter element, when utilized. If secondary
element shows evidence of fine “fuzz” (primary stage
media) or other particulate matter, remove element
and replace with new or cleaned, and retest unit.

e. Install new non-cleanable filter cartridge.


Replace all associated packings with new seals.

f. Install drain plug on filter bowl, if removed.


Partially fill filter bowl with new filtered hydraulic fluid 010005
to minimize entrapped air, and install bowl on filter Figure 5. Typical High Pressure
head. Tighten as required. SE Filter Assembly
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Page 8

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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15 August 2006 Page 1 of 8

ORGANIZATIONAL, INTERMEDIATE AND


DEPOT MAINTENANCE

CONTROLLED ENVIRONMENT WORK CENTER

HYDRAULIC SYSTEMS

NAVY USE ONLY

Reference Material

Human Engineering Design Criteria For Military Systems Equipment


and Facilities .......................................................................................................... MIL-STD-1472

Alphabetical Index

Subject Page No.

Controlled Environment Work Center Fabrication Requirements .................................................. 3


Existing Facilities ....................................................................................................................... 3
New Facilities ............................................................................................................................. 5
Controlled Environment Work Center Operating Procedures ........................................................ 6
Maintenance and Cleaning ........................................................................................................ 7
Operating Regulations ............................................................................................................... 6
Personnel Regulations ............................................................................................................... 7
Design Guidelines .......................................................................................................................... 2
Dimensions ................................................................................................................................ 2
Work Center Environment ......................................................................................................... 3
Introduction..................................................................................................................................... 2
Definitions .................................................................................................................................. 2
General Description ................................................................................................................... 2
Typical Aircraft Hydraulic Components Considered Contamination Critical .................................. 7

Record of Applicable Technical Directives

None
NAVAIR 01-1A-17 011 00
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Page 2

1. INTRODUCTION. physical facility itself. Strict adherence to the


operating procedures will allow the facility to be easily
NOTE maintained and contamination goals to be realistically
achieved.
USAF: This WP not applicable
8. DEFINITIONS.
2. Aircraft hydraulic system contamination control
a. Controlled Environment Work Center: An
requires a strong emphasis on controlling the amount
enclosed workspace, room, or facility in which
of contaminants a component can impart to the
humidity and inlet air are controlled.
aircraft hydraulic system. In order to establish this
control, depot and intermediate maintenance activities
b. Laminar Flow Work Station: A contamination
shall establish programs which ensure that dirty
controlled workbench used to ensure a high degree of
components will not contaminate hydraulic systems.
cleanliness around a component. The workstation
3. This section provides environmental and contains an atmosphere of extremely low airborne
cleanliness control recommendations for contamination. Laminar Flow Work Stations are
organizational, intermediate and depot level normally installed in controlled environment work
maintenance activities engaged in the repair, centers, and come in fixed or mobile module
overhaul, assembly, and test of hydraulic and construction.
pneumatic components. Local environmental
9. DESIGN GUIDELINES.
conditions may preclude full compliance with these
recommendations. The concept of optimum
10. The controlled environment work center can be
cleanliness during hydraulic and pneumatic
of two types:
component repair, assembly, and test must, however,
remain paramount. a. An existing area which is converted into a
controlled work center.
4. GENERAL DESCRIPTION. The ideal facility
(Paragraphs 8 thru 31) will provide the required
b. A facility which is fabricated expressly as a
degree of cleanliness at minimum cost. It has been
controlled work center. This approach is preferred,
determined that an effective and economical
but in the interest of time or for budgetary reasons,
approach to control contamination ingestion into
the former approach may be used with equal
critical components during final assembly, is to
effectiveness.
establish a controlled environment work center
incorporating a laminar flow workstation.
NOTE
5. Using this concept, contamination control is If unable to meet the requirements of a
effected through the separation of critical assembly Controlled Environmental Work Center,
function from other functions by the use of clean at a minimum, Laminar Flow Work
workstations, air conditioning, and room Stations shall be utilized both ashore and
pressurization techniques throughout the entire work afloat for buildup of contamination-critical
center. components.
6. The guidelines contained in this section are
intended to assist in establishing a controlled 11. DIMENSIONS. The overall size of the center will
environment work center housing Class 100 Vertical be dependent on the following factors:
Laminar Flow Work Stations. Designing,
dimensioning, fabricating, furnishing, operating and a. Existing space available.
environment are all addressed. These concepts, while
not new or innovative, represent contamination b. The volume of work to be handled.
control technology applied in a more practical manner
than existing clean-room requirements. c. The number of people who will be working in
the center.
7. In applying these concepts, the user must bear in
mind that the effectiveness of a component repair d. The furnishings which will be placed in the
facility is dependent upon the attitude and motivation center.
of the personnel utilizing the facility, as well as the
NAVAIR 01-1A-17 011 00
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Page 3

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.

j. Air conditioning equipment for pre-filtering,


14. CONTROLLED ENVIRONMENT WORK
cooling, heating, humidification, and dehumidification
CENTER FABRICATION REQUIREMENTS.
of the controlled work center should be provided as
required (Paragraph 13). The airflow to the work
15. EXISTING FACILITIES. In order to fabricate a center should be independent of the regular
controlled environment work center within an existing surrounding area airflow system.
structure, attention must be given to the following
design requirements: 16. Preparation and Fabrication. The following
general guidelines apply to preparation and
NAVAIR 01-1A-17 011 00
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Page 4

011001
Figure 1. Typical Controlled Environment Control Work Center
NAVAIR 01-1A-17 011 00
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Page 5

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
TO 42B2-1-12
Page 6

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

pockets (keys, handkerchiefs, billfolds) is permitted,


but should not be taken out or be used. Combs, paper
tissue, cosmetics, pocketbooks, and outerwear are
considered high potential sources of contamination Aircraft External Cleaning Compound, 7
and should be restricted to one area in the center. MIL-PRF-85570, Type II
29. PERSONNEL REGULATIONS. The following
general regulations should be practiced by all
personnel in a controlled environment work center:

a. Data sheets, log books, and manuals may be 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.

b. Personnel not regularly employed in the Isopropyl Alcohol, TT-I-735 9


center should not be allowed in the area.
a. Doors, walls, and windows should be spot
c. Each worker should be held accountable for cleaned with a sponge, detergent, and lukewarm
the cleanliness of his/her workspace, equipment, and water.
tools. Cleaning shall be done with approved wipes
and solvents. b. All waste receptacles should be removed
from the center before disposing of contents.
NOTE
c. Work center cleaning equipment should be
stored in a cabinet within the center. Scrub rags, rag
Tools that are used in repairing internal
mops, and scouring powder should never be used.
components shall not be painted.
Use only cellulose sponges (WP002 00, Table 3, Item
27), leather chamois skin mops (WP002 00, Table 3,
Item 26), and rubber (or elastromeric synthetic)
d. Personnel with persistent coughing, squeegees (WP002 00, Table 3, Item 28) for wet
sneezing, peeling sunburn, or other similar conditions cleaning of large areas. Sponges should be discarded
should be assigned duties outside the center. before they begin to deteriorate.
e. Mobile module workstations shall not be used d. Extra heavy duty swabbing such as for gross
as storage facilities. Only those objects being used in oil spills may require MIL-PRF-85570, Type II
assembly of the component shall be placed in the (WP002 00, Table 3, Item 30) in a 10 percent solution
Laminar Flow area. or MIL-D-16791 non-ionic detergent, Type I (WP002
00, Table 3, Item 29). Wear rubber gloves (WP002
f. Parts of components in process at the end of 00, Table 3, Item 16). Such compounds should be
a shift should be covered with plastic or molded chip- free of pine oil. One ounce of isopropyl alcohol
proof plastic trays or covers prior to turning off power (WP002 00, Table 3, Item 8) per gallon of water will
to the workstation. disperse the non-ionic detergent into solution and
reduce suds.
g. No abrasives, such as files and crocus cloth,
shall be permitted in the center. Repairs that require 31. The monthly cleaning routine is as follows:
grinding, filing or polishing using abrasives shall be Walls, floors and ceiling should be washed with a
performed outside the work center. solution of detergent and lukewarm water. This
cleaning should be accomplished at a time when the
30. MAINTENANCE AND CLEANING. Detailed center is not being used for normal operations.
regulations for maintenance and cleaning shall be
established by the user activity. To aid in the 32. TYPICAL AIRCRAFT HYDRAULIC
establishment of these regulations, the following COMPONENTS CONSIDERED CONTAMINATION
suggestions are offered: CRITICAL.
NAVAIR 01-1A-17 011 00
TO 42B2-1-12
Page 8

33. The following is a list of types of aircraft


hydraulic components that require environment/
cleanliness controls. Final assembly of those
components shall be performed within the Laminar
Flow Work Station or in a Controlled Environmental
Work Center (Paragraph 13). Components that
require Cleanliness controls include:

a. Servo Valves

b. Spool and Sleeve Assemblies

c. Hydraulic Pumps and Motors

34. As a rule, all safety of flight hydraulic


components shall be considered contamination
critical. When in doubt as to where a hydraulic
component should be disassembled, repaired,
overhauled, reassembled, or tested, perform the
operation in a controlled environment.
NAVAIR 01-1A-17 012 00
TO 42B2-1-12
15 August 2006 Page 1 of 8

ORGANIZATIONAL, INTERMEDIATE AND


DEPOT MAINTENANCE

SELECTION AND USE OF CLEANING MATERIALS

HYDRAULIC SYSTEMS

Reference Material

None

Alphabetical Index

Subject Page No.

Cleaning Solvents .......................................................................................................................... 2


Solvent Cleanliness ................................................................................................................... 2
Solvent Effectiveness ................................................................................................................ 2
Solvent Toxicity .......................................................................................................................... 2
Flammability ................................................................................................................................... 2
Autoignition Point ....................................................................................................................... 4
Fire Point.................................................................................................................................... 4
Flash Point ................................................................................................................................. 2
Introduction..................................................................................................................................... 2
Safety Precautions and First Aid .................................................................................................... 4
Solvent Contamination ................................................................................................................... 4
Solvent Selection ........................................................................................................................... 4
Wiping Materials ............................................................................................................................. 5
Recommended Wiping Cloths ................................................................................................... 5

Record of Applicable Technical Directives

None
NAVAIR 01-1A-17 012 00
TO 42B2-1-12
Page 2

1. INTRODUCTION. as temperature, time, cleaning method, and materials


must also be considered, with the result that a solvent
2. This section provides information for guidance in having a relatively low K-B value may often be best
the selection and use of cleaning solvents and wiping suited for a particular task. K-B values for some
materials. Consult the Material Safety Data Sheet representative and commonly used solvents are listed
(MSDS) for proper use and handling of cleaning in Table 1.
agents.
8. SOLVENT TOXICITY. A guide to the toxicity of
3. CLEANING SOLVENTS. solvents and other substances is published by the
American Conference of Government Industrial
4. Since cleaning agents (solvents) are frequently
Hygienists. The guide provides recommended
used in performing hydraulic system maintenance,
Threshold Limit Values (TLV) which represents
the selection of an appropriate agent is often an
maximum concentrations in the air of substances to
important consideration. The cleaning agent selected
which it is believed personnel may be repeatedly
must be compatible with the cleaning method used
exposed, day after day, without adverse effect. These
and with the materials used in construction of the
limits are usually stated as parts of the solvent vapor
system. It must be capable of removing unwanted
per million parts of air, compared on a volume basis.
substances to the desired degree. For critical
The highest recommended TLV for any solvent is
cleaning application, filter solvent through a 5-micron
1,000 parts per million (ppm) with some commonly
(absolute) filter prior to use. Many solvents, in
used solvents having a TLV as low as 100. To ensure
addition, present characteristic safety hazards. It is of
personnel safety, it is imperative that exposure to
the utmost importance that the user be aware of the
solvent vapors are limited to values less than the
hazards and exercise the required safety precautions.
recommended TLV. Table 1 provides a reference
Disregard for any of these factors can result in
source for the TLV of solvents commonly used in
incomplete cleaning, damage to equipment, or injury
aircraft maintenance.
to personnel.

5. SOLVENT CLEANLINESS. Most cleaning 9. Exposure to high temperature may dangerously


compound specifications do not impose stringent increase the volatility of many solvents and should be
requirements on the cleanliness of the fluid supplied. avoided. In addition to producing high levels of
For critical cleaning applications, it is therefore concentration, elevated temperatures may result in
required that the solvent be passed through a 5- the formation of toxic or acidic fumes, or possibly
micron (absolute) filter prior to use. explosive mixtures. Ensure adequate ventilation at all
times and avoid solvent vapor contact with hot
6. SOLVENT EFFECTIVENESS. Solvent power, or surfaces or open flame.
effectiveness as a dissolving agent, can be measured
in many ways. In order to be comparative, however, a 10. FLAMMABILITY.
known or established standard must be used. For
purposes of standardization, the solvent industry has 11. Flash point, fire point, and autoignition point are
adopted a test method known as the kauri-butanol (K- the three temperature values used to determine the
B) system. Solvent power as expressed by K-B flammability of a solvent.
values is the amount of solvent which, when added to
a standard kauri gum-butanol solution, will produce a 12. FLASH POINT. The flammability of a solvent is
specified degree of turbidity or cloudiness. Since in usually described by a value called its flash point.
most cases, 100 ml of benzene will produce the Several different test methods are employed to
specified level, the K-B number for benzene is 100.0, determine flash point, all of which involve raising the
and it serves as an arbitrarily accepted reference. temperature of the liquid under test, under specified
conditions until sufficient vapor is given off to produce
7. K-B values serve as a guide or index of relative momentary ignition when exposed to a specified
solvency power. The higher the K-B number the more flame. The flash point rating provides an indication of
effective a solvent may be generally considered to be. the ease with which a solvent can be ignited and
It must be emphasized, however, that K-B values may indicates its relative flammability. Table 1 lists the
not always be indicative of the most effective solvent minimum required flash points for solvent materials
for a particular cleaning situation. Other factors such commonly used in aircraft hydraulic maintenance.
Table 1. Solvent Selection Chart for Use in Hydraulic Maintenance
TO 42B2-1-12
NAVAIR 01-1A-17

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
TO 42B2-1-12
Page 4

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.

e. Avoid prolonged or repeated contact with the


skin or breathing of vapors.
Dry Cleaning Solvent, MIL-PRF-680 6
f. Prohibit smoking, welding, or use of open
flame in the vicinity of volatile or flammable solvents.

g. Dispose of contaminated solutions in


accordance with local safety regulations.
Dry Cleaning Solvent, A-A-59601 14

18. To prevent solvent contamination, it is h. Do not take internally.


imperative that extreme care be exercised when
utilizing these cleaning agents to clean internal
NAVAIR 01-1A-17 012 00
TO 42B2-1-12
Page 5

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.

27. Low lint non-woven wiping cloth, CCC-C-46,


Class 7, Number 9404 Duralace (WP002 00, Table 3,
Item 14) and lint-free synthetic wiping cloth, A-A-
59323 Types I and II (WP002 00, Table 3, Item 13)
are descriptively identified in Table 3. They are
specified for use in hydraulic maintenance and are
presently available in the supply system.

