* TM 1-1500-204-23-2

TECHNICAL MANUAL
AVIATION UNIT MAINTENANCE (AVUM)
AND AVIATION INTERMEDIATE MAINTENANCE (AVIM) MANUAL
FOR
GENERAL AIRCRAFT MAINTENANCE
(PNEUDRAULICS MAINTENANCE AND PRACTICES)
VOLUME 2

DISTRIBUTION STATEMENT A: Approved for public release; distribution is unlimited.

* This manual together with TM 1-1500-204-23-1, TM 1-1500-204-23-3 through TM 1-1500-204-23-10, dated 31

July 1992, supersedes TM 55-1500-204-25/1, dated 6 April 1970, including all changes.

HEADQUARTERS, DEPARTMENT OF THE ARMY

31 JULY 1992
 TM 1-1500-204-23-2
PRECAUTIONARY DATA

Personnel performing instructions involving operations, procedures, and practices which are included or implied
in this technical manual shall observe the following instructions. Disregard of these warnings and precautionary
information can cause serious injury, death, or an aborted mission.

WARNINGS, CAUTIONS, and NOTES are means of attracting attention to essential or critical information in a man-
ual. Definitions are outlined as follows:

An operating or maintenance procedure, practice, condition, statement, etc., which if not strictly
observed, could result in injury to or death of personnel.

An operating or maintenance procedure, practice, condition, statement, etc., which if not strictly
observed, could result in damage to, or destruction of equipment or loss of mission effectiveness or
long term health hazards to personnel.

NOTE

An essential operating or maintenance procedure, condition, or statement, which must be high-

lighted.

USING SOLVENTS/PAINTS
Standard precautions such as fire prevention and adequate ventilation shall be exercised when using solvents or
applying primer and coating.
Wear gloves or gauntlets when handling solvents as solvents may cause skin disorders.
Follow the Permissible Exposure Limit (PEL) and use Personal Protective Equipment (PPE) as outlined in
NIOSH/OSHA Occupational Health Guidelines for Chemical Hazards.
Store in nonflammable storage cabinets when not in use.

HOT BRAKES
If it is necessary to approach a wheel with a hot brake, do so either from directly in front or directly behind the aircraft.

Change 4 a
TM 1-1500-204-23-2

GROUND SUPPORT EQUIPMENT

Always operate all equipment in accordance with the operator’s manual.
To prevent accidental falls, appropriate maintenance platforms/safety stands illustrated in appropriate workstand
manuals or any other approved locally procured/manufactured safety stands/restraint equipment will be used when
working (above 4 feet) on aircraft in a non-tactical environment.
Install safety lock when an adjustable-height maintenance platform is in use.
Ensure the air hose used with compressed air is safe for the pressure being handled.

FIRE EXTINGUISHERS
Monobromotrifluoromethane (CF Br) is highly volatile, but not easily detected by odor. Although nontoxic, CF3Br
3

shall be considered in the same class as other freons and carbon dioxide , i.e., capable of causing danger to person-
nel primarily by reduction of oxygen available for proper breathing. The liquid may cause frostbite or low temperature
burns if allowed to come in contact with the skin.
Bromochloromethane (CB) is a narcotic agent of moderate intensity, but of prolonged duration. It is considered less
toxic than carbon tetrachloride, methylbromide, or the usual products of combustion. Normal precautions should be
taken while using bromochloromethane , including the use of oxygen masks.

HYDRAULIC FLUID
To avoid contamination, do not use previously opened cans of hydraulic fluid. A new, sealed can of fluid must be
opened and used. When opening can, clean top and use a clean sharp, unplated instrument to prevent contamina-
tion.

COMPRESSED AIR
Compressed air shall not be used for cleaning purposes unless reduced to less than 30 psi and then only with
effective chip-guarding and personal protective equipment.

NOISE HAZARD
Noise levels reached during ground runup of Army aircraft are of a level that may cause permanent hearing loss.
Maintenance personnel shall wear adequate hearing protection when working on aircraft with engines in operation.

PROPER USE OF PLATED TOOLS

Use only chrome plated steel or unplated steel tools for disassembly or reassembly procedures described in this
manual. Use of cadmium or zinc plated tools is not permitted since these platings are prone to chipping and flaking.
Should these chips or flakes become embedded in aircraft parts, galvanic corrosion will result. Should these chips
or flakes enter fuel or oil wetted components, they may eventually clog the filter or produce intergranular attack of
nickel or titanium base alloys at elevated temperature. All tools regardless of type plating should be serviceable and
free of chipping.

b Change 4
 TM 1-1500-204-23-2

SPECIAL INSTRUCTIONS
All equipment must be operated per the manufacturer’s operating instructions. If unavailable, instructions for the
use and care will be developed. SOPs will be prepared and used for all shop operations (refer to AR 385-95). The
supporting Safety Office will use their expertise to provide assistance. Guidance for industrial hazards can be found
in Code of Federal Regulations , and Chemical Hazards in NIOSH/OSHA Guidelines for Chemical Hazards.

CLEANING COMPOUND, MIL-PRF-87937, TYPE IV

Cleaning compounds can irritate eyes and skin. Wear protective gloves and goggles. Avoid repeated or prolonged
contact.

ALIPHATIC NAPHTHA
Aliphatic Naphtha is extremely flammable and toxic to eyes, skin and respiratory tract. Wear protective gloves and
goggles/shield. Avoid repeated or prolonged contact. Use only in well ventilated areas (or use approved respirator
as determined by local safety/industrial hygiene personnel). Keep away from open flame other sources of ignition.

DEGREASING SOLVENT, MIL-PRF-680

Degreasing solvent, MIL-PRF-680, is combustible and toxic to eyes, skin and respiratory tract. Wear protective
gloves and goggles/face shield. Avoid repeated or prolonged contact. Use only in well ventilated areas (or use
approved respirator as determined by local safety/industrial hygiene personnel). Keep away from open flame other
sources of ignition.

n-PROPYL BROMIDE
n-Propyl Bromide is toxic to eyes, skin, and respiratory tract. Wear protective gloves and goggles/face shield. Avoid
repeated or prolonged contact. Use only in areas with adequate mechanical or local exhaust ventilation (or use
approved respirator as determined by local safety/industrial hygiene personnel).

DENATURED ALCOHOL
Deleted

HFE-71DE
HFE-71DE is toxic to eyes, skin and respiratory tract and decomposes into other hazardous products when exposed
to extreme heat. Wear chemical protective gloves and goggles/face shield. Avoid repeated or prolonged contact.
Use only in well ventilated areas. If ventilation is not adequate, use approved respirator as determined by local
safety/industrial hygiene personnel. Keep away from open flames, welding or other sources of ignition.

Change 5 c
TM 1-1500-204-23-2

ISOPROPYL ALCOHOL
Isopropyl alcohol is flammable and toxic to eyes, skin and respiratory tract. Wear protective gloves and
goggles/shield. Avoid repeated or prolonged contact. Use only in well ventilated areas (or use approved respirator
as determined by local safety/industrial hygiene personnel). Keep away from open flame other sources of ignition.

d Change 4
 TM 1-1500-204-23-2
C6

CHANGE HEADQUARTERS
DEPARTMENT OF THE ARMY
NO. 6 WASHINGTON, DC., 2 March 2015

AVIATION UNIT MAINTENANCE (AVUM) AND AVIATION INTERMEDI-

ATE MAINTENANCE (AVIM)
FOR
GENERAL AIRCRAFT MAINTENANCE (PNEUDRAULICS MAINTENANCE
AND PRACTICES) VOLUME 2
HAZMAT STATEMENT
This document has been reviewed for the presence of SOLVENTS containing hazardous materials as defined by the EPCRA 302
and 313 lists by the AMCOM G-4 (Logistics) Environmental Division. As of the base through C03, dated 29 January 1999, all ref-
erences to Solvents containing hazardous materials have been removed from this document by substitution with non-hazardous or
less hazardous materials where possible.

DISTRIBUTION STATEMENT A: Approved for public release; distribution is unlimited.

TM 1-1500-204-23-2, Dated 31 July 1992, is changes as follows:

1. Remove and insert pages as indicated below. New or changed text material is indicated by a vertical bar
in the margin. An illustration change is indicated by a miniature pointing hand.

Remove Pages Insert Pages

A through C/(D blank) A through C/(D blank)

4-1 and 4-2 4-1 and 4-2
4-5 and 4-6 4-5 and 4-6
4-97 and 4-98 4-97 and 4-98

2. Retain this sheet in front of manual for references purposes.

By Order of the Secretary of the Army:

RAYMOND T. ODIERNO
Official: General, United States Army
Chief of Staff

GERALD B. O’KEEFE
Administrative Assistant to the
Secretary of the Army
1503401

Distribution:
Initially published in electronic media only. If at a later date this publication is printed, it will be distributed
in accordance with the initial distribution number (IDN) 313302, requirements for TM 1-1500-204-23-2.
 TM 1-1500-204-23-2
C5

CHANGE HEADQUARTERS
DEPARTMENT OF THE ARMY
NO. 5 WASHINGTON, DC., 11 July 2011

AVIATION UNIT MAINTENANCE (AVUM) AND AVIATION INTERMEDI-

ATE MAINTENANCE (AVIM)
FOR
GENERAL AIRCRAFT MAINTENANCE (PNEUDRAULICS MAINTENANCE
AND PRACTICES) VOLUME 2

HAZMAT STATEMENT
This document has been reviewed for the presence of SOLVENTS containing hazardous materials as de.ned by the EPCRA 302
and 313 lists by the AMCOM G-4 (Logistics) Environmental Division. As of the base through C03, dated 29 January 1999, all ref-
erences to Solvents containing hazardous materials have been removed from this document by substitution with non-hazardous or
less hazardous materials where possible.

DISTRIBUTION STATEMENT A: Approved for public release; distribution is unlimited.

TM 1-1500-204-23-2, Dated 31 July 1992, is changes as follows:

1. Remove and insert pages as indicated below. New or changed text material is indicated by a vertical bar
in the margin. An illustration change is indicated by a miniature pointing hand.

Remove Pages Insert Pages

c and d c and d
A and B A through C/(D Blank)
i/(ii blank) i/(ii blank)
3-8.1/(3-8.2 Blank) 3-8.1 and 3-8.2
3-9 and 3-10 3-9 and 3-10
4-5 and 4-6 4-5 and 4-6
4-9 and 4-10 4-9 and 4-10
4-51 and 4-52 4-51 and 4-52
4-74.1 and 4-74.2 4-74.1 and 4-74.2

2. Retain this sheet in front of manual for references purposes.

Change TM 1-1500-204-23-2
No. 5

By Order of the Secretary of the Army:

MARTIN E. DEMPSEY
General, United States Army
Official: Chief of Staff

JOYCE E. MORROW
Administrative Assistant to the
Secretary of the Army
1115304

Distribution:

To be distributed in accordance the initial distribution number (IDN) 313302,

requirements for TM 1-1500-204-23-2.
 TM 1-1500-204-23-2
C4

URGENT
CHANGE HEADQUARTERS
DEPARTMENT OF THE ARMY
NO. 4 WASHINGTON, DC., 12 January 2010

AVIATION UNIT MAINTENANCE (AVUM) AND AVIATION INTERMEDI-

ATE MAINTENANCE (AVIM)
FOR
GENERAL AIRCRAFT MAINTENANCE (PNEUDRAULICS MAINTENANCE
AND PRACTICES) VOLUME 2
This document has been reviewed for the presence of Class I Ozone Depleting Chemicals by the AMCOM G-4 (Logistics) Environ-
mental Division. As of the base through C03, dated 29 January 1999, all references to Class I Ozone Depleting Chemicals have
been removed from this document by substitution with chemicals that do not cause atmospheric ozone depletion EXCEPT Bromotrif-
fluoromethane (CF3BR); Fire Extinguisher Agent (Halon 1301).

This document has been reviewed for the presence of SOLVENTS containing hazardous materials as defined by the EPCRA 302
and 313 lists by the AMCOM G-4 (Logistics) Environmental Division. As of the base through C03, dated 29 January 1999, all ref-
erences to Solvents containing hazardous materials have been removed from this document by substitution with non-hazardous or
less hazardous materials where possible.

DISTRIBUTION STATEMENT A: Approved for public release; distribution is unlimited.

TM 1-1500-204-23-2, Dated 31 July 1992, is changes as follows:

1. Remove and insert pages as indicated below. New or changed text material is indicated by a vertical bar
in the margin. An illustration change is indicated by a miniature pointing hand.

Remove Pages Insert Pages

a through c/(d blank) a through d

----- A and B
i/(ii blank) i/(ii blank)
3-1 through 3-4 3-1 through 3-4
----- 3-4.1/(3-4.2 blank)
3-7 and 3-8 3-7 and 3-8
3-9 and 3-10 3-9 and 3-10
4-5 and 4-6 4-5 and 4-6
----- 4-6.1/(4-6.2 blank)
4-9 and 4-10 4-9 and 4-10
----- 4-10.1/(4-10.2 blank)
4-25 and 4-26 4-25 and 4-26
----- 4-26.1/(4-26.2 blank)
4-51 through 4-54 4-51 through 4-54
4-59 and 4-60 4-59 and 4-60
----- 4-60.1/(4-60.2 blank)
4-74.1 and 4-47.2 4-74.1 and 4-47.2
4-87 through 4-100 4-87 through 4-100
----- 4-100.1/(4-100.2 blank)
4-101 through 4-104 4-101 through 4-104
4-107 and 4-108 4-107 and 4-108
----- 4-108.1/(4-108.2 blank)
4-117 and 4-118 4-117 and 4-118
4-139 and 4-140 4-139 and 4-140
----- 4-140.1/(4-140.2 blank)
Change TM 1-1500-204-23-2
No. 4

By Order of the Secretary of the Army:

GEORGE W. CASEY, JR.

General, United States Army
Official: Chief of Staff

JOYCE E. MORROW
Administrative Assistant to the
Secretary of the Army
1000601

Distribution:

To be distributed in accordance the initial distribution number (IDN) 313302,

requirements for TM 1-1500-204-23-2.
 TM 1-1500-204-23-2
C3

CHANGE HEADQUARTERS
DEPARTMENT OF THE ARMY
NO. 3 WASHINGTON, DC., 29 January 1999

AVIATION UNIT MAINTENANCE (AVUM) AND AVIATION INTERMEDI-

ATE MAINTENANCE (AVIM)
FOR
GENERAL AIRCRAFT MAINTENANCE (PNEUDRAULICS MAINTENANCE
AND PRACTICES) VOLUME 2
DISTRIBUTION STATEMENT A: Approved for public release; distribution is unlimited.

TM 1-1500-204-23-2, Dated 31 July 1992, is changes as follows:

1. Remove and insert pages as indicated below. New or changed text material is indicated by a vertical bar
in the margin. An illustration change is indicated by a miniature pointing hand.

Remove Pages Insert Pages

i/(ii blank) i/(ii blank)

----- 3-8.1/(3-8.2 blank)
4-1 and 4-2 4-1 and 4-2
4-21 and 4-22 4-21 and 4-22
4-35 and 4-36 4-35 and 4-36
4-69 and 4-70 4-69 and 4-70

2. Retain this sheet in front of manual for references purposes.

TM 1-1500-204-23-2
C3
 TM 1-1500-204-23-2
C2

CHANGE HEADQUARTERS
DEPARTMENT OF THE ARMY
NO. 2 WASHINGTON, DC., 1 FEBRUARY 1994

AVIATION UNIT MAINTENANCE (AVUM) AND AVIATION INTERMEDI-

ATE MAINTENANCE (AVIM)
FOR
GENERAL AIRCRAFT MAINTENANCE (PNEUDRAULICS MAINTENANCE
AND PRACTICES) VOLUME 2
DISTRIBUTION STATEMENT A: Approved for public release; distribution is unlimited.

TM 1-1500-204-23-2, Dated 31 July 1992, is changes as follows:

1. Remove and insert pages as indicated below. New or changed text material is indicated by a vertical bar
in the margin. An illustration change is indicated by a miniature pointing hand.

Remove Pages Insert Pages

4-65 and 4-66 4-65 and 4-66

4-71 and 4-72 4-71 and 4-72
----- 4-74.1 and 4-74.2
4-75 and 4-76 4-75 and 4-76
----- 4-76.1/(4-76.2 blank)
4-169/(4-170 blank) 4-169/(4-170 blank)

2. Retain this sheet in front of manual for references purposes.

TM 1-1500-204-23-2
C2
 TM 1-1500-204-23-2
C1

CHANGE HEADQUARTERS
DEPARTMENT OF THE ARMY
NO. 1 WASHINGTON, DC., 30 JUNE 1993

AVIATION UNIT MAINTENANCE (AVUM) AND AVIATION INTERMEDI-

ATE MAINTENANCE (AVIM)
FOR
GENERAL AIRCRAFT MAINTENANCE (PNEUDRAULICS MAINTENANCE
AND PRACTICES) VOLUME 2
DISTRIBUTION STATEMENT A: Approved for public release; distribution is unlimited.

TM 1-1500-204-23-2, Dated 31 July 1992, is changes as follows:

1. Remove and insert pages as indicated below. New or changed text material is indicated by a vertical bar
in the margin. An illustration change is indicated by a miniature pointing hand.

Remove Pages Insert Pages

i/(ii blank) i/(ii blank)

4-1 through 4-4 4-1 through 4-4
4-25 and 4-26 4-25 and 4-26
4-35 and 4-36 4-35 and 4-36
4-73 and 4-74 4-73 and 4-74

2. Retain this sheet in front of manual for references purposes.

 TM 1-1500-204-23-2

LIST OF EFFECTIVE PAGES

Dates of issue for original and changed pages are:

Original . . . . . . . . . . . . . . . . . . . . . . . . . . 31 July 1992 Change 4 . . . . . . . . . . . . . . . . . . 12 JANUARY 2010

Change 1 . . . . . . . . . . . . . . . . . . . . . . . 30 JUNE 1993 Change 5 . . . . . . . . . . . . . . . . . . . . . . . . 11 JULY 2011
Change 2 . . . . . . . . . . . . . . . . . . 1 FEBRUARY 1994 Change 6 . . . . . . . . . . . . . . . . . . . . . . . . 2 March 2015
Change 3 . . . . . . . . . . . . . . . . . . 29 JANUARY 1999

TOTAL NUMBER OF PAGES IN THIS PUBLICATION IS , CONSISTING OF THE FOLLOWING:

Page No. *Change No. Page No. *Change No.

Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0 4-8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0
a ......................................... 4 4-9 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
b ......................................... 4 4-10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
c ......................................... 5 4-10.1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
d ......................................... 4 4-10.2 Blank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
A ......................................... 6 4-11 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0
B ......................................... 6 4-12 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0
C......................................... 6 4-13 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0
D Blank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 4-14 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0
i.......................................... 5 4-15 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0
ii Blank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 4-16 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0
1-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0 4-17 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0
1-2 Blank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0 4-18 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0
2-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0 4-19 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0
2-2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0 4-20 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0
2-3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0 4-21 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
2-4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0 4-22 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0
2-5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0 4-23 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0
2-6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0 4-24 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0
2-7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0 4-25 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
2-8 Blank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0 4-26 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
3-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 4-26.1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
3-2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 4-26.2 Blank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
3-3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 4-27 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0
3-4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 4-28 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0
3-4.1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 4-29 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0
3-4.2 Blank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 4-30 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0
3-5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0 4-31 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0
3-6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0 4-32 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0
3-7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 4-33 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0
3-8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0 4-34 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0
3-8.1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 4-35 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
3-8.2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 4-36 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0
3-9 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 4-37 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0
3-10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 4-38 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0
4-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 4-39 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0
4-2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 4-40 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0
4-3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 4-41 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0
4-4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 4-42 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0
4-5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 4-43 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0
4-6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 4-44 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0
4-6.1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 4-45 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0
4-6.2 Blank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 4-46 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0
4-7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0 4-47 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0

*Zero in this column indicates an original page.

Change 6 A
TM 1-1500-204-23-2

LIST OF EFFECTIVE PAGES (Cont)

Page No. *Change No. Page No. *Change No.

4-48 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0 4-95 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
4-49 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0 4-96 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
4-50 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0 4-97 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
4-51 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 4-98 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
4-52 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0 4-99 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
4-53 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 4-100 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
4-54 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0 4-100.1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
4-55 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0 4-100.2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
4-56 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0 4-101 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
4-57 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0 4-102 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
4-58 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0 4-103 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
4-59 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 4-104 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0
4-60 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 4-105 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0
4-60.1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 4-106 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0
4-60.2 Blank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 4-107 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
4-61 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0 4-108 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
4-62 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0 4-108.1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
4-63 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0 4-108.2 Blank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
4-64 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0 4-109 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0
4-65 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0 4-110 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0
4-66 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 4-111 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0
4-67 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0 4-112 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0
4-68 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0 4-113 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0
4-69 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 4-114 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0
4-70 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0 4-115 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0
4-71 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0 4-116 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0
4-72 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 4-117 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0
4-73 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 4-118 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
4-74 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0 4-119 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0
4-74.1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 4-120 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0
4-74.2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 4-121 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0
4-75 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 4-122 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0
4-76 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0 4-123 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0
4-76.1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 4-124 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0
4-76.2 Blank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 4-125 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0
4-77 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0 4-126 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0
4-78 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0 4-127 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0
4-79 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0 4-128 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0
4-80 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0 4-129 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0
4-81 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0 4-130 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0
4-82 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0 4-131 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0
4-83 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0 4-132 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0
4-84 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0 4-133 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0
4-85 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0 4-134 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0
4-86 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0 4-135 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0
4-87 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 4-136 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0
4-88 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 4-137 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0
4-89 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 4-138 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0
4-90 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 4-139 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
4-91 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 4-140 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
4-92 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 4-140.1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
4-93 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 4-140.2 Blank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
4-94 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 4-141 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0
*Zero in this column indicates an original page.
B Change 6
 TM 1-1500-204-23-2

LIST OF EFFECTIVE PAGES (Cont)

Page No. *Change No. Page No. *Change No.

4-142 ..................................... 0 4-169 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

4-143 ..................................... 0 4-170 Blank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
4-144 ..................................... 0 A-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0
4-145 ..................................... 0 A-2 Blank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0
4-146 ..................................... 0 Glossary-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0
4-147 ..................................... 0 G-2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0
4-148 ..................................... 0 Index-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0
4-149 ..................................... 0 Index-2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0
4-150 ..................................... 0 Index-3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0
4-151 ..................................... 0 Index-4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0
4-152 ..................................... 0 Index-5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0
4-153 ..................................... 0 Index-6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0
4-154 ..................................... 0 Index-7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0
4-155 ..................................... 0 Index-8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0
4-156 ..................................... 0 Index-9 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0
4-157 ..................................... 0 Index-10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0
4-158 ..................................... 0 Index-11 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0
4-159 ..................................... 0 Index-12 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0
4-160 ..................................... 0 Index-13 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0
4-161 ..................................... 0 Index-14 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0
4-162 ..................................... 0 Index-15 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0
4-163 ..................................... 0 Index-16 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0
4-164 ..................................... 0 Index-17 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0
4-165 ..................................... 0 Index-18 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0
4-166 ..................................... 0 Index-19 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0
4-167 ..................................... 0 Index-20 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0
4-168 ..................................... 0

*Zero in this column indicates an original page.

Change 6 C/(D blank)
 * TM 1-1500-204-23-2

TECHNICAL MANUAL HEADQUARTERS

DEPARTMENT OF THE ARMY
No. 1-1500-204-23-2 WASHINGTON, D.C., 31 JULY 1992
TECHNICAL MANUAL
AVIATION UNIT MAINTENANCE (AVUM)
AND AVIATION INTERMEDIATE MAINTENANCE (AVIM) MANUAL
FOR
GENERAL AIRCRAFT MAINTENANCE
(PNEUDRAULICS MAINTENANCE AND PRACTICES)
VOLUME 2
REPORTING ERRORS AND RECOMMENDING IMPROVEMENTS
You can improve this manual. If you find mistakes, or if you know of a way to improve these
procedures, please let us know. Mail your letter or DA Form 2028 (Recommended Changes
to Publications and Blank Forms) located in the back of this manual, directly to: Commander,
U.S. Army Aviation and Missile Command, ATTN: AMSAM-MMA-NP, Redstone Arsenal, AL
35898-5000. A reply will be furnished to you. You may also provide DA Form 2028 information to
AMCOM via e-mail, fax, or the World Wide Web. Our fax number is DSN 788-6546 or Commercial
(256) 842-6546. Our e-mail address is: [email protected]. Instructions for sending an
electronic 2028 may be found at the back of this manual immediately preceding the hard copy
2028. For the World Wide Web use: https://amcom2028.redstone.army.mil.

HAZMAT STATEMENT
This document has been reviewed for the presence of hazardous chemicals and toxic substances as defined by the EPCRA
302 and 313 lists by the AMCOM G-4 (Logistics) Environmental Division. As of the base document through change 04, dated
12 January 2010, all references to hazardous chemicals and toxic substances have been removed from this document by
substitution with non-hazardous or less hazardous materials where possible.

TABLE OF CONTENTS
Page

CHAPTER 1 INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1

CHAPTER 2 PNEUDRAULICS GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
CHAPTER 3 HYDRAULIC SHOP OPERATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
CHAPTER 4 HYDRAULIC MAINTENANCE PRACTICES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
APPENDIX A REFERENCES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-1
GLOSSARY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Glossary-1
INDEX ............................................................................ Index-1

* This manual together with TM 1-1500-204-23-1, TM 1-1500-204-23-3 through TM 1-1500-204-23-10, dated 31 July 1992, supersedes
TM 55-1500-204-25/1, dated 6 April 1970, including all changes.
Change 5 i/(ii blank)
 TM 1-1500-204-23-2

CHAPTER 1
INTRODUCTION

1-1. PURPOSE. This volume provides general infor- 1-2. SCOPE. General information to guide aircraft
mation pertaining to aircraft hydraulic and pneumatic maintenance personnel is covered within this volume;
systems. The application of materials and techniques however, no attempt has been made to include spe-
used on specific aircraft is not covered in this volume. cial parts or equipment which are applicable only to
Specific aircraft application, usage, and substitution are individual or specific aircraft. General information on
found in the individual aircraft maintenance manuals. aircraft hydraulic systems is contained in Chapter 2 and
This volume is of maximum benefit to the mechanic hydraulic shop operations are discussed in Chapter 3.
who desires information about tubing systems, flexible Procedures, techniques, and materials for maintenance
hoses, packings and O-rings, and aircraft system com- of tubing, hoses, packings, O-rings, reservoirs, filters,
ponents. This volume furnishes the mechanic a source pumps, accumulators, valves, brake systems, and
of information about how to perform various mechanical absorbing units are presented in Chapter 4.
functions which are used on all aircraft. This volume is
not a requisitioning authority, and applicable repair parts 1-3. CONSUMABLE MATERIALS. Refer to TM
and special tools list should be consulted to obtain the 1-1500-204-23-6 for consumable materials in this vol-
unit of issue and National Stock Number of the items ume.
required for maintenance.

1-1/(1-2 blank)
 TM 1-1500-204-23-2

CHAPTER 2
PNEUDRAULICS GENERAL

2-1. PNEUDRAULICS THEORY AND BASIC PRIN- the areas of piston heads. If we know this area, we can
CIPLES. The aircraft hydraulic system transmits engine compute the amount of force needed to start a mech-
power to distant points on the aircraft. This force is car- anism moving. In this manual, area is measured in
ried by hydraulic fluid confined in a system of tubing and square inches.
hoses.
(3) Pressure. Pressure is the force applied to
a. Qualities of Hydraulic Fluid. Hydraulic fluid one unit of area—usually 1 square inch. The pressure
can be described in terms of three physical qualities. on a piston head develops the force that operates a
mechanism. In our work, we measure pressure in
(1) Incompressibility. For practical purposes, pounds per square inch (psi).
liquids are incompressible. This means that even under
extremely high pressure a liquid cannot be made much (4) Computation. If you know any two of these
smaller. factors, you can easily compute the third by using the
equation illustrated in figure 2-1. To apply this equation,
(2) Expansion and contraction. Liquids ex- multiply the two lower factors together to get the top fac-
pand and contract with changes in temperature. When tor, and divide the top factor by the known lower factor
a liquid in a closed container is heated, the liquid ex- to get the unknown lower factor.
pands and puts pressure on the walls of the container.
As the liquid cools, the pressure decreases.

