NAVAIR 01-1A-17.pdf - Navy BMR material/NAVAIR 01-1A-17.pdf · (navy) navair 01-1a-17 (air force) to 42b2-1-12 15 august 2006 technical manual organizational, intermediate and depot

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

TECHNICAL MANUAL

ORGANIZATIONAL, INTERMEDIATE AND DEPOT MAINTENANCE

AVIATION HYDRAULICS MANUAL

N68936-04-D-0008

This publication supersedes NAVAIR 01-1A-17 dated 1 June 2002 and NAVAIR 17-15E-52 dated 1 April 2000.

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

PUBLISHED BY DIRECTION OF THE COMMANDER, NAVAL AIR SYSTEMS COMMAND

0801LP1060942

NAVAIR 01-1A-17 TO 42B2-1-12 15 August 2006 Page A

NUMERICAL INDEX OF EFFECTIVE WORK PACKAGES/PAGES

List of Current Changes

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

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 Dispose of superseded work packages/pages. Superseded classified work packages/pages shall be destroyed in accordance with applicable security regulations.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

Title Page A Numerical Index of Effective Work

Packages/Pages TPDR-1 List of Technical Publications

Deficiency Reports Incorporated HMWS-1 Warnings Applicable to Hazardous

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

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

Analysis

WP Number Title

WP Number Title

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

Materials 013 00 Repair, Test, and Maintenance of

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

Analysis Kit (P/N 57L414)

Total number of pages in this manual is 194, consisting of the following:

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

Title ............................................ 0 A................................................. 0 TPDR-1TPDR-2...................... 0 HMWS-1 HMWS-6.................. 0 001 00

1 ............................................. 0 2 Blank................................... 0

002 00 1 26..................................... 0

003 00 1 6....................................... 0

004 00 1 7....................................... 0 8 Blank................................... 0

005 00 1-10 ........................................ 0

006 00

1 11..................................... 0 12 Blank................................. 0

007 00 1 5....................................... 0 6 Blank................................... 0

008 00 1 3....................................... 0 4 Blank................................... 0

009 00 1 24..................................... 0

010 00 1 8....................................... 0

011 00 1 8....................................... 0

012 00 1 7....................................... 0 8 Blank................................... 0

013 00 1 12..................................... 0

014 00 1 12..................................... 0

015 00 1 24..................................... 0

016 00 1 5....................................... 0 6 Blank................................... 0

017 00 1-15........................................ 0 16 Blank ................................ 0

NAVAIR 01-1A-17

16 AUGUST 2006

PREVIOUSLY RELEASED TITLE PAGE CONTAINED INCORRECT SUPERSEDURE NOTICE. REMOVE TITLE PAGE AND A PAGE DATED 15 AUGUST 2006 AND REPLACE WITH ATTACHED PAGES. REMOVE PRINTED COPY OF IRAC 9 DISTRIBUTED WITH THE INITIAL REVISION DATED 15 AUGUST 2006.

NAVAIR 01-1A-17 TO 42B2-1-12 15 August 2006 TPDR-1


LIST OF TECHNICAL PUBLICATIONS DEFICIENCY REPORTS INCORPORATED

AVIATION HYRDRAULICS MANUAL

NAVY USE ONLY

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

IDENTIFICATION NUMBER/ QA SEQUENCE NUMBER LOCATION*

08981-02-0087, VR-52

09209-99-0006, HELANTISUBRON-14 WP009 00

09257-04-0011, VMFA (AW) 121 HMWS

09432-05-0010, VMGR-252 WP014 00

09465-02-0029, VAW-116 WP017 00 F14 (Sheet 4)

09465-05-0001, VAW-116 WP009 00

09496-01-0001, 0104273 Lucky Red Lions WP017 00 F14 (Sheet 4)

09935-04-0063, VMX-22 WP009 00

09995-04-0030, VAQ-129 WP017 00 F14 (Sheet 4)