28. CCC-C-46, Class 7, Number 9404 Duralace


(WP002 00, Table 3, Item 14) is a non-woven, binder
free, non-snag material. It is primarily intended as a
washing, polishing, and wiping cloth for critical
dry/solvent wiping use in aircraft maintenance.
NAVAIR 01-1A-17 012 00
TO 42B2-1-12
Page 6

Table 2. First Aid Treatment Guide

TYPE OF
CONTACT SYMPTOMS TREATMENT

Inhalation Anesthetic or narcotic effect. Varies from 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.
NAVAIR 01-1A-17 012 00
TO 42B2-1-12
Change 1 – 1 August 2008 Page 7/(8 Blank)

Table 3: Recommended Wiping Cloths

Specification Rating Description Application Characteristics

CCC-C-46 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
NAVAIR 01-1A-17 013 00
TO 42B2-1-12
15 August 2006 Page 1 of 12

ORGANIZATIONAL, INTERMEDIATE AND


DEPOT MAINTENANCE

REPAIR, TEST, AND MAINTENANCE

HYDRAULIC SYSTEMS AND COMPONENTS

NAVY USE ONLY

Reference Material

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

Alphabetical Index

Subject Page No.

Component Lubrication .................................................................................................................. 3


General Lubrication Instructions ................................................................................................ 3
Component Spline Maintenance.................................................................................................... 6
Reuse of Splines........................................................................................................................ 7
Spline Cleaning.......................................................................................................................... 6
Spline Inspection Requirements ................................................................................................ 7
Spline Lubrication ...................................................................................................................... 6
Component Testing........................................................................................................................ 2
Component Proof Pressure Testing .......................................................................................... 3
Nondestructive Testing .............................................................................................................. 2
Post-Installation Checks ............................................................................................................ 3
Hydraulic Component Leakage...................................................................................................... 4
Allowable and Excessive Leakage ............................................................................................ 5
Measurement of Leakage .......................................................................................................... 4
Hydraulic Pump Contamination Tests............................................................................................ 7
Analysis of Test Patches ........................................................................................................... 11
Contamination Testing Procedures ........................................................................................... 9
Patch Test Technique................................................................................................................ 7
Introduction .................................................................................................................................... 2
Component Repair and Overhaul .............................................................................................. 2
Maintenance Responsibilities .................................................................................................... 2
System Check Requirements .................................................................................................... 2

Record of Applicable Technical Directives

None
NAVAIR 01-1A-17 013 00
TO 42B2-1-12
Page 2

1. INTRODUCTION. 8. Component repairs shall normally be performed


only to the extent necessary to correct malfunctions.
NOTE However, when a C, D, or F repair kit is utilized, the
USAF: This WP not applicable complete kit shall be installed.

9. Component overhaul shall be performed in


2. This section provides general instructions and accordance with the applicable overhaul manual
information for repairing, overhauling, testing, and and/or other engineering directives.
performing maintenance on hydraulic systems and
hydraulic system components. Hydraulic systems and
components include pumps, pressure transducers, 10. Inspection of components disassembled for
motors, actuators, indicating devices, valves, sensors, repair or overhaul includes checking for visible
filters, reservoirs, manifolds, associated lines and damage to internal parts, contamination, thread
fittings, and working fluids, accumulators, linear and damage, misalignment, condition of plating, excessive
rotary control devices, modular and integrated wear, spring distortion and return to specified free
equipment. length, and in some cases, nondestructive inspection.

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

4. Hydraulic system component removal, repair,


12. Components shall be tested following repair to
installation, and test shall normally be performed in
verify their ability to perform intended functions. Test
accordance with detailed procedures provided in
will generally involve proof pressure, static leak, and
applicable maintenance, overhaul, and repair
performance measurements. Stationary test benches
publications. However, because many publications
utilized for testing shall be filled with hydraulic fluid
and directives relating to hydraulic system and
MIL-PRF-83282 (WP002 00, Table 3, Item 2).
component maintenance require revisions to reflect
Repaired components that are not to be installed
current requirements, the following additional
immediately shall be filled with MIL-PRF-83282
guidance is provided.
unless otherwise specified, and all openings capped
5. SYSTEM CHECK REQUIREMENTS. To ensure or plugged with approved metal closures.
safety of personnel and aircraft, it is directed that Components which have been repaired and are to be
when any hydraulic system component has been installed immediately subsequent to bench testing
installed, replaced, disconnected, or partially shall be drip-drained, capped and plugged as
disassembled on the aircraft, the specific hydraulic necessary, and made ready for installation.
system affected be pressurized and the installed or
repaired component given a complete and thorough 13. Tests shall be limited, where practicable, to
functional test. When the affected component is an those that relate to the specific repair action or
actuator, a sequencing valve, or a part or assembly of component malfunction. In all cases, it shall be
any hydraulically operated subsystem, the test shall determined that the component undergoing tests
include a complete cycling of the subsystem. A meets all applicable performance specifications for
thorough system check shall be accomplished to the intended end use.
determine that all performance requirements are
satisfied.
14. Subsequent to overhaul, complete testing shall
6. When operational tests require hoisting or jacking be performed in accordance with procedures in the
an aircraft to cycle the landing gear, care should be applicable overhaul manual or other applicable
exercised to ensure that jacks or hoisting slings are engineering directives.
properly positioned and secured, and that all
applicable safety precautions are observed. 15. NONDESTRUCTIVE TESTING. When
nondestructive testing is required, all inspections shall
7. COMPONENT REPAIR AND OVERHAUL. be performed by qualified/certified personnel.
NAVAIR 01-1A-17 013 00
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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.

19. Overhauled components shall be proof pressure


tested as specified in applicable overhaul manuals or Molydisulphide Grease, MIL-G-21164 10
other engineering directives.
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Page 4

the pressure compresses the O-ring and seals the


leak.

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.

d. Detail parts such as felt and leather wiping


rings, and cavities retaining fluid.
Never allow oil or grease to come in
contact with oxygen equipment. An
explosion and fire can result. 31. Allowable leakage, which exists on new or
overhauled components, will usually show as a
seepage, stain, or wet area. On many component
26. Clean up all spilled excess oil or grease. Some overhaul tests, no leakage is allowable after 2
types of synthetic compounds are harmful to rubber, minutes of operation or pressurization of the unit.
neoprene, and electrical material. They will also However, these same units may show a measurable
soften paint, and should be removed as soon as amount of acceptable leakage after longer periods of
possible. time. It is possible for seepage or allowable leakage
to collect in a cavity of a unit or in a depression of an
27. The lubrication requirements for each model of adjacent structure over a period of time and falsely
aircraft are given in the General Information and indicate excessive leakage. This is particularly true for
Servicing section of the applicable MIM and cylinders having felt wiper rings at the output shafts.
Maintenance Requirement Cards (MRC). These Allowable leakage accumulation on a flat area or a
instructions appear in the form of tables and charts. white painted surface often has the appearance of
When replacing or lubricating installed components, being excessive. During test of constant volume and
refer to these tables and charts for the specified variable displacement rotating piston-type hydraulic
grease, methods of application, and frequency. For pumps, if all requirements are met, except the case
exact locations of grease fittings and other lubricated drain leakage, it shall be authorized to allow a one
components, refer to applicable MIM/MRC. hundred percent increase of the leakage above the
design allowance. Rotating piston groups meeting this
28. HYDRAULIC COMPONENT LEAKAGE. increased leakage allowance need not be replaced
during repair or overhaul if routine processing
29. An O-ring seal, in design, is the most effective inspection indicates parts are not physically damaged
hydraulic sealing device for hydraulic systems and other than normal bore wear.
components. It allows very low friction for linear
movement. Its design provides positive seal as 32. MEASUREMENT OF LEAKAGE. Hydraulic
pressure is exerted against it. Therefore, it is possible systems and components may remain in a static
for an actuator shaft to show a slight leak or seepage unpressurized condition for lengthy periods of time.
such as a drop of fluid collecting on the sealing Leakage should not be checked immediately after
surface or piston shaft. In a static or no-pressure dormant periods. Systems should be activated,
condition there may be seepage. Because of this, brought to operating temperature, and components
actuating components are sometimes removed operated a number of times, after which any hydraulic
prematurely because personnel are unaware of this fluid should be wiped off before making leakage
fact. When the slightest hydraulic pressure is applied, checks or measurements.
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33. In many cases, leakage measurement is a


problem because of the location of the component. If
observation of the unit is not possible, one method of
checking for leakage is to wipe the surface clean
below the component and place a drop of hydraulic Hydraulic Fluid, SAE AS1241 5
fluid on the area. When this drip stabilizes, note its
size by outlining with a felt marker. Blot the drop, do a. When the fluid escaping is of an insignificant
not wipe because the mark will be removed. quantity and will have no detrimental effect on aircraft
Pressurize and cycle the suspected component, operation, and when correction of this slight leakage
correlating the area of wetted surface with area does not warrant the maintenance time involved, the
previously occupied by the drop. leakage is then termed “allowable”.

b. If the fluid leakage rate is such that the


34. Where fluid dropping may be observed directly, hydraulic reservoir level may be depleted or
do not wipe surface but pressurize and cycle the dangerously lowered during normal operation, or a
component until a drop falls free. Continue operating fire hazard created, or the safety of flight of the
component until another drop falls and compare aircraft otherwise compromised, the leakage is
results with leakage criteria outlined herein. termed “excessive”.

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.

f. Dynamic seals in motion, such as rod seals,


are considered acceptable if leakage does not
exceed one drop after five complete cycles. For
dynamic seals in a static condition, no more than one
Hydraulic Fluid, MIL-PRF-87257 4 drop shall form in succeeding 15 minute intervals,
with the component pressurized or unpressurized.
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g. When dynamic or static seals are internal and 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.

b. Install drive coupling and drive coupling


retainer in hydraulic pump or motor, if applicable.
Dry Cleaning Solvent, MIL-PRF-680 6
c. Install hydraulic pump or motor in accordance
with the applicable MIM.
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Page 7

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.

46. HYDRAULIC PUMP CONTAMINATION


TESTS.
Hydraulic Fluid, MIL-PRF-5606 1
47. Hydraulic pumps can represent a serious source
of contamination in an operating hydraulic system,
when not functioning properly. The typical aircraft
hydraulic pump contains many highly stressed
internal parts that move at high velocities and are
directly exposed to the operating fluid. The failure or Hydraulic Fluid, MIL-PRF-83282 2
excessive wear rate of any of these parts will produce
metallic debris that will enter the fluid and serve to
contaminate the entire system. As a result of its
internal design, a variable displacement piston-type
pump will normally generate minute amounts of Hydraulic Fluid, MIL-H-81019 3
contaminant through normal wear processes. These
contaminants are effectively controlled by the
system’s hydraulic filters, which are designed to
remove the normally generated pump contaminants
as they are produced. In order to ensure that a
hydraulic pump is not producing excessive amounts Hydraulic Fluid, MIL-PRF-87257 4
of contamination, it is required that contamination
tests be performed on the unit prior to its being
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TO 42B2-1-12
Page 8

013001
Figure 1. Patch Test Testing Hydraulic Pump Contamination Using
Contamination Analysis Kit 57L414
NAVAIR 01-1A-17 013 00
TO 42B2-1-12
Page 9

equivalent, prepare a test patch from each assembly


employing the following procedure:

Hydraulic Fluid, SAE AS1241 5

a. Clean filter elements installed in pump filter


assemblies. Hydraulic Fluid, MIL-PRF-5606 1
b. Operate pump in accordance with applicable
testing procedures for the period of time specified.

c. Retrieve contaminants from pump filter


assemblies by collecting fluid from bowl and flushing Hydraulic Fluid, MIL-PRF-83282 2
particulate off surface of the element utilizing filtered
solvent.

d. Collect fluids from each filter assembly and


individually analyze the fluids using contamination Hydraulic Fluid, MIL-H-81019 3
analysis kit or equivalent.

e. Evaluate resulting test patches to determine


pump acceptability. Compare patches to
Contamination Standards, if available, or test patches
from preceding tests to determine rate of pump Hydraulic Fluid, MIL-PRF-87257 4
cleanup.

51. CONTAMINATION TESTING PROCEDURES.


It is important the required procedures be closely
adhered to when patch testing pumps for Hydraulic Fluid, SAE AS1241 5
contamination output. Any deviations from the
techniques specified may result in test indications that
are either non-repeatable or not capable of proper
interpretation. Procedural requirements differ,
depending upon whether the test pump has been
Dry Cleaning Solvent, MIL-PRF-680 6
subjected to major rework in which internal parts have
been replaced, or to limited repair operations such as
a. Remove filter bowl and element from the filter
seal replacement or external adjustments.
assembly being tested and pour contents of the bowl
Paragraphs 52 and 53 provide detailed procedures
into a known clean sample container. Using filter-
for both applications and shall be considered as
equipped solvent, rinse bottle (such as provided with
minimum requirements for all such testing.
contamination analysis kit) with solvent MIL-PRF-680
NOTE (WP002 00, Table 3, Item 6). Flush as much residual
particulate matter as possible from both the inside
The following test shall be initially surface of the filter bowl and the outside surface of
performed subsequent to completion of the filter element, carefully collecting all flushing fluid
the first run-in period of the reworked in the same sample container. Identify sample
pump. Known clean elements will be container to indicate filter assembly from which fluid
installed in the pump filter assemblies was obtained. If contamination analysis kit is available
prior to initiation of the run-in period. for use in pump test area, the contamination test
Pump run-in will be accomplished in procedure may be simplified by collecting filter bowl
accordance with existing procedures. and flushing fluids directly in the stainless steel
funnel.

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.
NAVAIR 01-1A-17 013 00
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Page 10

and cycling rates are same as for first and second


run-in.

i. Repeat contamination tests of the pump filter


Contamination Standards furnished with assemblies in accordance with preceding steps a, b,
contamination analysis kit are not and c. Pump outlet and case drain test patches must
intended for use in this application and show no degradation from those obtained subsequent
shall not be so employed. to the second run-in period. Any evidence of an
increase in contamination output shall be cause for
rejection of the pump under test and the unit
c. Determine acceptability of pump disassembled and subjected to internal inspection.
contamination level by comparing resulting test
patches to applicable patch test standards, if
j. If test patches show continued improvement
available. If applicable standards are not available,
but are still considered unacceptable, the pump may
the resulting test patches shall be visually inspected
be subjected to additional run-in operation in an
for metallic contamination. A substantial quantity of
attempt to attain a satisfactory contamination level. In
discrete particles may be considered acceptable,
such situations it is advisable that the pump be
subsequent to the first run only, provided that they are
disassembled and inspected prior to continued run-in
detected in either pump outlet or case drain fluid
to ensure that all internal clearance and surface finish
samples. Very large amounts of metallic
requirements are within acceptable limits.
contamination may be indicative of internal failure,
Determination of final acceptability shall be
and the pump under test should be disassembled and
accomplished by comparison of the pump test
subjected to internal inspection prior to continued
patches to standard patches applicable to the model
operation. Evidence of any discrete particles on, or
pump tested, when available. Standard patches may
abnormal discoloration of, the inlet filter test patch
be locally produced with Fleet Support Team (FST)
shall be regarded as an indication that the hydraulic
approval. Refer to Paragraph 54 for additional
test stand being used is unacceptably contaminated.
information regarding evaluation of test results and
Required corrective action should be initiated. Refer
the development of standard patches.
to Paragraph 54 for additional information regarding
interpretation of test results.
NOTE
d. Replace previously removed filter elements
with new elements. Ensure that filter bowls are The following test shall be performed
thoroughly cleaned prior to reassembly using filtered subsequent to completion of the other
hydraulic fluid. Prefill bowls with filtered hydraulic fluid functional checks prescribed for the
to minimize air inclusion. component.