(3) Pressure transmission. Pressure applied

to a confined liquid is transmitted equally. If an opening
exists in a system, such as an actuator, the fluid will act
on it, causing it to move.

b. Computation of Force, Area, and Pres-

sure. Hydraulic systems are designed to take ad-
vantage of the characteristics of liquids as they relate
to force, area and pressure. These terms as used in
hydraulics are defined as follows:

(1) Force. Force is the amount of push or pull

applied to an object. The force applied to a piston head,
for example, is the energy applied to the total area of
the piston head. In this manual, we measure force in
pounds.
Figure 2-1. Computing Force Pressure and Area
(2) Area. Area is the measurement of a surface.
In the aircraft hydraulic system, we are concerned with

2-1
TM 1-1500-204-23-2

(a) Force computation. The force (F) in takes place in which a lack of resistance causes either
pounds can be obtained by multiplying the known val- piston 2 or 3, or both, to move upward. This momen-
ues of area (A) and pressure (P). tarily lowers the pressure in cylinders 2 and 3 while in
cylinder 1 it is still 5 psi. This unbalanced condition
(b) Pressure computation. Similiary, if the
cannot last. Fluid will flow from cylinder 1 to cylinders 2
force (F) and area (A) are known, F can be divided by
and 3. This is because pistons 2 and 3 are not confining
A to obtain pressure (P) in pounds per square inch.
the fluid as long as they move upward. Pascal’s law
(c) Area computation. Finally, to obtain area does not apply to this condition. When pistons 2 and 3
in square inches, force (F) is divided by pressure (P). reach the end of their strokes, the fluid stops flowing.
c. Computation of Volume, Area, and Length of At this point the fluid is again confined and the pressure
Stroke. You can use the same type of triangular equa- again equalizes—Pascal’s law applies once more.
tion to compute volume, area, and length of stroke. The e. Mechanical Advantage. In simple terms, me-
following definitions apply for this manual. chanical advantage is defined as the use of a small force
(1) Volume. Volume is a measurement of quan- over a great distance to obtain a great force over a short
tity expressed in cubic inches; for example, the amount distance. In other words, it is the amount by which the
of liquid in a cylinder or the amount of liquid displaced input effort is multiplied in the output of a device. Using a
by a pump or an actuating cylinder. claw hammer to remove a nail from a two-by-four piece
of lumber or using a jack to raise a vehicle are examples
(2) Area. As in the previous equation, area is a of mechanical advantage. The aircraft hydraulic system
surface measurement expressed in square inches. is designed to make full use of this principle since it is
(3) Length of stroke. Length of stroke is a mea- a system for transmitting engine power to distant points
surement of distance expressed in inches. The stroke in the aircraft where power is needed. This is accom-
length with which you will be concerned in this manual plished by multiplying the input effort (or force) enough
is the distance a piston moves in a cylinder. to do the required job-in other words, gaining a mechan-
ical advantage.
(4) Computation. If you know any two of these
factors, you can compute the third (see figure 2-2). As
in the previous equation, multiply the two lower factors
together to obtain the top factor and divide the top factor
by the known lower factor to obtain the unknown lower
factor. For example, a piston having an area of 8 square
inches moves a distance of 10 inches within a cylinder.
To find the volume of liquid moved, multiply the two lower
factors together—8 square inches (A) times 10 inches
(L)—to obtain V:80 cubic inches.
d. Pascal’s Law. Practical applications of hy-
draulic principles are based on Pascal’s law, which may
be stated in simple terms as follows: when a force is
applied to a confined fluid , the pressure is transmit-
ted equally in all directions. Pascal’s law applies for
confined fluids only. It follows then that the law does
not apply for fluids in motion since moving fluid is not
confined in the true sense of the word. Figure 2-3
shows graphic illustration of how Pascal’s law applies
in an aircraft hydraulic system. Note that when a force
is applied to the piston in cylinder 1, it is transmitted
to all portions of the confined fluid. If, for example, the
applied force is 5 psi, the pressure in cylinders 1, 2, and
3 and in the tubing will be 5 psi. But suppose a change Figure 2-2. Computing Volume, Length and Area

2-2
 TM 1-1500-204-23-2

Figure 2-3. Pascal’s Law

(1) Principle. In hydraulics, mechanical advan- (2) Application. An example of how to apply
tage can be explained as the ratio between two pistons mechanical advantage is shown in figure 2-5. Here we
with regard to the factors of area and force. In figure 2-4, want to find just how big the large piston must be to raise
you see a graphic illustration of this principle. Note the an 800-pound weight. Let us assume that we must raise
differences in the areas of the small and large pistons. the 800-pound weight by applying a 40-pound force to
This difference in size is the means by which mechan- the 4-square-inch piston. The mechanical advantage in
ical advantage is obtained. When a 50-pound force is this case is 20-800 pounds divided by 40 pounds—and
applied to the small pistons, the fluid pressure shows is expressed as the ratio 20:1. Multiplying 20 times 4
25 psi on the gauge, but 25 psi acting on the large pis- square inches (area of the small piston), we find that
ton gives an upward force of 250 pounds. This gain in the area of the large piston should be 80 square inches.
force (from 50 pounds to 250 pounds) is attained by in- Mechanical advantage also applies to the distance
creasing the surface area of the output piston. It is im- the piston moves, or length of stroke. Assuming that
portant to note that this 5-to-1 ratio does not change if the large piston must move 10 inches, multiplying this
the pounds per square inch change. If, for example, the factor by 20 gives 200 inches as the length of stroke
input force were limited to 20 psi or raised to 30 psi, the for the small piston. Of course, it would not be feasible
forces involved would obviously change but the ratio be- for the small piston to move that far on a single stroke.
tween the forces would still be 5 to 1. Therefore, the small piston must move through a series
of short repeated strokes.

2-3
TM 1-1500-204-23-2

f. Use of Air in Hydraulic Systems. When sub- and operating landing gear, wing flaps, wheel brakes,
jected to an applied force, a gas (such as air or nitro- and shock struts. In helicopters, hydraulic systems start
gen) acts in a manner similar to a spring: it yields but engines and operate brakes, shock struts, dampers,
pushes back with as much force as is being applied to flight control systems, loading ramps, folding pylons,
it. This characteristic of gases makes them useful in air- winch hoists, and hydraulic clutches. There are a
craft systems. number of reasons why hydraulic systems have been
designed for so many uses in aircraft.
(1) Gases used. Air is the gas commonly used
in hydraulic systems. It is used in accumulators, shock a. Ef.ciency . A hydraulic system is almost 100
struts, and emergency systems and for pressurizing sys- percent efficient. The slight loss of efficiency (a fraction
tem reservoirs. In terms of compressibility, almost any of 1 percent) is due to internal friction in the system
gas could be used, but many are dangerous because machinery.
they are flammable or explosive. Pure nitrogen is the
only safe substitute for atmospheric air in hydraulic sys- b. Ease of Operation. The moving parts of a hy-
tems, and it is the only substitute authorized. draulic system, being light in weight, can be quickly put
into motion or brought to rest. The valves used in a hy-
(2) Boyle’s law. Assuming a constant tempera- draulic system are capable of quickly starting or stop-
ture, the volume of a confined gas changes in opposite ping the flow of fluid under pressure, and very little effort
order to changes in pressure. For example, if a given is needed to operate them. For these reasons, the sys-
volume of gas is reduced to half its initial size, its pres- tem is easy for the operator to control.
sure doubles or, if the volume doubles, the pressure is
halved. This characteristic of gases is known as Boyle’s c. Ease of Installation. Hydraulic lines can be
law and is expressed by the equation: routed almost anywhere. Unlike mechanical systems,
V x P = V1 x P 1 which must follow straight pathways, the lines of a hy-
where draulic system can be easily bent around obstructions.
V = initial volume The major parts of hydraulic systems can be located in
P = initial pressure a wide variety of places.
V1 = changed volume
P 1 = changed pressure d. Size. Since the components of a hydraulic sys-
If the measurements of any three of these factors are tem are small in comparison with those of other systems,
known, the fourth factor can be determined. To illus- the space requirement is small.
trate, let us assume that 30 cubic inches of gas (V) at
a constant temperature and under 90-psi pressure (P) e. Lubrication. Most of the parts of a hydraulic
is forced into a 15-cubic-inch space (V 1). To find the system operate in a bath of oil, making the system
changed pressure (P1 ) we substitute in the equation as self-lubricating.
follows:
90 x 30 = 15 x P1 2-3. TYPES OF HYDRAULIC FLUID USED IN ARMY
2700 = 15P 1 AIRCRAFT. Hydraulic fluids are classified generally as
2700 vegetable-base, petroleum-base, and synthetic-base .
15 = P1
180 = P1
a. Vegetable-Base Fluid. Vegetable-base fluid is
no longer authorized for use in Army aircraft.
2-2. USES OF HYDRAULIC SYSTEMS IN ARMY
AIRCRAFT. Hydraulic systems perform a variety of b. Petroleum-Base Fluid. Petroleum-base fluid
functions in Army aircraft. They are used in fixed-wing has an odor similar to penetrating oil and is dyed red.
aircraft for such purposes as changing propeller pitch Synthetic rubber seals are used with this fluid.

2-4
 TM 1-1500-204-23-2

Figure 2-4. Mechanical Advantage

Figure 2-5. Application of Mechanical Advantage

2-5
TM 1-1500-204-23-2

(1) Petroleum-base fluid MIL-H-6083. MIL-H- ination is generally caused by poor maintenance prac-
6083 is still authorized for certain uses in Army aircraft. tices. Examples include leaving hydraulic lines open af-
It is used as a preservative oil in shock struts, hydraulic ter removing a part; wiping fittings with dirty rags; leaving
equipment, and spare parts, and as a testing and flush- valves, tubing, etc., uncovered on workbenches; chang-
ing oil for some components. It should not be used in ing fluid with dirty test equipment; and installing new or
operational aircraft hydraulic systems. rebuilt parts that have not been properly cleaned. Hy-
draulic fluid (red color), MIL-H-83282 or MIL-H-5606,
(2) Petroleum-base fluid MIL-H-5606. MIL-H- shall be used in all hydraulic systems. The choice of
5606 is being phased out for most Army aircraft, and MIL-H-83282 or MIL-H-5606 depends on the particular
being replaced with synthetic-base fluid MIL-H-83282. It hydraulic system and the ambient temperature. Refer to
is, however, still used for cold weather operation. Refer the aircraft manual or to 55-1500-334-25.
to the following paragraph and paragraph 4-21 for more
information on this fluid and its conversion. a. Detecting Fluid Contamination. A kit
has been developed, part number 57L414, NSN
c. Synthetic-Base Fluid MIL-H-83282 . As stated 6630-00-150-6486, to sample fluid for contamination in
above, MIL-H-5606 is being replaced in most operations order to help control contamination in aircraft. Contam-
by MIL-H-83282. MIL-H-83282 has a higher flash point ination checks should become a routine part of your
and fire point, as well as additives which provide better work. You should check for dirt, metal, and visible solids
anti-wear characteristics and provide better resistance every time a unit is removed or disassembled. Normal
to corrosion and oxidation. Refer to paragraph 4-21 for contamination checks for most aircraft are made by
more information on this fluid and its conversion. examining the condition of the filter elements. For ex-
ample, a clogged filter or an extended filter indicator pin
d. Precautions. Use of the correct, uncontami- is a symptom of contaminated fluid. These findings, as
nated fluid in a particular hydraulic system is critical for well as a pump failure, require flushing of the system.
the continued serviceability of that system.
b. System Flushing. Evidence of contamination
(1) Proper fluid. You must be extremely careful makes it necessary that hydraulic system be flushed.
to use only the fluid authorized for a particular compo-
nent or system. To determine the correct fluid, consult
the applicable technical manual. In addition, read the
instruction plate affixed to the individual unit or reservoir
and check the color of the fluid contained in the system. To avoid contamination, do not use hydraulic
fluid that shows evidence of contamination or is
in open cans that are stored uncovered/unpro-
(2) Drained fluid. Fluid drained, for any reason,
tected. Unused fluid may be kept in filler pumps
from a hydraulic system or component shall not be
or sealed jars.
reused.
(1) Fluid. Hydraulic fluid, MIL-H-5606 or MIL-H-
(3) Disposition of containers. Hydraulic fluid 83282 , shall be used for flushing systems and compo-
containers, when emptied, shall be destroyed. nents. Discard after use.
(2) Accidental servicing. In the event that a
2-4. FLUID CONTAMINATION. Contamination in a system or component is inadvertently serviced with in-
hydraulic system is the presence of any material other correct type fluid, drain fluid, flush system, and replace
than the hydraulic fluid being used. This includes water, all packings and gaskets in affected components.
metal, dust, and other solids. Contamination sources c. Contamination Prevention. Contamination
may be internal or external. Internal contamination can can be prevented by taking the following precautions:
cause abnormal wear of the pump or of other compo-
nents. When filters are used too long (especially the (1) Cap or plug all open connections when re-
paper element type), particles may begin breaking off moving a part.
from the filter element. Moving seals and backup rings (2) Never use dirty rags to wipe off connections.
also add contamination to the system. External contam-

2-6
 TM 1-1500-204-23-2

(3) Clean and deburr new tubing and fittings be- (7) Handle flexible hydraulic hoses carefully.
fore installing them. Particles from their walls enter the system when hoses
are kinked or run over or when quick disconnections
(4) Store new or overhauled parts in sealed con- are not cleaned before being joined.
tainers.
(8) Fluid drained, for any reason, from a hy-
(5) Before installing a pump, fill it with hydraulic draulic system or component shall not be reused.
fluid.
(9) Hydraulic fluid containers, when emptied,
(6) Take good care of test stands and ground shall be destroyed.
equipment.

2-7/(2-8 blank)
 TM 1-1500-204-23-2

CHAPTER 3
HYDRAULIC SHOP OPERATIONS

3-1. GENERAL SHOP RULES. The practices and spills shall be cleaned up immediately. Approved
procedures described in this chapter pertain to the sweeping compound may be used to remove these
manufacturing and repair functions of aviation activities materials from the floor.
and are applicable to all levels of maintenance. Be-
cause of the many types of Army aircraft, each shop
within the manufacturing and repair section must, of
necessity, have personnel trained in general practices
and procedures to the extent that different types and Floors shall not be cleaned with volatile or
model aircraft do not upset a smooth running shop. flammable liquids.

a. Responsibility. All supervisory personnel in (2) Floors shall be maintained smooth and
the manufacturing section are responsible for a contin- clean, free of all obstructions and slippery substances.
uing and effective shop safety program. To implement Holes and irregularities in floors shall be repaired to
and maintain this program, shop supervisors will uti- maintain a level surface free from tripping hazards.
lize bulletin boards, signs, and any other effective
method. Shop personnel will cooperate in the shop (3) All unnecessary materials on walls shall be
safety program by making helpful recommendations, removed and projections shall be kept to a minimum.
and continually exercising care and caution in the op-
eration of all shop equipment. All shop personnel will (4) Aisles shall be clearly defined and kept free
strive to improve the safety program and be especially of hazardous obstructions. Where possible, aisles shall
alert to observe and correct hazardous conditions and be suitably marked by painting.
unsafe shop practices. All accidents, no matter how
minor, shall be reported to the shop supervisor, and all (5) All machines, work benches, aisles, etc.,
published instructions regarding safety shall be strictly shall be adequately illuminated.
adhered to. Also, safety engineers and safety officers
will ensure that proper safety procedures are adhered (6) Some units that you will disassemble are
to in accordance with AR 385-10, The Army Safety made up of small parts that can easily be lost, broken, or
Program; AR 385-30, Safety Color Code Markings and mixed with other parts. A unit improperly reassembled
Signs, AR 385-32, Protective Clothing and Equipment; or one reassembled with defective parts is the starting
The Occupational Safety and Health Act of 1971, OSHA place for an aircraft accident.
1910.251; all applicable fire codes, NFPA 410; and
other accepted civilian and military safety practices. (7) Wornout parts should be disposed of
through the proper supply channels and never placed
b. Shop Housekeeping. Housekeeping is the on the floor where they can become dangerous or
yardstick by which the shops in the manufacturing forgotten.
section are judged. A clean, well arranged shop is a
safe shop and reflects credit on all personnel concerned (8) After servicing equipment with hydraulic fluid
with its operation. The following shop practices shall be from a can, do not attempt to reseal the can. Any hy-
observed: draulic fluid remaining in a can must be immediately
transferred to an approved airtight, pressure venting,
(1) Oil pans or drip pans shall be used where stainless steel storage reservoir, an approved hydraulic
leaking oil, grease, and similar materials may cause servicing unit or a hydraulic test stand containing the
hazardous accumulations on equipment or floors. All same hydraulic fluid.

Change 4 3-1
TM 1-1500-204-23-2

(9) Containers of hydraulic fluid which have (f) Ensure that all unauthorized personnel
been accidently left unsealed shall be considered con- are clear of area before opening valves or energizing
taminated and shall be destroyed. electrical circuits for starting machinery.

NOTE (g) Suitable mechanical guards, such as en-

closures or barricades, shall be permanently installed on
To avoid contamination, do not use previously all machinery not already equipped with such to elimi-
opened cans of hydraulic fluid. Cans of hy- nate danger of injury from moving parts.
draulic fluid can not be resealed. Immediately
transfer unused hydraulic fluid to an approved (h) Machinery shall not be adjusted, re-
airtight, pressure venting, stainless steel stor- paired, oiled, or cleaned while machine is in operation
age reservoir, an approved hydraulic servicing or power is on.
unit or a hydraulic test stand containing the
same hydraulic fluid. When opening can, clean (i) Personnel operating machinery shall
top and use a clean, sharp, unplated instru- wear protective clothing as prescribed. A protective
ment to prevent contamination. Can openers face shield or goggles shall be worn when operating a
attached to the aircraft must be cleaned before grinder regardless of whether grinder is equipped with
using. attached shields.
c. Shop Safety. Unsafe equipment and fire haz- (j) Jewelry shall not be worn while performing
ards are the main factors to be observed while planning any maintenance.
safety procedures.
(2) Fire Safety. A constant vigilance must be
(1) Equipment safety. Unsafe equipment shall maintained to seek out fire hazards. Fire hazards are
be reported immediately. The following equipment constantly present in the shop where sparks, friction,
safety practices shall be observed: or careless handling can cause an explosion that may
destroy equipment or buildings, and injure or kill per-
(a) Machines shall be located to provide op- sonnel. Refer to AR 385-10, The Army Safety Program
erators with sufficient space to handle materials and per- and the Occupational Safety and Health Act of 1971.
form job operations without interference. The following fire safety practices shall be observed:
(b) Bolt down all machinery that can move or (a) NO SMOKING signs shall be placed in ar-
walk due to vibration (drill press, bench grinder, etc.). eas where smoking could create a fire hazard.
(c) Substantial low resistance conductors (b) Personnel shall be trained in the use,
shall be used to ground all stationary and portable knowledge, and location of shop fire fighting equipment.
machines, equipment, or other devices in which static
charges may be generated, or which require electrical (c) Each shop shall be equipped with fire ex-
circuits of a hazardous nature. tinguishers suited for type of fire most likely to occur.
(d) Shop machinery shall be operated only
by qualified personnel observing safe practices.

(e) Safety devices, such as guards, inter-

locks, automatic releases, and stops, shall always be
kept in operating condition.

3-2 Change 4
 TM 1-1500-204-23-2

(d) Use correct fire extinguisher for class of 3-2. MAINTENANCE OF SHOP EQUIP-
fire as follows: MENT. Maintenance of shop equipment consists of
cleaning, preventive maintenance, and replacement
• Class A fire (wood, paper, trash, etc). of defective parts. Preventive maintenance includes
Use water or soda-acid fire extin- before-operation, during-operation, after-operation
guisher. services performed by operator, and scheduled
services to be performed at designated intervals.
• Class B fire (oil, paint, fuel, grease, Consult the operation and service instructions manual
etc). Use bromotrifluoromethane or for specific maintenance instructions on particular types
carbon dioxide fire extinguisher. of equipment.
• Class C fire (electrical equipment). a. Hydraulic Filler and Bleeder Unit. The hy-
Use bromotrofluoromethane or car- draulic filler and bleeder shown in figure 3-1 is used
bon dioxide fire extinguisher. for servicing and bleeding aircraft hydraulic systems
• Class D fire (combustible metals)
and associated hydraulic equipment. The unit consists
of a hydraulic fluid storage tank with an air pressure
magnesium, titanium, zirconium,
indicator, air filler and fluid filler valve, and a servicing
sodium, lithium, and potassium. Use
hose and valve. The following are general instructions
dry powder type fire extinguisher.
for maintenance and service:
(e) Oily waste, rags, and similar combustible
materials shall be discarded in self-closing metal con-
tainers which shall be emptied daily.
Do not attempt to service or perform mainte-
(f) Flammable materials shall not be stored in nance on filler and bleeder unit until all air pres-
the shop. sure has been released. Failure to comply can
result in damage to equipment or personnel.
(g) Use only approved cleaning solvents.
Do not use any filler and bleeder unit unless it is
d. Shop Tools and Materials. Handling tools and equipped with a safety relief valve to bleed off
materials requires observance of the following common excessive air pressure. Failure to comply can
safety practices: result in injury or death.

Degreasing solvent, MIL-PRF-680, is com-

(1) Do not leave tools or objects in elevated po-
bustible and toxic to eyes, skin and respiratory
sitions from which they can fall or be knocked off.
tract. Wear protective gloves and goggles/face
shield. Avoid repeated or prolonged con-
(2) Do not point a compressed airstream toward tact. Use only in well ventilated areas (or use
any part of the body. approved respirator as determined by local
safety/industrial hygiene personnel). Keep
(3) All unserviceable tools will be plainly marked away from open flame other sources of ignition.
and removed from service.
(1) Clean reservoir and fittings with a cloth
(4) Electrical cables and air hoses to portable moistened in degreasing solvent, MIL-PRF-680, and
units will be laid out so there is no danger of tripping. wipe dry with a clean cloth.
(5) Electrical tools must be connected to a low
resistance ground.

Change 4 3-3
TM 1-1500-204-23-2

(4) Keep reservoir filled to specified level with

hydraulic fluid, MIL-H-5606 or MIL-H-83282 .
NOTE
Consult applicable operation and service in-
structions manual for specific air pressurizing
procedures.

(5) Replace flexible hose connections or man-

ual control valve when leaking.

(6) Replace defective valve core in valve stem

and defective gauge unit with a like serviceable item.

(7) Replace flexible hose that is frayed, cut, and

deteriorated.

Figure 3-1. Typical Hydraulic System Filler and b. Hydraulic Test Stand, Fixed. This test stand is
Bleeder used for adjusting, flushing, and testing the performance
and operating characteristics of hydraulic system com-
NOTE ponents to determine serviceability status.

Calibration of hydraulic gauges is accomplished

in the instrument shop which is equipped with
hydraulic instruments. Oil preservatives, MIL- Supervisors shall ensure that only qualified per-
H-6083, will be utilized at time of overhaul dur- sonnel operate, service, and maintain hydraulic
ing depot maintenance as a calibrating medium test equipment. Because of the high pressures
in lieu of test fluid, MIL-H-5606. Recalibra- involved in testing, proper precautions must be
tion of flow indicators on test stands will be re- taken to prevent damage or injury to the opera-
quired if the fluid for which the equipment is cal- tor in case of line rupture.
ibrated does not conform to the requirements of
oil preservatives, MIL-H-6083. Degreasing solvent, MIL-PRF-680, is com-
bustible and toxic to eyes, skin and respiratory
(2) Remove corrosion, where paint has tract. Wear protective gloves and goggles/face
chipped, by scouring with crocus cloth, Federal Speci- shield. Avoid repeated or prolonged con-
fication P-C-458. tact. Use only in well ventilated areas (or use
approved respirator as determined by local
(3) Touch up areas with original finish paint safety/industrial hygiene personnel). Keep
where corrosion was removed. away from open flame other sources of ignition.

3-4 Change 4
 TM 1-1500-204-23-2

(1) Cleaning. Clean test stand by wiping with a and service instructions manual for specific test stand;
cloth moistened in degreasing solvent, MIL-PRF-680, however, the following will be used as a general guide:
and wiping dry with a clean cloth.
(a) With machine operating under full-load
(2) Daily inspection. Daily inspection will con- conditions, make a complete visual inspection of test
sist of the following: stand to determine if there is any leakage.

(a) Visually inspect entire test stand for signs (b) Disconnect electrical power and examine
of leaking valves, fittings, and connections. all electrical connections in junction box for loose or bro-
ken leads.
(b) Examine fluid level in reservoir and add
hydraulic fluid, MIL-H-6083, as necessary. (c) Remove sump cover and clean out any
dirt or lint with a clean cloth. Remove sump drain plugs
NOTE and flush sump with test fluid from machine. Reinstall
sump drain plug.
Preservative hydraulic fluid shall be used in all
hydraulic test stands permanently installed in (d) Examine filters and replace filter ele-
the shop. ments in accordance with applicable operation and
service instructions manual.
(c) Inspect for worn bearings, packings, or
broken seals at drive shafts on pump and motor. c. Hydraulic Test Stand, Portable, Gasoline En-
gine-Driven. This test stand shown in figure 3-2 is
(d) Examine test stands for proper operation used directly on the aircraft, and simulates the engine-
and correct reading of gauges. driven hydraulic pump in performing system operational
checks, checking system for leaks, and filling or flushing
(3) Periodic inspection. For frequency and the system.
scope of periodic inspection, consult the operation

Change 4 3-4.1/(3-4.2 blank)

 TM 1-1500-204-23-2

Figure 3-2. Typical Gasoline Engine-Driven Hydraulic Test Stand

(1) Daily inspection. When test stand is used ment panel. Ensure that all instrument glasses are in-
daily, the following inspections are required. Otherwise, tact and not broken.
daily inspections shall be observed each time test stand
is put into use. (e) Examine fuel level in fuel tank, and refill
as required with gasoline, MIL-G-5572, Grade 80/87.
(a) Examine fluid level in hydraulic reservoir Examine fuel filter for contamination and sediment bowl
and refill as required with hydraulic fluid, MIL-H-5606 or for dirt or water.
MIL-H-83282.
(f) Examine oil level in engine crankcase and
(b) Inspect tires on trailer assembly for spec- gearbox transmission. Add oil as required.
ified inflation.
(g) Examine electrolyte level in batteries,
(c) Examine interior of housing and cabinet adding distilled water as required. Ensure that battery
for broken wiring, worn insulation, and loose connec- cables are securely fastened, and top of battery is
tions. Examine all tubing for loose fittings and leakage. clean.

(d) Ensure that all controls move freely and

that control handles are secure on control and instru-

3-5
TM 1-1500-204-23-2

(h) Prior to first use of test stand, examine NOTE

pressure gauge to determine that maximum hydraulic
pressure is obtainable, and inspect for high pressure When test stand is out of operation for lengthy,
leaks. intermittent periods, batteries should be tested
more frequently, or placed on trickle charge in
(2) Periodic inspection. For frequency and battery charge.
scope of periodic inspection, consult the operation and
service instructions manual for the specific test stand;
(h) Examine engine ignition timing, magneto
however, the following will be used as a general guide:
point condition, and gap.
(a) Visually inspect interior of hydraulic reser-
(3) Lubrication. Consult applicable operation
voir for possible accumulation of sludge. Inspect and re-
and service instructions manual of particular hydraulic
place reservoir vent filter when necessary.
test stand for type of lubricant, time of application,
amount and point of lubrication.
(b) Examine tire treads on trailer assembly
for uneven wear. Rotate tires when necessary. d. Hydraulic Hose Testing Unit. The hose testing
units commonly used are designed to provide hydraulic
(c) Carefully inspect housing and cabinet as- pressure to 15,000 psi for proof pressure and leakage
sembly for loose screws, bolts, and nuts. Tighten as tests on aircraft hose assemblies. See figure 3-3 for a
required. typical unit. Prior to use the operator should:

(d) Inspect fuel system for loose fittings that (1) Examine fluid level in the reservoir. Add hy-
may cause fuel leakage. Examine and replace fuel filter draulic fluid, MIL-H-6083, as required.
as necessary.
(2) Inspect entire unit for loose connections, de-
(e) Examine oil level in engine crankcase and fective lines, or fittings. Tighten or replace as required.
gearbox transmission, and add oil as required. Replace
engine oil filter. Examine oil-bath type air cleaner and
service as necessary.

(f) Remove and examine spark plugs, and

clean with spark plug cleaner. Discard all unserviceable
spark plugs.

(g) Inspect battery cell electrolyte with a hy-

drometer. A specific gravity reading of 1.150 or less in-
dicates a low battery charge.

Figure 3-3. Typical Hydraulic Hose Testing Unit

3-6
 TM 1-1500-204-23-2

e. Tube-Bending Machine, Hand-Operated. The

tube-bending machine shown in figure 3-4 is used for (1) Cleaning. Keep tube-bending machine free
portable bending of various sizes of hydraulic rigid tub- from grease and dirt by cleaning with a cloth moistened
ing. in degreasing solvent, MIL-PRF-680, and wiping dry
with a clean cloth.

(a) Corrosion prevention. After cleaning, to

prevent tube-bending machine and accessories from
Degreasing solvent, MIL-PRF-680, is com- rusting, apply a light coat of oil, MIL-L-7870, to surfaces.
bustible and toxic to eyes, skin and respiratory
tract. Wear protective gloves and goggles/face (b) Corrosion removal. When rust spots are
shield. Avoid repeated or prolonged con- present, they may be removed by scouring with crocus
tact. Use only in well ventilated areas (or use cloth, Federal Specification P-C-458. Touch up with the
approved respirator as determined by local original finish.
safety/industrial hygiene personnel). Keep
away from open flame other sources of ignition.

Figure 3-4. Tube Bending Machine

Change 4 3-7
TM 1-1500-204-23-2

(2) Periodic inspection. For frequency and f. Master Gauge Unit. This unit consists of a pres-
scope of periodic inspection, consult operation and ser- sure gauge, a manual control valve, and length of flexi-
vice instructions manual for specific bending machine; ble hose with connecting fittings. A typical unit is shown
however, the following shall be used as a general guide: in figure 3-5.

(a) Visually inspect tube-bending machine (1) Replace flexible hose when it becomes
for cracks, loose bolts and nuts, mounts for security, frayed, cut, or deteriorated.
and defective or damaged parts.
(2) Replace gauge or control valve when found
(b) Lubricate tube-bending machine as re- to be defective.
quired.