21560-04-0003, USS WASP (LHD-1) WP017 00

30328-03-0309, NATEC Detachment Oceana WP004 00

30332-04-0031, NATEC Detachment North Island WP009 00

30332-04-0032, NATEC Detachment North Island WP005 00

30340-03-1006, NATEC Detachment Jacksonville WP015 00




39782-97-0073, CO Hanger 301 Suite 202 WP017 00

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

39784-05-0082, HX-21 WP017 00

44314-06-0010, AIMD Brunswick WP004 00

44329-02-0066, CVWP DET AIMD HMWS, WP017 00

57025-98-0061, COMNAVAIRPAC WP017 00 F14 (Sheet 4)

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

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

WARNINGS APPLICABLE TO HAZARDOUS MATERIALS

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

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

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

EXPLANATION OF HAZARDOUS SYMBOLS

Biological

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

Chemical

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

Cryogenic

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

Explosion

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

Eye Protection

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

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

EXPLANATION OF HAZARDOUS SYMBOLS (Cont)

Fire

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

Poison

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

Radiation

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

Vapor

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


HAZARDOUS MATERIALS WARNINGS

Index Material Warning

1 Hydraulic Fluid, MIL-PRF-5606

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



3 Hydraulic Fluid, MIL-H-81019



HAZARDOUS MATERIALS WARNINGS (Cont)




5 Hydraulic Fluid, SAE AS1241

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

6 Dry Cleaning Solvent, MIL-PRF-680

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




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

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

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

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

9 Isopropyl Alcohol, TT-I-735

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

10 Molydisulphide Grease, MIL-G-21164

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

11 General Purpose Aircraft Grease, MIL-PRF-81322

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




12 General Purpose Aircraft Grease, MIL-PRF-32014

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

13 Test Filter Patch Membrane SMWP04700 and SMWP02500

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

14 Dry Cleaning Solvent, A-A-59601

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

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


ALPHABETICAL INDEX


WP Title Number

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

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


INTRODUCTION


1. PURPOSE.

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

3. SCOPE.

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

5. APPLICATION.

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

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

NOTE

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

be followed as specified in WP008 00 thru WP010 00.

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

9. REQUISITION AND AUTOMATIC DISTRIBUTION OF NAVAIR TECHNICAL MANUALS.

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

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

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

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

13. MANUAL ISSUE DATE.

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

15. EFFECTIVITIES.

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

17. QUALITY ASSURANCE PROCEDURES.

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

19. SAFETY SUMMARY.

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

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

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

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

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

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

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

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

c. Have periodic checks on hearing ability.

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

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

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

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

WARNING

Extreme caution shall be taken when

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

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

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

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

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

29. WARNINGS, CAUTIONS, AND NOTES.

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

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

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

NOTE

Highlights an essential procedure to ensure correct maintenance.

31. ABBREVIATIONS.

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

33. GLOSSARY.

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

35. GRAPHIC SYMBOLS FOR FLUID POWER DIAGRAMS.

NOTE

Aircraft symbols may vary with different manufacturers.

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

37. CONSUMABLE MATERIALS.

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

39. RELATED PUBLICATIONS.

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

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

Table 1. Abbreviations

Abbreviation Definition

ADRL Automatic Distribution Requirements List

AFPET Air Force Petroleum Office

AMMRL Aircraft Maintenance Material Readiness List

ASG Aircraft Sustainment Group

COMNAVAIRFORINST Commander Naval Air Forces Instruction

CSE Common Support Equipment

FST Fleet Support Team

gpm Gallons Per Minute

GSE Ground Support Equipment

IMA Intermediate Maintenance Activity

MIM Maintenance Instruction Manual

ml Milliliter

MRC Maintenance Requirement Cards

MSDS Material Safety Data Sheet

NADEP Naval Air Depot

NAMPSOP Naval Aviation Maintenance Program Standard Operating Procedures

NATEC Naval Air Technical Data and Engineering Service Command

NAVAIR Naval Air Systems Command

NAWCAD Naval Air Warfare Center, Aircraft Division

NOAP Naval Oil Analysis Program

OMA Organizational Maintenance Activity

OSH Occupational Safety and Health

QA Quality Assurance

PODS Portable Oil Diagnostic System

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

Table 1. Abbreviations (Cont)

PSE Peculiar Support Equipment

ppm Parts Per Million

SE Support Equipment

TLV Threshold Limit Values

TO Technical Order

TPDR Technical Publication Deficiency Report

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

Table 2. Glossary

Term Definition

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

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

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

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

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

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

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

Contamination Level A quantitative term specifying the degree of contamination.