Known clean elements will be installed in


e. Perform second pump run-in as specified in the pump filter assemblies prior to
applicable procedure. Ensure that total run-in time, initiation of functional testing. Functional
flow and cycling rates are the same as for first run-in. testing will be accomplished in
accordance with existing applicable
f. Repeat contamination tests of the pump filter procedures.
assemblies in accordance with preceding steps a, b,
and c. Pump outlet and case drain filter test patches
should show less general discoloration and fewer 53. Testing for Pumps Subjected to Minor Repair
metal particles than that observed subsequent to the and Functional Test. Individually test the pump
first run-in period. If test patches indicated increased outlet, case drain, and inlet filter assemblies to
contamination compared to that previously observed, determine their contamination levels. Using
testing shall be terminated and the pump contamination analysis kit or equivalent, prepare a
disassembled and subjected to internal inspection. test patch from each assembly employing the
following procedure:
g. Replace filter elements in accordance with
step d above.

h. Perform final pump run-in as specified in


applicable procedure. Ensure that total run time, flow, Hydraulic Fluid, MIL-PRF-5606 1
NAVAIR 01-1A-17 013 00
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Page 11

c. Determine acceptability of pump


contamination level by comparing resulting test
patches to applicable patch test standards, if
Hydraulic Fluid, MIL-PRF-83282 2 available. If applicable standards are not available,
the resulting test patches shall be visually inspected
for contamination and a determination of acceptability
made based upon prior experience with the same
model pump and testing procedure. Very large
Hydraulic Fluid, MIL-H-81019 3 amounts of metallic contamination may be indicative
of internal failure and the pump under test should be
disassembled and subjected to internal inspection
prior to continued operation. Evidence of any discrete
particles on, or abnormal discoloration of, the inlet
Hydraulic Fluid, MIL-PRF-87257 4 filter test patch shall be regarded as an indication that
the hydraulic test stand being used is unacceptably
contaminated. Required corrective action should be
initiated. Refer to Paragraph 54 for additional
information regarding interpretation of test results.
Hydraulic Fluid, SAE AS1241 5
54. ANALYSIS OF TEST PATCHES. Standard
patches to which pump test patches can be compared
may or may not be available for a specific model
pump. In the absence of an applicable standard, it
becomes necessary that the operator have prior
Dry Cleaning Solvent, MIL-PRF-680 6 experience in performing the same test on identical
a. Remove filter bowl and element from the filter model pumps and a thorough understanding of the
assembly being tested and pour contents of the bowl test technique involved, if accurate judgments on
into a known clean sample container. Using filter- pump acceptability are to be made. Several factors
equipped solvent rinse bottle and solvent MIL-PRF- determine the total amount of particulate matter
680 (WP002 00, Table 3, Item 6), flush as much normally discharged from a hydraulic pump during
residual particulate matter as possible from both the test stand operation. The most significant are:
inside surface of the filter bowl and the outside
a. Cleanliness level of the inlet fluid.
surface of the filter element, carefully collecting all
flushing fluid in the same sample container. Identify b. Rate of internal wear.
sample container to indicate filter assembly from
which fluid was obtained. If the contamination c. Total volume of fluid pumped during the test
analysis kit is available for use in pump test area, the period.
contamination test procedure may be simplified by
collecting filter bowl and flushing directly in the 55. By supplying the pump under test with fluid
stainless steel funnel. filtered to 3 microns (absolute), the effect of inlet fluid
cleanliness upon the test result is eliminated. For all
b. Prepare separate test patches from each of practical purposes, the pump inlet fluid may be
the pump filter samples utilizing contamination considered to be free of particulate matter, with this
analysis kit and detailed instructions provided with the condition verified by the inlet filter test patch. The
equipment. Refer to WP017 00 for additional amount of contaminants present on the pump
information relative to its use. discharge and case drain test patches becomes a
function of the pump’s wear rate and the total volume
of fluid transferred by it. Since the total amount of fluid
pumped remains fairly constant when testing in
accordance with a specific test procedure, the amount
Contamination Standards furnished with of discharge and case drain contaminants observed
contamination analysis kit are not corresponds to the rate at which the pump is
intended for use in this application and “wearing”, or producing contamination.
shall not be so employed.
56. A hydraulic pump reworked to the extent that
internal moving parts have been replaced or
NAVAIR 01-1A-17 013 00
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Page 12

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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ORGANIZATIONAL, INTERMEDIATE AND


DEPOT MAINTENANCE

PROTECTIVE CLOSURES

HYDRAULIC SYSTEMS

NAVY USE ONLY

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

Subject Page No.

Protective Closure Application ....................................................................................................... 2


Blank-Off Plates ............................................................................................................................. 3
Protective Closure Description ....................................................................................................... 2
Introduction..................................................................................................................................... 2

Record of Applicable Technical Directives

None
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1. INTRODUCTION. accessories, and components except as external


closures for shipping and storage.
NOTE
NOTE
USAF: This WP not applicable
Polyethylene plastic closures may be
NOTE used when shipping hydraulic equipment
and components if and only if they have
Plastic covers shall only be used for been drained of all hydraulic fluid prior to
Dyna Tubes ONLY (See Figure 1 for shipping.
examples of Dyna Tubes). Refer to
NAVAIR 01-1A-20 for further Dyna Tube
information. Plastic covers are not f. Plastic closures (Tables 8 and 9) may be used
recommended for fluid fittings. to seal electrical fittings and receptacles or other non-
fluid openings where contamination is not considered
a problem. Polyethylene plastic closures may also be
2. Contamination caused by entry of foreign matter used for shipping purposes as long as all hydraulic
into open lines and parts of hydraulic system fluid has been drained from the system equipment
equipment is hazardous and expensive. To protect and components prior to shipping.
hydraulic systems from contaminants, use protective
closures.

3. PROTECTIVE CLOSURE DESCRIPTION.


In all cases where there is a choice
4. Two types of protective metal closures are between an internal or external
approved for sealing hydraulic equipment. These installation, use the external type of
caps and plugs conform to the appropriate military closure. Never blank-off openings with
and industry specifications (Table 1). Additional wooden plugs, paper, rags, tape, or other
protective closures are identified in Tables 2 through unauthorized devices.
9.

5. PROTECTIVE CLOSURE APPLICATION.

6. Guidelines for selection and use of protective


closures for hydraulic equipment are as follows:
Plastic and light aluminum closures are
a. Use caps and plugs of the proper size and NOT to be used on aircraft under any
material. circumstance. Doing so could result in
personal injury and equipment damage.
b. Only use approved metal and plastic caps
and plugs to protect hydraulic systems.
g. Only use high pressure approved metal
c. Every effort shall be made to protect spare or protective closures to seal open ports of all hydraulic
removed components, lines, hoses and open aircraft lines and accessories on the aircraft. See Tables 2, 3,
hydraulic lines and hoses from external 6 and 7 for list of approved protective closures.
contamination.
h. Use metal protective closures to seal new
d. High pressure closures are required for any and reusable hydraulic tubing and hose assemblies.
disconnected lines on components being tested on
the test benches and stands. i. Keep all protective closures clean, sorted by
size, properly identified, and stored in readily
e. Use closures of metal construction accessible bins.
conforming to specifications listed in Table 1 for
sealing hydraulic system equipment, lines, tubes,
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j. Check protective closure visually for


cleanliness, thread damage, or sealing deformation
before using.

k. Rubber, plastic or unthreaded type protective


closures designed to fit over open ends of bulk hose
and tubing shall be used in accordance with design
function only. Do not use this type of protective
closure as a plug for insertion into open lines, hoses,
or ports of hydraulic equipment.

l. Remove protective closures before installing


equipment. If an opening normally requiring protection
is found uncovered, the part or assembly shall be
cleaned and checked before installation or assembly.

7. POLYETHYLENE PROTECTIVE CLOSURES.


High density polyethylene protective caps and plugs
(Tables 8 and 9 Figures 9 and 10) may only be used
for shipping purposes if all hydraulic fluid has been
drained from the system equipment and components
prior to shipping. They may also be used to seal
electrical fittings and receptacle or other non-fluid
openings where contamination is not considered a
problem.

8. BLANK-OFF PLATES.

9. Blank-off plates (Figure 2) are used as follows:

Do not use fiber, plastic, or masonite


blank-off plates where pressure or
retention of hydraulic fluid is required.

a. Use blank-off plates to seal and protect


flange-type connections.

b. Use a gasket and metal plate where


retention of hydraulic fluid is required.

c. If plastic blank-off plates are used, plastic


material shall conform to NAS847, “Caps and Plugs,
Protective, Dust and Moisture Seal”.
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014001

Figure 1: Dyna Tube Examples

014002
Figure 2. Typical Blank-Off Plates
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014003

Figure 3: AN929-D High Pressure Aluminum Caps

014004
Figure 4: AS5168-D High Pressure Aluminum Plugs

014005
Figure 5: NAS817 Light Aluminum Caps for Storage and Shipping
NAVAIR 01-1A-17 014 00
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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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Table 1. Protective Caps and Plugs

TYPE APPLICABLE
(Note 1) APPLICATION SPECIFICATION

Cap Protective, Flared Fitting NAS817

Cap Beaded Hose Connection, Plastic, NAS839


Protective

Cap Pipe Thread NAS846

Cap Assembly, Pressure Seal Flared Tube AN929


Fitting

Cap Pressure Seal, Flareless Tube Fitting SAE AS21914

Plug Flared Tube End and Straight Threaded NAS818


Boss or SAE AS5168 (Note 3)

Plug Protective, Flareless Tube End (Plastic) NAS838

Plug Protective, Flareless Tube End (Metal) NAS842

Plug Flareless Tube SAE AS21913 (Note 2)

Plug Flared Tube Precision Type SAE AS5168 (Note 3)

Plug Pipe Thread NAS840

Plug Bleeder, Screw Thread SAE AS5169

Plug Machine Thread AMS 5646 Preformed MS9404


Packing

Plug Bleeder, Screw Thread Precision Type SAE AS5169

Notes: 1. When ordering from supply, be sure to specify metal caps or plugs.

2. Industry specification, SAE AS21913, shall be used in lieu of MS21913.

3. Industry specification, SAE AS5168, shall be used in lieu of AN806.


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Table 2. High Pressure Aluminum Caps (blue in color)

{Meets SAE AS4841 specification (supersedes MIL-F-5509)}

Part Units of Cap


Item Number National Stock Issue Thread Tubing
No. (P/N) Nomenclature Number (NSN’s) (U/I) Size Size

1 AN929-D2 Cap, Threaded, 7075 Anodized 4730-00-633-4398 EA 5/16" 1/8"


Aluminum

2 AN929-D3 Cap, Threaded, 7075 Anodized 4730-00-221-2126 EA 3/8" 3/16"


Aluminum

3 AN929-D4 Cap, Threaded, 7075 Anodized 4730-00-278-5006 EA 7/16" 1/4"


Aluminum

4 AN929-D5 Cap, Threaded, 7075 Anodized 4730-01-061-4150 EA 1/2" 5/16"


Aluminum

5 AN929-D6 Cap, Threaded, 7075 Anodized 4730-00-585-8769 EA 9/16" 3/8"


Aluminum

6 AN929-D8 Cap, Threaded, 7075 Anodized 4730-00-541-8296 EA 3/4" 1/2"


Aluminum

7 AN929-D10 Cap, Threaded, 7075 Anodized 4730-00-221-2127 EA 7/8" 5/8"


Aluminum

8 AN929-D12 Cap, Threaded, 7075 Anodized 4730-00-221-2128 EA 1-1/16" 3/4"


Aluminum

9 AN929-D16 Cap, Threaded, 7075 Anodized 4730-00-221-2129 EA 1-3/8" 1"


Aluminum

10 AN929-D20 Cap, Threaded, 7075 Anodized 4730-00-221-2130 EA 1-5/8" 1-1/4"


Aluminum

11 AN929-D24 Cap, Threaded, 7075 Anodized 4730-00-826-6462 EA 1-7/8" 1-1/2"


Aluminum

12 AN929-D28 Cap, Threaded, 7075 Anodized 4730-00-221-2116 EA 2-1/4" 1-3/4"


Aluminum

13 AN929-D32 Cap, Threaded, 7075 Anodized 4730-00-221-2117 EA 2-1/2" 2"


Aluminum

Notes: 1. See Figure 3 for examples of AN929D high pressure aluminum caps (blue in color).
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Table 3. High Pressure Aluminum Plugs (blue in color)

{Meets SAE AS4841 specification (supersedes MIL-F-5509)}

Part Units of Cap


Item Number National Stock Issue Thread Tubing
No. (P/N) Nomenclature Number (NSNs) (U/I) Size Size

1 AS5168-D02 Plug, Threaded, 7075 Anodized 4730-00-287-0109 EA 5/16" 1/8"


Aluminum

2 AS5168-D03 Plug, Threaded, 7075 Anodized 4730-00-287-0100 EA 3/8" 3/16"


Aluminum

3 AS5168-D04 Plug, Threaded, 7075 Anodized 4730-00-287-0110 EA 7/16" 1/4"


Aluminum

4 AS5168-D05 Plug, Threaded, 7075 Anodized 4730-00-287-0111 EA 1/2" 5/16"


Aluminum

5 AS5168-D06 Plug, Threaded, 7075 Anodized 4730-00-287-0112 EA 9/16" 3/8"


Aluminum

6 AS5168-D08 Plug, Threaded, 7075 Anodized 4730-00-287-0113 EA 3/4" 1/2"


Aluminum

7 AS5168-D10 Plug, Threaded, 7075 Anodized 4730-00-287-0116 EA 7/8" 5/8"


Aluminum

8 AS5168-D12 Plug, Threaded, 7075 Anodized 4730-00-287-0117 EA 1-1/16" 3/4"


Aluminum
4730-00-080-3091

9 AS5168-D16 Plug, Threaded, 7075 Anodized 4730-00-287-0118 EA 1-3/8" 1"


Aluminum

10 AS5168-D20 Plug, Threaded, 7075 Anodized 4730-00-640-5104 EA 1-5/8" 1-1/4"


Aluminum

11 AS5168-D24 Plug, Threaded, 7075 Anodized 4730-00-287-0115 EA 1-7/8" 1-1/2"


Aluminum

12 AS5168-D28 Plug, Threaded, 7075 Anodized 4730-00-640-0633 EA 2-1/4" 1-3/4"


Aluminum

13 AS5168-D32 Plug, Threaded, 7075 Anodized 4730-00-287-0120 EA 2-1/2" 2"


Aluminum

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)

{Meets NAS817 specification}

Part Units of Cap


Item Number National Stock Issue Thread Tubing
No. (P/N) Nomenclature Number (NSN’s) (U/I) Size Size