Figure 3-5. Typical Master Gauge Unit

3-8
 TM 1-1500-204-23-2

g. Hydraulic Fluid Dispenser, Aircraft, (j) Recharge the bladder as required. If 3-1/2
AF-5, NSN 4930-00-245-1832. to 4 gallons of oil used to charge the tank, a sufficient air
cavity will be left to expel the liquid charge with a single
(1) Model AF-5 Hydraulic Fluid dispenser con- air charge.
tains a buna N and nylon cord bladder in which air pres-
sure is maintained in order to eject oil from the machine. (k) Stencil the dispenser to show the specifi-
This special bladder is approximately fills the tank’s vol- cation number of the fluid that it contains.
ume.
(l) The discharge nozzle end of the dispens-
(2) The purpose of the bladder is to separate ing line shall be wiped clean prior to and after each use,
the hydraulic fluid in the tank from the compressed air and protected from contamination by a small amount of
used to expel fluid into a hydraulic system, thereby in- plastic food wrap and rubber band.
suring that no air or condensation will contaminate the
hydraulic fluid or brake system. h. Hydraulic Fluid Reservoir Servicing Unit
(RSU), Aircraft, part number 06-5022-6500-A7,
(3) This type of construction requires special NSN 4940-01-504-5279.
procedure in filling dispenser and charging it with com-
pressed air. (1) Contamination of hydraulic system can has
been indentified as a possible cause of several aircraft
(4) To fill the dispenser. incidences. It is an accepted fact that contamination
shortens the service lives of hydraulic components. Use
(a) Close the valve at the outer end of the of the recently introduced Army standard Reservoir Ser-
hose. vicing Unit (RSU) provides a quick and easy means of
filling aircraft reservoirs with hydraulic fluid that is clean,
(b) Open the bleeder valve located under the dry and air free.
pressure gauge. Do not tamper with the pressure relief
valve. This bleeder valve drains air cavity. (2) Up to 2 gallons of hydraulic fluid can be
added to the RSU. This needs to be done in a clean dry
(c) To deflate the bladder completely, put no area. The RSU even comes with its own can opener
more than 10 psi of air pressure into the fluid cavity of the and a sight gauge is provided to determine fill level. A
tank through the air valve located in the filler cap. This dual check valve in the fill cap prevents overpressure,
will reduce the size of the bladder to allow maximum oil limits vacuum and controls entry of water into the fluid.
capacity in the tank. This allows storage of the hydraulic fluid over extended
periods without picking up contaminants and eliminates
(d) When all air stops coming from the blad- the need to dispose of the unused fluid.
der bleeder valve, thus indicating that the bladder is flat,
close the bleeder valve. (3) Fluid is dispensed from the RSU using a
manual pump with a 200 psi output pressure rating.
(e) Release the air pressure in the oil cavity of The output hose is fitted with a 2-micron filter to control
the tank by pressing the red tank air drain button. When solid contamination. A bulkhead connector and a return
pressure gauge reads zero and no further air flows from tube are provided to allow the output hose to be flushed
the button valve, remove the filler cap. prior to connecting to an aircraft. The return tube is
transparent so that the fluid can also be checked for air
(f) Pour up to 5 gallons of hydraulic fluid into bubbles. The aircraft reservoir is filled by pumping the
the tank. Replace filler cap and tighten with wrench. fluid through the quick disconnect fitting on the ground
support return port for the hydraulic system to be ser-
(g) Inflate bladder through the air valve lo- viced. Simple steps involving flushing the hose, filling
cated under the pressure gauge to 10 psi. the reservoir, and stowing the output quick disconnect
are listed on a decal on the side of the reservoir. The
RSU delivers 4 cu. in. of fluid per stroke or 17 strokes
(h) Bleed all trapped air from the fluid cavity
per quart.
by pressing the red button valve and holding it until a
clear stream of hydraulic oil ejects.

(i) Inflate bladder through air valve under

pressure gauge until the pressure relief valve pops. Do
not exceed 50 psi.

Change 5 3-8.1
TM 1-1500-204-23-2

(4) Initial issue RSUs have been configured with 83282, is relabeled and adequate controls are in place
quick disconnect fittings based on the helicopter model to insure MIL-PRF-5606 is not inadvertently added to
supported. An adapter with a snap-tite quick disconnect the helicopter flight systems.
couopling used to fill the AGPU reservoir is also shipped
with each initial issue RSU. Only a basic configuration (6) The RSU is supported by a commercial
without quick disconnects is being stocked under NSN manual with an illustrated parts list. NSNs are available
4940-01-504-5279. All quick disconnected fittings used on the following: output hose, NSN 4720-00-484-5765;
are stocked items and are listed in the commercial man- clear return tube, NSN 4720-01-038-2651; and asso-
ual. ciated fitting, NSN 4730-00-472-4093. All other repair
parts will have to be ordered through the supplier. The
(5) The RSU is fully capable of replacing the only maintenance requirement is replacement of the
Filler and Bleeder Unit, P/N AF5, NSN 4910-00-245- filter element in the output hose. High handle force
1832, (the R2D2). However, servicing personnel need while in the re-circulating condition indicates the need
to ensure that the RSU, which is labeled with MIL-PRF- for filter element replacement.

3-8.2 Change 5
 TM 1-1500-204-23-2

3-3. HANDLING OF HYDRAULIC FLUID IN 55-GAL-

LON DRUMS. Correct storage and handling of hy- (1) Faucet. If small quantities of hydraulic fluid
draulic fluid is critical to ensure a supply of uncontami- are to be used, a faucet may be installed in the 3/4-inch
nated fluid for aircraft servicing. closure for use while the drum is in a horizontal position.
The faucet must be thoroughly wiped with hydraulic fluid
a. Storage. Store 55-gallon drums horizontally prior to use. Fluid should be permitted to flow for a short
with the closures at the 9 o’clock and 3 o’clock positions. period to flush any contamination that may have accu-
This prevents contaminating material from collecting mulated in the faucet.
around the top of the drum and around the closures.
The drums should be placed in covered storage either
under a roof or covered by a plastic sheet or tarpaulin.
Prior to inserting pump in drum, the drum must
b. Cleaning. Prior to use or prior to standing be cleaned as per paragraph 3-3 b. Prior to
the drum on end, the top of the drum should be thor- drawing off hydraulic fluid to be used in aircraft,
oughly brushed with a stiff brush to remove all gross a small amount of fluid must be flushed through
contaminating material. The top and particularly the the pump. Failure to comply may result in con-
closures should then be wiped with lintless rags satu- tamination of fluid, rendering it useless.
rated with hydraulic fluid MIL-H-5606, MIL-H-6083 or
MIL-H-83282.

c. Withdrawing Fluid from Drum. Fluid can be

withdrawn from the drum using the following methods: MIL-PRF-87937, Type IV cleaning compounds
can irritate eyes and skin. Wear protective
gloves and goggles. Avoid repeated or pro-
longed contact.

Use an apron, goggles, protective glasses, and (2) Pumps. If large quantities of hydraulic fluid
protective gloves when working with solvents or are needed, the following new, thoroughly cleaned,
hydraulic fluid as fluid can be absorbed into the hand-operated pumps may be used. (See Chapter 1,
skin. Part 1, FM 10-69).

Change 5 3-9
TM 1-1500-204-23-2

Dispensing pump, hand-driven, piston-type,

self-measuring type, 1-quart-per-stroke.

Never siphon by mouth. Ingestion of hydraulic 12 GPM, hand-driven dispensing pump (100 cy-
fluid can cause sickness or be fatal. cles per minute).

NOTE 15 GPM, piston-type, hand-driven dispensing

pump with 20-foot hose (22 gallons per 100 rev-
It is necessary to clean even new pumps olutions).
to prevent contamination of hydraulic fluid.
Cleaning may be accomplished by pumping (3) Nozzles. The discharge nozzle end of the
approximately 1 gallon of cleaning compound dispensing line shall be wiped clean prior to and after
MIL-PRF-87937 through the pump. After drain- each use, and protected with a small piece of plastic
ing the cleaning solvent completely, pump food wrap and rubber band. This procedure will elimi-
approximately 5 gallons of the appropriate hy- nate contamination from entering the nozzle.
draulic fluid through the pump. Thoroughly
clean and wipe the portions of the pump to d. Transporting Fluid to Aircraft. Hydraulic fluid
be installed in the 55-gallon drum with clean, may be transported from bulk storage to the aircraft in
lint-free rags saturated with the appropriate an approved hydraulic servicing unit.
hydraulic fluid, before installing the pump in the
drum.

3-10 Change 4
 TM 1-1500-204-23-2

CHAPTER 4
HYDRAULIC MAINTENANCE PRACTICES
4-1. GENERAL. This chapter provides general in- WW-T-700/4 and WW-T-700/6, is the most widely used
structions for maintenance of aircraft hydraulic systems, tubing for general purpose lines of low and medium
the materials required, and methods to be used. A pressures. It is easily flared, and is soft enough to
systematic application of the basic information in this be formed with handtools. It should be handled with
chapter will result in more efficient maintenance prac- care to prevent scratches, dents, and nicks. Aluminum
tices. In those cases where specific instructions for a alloy tubing is used with either of two types of con-
particular aircraft are required, refer to the applicable nections; flared joint for mechanical connections, or
aircraft maintenance manual. Materials and processes beaded end for use with clamps and flexible hose
recommended are identified by military or federal spec- connections. In hydraulic systems, 5052-0 aluminum
ification number or by manufacturer. alloy tubing, Federal Specification WW-T-700/4, is
4-2. TUBING SYSTEMS AND REPAIRS. Tubing used for reduced pressure (1500 psi maximum) and
used in aircraft hydraulic systems carries pressure to return lines. Aluminum alloy tubing 6061 and 6062
distant points in the aircraft to provide control of various MIL-T-7081, may be used for high pressure lines (3000
critical components. Failure of this tubing will result in psi). Use of MIL-T-7081 tubing in aircraft is limited by
pressure loss and subsequent loss of control, resulting MIL-H-5440. Tubing conforming to Federal Specifica-
in possible destruction to aircraft and injury or death. tions WW-T-700/1 and WW-T-700/6 shall not be used
in hydraulic systems.
a. Types. Corrosion-resistant steel tubing and
aluminum alloy tubing are used in aircraft for fuel, (3) Copper tubing. High pressure oxygen sys-
oil, coolant, oxygen, instrument, hydraulic, and vent tems use 3/16-inch diameter, 0.032-inch wall thickness
lines, as well as for electrical conduits and ventilating copper tubing, Federal Specification WW-T-799, Type
ducts. Copper tubing generally has been superseded N. Fittings are silver soldered onto the tubing in accor-
as a general purpose tubing by aluminum alloy tubing dance with MIL-B-7883, before tubing is installed.
because of its lighter weight, ease of forming, and (4) Rigid Tubing. The tubing used to produce
resistance to corrosion and fatigue. Tubing material can rigid tubing assemblies is sized by its outside diameter
be identified by visual inspection or by the aluminum (OD) and wall thickness. Outside diameter sizes are in
alloy designation stamped on the surface. sixteenth-of-an-inch increments, the number of the tube
(1) Corrosion-resistant steel tubing . Corro- indicating its size in sixteenths of an inch. For example,
sion-resistant steel tubing, MIL-T-8504 and MIL-T-6845, the number 6 tubing is 6/16 or 3/8 inch, number 8 tub-
is used in high pressure hydraulic systems (3000 psi) ing is 8/16 or 1/2 inch, and so forth. Wall thickness is
such as landing gear, wing flaps, and brakes. External specified in thousandths of an inch. Most aircraft main-
brake lines should always be made of steel to pre- tenance manuals contain a table which lists the original
vent damage caused by flying gravel and stones and material and acceptable substitutes and gives the wall
ground handling accidents. On hydraulic systems using thickness for each.
1/2-inch corrosion-resistant tubing or larger, aluminum b. Tubing Identification. The Army uses two
alloy nuts and sleeves may be used. Steel nuts and types of identification systems to code hydraulic plumb-
sleeves should be used on 3/8-inch corrosion-resistant ing lines of aircraft. The two systems used are the
tubing or smaller. Corrosion-resistant steel tubing does printed-symbolized tape system (see figure 4-1), the
not have to be annealed for flaring or forming. The preferred method, and the solid-color band (see figure
flared section is somewhat strengthened by cold work- 4-2), the alternate method. This identification will be
ing and consequent strain hardening. The high tensile applied in accordance with TM 1-1500-204-23-1, para-
strength of corrosion-resistant steel tubing permits use graph 6-3.
of thinner walls than those of aluminum alloy tubing, but c. Tubing Damage. Damage such as nicking and
the weight is about the same as thick-walled aluminum scratching of tubing can be minimized by using care.
alloy tubing. Most damage of this kind occurs from careless handling
(2) Aluminum alloy tubing. Aluminum alloy of tools during maintenance of aircraft. Any dent less
tubing, Federal Specification WW-T-700/1, is used for than 20 percent of tubing diameter is not objectionable
general purpose lines and conduits of low fluid pressure, unless it is on the heel of a short bend radius. A nick no
such as instrument lines, and electrical and ventilating deeper than 15 percent of wall thickness of aluminum,
conduits. Aluminum alloy tubing Federal Specifications aluminum alloy, copper, or steel, and is not in the heel
of the bend, may be reworked by

Change 3 4-1
TM 1-1500-204-23-2

changes in metal tubing material that

greatly reduces the ability to withstand
internal pressure and vibration. Any
visible penetration of the tube of the tube
wall surface (i.e., any visible damage to
or removal of metal from the tube wall) by
chafing, galling or fretting is cause for:
(2) Correction of the conditions that
originated the damage.
(3) Replacement of the tube assembly or
damaged section thereof regardless of
the type metal, system media, or pressure
ranges involved.
d. Cutting Tubing. To ensure a good flared tub-
ing connection, tubing should be cut squarely, and the
end deburred before it is flared (see figure 4-3). The
standard tubing cutter is clamped over tubing and ro-
Figure 4-1. Printed - Symbol Identification Tape tated toward its open side as cutting wheel is gradually
fed into tube by turning thumbscrew. The cutting wheel
should be fed into the tube only while the cutter is being
rotated, as dents will be caused in tubing if the cutter is
note moving. Moderate or light tension on thumbscrew
will prevent bending and excessive burrs on tubing. If
a cutter is not available, a hacksaw blade with 32 teeth
per inch can be used.

Figure 4-2. Solid Color Band Identification

burnishing with hand tools. Nicked tubing is not only

weaker as to internal pressure, but such nicks must be
burnished out to reduce a notch effect. If nicks are not
burnished out, concentration under vibration will cause
weakening and breaking at nicked point. Burnishing
removes notches by removal of surrounding material.
Burnishing is not allowed in the heel of bends where
material has already been stretched thin during form-
ing. Where tubing is used for fluid’s (liquid or gaseous)
at atmospheric pressure or less, bursting strength of
tubing is unimportant and, therefore, dents and nicks
may be disregarded providing that the tubing is struc-
Figure 4-3. Cutting Tube with Tube Cutter
turally sound for its specific application, internally unob-
structed, and that is remains leaktight at all times. Dents e. Bending Tubing. Tubing may be bent with any
can be removed from tubing by drawing a bullet through one of a variety of bending tools. The hand bending tool
tubing. The diameter of the bullet must be equal to or is shown in figure 4-4. Bending in a smaller radius than
slightly less than the inside diameter of the tubing. When limits shown in table 4-1.1, or forming flattened, kinked,
inspecting for damage of tube and tube assemblies, in- or wrinkled bends should be avoided (see figure 4-5).
spect for chafing, galling, or fretting, which may reduce MIL-T-7081-6061T-6 aluminum tubing may be formed
ability of tubing to withstand internal pressure and vibra- through tubing processes by maintaining a 1-inch bend
tion. Replace tubing which shows chafing, galling, or radius for 1/4-inch and 3/8-inch tubing. All sizes above
fretting damage in excess of limits presented in table4-1. 3/8 inch will require the use of a mandrel to form. Bends
in 5/16 inch outside diameter oxygen tubing should
(1) Damage such as chafing, galling or
fretting produces mechanical property

4-2 Change 6
 TM 1-1500-204-23-2

have a radius for 1/4-inch and 3/8-inch tubing. All sizes of hot water, as this reduces tendency of alloy to stick
above 3/8 inch will require the use of a mandrel to form. to inside of tubing.
Bends in 5/16 inch outside diameter oxygen tubing
should have a radius or curvature of at least 11/16 inch. (2) Tube flattening. In some cases, a certain
Tubing may be bent without the aid of tools by carefully amount of flattening may occur when bending tubing
forming desired radius by hand; however, this method regardless of procedure used, especially on thin-walled
is crude and should be used only in absence of proper tubing bent to minimum bend radii. As tube flattens,
tools. Aluminum alloy tubing used in oxygen systems it assumes the shape of an ellipse in cross section,
should not be hand bent. Tubing 1/2 inch outside and the area is reduced. This restriction either reduces
diameter or larger should be packed with fusible alloy, amount of fluid actually delivered, or requires additional
Federal Specification QQ-F-838, to prevent cracked or pumping power to overcome increased line friction.
wrinkled bends. When bending tubing, a large radius When tube is flattened so that minor axis of ellipse is
should be formed and gradually worked down to desired 75 percent of normal tube diameter, area is reduced to
radius. 90 percent of original. Further flattening of tube may be
considered as cause for rejection.

(3) Tube bend data drawing. Tube bend data

A torch or flame should never be applied to tub- shall be prepared on A size drawings in accordance with
ing or fusible alloy, as excessive heat will destoy format shown in figure 4-6. Local forms for tube bend
both strength of heat-treated tubing and melting data are no longer acceptable. Points of possible con-
characteristics of fusible alloy. Boiling water will fusion are explained in the following paragraphs.
not melt fusible alloy after a flame has been ap-
plied. (a) Distance from Y end. DISTANCE FROM
Y END column shows the measured distance from the
(1) Use of fusible alloy for bending tubing. A Y end to the first bend, the measured distance from Y
bending machine should be used when bending alu- end to the second bend, etc. This distance can be mea-
minum or duralumin tubing. Before bending, most sured either by making all measurements before any
aluminum alloy tubing is in annealed condition, and bending takes place, or by utilizing scale on the bending
should be packed with fusible alloy, Federal Specifica- machine.
tion QQ-F-838. One end of tube to be bent is closed
to prevent leakage of fusible alloy. Tubing and ladle (b) Dial setting. DIAL SETTING column
containing fusible alloy is immersed in a tank of boiling shows degree of bend from the horizontal reference
water until alloy is melted. Melting point of the fusible plane. This column is based on a 360-degree graduated
alloy is 160 degrees (71 degrees C). For ordinary tubing dial for the bending machine. Where a dial is graduated
lengths, a hot water tank similar to that used in plating in 180 degrees, right and left indications are used, and it
shops may be used. For longer lengths, a special tank is necessary to compute necessary setting for settings
may be constructed, or a length of pipe used so that more than 180 degrees. This calculation consists of
both tubing and ladle will be completely submerged. subtracting the dial setting shown from 360 degrees.
When fusible alloy has melted, it is poured into tubing. Result will be proper setting for left side of dial. Dial
Both tubing and ladle are kept beneath surface of hot settings less than 180 degrees are identified for both
water during pouring operation so that molten alloy types of dials. For continuity of operation, dial settings
will displace water in tubing. Remove tubing from hot are based on continual clockwise rotation of dial.
water and cool with cold water or allow to air cool until NOTE
fusible alloy is solidified. Tubing can then be bent with
a bending machine or form blocks. Fusible alloy should Example: For a desired dial setting of 286 de-
be cold when bending tubing, and tubing should be bent grees, the reading on a 360-degree dial is 286
slowly. When bending operation is completed, fusible degrees. To determine the reading on a 180 de-
alloy may be removed from tubing by immersing both gree dial for a dial setting of 286 degrees, sub-
tubing and ladle in tank of hot water and pouring alloy tract 286 degrees from 360 degrees. The differ-
back into ladle. When pouring alloy back into ladle, ence (74 degrees) is the reading as read on the
both tubing and ladle should be kept beneath surface left side of the dial.

Change 1 4-3
TM 1-1500-204-23-2

Figure 4-4. Bending Tube with Bending Machine

4-4 Change 1
 TM 1-1500-204-23-2

Titanium tubing with any nicks or scratches deeper than the values listed on table 4-1 shall be replaced.
Steel and aluminum alloy tubing manufactured from material listed in table 4-1 which has nicks or scratches
penetrating more than 15 percent of wall thickness shall be replaced.
Table 4-1. Allowable Tube Defect Depth-Hydraulic Pressure (3000 psi) and Return Lines (1500 psi)

Tube Material Defect Type Tube OD (Note 1)

(Pressure) 1/4 3/8 1/2 5/8 3/4 1 1 1/4
TI-3-AL-2.5V Chafed .006 .007 .008 .010 .011 .012 —
Material (3000 Dented .005 .007 .010 .015 .018 .020 —
psi)
304 1/8H Chafed .006 .007 .008 .010 .011 .012 —
(3000 psi) Dented .005 .010 .020 .030 .040 .040 —
6061T6 (1500 Chafed .015 .015 .010 .005 .004 .015 .003 .015 .003 .015
psi Except (Note 2) (Note 2) (Note 2)
Suction Line) Dented .015 .015 .010 .005 .005 .005 .005
Notes: 1. All dimensions are in inches 2. Suction Line

Table 4-1.1. Bend Radii for Conduit and Fluid Lines1

Minimum bend radii2 Steel tubing

Desirable Minimum
Nominal tube 1100-1/2H, 5052-O radius radius4
OD (inches) (inches) Corrosion resistant3 (inches) (inches) (inches)
1/8 3/8 — — —
3/16 7/16 21/32 3/4 3/8
1/4 9/16 7/8 1 3/8
5/16 11/16 — 1 1/4 3/8
3/8 15/16 1 5/16 1 1/2 3/8
1/2 1 1/4 1 3/4 2 1/2
5/8 1 1/2 2 3/16 2 1/2 5/8
3/4 1 3/4 2 5/8 3 3/4
7/8 2 — 3 1/2 7/8
1 3 3 1/2 4 1
1 1/8 3 1/2 — 4 1/2 1 1/4
1 1/4 3 3/4 4 3/8 5 1 1/2
1 3/8 4 1/4 — 5 1/2 1 3/4
1 1/2 5 5 1/4 6 2 1/8
1 5/8 6 — 6 1/2 2 1/2
1 3/4 7 6 1/8 7 2 7/8
1 7/8 7 1/2 — 7 1/2 3 1/4
2 8 7 8 3 5/8
1
Bend radii measured to inside of bend.
2
Increase bend radii when wall thickness is below standard.
3
Equal to 3–1/2 times tube diameter.
4
The minimum radius will be used only when the desirable radius cannot be used.

Change 6 4-5
TM 1-1500-204-23-2

(c) Distance B. Distance B is the distance or steel wool. If tubing slips in the tool during the flaring
from the last bend to the end of the tube. This mea- operation and the cleaning procedure does not work,
surement may be made with original measurements, clamping blocks should be dipped in a 20 percent solu-
but should be rechecked after final bending operation. tion, by weight, of sodium hydroxide, Military Standard
MS36037, or potassium hydroxide, Military Standard
f. Flaring Tubing. As system pressures increase, MS36035, in water. This will remove the aluminum alloy
tubing joints must be designed so as not to be adversely particles. The inner surface of clamping blocks should
affected by increasing pressures. Single flared tubing never be sandpapered, ground, or refinished, as this
is used for tubing joints on all sizes of steel tubing, will render the tool unsatisfactory for use.
6061 aluminum alloy tubing, MIL-T-7081 , and all sizes
of 5052 aluminum alloy tubing, Federal Specification
WW-T-700/4, above 1/2-inch OD. Double flared tubing
is used for tubing joints on all sizes of 5052 aluminum
alloy having an OD of 1/2 inch or less. Double flaring
reduces cutting of flare by overtightening and failure of
tube assembly under operating pressure. See figures
4-7 and 4-8 for tube dimensions.

Isopropyl alcohol is flammable and toxic to

eyes, skin and respiratory tract. Wear pro-
tective gloves and goggles/face shield. Avoid
repeated or prolonged contact. Use only in well
ventilated areas (or use approved respirator as
determined by local safety/industrial hygiene
personnel). Keep away from open flames,
sparks or other sources of ignition.

Figure 4-5. Acceptable and Unacceptable Tubing

Aliphatic naphtha is flammable and toxic to Bends
eyes, skin and respiratory tract. Wear pro-
tective gloves and goggles/face shield. Avoid (2) Preparing tubing end for flaring. The tub-
repeated or prolonged contact. Use only in ing end is prepared using the following procedures (see
well-ventilated areas ( or use approved respi- figure 4-9):
rator as determined by local safety/industrial
hygiene personel). Keep away from open (a) File end of tubing square with fine flat file.
flames, sparks or other sources of ignition.
(b) Remove burrs from inside and outside of
(1) Preparing flaring tool for flaring. Before tubing with burring tool.
using flaring tool, clamping surfaces should be free from
oil, grease, or aluminum particles. Clamping surfaces (c) Remove all filings, chips, and grit from in-
may be cleaned with naphtha, Federal Specification side of tube.
TT-N-95, or isopropyl alcohol, Federal Specification
TT-I-735, and a stiff fiber brush. Do not use a wire brush

4-6 Change 5
 TM 1-1500-204-23-2

(d) Clean tubing. 33584, on all grades of aircraft tubing including 1/8-inch
through 3/4-inch, 1/4-hard, corrosion-resistant steel.
(e) Inspect tubing end to see if it is round, cut Correct use of the flare tool will give a perfect flare.
square, clean, and free from draw marks and scratches. Incorrect double flares, as shown in figure 4-11, should
Draw marks and scratches are likely to spread and split be cut off and another flare made. A short inner flare
tubing when it is flared. should not be used because of short bearing surface
for the fitting nipple. The short inner flare is caused by
(3) Flaring tool. The flaring tool shown in figure inserting tubing too low in clamp blocks or by tubing
4-10 is suitable for producing tubing flares having a slipping during flaring operation. Improper tightening,
74-degree included angle. It will produce a double lap jamming of tightening screw, or dirt on inner surface of
flare, conforming to Military Standard MS33538, on clamp blocks will cause tubing to slip. A long inner flare
3/16-inch through 3/4-inch mild aluminum tubing, and should not be used because it will restrict fluid flow. The
a single lap flare, conforming to Military Standard MS long inner flare is caused by improper gauging.

Change 4 4-6.1/(4-6.2 blank)

 TM 1-1500-204-23-2

Figure 4-6. Tube Bend Data Drawing

4-7
TM 1-1500-204-23-2

Figure 4-8. Dimensions for Double-Flared Tubing

Figure 4-9. Properly Burred Tube

Figure 4-7. Dimensions for Single-Flared Tubing

4-8
 TM 1-1500-204-23-2

NOTE shield. Avoid repeated or prolonged con-

tact. Use only in well ventilated areas (or use
Tubing should be flared by the single flare approved respirator as determined by local
method only in an emergency when a double safety/industrial hygiene personnel). Keep
flare tool is not available. away from open flame other sources of ignition.

Compressed air shall not be used for cleaning

purposes unless reduced to less than 30 psi
and then only with effective chip-guarding and
personal protective equipment.

To avoid oil base contamination, clean oxygen

tubing and fittings in accordance with paragraph
4-2g(2).

Figure 4-10. Flaring Tool NOTE

Store solvent in nonflammable storage cabinet

when not in use.

(1) Cleaning process. Clean tubing with suit-

able solvent to remove dirt, grit, or other foreign matter.
Always check the applicable technical manual (TM) for
any special procedures for cleaning and testing. If no
particular type of solvent is specified in the applicable
TM, use degreasing solvent, MIL-PRF-680, Type II, for
Figure 4-11. Tubing with Double Lap Flare petroleum and synthetic-base fluid lines. The part will
be soaked and washed thoroughly in the solvent. All
g. Cleaning Tubing. After tubing is bent and ends parts must be completely dry before being assembled
are flared, it will thoroughly cleaned prior to installation or installed. Use compressed dry, filtered air to dry
in the aircraft. parts. Keep solvent in a tightly sealed container. When
using solvent indoors, be sure that the work area is
well-ventilated.

Degreasing solvent, MIL-PRF-680, is com- (2) Cleaning oxygen system tubing. All oil and
bustible and toxic to eyes, skin and respiratory grease will be removed from oxygen tubing and fittings
tract. Wear protective gloves and goggles/face using one of the following methods.