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

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

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

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

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

Table 2. Glossary (Cont)

Term Definition

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

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

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

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

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

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

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

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

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

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

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

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


Term Definition

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

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

Humidity The amount or degree of moisture in the air.

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

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

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

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

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

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

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

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

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

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


Term Definition

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

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

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

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

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

Naval Air Warfare Center, Aircraft Division (NAWCAD)

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

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

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

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

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

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

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

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

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


Term Definition

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

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

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

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

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

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

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

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

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

NAVAIR 01-1A-17 002 00 TO 42B2-1-12 Page 11


Term Definition

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

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

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

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

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

Test Stands, Stationary Hydraulic

AF-Test Stand, Hydraulic Component

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

TFE A tetrafluoroethylene resin.

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

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

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

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

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

00200101

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

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

00200102

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

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

00200103


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

00200104


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

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

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

00200106


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

Table 3. Consumable Materials List

Item No. Nomenclature Specifications Intended Use

HYDRAULIC FLUIDS

1 Hydraulic Fluid, Aircraft, Missile, and Ordnance

MIL-PRF-5606 NATO No. H-515

Refer to WP003 00.

2 Hydraulic Fluid, Fire Resistant


Refer to WP003 00.

3 Hydraulic Fluid, Ultra-Low-Temperature

MIL-H-81019 Refer to WP003 00.

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


Refer to WP003 00.

5 Hydraulic Fluid, Phosphate Ester

SAE AS1241 Refer to WP016 00.

SOLVENTS

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

7 Dry Cleaning Solvent

NOT APPLICABLE TO NAVY

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

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

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

Calibration fluid for the HIAC particle counter.

LUBRICANTS

10 Grease, Molybdenum Disulfide, For Low and High Temperatures

MIL-G-21164 NATO No. G-353

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

11 Grease, Aircraft General Purpose Wide Temp. Range

MIL-PRF-81322 NATO No. G-395

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

* Manufacturers part number and CAGE Code.

NAVAIR 01-1A-17 002 00 TO 42B2-1-12 Page 19

Table 3. Consumable Materials List (Cont)


12 Grease, Aircraft General Purpose Wide Temp. Range

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

CLOTHS AND CLEANING PADS

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

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

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

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

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

Refer to WP012 00.

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

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

GLOVES

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

Protecting hands from cleaning compounds.

17A Glove, Poly-D, Disposable *35-125 (12036)

Glove, Nitrile, Disposable, Powder-free

Various Laboratory Supply Distributors

Handling Phosphate Ester fluids. 17B

CONTAINERS

18 Bottle, Prescription, Glass 8 ounce

A-A-50983 Sample bottles for testing solvents.

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

*2002-0004 (05178) NSN 6640-61-330-4902

19B Bottle, Polypropylene *02-893A (1JGK5)

Sample bottles for phosphate ester fluid.

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

*Manufacturers part number and CAGE Code.

NAVAIR 01-1A-17 002 00 TO 42B2-1-12 Page 20

Table 3. Consumable Materials List (Cont)


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

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

22 Bottle Caps, Electronic Particle Counter

P/N 240-480 NSN 5340-01-470-8709

Sample collection bottle caps for the HIAC sampling unit.

23 Electronic Particle Counter Safety Coated Bottle 250 ml capacity

P/N 219-457 NSN 5340-01-470-8720

Sample collection bottle caps for the HIAC hydraulic sampling unit.

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

GLC-09190 Sample collection bottles for the HACH Ultra Analytics, Hydraulic Particle Counter

25 Bottle, Screw Cap, 4 ounce capacity

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

Sample collection bottles for the Patch Test Kit.