1 NAS817-2 Cap, Threaded, 3003 Anodized 5340-00-682-2112 EA 5/16" 1/8"


Aluminum

2 NAS817-3 Cap, Threaded, 3003 Anodized 5340-00-158-1313 EA 3/8" 3/16"


Aluminum
5340-00-804-0790

3 NAS817-4 Cap, Threaded, 3003 Anodized 5340-00-682-2113 EA 7/16" 1/4"


Aluminum
5340-01-081-8282

4 NAS817-5 Cap, Threaded, 3003 Anodized 5340-00-682-2114 EA 1/2" 5/16"


Aluminum
5340-00-804-0776

5 NAS817-6 Cap, Threaded, 3003 Anodized 5340-00-682-2115 EA 9/16" 3/8"


Aluminum
5340-01-016-8180

6 NAS817-8 Cap, Threaded, 3003 Anodized 5340-00-682-2116 EA 3/4" 1/2"


Aluminum

7 NAS817-10 Cap, Threaded, 3003 Anodized 5340-00-682-2117 EA 7/8" 5/8"


Aluminum
5340-00-804-0768

8 NAS817-12 Cap, Threaded, 3003 Anodized 5340-00-682-2118 EA 1-1/16" 3/4"


Aluminum

9 NAS817-16 Cap, Threaded, 3003 Anodized 5340-00-682-2119 EA 1-3/8" 1"


Aluminum

10 NAS817-20 Cap, Threaded, 3003 Anodized 5340-00-804-0788 EA 1-5/8" 1-1/4"


Aluminum

11 NAS817-24 Cap, Threaded, 3003 Anodized 5340-01-004-0107 EA 1-7/8" 1-1/2"


Aluminum

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)

{Meets NAS818 specification}

Part Units of Cap


Item Number National Stock Issue Thread Tubing
No. (P/N) Nomenclature Number (NSN’s) (U/I) Size Size

1 M5501/1-2 Plug, Threaded, 3003 Anodized 5340-00-804-1229 EA 5/16" 1/8"


Aluminum

2 M5501/1-3 Plug, Threaded, 3003 Anodized 5340-00-804-1224 EA 3/8" 3/16"


Aluminum

3 M5501/1-4 Plug, Threaded, 3003 Anodized 5340-00-433-3253 EA 7/16" 1/4"


Aluminum

4 M5501/1-5 Plug, Threaded, 3003 Anodized 5340-00-804-1228 EA 1/2" 5/16"


Aluminum

5 M5501/1-6 Plug, Threaded, 3003 Anodized 5340-00-292-3292 EA 9/16" 3/8"


Aluminum

6 M5501/1-8 Plug, Threaded, 3003 Anodized 5340-00-828-8802 EA 3/4" 1/2"


Aluminum

7 M5501/1-10 Plug, Threaded, 3003 Anodized 5340-00-804-1230 EA 7/8" 5/8"


Aluminum

8 M5501/1-12 Plug, Threaded, 3003 Anodized 5340-01-186-6879 EA 1-1/16" 3/4"


Aluminum

9 M5501/1-16 Plug, Threaded, 3003 Anodized 5340-00-804-1245 EA 1-3/8" 1"


Aluminum

10 M5501/1-20 Plug, Threaded, 3003 Anodized 5340-00-804-1248 EA 1-5/8" 1-1/4"


Aluminum

11 M5501/1-24 Plug, Threaded, 3003 Anodized 5340-01-217-1791 EA 1-7/8" 1-1/2"


Aluminum

12 M5501/1-32 Plug, Threaded, 3003 Anodized 5340-00-804-1254 EA 2-1/2" 2"


Aluminum

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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Table 6. High Pressure Carbon Steel Caps (gold in color)

Units
Part of Cap
Item Number National Stock Issue Thread Tubing
No. (P/N) Nomenclature Number (NSN’s) (U/I) Size Size

1 MS21914V2P Cap, Threaded, Steel Tube Fitting, 4730-00-541-0677 EA 5/16" 1/8"


Cadmium Plated w/ Supplementary
Chromate Treatment

2 MS21914V3P Cap, Threaded, Steel Tube Fitting, 4730-00-289-8633 EA 3/8" 3/16"


Cadmium Plated w/ Supplementary
Chromate Treatment 4730-01-547-5929

3 MS21914V4P Cap, Threaded, Steel Tube Fitting, 4730-00-640-0632 EA 7/16" 1/4"


Cadmium Plated w/ Supplementary
Chromate Treatment 4730-01-542-7724

4 MS21914V5P Cap, Threaded, Steel Tube Fitting, 4730-00-618-9069 EA 1/2" 5/16"


Cadmium Plated w/ Supplementary
Chromate Treatment 4730-01-548-6275

5 MS21914V6P Cap, Threaded, Steel Tube Fitting, 4730-00-618-3572 EA 9/16" 3/8"


Cadmium Plated w/ Supplementary
Chromate Treatment 4730-01-540-8876

6 MS21914V8P Cap, Threaded, Steel Tube Fitting, 4730-00-289-8634 EA 3/4" 1/2"


Cadmium Plated w/ Supplementary
Chromate Treatment 4730-01-542-7727

7 MS21914V10P Cap, Threaded, Steel Tube Fitting, 4730-00-618-4227 EA 7/8" 5/8"


Cadmium Plated w/ Supplementary
Chromate Treatment 4730-01-542-7677

8 MS21914V12P Cap, Threaded, Steel Tube Fitting, 4730-00-202-8792 EA 1-1/16" 3/4"


Cadmium Plated w/ Supplementary
Chromate Treatment 4730-01-542-7684

9 MS21914V16P Cap, Threaded, Steel Tube Fitting, 4730-00-274-7120 EA 1-3/8" 1"


Cadmium Plated w/ Supplementary
Chromate Treatment 4730-01-542-7687

10 MS21914V20P Cap, Threaded, Steel Tube Fitting, 4730-00-554-8917 EA 1-5/8" 1-1/4"


Cadmium Plated w/ Supplementary
Chromate Treatment 4730-01-542-7689

11 MS21914V24P Cap, Threaded, Steel Tube Fitting, 4730-00-834-4358 EA 1-7/8" 1-1/2"


Cadmium Plated w/ Supplementary
Chromate Treatment 4730-01-542-7694

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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Table 7. High Pressure Carbon Steel Plugs (gold in color)

Units
Part of Cap
Item Number National Stock Issue Thread Tubing
No. (P/N) Nomenclature Number (NSN’s) (U/I) Size Size

1 MS21913V2P Plug, Threaded, Steel Tube Fitting, 4730-01-068-3245 EA 5/16" 1/8"


Cadmium Plated w/ Supplementary
Chromate Treatment 4730-01-542-7608

2 MS21913V3P Plug, Threaded, Steel Tube Fitting, 4730-00-289-8632 EA 3/8" 3/16"


Cadmium Plated w/ Supplementary
Chromate Treatment 4730-01-547-6331

3 MS21913V4P Plug, Threaded, Steel Tube Fitting, 4730-00-595-2612 EA 7/16" 1/4"


Cadmium Plated w/ Supplementary
Chromate Treatment 4730-01-542-7624

4 MS21913V5P Plug, Threaded, Steel Tube Fitting, 4730-00-541-1465 EA 1/2" 5/16"


Cadmium Plated w/ Supplementary
Chromate Treatment 4730-01-542-7635

5 MS21913V6P Plug, Threaded, Steel Tube Fitting, 4730-00-203-3709 EA 9/16" 3/8"


Cadmium Plated w/ Supplementary
Chromate Treatment 4730-01-542-7639

6 MS21913V8P Plug, Threaded, Steel Tube Fitting, 4730-00-202-8341 EA 3/4" 1/2"


Cadmium Plated w/ Supplementary
Chromate Treatment 4730-01-542-7646

7 MS21913V10P Plug, Threaded, Steel Tube Fitting, 4730-00-966-5695 EA 7/8" 5/8"


Cadmium Plated w/ Supplementary
Chromate Treatment 4730-01-542-7303

8 MS21913V12P Plug, Threaded, Steel Tube Fitting, 4730-00-289-8627 EA 1-1/16" 3/4"


Cadmium Plated w/ Supplementary
Chromate Treatment 4730-01-542-7314

9 MS21913V16P Plug, Threaded, Steel Tube Fitting, 4730-00-289-8626 EA 1-3/8" 1"


Cadmium Plated w/ Supplementary
Chromate Treatment 4730-01-550-6518

10 MS21913V20P Plug, Threaded, Steel Tube Fitting, 4730-00-289-8625 EA 1-5/8" 1-1/4"


Cadmium Plated w/ Supplementary
Chromate Treatment 4730-01-542-7614

11 MS21913V24P Plug, Threaded, Steel Tube Fitting, 4730-01-067-3944 EA 1-7/8" 1-1/2"


Cadmium Plated w/ Supplementary
Chromate Treatment 4730-01-542-7616

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

1 DC-3 Cap, Threaded, High-Density 5340-01-178-7855 EA 3/8"-28 3/16"


Polyethylene, seals out contaminants
while protecting threads

2 DC-4 Cap, Threaded, High-Density 5340-00-435-9188 EA 7/16"-24 1/4"


Polyethylene, seals out contaminants
while protecting threads

3 DC-5 Cap, Threaded, High-Density 5340-01-114-0773 EA 1/2"-24 5/16"


Polyethylene, seals out contaminants
while protecting threads

4 DC-6 Cap, Threaded, High-Density 5340-00-364-9560 EA 9/16"-20 3/8"


Polyethylene, seals out contaminants
while protecting threads

5 DC-8 Cap, Threaded, High-Density 5340-00-376-8953 EA 3/4"-20 1/2"


Polyethylene, seals out contaminants
while protecting threads

6 DC-10 Cap, Threaded, High-Density 5340-00-620-4901 EA 7/8"-18 5/8"


Polyethylene, seals out contaminants
while protecting threads

7 DC-12 Cap, Threaded, High-Density 5340-00-435-9187 EA 1-1/16"-16 3/4"


Polyethylene, seals out contaminants
while protecting threads

8 DC-14 Cap, Threaded, High-Density 5340-01-114-0774 EA 1-1/8"-16 7/8"


Polyethylene, seals out contaminants
while protecting threads

9 DC-16 Cap, Threaded, High-Density 5340-01-114-0775 EA 1-3/8"-14 1"


Polyethylene, seals out contaminants
while protecting threads

10 DC-20 Cap, Threaded, High-Density 5340-01-114-0201 EA 1-5/8"-14 1-1/4"


Polyethylene, seals out contaminants
while protecting threads

11 DC-21S Cap, Threaded, High-Density 5340-01-184-6883 EA 1-37/64"-14 1-1/4"


Polyethylene, seals out contaminants
while protecting threads

12 DC-24 Cap, Threaded, High-Density ------------------------ EA 1-7/8"-14 1-1/2"


Polyethylene, seals out contaminants
while protecting threads

13 DC-25S Cap, Threaded, High-Density 5340-01-114-0202 EA 1-27/32"-14 1-1/2"


Polyethylene, seals out contaminants
while protecting threads

Notes: 1. See Figure 9 for examples of plastic caps for storage and shipping (light blue in color).
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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

1 DP-3 Plug, Threaded, High-Density 5340-01-114-0205 EA 3/8"-28 3/16"


Polyethylene, seals out contaminants
while protecting threads

2 DP-4 Plug, Threaded, High-Density 5340-01-084-5529 EA 7/16"-24 1/4"


Polyethylene, seals out contaminants
while protecting threads

3 DP-5 Plug, Threaded, High-Density 5340-01-115-1097 EA 1/2"-24 5/16"


Polyethylene, seals out contaminants
while protecting threads

4 DP-6 Plug, Threaded, High-Density 5340-01-089-9029 EA 9/16"-20 3/8"


Polyethylene, seals out contaminants
while protecting threads

5 DP-8 Plug, Threaded, High-Density 5340-01-080-9472 EA 3/4"-20 1/2"


Polyethylene, seals out contaminants
while protecting threads

6 DP-10 Plug, Threaded, High-Density 5340-01-104-6066 EA 7/8"-18 5/8"


Polyethylene, seals out contaminants
while protecting threads

7 DP-12 Plug, Threaded, High-Density 5340-01-085-4233 EA 1-1/16"-16 3/4"


Polyethylene, seals out contaminants
while protecting threads

8 DP-14 Plug, Threaded, High-Density ------------------------ EA 1-1/8"-16 7/8"


Polyethylene, seals out contaminants
while protecting threads

9 DP-16 Plug, Threaded, High-Density 5340-01-113-3830 EA 1-3/8"-14 1"


Polyethylene, seals out contaminants
while protecting threads

10 DP-20 Plug, Threaded, High-Density 5340-01-201-5562 EA 1-5/8"-14 1-1/4"


Polyethylene, seals out contaminants
while protecting threads

11 DP-21S Plug, Threaded, High-Density ------------------------ EA 1-37/64"-14 1-1/4"


Polyethylene, seals out contaminants
while protecting threads

12 DP-24 Plug, Threaded, High-Density 5340-01-201-5563 EA 1-7/8"-14 1-1/2"


Polyethylene, seals out contaminants
while protecting threads

13 DP-25S Plug, Threaded, High-Density ------------------------ EA 1-27/32"-14 1-1/2"


Polyethylene, seals out contaminants
while protecting threads

Notes: 1. See Figure 10 for examples of plastic caps for storage and shipping (light blue in color).
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ORGANIZATIONAL, INTERMEDIATE AND


DEPOT MAINTENANCE

HYDRAULIC SEALS

HYDRAULIC SYSTEMS

Reference Material

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


Packing, Preformed, Hydraulic, +275 Degrees F ...................................................... SAE AS28775
Packing, Preformed, Straight Thread Tube Fitting Boss ........................................... SAE AS28778
Retainers, Hydraulic and Pneumatic, Polytetrafluoroethylene, Single Turn .............. SAE AS8791
Retainer, Packing Backup, Single Turn Polytetrafluoroethylene ............................. MS28774
Packing, Preformed, Straight Thread Tube Fitting Boss, Type I Hydraulic ............... SAE AMS-P-5510
Rubber Products: Recommended Shelf Life ............................................................. MIL-HDBK-695

Alphabetical Index

Subject Page No.