Change 4 4-9
TM 1-1500-204-23-2

HFE-71DE is toxic to eyes, skin and respiratory Aliphtatic Naphtha is extremely flammable and
tract and decomposes into other hazardous toxic to eyes, skin and respiratory tract. WEar
products when exposed to extreme heat. Wear protective gloves and goggles/shield. Avoid re-
chemical protective gloves and goggles/face peated or prolonged contact. Use only in well
shield. Avoid repeated or prolonged contact. ventilated areas ( or use approved respirator
Use only in well ventilated areas. If ventilation as determined by local safety/industrial hygiene
is not adequate, use approved respirator as personnel). Keep away from open flame other
determined by local safety/industrial hygiene sources of ignition.
personnel. Keep away from open flames, weld- Isopropyl alcohol, TT-I-735 is flammable and
ing or other sources of ignition. toxic to eyes, skin and respiratory tract. Wear
protective gloves and goggles/shield. Avoid
n-Propyl Bromide is toxic to eyes, skin, and repeated or prolonged contact. Use only in well
respiratory tract. Wear protective gloves and ventilated areas (or use approved respirator as
goggles/face shield. Avoid repeated or pro- determined by local safety/industrial hygiene
longed contact. Use only in areas with ade- personnel). Keep away from open flame other
quate mechanical or local exhaust ventilation sources of ignition.
(or use approved respirator as determined by
local safety/industrial hygiene personnel). (b) Method B. Tubing shall be flushed with
naphtha, Federal Specification TT-N-95. Tubing is then
(a) Method A. A vapor degreasing method blown clean and dry of all solvent with water-pumped
with stabilized n-propyl bromide or HFE-71DE shall be air. Tubing shall be flushed with anti-icing fluid, Military
used. Proper cleaning is assured by allowing tubing Specification TT-I-735, and rinsed with fresh water. Tub-
and fittings to remain in vapor degreaser until operating ing is dried with a stream of clean, dry, water-pumped air
temperature is obtained. Tubing is blown clean and or by heating at a temperature of 250 to 300 degrees F
dried with a stream of clean, dry, oil free air. Clean, dry, (121 to 149 degrees C for a suitable period. After clean-
nitrogen, -40 degrees C/F dewpoint, Federal Specifica- ing, aluminum tubing should be treated with a brush coat
tion BB-N-411, may be used in place of dry air. Every of chemical film MIL-C-5541. If light corrosion is found,
precaution should be taken to ensure the tubing and apply a coat of enamel over chemical film. In cases of
fittings are clean. severe corrosion pitting, replace the tubing.

4-10 Change 5
 TM 1-1500-204-23-2

Remove dents and scratches, and be sure all nuts and

sleeves are snugly mated and securely fitted by proper
flaring. The tube assembly should be clean and free of
all foreign matter.

(1) AN parts in tube assemblies. In the

manufacture of tube assemblies, an AN818 nut and an
MS20819 sleeve are used with the flared end of the
tube for attaching tube assembly to other AN parts in
the aircraft system. A AN817 sleeve nut is available
for the same functional purpose, but is not widely used
(see figure 4-14). All of these fittings have straight
threads conforming to MIL-S-7742. Government Stan-
dard fittings have superseded all other types of fittings,
and should be used in preference to all others.

NOTE

The Department of Defense is in the process

of changing AN designations for Government
Standard parts of MS designations. Any infor-
mation pertaining to AN parts is equally perti-
nent for MS parts which supersede AN parts.

Figure 4-12. Beading Large Tubing (a) Tubing fittings AN 818 and MS
20819. The AN 818 nut is made of steel or aluminum
h. Beaded Tubing Joints. Beaded joints are used alloy and MS 20819 sleeves are made from corro-
on low pressure lines. The most practical and rapid way sion-resistant steel. These parts are shown installed in
of forming beads is by using a tool with a rolling action figure 4-15. On these fittings, size is given as a dash
as shown in figure 4-12. Dimensions for beaded joints number which equals the tubing outside diameter in
are given in figure 4-13. sixteenths of an inch.

i. Installation of Flared Tubing. Before installing

a tube assembly in an aircraft, inspect the line carefully.

Change 4 4-10.1/(4-10.2 blank)

 TM 1-1500-204-23-2

NOTE
USE OF TYPE A AND B OPTIONAL ON CORROSION
RESISTANT STEEL AND BRASS TUBING 3/4 INCH OVER.
REMOVE ALL BURRS AND SHARP EDGES

Figure 4-13. Bead Dimensions

4-11
TM 1-1500-204-23-2

NOTE

Depot level activities, including commercial

contractors, affecting overhaul, repair, or mod-
ification of service aircraft are prohibited from
using antiseize compounds on flared tubing
threads. These activities will replace fittings
that are manufactured to maximum or minimum
thread tolerances.
(d) Replace cracked fitting
sleeves. Cracked fitting sleeves installed on fuel,
hydraulic, water, and pneumatic tubing subjected
to pressures up to and including 3000 psi are not
considered unsafe and do not need to be replaced
unless a leak occurs. If a leak occurs, they must
Figure 4-14. Tube and Fitting Alignment be replaced. An exception to this is when a line is
disconnected for any other reason, all cracked fitting
sleeves shall be replaced with serviceable fitting
sleeves. These instructions also apply to cracked fitting
sleeves on return, vent, and drain lines. The above
statements are not to be interpreted to mean that a
cracked fitting sleeve or sleeves cannot be replaced at
the discretion of responsible quality control personnel.
Minor surface corrosion on sleeves and fittings, while
not desirable, is acceptable. Whether or not corroded
sleeves and fittings will be replaced is also at the
discretion of responsible quality control personnel.

(2) Installation and replacement of tubing

Figure 4-15. Tubing Fittings assemblies. Before a tubing assembly is installed in
an aircraft, it shall be carefully inspected. Dents and
(b) Identification of tubing fittings. AN fit- scratches shall be removed, proper nuts and sleeves
tings are easily identified by their distinguishing colors; installed, and a proper fit obtained where tubing is
blue for aluminum alloy and black for steel. Aluminum- flared. Tubing assembly shall be clean and free from
bronze fittings are cadmium plated, and are not other- all foreign matter. Sleeve and nuts shall be screwed to
wise colored. Only steel fittings are used with steel tub- mating fitting by hand and nuts tightened with proper
ing 3/8-inch outside diameter and smaller. Intermixing wrench. Tubing shall not be pulled into place with the
of tubing and fittings, other than above is permissible. nut, but shall be properly aligned prior to tightening. If
tubing assemble is long; edges of cutout shall be taped
before tubing is installed. The fitting wrench or open
(c) Thread compounds. Thread com-
end wrench shall be used when tightening. Pliers shall
pounds should not be used on flared tubing fitting
never be used to tighten fittings. Adjustable open end
threads. Use of thread compounds should be limited
wrenches may be used only when proper tools are not
to tapered male pipe threads. In rare instances, it is
available. Overtightening nuts may severely damage or
possible to obtain a flared tubing fitting manufactured
completely cut off tubing flares or may result in damage
to maximum tolerance which, when coupled to a tubing
to sleeve or nut of fitting. If nut and sleeve are removed
nut manufactured to minimum tolerance, will be difficult
from a section of tubing, and flares are found to retain
to tighten. If this occurs, organizational, and direct and
less than 50 percent of their original wall thickness,
general support maintenance activities are authorized
tube shall be replaced. Undertightening nuts may also
to apply tape, MIL-T-27730, to the first three threads
be serious, as this may allow tubing to blow out or leak
to reduce friction. Tape should not be allowed on the
at fitting because of insufficient grip on flare by sleeve.
fitting cone as this will prevent metal-to-metal contact.
Use of torque wrenches will prevent undertightening. A
nut shall never be tightened to a torque when pressure
is on system, as this will tend to cut flare without adding

4-12
 TM 1-1500-204-23-2

any appreciable torque to fitting. Maximum wrench depending on the hose type. In the absence of a hose
torques, in inch-pounds, for fitting nuts on various sizes clamp torque wrench, the fingertight-plus-turns method
and types of tubing are shown in table 4-2. shown in table 4-3 should be used. Due to the variance
in hose clamp design and hose structure, values given in
j. Installation of Beaded Tubing. Beaded tubing table 4-3 are approximate and care should be exercised
is used in low-pressure applications using rubber hose when tightening clamps by this method.
and hose clamps (see figure 4-16).
NOTE
(1) Proper sealing of hose connections. To
prevent breakage of hose clamps and damage to hose, Aircraft hose constructed with synthetic com-
instructions on tightening hose clamps shall be followed pound has tendency to cold flow. Therefore,
carefully. When available, use any approved torque when new hose is installed, clamps should, af-
wrench to torque hose clamps as per (2) or (3) below, ter a period of time, be retightened in order to
maintain original torque value. This is caused
by synthetic rubber flowing from under clamp-
ing area and not from loosening of clamps.

Figure 4-16. Installed Low-Pressure Hose

Table 4-2. Hydraulic Tubing B-Nut (AN818) Torque Values

Torque on tube nut

Tube outside diameter Aluminum alloy tubing Steel tubing
1/4 Inch 40-65 Inch-Pounds 135-150 Inch-Pounds
5/16 Inch 60-80 Inch-Pounds 180-200 Inch-Pounds
3/8 Inch 75-125 Inch-Pounds 270-300 Inch-Pounds
1/2 Inch 150-250 Inch-Pounds 450-500 Inch-Pounds
5/8 Inch 200-350 Inch-Pounds 650-700 Inch-Pounds
3/4 Inch 300-500 Inch-Pounds 900-1,000 Inch-Pounds
1 Inch 500-700 Inch-Pounds 1200–1400 Inch-Pounds

4-13
TM 1-1500-204-23-2

Table 4-3. Hose Clamp Tightening, Fingertight-Plus Turns Method, Beaded Tubing

Clamps, radial
Clamp, worm screw-type (10 and other type (28
Initial installation only threads per inch) threads per inch)
Self-Sealing Hose Fingertight Plus 2 Complete Turns Fingertight Plus 2 1/2
Complete Turns
Approximately 25 to 30
Inch-Pounds
All Other Aircraft Hose Fingertight Plus 1 1/2 Complete Fingertight Plus 2
Approximately 25 to 30 Turns Complete Turns
Inch-Pounds

(2) Clamps on self-sealing hose. Hose clamps

installed on self-sealing hose shall be tightened to a
torque of 25 inch-pounds minimum to 30 inch-pounds
maximum for original installation, and maintained at this
torque value. When sealing is not effective at 30 inch-
pounds, component parts of connection shall be exam-
ined, and unserviceable parts replaced. Under no cir-
cumstances shall hose clamp be tightened in excess
of 30 inch-pounds in an attempt to effect sealing. This
added torque will reduce safety factor of hose clamps as
well as destroy hose and connection.
(3) Clamps on nonself-sealing hose. Hose
clamps installed on nonself-sealing hose shall be in-
stalled and maintained at a torque of 25 inch-pounds
minimum to 30 inch-pounds maximum. If satisfac-
tory sealing is not accomplished at a torque of 30
inch-pounds, component parts of connection shall be
examined and unserviceable parts replaced.
4-3. FITTINGS. Hydraulic fittings are used throughout
the hydraulic system to provide simple connections be-
tween hydraulic components and tubing. Standard MS
Figure 4-17. MS Fitting and Components
(flareless) and AN (flared) fittings are used in Army air-
craft. Both types are made in many different shapes
and designs. They may be ordered in either male or
female design or in a combination design (male on one
end and female on the other). The hydraulic repairer
is concerned with installing both the AN and MS fittings
in aircraft hydraulic systems. Normally, the fittings to be
used in an aircraft hydraulic system are selected accord-
ing to the design of the system. The hydraulic repairer
repairs fitting failures by duplicating the original installa-
tion.

4-14
 TM 1-1500-204-23-2

a. Flareless Fittings. The main feature of MS fit-

tings is that they can be used to connect unflared tubing.
An MS fitting has a counterbore in which the tube end
is installed. In the half-sectional view of an MS fitting in Compressed air shall not be used for cleaning
figure 4-17, notice the 24-degree beveled portion of the purposes unless reduced to less than 30 psi
counterbore and its seat. The seat forms a slope for the and then only with effective chip-guarding and
tube during the connection of one tube to another tube or personal protective equipment.
for a tube to a component and the beveled area causes
the tube connector sleeve to seal the connection as the (3) Installation of flareless fittings. MS fittings
tube B-nut is tightened. must be inspected before installation. If it is impos-
sible to see through a fitting or tube, blow clean, dry
(1) Identification of flareless fittings. MS fit- compressed air through it to be certain that no obstruc-
tings are made of aluminum alloy or steel. Aluminum tions exist. Any lines that have caps removed in storage
alloy fittings can be identified visually by their yellow or before installation should be flushed with clean hy-
color, which is caused from the anodizing treatment. draulic fluid . Male threads and sleeves of the fittings
The cadmium plating on steel fittings are identified by being assembled should be lubricated with the type of
letter-number codes; for example, MS21900-4, which is hydraulic fluid used in the system. On fittings with ta-
interpreted as follows: pered threads, use antiseize compound on the threads,
except for the first three, which are left dry.

(a) Gasket. To make a connection between

MS . . . . . prefix (military specification)
tubing and a component, the proper gasket is selected,
21900 . . . design part number (adapter, lubricated, and installed in position as shown in figure
flare-less tube to AN flared tube) 4-19. The fitting is screwed into the boss of the compo-
nent until it bottoms on the boss.
4 ....... size of fitting in sixteenths of an nch
(4/16 (inch) (b) Installing tubing. When connecting tub-
ing to an MS fitting, the tube should be aligned with
The material from which the fittings are made is indi- the fitting and the nut should be started by hand with-
cated by the absence of a letter at the end of the MS out excessive strain on the line (see figure 4-20). Do
number or by the addition of a letter at the end of the not use force to align tubing. Tube alignment can often
number, for example: be obtained by loosening clamps on connecting lines or
MS21900-4 is made from carbon steel. by rotating fittings. Both ends of the tubing should be
MS21900-8-D is made from aluminum alloy. connected and tightened until a decided increase in re-
MS21900-8-S is made from corrosion-resistant steel, sistance to turning of the B-nut is encountered. At this
class 347. point, tighten the clamps, ensuring that they do not pull
the tubing out of alignment and place it in a binding po-
(2) Types off flareless fittings. See figure 4-18 sition. Complete the installation by turning the B-nut
for examples of MS flareless fittings. one-sixth of a turn. See figure 4-21 for turns and torque
values. Pressurize the hydraulic system and inspect
for leaks. If leakage is noted, release system pressure
and completely loosen the B-nut. If possible, rotate the
sleeve to a new position and then retorque the B-nut to
its previous position plus one-sixth of a turn. Normally
this will stop the leak, but if it does not, replace the as-
sembly.

4-15
TM 1-1500-204-23-2

Figure 4-18. MS Flareless Fittings

4-16
 TM 1-1500-204-23-2

(c) Tube-to-tube connections. To make a (b) Resetting (installation). Tighten the

tube-to-tube connection, the tube B-nut is tightened MS21921 nut in accordance with table 4-5.
until a definite resistance is felt and is then turned
one-sixth of a turn farther. The upper wrench is held (c) Boss installation of fitting end, style E.
stationary while the lower wrench is moved upward This fitting can be installed as follows:
until the B-nut is tightened a sufficient amount (see
figure 4-22). On this tube connection, like most others, 1 Lubricate the packing in appropriate liq-
a 1/8-inch colored stripe may be painted across the uid (refer to table ).
completed assembly so that loosening can be readily
detected (see figure 4-23). 2 Install packing on the fitting as shown in
detail A, figure 4-25.
(4) Bulkhead fitting installation. These fittings
are used for connecting tubing to components of the sys- 3 Screw the fitting assembly into the boss
tem, and for connecting sections of tubing where the line using installation torque in accordance with table 4-7.
passes through a bulkhead and the fitting is secured to
the bulkhead, as shown in figure 4-24. Refer to table (d) Installation of AN 924 jamnut. Torque
4-4 for the correct fitting size. values can be found in table 4-8.
(a) Hand presetting of MS21922 b. Oxygen System Tapered Pipe Thread. Ta-
sleeve. The MS21922 sleeve can be preset using the pered pipe thread fittings are a versatile and efficient
following procedures: method of connecting tubing to components.
1 Bottom the tube end firmly in the seat of (1) Tubing fittings tapered pipe threads. Pipe
the preset tool or fitting. threads should conform to MIL-P-710-5. Straight thread
and tapered pipe thread are shown in figure 4-26.
2 Tighten the MS21921 nut 1 1/6 turns
past the point of ring grip on all sizes and materials for NOTE
all types of fittings or tubes. When installing pipe thread fittings, fittings
should be tightened but not enough to damage
threads or crack the part in which fitting is being
installed.

Figure 4-19. MS Fitting Gasket Installation Figure 4-20. Tubing Alignment

4-17
TM 1-1500-204-23-2

TIGHTENING-RULE OF THUMB (FLAT

TUBING SIZE TORQUE (INCH POUNDS) TURNS AFTER PRETIGHTENING)
NORMAL TIGHT EXTRA TIGHT

ALUMINUM – 3 65 TO 95
OR STEEL – 4 100 TO 150 1 TO 1 1/2 2 MAXIMUM
– 6 175 TO 300 1 TO 1 1/2 2 MAXIMUM
– 8 325 TO 500 1 TO 1 1/2 2 MAXIMUM
– 10 400 TO 700 1 TO 1 1/2 2 MAXIMUM
– 12 500 TO 800 1 TO 1 1/2 2 MAXIMUM
– 16 500 TO 800 1 TO 1 1/2 2 MAXIMUM
ALUMINUM – 20 600 TO 900 1 TO 1 1/2 2 MAXIMUM
– 24 600 TO 900 5/6 TO 1 1 1/2 MAXIMUM

Figure 4-21. MS Turns and Torque Values

Figure 4-23. Marking MS Fitting

Figure 4-22. Tubing-To-Tubing Connections

4-18
 TM 1-1500-204-23-2

Figure 4-24. Bulkhead Flareless Fiting Installation

Table 4-4. Bulkhead Flareless Fitting Installation

AN960 washer
thickness
AN960 washer (bulkhead
Fitting Bulkhead hole thickness (bulkhead Bulkhead hole 0.187 thick
size dia (ref)* 0.187 thick or less) Fitting size dia (ref) or less)
-2 0.318/0338 -10 0.880/0.900
-3 0.380/0.400 -12 1.068/1.088
-4 0.443/0.463 0.062 -16 1.318/1.338 0.094
-5 0.505/0.523 -20 1.630/1.650
-6 0.568/0.588 -24 1.880/1.900
-8 0.755/0.775 0.094 -32 2.505/2.525

NOTE

For hole sizes shown (based on AN9601D), no washer required with , Style S. For bulkheads thicker than
0.187 or with , Style E for all thickness.

4-19
TM 1-1500-204-23-2

(a) Theory of pipe thread seal. The (4) Unscrew fitting to approximate position de-
threaded portion of a pipe fitting is tapered so that sired but not more than 360 degrees.
when it is tightened, the part with the external thread
(male) is forced into the internally threaded (female) (5) Tighten locknut lightly.
part, creating a seal.
(6) Assemble flared tubing to fitting.
(b) Tightening fittings with pipe
threads. Extreme care shall be taken when tightening (7) Tighten locknut against boss.
pipe fittings. Overtightening causes distortion, cracking,
and leaks. Tighten 1/8-inch fittings to a torque of 125 e. Universal Fittings AN 832, AN 833, and AN
to 175 inch-pounds, 1/4-inch fittings of 200 to 300 834 High Pressure. It is necessary to use a backup
inch-pounds, and 3/8-inch fittings to a torque of 300 to washer in the check nut when combination bulkhead
400 inch pounds. and universal fittings are installed in bosses on sys-
tems where pressures exceed 1000 psi. This method
(2) Tubing fitting thread lubricants. Vari- eliminates the possibility of high pressure extending the
ous lubricants and antiseize compounds are used on rubber gasket into threaded areas of fitting. A leather
threads to prevent seizing and difficulty in disassembly. washer (MS28777) is used to prevent this extrusion
Threads that give the most trouble are male and female of the rubber gasket. A Teflon backup ring (MS9058)
cast aluminum alloy tapered pipe threads. Pipe threads is used in lieu of the leather washer in systems where
secure their sealing features by interlocking of threads. temperature in excess of 160° F (71° C) are anticipated.
Threads being tapered become highly stressed in final The method of installation is as follows:
torqued condition. Due to this high stress and peculiar
stress-strain characteristics of aluminum alloy, threads (1) Install nut as high up on fitting as possible.
may deform permanently, causing sufficient misalign- Add leather washer and gasket in position shown in de-
ment to make it difficult to disassemble unit. It is highly tail A, figure 4-27.
desirable that male parts be made of different mate-
rial and properly lubricated with antiseize compound. (2) Screw fitting assembly into boss until first
Federal Specification TT-S-1732, or equivalent. Low thread at top of fitting groove is from 3/16- to 1/8-inch
pressure lines with low torque anodized aluminum alloy from top surface of boss, as shown in detail B, figure
fittings and with antiseize compound used, may be 4-27.
disassembled under normal conditions.
(3) Hold fitting stationary and screw nut down
c. Straight Pipe Thread. Straight pipe thread is until it seats on boss. Slight extrusion of leather washer
used on fittings in hydraulic components connected to between surface of boss and nut is considered satisfac-
tubing. It is shown in figure 4-26. tory, as shown in detail C, figure 4-27.
d. Universal Fittings AN 832, AN 833, and AN 854 (4) Tighten locknut against boss
Low Pressure. These fittings are used for connecting
tubing to components of the system and for connecting
f. Rosan Fluid Fittings. The Rosan fluid fitting is
sections of tubing where the line passes through a bulk-
a one-piece, thin wall insert with an external lockring.
head and fitting is secured to the bulkhead. These fit-
The Rosan insert is fabricated from 6AL-4V titanium per
tings are satisfactory for pressures up to and including
AMS4967. The lockring is fabricated from A-286 corro-
1000 psi. For information pertaining to systems of over
sion-resistant steel per AMS5734 and is retained on the
1000 psi, refer to paragraph e. Bulkhead fittings shall
insert by a controlled interference fit. The Rosan fluid
be installed on system components as follows:
fitting is used to provide semi-permanent port mounted
installations and is compatible with Dynatube or flared
(1) Assemble nut on fitting end and screw all the tube ends. The unique features of the Rosan fluid fitting
way back to clear gasket groove. are as follows.
(2) Place gasket or equivalent performed pack- (1) Lockring provides positive lock.
ing in gasket groove.
(2) No lockwiring required.
(3) Screw fitting into boss until gasket contacts
boss.

4-20
 TM 1-1500-204-23-2

Table 4-5. Torque Values for MS21921 Coupling Nut Based on Lubrication Method, or Dry (Lubrication -
None) as Directed in Applications Column and Appropriate Lubricant Column, Table 4-6

Alum (6061-T6) tubing wall

Tube Code1 thickness (in) Torque (lb in.)
heavy thin min. max.
-2
-2
-2 A, B 50 60
-2
-3 C 0.028 95 105
-3
-3 A, B 95 105
-3
-4 C 0.035 135 145
-4 D 0.028 120 135
-4 A, B 135 145
-4
-5
-5
-5 A, B 170 190
-5
-6 C 0.049 215 245
-6 D 0.028 190 215
-6 A, B 215 245
-6
-8 C 0.065 470 510
-8 D 0.035 340 380
-8 D 0.049 340 380
-8 A, B 470 510
-10 C 0.083 620 680
-10 D 0.035 380 450
-10 D 0.049 380 450

-10 A, B 620 680

-12 C 0.095 855 945
-12 D 0.049 400 470
-12 D 0.065 400 470
-12 A, B 855 945
-16 C 0.065 1140 1260
-16 D 0.049 750 850
-16 A, B 1140 1260
See footnotes at end of table.

Change 3 4-21
TM 1-1500-204-23-2

Table 4-5. Torque Values for MS21921 Coupling Nut Based on Lubrication Method, or Dry (Lubrication -
None) as Directed in Applications Column and Appropriate Lubricant Column, Table 4-6 — Continued

Alum (6061-T6) tubing wall

Tube Code 1 thickness (in) Torque (lb in.)
heavy thin min. max.
-20

-20 D 0.049 1000 1100

-20 A, B 1520 1680
-20
-24
-24
-24 A, B 1900 2100
-24
-32
-32
-32 A, B 2660 2940
-32

1
Code
A Steel, corrosion-resistant or titanium nut tube or fitting.
B Aluminum fittings or nuts used with cres tubing.
C Aluminum fittings or nuts used with heavy wall aluminum tubing (6061-T6).
D Aluminum fittings or nuts used with thin wall aluminum tubing (6061-T6).

Table 4-6. Packing and Lubricant Selection

Appropriate
Application Specification number lubricant
Hydraulic (Petroleum Base) MS28778, MIL-R-83248/1, System Fluid
MS3393, MIL-R-83248/2
Hydraulic (Phosphate Ester) NAS1612 System Fluid
Pneumatic MS9385 MIL-G-4343
Engine Lubricant (Petroleum Base) MS9387 System Fluid
Engine Lubricant (Synthetic Base)
Engine fuel (Gasoline: JP-3, -4, -5,
-6; RJ-1; RP-1; HEF-2 )
Oxygen MS9385 None
Vacuum NAS1596 None
Coolant (Ethylene Glycol) MS28778 None
Coolant (Silicate Esters)

4-22
 TM 1-1500-204-23-2

Figure 4-25. Installation of Fitting End

Table 4-7. Torque Values for Boss Installation Using Packings (In-Lb) (Fittings Per , Style E, AN6289 Nut
Used With Fittings Per , Style E or S, all Materials, Based on Lubrication Method, or Dry (Lubrication -
None) as Directed in Applications Column and Appropriate Lubricant Column, Table 4-6)

Torque
Size Tube OD (in.) (ref) Thread
min. max.
-2 1/8 (0.125) 5/16-24 50 55
-3 3/16 (0.187) 3/8 -24 65 75
-4 1/4 (0.250) 7/16-20 95 105
-5 5/16 (0.312) 1/2 -20 125 135
-6 3/8 (0.375) 9/16-18 155 165
-8 1/2 (0.500) 3/4 -16 280 305
-10 5/8 (0.625) 7/8 -14 380 405
-12 3/4 (0.750) 1 1/16-12 550 600
-16 1 (1.000) 1 5/16-12 800 900
-20 1 1/4 (1.250) 1 5/8 -12 900 1000
-24 1 1/2 (1.500) 1 7/8 -12 900 1000
-32 2 (2.000) 2 1/2 -12 900 1000

4-23
TM 1-1500-204-23-2

Table 4-8. Torque Values for AN924 Jamnut Used on Fittings Per Style E or S in Bulkhead Installations
(In-Lb)

Size Tube OD (in.) (ref) Thread Torque

min. max.
-2 1/8 (1.25) 5/16 — 24 35 50
-3 3/16 (1.87) 3/8 — 24 65 80
-4 1/4 (0.250) 7/16 — 20 85 105
-5 5/16 (0.312) 1/2 — 20 105 125
-6 3/8 (0.375) 9/16 — 18 120 150
-8 1/2 (0.500) 3/4 — 16 240 280
-10 5/8 (0.625) 7/8 — 14 320 380
-12 3/4 (0.750) 1 1/16 — 12 500 600
-16 1 (1.000) 1 5/16 — 12 720 880
-20 1 1/4 (1.250) 1 5/8 — 12 960 1200
-24 1 1/2 (1.500) 1 7/8 — 12 1200 1440
-32 2 (2.000) 2 1/2 — 12 1400 1500

NOTE

Fitting shall be restrained from turning when torquing to values given in table 4-6 and this table.

(3) Standard fitting ends per MS33656, or Dy-

natube.

(4) Quick replacement of packing without dam-

age to the fitting or port.

(5) Standard packings used in assembly.

(6) Only one wrench required during removal

and installation of tubing.

Figure 4-26. Straight Thread and Pipe Thread

4-24
 TM 1-1500-204-23-2

the tubing is fitted. This flared area of the fitting is the

sealing surface and must be maintained. Any bad flare
on this sealing surface will show up as a hydraulic leak.

(1) Identification. AN flared fittings can be iden-

tified by the part number, as described in table 4-9.

(2) Types. See figure 4-28 for examples of flared

fittings.

(3) Use of old fittings in oxygen systems. In

repairing oxygen systems, it is usually possible to use
the old fittings. Fittings should be cleaned before they
are installed. Refer to paragraph 4-2 g (2) for cleaning
procedure for oxygen fittings.

(4) Repairing tubing fittings. See figure 4-29

for repairable and non-repairable defects of tubing
fittings. Tubing fittings may be repaired provided 80
percent of seat remains after repair. The only marks
Figure 4-27. Combination Bulkhead and Universal allowed on seat surface are annular tool marks of 100
Fitting Assembly micro inches root mean square maximum. Fittings that
cannot be salvaged by this method should be rejected.
(7) Installation of Rosan Fluid Fitting will be in- Reworked aluminum alloy fittings should be anodized.
stalled in accordance with TM 43-0104. Minor scratches are not cause for replacement. If
wrench damage to a hexagonal section of a fitting does
g. Flared Fitting. Flared fittings, like flareless not exceed one corner, it should be reworked with a
(MS) fittings, come in many different shapes. The main fine file in such a manner as to leave no file marks.
difference between AN and MS fittings is the manner in A maximum of one corner may be reworked provided
which the hydraulic tube fits to the fitting. The MS fitting 75 percent of reworked flange width is not damaged.
has a counterbore in which the tubing is inserted; the Damaged threads should be inspected and repaired.
AN fitting has a 37 degree flared (beveled) face to which

Change 4 4-25
TM 1-1500-204-23-2

NOTE not be salvaged by this repair should be con-

demned.
All screw threads MIL-S-7742, that are within
the pitch diameter tolerances of Class 2, after 4-4. REPAIR OF TUBING ASSEMBLIES. Scratches
rework, are acceptable for further use. or nicks no deeper than 10 percent of the wall thickness
in aluminum alloy tubing may be repaired, if they are
Deleted not in the heel of a bend. Replace lines with severe die
marks, seams, or splits in the tube Any crack or defor-
High pressure hose end fitting assemblies, 300 mity in a flare is also unacceptable and is cause for rejec-
psi and swage-type fittings of any pressure tion. A dent of less than 20 percent of the tube diameter
range, should not be reworked. MIL-F-8789 is not objectionable, unless it is in the heel of a bend.
states that MS28760 and MS28761 fittings Dents can be removed by drawing a bullet of the proper
should be used only once. size through the tube by means of a length of cable.
Coupling nuts sometimes modified for use on
hose end fitting assemblies are not interchange-
able with AN818 nuts. All AN fittings that can-

Table 4-9. AN Flared Fitting Identification

Material Color Code

Aluminum Alloy Blue D
Steel Black None
Brass Natural B
AN 819 (Sleeves) Aluminum Bronze Cadmium Plated Z

NOTE

Size: The dash number following the AN number indicates the size of the tubing (or hose) for which the
fitting is made, in 16ths of an inch. This size measures the O. D. of tubing and the I. D. of hose. Fittings
having pipe threads are coded by a dash number, indicating the pipe size in 8ths of an inch. The material
code letter, as noted above, follows the dash number.
EXAMPLE:

a. Precautions. The following precautions should (1) Take extreme care to remove all chips,
be followed to ensure an effective repair: burrs, and foreign material from tubing during repair.