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

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

CONTROLLED ENVIRONMENT WORK CENTER CLEANING MATERIALS

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

28 Sponge, Cellulose Commercially available Refer to WP011 00.

29 Squeegee Commercially available Refer to WP011 00.

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

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

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

*Manufacturers part number and CAGE Code.

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

Table 4. Related Publications

Publication Number Title

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

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

AFI 21-101 Aerospace Equipment Maintenance Management

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

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

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

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

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

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

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

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

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

AN929 Cap Assembly, Pressure Seal Flared Tube Fitting

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

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

COMNAVAIRFORINST 4790.2 Maintenance Program, Naval Aviation

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

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

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

Table 4. Related Publications (Cont)


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

MIL-DTL-32066 Gloves, Rubber, Industrial

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

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

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

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

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

MIL-HDBK-695 Rubber Products: Recommended Shelf Life

MIL-PRF-32014 Grease, Aircraft and Instrument

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

MIL-PRF-680 Dry Cleaning Solvent

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

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

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

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

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

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

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

MS28774 Retainer, Packing Backup, Single Turn Tetrafluoroethylene

MS9404 Plug, Machine Thread AMS5646, Preformed Packing

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



NAS 1638 Cleanliness Requirements of Parts Used in Hydraulic Systems

NAS817 Cap - Protective, Flared Fitting

NAS818 Plug-Protective, Flared Tube, Hose Assembly

NAS838 Plug - Protective, Flareless Tube End (Plastic)

NAS839 Cap - Beaded Hose Connection, Plastic, Protective

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

NAS842 Plugs, Protective, Flareless Tube End (Metal)

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

NAS847 Caps and Plugs, Protective, Dust and Moisture Seal

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

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

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

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

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

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

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

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

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

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



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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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



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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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



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

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

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

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

SAE AS1241 Fire Resistant Phosphate Ester Hydraulic Fluid for Aircraft

SAE AS1290 Graphic Symbols for Aircraft Hydraulic and Pneumatic Systems

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

SAE AS28778 Packing, Preformed, Straight Thread Tube Fitting

SAE AS21913 Plug, Flareless Tube

SAE AS4841 Fittings, 37 Degree Flared, Fluid Connection

SAE AS5168 Fitting, Plug, Tube End, Flared

SAE AS5169 Fitting, Port Plug and Bleeder

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

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

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

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

TT-I-735 Isopropyl Alcohol

UL 30 UL Standard for Metal Safety Cans



DESCRIPTION

HYDRAULIC SYSTEMS AND HYDRAULIC FLUIDS

Reference Material

None

Alphabetical Index

Subject Page No.

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

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

Record of Applicable Technical Directives

None

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

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

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

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

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

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

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

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

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

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

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

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

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

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

003001

Figure 1. Typical Fighter Hydraulic System

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

003002

Figure 2. Heavy Aircraft Hydraulic System

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

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

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

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

15. HYDRAULIC FLUIDS USED IN MILITARY AIRCRAFT.

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

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

Hydraulic Fluid, MIL-PRF-5606 1

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

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


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

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

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

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

Hydraulic Fluid, MIL-H-81019 3

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


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

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

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

Hydraulic Fluid, SAE AS 1241 5

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

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



HYDRAULIC FLUID CONTAMINATION

HYDRAULIC SYSTEMS

Reference Material

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

Alphabetical Index

Subject Page No.

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

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

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

Record of Applicable Technical Directives

None

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

1. INTRODUCTION.

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

3. SOURCES AND EFFECTS OF CONTAMINATION.

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

NOTE Hydrocarbon based fluids, MIL-PRF-

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

NAVAIR 01-1A-17 004 00 TO 42B2-1-12 Page 4

17. AIR CONTAMINATION. Hydraulic fluids are adversely affected by dissolved, entrained, or free air. Air may be introduced thro

Documents

NAVAIR 01-1A-17.pdf - Navy BMR material/NAVAIR 01-1A-17.pdf · (navy) navair 01-1a-17 (air force) to 42b2-1-12 15 august 2006 technical manual organizational, intermediate and depot