Backup Rings ................................................................................................................................. 18


Backup Ring Identification ......................................................................................................... 18
Backup Ring Installation ............................................................................................................ 19
Introduction..................................................................................................................................... 2
Definitions .................................................................................................................................. 2
Packings ......................................................................................................................................... 2
Gaskets ...................................................................................................................................... 11
Preformed Packing Identification ............................................................................................... 13
Preformed Packing Lubrication.................................................................................................. 18
Preformed Packing Removal and Installation............................................................................ 14
Preformed Packing Storage....................................................................................................... 14
Service Life of Preformed Packings .......................................................................................... 13
Spring Seals............................................................................................................................... 3
T-Rings ...................................................................................................................................... 2

Record of Applicable Technical Directives

None
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1. INTRODUCTION. 6. As defined by MIL-G-5514, the term “packing”


refers to the synthetic rubber component of either a
2. Hydraulic seals are used in the hydraulic systems dynamic seal, a static seal, or a gasket. Although a
of aircraft and related support equipment (SE) to gasket is one form of static seal and is often called a
minimize internal and external leakage of hydraulic static seal due to the fact that there are no moving
fluids. By minimizing or preventing such leakage, the parts associated with it, the two terms must not be
seals are vital to maintaining the operating pressure interchanged indiscriminately. A gasket is often used
of a hydraulic system. in exterior applications where exposure to air is a life
factor. A packing compound designed for use in such
3. DEFINITIONS. Military Specification MIL-G-5514 circumstances may be unsuitable for use as part of a
defines the following: static seal designed only for contact with hydraulic
fluid. Packing materials are designed to have
a. Seal: A device to retain fluid within a particular properties under certain conditions and for
hydraulic component. A seal may consist of two or contact with certain media. A packing compound
more components, such as a packing in a gland, or a designed to have excellent sealing characteristics
packing and backup ring in a gland. with one medium may have hazardous characteristics
with another medium. An example of this is the
b. Packing: The component of a seal which difference between a packing designed for a fuel
serves as a sealing medium by nature of its plastic or system and one designed for a hydraulic system. By
elastic properties, or its ability to deform into the the nature of its compound, a fuel system packing has
shape of the gland. a greater volume increase than a hydraulic packing
which requires precision dimensional stability.
c. Gland: The component of the seal which Substitution of a fuel packing for a hydraulic packing
forms the cavity or inclusion which surrounds and is prohibited.
supports the packing and controls the squeeze.
7. Preformed packings used in Naval and Air Force
d. Squeeze: The dimension by which a packing aircraft hydraulic installations are normally
is distorted from its molded shape when installed in a manufactured of synthetic rubber and are made in
packing gland. various forms. The O-ring is the type most extensively
employed. Circular in shape, its cross section is small
e. Dynamic seal: A type of seal where there is in relation to its diameter. It is molded and trimmed to
relative motion between some part of the gland and extremely close tolerances.
the packing, such as piston or shaft seal.
8. Packings other than O-rings are also used, to a
f. Static seal: A type of seal where there is no lesser extent, to seal aircraft and hydraulic SE. These
relative motion between the packing and any part of packings are usually employed in specific sealing
the gland, although limited freedom may be provided applications such as landing gear shock struts, rotary
to permit the packing to change its shape within the actuators, and in areas of extreme temperature
gland when under pressure. buildup. The following provides a brief description of
the more commonly used special application seals.
g. Gasket: A type of seal which is formed by
crushing packing material into the gland such that the 9. T-RINGS. The T-ring shown in Figure 1 resists
cavity formed by the gland is normally filled with the spiraling and rolling in glands because of its inverted
packing material. tee design. It is sometimes used in applications where
spiraling or rolling causes O-ring failure. T-rings are
h. Backup ring: A device used to prevent also used in applications where large clearances
pressure and friction from extruding the O-ring could occur due to expansion of thin wall hydraulic
packing through the clearance gap of a seal. cylinders. The T-sealing ring is installed under radial
compression and provides a positive seal at zero or
i. TFE: A tetrafluoroethylene resin. low pressure. Backup rings, normally one on each
side, ride free of T-ring flanges and rod or cylinder
4. For further clarification of the above terminology, wall. These clearances keep seal friction to a
and for additional information, read paragraphs 5 and minimum at low pressure. When pressure is applied,
6. the T-sealing ring acts to provide positive sealing
action as fluid pressure increases.
5. PACKINGS.
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a. Glyd Ring. Figure 2 depicts a ring designed


to prevent O-ring extrusion. No backup rings are
required.

b. Cap Seal. The seal shown in Figure 3 is less


frequently used and is not recommended for new
design applications. The Cap Seal is a ring designed
to prevent O-ring extrusion and is usually used in
grooves designed for O-rings with no backup rings.
Because of crowding in the groove, Cap Seals often
present installation difficulties.

c. Channel Seal. Figure 4 shows a ring


designed as a replacement for conventional sealing
methods (O-ring and backup rings in combination)
and is directly interchangeable with a dual backup
and O-ring combination. Channel Seals are
manufactured to the gland and groove dimensions of
MIL-G-5514. Channel Seals are used primarily in
dynamic hydraulic and pneumatic sealing
applications.

d. Double Channel Seal. Figure 5 shows a type


015001
of seal particularly effective in sealing excessive Figure 1. T-Sealing Ring
clearances and high pressures. It is used in
combination, as are all Channel Seals, with O-rings.
The Double Delta Channel Seal is manufactured to
gland and groove dimensions of MIL-G-5514.

10. SPRING SEALS. The Spring Seal consists of a


flat helical spring inside a modified “C” section Teflon
ring. Figure 6 shows the spring sealing action
principle in which the action of the spring exerts equal
pressure and provides permanent resiliency to assure
a reliable seal. Spring seals are manufactured in
various sizes and shapes conforming to the groove
and gland dimensions of MIL-G-5514. Figure 7 shows
spring seal styles and typical installations.

NOTE

Spring seals should always be installed so


that the open side of the cover faces
toward system pressure.

11. The spring seal is not as flexible as conventional


O-rings, therefore extreme care shall be exercised
when installing the seal. Special tooling is required to 015002
install spring seals. Refer to applicable Maintenance Figure 2. Typical Glyd Ring Installation
Instruction Manual (MIM) or Technical Order (TO) for
specific installation techniques, procedures, and
tooling requirements.
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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
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015007
Figure 7. Spring Seal and Typical Installations
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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
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Table 1. O-Ring Part Numbers Cross Over to Material Specification

Part Number Part Number Specification Previous Part Number Material Specification
AA55549-XX A-A-55549 MA90064-XX ZZ-R-765, AMS3302
AS3084-XX AS3084 AS3804-XX AMS 7280
AS3085-XXX AS3085 AS3085-XXX AMS 7280
AS3208-XX AS3208 AS3208-XX AMS 7276
AS3209-XXX AS3209 AS3209-XXX AMS 7276
AS3551-XXX AS3551 MS9241-XXX AMS 7272
AS3551-XXX AS3551 MS9355-XX AMS 7272
AS3569-XXX AS3569 AN123951 THRU AN124050 AMS 7270
AS3570-XXX AS3570 AN123851 THRU AN123950 AMS 7274
AS3578-XXX AS3578 MS9020-XX AMS 7271
AS3578-XXX AS3578 MS9021-XXX AMS 7271
AS3581-XXX AS3581 MS9970-XXX AMS 7259
AS3582-XXX AS3582 MS9068-XXX AMS 3304
M83248/1-XXX MIL-R-83248 MS17413-XXX MIL-R-83248, AMS-R-83248
M83248/1-XXX MIL-R-83248/1 M83248/1-XXX MIL-R-83248, AMS-R-83248
M83248/2-XXX MIL-R-83248/2 M83248/2-XXX MIL-R-83248, AMS-R-83248
M83461/1-XXX MIL-P-83461/1 M83461/1-XXX MIL-P-83461, AMS-P-83461
M259888-XXX NSA8200 NSA8200-XXX MIL-R-25988, AMS-R-25988
M259888-XXX NSA8203 NSA8203-XXX MIL-R-25988, AMS-R-25988
M25988/1-XXX MIL-R-25988 M25988/1-XXX MIL-R-25988, AMS-R-25988
M25988/2-XXX MIL-R-25988 M25988/2-XXX MIL-R-25988, AMS-R-25988
M25988/3-XXX MIL-R-25988 M25988/3-XXX MIL-R-25988, AMS-R-25988
M25988/4-XXX MIL-R-25988 M25988/4-XXX MIL-R-25988, AMS-R-25988
M83248/1-XXX MIL-R-83248/1 MS9387-XX MIL-R-83248, AMS-R-83248
M83248/1-XXX MIL-R-83248/1 MS9388-XXX MIL-R-83248, AMS-R-83248
M83248/1-XXX NAS1593 NAS1593-XXX MIL-R-83248, AMS-R-83248
M83248/2-XXX NAS1594 NAS1594-XXX MIL-R-83248, AMS-R-83248
M83248/1-XXX NAS1595 NAS1595-XXX MIL-R-83248, AMS-R-83248
M83248/2-XXX NAS1596 NAS1596-XX MIL-R-83248, AMS-R-83248
MA3362XXXXX MA3362 MA3362XXXX AMS7276
MA3434XXXXX MA3434 MA3434XXXX AMS7273
MA3442XXXXX MA3442 MA3442XXXX AMS7267
MA3445XXXXX MA3445 MA3445XXXX MIL-R-83485, AMS-R-83485
MS28772-XXX AS28772 MS28772-XXX MIL-P-5516, AMS-P-5516
MS28775-XXX AS28775 AN6227-XXX MIL-P-25732, AMS-P-25732
MS28775-XXX AS28775 AN6230-XXX MIL-P-25732, AMS-P-25732
MS28775-XXX AS28775 MS28775-XXX MIL-P-25732, AMS-P-25732
MS28778-XX AS28778 AN6290-XX MIL-P-5510, AMS-P-5510
MS28778-XX AS28778 MS28778-XX MIL-P-5510, AMS-P-5510
MS29512-XX AS29512 MS29512-XX MIL-P-5315, AMS-P-5315
MS29513-XXX AS29513 MS29513-XXX MIL-P-5315, AMS-P-5315
MS29561-XXX AS29561 MS29561 MIL-R-7362, AMS-R-7362
MS3393-XX AS33931 MS3393-XX MIL-P-81716
MS90064-XX MS90064 MS90064-XX ZZ-R-765, AMS3304
MS9385-XX AS9385 MS9385-XX AMS 7267
MS9386-XXX AS9386 MS9386-XXX AMS 7267
MS9966-XX AS9966 MS9966-XX AMS 7273
MS9967-XXX AS9967 MS9967-XXX AMS 7273
NAS617-XXX NAS617 NAS617-XXX MIL-R-7362, AMS-R-7362
NAS1611-XXXA NAS1611 NAS1611-XXX NAS1613
NAS1612-XXA NAS1612 NAS1612-XX NAS1613
NSA8201-X NSA8201 NSA8201-X NAS1613
NSA8204-XXX NSA8204 NSA8204-XXX NAS1613
NSA8205-XXX NSA8205 NSA8205-XXX AMS 3242
NSA8206-XXX NSA8206 NSA8206-XXX AMS 7267
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Table 2. O-Rings and Backup Rings for Equipment Applications


O-RINGS BACKUP RINGS

SAE AS28775 SINGLE SPIRAL, SINGLE DOUBLE SPIRAL,


(Formerly AN6227 SCARF CUT (EXCEPT FOR SINGLE SCARF
and AN6230) THOSE MARKED WITH A (Y), CUT, MADE
MADE FROM TEFLON FROM TEFLON

NOM DIM. SPEC NOM DIM. SPEC NOM DIM. SPEC


ID T NO. ID T W NO. ID T W NO.

1/8 1/16 SAE AS28775-006 9/64 3/64 3/64 SAE AS8791-6 1/8 3/64 3/64 MS28782-1
5/32 1/16 SAE AS28775-007 11/64 3/64 3/64 SAE AS8791-7 5/32 3/64 3/64 MS28782-2
3/16 1/16 SAE AS28775-008 13/64 3/64 3/64 SAE AS8791-8 3/16 3/64 3/64 MS28782-3
7/32 1/16 SAE AS28775-009 15/64 3/64 3/64 SAE AS8791-9 7/32 3/64 3/64 MS28782-4
1/4 1/16 SAE AS28775-010 17/64 3/64 3/64 SAE AS8791-10 1/4 3/64 3/64 MS28782-5
5/16 1/16 SAE AS28775-011 21/64 3/64 3/64 SAE AS8791-11 5/16 3/64 3/64 MS28782-6
3/8 1/16 SAE AS28775-012 25/64 3/64 3/64 SAE AS8791-12 3/8 3/64 3/64 MS28782-7
3/8 3/32 SAE AS28775-110 25/64 3/64 3/32 SAE AS8791-110 3/8 3/64 3/32 MS28782-8
7/16 3/32 SAE AS28775-111 29/64 3/64 3/32 SAE AS8791-111 7/16 3/64 3/32 MS28782-9
15/32 1/16 SAE AS28775-013* 29/64 3/64 3/64 SAE AS8791-13
1/2 1/16 SAE AS28775-014* 33/64 3/64 3/64 SAE AS8791-14
1/2 3/32 SAE AS28775-112 33/64 3/64 3/32 SAE AS8791-112 1/2 3/64 3/32 MS28782-10
9/16 1/16 SAE AS28775-015* 37/64 3/64 3/64 SAE AS8791-15
9/16 3/32 SAE AS28775-113 37/64 3/64 3/32 SAE AS8791-113 9/16 3/64 3/32 MS28782-11
5/8 1/16 SAE AS28775-016* 41/64 3/64 3/64 SAE AS8791-16
5/8 3/32 SAE AS28775-114 41/64 3/64 3/32 SAE AS8791-114 5/8 3/64 3/32 MS28782/12
11/16 1/16 SAE AS28775-017* 45/64 3/64 3/64 SAE AS8791-17
11/16 3/32 SAE AS28775-115 45/64 3/64 3/32 SAE AS8791-115 11/16 3/64 3/32 MS28782-13
3/4 1/16 SAE AS28775-018* 49/64 3/64 3/64 SAE AS8791-18
3/4 3/32 SAE AS28775-116 49/64 3/64 3/32 SAE AS8791-116 3/4 3/64 3/32 MS28782-14
3/4 1/8 SAE AS28775-210 49/64 3/64 1/8 SAE AS8791-210 3/4 3/64 1/8 MS28782-15
13/16 1/16 SAE AS28775-019* 53/64 3/64 3/64 SAE AS8791-19
13/16 3/32 SAE AS28775-117* 53/64 3/64 3/32 SAE AS8791-117
13/16 1/8 SAE AS28775-211 53/64 3/64 1/8 SAE AS8791-211 13/16 3/64 1/8 MS28782-16
7/8 1/16 SAE AS28775-020* 57/64 3/64 3/64 SAE AS8791-20
7/8 3/32 SAE AS28775-118* 57/64 3/64 3/32 SAE AS8791-118
7/8 1/8 SAE AS28775-212 57/64 3/64 1/8 SAE AS8791-212 7/8 3/64 1/8 MS28782-17
15/16 1/16 SAE AS28775-021* 61/64 3/64 3/64 SAE AS8791-21
15/16 3/32 SAE AS28775-119* 61/64 3/64 3/32 SAE AS8791-119
15/16 1/8 SAE AS28775-213 61/64 3/64 1/8 SAE AS8791-213 15/16 3/64 1/8 MS28782-18
1 1/16 SAE AS28775-022* 1-1/64 3/64 3/64 SAE AS8791-22
1 3/32 SAE AS28775-120* 1-1/64 3/64 3/32 SAE AS8791-120
1 1/8 SAE AS28775-214 1-1/64 3/64 1/8 SAE AS8791-214 1 3/64 1/8 MS28782-19
1-3/64 1/16 SAE AS28775-023* 1-5/64 3/64 3/64 SAE AS8791-23
1-1/16 3/32 SAE AS28775-121* 1-5/64 3/64 3/32 SAE AS8791-121
1-1/16 1/8 SAE AS28775-215 1-5/64 3/64 1/8 SAE AS8791-215 1-1/16 3/64 1/8 MS28782-20
1-1/8 1/16 SAE AS28775-024* 1-9/64 3/64 3/64 SAE AS8791-24
1-1/8 3/32 SAE AS28775-122* 1-9/64 3/64 3/32 SAE AS8791-122
1-1/8 1/8 SAE AS28775-216 1-9/64 3/64 1/8 SAE AS8791-216 1-1/8 3/64 1/8 MS28782-21
1-3/16 1/16 SAE AS28775-025* 1-13/64 3/64 3/64 SAE AS8791-25
1-3/16 3/32 SAE AS28775-123* 1-13/64 3/64 3/32 SAE AS8791-123
1-3/16 1/8 SAE AS28775-217 1-13/64 3/64 1/8 SAE AS8791-217 1-3/16 3/64 1/8 MS28782-22
1-1/4 1/16 SAE AS28775-026* 1-17/64 3/64 3/64 SAE AS8791-26
1-1/4 3/32 SAE AS28775-124* 1-17/64 3/64 3/32 SAE AS8791-124
1-1/4 1/8 SAE AS28775-218 1-17/64 3/64 1/8 SAE AS8791-218 1-1/4 3/64 1/8 MS28782-23
1-5/16 1/16 SAE AS28775-027* 1-21/64 3/64 3/64 SAE AS8791-27
1-5/16 3/32 SAE AS28775-125* 1-21/64 3/64 3/32 SAE AS8791-125
1-5/16 1/8 SAE AS28775-219 1-21/64 3/64 1/8 SAE AS8791-219 1-5/16 3/64 1/8 MS28782-24
1-3/8 1/16 SAE AS28775-028* 1-25/64 3/64 3/64 SAE AS8791-28
1-3/8 3/32 SAE AS28775-126* 1-25/64 3/64 3/32 SAE AS8791-126
1-3/8 1/8 SAE AS28775-220 1-25/64 3/64 1/8 SAE AS8791-220 1-3/8 3/64 1/8 MS28782-25
1-7/16 3/32 SAE AS28775-127* 1-29/64 3/64 3/32 SAE AS8791-27
1-7/16 1/8 SAE AS28775-221 1-29/64 3/64 1/8 SAE AS8791-221 1-7/16 3/64 1/8 MS28782-26
1-1/2 3/32 SAE AS28775-128* 1-33/64 3/64 3/32 SAE AS8791-128
1-1/2 1/8 SAE AS28775-222 1-33/64 3/64 1/8 SAE AS8791-222 1-1/2 3/64 1/8 MS28782-27
1-1/2 3/16 SAE AS28775-325 1-33/64 5/64 3/16 SAE AS8791-325 1-1/2 1/16 3/16 MS28782-28
1-9/16 3/32 SAE AS28775-129* 1-37/64 3/64 3/32 SAE AS8791-129
1-5/8 3/32 SAE AS28775-130* 1-41/64 3/64 3/32 SAE AS8791-130
1-5/8 1/8 SAE AS28775-223* 1-41/64 3/64 1/8 SAE AS8791-223 1-5/8 3/64 1/8 MS28783-1
1-5/8 3/16 SAE AS28775-326 1-41/64 5/64 3/16 SAE AS8791-326 1-5/8 1/16 3/16 MS28782-29
1-11/16 3/32 SAE AS28775-131* 1-45/64 3/64 3/32 SAE AS8791-131
1-3/4 3/32 SAE AS28775-132* 1-49/64 3/64 3/32 SAE AS8791-132
1-3/4 1/8 SAE AS28775-224* 1-49/64 3/64 1/8 SAE AS8791-224 1-3/4 3/64 1/8 MS28783-2
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Table 2. O-Rings and Backup Rings for Equipment Applications (Cont)