4-26 Change 4
 TM 1-1500-204-23-2

(2) Any open line or fitting that will be left unat- (3) Cut a repair section of same diameter as
tended will be capped or plugged to prevent possible damaged tubing 1/2 inch shorter than removed dam-
contamination of the entire hydraulic system. aged portion. Deburr repair section and bead. Clean
tube.
b. Repair of Low-Pressure Tubing Assembilies
. Low-pressure tubing assembilies can be repaired by (4) Cut two synthetic hose connections of
the following procedures: proper length and install a hose clamp over each end
of each hose connection. Slip both hose connections
(1) Remove damaged portion of tube, deburr re- well back over original tube. See figure 4-31 for tubing
maining ends, and remove cuttings from tube interior clearances.
(see figure 4-30).

(2) If possible, bead remaining tube ends.

Change 4 4-26.1/(4-26.2 blank)

 TM 1-1500-204-23-2

Figure 4-28. AN Flared Fittings

(5) Position repair insert. 4-10 are approximate and care should be exercised
NOTE when tightening clamps by this method.
When positioning hose clamps or tightening NOTE
screws, care should be taken to prevent screws
from chafing or damaging adjacent parts. (a) Hose clamps installed on self-sealing
Where such damage is possible, hose clamps hose shall be tightened to a torque of 25 inch-pounds
should be repositioned on hose. minimum to 30 inch-pounds maximum for original in-
(6) Slip hose connections midway over junction stallation, and maintained at this torque value. When
formed by original tube and repair section. Use glycer- sealing is not effective at 30 inch-pounds, component
ine, Federal Specification O-G-491, on metal pipe to aid parts of connection shall be examined, and unservice-
sliding of rubber hose. able parts replaced. Under no circumstances shall hose
(7) Tighten hose clamps. To prevent breakage clamp be tightened in excess of 30 inch-pounds in an
of hose clamps and damage to hose, instructions on attempt to effect sealing. This added torque will reduce
tightening hose clamps shall be followed carefully. safety factor of hose clamp as well as destroy hose and
When available, use any approved torque wrench to connection.
torque clamps as per (a) OR (b) below, depending on
the hose type. In the absense of a hose clamp torque (b) Hose clamps installed on nonself-sealing
wrench, the fingertight-plus-turns method shown in hose shall be installed and maintained at a torque of 25
table 4-10 should be used. Due to the variance in hose inch-pounds minimum to 30 inch-pounds maximum. If
clamp design and hose structure, values given in table satisfactory sealing is not accomplished at a torque of

4-27
TM 1-1500-204-23-2

Figure 4-29. Damaged Fittings

Figure 4-30. Repair of Low-Pressure Tubing

4-28
 TM 1-1500-204-23-2

Figure 4-31. Tubing End Clearance for Low-Pressure Tubing Repair

4-29
TM 1-1500-204-23-2

Table 4-10. Hose Clamp Tightening, Fingertight-Plus Turns Method

Clamps, Radial and

Clamp, worm screw-type (10 threads other type (28 threads
Inital Installation only per inch) per inch)
Self-Sealing Hose Fingertight Plus 2 Complete Turns Fingertight Plus 2 1/2
Complete Turns
Approximately 25 to 30
Inch-Pounds
All Other Aircraft Hose Fingertight Plus 1 1/2 Complete Turns Fingertight Plus 2
Approximately 25 to 30 Complete Turns
Inch-Pounds

30 inch-pounds, component parts of connection shall be assembly will amount to replacement of tubing only. If
examined and unserviceable parts replaced. tubing is small and made of soft material, assembly may
be formed during installation by hand bending. How-
(c) Hose clamps installed on rubber nipple- ever, if tubing is of such material and size that hand
type fuel cell fittings and fuel system molded rubber con- bending is impractical, care shall be taken to remove
nections shall be tightened to a torque of 15 inch-pounds assembly without further damage or distortion so that it
for original installation, and maintained at finger-tight can be used as a forming template. This will allow du-
plus 1 1/4 turns. Fuel cell fittings are very easily dam- plication as to length, bends, and angles. All tubing for
aged by hose clamps; therefore, these torque values replacement in low pressure oxygen systems shall
shall be followed.

(d) As an alternate method, hose clamps

may be tightened with a special hose clamp tool easily
fabricated from a long midget socket (figure 4-32). A
slot is cut through hex end of socket wide enough and
deep enough to accommodate thumbscrew portion of
hose clamp. This type of tool may be used on the end
of a ratchet or extension.

c. Repair of High-Pressure Tubing Assemblies

. High-pressure tubing assembly can be repaired ei-
ther by removal of the damaged section and a union in-
stalled, or by replacement of the entire tubing assembly.

(1) Repair. The damaged portion of tubing is cut

out and removed (see figure 4-33). The ends of the re-
maining tubing are cleaned and deburred. If the dam-
aged section of the tubing does not exceed the length of
a union, a new tube section is not needed.

(2) Replacement. If a tubing assembly is to be

replaced, fittings can usually be salvaged and replacing Figure 4-32. Tightening Hose Clamp with Socket

4-30
 TM 1-1500-204-23-2

TUBING
CODE MATERIAIL SPECIFICATION
a Aluminum FED SPEC
5052-0 WW-T-700/4
b Aluminum FED SPEC
2024T WW-T-700/3
c Corrosion-
Resistant
Steel
Annealed MIL-T-8504
d Corrosion-
Resistant
Steel 1/4 hard MIL-T-6845

2 Minimum burst pressures. In accor-

dance with MIL-H-5440, the following minimum tube
burst pressures are required for the noted system pro-
cedures:

Figure 4-33. Repairing High-Pressure Tubing SYSTEM PRESSURE BURST PRESSURE

1,000 4,000
be made of aluminum alloy conforming to Federal Spec- 1,500 6,000
ification WW-T-700/4.
3,000 12,000
NOTE

Copper tubing of same outside diameter and 3 Conversion factors. Following are the
wall thickness may be used in oxygen systems conversion factors for the materials in table 4-11 and the
only in case of emergency, and should conform three system pressures.
to Federal Specification WW-T-799, Type N.
Steel tubing shall not be used because it loses
its ductility and becomes brittle at low tempera- SYSTEM
ture. MATERIAL PRESSURE CONVERSION
CODE (PSI) FACTOR
(a) Tubing material. When replacing a dam- a 1,000 1,380
aged tubing assembly, the same size and material shall 1,500 2,070
be selected. Where like materials are not available, wall 3,000 4,140
thickness which can be used for various diameters and
tubing materials under applicable system pressure are b 1,000 625
shown in table 4-11. The following paragraphs explain 1,500 938
the use of this table.
3,000 1,875
1 Explanation of codes. The following c 1,000 533
information applies to the code symbols. The codes 1,500 800
shown in table 4-11 indicate that these sizes are stan-
3,000 1,600
dard.
d 1,000 333
1,500 500
3,000 1,000

4-31
TM 1-1500-204-23-2

4 Use of table. For example, the minimum straight runs not having rigid connections on each end.
standard wall thickness must be determined for a 1/2 A fluid line is a mechanical part when installed, and is
inch outside diameter (OD), 1/4 hard corrosion-resistant sensitive to vibration; therefore, direct, straight-line con-
steel tube for a 3,000 psi system. From the above para- nections shall never be made between two solid fixed
graph, the conversion factor is 1000. From table 4-11, attachment points, as bends allow tubing to expand and
the nearest value must be found that applies to this ma- contract under temperature differences. All bends shall
terial. This value is 1,120. This indicates a 1/2 inch OD be started a reasonable distance from fittings, so sleeve
x 0.028 inch tube, which is a standard size indicated by and nut can be slipped back along tubing for inspection.
the code d for 1/4 hard corrosion-resistant steel. This will also prevent tubing from binding against sleeve.
Tubing assemblies shall be formed prior to installation
5 Burst pressure. Taking any value from so it will not be necessary to pull assembly into align-
the table, it is easy to determine the actual burst pres- ment by use of coupling nut. If old tubing is intact and
sure for a tube. The following factors are multiplied by the bends have not been changed, it may be used as
the pressure values shown in table 4-11 to produce the a template. If rerouting is required and a new template
actual burst pressure. must be made, proceed as follows:

BURST
PRESSURE 1 Place material selected for use as a
MATERIAL CODE FACTOR template into one of the fittings where tube is to be
connected.
a 2.9
b 6.4 2 Form necessary bends in template.
c 7.5
3 Remove template and use pattern to
d 12 bend new tube.

4 Select path with least total degrees

For example, the system pressure producing 10,000 psi bend. This reduces flow loss and simplifies bending.
stress on the wall of a 1/4 inch OD x 0.012 annealed
corrosion-resistant steel tube is 960. If the system pres-
5 Use path, if possible, with all bends in
sure is 1,500 psi, the minimum burst pressure is 6,000.
same plane.
Multiplying 960 by the burst pressure factor of 7.5 for
this material, the actual burst pressure is 7,100 psi, well
above the minimum of 6,000 required for this system. 6 Lay out path which provides for either
brackets or clamps to be used as supports at intervals
not greater than those given in table 4-12.
(b) Layout. A piece of tubing approximately
10 percent longer than length of tubing to be replaced
should be cut. After required bends have been made, 4-5. FLEXIBLE HOSE ASSEMBLIES. Flexible hose
new tubing may be 1/2 to 2 inches longer than old tubing. is used in aircraft plumbing to connect moving parts with
Allowances should be made for flaring operation. The stationary parts in locations subject to vibration or where
amount of tubing in excess of amount required to flare a great amount of flexibility is needed. It can also serve
tube should be cut off. as a connector in metal tubing systems.

NOTE
After cutting, bending, and flaring operations,
oxygen tubing assemblies should be cleaned in Do not use flexible hose and hose assemblies in
accordance with paragraph 4-2g(2). oxygen systems, as they readily absorb grease
and oil. Failure to comply may result in damage
d. Template. A path should not be selected that to aircraft of injury to personnel.
requires no bends unless original tubing had a path with
no bends. A section of tubing cannot be cut and flared a. Identification of Flexible Hose. Aircraft hose
accurately enough to be installed without bends and or hose assemblies can be readily identified as to age
still avoid initial mechanical strain on tubing except in and

4-32
 TM 1-1500-204-23-2

Table 4-11. Determining Tube Thickness and Burst Pressure.

Outside Tube thickness (inches).

diameter
(inches) 0.012 0.016 0.020 0.028 0.035 0.042
1/8 c, d c, d a, c, d a, c, d
1920 2560 3200 4480 5600 6720
3/16 c, d c, d a, c, d a, b, c, d b
1280 1707 2133 2987 3733 4480
1/4 c, d c, d c, d a, b, c, d a, b, c, d
960 1280 1600 2240 2800 3360
5/16 c, d c, d c, d b, c, d a, b, c, d a
768 1024 1280 1792 2 240 2638
3/8 c, d a, b, c, d a, b, c, d a, b
640 854 1067 1493 1867 2240
1/2 c, d a, b, c, d a, b, c, d a
480 640 800 1120 1400 1680
5/8 c, d a, b, c, d a, b, c, d a
384 512 640 896 1120 1344
3/4 c, d b, c, d b, c, d b
427 533 747 933 1120
1 a, c, d a, b, c, d
320 400 560 700 840
1 1/8 b, c, d
284 356 498 622 747
1 1/4 a, b, c, d
256 320 448 560 672
1 3/8 c, d
233 291 407 509 611
1 1/2 a b, c, d c, d
213 267 373 467 560
2 a, b, c, d
160 200 280 350 420

4-33
TM 1-1500-204-23-2

Table 4-11. Determining Tube Thickness and Burst Pressure. — Continued

Outside Tube thickness (inches).

diameter
(inches) 0.049 0.058 0.065 0.083 0.095 0.109 0.120
1/8 7840
3/16 b, c, d
5227 6187 6933 8853
1/4 b, c, d b
3920 4640 5200 6640 7600 8720
5/16 b, c, d b, c, d b, c, d b b
3136 3712 4160 5312 6080 6976 7680
3/8 a, b, c, d b, c, d b, c, d b, c, d b b
2613 3093 3466 4427 5067 5813 6400
1/2 a, b, c, d a, b, c, d a, b, c, d b, c, d b, c, d b b, c, d
1960 2320 2600 3320 3800 4360 4800
5/8 a, b, c, d b, c, d a, b, c, d b b, c, d c, d
1568 1856 2080 2656 3040 3488 3840
3/4 b, c, d b, c, d b, c, d b, c, d b, c, d
1307 1547 1733 2213 2533 2907 3200
1 a, b, c, d b a, b, c, d b, c, d b c, d
980 1160 1300 1660 1900 2180 2400
1 1/8 b, c, d b, c b, c, d b b b, c, d
871 1031 1156 1476 1689 1938 2133
1 1/4 a, b, c, d b b, c, d b, c, d
784 928 1040 1328 1520 1744 1920
1 3/8 b, c, d b, c, d b b, c, d
713 844 945 1207 1382 1585 1745
1 1/2 a, b, c, d b, c, d a, b, c, d b b, c, d b
653 773 867 1107 1267 1453 1600
2 a, b, c, d b a, b, c, d b b, c, d b
490 580 650 830 950 1090 1200

4-34
 TM 1-1500-204-23-2

manufacturer by code markings which are repeatedly (2) Store hose or hose assemblies on racks
stenciled along the full length of the hose. which support and protect hose and hose assemblies.

(1) Markings. The identification markings will ei- (3) Store hose or hose assemblies so that older
ther be manufacturer’s code number or manufacturer’s items are used first.
symbol, also date of manufacture in quarter year and
year, size of hose, and specification of hose in numer- c. Replacement of Flexible Hose. Inspection and
als (figures 4-34 through 4-38). replacement of hose or hose assemblies will be accom-
plished at inspection periods perscribed in applicable
(2) Stripe. The indicator stripe or code symbol aircraft maintenance manual or whenever defects listed
along length of hose shall, in all cases, identify hose below are evident.
manufacturer.
(1) Deterioration. Replace all hose and hose
(3) Temperature range. The indicator stripe in- assemblies showing signs of deterioration indicated by
dicates that hose is suitable for use through a tempera- separation of rubber cover or braid from inner tube,
ture range of -65 to 160°F (-54 to 71°C). cracks, hardening and lack of flexibility.

(4) Hose. MIL-H-8788. This hose will appear in (2) Cold Flow. Replace hose or hose assem-
assemblies only blies showing signs of excessive cold flow indicated
by deep permanent impressions and cracks in hose or
(a) Markings. Hose in each assembly will be cover produced by pressure of hose clamps and head
marked with quarter year and year of manufacture of of nipple chafing.
hose, hose size, specification number, and an indicator
stripe in the form of a yellow dot and dash code, showing (3) Weather checking. Weather checking of
direction of natural lay of hose. Markings are repeated rubber is caused by sunlight and atmospheric oxidiza-
at intervals of not more than 9 inches along length of tion.
hose.
(a) Early stages. Rubber hoses, tubing or
(b) Identification tag. This hose is also iden- rubber outer coated surfaces will show fine line cracks
tified by a removable metal tag or band, installed at the or crazing but will be pliable when squeezed between
factory when hose is assembled, showing part number the fingers or rolled between the hands. This is a sign
of hose assembly, date of assembly, and name or trade- of the early stages of deterioration.
mark of manufacturer.
(b) Advanced deterioration. As deteriora-
b. Storage of Hose and Hose Assemblies. Hose tion continues, the cracks and crazing become more
or hose assemblies shall be stored as follows: prominent, and when the rubber hose or tubing is
squeezed or rolled, the item will break, shatter, or turn
to powder, thus becoming useless.

(c) Inspection. Rubber products should be

Do not store hose or hose assemblies in piles.
carefully inspected prior to installation and during use
To do so will result in decreased strength and
for weather checking.
integrity.
(d) Replacement. Replace hose or hose as-
(1) Seal both ends of bulk hose. Cap or plug
semblies with weather checking that is deep or wide
each hose or hose assembly as outlined in paragraph l.
enough to expose fabric.

Change 3 4-35
TM 1-1500-204-23-2

NOTE

•The black rubber coming out between the wire

braid only occurs with hose which conforms to
MIL-H-83797. This is a result of the manufac-
turing process and is normal.

•The replacement hose shall be a duplicate of

hose removed as to the length, OD, ID, and
contour (except as directed).
Figure 4-34. Flame and Aromatic-Resistant Hose,
(4) Excessive wire damage. (Braided wire
MIL-H-8794
cover). Wire damage can be identified using the follow-
ing guidelines.

Table 4-12. Maximum Distance between Supports for Fluid Tubing, Military Specification MIL-H-5440

Distance between supports (inches)

Tubing outside diameter (inches) Aluminum alloy Steel
1/8 9 1/2 11 1/2
3/16 12 14
1/4 13 1/2 16
5/16 15 18
3/8 16 1/2 20
1/2 19 23
5/8 22 25 1/2
3/4 24 27 1/2
1 26 1/2 30 1/2
1 1/4 28 1/2 31 1/2
1 1/2 29 1/2 32 1/2

4-36
 TM 1-1500-204-23-2

Figure 4-35. Nonself-Sealing, Aromatic and Heat-Resistant Hose, MIL-H-6000

12 or more broken wires per assembly or per lineal foot

whenever assemblies exceed 12 inches in length.

(c) Above 500 psi. For hose assemblies

which operate at 500 psi and above, excessive wire
damage consists of two or more broken wires in a single
plait, two or more adjacent wires, one or more broken
wires in an area where kinking is suspected, six or more
broken wires per assembly or per lineal foot whenever
assemblies exceed 12 inches. Crossed reinforcing or
Figure 4-36. Flame Aromatic, and Oil-Resistant random broken wires are not causes for rejection.
Hose MIL-H-7938
(5) Leakage. Hose assemblies will be replaced
NOTE
when leakage occurs with hydraulic pressure applied.
Whenever operating pressure of a hose assem-
bly is unknown, it will be assumed to be 1500 psi (6) Static leakage. With no pressure applied,
or greater. leakage exceeding one drop per hour will be cause for
replacement of the assembly.
(a) Below 30 psi. For hose assemblies used
as vents and hose assemblies which operate below 30 (7) Abrasion, kinking, distortion, bulging, col-
psi, excessive wire damage as described herein will not lapse, or sharp bending. Any evidence of these con-
apply. Replacement of these assemblies will be at the ditions will require replacement of hose assemblies.
discretion of the local inspector/mechanic using good
shop practice and experience. NOTE

Hoses need to be changed for abrasion only if

(b) Below 500 psi. For hose assemblies the metal reinforcement is exposed (this note
which operate below 500 psi, excessive wire damage does not apply to braided wire covered hoses).
consists of four or more broken wires in a single plait,
(8) Internal damage. Inspect internal restriction
due to collapse, wire braid puncture, or other damage
by one of the following methods.

4-37
TM 1-1500-204-23-2

(a) Internal inspection. The various con- • Mutilations, nicks, and distortions
structions of hose assemblies are inspected as follows: caused be overtightening, scratches, or
other damage to the cone seat sealing
1 Straight hose assemblies. Insert light surface.
at one end and inspect by looking through from the op-
posite end. • Backed out retaining wires on swivel
nuts.
2 Hose assembly with elbow fitting one • Mutilation or other damage to threaded
end. Insert flexible inspection light into elbow fitting and areas.
examine by looking through from the opposite end.
• Damage to the finish which would affect
3 Hose assembly with elbow fittings the corrosion-resistance of the fitting.
both ends. Insert flexible inspection light into one end
and examine from the opposite end using a dental-type NOTE
mirror. This procedure is practical on large size hose
assemblies only. Do not intermix the socket and nipple from one
manufacturer with those of another. All fittings
are marked with the manufacturer’s symbol.
(b) Other configurations and small size
Also, do not reuse aluminum sockets on high
hose assemblies. Pass a ball of proper size (refer
pressure hose fittings.
to table 4-13) through the hose assembly to check for
restriction or kinking.
(3) Equipment required. The following equip-
ment is required for field fabrication of high pressure
d. Instructions for Repair of Flexible Rubber
hose assemblies:
Hose. Replace all defective hose assemblies without
attempting repair. MS28759, MS28762, MS28741, and • Wire brush or soft wire wheel.
AN6270 hose assemblies are field fabricated, and are
replaced as a complete unit. However, fittings from • 6 inch slip-joint pliers.
the old hose assemblies should be reused on the new
assemblies when they are in good condition. All factory • Knife (leather or linoleum), ground as
assembled hose, or field assembled hose which has shown in figure 4-39.
been in storage, shall be subjected to pressure test
prior to installation in accordance with paragraph 4-5 f. • Fine tooth hacksaw.

e. Instructions for Assembly of High Pres-

• 10,000 psi hydrostatic test machine.
sure (3000 psi) Hose Assemblies MS28759 and • Standard wrenches.
MS28762. High pressure hose assemblies MS28759
and MS28762 are fabricated from high pressure bulk • Shop vise.
hose conforming to MIL-H-8788 or MIL-H-8790, and
fittings conforming to Military Standards MS28760 and (4) Determine correct length of hose. Deter-
MS28761. mine correct length of hose required as shown in table
4-14 and figure 4-40. Cut hose squarely using a fine
(1) Visually check bulk hose. Visually check tooth hacksaw. Using compressed air, clean hose after
bulk hose when hose is cut for assembly. Check hose cutting to remove all cutting residue.
for mutilations, mandrel joints, marks, seams, and
excessive graphite. (5) Hose and fittings assembly. Assemble
hose and fittings using following procedures and figure
(2) Visually check fittings. Check fittings for: 4-41, steps 1 through 9:

4-38
 TM 1-1500-204-23-2

NOTE

Do not reuse high pressure hose which has

been in service. Also, never reinstall a fitting on
same area of hose in which it was first installed.
If an error is made in assembly, cut away the old
area, or use a new length of hose, and reinstall
the fitting.

(a) Using position notch on socket (step 1),

determine and mark that portion of hose end to be con- Figure 4-39. Knife for Cutting Flexible Hose
fined within end fitting socket. This amount of hose outer
cover is to be stripped. Table 4-13. Inspection Ball Size Chart

Ball size
Hose dash size (inches)
-4 3/32
-5 9/64
-6 13/64
-8 9/32
Figure 4-37. Nonself-Sealing, Aromatic-Resistant -10 3/8
Hose MIL-H-5593
-12 1/2
-16 47/64
-20 61/64

NOTE

These are standard master ball sizes.

Figure 4-38. Self-Sealing, Aromatic-Resistant

Hose, MIL-H-7061

4-39
TM 1-1500-204-23-2

Table 4-14. Hose Cutoff Factor, MIL-H-8788 or MIL-H-8790 Hose (in Inches)

Fitting Hose Size (Dash No. and/or Letter)

Part No. -3 -4 -5 -6 -8 -10 -12 -16 -20 -24 -3 2
Straight MS27616 0.92 1.02 1.16
Flared
MS27053 0.70 0.74 0.77 0.81 0.93 1.05 1.13 1.30 1.44 1.66
MS28760 0.79 0.99 1.10 1.19 1.35 1.59
MS18085 0.42 0.41 0.42 0.47 0.58 0.63 0.61 0.67 0.79 0.86
MS24587 0.60 0.60 0.70 0.77 0.94 1.00 1.00 0.94 0.99 1.09 1.24
MS27404 0.46 0.55 0.68 0.73
MS87018 0.64 0.65 0.70 0.76 0.94 0.99 1.00 1.16 1.34 1.44 1.62
OR
M83798/1 0.742 0.742 0.762 0.842 0.972 1.052 1.112 1.342 1.542 1.702
4

Fitting Hose Size (Dash No. and/or Letter)

Part No. -3 -4 -5 -6 -8 -10 -12 -16 -20 -24 -3 2
45 MS27617 1.58 1.87 2.16
Degree
Flared
MS27055 1.08 1.18 1.22 1.29 1.79 1.58 2.05 2.14 2.24 2.75
MS28780 1.07 1.36 1.45 1.58 2.25 2.47
MS18086 1.29 1.28 1.33 1.38 1.44 1.63 2.07 2.29 2.33 2.74
MS27226 1.08 1.12 1.34 1.38 1.55 1.70 1.89 1.85 2.16 2.38 2.84
3 3 3 3 3
MS27059 1.08 1.18 1.22 1.29 1.79
MS87019 1.05 1.02 1.12 1.22 1.30 1.44 1.76 1.83 2.13 2.28 2.69
OR
M83798/2 0.942 1.072 1.142 1.222 1.312 1.442 1.722 2.032 2.312 2.532
4
0.773 0.833 0.943 0.973 1.353
See footnotes at end of table.

4-40
 TM 1-1500-204-23-2

Table 4-14. Hose Cutoff Factor, MIL-H-8788 or MIL-H-8790 Hose (in Inches) — Continued

Fitting Hose Size (Dash No. and/or Letter)

Part No. -3 -4 -5 -6 -8 -10 -12 -16 -20 -24 -3 2
90 MS27618 1.12 1.25 1.44
Degree
Flared
MS27057 0.86 0.91 0.97 1.03 1.31 1.41 1.92 2.05 2.34 2.68
MS28781 0.94 1.21 1.29 1.41 2.24 2.53
MS18087 1.03 1.03 1.09 1.15 1.18 1.37 2.00 2.25 2.28 2.28
MS27224 0.93 0.99 1.19 1.23 1.39 1.53 1.76 1.75 2.09 2.34 2.80
MS27060 0.863 0.913 0.973 1.033 1.313
MS87020 0.89 0.89 0.96 1.07 1.14 1.27 1.63 1.74 2.06 2.22 2.65
OR
M83798/3 0.792 0.942 0.982 1.072 1.152 1.272 1.592 1.932 2.232 2.472
4
0.563 0.583 0.603 0.723 0.883
Fitting Hose Size (Dash No. and/or Letter)
Part No. -3 -4 -5 -6 -8 -10 -12 -16 -20 -24 -3 2
Straight MS27629 1.07 1.23 1.39
Flareless
MS27381 0.92 0.89 0.93 1.02 1.16 1.32 1.40 1.58 1.72 2.07
MS28761 0.94 1.17 1.32 1.42 1.60 1.85
MS87021 0.85 0.80 0.86 0.96 1.17 1.26 1.27 1.44 1.62 1.85
OR
M83798/4 0.922 0.852 0.892 1.002 1.152 1.152 1.272 1.502 1.692 2.032
4

See footnotes at end of table.

4-41
TM 1-1500-204-23-2

Table 4-14. Hose Cutoff Factor, MIL-H-8788 or MIL-H-8790 Hose (in Inches) — Continued

Fitting Hose Size (Dash No. and/or Letter)

Part No. -3 -4 -5 -6 -8 -10 -12 -16 -20 -24 -32
45 MS27630 1.67 2.00 2.31
Degree
Flareless
MS27382 1.23 1.29 1.32 1.43 1.95 1.77 2.23 2.33 2.61 3.03
MS27384 1.233 1.293 1.323 1.433 1.953
MS87022 1.20 1.12 1.23 1.36 1.45 1.63 1.93 2.03 2.33
OR
83798/5 1.032 1.772 1.252 1.352 1.462 1.632 1.902 2.222 2.492 2.802
4
0.923 0.943 1.053 1.113 1.503
Fitting Hose Size (Dash No. and/or Letter)
Part No. -3 -4 -5 -6 -8 -10 -12 -16 -20 -24 -32
90 MS27631 1.12 1.25 1.44
Degree
Flareless
MS27383 0.86 0.91 0.97 1.03 1.31 1.41 1.92 2.05 2.34 2.68
3 3 3 3 3
MS27385 0.86 0.91 0.97 1.03 1.31
MS87023 0.89 0.89 0.96 1.07 1.14 1.27 1.63 1.74 2.06
OR
M83798/6 0.79 2 0.94 2 0.98 2 1.07 1.15 2 1.27 1.59 1.93 2 2.23 2 2.47
2 2 2 2

4
0.893 0.893 0.963 1.073 1.143
See footnotes at end of table.