O-RINGS BACKUP RINGS

SAE AS28775 SINGLE SPIRAL, SINGLE DOUBLE SPIRAL,


(Formerly AN6227 SCARF CUT (EXCEPT FOR SINGLE SCARF
and AN6230) THOSE MARKED WITH A (Y), CUT, MADE
MADE FROM TEFLON FROM TEFLON

NOM DIM. SPEC NOM DIM. SPEC NOM DIM. SPEC


ID T NO. ID T W NO. ID T W NO.

1-3/4 3/16 SAE AS28775-327 1-49/64 5/64 3/16 SAE AS8791-327 1-3/4 1/16 3/16 MS28782-30
1-13/16 3/32 SAE AS28775-133* 1-53/64 3/64 3/32 SAE AS8791-133
1-7/8 3/32 SAE AS28775-134* 1-57/64 3/64 3/32 SAE AS8791-134
1-7/8 1/8 SAE AS28775-225* 1-57/64 3/64 1/8 SAE AS8791-225 1-7/8 3/64 1/8 MS28783-3
1-7/8 3/16 SAE AS28775-328 1-57/64 5/64 3/16 SAE AS8791-328 1-7/8 1/16 3/16 MS28782-31
1-15/16 3/32 SAE AS28775-135* 1-61/64 3/64 3/32 SAE AS8791-135
2 3/32 SAE AS28775-136* 2-1/64 3/64 3/32 SAE AS8791-136
2 1/8 SAE AS28775-226* 2-1/64 3/64 1/8 SAE AS8791-226 2 3/64 1/8 MS28783-4
2 3/16 SAE AS28775-329 2-1/64 5/64 3/16 SAE AS8791-329 2 1/16 3/16 MS28783-32
2-3/16 3-32 SAE AS28775-137* 2-5/64 3/64 3/32 SAE AS8791-137
2-1/8 3/32 SAE AS28775-138 2-9/64 3/64 3/32 SAE AS8791-138
2-1/8 1/8 SAE AS28775-227* 2-9/64 3/64 1/8 SAE AS8791-227 2-1/8 3/64 1/8 MS28783-5
2-1/8 3/16 SAE AS28775-330 2-9/64 5/64 3/16 SAE AS8791-330 2-1/8 1/16 3/16 MS28782-33
2-3/16 3/32 SAE AS28775-139* 2-13/64 3/64 3/32 SAE AS8791-139
2-1/4 3/32 SAE AS28775-140* 2-17/64 3/64 3/32 SAE AS8791-140
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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Table 2. O-Rings and Backup Rings for Equipment Applications (Cont)


O-RINGS BACKUP RINGS

SAE AS28775 SINGLE SPIRAL, SINGLE DOUBLE SPIRAL,


(Formerly AN6227 SCARF CUT (EXCEPT FOR SINGLE SCARF
and AN6230) THOSE MARKED WITH A (Y), CUT, MADE
MADE FROM TEFLON FROM TEFLON

NOM DIM. SPEC NOM DIM. SPEC NOM DIM. SPEC


ID T NO. ID T W NO. ID T W NO.

5 1/4 SAE AS28775-429 5-3/64 7/64 15/64 SAE AS8791-429 5 3/32 15/64 MS28782-56
5-1/8 1/4 SAE AS28775-430 5-11/64 7/64 15/64 SAE AS8791-430 5-1/8 3/32 15/64 MS28782-57
5-1/4 1/4 SAE AS28775-431 5-19/64 7/64 15/64 SAE AS8791-431 5-1/4 3/32 15/64 MS28782-58
5-3/8 1/4 SAE AS28775-432 5-27/64 7/64 15/64 SAE AS8791-432 5-3/8 3/32 15/64 MS28782-59
5-1/4 1/4 SAE AS28775-433 5-39/64 7/64 15/64 SAE AS8791-433 5-1/2 3/32 15/64 MS28782-60
5-5/8 1/4 SAE AS28775-434 5-43/64 7/64 15/64 SAE AS8791-434 5-5/8 3/32 15/64 MS28782-61
5-3/4 1/4 SAE AS28775-435 5-51/64 7/16 15/64 SAE AS8791-435 5-3/4 3/32 15/64 MS28782-62
5-7/8 1/4 SAE AS28775-436 5-59/64 7/16 15/64 SAE AS8791-436 5-7/8 3/32 15/64 MS28782-63
6 1/4 SAE AS28775-437 6-3/64 7/16 15/64 SAE AS8791-437 6 3/32 15/64 MS28782-64
6-1/4 1/4 SAE AS28775-438 6-9/32 7/16 15/64 SAE AS8791-438 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.

4. ALL measurements are expressed in inches.


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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):

Hydraulic Fluid, SAE AS1241 5


Use only SAE AS5179 (formerly AN6289)
nut which has an external identification a. Lubricate fitting threads and O-ring with
notch. The SAE AS5179 (formerly system fluid.
AN6289) nut has a flat surface on one
side and a retaining groove on the other b. Nut shall not move from its original
side. The retaining groove is designed to assembled position while screwing fitting assembly
accept Teflon backup ring MS28773. into port finger-tight.

c. Maintain nut in position with one wrench; use


a. Position nut with retaining groove side facing second wrench to rotate fitting inward not more than
mating body. one turn to achieve proper positioning.

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.

f. Install O-ring onto seal area of fitting.


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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

Table 3. O-Rings for Straight Thread Tube Fitting Installations


NOMINAL
DIMENSIONS OF O-RINGS
TUBING
O-RING TEFLON
OD ID W
SPEC NO. BACKUP RING

1/8 15/64 1/16 SAE AS28778-2 MS28773-02

3/16 5/16 1/16 SAE AS28778-3 MS28773-03

1/4 11/32 5/64 SAE AS28778-4 MS28773-04

5/16 13/32 5/64 SAE AS28778-5 MS28773-05

3/8 15/32 5/64 SAE AS28778-6 MS28773-06

1/2 21/32 3/32 SAE AS28778-8 MS28773-08

5/8 3/4 3/32 SAE AS28778-10 MS28773-10

3/4 15/16 1/8 SAE AS28778-12 MS28773-12

1-1/4 1-15/32 1/8 SAE AS28778-20 MS28773-20

1-1/2 1-23/32 1/8 SAE AS28778-24 MS28773-24

Notes: 1. MS28778 replaces AN6290. Use corresponding dash number to obtain part number.

2. Industry specification, SAE AS28778, replaces military specification, MS28778.

3. MS28773 Teflon backup ring used with SAE AS28778 (formerly MS28778) preformed
packings have corresponding dash numbers. EXAMPLE: Use MS28773-05 Teflon ring with
MS28778-5 packing and AN6289-5 nut.

4. MS28773 replaces MS9058 and MS9484.

5. All dimensions are measured in inches.

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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identification, and cure date. There are no exceptions


to this requirement.

f. Contamination by fluids leaking from parts


stored above and adjacent to preformed packing
surfaces.

g. Contamination caused by adhesive tapes


applied directly to preformed packings surfaces. A
torn package shall be secured with a pressure-
sensitive, moisture-proof tape, but the tape must not
contact the preformed packing surfaces.

h. Retention of overage parts caused by


improper storage or illegible identification. Preformed
packings shall be arranged so the older seals are
used first. Overage or nonidentifiable packings shall
be discarded.
015011
Figure 11. O-Ring Package Identification 22. The manufacturer’s cure date is one of the most
important printed items listed on the package shown
21. PREFORMED PACKING STORAGE. Proper in Figure 11. This cure date is denoted in quarters.
storage practices must be observed to prevent For example, the cure date 2Q77 indicates that the
deformation and deterioration of rubber preformed preformed packing was manufactured during the
packings. Most synthetic rubbers are not damaged by second quarter of 1977. Synthetic rubber parts
several years of storage when kept in the original manufactured during any given quarter are not
unopened package and out of direct sunlight. considered one quarter old until the end of the
However, most synthetic rubbers deteriorate when succeeding quarter. Preformed packing shelf life is
exposed to heat, light, oil, grease, fuels, solvents, computed from the cure date. The term cure date is
thinners, moisture, strong drafts, or ozone (form of used in conjunction with the replacement kits which
oxygen formed by an electrical discharge). Damage contain preformed packings, parts, and hardware for
by exposure is magnified when rubber is under repair of components. The age of preformed packings
tension, compression, or stress. There are several in a spare part is determined from the assembly date
conditions to be avoided: recorded on the service or identification plate and/or
on the exterior of the assembly. Refer to MIL-HDBK-
695 for shelf life of preformed packings.
a. Deformation as a result of improper stacking
of parts and storage containers.
NOTE
b. Creasing caused by force applied to corners
and edges, and by squeezing between boxes and Be sure to always check the shelf life and
storage containers. never install an O-ring that is past its shelf
life.
c. Compression and flattening, as a result of
storage under heavy parts.
23. PREFORMED PACKING REMOVAL AND
INSTALLATION. Successful operation of a hydraulic
d. Punctures caused by staples used to attach
system and the units within depends greatly upon the
identification.
methods and procedures used in handling and
installing hydraulic packings. These packings are
e. Deformation and contamination due to comparatively soft and must not be subjected to
hanging the preformed packings from nails or pegs. nicks, scratches, or dents. They must be kept free of
Preformed packings shall be kept in their original dirt and foreign matter and should not be exposed to
envelopes, which provide preservation, protection,
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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.

25. When removing or installing O-rings, avoid using


pointed or sharp-edged tools which might scratch or Hydraulic Fluid, MIL-PRF-83282 2
mar hydraulic component surfaces or cause damage
to the O-rings. Contact of the seal removal and
installation tools with cylinder walls, piston heads, and
related precision components is not desirable.
Hydraulic Fluid, MIL-H-81019 3
26. Figure 13, View A shows how the hook type
removal tool is positioned under the O-ring and then
lifted to allow the extractor tool, as well as the
removal tool, to pull the O-ring from its cavity. View B
shows the use of another type of extractor tool in the Hydraulic Fluid, MIL-PRF-87257 4
removal of internally installed O-rings.

27. Figure 13, View C illustrates how the extractor


tool is positioned under both O-rings at the same
time. This method of manipulating the tool positions
both O-rings, with minimum effort. View D shows Hydraulic Fluid, SAE AS1241 5
practically the same removal as View C except for the
use of a different type of extractor tool.

28. Removal of external O-rings is less difficult than


removal of internally installed O-rings. Figure 13, Do not use petrolatum to lubricate O-rings
View E and F illustrate two accepted removal or the insides of hydraulic components.
methods. View E shows the use of a spoon type
extractor, which is positioned under the seal. After the Do not use adhesive tape as an aid to
O-ring is dislodged from its cavity, the spoon is held installation of O-rings. Gummy substances
stationary while simultaneously rotating and left by adhesives are extremely
withdrawing the piston. View F installation is similar to detrimental to hydraulic systems.
View E, except only one O-ring is installed and a
different type extractor tool is used. The wedge type
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Page 16

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.
NAVAIR 01-1A-17 015 00
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Page 19

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.

42. When Teflon spiral rings are being installed in


external grooves, the ring should have a left-hand
During installation of scarf backup rings, spiral. As the ring is inserted into the groove, rotate
ensure gap overlap conforms to MS28774. the component in a clockwise direction. This action
will tend to contract the ring diameter and reduce the
possibility of damage to the ring.
41. When Teflon spiral rings are being installed in
internal grooves, the ring must have a right-hand
NAVAIR 01-1A-17 015 00
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Page 20

015014
Figure 14. O-Ring Installation
NAVAIR 01-1A-17 015 00
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Page 21

015015
Figure 15. Backup Ring Configuration

RIGHT WRONG

015016
Figure 16. Location of Single Backup Ring
NAVAIR 01-1A-17 015 00
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Page 22

015017
Figure 17. Teflon Backup Ring Installation - External
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Page 23

015018
Figure 18. Teflon Backup Ring - Damages Caused by Improper Handling
NAVAIR 01-1A-17 015 00
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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

ORGANIZATIONAL, INTERMEDIATE AND


DEPOT MAINTENANCE

PHOSPHATE ESTER HYDRAULIC FLUID

HYDRAULIC SYSTEMS

Reference Material

Cleanliness Requirements of Parts Used in Hydraulic Systems ................................ NAS 1638


Contamination Classification for Hydraulic Fluids ........................................................ SAE AS4059

Alphabetical Index

Subject Page No.

Introduction..................................................................................................................................... 2
Phosphate Ester Fluids and Component Storage.......................................................................... 3
Component Storage ................................................................................................................... 3
Phosphate Ester Fluid Storage .................................................................................................. 3
Using Phosphate Ester Fluid.......................................................................................................... 2
Handling ..................................................................................................................................... 2
Safety Precautions ..................................................................................................................... 2
Phosphate Ester Fluid System Surveillance .................................................................................. 3
Hydraulic Contamination Analysis ............................................................................................. 3

Record of Applicable Technical Directives

None
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Page 2

1. INTRODUCTION. 4. HANDLING. Phosphate ester fluids should be


handled with extreme care. However, care should be
2. Skydrol LD-4, Skydrol 500B-4 and Hyjet IV-A are taken to avoid spilling phosphate ester fluids on
trade names for phosphate ester fluids SAE AS 1241 certain paints and plastic materials, since this fluid
(WP002 00, Table 3, Item 5) that are qualified for use may cause them to soften. Refer to Tables 1 and 2 for
in military aircraft. Phosphate ester fluids are clear, a list of materials which phosphate ester fluids affect,
light purple, fire-resistant hydraulic fluids having a and those which are resistant to it. If a small amount
viscosity of approximately 500 centistokes at -40°F of phosphate ester fluid is spilled during handling, it
(-40°C). should be wiped up immediately with a dry cloth,
disposable paper towel, or an oil absorbent pad.

5. Tools having painted areas or vinyl chloride


plastic handles should not be allowed to soak in
phosphate ester fluids. Many nonmetallic materials
Do not store phosphate ester fluid near are resistant to phosphate ester fluids and will not be
hydraulic fluids MIL-PRF-5606, MIL-PRF- adversely affected; others are not resistant and will
87257 or MIL-PRF-83282. Do not use soften slowly. Since it is difficult to distinguish visually
packings, seals, or gaskets designed for between materials that are resistant and those that
use in MIL-PRF-5606, MIL-PRF-87257 or are not, all materials wetted with phosphate ester
MIL-PRF-83282 hydraulic systems in fluids must be wiped clean as soon as possible after
phosphate ester fluid systems. Do not coming in contact with the fluid.
mix phosphate ester fluids with any other
type of hydraulic fluid.
6. SAFETY PRECAUTIONS. Phosphate ester fluids
are slightly toxic. Applicable Material Safety Data
Sheets (MSDS) shall be reviewed prior to usage.
3. USING PHOSPHATE ESTER FLUID.

7. Phosphate ester fluids (WP002 00, Table 3, Item


5) cause pain when in contact with eye tissue. First
aid treatment includes flushing the eye with clear
Hydraulic Fluid SAE AS1241 5 water, and shall be followed by prompt medical
attention.

8. Phosphate ester fluids are severely irritating to


the skin and should be washed off immediately upon
contact.

If hydraulic fluid is decomposed by heat, 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.

11. Phosphate ester fluids can remove protective


paint or lacquer finishes.
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Change 2 – 1 August 2014 Page 3

Table 1. Materials Affected by Phosphate Ester Fluid

MATERIALS EFFECT

Acrylics swells and softens

Cellulose Butyrate plasticizes

Cellulose Nitrate plasticizes

Hypalon swells and softens

Polystyrene dissolves

Polyvinyl Chloride (PVC) plasticizes

Viton swells and softens

Vulcaprene swells and softens

Vulcollan swells and softens

12. PHOSPHATE ESTER FLUIDS AND 15. PHOSPHATE ESTER FLUID SYSTEM
COMPONENT STORAGE. SURVEILLANCE.

NOTE

Navy aircraft (TC-4C and C-20D) utilizing


phosphate ester fluids are contractor
Do not store phosphate ester fluids near maintained in accordance with FAA
petroleum or synthetic based fluids due requirements. Therefore, those affected
to the possibility of inadvertent mixing. aircraft are exempt from NAVAIR fluid
surveillance requirements. The following
information is provided to enable use of
Contamination Analysis Kit 57L414 for
13. PHOSPHATE ESTER FLUID STORAGE. Store
diagnostic purposes only.
phosphate ester fluids (WP002 00, Table 3, Item 5)
fluids in a dry, clean, indoor area if possible. These
fluids must be stored, handled, and serviced with
16. The methods and procedures used to process
great care to ensure maximum cleanliness at all
and analyze phosphate ester fluid samples are the
stages from container to aircraft hydraulic system.
same as for hydraulic fluids MIL-PRF-83282 (WP002
Phosphate ester fluids shall be stored in the original
00, Table 3, Item 2) except as outlined below.
containers. These fluids will not freeze and generally
may be handled like any high-grade petroleum fluids.
17. HYDRAULIC CONTAMINATION ANALYSIS.
Shelf life is five years.
18. Patch Testing (NAVY USE ONLY). A modified
14. COMPONENT STORAGE. Components in or reconfigured contamination analysis kit is not
storage that are used in phosphate ester fluid available for processing phosphate ester fluid
systems shall be issued and installed within six samples. The parts required for processing
months, if possible. Components filled with phosphate phosphate ester fluid samples are procured
ester fluid and placed in storage should be drained separately and from various companies. These parts
and refilled after one year. Components shall be may or may not have national stock numbers.
capped with approved metal closures (refer to WP014 Therefore, direct procurement of parts from the
00) at all times and stored in polyethylene bags. company is necessary.
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Page 4

Table 2. Materials Resistant to Phosphate Ester Fluid

MATERIALS DEGREE OF RESISTANCE

Acetal (Delrin or Celcon) Excellent

Cellulose Triacetate Good

Chlorinated Polyether Excellent

Ethylene Propylene Excellent

Fluorisant Excellent

Fluorinated Ethylene Excellent

Formvar Excellent

Polyamide Excellent

Polyethylene Excellent

Polyvinyl Alcohol (PVA) Excellent

Polyisobutylene Excellent

Teflon Excellent

Teflon FEP Excellent

Phenolic Laminates Generally unaffected

Alkyds (Dialkyl Phthalate only) Good

Melamine Formaldehyde Excellent

Phenol Formaldehyde (phenolics, Micarta, Excellent


Formica, etc.)

Polyester (Mylar, Dacroneta) Excellent


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Change 2 – 1 August 2014 Page 5

b. Process phosphate ester samples by


following the procedures in accordance with WP017
00, except that washing the filter membrane with an
Hydraulic Fluid SAE AS1241 5 additional 50 to 70 milliliters of cleaning solvent MIL-
PRF-680 (WP002 00, Table 3, Item 6) is required
after all fluid has passed through it.

Dry Cleaning Solvent, MIL-PRF-680 6

Do not place a wet filter membrane in a


petri slide. Do not allow phosphate ester
fluids to come into contact with the petri
slides, they will turn milky white and will
have to be discarded.
Use polyethylene, sample bottles with
polypropylene screw closures (WP002
00, Table 3, Item 18A), polypropylene c. Allow the filter membrane to dry completely
sample bottles (WP002 00, Table 3, Item
before performing contamination analysis.
18B) or glass sample bottles (refer to
WP002 00) for phosphate ester fluid
samples. The polyvinyl chloride sample d. Immediately after processing phosphate ester
bottles furnished with the Contamination fluid samples, rinse all components contacting
Analysis Kit 57L414 are not compatible phosphate ester fluid with a generous amount of
with phosphate ester fluid. cleaning solvent, MIL-PRF-680, (WP002 00, Table 3,
Item 6) and wipe dry with an ultra-clean, lint-free,
disposable wiping cloth (WP002 00, Table 3, Item
NOTE 13A).

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.

a. Thoroughly rinse all components used for


processing fluid samples with cleaning solvent MIL-
PRF-680 (WP002 00, Table 3, Item 6). Refer to
WP017 00 for Contamination Analysis Kit 57L414
parts breakdown. Ensure all traces of previously
processed fluid samples are removed from all
components which have come into contact with the
fluid.
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Change 2 – 1 August 2014 Page 6

NOTE

NAS 1638 has been superseded by SAE


AS 4059. No conversion is required for
the contamination classifications. For
example, SAE AS4059 Class 6 is the
same as NAS 1638 Class 6.

20. SAE AS4059 Cleanliness Standard (Formerly


NAS 1638). Some aircraft systems use NAS 1638
(superseded by SAE AS4059) as the fluid cleanliness
standard for determining the degree of particulate
contamination class of hydraulic fluid, i.e. C-40, P-8,
C-9, etc. These aircraft systems should be operated
at Class 8 or better. The support equipment for these
Navy systems should deliver fluid at Class 6 or better.
For USAF cleanliness standards refer to the
applicable aircraft maintenance manuals.
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15 August 2006 Page 1 of 16

ORGANIZATIONAL, INTERMEDIATE AND


DEPOT MAINTENANCE

HYDRAULIC FLUID CONTAMINATION ANALYSIS KIT (P/N 57L414)

HYDRAULIC SYSTEMS

NAVY USE ONLY

Reference Material

None

Alphabetical Index

Subject Page No.

Cleanliness ..................................................................................................................................... 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

Record of Applicable Technical Directives

None
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1. INTRODUCTION. 9. SAMPLES BOTTLES. Twenty-four, 120-ml


capacity, bottles (Figure 14, Index No. 13), are used
2. During normal operation, hydraulic systems to collect fluid samples.
become contaminated with metallic and nonmetallic
particles. Particulate contamination may result from
internal wear or failure of system components, or
incorrect maintenance and servicing operations. The
procedures herein provide a method of determining
the particulate level in a hydraulic system and the
presence of free water or other foreign substances.

3. This work package describes the fluid


contamination analysis kit and how it is used to
evaluate contamination levels in Naval aircraft
hydraulic systems and support equipment (SE). The
equipment employs a patch test method in which a
fluid sample of known volume is filtered through a test
filter membrane of known porosity. All particulate
matter in excess of a size determined by the filter
characteristics is retained on the surface of the
membrane, causing it to discolor an amount
proportional to the particulate level of the fluid
sample.
017001
4. The typical color of contamination in any given
system remains fairly uniform and the degree of filter
Figure 1: Hydraulic Fluid Contamination Analysis Kit
membrane discoloration may be correlated with a
level of particulate contamination. By visually
comparing the test filter with Contamination 10. GRADUATED CYLINDER. The graduated
Standards representative of known contamination cylinder (Figure 14, Index No. 14), having a capacity
levels, a judgment can be made as to the of 100-ml marked in increments, is used to measure
contaminant level of the system sampled. Free water the volume of sample fluid to be filtered.
will be seen either as droplets during the fluid sample
processing or as a stain on the test filter. 11. FILTER MOUNTS. Transparent Petri slides
(Figure 14, Index No. 16), with covers hold the 47-mm
5. DESCRIPTION test filters flat for examination and protect them from
additional contamination.
6. The kit contains components for collecting,
processing and analyzing fluid samples. Descriptions 12. FILTERS. Filters are of the cellulose ester
of kit parts are as follows (Figure 1). membrane type with a mean-pore size of 5-microns.
Discs of 47-mm diameter (Figure 14, Index No. 17),
7. FILTER HOLDER. To effect vacuum filtration of are used to filter fluid samples; Discs of 25-mm
a test sample; a filter assembly (Figure 14, Index No. diameter (Figure 14, Index No. 18), are used to filter
1) is used consisting of a 100-ml funnel, with highly solvent.
polished inner walls; a filter support; a locking ring;
and a 500-ml flask. The funnel and base attach to the 13. SYRINGE AND VALVE. The pump action of the
flask in a way that allows a vacuum to be drawn in the syringe and valve (Figure 14, Index No. 19) is used to
chamber beneath the filter. evacuate the 47-mm filter holder. On the down
stroke, air is drawn through the side port into the
8. WASH BOTTLES. Two polyethylene 500-ml barrel of the syringe. On the expel stroke, air is
bottles (Figure 14, Index No. 12), each fitted with a forced out through the end port.
dispensing tube and a spout, are used to dispense
solvent required in the sampling and analysis 14. STANDARD. The processed fluid samples are
procedures. One of the bottles is fitted for a filter compared to the standard (Figure 14, Index No. 22) to
holder that attaches to the spout and accepts a 25- determine the level of contamination in the system or
mm filter. component being analyzed.
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Change 2 – 1 August 2014 Page 3

Dry Cleaning Solvent, MIL-PRF-680 6

15. In addition to the analysis kit components, a


cleaning compound/solvent, lint-free wiping cloths,
and waste containers are needed to obtain and
analyze fluid samples. Dry cleaning solvent, MIL-
PRF-680 (WP002 00, Table 3, Item 6), is the only
chemical currently authorized for use in conducting
Hydraulic Fluid Contamination Analysis Test (patch
test).
017002
16. PREPARATION FOR USE.

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.

18. If the flush bottle is damaged, the wash bottle


may be modified by carefully cutting off the tip with a Dry Cleaning Solvent, MIL-PRF-680 6
sharp knife or razor blade so that the filter unit will fit.
The damaged bottle may be used for flushing of a. Remove cap from flush bottle and fill with dry
fittings and sampling points. cleaning solvent, MIL-PRF-680 (WP002 00, Table 3,
Item 6).
19. FILTER HOLDER.
b. Replace cap and ensure filter unit is in place,
a. The Swinnex filter holder (Figure 14, Index close hole in cap with finger, and squeeze bottle to
No. 11) consists of two threaded halves and an dispense filtered solvent.
internal support screen. With it disassembled, use
forceps (Figure 14, Index No. 15) to place a 25-mm NOTE
filter membrane (Figure 14, Index No. 18) onto the
exposed aided flat surface. Place the metal When using Swinnex filters, if air
perforated disc on top of the filter membrane to becomes trapped between filter and
provide support for both sides of the membrane. inside nozzle of flush bottle, flow will
Reassemble the parts, finger tight, and gently press stop. To eliminate airlock, remove filter
the filter holder assembly on the spout of the flush from outlet spout and purge air before
bottle having the shorter spout (Figure 2). filtering. If clogging persists, replace filter.

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.

22. SAMPLE BOTTLES. Clean the required number


NOTE of sample bottles prior to use by rinsing and flushing
with filtered solvent using the filtered solvent
Replace the 25-mm filter in the Swinnex dispenser.
filter holder when the fluid flow is reduced
to drips instead of a steady flow.
NAVAIR 01-1A-17 017 00
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Change 2 – 1 August 2014 Page 4

NOTE Careful attention to the detailed procedures given


below will assure that the effects of external
Bottles that are not absolutely clean may contaminants are minimized.
cause a hydraulic system to be rejected
needlessly.

a. Fill the bottle to be cleaned approximately


half full. Replace cap on opening, agitate the sample Hydraulic Fluid, MIL-PRF-5606 1
bottle several times, remove cap, and dump
contents. Repeat three or more times to remove
residual hydraulic fluid.

b. When the bottle is considered clean, flush Hydraulic Fluid, MIL-PRF-83282 2


external threads of the sample bottle and internal
threads of the bottle cap with filtered solvent from
dispenser. Replace cap on bottle.