4-42
 TM 1-1500-204-23-2

Table 4-14. Hose Cutoff Factor, MIL-H-8788 or MIL-H-8790 Hose (in Inches) — Continued

Fitting Hose Size (Dash No. and/or Letter)

Part No. -8 -10 -12 -16 -20 -24 -32 -40 -48
Straight MS27054 1.27 1.35 1.55 1.61 1.69 1.81
Flange
MS27232 1.64 1.65 1.67 1.53 1.53 1.46 1.66 1.98 1.98
MS18088 0.53 0.53 0.53 0.53 0.56 0.62
MS87024 1.25 1.30 1.50 1.34 1.52
OR
M83798/7 1.25 1.46 1.77 2 1.60
2 2 2

Fitting Hose Size (Dash No. and/or Letter)

Part No. -3 -4 -5 -6 -8 -10 -12 -16 -20 -24 -32
45 MS27056 1.25 1.42 1.90 1.98 2.22 2.50
Degree
Flange
Fitting Hose Size (Dash No. and/or Letter)
Part No. -8 -10 -12 -16 -20 -24 -32 -40 -48
45 MS27230 1.74 1.69 1.96 2.16 2.50 3.04 3.34
Degree
Flange
MS28749 1.44 1.53 1.74 1.69 1.96 2.16 2.51 3.04 3.34
MS18089 1.35 1.53 1.97 2.14 2.18 2.53
MS87025 1.60 1.68 1.93 2.03 2.36
OR
M83798/8 1.572 1.87 2.112 2.292
2

See footnotes at end of table.

4-43
TM 1-1500-204-23-2

Table 4-14. Hose Cutoff Factor, MIL-H-8788 or MIL-H-8790 Hose (in Inches) — Continued

Fitting Hose Size (Dash No. and/or Letter)

Part No. -8 -10 -12 -16 -20 -24 -32 -40 -48
90 Degree MS27058 1.21 1.42 1.92 2.05 2.34 2.68
Flange
MS27228 1.76 1.75 2.09 2.34 2.80 3.42 3.80
MS28750 1.39 1.52 1.76 1.75 2.09 2.34 2.80 3.42 3.80
MS18090 1.18 1.37 2.00 2.25 2.28 2.78
MS87026 1.63 1.74 2.06 2.22 2.65
OR
M83798/9 1.592 1.93 2.232 2.472
2

1. Cutoff factor for one fitting.

2. Hose fittings manufactured by Stratoflex (98441) have different cutoff factors.
3. Forged elbow.
4. Either part number may be used until one of the part numbers is deleted.

(b) Using knife, cut around mark made in (a)

above step 2 of figure 4-40. Make sure cut is through (d) Using wrenches, screw nipple end fitting
to wire braid. Slit this section of outer cover lengthwise onto nipple end with counterclockwise movement and
(step 3). Pry up outer cover and use pliers to twist cover start nipple hex nut onto opposite end using clockwise
off (step 4). Using wire brush or soft wire wheel, remove movement (step 7).
any rubber particle adhering to the wire braid (step 5).
Exercise extreme care when operation to ensure that (e) Lubricate nipple threads (step 8) and in-
wire braid is not loosened, frayed, or flared when brush- side of hose liberally using a light motor oil or hydraulic
ing. fluid, MIL-H-5606.

(c) Place socket in a vise. Screw hose into (f) Position wrench on nipple hex nut and in-
the socket counterclockwise until it bottoms (step (b)); stall nipple assembly into socket and hose by turning nut
then back off 1/4 turn. clockwise (step 9). Maximum allowable gap between
nipple hex and socket in 1/16 inch.
NOTE
(6) Inspect hose assembly internally. Inspect
Avoid excessive turning of hose in aluminum hose assembly internally for cut or bridged inner tube,
sockets. This will tend to grind away material obstructions and cleanliness. Minimum inner diameter
from the buttresses inside socket. for a bulged inner tube is shown in table 4-15. Inspect
for proper gap between nipple hex hex and socket. En-
sure that nut swivels freely.

4-44
 TM 1-1500-204-23-2

Figure 4-40. Determining Hose Assembly Length

4-45
TM 1-1500-204-23-2

Figure 4-41. Field Fabrication of High-Pressure Hose Assemblies

4-46
 TM 1-1500-204-23-2

Hoses to be tested shall be securely restrained

to prevent whipping in case the fittings should Make no adjustments, under any condition, of
blow off. Longer hoses should have several re- assembly gap or position angle after test and fi-
straints. The test is best conducted with hose in nal acceptance of completed hose assemblies.
an enclosure having a heavy transparent plastic Install the following polyethylene protective
cover which can be fastened closed. Personnel plugs in end fittings of hose assemblies that are
shall wear eye and face protection. Failure to not to be installed immediately after fabrication:
comply may result in injury or death. NAS 815-(*size) A (*same dash number as
fitting). Close openings in flanges (or other
special fittings) using pressure sensitive tape or
other adequate means to prevent entrance of
foreign material. Failure to comply may result
in contamination of the hydraulic system.

Table 4-15. Operating, Proof, and Burst Test Pressures for MS28759 and MS28762 Hose Assemblies

Minimum
Proof Burst Inside Bend inner dia.
Tube OD Hose Operating pressure pressure radius at bulge
Size (inches) assembly pressure (psi) (psi) (psi) (min) (inches) (inches)
-4 1/4 MS28759 3000 8000 16,000 3 0.146
MS28762
-5 5/16 MS28759 3000 7000 14,000 3 3/8 0.177
MS28762
-6 3/8 MS28759 3000 7000 14,000 5 0.271
MS28762
-8 1/2 MS28759 3000 7000 14,000 5 3/4 0.365
MS28762
-10 3/8 MS28759 3000 6000 12,000 6 1/2 0.455
MS28762
-12 3/4 MS28759 3000 6000 12,000 7 3/4 0.568
MS28762
-16 1 MS28759 3000 5000 19,000 9 5/8 0.778
MS28762

4-47
TM 1-1500-204-23-2

f. Proof Testing of Flexible Hose Assemblies using a hydrostatic test unit filled with hydraulic fluid
. All field fabricated hose assemblies which have conforming to MIL-H-5606 for MIL-H-6083, lubricating
passed the visual inspection shall be proof tested. oil MIL-L-6082, or water.
Hose assemblies drawn from stock shall be inspected
for defects such as mishandling damage and proper (2) Test hose assemblies to be used in instru-
banding and proof tested if necessary (refer to tables ment applications using dry, oil-free air or nitrogen, Fed-
4-16, 4-17, 4-18, and 4-19). eral Specifications BB-N-411, Grade A, Type 1.

(1) Test hose assemblies to be used in hy- (3) Connect hose assembly to be tested to hy-
draulic, pneumatic, fuel, oil, and coolant applications drostatic test unit, air supply, or nitrogen supply as

Table 4-16. Operating, Proof, and Burst Test Pressures for MS28741 Medium Pressure Hose Assemblies,
using Single Wire Braid Hose, Military Specification MIL-H-8794

Hydraulic Fuel Oil

Proof Oper- Proof
Tube Operating Proof Operat- pres- ating Surge pres- Burst
OD pressure pressure ing pres- sure pressure pressure sure pressure
Size (inches) (psi) (psi)1 sure (psi) (psi)1 (psi) (psi) (psi) 1 (psi)
-3 3/16 3000 6000 1000 1500 50 400 600 12,000
-4 1/4 3000 6000 1000 1500 50 400 600 12,000
-5 5/16 3000 5000 1000 1500 50 400 600 10,000
-6 3/8 2000 4500 1000 1500 50 400 600 9000
-8 1/2 2000 4000 1000 1500 50 400 600 8000
-10 5/8 1750 3500 1000 1500 50 400 600 7000
-12 3/4 1500 3000 1000 1500 50 400 600 6000
-16 1 800 1600 750 1000 50 400 600 3200
-20 1-1/4 600 1250 500 750 50 400 600 2500
-24 1-1/2 500 1000 250 375 50 400 600 2000
-32 2 350 700 200 300 50 400 600 1400
-40 2-1/2 200 300 1000
-48 3 200 300 800
1. Hold proof-test pressure for not less than 30 seconds nor more than 5 minutes.

4-48
 TM 1-1500-204-23-2

Table 4-17. Operating, Proof, and Burst Test Pressures for MIL-H-83796 Medium Pressure Hose
Assembly, Lightweight

Burst
pressure
Hose size Operating pressure (psi) Proof pressure (psi)1, 2 (psi) (min)
-3 1,000 3,000 6,000
-4 1,000 3,000 6,000
-5 1,000 3,000 6,000
-6 1,000 3,000 6,000
-8 1,000 2,500 5,000
-10 1,000 2,500 5,000
-12 1,000 2,000 4,000
-16 750 1,500 3,000
-20 500 1,300 2,000
-24 250 800 1,750
-32 200 600 1,200
1. Assemblies having aluminum flange fittings shall be pressure tested at the rated proof pressure
or 1,500 psig, whichever is less.
2. Hold proof-test pressure for not less than 30 seconds nor more than 5 minutes.

appropriate and apply correct pressure for hose as-

sembly being tested. Proof pressure for MS28759 and
MS28762 hose assemblies are shown in table 4-15.
Hoses to be tested shall be securely restrained
Proof pressures for MS28741 hose assemblies are
to prevent whipping in case the fittings should
shown table 4-16. Proof pressures for MIL-H-83796 are
blow off. Longer hoses should have several re-
shown in table 4-17. Proof pressures for MIL-H-83797
straints. The test is best conducted with hose in
hose are shown in table 4-18. Proof pressures for
an enclosure having a heavy transparent plastic
AN6270 hose assemblies are shown in table 4-19. The
cover which can be fastened closed. Personnel
torque to apply to the swivel nut of the hose assembly
shall wear eye and face protection. Failure to
when installing on adapter ends is given in table 4-20.
comply may result in injury or death.

(4) Observe all hose assemblies proof tested

with a liquid test medium for leakage from hose or
around fittings. Apply proof pressure for not less than
30 seconds and not more than 5 minutes.

4-49
TM 1-1500-204-23-2

Table 4-18. Operating, Proof, and Burst Test Pressure for MIL-H-83797 Medium Pressure Hose

Operating Proof Operating

pressure (psi) pressure Burst pressure (psi) Bend radius temperature (fluid
Hose size (max) (psi) 1,2 (min) inches (min) or ambient)3
-3 1,000 3,000 6,000 1.75 -65 °F to +250 °F
-4 1,000 3,000 6,000 2.00 -65 °F to +250 °F
-5 1,000 3,000 6,000 2.25 -65 °F to +250 °F
-6 1,000 3,000 6,000 2.50 -65 °F to +250 °F
-8 1,000 2,500 5,000 3.50 -65 °F to +250 °F
-10 1,000 2,500 5,000 4.00 -65 °F to +250 °F
-12 1,000 2,000 4,000 4.50 -65 °F to +250 °F
-16 750 1,500 3,000 5.50 -65 °F to +250 °F
-20 500 1,300 2,000 8.00 -65 °F to +250 °F
-24 250 800 1,750 9.00 -65 °F to +250 °F
-32 200 600 1,200 12.50 -65 °F to +250 °F
1. Assemblies having aluminum flange fittings shall be pressure tested at the rated proof pressure or 1,500
psig, whichever is less.
2. Hold proof-test pressure for not less than 30 seconds nor more than 5 minutes.
3. -54 °C to 121 °C.

NOTE NOTE

Tighten cap on hose assembly only after all On hose having a braided cover, do not con-
trapped air has bled from line. fuse entrapped air with leakage. Agitate hose
assembly under water to remove surface bub-
(5) Immerse all hose assemblies proof tested bles.
with a gas test medium in water and observe for leak-
age from hose or around fittings. Apply proof pressure (6) Reject hose assemblies showing evidence
for not less than 30 seconds and not more than 5 min- of leakage.
utes.

4-50
 TM 1-1500-204-23-2

Table 4-19. Operating, Proof, and Burst Test Pressures for AN6270 Hose Assembly using MIL-H-5593
Low Pressure Hose

Burst
Proof pressure pressure
Size Tube outside diameter Operating pressure (psi)1 (psi)
2 1/8 300 600 2000
3 3/16 250 500 1700
4 1/4 200 400 1250
6 3/8 150 300 1000
8 1/2 150 250 750
10 5/8 150 250 700
1
Hold proof test pressure for a minimum period of 60 seconds and a maximum of 5 minutes.

(9) Install following polyethylene protective

plugs in end fittings of hose assemblies that are not
to be installed immediately after fabrication: NAS
Degreasing solvent, MIL-PRF-680, is com- 815-(*size) A (*same dash number as fitting). Close
bustible and toxic to eyes, skin and respiratory openings in flanges (or other special fittings) using
tract. Wear protective gloves and goggles/face pressure sensitive tape or other adequate means to
shield. Avoid repeated or prolonged con- prevent entrance of foreign material.
tact. Use only in well ventilated areas (or use
approved respirator as determined by local g. Identification Tags for Field Fabricated Hose
safety/industrial hygiene personnel). Keep Assemblies. An identification tag must be affixed to
away from open flame other sources of ignition. each field fabricated hose assembly.

(7) After proof test of a hose assembly using hy- (1) Make tags from aluminum alloy 5052-0, Fed
draulic fluid or oil as a test medium, flush or dip assembly Spec QQ-A-250/8C, 0.020 inch thick, 0.75 inch wide,
in or degreasing solvent, MIL-PRF-680. Drain assembly with the size of the band in accordance with figure 4-42.
and dry using dry compressed air. Drain and dry with dry Mark tags to show data of pressure test, federal stock
compressed air hose assemblies tested using water as number or part number, operating pressure, and depot
pressure fluid. or unit code or name.

(8) Visually inspect instrument hose assemblies (2) Mark tags by impression stamping, engrav-
which were proof tested using a gas test fluid for evi- ing, or etching.
dence of oil or hydraulic fluid on internal surfaces of hose
assembly. Clean hoses showing evidence of this con-
tamination as specified in step (7).

Change 5 4-51
TM 1-1500-204-23-2

(3) Attach tag to hose by passing tab end of tag (2) Inspect fittings as outlined in paragraph 4-5
through slot in opposite end, drawing tag up snug, and e(2). Aluminum sockets for medium and low pressure
bending tab back against hose. Ensure that tag is tight hose assemblies can be reused if undamaged.
enough on hose so that it will not come off over hose
end fittings. (3) Assembly equipment required shall cor-
respond to paragraph 4-5 e(3) with the addition of
h. Instructions for Assembly of Medium Pres- Aeroquip kit, part number S-1051.
sure, MS28741, and Low Pressure, AN6270, Hose
Assemblies. Medium pressure hose assemblies are (4) Determine hose length as outlined in para-
fabricated from bulk hose conforming to MIL-H-8794, graph 4-5e(4). Do not remove cover after cutting hose
and fittings conforming to Military Standard MS28740. to length.
Low pressure hose assemblies are fabricated from bulk
hose conforming to MIL-H-5593 and fittings conforming (5) Assemble hose and fittings using following
to Military Standard MS27404. procedure and figure 4-43 steps 1 through 4.

(1) Inspect hoses as outlined in paragraph 4-5 (a) Place socket in a vise. Screw hose into
e(1). socket counterclockwise until it bottoms; then back off
1/4 turn.

Table 4-20. Proof Test Torque Values MS Flared Swivel Nut Fittings (Reference and 10064)

Torque
Tubing size O/D inch Hose size Maxi-
I/D inch Dash fitting size Minimum mum
3/16 —3 70 100
1/4 —4 70 120
5/16 —5 85 180
3/8 —6 100 250
1/2 —8 210 420
5/8 —10 300 480
3/4 —12 500 850
1 —16z 700 1150
1 1/4 —20z 1000 1300
1 1/2 —24z 1000 1400

4-52
 TM 1-1500-204-23-2

NOTE assembly tool is removed. Maximum allowable gap be-

tween socket and nut or nipple hex is 1/16 inch.
Do not overtighten vise on thin-walled sockets
of lightweight fittings. Outer cover of hose is not (6) Inspect hose assembly for cut inner tube,
stripped. obstructions, and cleanliness. Inspect for proper gap
between nut or nipple hex and socket.
(b) Tighten nipple and nut on appropriate as-
sembly tool from Aeroquip kit, part number S-1051.

(c) Lubricate nipple threads and inside of

hose liberally using a light minor oil or hydraulic fluid, Make no adjustment, under any condition, of
MIL-H-5606. assembly gap or position angle after test and
final acceptance of complete hose assembly.
(d) Screw nipple into socket and hose using Failure to comply may compromise the integrity
a wrench on nipple hex nut. Nut must swivel freely when of the hose assembly.

Figure 4-42. Identification Tags for Field Fabricated Hose Assemblies

Change 4 4-53
TM 1-1500-204-23-2

Figure 4-43. Assembly of Medium and Low-Pressure Hose Assemblies

4-54
 TM 1-1500-204-23-2

(7) Proof test hose assemblies in accordance (1) Use. Medium pressure Teflon hose assem-
with 4-5f blies (1,500 psi maximum operating pressure) meeting
the dimensions and installed minimum bend radii of ta-
(8) Hose assemblies shall be identified as out- ble 4-21 are suitable for use in fuel, lubrication, pneu-
lined in 4-5g. matic, and hydraulic systems. Use in other systems
shall meet the considerations of paragraph 6.1 of MIL-
i. Assembly of Medium-Pressure Tetrafluo- F-27267 and paragraph 6.1 of MIL-H-27272.
roethylene (Teflon) Hose Assemblies. The following
paragraphs provide instructions for identification of
bulk Tetrafluoroethylene (commonly known as Teflon
and will be referenced as Teflon in this manual) hose
conforming to MIL-H-27267 and end fittings conform- Hose assemblies conforming to MIL-H-25579
ing to MIL-F-27272 and Drawing MS27053 through and hose assemblies conforming to use dif-
MS27089. Specific instructions are provided for inspec- ferent hose and fittings. DO NOT interchange
tion, removal, cleaning, disassembly, installation and components between assemblies. Improper
disposition of Teflon hose assemblies fabricated from combinations of hose and fittings lead to life
bulk hose and end fittings. endangering failures.

Table 4-21. Tetrafluoroethylene Hose MIL-F-27272 (in Inches)

Bend
Hose size Hose ID Tube wall thickness Hose OD radius
-3 0.125 0.040 0.250 2
-4 0.188 0.040 0.312 2
-5 0.250 0.040 0.375 2
-6 0.313 0.040 0.446 4
-8 0.406 0.043 0.562 4 5/8
-10 0.500 0.047 0.656 5 1/2
-12 0.625 0.047 0.789 6 1/2
1
-16Z 0.875 0.047 1.109 7 3/8
-20Z1 1.125 0.050 1.359 11

-24Z1 1.375 0.070 1.672 14

1. Z indicates a double layer of wire braid reinforcement.

4-55
TM 1-1500-204-23-2

(2) Identification. Teflon hose and hose assem- (3) Handling. Exercise extreme care when han-
blies, and fittings are identified in the following para- dling bulk Teflon hose and hose assemblies to prevent
graphs: injury to hands from the wire braid ends and damage to
(a) Size. Bulk Teflon hose manufactured to hose due to kinking. Kinking results when hose is bent
requirement of MIL-H-27267 shall conform to dimen- to a shorter radius than specified in table 4-21 and from
sions referenced in table 4-21. twisting during installation. Teflon hose assemblies tend
to conform to the shape of installed positions on hot fluid
(b) Appearance and markings. Hose con-
lines; therefore, exercise care in handling and removing
struction shall be a smooth bore (firm, waxy feeling)
these lines to prevent straightening which could result
inner tube covered with corrosion-resistant steel wire
in kinking. A kinked Teflon hose must not be installed
braid. Hose shall be identified by an identification band
since this will result in a failure at point of kink.
spaced at 3-foot intervals, marked with specification
number and manufacturer’s code number as listed in (4) Maintenance Inspection and Replacement
Federal Handbook H4-1. Criteria. Inspect installed Teflon hose assemblies for
evidence of deterioration due to wire fatigue or chafing at
(c) Fittings. All end fitting assemblies con- the specified periods prescribed in the applicable aircraft
forming to MIL-F-27272 are identified by an attached inspection or maintenance manuals and replace when
cardboard disc marked with MS number, manufac- any of the following conditions are found.
turer’s part number, name or trademark. All component
parts of end fitting assemblies conforming to referenced (a) Leaking. Static leakage exceeding 1 drop
specification are impression stamped with MS numbers per hour.
as listed in paragraph 3 of the referenced specification. (b) Excessive Wire Damage. Excessive
wire damage consists of 2 or more broken wires in a sin-
gle plait, or more than 6 broken wires per assembly or
per lineal foot whenever assemblies exceed 12 inches
To eliminate the possibility of hose failure by in length. Broken wires where kinking is suspected are
mismatch of similar type fittings, check each evidence by sharp dents or twisted wire braid.
item of the assembly carefully to ensure that it
conforms to the proper Military Standard (MS) NOTE
prior to the assembly of the hose.
(d) Hose assemblies. Factory fabricated Crossed reinforcing or random broken wires is
Teflon hose assemblies are identified by a permanently not cause for replacement.
attached metal band marked with MIL-H-25579 , op- (c) Distortion. Any evidence of abrasion,
erating pressure in psi, assembly part number, date kinking, distortion, bulging, or sharp bends.
of proof test and hose manufacturer’s code number.
(d) Hoses from stock. Hose assemblies
Locally manufactured or tested Teflon hose assemblies
drawn from stock shall be inspected for defects such as
shall be identified by a metal band made from Federal
mishandling damage and proper banding. Hoses that
Specification QQ-A-250/8, 5052-0 aluminum alloy ,
are suspected to have damage or are not banded will
0.020 inch thick, 0.75 inch wide, in accordance with
be proof-tested and banded.
figure 4-42. The markings on the band may be impres-
sion stamped, etched or engraved to include date of (e) Hoses removed from aircraft. Hose as-
pressure test, Federal stock number or part number, semblies removed from an aircraft shall be inspected,
operating pressure, and depot or unit code or name. if proof tested, and banded.
the pressure test date is more than one year prior to (5) Hose Assemblies and Pump Pressure
installation in the aircraft or system, the assembly shall Lines. Clean hose assemblies removed from instal-
be retested and banded prior to installation. Original lation for reasons other than cited in paragraph 4-5i
manufacture date of all retested hoses shall be brought (8) and pump pressure lines removed by replacement
forward onto the new band, if available. schedule in

4-56
 TM 1-1500-204-23-2

accordance with instructions contained in paragraph (a) Cleaning. Clean fittings in accordance
4-5i (9). with paragraph (9).
(6) Internal Inspection. Inspect hose assem- (b) Finishes. Examine all fitting details with
blies internally for evidence of tube restriction due to anodized or plated finish for corrosion damage. Con-
collapse, wire braid puncture, or other damage. Follow- demn corrosion-damaged parts. Minor scratches are
ing methods for internal inspection are recommended. not cause for replacement; however, parts with wrench,
(a) Straight hose assemblies. Insert light at vise jaw, or similar marks shall be replaced.
one end and inspect by looking through from the oppo- (c) Flanges, sealing faces and/or swivel
site end. nuts. Inspect these components as follows:
(b) Hose assembly with elbow fitting one
end. Insert flexible inspection light into elbow fitting and
examine by looking through the opposite end.
(c) Hose assemblies with elbow fitting both Use care when handling flange fittings to pre-
ends. Insert flexible inspection light into one end and vent damaging the gasket, flange or sealing
examine from the opposite end using a dental-type mir- face of pad or fitting. Failure of equipment could
ror. This procedure is only practical on large size hose result.
assemblies.
1 Check for wraping of the flange.
(7) Disassembly. The hose can be completely
disassembled using the following procedures (see figure 2 Check for damage to the sealing face of
4-45): the flange fitting. Any damage, nicks, scratches, etc.,
will be cause of rejection.
(a) Place socket in vise and remove nipple
3 Check for multilated threads and evi-
assembly by applying wrench to nipple hex (see figure
dence of overtightening. (This will show up as a belied
4-45, detail A).
condition or pulled condition or flared connections and
(b) Remove socket from vise and tap edge may result in a frozen or tight swiveling nut).
of pocket against flat surface to loosen pull socket back
onto hose to expose hose end and sleeve insert (see 4 Examine for backed-out retaining wires
figure 4-45, detail B). on wired-on swivel nuts. If backed-out wires are found,
drive wire back into nut using a drift pin of proper size
(c) Remove sleeve inserting end of nipple and ball peen hammer.
into sleeve internal diameter and gently pry sleeve from
inner tube (see figure 4-45, detail C). (d) Nipples. Visually inspect for sealing sur-
face (chamfered area) for damage or galling on stain-
(d) Remove socket by pulling or threading
less nipples (figure 4-46) and for the following defects:
socket from hose.
(e) Remove hose fitting on opposite end of 1 Nicks, spiral or longitudinal scratches or
assembly. scoring which could create an escape passage for fluids.
(f) All removed hose will be condemned and 2 Flare-out or distortion of cone seats re-
disposed of in accordance with existing regulations. sulting from overtorquing.
(8) Reusability Check. Use the following proce- 3 Damaged or galled threads (nipple to
dures to determine whether parts that are removed may socket thread) test by threading a new socket of proper
be reused. size on to the nipple threads.

4-57
TM 1-1500-204-23-2

Figure 4-45. Field Disassembly of Teflon Hose

4-58
 TM 1-1500-204-23-2

4 Test for overtorquing by placing a new products when exposed to extreme heat. Wear
sleeve insert of proper size and type for the nipple as- chemical protective gloves and goggles/face
sembly on the nipple in the normal assembled position. shield. Avoid repeated or prolonged contact.
Check for clearance between the sleeve and nipple Use only in well ventilated areas. If ventilation
faces (figure 4-47). Clearance shall exist for good is not adequate, use approved respirator as
nipple assemblies. determined by local safety/industrial hygiene
personnel. Keep away from open flames, weld-
5 Visually inspect wrench flats on forged-
ing or other sources of ignition.
type elbow nipple assemblies for excessive damage.
(a) Cleaning fluids. Any of the following
(e) Socket. The socket will be inspected for
cleaning fluids or other acceptable commercial de-
the following defects:
greasing solvents may be used for cleaning Teflon hose
1 Visually inspect for distortion or egg-ing assemblies.
and test for damaged threads by threading a new nipple
assembly of proper size into the socket threads.
FLUID SPECIFICATION
2 Visually inspect for stress cracks. (Usu- Dry Cleaning Solvent MIL-PRF-680
ally appear as longitudinal.)
Cleaning Compound, Solvent HFE 71DE
(f) Sleeve. The sleeve will be inspected for
the following defects.
1 Check for out-of-roundness.
2 Check sealing surface for warpage and
damage to mating surface.
(9) Cleaning. Clean and degrease hose assem-
blies and component parts before inspection.

Figure 4-46. Nipple Assembly Surface

Degreasing solvent, MIL-PRF-680, is com-

bustible and toxic to eyes, skin and respiratory
tract. Wear protective gloves and goggles/face
shield. Avoid repeated or prolonged con-
tact. Use only in well ventilated areas (or use
approved respirator as determined by local
safety/industrial hygiene personnel). Keep
away from open flame other sources of ignition.
Figure 4-47. Nipple Assembly Clearance
HFE-71DE is toxic to eyes, skin and respiratory
tract and decomposes into other hazardous

Change 4 4-59
TM 1-1500-204-23-2

(b) Hose assemblies. Flush or dip hose as-

semblies in cleaning fluid and brush, if necessary, to dis-
lodge deposits.
End fittings shall not be installed on used aircraft
hose MIL-H-27267 and/or MIL-H-25579. Fail-
ure to comply may result in compromise of the
Do not wire-brush dry tube surfaces. Failure
integrity of the hose assembly.
to comply will result in destruction of the hose
assembly. NOTE
Assembly mandrels are not needed for hand
assembly of fittings.
(b) Hose length. Determine hose length by
Degreasing solvent, MIL-PRF-680, is com-
subtracting cutoff factor (table 4-22) from desired hose
bustible and toxic to eyes, skin and respiratory
assembly length. Cut hose squarely. To prevent a flare-
tract. Wear protective gloves and goggles/face
out of the wire end during the cutoff operation, (figure
shield. Avoid repeated or prolonged con-
4-48, detail A) a piece of masking tape can be wrapped
tact. Use only in well ventilated areas (or use
around the hose at the point. After the hose is cut, and
approved respirator as determined by local
before proceeding with the assembly, the tape must be
safety/industrial hygiene personnel). Keep
removed.
away from open flame other sources of ignition.
(c) Install sockets. To facilitate assembly on
(c) Component parts. Thoroughly clean all sizes up to -8, place two sockets skirt-to-skirt in vise
component parts by dipping and brushing where nec- (figure 4-48, detail B) and work hose through sockets
essary in degreasing solvent, MIL-PRF-680. with a pushing, twisting motion. Insert neck down to
facilitate assembly.
(d) Cleaning hose assemblies after proof
test. Flush or dip hose assemblies in cleaning fluid and (d) Size tube and flare braid. Place nipple in
drain. vise. Push hose onto the nipple to size tube ID and to aid
in separating the wire braid from the tube (figure 4-48,
(10) Assembly procedures. The following detail B). Remove hose from the nipple.
steps shall be followed when fabricating hose assem-
blies from new or salvaged components (see figure (e) Install sleeve. Carefully insert sleeve be-
4-48). tween braid and tube OD using caution that no wires
are trapped between the sleeve and tube OD. Complete
(a) Tools required. Use common hand tools, positioning by pushing end of sleeve against flat sur-
i.e., wrench, hacksaw, protractor, vise and hydraulic test face until tube bottoms against shoulder sleeve ID (fig-
stand. ure 4-48 detail C). Visually inspect to see that tube end
is bottomed against sleeve shoulder and that no wires
are trapped under sleeve.
Hose assemblies conforming to MIL-H-25579 (f) Sizing tube to sleeve. Size tube to sleeve
and hose assemblies conforming to use dif- by pushing nose over the nipple until the sleeve bottoms
ferent hose and fittings. DO NOT interchange against the nipple chamber. Remove and recheck to be
components between assemblies. Improper certain that the sleeve is still properly positioned. Again
combinations of hose and fittings lead to life push hose over the nipple and bottom sleeve against the
endangering failures. nipple chamfer.

4-60 Change 4
 TM 1-1500-204-23-2

NOTE bly from vise and regrip by socket. Using a wrench on

nipple hex, tighten to a gap of 1/32 inch nominal (gap
No lubrication is needed, as components are may vary from 0.025 to 0.045 inch) (figure 4-48, details
permanently dryfilm lubricated. D and E).
(g) Engage socket and tighten. Slide socket
forward and engage threads by hand. Remove assem-

Change 4 4-60.1/(4-60.2 blank)

 TM 1-1500-204-23-2

Figure 4-48. Medium-Pressure Teflon Hose Assembly Procedure (Sheet 1 of 3)

4-61
TM 1-1500-204-23-2

Figure 4-48. Medium-Pressure Teflon Hose Assembly Procedure (Sheet 2 of 3)

4-62
 TM 1-1500-204-23-2

Figure 4-48. Medium-Pressure Teflon Hose Assembly Procedure (Sheet 3 of 3)

4-63
TM 1-1500-204-23-2

NOTE (a) Method for standard elbow fit-

tings. Standard elbow fittings are positioned as follows:
If fitting gap after assembly is less than 0.025
inch, back socket off until it rotates freely on 1 Establish base position. Base position
hose, then repeat paragraph (g). may be the top of a workbench or an elbow mounted in
a vise.
(h) Final assembly. Install opposite hose
end fitting using paragraphs (d) through (g) above. 2 Position and measure position angle.
See figure 4-48, details F and G for proper reading
NOTE of position angles. While opposite fitting is still loose
enough to swivel by hand, turn to required angle and
If both fittings are elbow fittings, the relative po- measure using an adjustable protractor or other suitable
sition angle (index angle between fittings) must angle measuring advice.
be set before tightening to final gap.
3 Complete fitting assembly by mounting
(i) Proof test. Proof test hose assembly as in vise to hold elbow or hose from turning while tighten-
described in proof test procedures, paragraph 4-5 i(12). ing to required gap (see figure 4-48, detail H).
(11) Setting position angle on elbow hose as-
semblies. Two methods may be used to establish the
proper position angle of fittings when an elbow fitting is
used on both ends.

Table 4-22. Teflon Hose Cutoff Factors (in Inches)

MS swivel or fittings MS flange fittings

A B C D E F
Size ST 45 degrees 90 degrees ST 45 degrees 90 degrees
—3 1.40 2.16 1.72
—4 1.48 2.36 1.82
—5 1.54 2.44 1.94
—6 1.62 2.58 2.06
—8 1.86 3.58 2.62 2.54 2.50 2.42
—10 2.10 3.16 2.82 2.70 2.84 2.82
—12 2.26 4.10 3.84 3.10 3.89 3.84
—16Z 2.60 4.28 4.10 3.22 3.96 4.10
—20Z 2.88 4.84 4.68 3.38 4.44 4.68

4-64
 TM 1-1500-204-23-2

4 Recheck position angle to be sure posi- NOTE

tion angle has not changed.
Proof pressures for flange fittings are reduced to
(b) Method for special elbow bends and/or avoid possible distortion of the flange and shoul-
preformed hose. Special elbows and preformed hose der by exceeding design pressure limitations for
are positioned as follows: flange fittings.

1 Assemble one end of the hose assem- (b) Proof test medium. Proof test medium
bly as described above. shall be hydraulic oil, MIL-H-5606.

2 Determine required angles. Required (c) Cleaning. Clean and drain hose assem-
angles may be obtained from the hose assembly part bly after proof test as directed in paragraph (9).
number by comparison with a known good hose assem-
bly or with an assembly mocked-up on the installation. NOTE
Preferably the assembly to be repaired should be set up
on a fiat surface, vises and parallels set and clamped, Application of an identifying mark such as a
and required angles set on protractor before the assem- paint dot, indicating satisfactory proof test, is
bly is disassembled. See figure 4-48, details I, J, and K recommended.
for this setup.
(d) Capping. Cap or plug all hose assemblies
3 Establish base positions and check an- to ensure cleanliness.
gle, drop dimension and assembly length. Angle vises
shall be tilted so that the flange mounting plates are (13) Installation. The following procedures and
parallel to the face of the flange and the flange mount- precautions will be followed when installing Teflon hose
ing holes lined up with the bolt holes already tapped in assemblies (see figure 4-49).
the mounting plates. Any necessary spacing with par-
allel bars shall be done at this time. When this proce-
dure is followed properly, the result will be a fixture with
the proper angles, drop dimensions, and lengths estab-
Do not place wrench on socket of hose fitting
lished. See figure 4-48, details I, J. K, and L for this
when installing hose assembly. Failure to com-
setup.
ply will compromise the strength and integrity of
the union between the hose and fitting.
4 Complete fitting assembly by mounting
in vise to hold elbow or hose from turning while tighten-
(a) Route and securely clamp Teflon hose as-
ing to required gap.
semblies to avoid abrasion, and particularly to prevent
kinking where flexing occurs.
5 Recheck position angle to be sure posi-
tion angle has not changed.
(b) Eliminate chafing against structure, mov-
ing parts, or other assemblies by clamping and use of
(12) Proof test procedures. Proof test all hose chafing guard if necessary.
assemblies after assembly for a minimum period of
30 seconds and maximum period of 5 minutes, using
(c) Support Teflon hose assemblies by
Tester, Hose Assembly, Part Number 78344, FSN
clamping every 24 inches. Closer support is preferred if
4920-00-855-9035.
possible. Support flexible hose assemblies by clamping
so that they cannot cause deflection of rigid connecting
(a) Proof test pressures. Recommended assemblies. Support clamps shall not restrict travel or
proof test pressures are listed in table 4-23. cause hose to be subjected to tension, torsion, com-
pression or shear stress during flexing cycles. Select
proper size support clamps as indicated in table 4-24.

4-65
TM 1-1500-204-23-2

Table 4-23. Proof Test Pressures, Medium-Pressure Teflon Hose Assemblies

Hot size Swivel end fittings Flanged fittings

—3 3000 psi
—4 3000
—5 3000
—6 3000
—8 3000 1500psi
—10 3000 1500
—12 2000 1500
—16Z 2500 1250
—20Z 2000 1000
—24Z 2000 1000

(d) When installation of Teflon hose assem- (b) Hose. Tape ends of hose to prevent wire
blies requires bending, the radius shall not be less than flareout. Storage in a straight position is preferred. If
minimum bend indicated in table 4-21. A larger radius coiling is necessary, large loose coils are preferred.
than minimum allowed is preferred.

(e) The following precaution in flexing instal-

lations will help prevent kinking. Bend hose in the same
planes as movement to avoid twisting. Under no circumstances shall hose be piled to a
height which could result in damage to the lower
(f) Hose flexing in two directions shall be sections. This caution applies to hose in cartons
clamped at the point where hose changes planes. This as well as to unpackaged hose.
has the effect of dividing the hose into sections, each in
one plane. (c) Hose assemblies. Cap or plug ends of all
hose assemblies during storage with polyethylene pro-
(g) Install flared swivel connections accord- tective plugs conforming to National Aerospace Stan-
ing to torque values shown in table 4-25. dard NAS 815 or to paragraph 4-5k.

(14) Storage of hose and assemblies. Teflon (15) Hose disposition. Condemn all hose or fit-
hoses will be stored in accordance with the following tings which are scrapped on tear-down, or hose and
paragraphs. hose assembly in supply which become damaged, dete-
riorated, or otherwise unsatisfactory for use on aircraft,
missiles, and related accessories in accordance with ex-
(a) Age limitations. Teflon hose has a nearly
isting disposition instructions.
unlimited life in storage. No age limitations have been
established on medium pressure hose, MIL-H-27267,
and high pressure hose, .

4-66 Change 2
 TM 1-1500-204-23-2

Figure 4-49. Teflon Hose Installation Procedures, Right and Wrong

4-67
TM 1-1500-204-23-2

Table 4-24. Support Clamp Sizes (For Use with MIL-H-27267 Hose of Teflon)

Hose Size -3 -4 -5 -6 -8 -10 -12 -16 Z -20Z -24Z

Clamp Size (MS1919) 5 6 7 8 10 11 13 18 22 27

Table 4-25. Installation Torque Values MS Flared Swivel

Nut fittings (reference AND10064)

Torque (in-lb)
Fitting Size Min Max
—3 70 100
—4 70 120
—5 85 180
—6 100 250
—8 210 420
—10 300 480
—12 500 850
—16Z 700 1150
—20Z 1000 1300
—24Z 1000 1400

j. Assembly of High-Pressure Tetrafluoroethy- (a) Hose. Bulk Teflon manufactured to re-

lene (Teflon) Hose Assemblies. The following quirements of shall conform to dimensions referenced
paragraphs provide instructions for identification of bulk in table 4-26. Hose construction shall be a smooth bore
Tetrafluoroethylene (commonly known as Teflon and will (firm, waxy feeling) inner tube covered with corrosion
be referenced as Teflon in this manual) hose conforming resistant steel wire braid. Hose shall be identified by an
to AS-604A and and end fittings conforming to Drawings identification band spaced at 3-foot intervals, marked
, and NAS 1760. Specific instructions are provided for with specification number and manufacturer’s code
inspection, removal, cleaning, disassembly, installation number as listed in Cataloging Handbook H4/48.
and disposition of Teflon hose assemblies fabricated
from bulk hose and end fittings. (b) Fittings. All end fitting assemblies con-
forming to Military Standards , and National Aerospace
(1) Use. High-pressure Teflon hose assemblies Standards are identified by an attached cardboard disc
(3,000 PSI maximum operating pressure) meeting the marked with MS number, manufacturer’s part number,
dimensions and installed minimum band radii are suit- name or trademark. All component parts of end fitting
able for use in pneumatic and hydraulic systems. Use assemblies conforming to reference specification are
in other systems shall meet the considerations of and impression stamped with the appropriate specification
Military Standards MS27363 through MS27374, , and number.
NAS 1760.

(2) Identification. Hoses and components can

be identified by the following guidelines.

4-68
 TM 1-1500-204-23-2

To eliminate the possibility of hose failure by Hose assemblies conforming to MIL-H-25579

mismatch of similar type fittings, all MS and and hose assemblies conforming to use dif-
NAS numbers shall be verified by supervisory ferent hose and fittings. DO NOT interchange
and/or quality control personnel to ensure that components between assemblies. Improper
the MS or NAS number is correct for that partic- combinations of hose and fittings lead to life
ular application. endangering failures.

(c) Hose assemblies identification. The

following paragraph describe how to identify factory
fabricated, locally manufactured or tested Teflon hose
assemblies. Used end fittings and aircraft hose shall not be
reused in fabrication of , Aircraft Hose. Failure
1 Factory fabricated. Factory fabricated to comply will compromise the integrity of as-
Teflon hose assemblies are identified by a permanently sembled hoses.
attached metal band marked with the appropriate spec-
ification, operation pressure in psi, assembly part num- (b) Assembly procedure for high pressure
ber, date of proof test, and hose manufacturer’s code Teflon hose (). See figure 4-50. The following steps
number. shall be followed when fabricating hose assemblies from
new components.
2 Locally manufactured or tested. Locally
manufactured or tested Teflon hose assemblies shall be 1 Hose length. Determine hose cutoff
identified by a metal band made from Federal Specifica- length by subtracting fitting cutoff factor from the hose
tion QQ-A-250/8C, 5052-0 aluminum alloy, 0.020 inch assembly length or by calculating the length from the
thick, 0.75 inch wide, in accordance with figure 4-42. information shown on the hose assembly drawing (see
The markings on the band may be impression stamped, table 4-27). The cutoff length may also by determined
etched or engraved to include date of pressure test, Fed- by measuring the used length of hose being replaced.
eral Stock Number of part number, operating pressure, Cut hose squarely. A hose cutoff wheel is recom-
and depot or unit code or name. If the pressure test date mended. However, a fine tooth hacksaw may be used.
is more than one year prior to installation in the aircraft or To prevent a flare-out of the wire end during the cutoff
system, the assembly shall be retested and banded prior operations, wrap tape around the hose at the cutoff
to installation. Original manufacture date of all retested point. After the hose is cut, and just prior to installing
hoses shall be brought forward on to the new band, if sockets, the tape must be removed (see figure 4-50,
available. detail A).

(3) Handling and inspection. Refer to para- 2 Install sockets. Place two sockets skirt-
graph 4-5i(3),(4). to-skirt in a vise and work hose through sockets with a
twisting, pushing motion. Inserting sockets over neck
(4) Disassembly. Refer to paragraph 4-5i(7). down end of hose will facilitate assembly. On extra long
assemblies, the sockets may be installed on each end
of the hose individually (see figure 4-50, detail B),
(5) Cleaning. Refer to paragraph 4-5i(9).
3 Size tube and flare braid. Place nipple
(6) Assembly. High-pressure Teflon hose can
hex in vise. Push one end of hose onto the nipple and
be assembled using the procedures provided in the
work gently in circular motion to aid in separating the
following paragraphs.
wire braid from the tube. Remove hose from nipple (see
figure 4-50, detail C).
(a) Tools required. Use common hand tools,
i.e., wrench, hacksaw, protractor, vise, and hydraulic
test stand.

Change 3 4-69
TM 1-1500-204-23-2

Figure 4-50. Field Assembly of High-Pressure Teflon Hose,

4-70
 TM 1-1500-204-23-2

Table 4-26. Tetraflouroethylene Hose (in Inches)

Bend
Hose size Hose ID Tube wall thickness Hose OD radius
—4 0.212 0.035 0.390 3.000
—6 0.298 0.035 0.485 5.000
—8 0.391 0.045 0.605 5.750
—10 0.485 0.045 0.720 6.500
—12 0.602 0.045 0.884 7.750
—16 0.852 0.045 1.280 9.625
—20 1.101 0.045 — 12.000

4 Install sleeve. Carefully insert sleeve Measure gap.Gap is measured between socket and nip-
between braid and tube OD, using caution that no wires ple hex, as shown in figure 4-50, detail G.
are trapped between the sleeve and tube OD. Complete
positioning by pushing end of sleeve against flat surface NOTE
until tube bottoms against shoulder in sleeve ID. Visually
inspect to see that tube end is bottomed against sleeve Standard elbow fittings may be assembled us-
shoulder and that no wires are trapped under sleeve ing the procedure above. Special elbows may
(see figure 4-50, detail D). be assembled by holding the nipple in a vise.

5 Size tube to sleeve. Size tube to sleeve (c) Setting position angle on elbow hose as-
by pushing hose onto the nipple until the sleeve bottoms semblies. Refer to paragraph 4-5i(11).
against the nipple chamfer. Remove and recheck to be
certain that the sleeve is still properly positioned. Again (7) Cleaning, inspection, and proof test-
push hose onto the nipple until the sleeve is bottomed ing. Hose assemblies are cleaned, inspected, and
against the nipple chamfer (see figure 4-50, detail E). proof tested as described in the following paragraphs.

NOTE NOTE

When assembling new fittings, no lubrication is Proof test shall be verified by quality control per-
needed because component parts are dry-film sonnel.
lubricated at the time of manufacture.
(a) Cleaning. Clean hose after cutting to
6 Engage socket and tighten. Slide length. Be sure all cutting residue is dislodged. After
socket forward and thread onto nipple by hand. (Special assembly, clean each hose assembly internally using
tool required for -12 size.) Remove assembly and place clean, dry compressed air.
the socket in vise. Using a wrench on the nipple hex,
tighten to a gap of 1/32 inch nominal for all sizes. (Gap
may vary from 0.023 to 0.046 inch) (see figure 4-50,
detail F).

4-71
TM 1-1500-204-23-2

Table 4-27. Hose Cutoff Factors, Hose (In Inches)

MS swivel or fittings MS flange fittings

Size A B C A B C
ST 45 degrees 90 degrees ST 45 degrees 90 degrees
—4 .92 2.06 1.69 1.15 2.19 1.69
—6 1.04 32.35 1.92 1.26 2.50 1.92
—8 1.16 2.61 2.10 1.46 2.81 2.10
—10 1.21 2.74 2.26 1.50 2.94 2.26
—12 1.27 3.06 2.40 1.71 3.35 2.40
—16 1.33 3.84 2.74 1.92 3.76 2.74

Table 4-28. Proof Test Pressures, High-Pressures 4-28 for not less than 30 seconds and not more than
Teflon Hose Assemblies 5 minutes. Test with hydraulic oil conforming to MIL-
H-5606 for tests conducted at room temperature. Any
Swivel evidence of leakage from hose or fittings or any other
end evidence of malfunction shall constitute failure.
Hose size fittings
NOTE
—3 6000 PSI
Inspect all hose with fire sleeving after proof
—4 6000 PSI
testing for fluid contamination. Contaminated
—5 6000 PSI sleeving will be replaced.
—6 6000 PSI (8) Installation of hose assembly. Refer to
—8 6000 PSI paragraph 4-5i(13). Refer to table 4-29 for support
clamp sizes.
—10 6000 PSI
—12 6000 PSI (9) Storage of hose and assemblies. Refer to
paragraph 4-5 i(14).
—16 6000 PSI
—20 6000 PSI (10) Hose disposition. Refer to paragraph 4-5
i(15).
(b) Inspect. Inspect hose assembly inter- (11) DELETE.
nally for cut or bulged inner tube, obstructions and
cleanliness. Examine hose assemblies and fittings for k. Self-Sealing Hose for Aromatic Fuel, MIL-H-
hose push-out. Inspect for proper gap between nut and 7061. Instructions for the use of self-sealing hose are
socket or hex and socket. Nuts should swivel freely. contained in the following paragraphs.
(c) Proof pressure test. All hose assemblies
shall be pressure tested to the values specified in Table

4-72 Change 2
 TM 1-1500-204-23-2

Table 4-29. Support Clamp Sizes (For use with Hose of Teflon)

Hose Size -3 -4 -5 -6 -8 - 10 - 12 - 16 -20

Clamp Size 5 7 7 9 11 12 14 18 22
(MS21919)

(1) Identification. Self-sealing aircraft hose or (c) Inspection. Inspect hose assembly inter-
hose assemblies can be readily identified as to age and nally for cut or bulged inner tube (refer to table 4-30),
manufacturer by code markings which are stencilled obstructions, and cleanliness. Inspect for proper gap
along the full length of the hose, at least 12 inches apart, between nut and nipple hex and socket.
placed immediately adjacent to the color line (see figure
4-38). The cover of the hose will have a red stripe along (5) Identification tag. Hose assembly shall be
its length parallel to the longitudinal axis. The stripe identified as outlined in paragraph 4-5g.
maybe gum inlaid or gasoline and oil-resistant lacquer.
(6) Proof testing of hose assembly. All field-
(2) Inspection. Self-sealing hose and hose fabricated hose assemblies which have passed the vi-
assemblies will be free from defects such as cracks, sual inspection shall be proof tested. Hose assemblies
cuts, breaks, blisters, looseness exposed braid, and drawn from stock shall be inspected for defects such
restricted inside diameter. Surface irregularities such as mishandling damage and proper banding, and proof
as mold marks, laps, or air bubbles, as distinguished tested if necessary. Proof testing procedures are:
from cracks or cuts, shall not be cause for rejection.
(a) Connect hose assembly to be tested to
(a) Deterioration. Inspect hose as outlined in hydrostatic test unit, air supply, or nitrogen supply, as ap-
paragraph 4-5c(1). propriate, and apply correct pressure for hose assembly
being tested. Proof pressure for MIL-H-7061 hose as-
(b) Fittings. Inspect hose fittings as outlined sembly is shown in table 4-31.
paragraph 4-5 e(2).
(b) Observe hose assemblies proof tested
(3) Design and construction. Hose shall be with a liquid test medium for leakage from hose or
constructed of a seamless, smooth-bore, compounded around fittings. Apply proof pressure for not less than
inner tube, a reinforcement, and an outer compounded 30 seconds and not more than 5 minutes.
cover. The hose shall be constructed as to permit
ready assembly with standard hose fitting connection NOTE
ends, tubing ends, pipe threaded adapters, and hose
clamps, conforming to AN 840, MS28752, MS28753, Tighten cap on hose assembly only after all
MS28754, MS28755, MS28756, MS33660, MS33658, trapped air has bled from the line.
and MIL-C-6985, and Aeroquip kit part number S-1051.
(c) Immerse hose assemblies proof tested
(4) Hose assembly. Assemble hose as outlined with a gas test medium in water, and observe for leak-
in paragraph 4-5 d. age from hose or around fittings. Apply proof pressure
for not less than 30 seconds and not more than 5
(a) Hose length. Determine correct hose minutes.
length as outlined in paragraph (4).
(d) Reject hose assemblies showing evi-
(b) Assembly. Assemble hose and fittings, dence of leakage.
as outlined in paragraph 4-5 h(5) and figure 4-43.

Change 1 4-73
TM 1-1500-204-23-2

Table 4-30. Coupling Bulge, MIL-H-7061 Hose Assembly

Minimum
Minimum bulge bulge
Hose size diameter Hose size diameter
-3 0.094 -10 0.469
-4 0.141 -12 0.563
-5 0.203 -16 0.750
-6 0.266 -20 1.000
-8 0.344 -24 1.250
-32 1.625

Table 4-31. Proof Test and Operating Pressure (psi) for MIL-H-7061

Max. Min.
Hose Wall oper. Proof burst
Hose ID Hose OD Thickness press. press. press.
Hose
size Nom. High Low High Low High Low (psi) (psi) (psi)
-10 5/8 .640 .609 1.328 1.234 .344 .313 100 200 400
-12 3/4 .781 .719 1.453 1.359 .348 .308 100 200 400
-16 1 1.031 .969 1.703 1.609 .348 .309 100 200 400
-20 1 1/4 1.281 1.219 2.031 1.906 .383 .336 75 125 250
-24 1 1/2 1.531 1.469 2.281 2.156 .383 .336 75 125 250
-32 2 2.031 1.969 2.781 2.656 .383 .336 45 75 150
-40 2 1/2 2.531 2.469 3.281 3.156 .383 .336 45 75 150
-48 3 3.031 2.969 3.968 3.844 .476 .430 45 60 150

NOTE

Hose wall thickness is ID to hose OD. The wall thickness must be held; however, the hose cannot exceed
specified ID and dimensions.

4-74
 TM 1-1500-204-23-2

seals. These plugs and seals are of plastic (polyethyl-

ene) , aluminum, steel (cadmium or zinc plates), rub-
ber, and synthetic rubber. They will not scale or chip
Degreasing solvent, MIL-PRF-680, is com- and require no tools for installation, hand tightening be-
bustible and toxic to eyes, skin and respiratory ing sufficent to provide proper protection. After removal,
tract. Wear protective gloves and goggles/face plugs and seals shall be thoroughly cleaned and sorted
shield. Avoid repeated or prolonged con- for reuse.
tact. Use only in well ventilated areas (or use
approved respirator as determined by local NOTE
safety/industrial hygiene personnel). Keep
away from open flame other sources of ignition. Plugs or seals shall not be used under operating
pressures.
(e) After proof test of a hose assembly us-
ing hydraulic fluid or oil as a test medium, flush or dip
(2) Alternate sealing methods. Exposure to
assembly in degreasing solvent, MIL-PRF-680. Drain
high temperature and dust conditions, such as in desert
assembly and dry using by compressed air. Those as-
climates, cause plastic and rubber closures to shrink,
semblies tested with water as the pressure fluid will be
deteriorate, and become difficult or impractical to use.
drained and dried with dry compressed air.
Heavy aluminum foil may be used to protect plugs
and seals from deterioration and prevent dirt and sand
(f) Install the following polyethylene protec- from entering tubing, connectors, and threaded fittings,
tive plugs in end fittings of hose assemblies that are not especially on equipment stored outside. Heavy alu-
to be immediately installed after fabrication: NAS 815- minum foil may also be used to protect open lines,
(*size) (*same dash number as fitting). Close openings connections, quick disconnect couplings, etc., when
in flanges (or other special fittings) using pressure sen- standard AN-SAE threaded closures are not available.
sitive tape or other adequate means to prevent entrance Recommended aluminum foil thickness is from 0.003 to
of foreign material. 0.005 inch, and can be locally procured or requisitioned
from Federal Stock Class 9535.
l. Use of Dust Plugs, Dust Caps. and Moisture
Seals. The following paragraphs provide instructions NOTE
for use of plugs, caps, and seals.
Prior to connection on any lines where alu-
(1) Sealing with plugs, caps, and seals. Dust minum foil has been used with standard
plugs, dust caps, and moisture seals shall be used to AN-SAE threaded closures, a thorough inspec-
provide proper closures to prevent leakage and contam- tion will be made to ensure that no foil has
ination of aircraft systems when lines or units are discon- entered lines. Any conflict between this manual
nected for maintenance, repair, shipping, storage, and and the manual for a particular aircraft or other
bulk material in free stock. See figures 4-51 through item of equipment concerning use of aluminum
4-56 for types of dust plugs, dust caps, and moisture foil will void instruction in paragraph (2).

Change 5 4-74.1
TM 1-1500-204-23-2

m. Instructions for Field Assembly of Light- the size of tube, length of assembly, and types of fittings.
weight Rubber Hose Assembly. MIL-H-83796/1 thru In absence of any of the foregoing, proceed as follows:
MIL-H-83796/9. Lightweight hose assemblies are
fabricated from bulk hose conforming to MIL-F-83978,
and are used for fuel and oil systems. The lightweight From the aircraft parts manual, find the figure which
hose assemblies are not recommended for vacuum or shows location and general position of hose.
hydraulic impulse application.
(1) Inspect hose as outlined in paragraph 4-5 e With the fittings loosely assembled in their proper posi-
(1). tion on the aircraft, cut a piece of hose approximately
(2) Inspect fittings as outlined in paragraph 4-5 three inches longer than will be required.
e (2).
Hold or tape one end of hose even with groove of one
NOTE nut, and maneuver the remainder of hose into a final
Because of contamination by foreign matter or position over other nut. Mark required length as deter-
unseen damage and wear, and because parts of mined by groove of second fitting and cut to size.
fittings from different manufacturers are not in-
terchangeable, do not salvage or reuse fittings.
(3) The listed equipment and material are re-
quired for field assembly. A hose too short will put too much tension on
assembly, or a hose too loose will flap and pos-
• Shop vise. sibly become chafed.
• Fine tooth hacsaw.

• Masking tape. Fabricate hose assembly per instructions.

(5) Cut Hose Equally to Length. Use hose
• 10,000 psi hydrastatic test machine. cut-off machine or fine-tooth hacksaw. To minimize wire
• Standard wrenches. braid flare-out, wrap hose with masking tape and saw
through tape. Refer to step 2, figure 4-50A. Remove
• Feeler gage. tape before doing step 3. Check to see that no wire of
outside braid has become bent over end of hose.
• Measuring tape.
(4) Determine length of hose required to make (6) With socket in a vise as shown step 3, figure
assembly length "L" by use of cut-off notices on the 4-50A, insert hose into socket.
socket. Refer to step 1, figure 4-50A.
NOTE
(a) When required to fabricate a new hose
assembly without any sample, drawing, or other data to Use a twisting, pushing motion to push hose
determine length requirements, check the aircraft parts into socket to a depth equal to cut-off notch. A
manual for a Military Specification (MS) identification dimensional check must be made to insure that
number. An MS number contains a code which depicts hose is inserted to a proper depth.

4-74.2 Change 2
 TM 1-1500-204-23-2

(7) While socket is still in vise, mark hose posi- Maximum allowable gap between hex and socket is
tion with paint, grease pencil, or tape. Refer to step 3, 0.031 of an inch.
figure 4-50A.
(c) The tolerance on angular alignment is ±5
(8) Lubricate inside of hose, nipple thread, and degrees on hose lengths up to 36 inches and ±10 de-
all mating surfaces. Refer to step 4, figure 4-50A. Use grees on hose lengths greater than 36 inches.
SAE 30 lubricating oil.
NOTE
(9) Carefully insert and engage nipple and
socket threads while holding hose in position with other Check for hose push-out by observing hose po-
hand. Refer to step 5, figure 4-50A. Make sure that sition mark. No change should be evident.
hose does not push out of socket by observing mark
make in step 3, figure 4-50A. On flange elbow fittings, (12) Clean, inspect and proof test as instructed
drop flange over threaded end of nipple. Nipple shoul- in paragraph 4-5f and table 4-17. Identify as instructed
der must fit into counterbore of flange. in paragraph 4-5 g.

(10) While still holding hose, complete assem- (13) After installation on aircraft, in addition to all
bly of nipple and socket by use of a wrench. Refer to regular inspections, check that position and shape con-
step 7, figure 4-50A. The method of determining proper form to general conditions shown in aircraft parts man-
tightening shall be measurement of gap between socket ual.
and nipple with a feeler gage. The gap shall be 0.000
inch minimum to 0.031 inch maximum. After complet- 4-6. INSTALLATION OF FLEXIBLE NOSE. General
ing assembly of nipple into socket, check hose position instructions to be followed when installing flexible hose
mark that was made in step 3, figure 4-50A. No push out are outlined in paragraphs a through k and in figure 4-57.
is permitted for size -3 through -10. In sizes -12 through
-32, 1/32 inch is allowable. a. Lubrication. Never, under any conditions, use
oil on self-sealing hose as an aid to installation. Oil or
(11) On hose assemblies having angle fitting on water may be used on all other types of fuel, oil, and
both ends, adjustment may be necessary to obtain the
desired position angle between to elbows. Refer to step
8, figure 4-50A. In order to prevent backing elbows to po-
sition, the following procedure should supplement steps
6 and 7:

(a) Tighten both elbows to 0.040 if an inch

clearance of socket then start to position for relative an-
gle between elbows. Refer to step 7, figure 4-50A.
Figure 4-51. Plastic Protective Dust Plug and
(b) Finish assembly by adjusting both el- Moisture Seal (AN-SAE Threaded)
bows. Backing off to position should be avoided.