23. OPERATIONAL PROCEDURES.


Hydraulic Fluid, MIL-H-81019 3
24. SAMPLE COLLECTION. It is essential that
samples taken from aircraft hydraulic systems and
SE be representative of the fluid in the system under
test. Aircraft samples should be taken immediately
after aircraft flight. If post flight samples cannot be
obtained the system shall be cycled in accordance Hydraulic Fluid, MIL-PRF-87257 4
with the applicable Maintenance Instruction Manual
(MIM) or Maintenance Requirement Cards (MRC),
before drawing a sample. Before sampling SE
hydraulic systems, circulate the fluid for a minimum
of 5 minutes at full flow rate or for a proportionately
Hydraulic Fluid, SAE AS1241 5
longer time at a lower flow rate. For SE with a
capacity of 3 gallons or less, a 5 minute recirculation
period is not required. However, to ensure a
representative sample is pulled, perform 5-6 pump
strokes on the equipment prior to sampling.
Dry Cleaning Solvent, MIL-PRF-680 6
25. Naval Aviation Hydraulics Fluids Contamination
Standards applies to the following fluids: NOTE

MIL-PRF-5606 Hydraulic fluid sampling points for most


Naval aircraft are designated in the
MIL-H-81019 applicable MIM. Refer to WP005 00 for
general information concerning selection
MIL-PRF-83282 of sampling points in those instances
where none are specified.
MIL-PRF-87257

SAE AS1241 a. Remove dirt and other external contaminants


from the sampling point by wiping with clean
26. Accurate determination of hydraulic contaminant disposable wiping cloths (WP002 00, Table 3, Item
levels requires proper sampling techniques using 14).
equipment and materials that are known to be clean.
Any foreign matter contaminants in the sample fluid
or testing equipment will cause erroneous results.
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NOTE 30. Fluid samples that are hazy or pink in


appearance indicate the presence of water. Another
Sampling points and bottles that have not identical sample bottle filled with a standard of
been adequately cleaned prior to use unused fluid can be used for comparison. If water is
may produce erroneous test results and observed, take another sample from the system to
needless rejection of the system under verify the indication and initiate corrective
test. maintenance.

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.

27. Aircraft filter assemblies are sampled by


removing the filter bowl and transferring the fluid
contents of both the bowl and the element to a clean
sample bottle. The contents of fluid obtained will
vary with the type of filter assembly. Do not use filter
bowl samples for patch testing. Filter bowl samples
are used to determine types of contaminants.

28. CONTAMINATION ANALYSIS PROCEDURES

29. SAMPLE PROCESSING. Prior to sample


processing, the fluid under test should be carefully 017003

examined for possible free water. Water can be


recognized in hydraulic fluid sample from the Figure 3: Disengaging Filter Holder from Flask
formation of droplets usually settling at the bottom of
the fluid sample bottle. Allow the fluid sample to b. Connect tube and adapter to the vacuum port
remain motionless for 10 minutes or longer to on syringe to the filter holder assembly base (Figure
facilitate the formation of visible water droplets. 4). Note that the tube and adapter are normally left
connected to the syringe but may be removed for
cleaning or replacement.
NAVAIR 01-1A-17 017 00
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Change 2 – 1 August 2014 Page 6

d. Remove funnel from the filter holder assembly


by rotating the outer knurled ring counterclockwise
until disengaged and lift upward. Using forceps,
carefully remove a single 47-mm filter membrane
(Figure 14, Index No. 17) from its package and place
it on top of the wire mesh filter support screen on the
filter holder assembly (Figure 6). Insure that the
blue separator discs are not installed with the filter
membrane.

e. Place support screen gasket (Figure 14, Index


No. 7) between the test filter membrane and the
stainless steel funnel.

017004

Figure 4: Attaching Syringe to Filter Holder


NOTE

Rapid evaporation of the filtered solvent


may result in the condensation of
atmospheric moisture on the funnel
surface. This can cause inaccurate
indications of free water in the sample
under test. Carefully inspect for
condensation on the funnel surface. If
017006
condensation is present, move
equipment to an air-conditioned
workspace. Figure 6: Installing Test Filter and Support
Screen Gasket

c. Using the filtered solvent dispenser, wash


NOTE
down the inside wall of the stainless steel funnel
(Figure 5) to flush away any surface contamination
Packaged filter membranes are
present. Ensure funnel screen is also clean with
filtered solvent. separated by blue discs. Remove
separators before installing filter
membrane in equipment.

f. Install funnel on the filter holder assembly and


secure by rotating the outer knurled ring clockwise
until fully seated (Figure 7).

g. Using filtered solvent, repeatedly rinse the


inside of the graduated cylinder to remove all
possible contaminants. Pour out residual solvent.
Measure out approximately 15 ml of filtered solvent,
using the cleaned graduated cylinder, and pour into
the stainless steel funnel to pre-wet the filter
membrane.

017005

Figure 5: Rinsing Inside Wall of Funnel


NAVAIR 01-1A-17 017 00
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Page 7

017007
017009
Figure 7: Reinstalling Filter Holder
Figure 9: Rinsing Out Graduated Cylinder
h. Shake the bottle of sample fluid to be
processed to distribute uniformly its particulate
content. Remove cap from the sample bottle and 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

Figure 8: Measuring Test Sample


Figure 10: Filtering Sample Fluid
i. Using the filtered solvent dispenser, wash
down the inside of the graduated cylinder with clean
solvent until it contains approximately 100 ml of fluid
(Figure 9).
NAVAIR 01-1A-17 017 00
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Page 8

k. Carefully observe the filtration process in the


funnel and note the decreasing fluid level. When the
fluid level drops to the narrow neck of the funnel,
pour the remaining contents of the graduated
cylinder into the funnel. Pour contents to wash down When dry cleaning solvent is used as the
the inside of the funnel, insuring that solvent is not filtered solvent, the test filter membrane
poured directly onto the filter membrane. must be dried thoroughly prior to placing
in Petri slide. Solvents fumes will craze
l. When filtration is complete, remove the funnel and cloud the Polystyrene Petri slides.
only and inspect the filter surface. If the central area
shows a pinkish color, indicating that the filter (4) Place test filter on an uncovered Petri
membrane still has a residue of hydraulic fluid, slide (Figure 12).
replace the funnel, and direct a stream of clean
solvent from the filtered solvent dispenser against
the walls of the funnel until fluid reaches to the top of
the tapered portion. Operate the syringe again to
initiate filtration, and allow all of this fluid to pass
through the filter.

NOTE

Free water, when presenting the fluid


sample, may be seen as droplets on the
surface of the test filter membrane
immediately after completion of filtration. 017012
If these droplets do not remain on the
filter for an extended period of time, Figure 12: Placing Filter in Petri Slide
immediate observation is essential.

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

Figure 11: Remove Test Filter and Support


Screen Gasket
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Change 2 – 1 August 2014 Page 9

36. Filter bowl patch residues should be evaluated


qualitatively based upon requirements of applicable
manuals and utilizing experience relative to normal
contaminates for specific aircraft systems and hours
of operation. Considerable experience is required to
adequately perform visual evaluation of filter bowl
residues. Experience has shown analysis of main
pressure line and case drain filter bowl residue to be
useful in verifying failure of the upstream in these
particular assemblies. Residue in other filter
assemblies is affected by so many other
017013 components and factors as to render their
interpretation difficult. Filter bowl residue should be
Figure 13: Comparing Test Filter Contamination analyzed only as a means of identifying or verifying
Standards suspected component failure. Such utilization shall
be limited to examination of residue from those filter
assemblies directly downstream of the component.
NOTE
Test Patches that show a residual pink 37. CLEANLINESS
color may be the result of failure to have
washed the filter adequately. Some new 38. The accurate determination of hydraulic
hydraulic fluids will also exhibit a residual contaminant levels requires proper sampling
pink background as shown by example in techniques and the use of equipment and materials
the contamination methods. that are known to be clean. Any foreign matter which
is allowed to contaminate the sample fluid or testing
33. The maximum acceptable particulate level for equipment will cause erroneous results. Careful
Naval aircraft is Navy Standard Class 5, and for attention to the detailed procedures herein will
related SE is Navy Standard Class 3. assure that the effects of external contaminants are
minimized.
34. Visible free water present in either the sample
bottle or on the surface of the test patch (at 39. KIT COMPONENT MAINTENANCE
completion of filtration) is cause for rejection of the
system under test. A stain on the test filter a. The filter holder has two Teflon lock wheels
membrane may be an indication of the presence of which help provide the sealing action required to
free water. When a stain is seen on the test patch, a maintain a vacuum. After extensive use flats occur
second fluid sample from the system under test on the bottom side of the lock wheels, which may
should be obtained and processed so that water result in poor sealing.
content can be confirmed prior to system rejection.
Ensure that observed water is not a result of b. The syringe and valve assembly should be
atmospheric condensation during the sampling cleaned at regular intervals by flushing with cleaning
process. solvent. The O-ring seal on the syringe plunger
should be lubricated with a thin film of hydraulic fluid.
35. Should the system under test fail to meet the
Navy Standard, Class 5 particulate requirement or c. Additional or spare parts for the Hydraulic
should it exhibit free water, the system must be Fluid Contamination Analysis Kit can be open
decontaminated in accordance with procedures purchased directly from the applicable part vendor.
provided in the applicable MIM. Vendor codes can be found in Figure 14 (Sheet 5 of
5) following the item description.
NOTE

If the result is inconclusive or if a 40. ILLUSTRATED PARTS BREAKDOWN.


shadowy effect occurs due to incidence
of light on the Petri slide, remove patch
from Petri slide for comparison with
Contamination Standards.
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Change 2 – 1 August 2014 Page 10

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.

45. DESCRIPTION. This column lists the item


nomenclature plus those modifiers necessary to
identify the item. The assemblies, subassemblies,
detail parts and attaching parts are properly
identified (named or indented) to show their
relationship to the assembly. Attaching parts are
listed immediately after the part they are attached to
and preceding any details of the assembly. The
caption/ATTACHING PARTS/ appears in the
description column preceding the attaching parts
and the symbol -*- is used to indicate the end of the
attaching parts for that part or assembly.

46. VENDOR CODES. Vendor code numbers are


listed in // following the nomenclature of the part.
This code is in accordance with cataloging
handbook H4/H8, Commercial and Government
Entity (CAGE) codes. If a code has not been
assigned, the vendors complete name and address
will appear. Manufacturer's codes are not listed for
government standard parts.

47. MAKE FROM. From for those simple items (i.e.,


hoses, lines, tubes, brackets, cables, etc.) coded for
local manufacture, the material from which the item
is manufactured will be included in // after the item
nomenclature or vendor code number.

48. UNITS PER ASSEMBLY. This column will list


the total number of each part required per assembly
or subassembly and are not necessarily the total
number used in the end item of equipment. The
abbreviation AR (As Required) is used to identify
NAVAIR 01-1A-17 017 00
TO 42B2-1-12
Page 11

Table 1: Source, Maintenance, and Recoverability Codes

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

SPECIAL HANDLING FOR DISPOSAL


A
(CONSUMABLE APPLICATION)

O REPAIRABLE ITEM. CONDEMN AT ORG. LEVEL

H AFLOAT REPAIRABLE ITEM,


F ASHORE CONDEMN AT IMA LEVEL
G BOTH
REPAIRABLE ITEM,
S (L)
CONDEMN AT SPECIALIZED IMA

D REPAIR AT DEPOT OR COMMERCIAL


NAVAIR 01-1A-17 017 00
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Change 2 – 1 August 2014 Page 12

017014

Figure 14: Hydraulic Fluid Contamination Kit (Sheet 1 of 5)


NAVAIR 01-1A-17 017 00
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Change 2 – 1 August 2014 Page 13

017014

Figure 14: Hydraulic Fluid Contamination Kit (Sheet 2 of 5)


NAVAIR 01-1A-17 017 00
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Change 2 – 1 August 2014 Page 14

017014

Figure 14: Hydraulic Fluid Contamination Kit (Sheet 3 of 5)


NAVAIR 01-1A-17 017 00
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Change 2 – 1 August 2014 Page 15

Exploded Diagram of Vacuum Syringe (Figure 14, Index No. 19)


017014

Figure 14: Hydraulic Fluid Contamination Kit (Sheet 4 of 5)


NAVAIR 01-1A-17 017 00
TO 42B2-1-12
Change 2 – 1 August 2014 Page 16

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

9 XX6300129 . . FLASK, VACUUM, STAINLESS STEEL /08071/ 1 PAOZZ


10 XX2004701 . . RING, FUNNEL, LOCKING/08071/ 1 XBOZZ
11 XX6504707 . HOLDER, SWINNEX FILTER /08071/ 1 PAOZZ
12 XX6504704 . BOTTLE, WASH (500-ml) /08071/ 1 PAOZZ
13 XX6504709 . BOTTLE, SAMPLE, PLASTIC (120-ml) /08071/ 1 PAOZZ
14 08-572D . CYLINDER, GRADUATED (100-ml) /22527/ 1 22527
15 XX6200006 . FORCEPS, STAINLESS STEEL /08071/ 1 PAOZZ
16 PD1504700 . SLIDES, PETRI /08071/ 1 PAOZZ
17 SMWP04700 . FILTER, TEST MEMBRANES (47-mm) /08071/ 4 PAOZZ
18 SMWP02500 . FILTER, SOLVENT MEMBRANES (25-mm) /08071) 1 PAOZZ
19 XX6200035 . SYRINGE, VACUUM/08071 KIT AVAIL 1 PAOZZ
. . SEE FIGURE 14 (SHEET 4 OF 5) FOR
EXPLODED DIAGRAM OF VACUUM SYRINGE
20 XX6504710 . . TUBE AND ADAPTER WITH CLAMPS /08071/ 1 PAOZZ
21 2-006 . . VALVE O-RING, BUNA-N /02697/ 1 PAOZZ
22 XX6504713 . STANDARDS, CONTAMINATION /08071/ 1 PAOZZ
23 3074 . TOP INSERT /08071/ 1 PAOZZ
24 3075 . BOTTOM INSERT /08071/ 1 PAOZZ
25 3076 . SYRINGE HOLDER INSERT/08071/ 1 PAOZZ
26 XX6504712 . KIT, PARTS CONTAMINATION /08071/ 1 PAOZZ
XX6200036 . . KIT, PARTS VACUUM SYRINGE/08071 1 PAOZZ
XX6300123 . . BASE O-RING BUNA-N /08071/ 2 PAOZZ
XX6504704 . . BOTTLE, WASH (500-ml) /08071/ 2 PAOZZ
XX6504709 . . BOTTLE, SAMPLE PLASTIC (120-ml) /08071/ 24 PAOZZ
. . CYLINDER, GRADUATED /08071 1 PAOZZ
27 XX6200036 . . KIT, PARTS VACUUM SYRINGE /08071/ 1 PAOZZ
. . . PLUNGER O-RING, BUNA-N /02697/ 1 PAOZZ
. . . VALVE O-RING, BUNA-N /02697/ 2 PAOZZ
. . . BALL, VALVE STAINLESS STEEL 2
. . . SPRING, BARREL COMPRESSION VALVE 2
. . . GASKET, VALVE, TEFLON 2
. . . SPRING COMPRESSION VALVE 2
017014

Figure 14: Hydraulic Fluid Contamination Kit (Sheet 5 of 5)

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