Change 2 4-75
TM 1-1500-204-23-2

coolant hose when installation is made; however, oil only

should be used on hydraulic and pneumatic hose.

b. Hose Installation. Install hose so that it will not

be subject to twisting under any condition of operation,
and there will be no tendency for the connecting fittings
to loosen. When replacing hose in hydraulic, fuel oil,
alcohol, water injection, and pneumatic systems, hose
installed should be a duplicate of hose removed as to
length, outside diameter, inside diameter, material, type,
and contour unless otherwise directed.

c. Bends. When bends are required in installing

hose in fluid systems, the radii shown in table 4-32 Figure 4-53. Steel Protective Dust Cap
should be the minimum radii maintained at times for
fuel, oil, and coolant systems. Table 4-32 also shows
minimum bend radii for hydraulic and pneumatic sys-
tems. A radius larger than the minimum allowed is
preferred.

d. Hose Restriction. When hose is installed

through holes in brackets, or when supporting clips are
used, there must be no reduction in diameter of hose.
If this condition is present, flow will be reduced and
damaged to hose may occur.
Figure 4-54. Aluminum Protective Dust Plug and
e. Support. Support hose at least every 24 inches. Moisture Seal
Closer supports are preferred. Support flexible lines so
that they will not cause deflection of rigid connecting
lines. Flexible hose between two rigid connections

Figure 4-52. Steel Protective Dust Plug and

Moisture Seal

4-76
 TM 1-1500-204-23-2

Figure 4-50A. Field Assembly of Lightweight Rubber Hose

Change 2 4-76.1/(4-76.2 blank)

 TM 1-1500-204-23-2

may have excessive motion restrained where neces- adequate bend is provided between last point of support
sary, but should never be rigidly supported. and attachment to engine or accessory. This prevents
possibility of hose being pulled off nipple due to engine
f. Chafing. Eliminate chafing by using suitable movement.
bulkhead-type grommets or cushioned clips and ensur-
ing adequate clearance. i. Hose Clamp. When a length of hose is con-
nected to engine with a hose clamp, support hose firmly
g. Temperature Protection. Protect hose installa- to prevent vibrational and torsional strain on hose con-
tion from excessive temperature such as exhaust blasts, nection. When possible, place support approximately 3
supercharger ducts, and the like, by either shrouding or inches from engine connection.
relocation. Use of flame-resistant hose is preferred for-
ward of firewall as this area is subject to high tempera- j. Hose Markings. When possible, install hose so
ture under certain conditions. all markings on hose are visible.

h. Hose Connections to Engines. Where hose k. MS Flared Swivel Connectors

connections are made to engines or to engine-mounted Torquing. Torque MS flared swivel connectors in
accessories, install hose so 1 1/2 inches of slack or an accordance with tables 4-33 and 4-34.

Table 4-32. Minimum Bend Radii of Hose for Fuel, Oil, and Coolant Systems

Hose (Military Specification

No.) Size Correct radii
MIL-H-8794 All See MS33790
MIL-H-7061 Up to and including 1 1/4 R = 6 x inside
inch inside diameter diameter
MIL-H-7061 Larger than 1 1/4 inch R = 12 x inside
inside diameter diameter
MIL-H-5593 All R = 12 x inside
diameter
MIL-H-6000 All R = 12 x inside
diameter
MIL-H-7938 All R = 12 x inside
diameter

4-77
TM 1-1500-204-23-2

Table 4-33. Installation Torque Values MS Flared Table 4-34. Hose End Fitting And Coupling Nut
Swivel Nut Fittings (Reference AND 10064) Installation Torque In Inch-Pounds

Tubing size OD inch Torque Dash Material 1 Material II2

Dash size Minimum Maximum Minimum Maximum
Hose size ID inch fitting size Min. Max.
2 75 85 20 30
3/16 —3 70 100
3 95 105 25 35
1/4 —4 70 120
4 135 145 50 65
5/16 —5 85 180
5 170 190 70 90
3/8 —6 100 250
6 215 245 110 130
1/2 —8 210 420
8 430 470 230 260
5/8 —10 300 480
10 620 680 330 360
3/4 —12 500 850
12 855 945 460 500
1 —16Z 700 1150
16 1140 1260 640 700
1-1/4 —20Z 1000 1000
20 1520 1680 800 900
1-1/2 —24Z 1000 14000
24 1900 2100 800 900
32 2660 2940 1800 2000
1. Material I - Steel, corrosion resistant, and titanium fittings.
2. Material II - Aluminum fittings.

Figure 4-55. Plastic Protective Dust Cap

Figure 4-56. Plastic Protective Dust Cap (AN-SAE

Friction)

4-78
 TM 1-1500-204-23-2

NOTE els, solvents, thinners, moisture, strong drafts, or ozone

(form of oxygen formed from an electrical charge). Dam-
•The fitting nipple should be restrained while ap- age by exposure is magnified when rubber is under ten-
plying torque to the nut at the fitting to prevent sion, compression, or stress. Conditions to be avoided
galling of the sealing surfaces. All adapters to include the following:
hose fitting threads and contact surfaces shall
be lubricated prior to application of torque. • Defects in shape resulting from im-
proper stacking of parts and from stor-
•To find the dash size of a given fitting look age in improper containers.
on the fitting itself at the part number which is
stamped on it. The last number of the part num- • Creasing caused by force applied to cor-
ber following the dash is the fitting size, in six- ners and edges any by squeezing rings
teenths of an inch. between boxes and storages contain-
ers.
•If the part number is not stamped on the fitting,
measure the outside diameter of the tubing or • Compression and flattening as a result
the inside diameter of the hose to which the of storage under heavy parts.
fitting is attached.
• Punctures caused by staples used in at-
4-7. HYDRAULIC PACKINGS AND taching identification.
O-RINGS. Hydraulic seals are used throughout aircraft
hydraulic systems to prevent internal and external • Hanging O-rings from nails or pegs
leakage of hydraulic fluid, thereby preventing loss of where they are apt to become dirty and
system pressure. Seals used between non-moving to develop defective shapes (O-rings
components are called gaskets, which are generally should be kept in their original en-
referred to as O-rings. Seals inside a sliding or moving velopes).
part are called packings.
• Allowing rings to become oily or dirty by
a. O-Rings. O-rings used as gaskets are used in fluids leaking from parts stored above
the sealing of boss fittings, end caps of actuators, pis- and adjacent to O-ring surfaces.
ton accumulators, and other installations where moving
parts do not come in contact with the seal. Some O-rings
• Applying adhesive tape directly to O-ring
surfaces (a torn O-ring package should
are used as packings where relative motion is encoun-
be secured with a pressure-sensitive,
tered. Figure 4-58 shows a typical O-ring cross-section.
moisture proof tape, but the tape must
not contact the O-ring surface.
(1) Identification. O-rings are manufactured
according to military specifications. They are identified • Keeping over-age parts as a result of im-
from the technical information printed on the O-ring proper storage arrangements or unread-
package (see fig. 4-59). Because the size of O-rings able identification. O-rings should be ar-
cannot be positively identified by visual examination ranged so that older seals are used first.
without the use of special equipment, O-rings are pack-
aged in individual sealed envelopes labeled with all the
necessary data. Colored dots, dashes, and stripes or
combinations of dots and dashes on the surface of the
O-ring are no longer used to identify O-rings.

(2) Storage. Proper storage practices must be

observed to protect O-rings. Most synthetic rubbers are Figure 4-58. O-Ring
not damaged by several years of storage under ideal
conditions. Their enemies are heat, light, oil, grease, fu-

4-79
TM 1-1500-204-23-2

Figure 4-57. Hose Line Installation Aids for All Types of Hoses

4-80
 TM 1-1500-204-23-2

(a) Cleaning. After all O-rings are removed,

cleaning of the parts that will receive new O-rings is
mandatory. Ensure that the area used for such instal-
lations is clean and free from all contamination.

(b) Inspection. Each replacement O-ring

should be removed from its sealed package and in-
spected for defects such as blemishes, abrasions, cuts,
or punctures. Although an O-ring may appear perfect
at first glance, slight surface flaws may exist. These
can prevent satisfactory O-ring performance under
the variable operating pressures of aircraft systems.
Figure 4-59. O-Ring Identification O-rings having flaws that will affect their performance
should be rejected.
(3) Removal. When removing O-rings, care
must be taken to ensure that the groove surface is not (c) Sizing. Ensure that O-ring is of proper
marred or scratched (see figure 4-60). The correct size. Uniform pressure on O-ring in installed position is
tool should be used in order to minimize this kind of necessary for satisfactory operation.
damage. A variety of these tools may be used on any
given job. They should be made from soft metal such
as brass and aluminum; however, tools made from
phenolic rod, plastics, and wood may also be used.
Avoid using pointed or sharp-edged tools that might O-ring splicing and O-ring assortment kits do
damage the O-ring. not meet the specific requirements for O-ring
usage on aviation equipment and are not au-
(a) Removing internal O-rings. During re- thorized for use on Army aircraft. Use of unau-
moval of O-rings, the hook type removal tool is put thorized O-rings may compromise the integrity
under the O-ring and then lifted to allow the extractor and safety of equipment and personnel.
tool to pull the O-ring from its place. See figures 4-61
through 4-64 for removal of various configurations of
O-rings.
Never use adhesive tapes to cover danger ar-
(b) Removing external O-rings. It is less dif- eas on components. Gummy substances left
ficult to remove external O-rings than internal ones. Two by the adhesives are extremely detrimental to
accepted removal methods are described in the follow- hydraulic systems.
ing paragraphs.
(d) Installation. Immerse rings to be installed
1 Spoon-type extractor.A spoon-type ex- in hydraulic systems in hydraulic fluid, MIL-H-5606 or
tractor is positioned under the seal, as shown in figure MIL-H-83282. During installation, avoid rolling and
4-65. After the O-ring is taken from its cavity, the spoon twisting the O-ring to put it into place. If possible, keep
is held still while the piston is rotated and withdrawn. the position of the O-ring mold line constant. After the
O-ring is placed in the cavity provided, gently roll the
2 Wedge-type extractor.A Wedge-type O-ring with the fingers to remove any twist that might
extractor tool is inserted under an O-ring as shown in have occurred during installation. When the O-ring
figure 4-66, and the hook type removal tool hooks the installation requires spanning or inserting through sharp
O-ring. A slight pull on the hook removes the O-ring threaded areas, ridges, slots, and edges, use protective
from its cavity. measures such as the O-ring entering sleeves shown in
figures 4-67 through 4-69. If the recommended O-ring
(4) Installation. O-rings, as a rule, require no entering sleeve (soft thin-wall metallic sleeve) is not
adjustment in installation, but the precautions described available, paper sleeves and covers may be made by
in the following paragraphs must be observed or early using seal package (gloss side out) or lint-free bond
failure will result. paper.

4-81
TM 1-1500-204-23-2

Figure 4-60. Removing O-Ring

Figure 4-62. Internal O-Ring Removal (Wedge-Type

Extractor)

Figure 4-61. Internal O-Ring Removal (Pull-Type

Extractor)

Figure 4-63. Internal O-Ring Removal (Push-Type

Extractor)

4-82
 TM 1-1500-204-23-2

b. Elliptical Rings. The care and handling of ellip-

tical rings are the same as for O-rings, but elliptical rings
are used in fewer applications, such as in some landing
gear struts. Figure 4-70 shows a typical elliptical ring
cross-section.

c. V-ring Packings. V-ring packings used in Army

aircraft hydraulic installations are made of synthetic rub-
ber. They are used in units that contain moving parts,
such as actuating cylinders and selector valves.

(1) Removal and cleaning. V-ring packings are

removed by much the same methods as for O-rings. Af-
ter packings are removed, the area in the component
must be thoroughly cleaned to prevent contamination or
possible harm to the packings during or after installation.

(2) Inspection. Visually inspect each V-ring

packing for cuts, nicks, or flaws before installation, and
discard when any evidence of these effects is present.

(3) Installation. Figure 4-71 shows V-ring pack-

ings in various stages of installation. Prior to installation, Figure 4-65. External O-Ring Removal
immerse V-ring packings in hydraulic fluid, MIL-H-5606 (Spoon-Type Tools)
or MIL-H-83282.

(a) Installation over threads. Protect V-ring

packing lips when ring is installed over threads of similar
projections, as shown in figure 4-71.

Figure 4-66. External O-Ring Removal

(Wedged-Type Extractor)

Figure 4-64. Dual Internal O-Ring Removal

4-83
TM 1-1500-204-23-2

(b) Installation precautions. Install V-ring applicable to O-rings must be taken to avert contamina-
packing individually, making certain that packing is tion of backup rings and damage to hydraulic compo-
properly seated by tapping lightly with a small, clean, nents.
well-rounded blunt rod or similar instrument. Do not use
screwdriver or other sharp tools. Do not install rings a. Identification. Backup rings are not color
in sets, that is, more than one ring at a time. V-ring coded or otherwise marked and must be identified from
packings must never be squeezed excessively nor package labels. The dash number, which follows the
be loose in gland, but should be held firm to operate specification number on the package, shows the size,
properly. Packing should contact gland walls on both and in some cases relates directly to the dash number,
inside and outside diameter. of the O-ring for which the backup ring is dimension-
ally suited. For example, the single spiral Teflon ring
4-8. BACKUP RINGS. Backup rings are used to MS28774-6 is used with the MS28775-006 O-ring and
support O-rings and to prevent them from wearing, thus the double spiral Teflon ring MS28782-1 is used with
causing leakage. Teflon backup rings are generally the AN6227B-1 O-ring.
used with both packings and gaskets; however, leather
backup rings may be used with gasket type seals in sys- b. Installation. Care must be taken during han-
tems operating up to 1,500 psi. Teflon rings are made dling and installation of backup rings. If possible, backup
from a fluorocarbon-resin material which is tough and rings should be put on by hand and without the use of
friction resistant and which is more durable than leather. sharp tools.
Backup rings made from Teflon do not deteriorate with
age, they are unaffected by any other system fluid or (1) Teflon backup rings. Teflon backup rings
vapor, and they tolorate temperature extremes greater must be inspected before reuse and must be discarded
than those encountered in high-pressure hydraulic if there is evidence of compression damage, scratches,
systems. Precautions similar to those cuts, nicks, and fraying conditions.

Figure 4-68. Internal O-Ring Installation (Metallic

Sleeve)

Figure 4-67. Internal O-Ring Installation (Paper

Cover)

4-84
 TM 1-1500-204-23-2

Figure 4-69. External O-Ring Installation

(a) Stretching. Before installing a Teflon spi-

ral ring in an internal groove, stretch it slightly, as shown
in figure 4-72. While the Teflon ring is being put in the
groove, turn the component in a clockwise direction (see
figure 4-73). This will tend to expand the ring diameter
and will reduce the possibility of damage to the ring.

Figure 4-70. Elliptical Ring

Figure 4-71. V-Ring Packings in Various Positions of Assembly

4-85
TM 1-1500-204-23-2

(b) Changing spiral. Before installing a by weight, in a vessel which can be heated to and main-
Teflon spiral ring in an external groove, you must tained at 155° (± 5°) F (68° (± 2.8°) C.)
change the right-hand spiral of the ring to a left-hand
one, as shown in figure 4-74. As you put the ring into (b) Completely submerge leather backup
the groove, turn the component in a clockwise direction. rings in solution, and let soak for a period of not less
This will tend to contract the ring diameter and will than 15 minutes.
reduce the possibility of damage to the ring.
(c) Remove backup rings from soaking ves-
(c) Single installation. Backup rings may be sel and wipe off excess moisture. Immediately install
installed singly if pressure acts on only one side of the rings as required in external seal grooves, with grain
seal. In figure 4-75, the backup ring is installed next to (hair) side of backup ring toward side of groove, en-
the O-ring and opposite to the pressure force. suring that backup ring is well seated against one side
of groove to maintain flatness when drying (see figure
(d) Dual installation. When dual backup 4-77).
rings are installed, the split scarfed ends must be stag-
gered, as shown in figure 4-76. (d) Place seal with backup ring installed in
drying oven with means provided for air circulation at
(2) Leather backup rings. Leather backup ambient temperature of 155° (± 5°) F (68° (±2.8 °) C.)
rings also must be inspected before reuse for defects. for a period of not less than 25 minutes.
Defective rings must be discarded. To install a leather
backup ring, proceed as follows: (e) Remove from oven and allow to return to
room temperature before attempting to install.
(a) Prepare a solution of distilled water and
0.05-percent sodium dichromate, Federal Specification
O-S-595,

Figure 4-73. Installing Teflon Backup Ring

Figure 4-72. Stretching Teflon Backup Ring

4-86
 TM 1-1500-204-23-2

4-9. SWAGED TUBING REPAIRS. The basic ele- existing ones. Because the system is portable, it can
ment of this repair technique is the Permaswage fitting be used in the field as well as in the shop. Fittings used
that is mechanically attached to a tube by radial swag- on Army helicopters include combinations of permanent
ing. These fittings make permanent and separable and threaded fittings for flareless connectors (See Fig-
connectionsb between metal tubes. It works by deform- ure 4-74) as well as permanent to permanent unions,
ing the metal fitting onto a tube radially, 360 around the elbows, tees, and crosses (See Figure 4-75). While
circumference, using Deutsch Lightweight Tool (DTL). numerous additional type and styles of Permaswage
The interference between the fitting and tube produce fittings are available, only those useable on current
a leak resistance seal that is structurally sound. This Army helicopter tubing are addressed
system can be used to produce new tubes or to repair

Figure 4-74. Separable Permaswage Fittings - Flareless

Figure 4-75. Permanent to Permanent Permaswage Fittings

Change 4 4-87
TM 1-1500-204-23-2

a. Description of Equipment. The new Deutsch and then deburred. The installation depth is properly
DTL tooling with lighter weight and more compact heads marked and the chosen fitting is placed on the tube.
replaces the now obsolete Dl2000 series tooling pre- Next the swage tool is placed so it surrounds the fit-
viously addressed in this paragraph. Deutsch field re- ting. The swaging tool is then activated by pressure from
pair kit, PIN DLTFRPSKT3029 has been added to LIN the pump. This causes the swage tool to radially com-
T57982, NSN 5180-01-115-7008, which previously au- press the fitting and tube. Enough pressure is applied to
thorized only Deutsch field tool kit PIN D12102C-15- swage the fitting on the tube. ’The swaged connection
H10. Both of these kits include a hand hydraulic pump, is then inspected.
head assemblies, and all other tools and gauges needed
to install swaged fittings on tube sizes 4 (114), 6 (3/8), c. Preparation for Swaging. Complete the fol-
8 (112), 10 (518), 12 (314), and 16 (1 in). Deutsch field lowing steps:
repair kit, PIN DLTFRPSKT3003 has been added to LIN
T57914, NSN 51 80-01 -1 15- 7007, which previously (1) Check sizes and material:
authorized only Deutsch field tool kit PIN D12102C-03-
H01. These kits include a hand hydraulic pump, head (a) Check material compatibility between
assemblies and all other tools and gauges needed to tubing and fitting (see Table 4-35).
install swaged fittings only on tube sizes 4 (114) and 6
(318). An additional kit PIN, DLTFRPSKT3001 is avail- (b) Check for satisfactory thickness of tube
able through GSA under NSN 51 80-01 -341 -4030. The walls based on tube OD, material and system/line oper-
size 16 (1 in) head only required to support the CH-47 ating pressure (see Table 4-35).
is not included in this kit.
(c) Select fitting size based on tube OD.
b. Summary of Operation. The operation starts
by preparing the tube. The tube to be connected is cut

4-88 Change 4
 TM 1-1500-204-23-2

Table 4-35. Recommended Fitting/Tube Material & Wall Thickness Combinations (0-3000 psi)

Tube OD (inch sizes)

Max Line 1/4" 3/8" 1/2" 5/8" 3/4" 1"
Fitting Tube Pressure
Material Material (psi) -04 -06 -08 -10 -12 -16
6061-T6 AL 6061-T6 AL 1,500 .035 .035 .035 — — —
(AMS-QQ- (AMS4083)
A-225) 1,000 .020 .028 .028 .035 .035 .042
.035 .049
500 — — — — — .035
200 .020 .020 .020 .020 .020 .020
21-6-9 8061-T6 AL 3,000 .035 .049 .064 .065 .095 —
CRES (AMS4083) — —
(AMS5656) 1,500 .035 .035 .035 .065
1,00 .020 — — .035 .035 —
500 .028 035 .035 .035 .035 .035
3AL-2.5V 3,000 .016 .020 .026 .032 .039 .051
CWSR TI .026
(AMS4944
or
AMS4945)
3AL-2.5V 3,000 — .028 .028 .046 .058 .073
ANNEAL .035
TI (AMS
4943 or
GM3118A)
21-6-9 3,000 .016 .020 .026 .032 .039 .052
CRES .033
(AMS5581) — — — — — —
2,000
1,500 — — — — — .020
1,000 — — — — — —
500 — — — — — —
350 — — — — — —
304 1/8HD 3,000 .02 .028 .035 .042 .058 .065
CRES — — — — — —
(AMS5566 1,500
or AM5854)

Change 4 4-89
TM 1-1500-204-23-2

(1) Tube Condition Prior to Installation. The

tube should be clean from any paint or other foreign ma- Table 4-36. Minimum Straight Tube Length
terials (Swaging is permitted on Alodine finish). There Required Before Bend
should not be any flat spots, scratches or nicks on the
tube. Cleaning operations on the OD of the tube can Tube OD “L” Minimum Straight Length
take place prior to installation. Lightly clean the tub with
a rag or Scotch Bright, provided that in all cases the area 1/4” .915
of the swage remains within the tube tolerance. In all 3/8” .990
cases the O.E.M.’s installation and maintenance speci-
fications take precedence. 1/2” 1.493
5/8” 1.533
NOTE
3/4” 1.603
A minimum length of straight tube (before a
1” 1.748
bend) is required to produce a satisfactory con-
nection. (See Table 4-36 and Figure 4-76).

Figure 4-76. Minimum Straight Length

(2) Cut Tube (if needed). (c) Retract cutting wheel of tube cutter by
turning drive screw counterclockwise. Use screwdriver
(a) Select tube cutter based on tube size. or men wrench. (See Figure 4-77)
(See Table 4-37)
(d) Open cutter head by rotating tube cutting
(b) Mark cutting point on tube. assembly inside cutter handle.

4-90 Change 4
 TM 1-1500-204-23-2

(e) Slide tube cutter over tube. (h) Further extend cutting wheel by turning
drive screw in tube cutter 1/20 to 1/10 turn clockwise.
(f) Extend cutting wheel of tube cutter by
turning drive screw clockwise until cutting wheel touches (i) Repeat steps (g) and (h) (of Section 5.2)
tube. Further extend cutting wheel by turning drive until tube has been cut. CAUTION: Do not overturn the
screw in tube cutter (approximately 1/6 turn clockwise). cutting wheel in order not to deform the tube.

(g) Rotate tube cutter handle around tube un-

til there is a noticeable ease of rotation.

Table 4-37. Tube Cutter, Spare Cutter Wheel, & Misc Components

Spare Cutter
Sizes Tube Cutter PN Wheel PN Misc. Components PN
1/4” through 3/8” D12530-001 D12530-109 Hex Key DTL5103-104-01
1/2” thrugh 3/4” D12531-001 D12531-109 Marking Pen DTL5301-100-01
7/8” through 1 1/2” D12532-001 D12532-109 Swage Lube DTLSWLUB0001

Figure 4-77. Tube Cutter

Change 4 4-91
TM 1-1500-204-23-2

(3) Deburr Tube. towards tube. Continue to rotate until end of tube is
deburred.
(a) Select deburring tool stem assembly,
based on tube OD. (See Table 4-38). (f) WITHOUT DEPRESSING PLUNGER,
withdraw deburring tool from tube until first ridge of
(b) Insert stem assembly into deburring tool rubber plug is exposed. Wipe ridge clean. Check end of
handle. Turn stem assembly clockwise until finger tight, tube for satisfactory deburring. (Leave deburring tool In
while depressing plunger. tube until step (h). If tube is not satisfactorily deburred,
push tool back into tube and repeat steps (e) and (f).
(c) Release plunger, and check to see that
rubber plug is expanded. Lightly lubricate rubber plug (g) Wipe outside of tube clean.
of stem assembly with swage lube.
(h) Remove deburring tool from tube.
(d) Depress plunger of deburring tool and In-
sert deburring tool into end of tube. Release plunger. (i) Depress plunger of deburring tool and un-
screw stem from handle. Wipe stem dean, lightly lubri-
(e) Hold tube, and rotate knurled handle of cate and store.
deburring tool clockwise while applying slight pressure

Table 4-38. Deburring Tool and Stem Assembly

Part Numbers for Standard Stem Assemblies

Size Deburring Tool Stem Assembly NSN
1/4 D9851-14 D9851-13-04 5110-00-05-5650
3/8 D9851-14 D9851-13-06 5110-00-133-1477
1/2 D9850-14 D9851-13-08 5110-00-003-0535
5/8 D9850-14 D9851-13-10 5110-00-003-0536
3/4 D9850-14 D9851-13-12 5110-00-003-0537
1 D9850-14 D9851-13-16 5110-00-784-7946

4-92 Change 4
 TM 1-1500-204-23-2

Figure 4-78. Deburring Tool

(4) Mark Insertion Depth on Tube.

(a) Mark tube as indicated by insertion mark-
NOTE ing tool. (See Figure 4-79.1) Use marking pen supplied
in tool kit, or any other suitable marking method. Mark
If the insertion marking tool is not available, tube in at least two places, 180 degrees apart.
mark the insertion depth per the dimensions on
Table 4-39. Be sure to use correct slot in mark- (b) Slide fitting onto tube.
ing guide and mark tube the entire length of the
slot in marking guide.

Table 4-39. Marking Insertion Marks without Insertion Marking Tool

Tube OD “A” “B” Part Numebr

1/4 .615” .915” DLT5302-013-01
3/8 .690” .990”
1/2 1.193” 1.493” DLT5302-031-01
5/8 1.233” 1.533”
3/4 1.303” 1.603”
1 1.440” 1.745” DLT5302-040-01
Locate points "A" and "B" distances from end of the tube. The distance "A" is the
minimum insertion depth, and "B" is the maximum insertion depth. The insertion
mark made on the tube must extend between "A" and "B".

Change 4 4-93
TM 1-1500-204-23-2

Figure 4-79.1. lnsertion Marking Tool

d. Operation Instructions for Swage Tool- (e) Check the insertion mark using the proper
ing. Complete the following steps: Deutsch marking tool for the tube size.

(f) Ensure proper insertion of the fitting. Part

of the insertion mark must be visible with the fitting is in
place.
This tooling is subject to extremely high pres-
sure during swaging. Improper use may result (g) Ensure that the stop endplate on the head
in tool failure or personal injury. assembly is not pushed by the fitting. The fitting must
just touch the stop endplate prior to the swaging.
(1) DLTPre-Swage Inspection Procedure.
(h) Verify that the material, size and wall
(a) Inspect the tube ends to be swaged for thickness of the tube are as specified.
burrs on the outer diameter and the inner diameter. If
not deburred properly, it will cut the silicone seal and (i) Ensure correct fitting part number and
scratch the I.D. of the fittings. size.
(b) Check the swage dies for size and to en- (j) Verify that the pump develops 10,000
sure they are free of foreign material between slots. The ±250 psi hydraulic pressure. If using a pneumatic pump,
two halves must be a matched set. the pump inlet air pressure should be 80 - 120 psi.
(c) Check the power unit model number and
head assembly part number.

(d) Check to ensure the head and the

dieblock are positioned correctly with respect to the
dies and the fitting.

4-94 Change 4
 TM 1-1500-204-23-2

(k) Ensure that the two ends of the tubes be- 1 Position the fitting on the tube so that
ing connected, or a tube end being connected to a sep- part of the tube insertion mark is covered by the fitting.
arable joint, are aligned within a reasonable amount. No Make sure part of the tube insertion mark is also outside
more than finger pressure must be applied to align the the fitting.
two tube ends.
(h) Position Swage Tool.
(l) When B-nuts are involved tighten the
B-nuts first, and then perform the swage in the preferred 1 Slide head assembly over fitting and
sequence. tube. Ensure beveled end of die is towards center of
fitting.
(2) Preparation of Tooling.
2 Slide head assembly into power unit.
(a) Select proper power unit and head as- Head assembly will fit on power unit only one way —
sembly based on tube OD. (See Table 4-39.1) position knurled strip on head assembly on same side
as knurled strip on power unit. (See Figure 4-79)
(b) Push lower die/holder assembly out of
head assembly. 3 Move the power unit toward the center
of the fitting, until the fitting hits the end plate stop.
(c) Make sure upper and lower halves of die
have same serial number. (3) Swage Connection. Apply hydraulic pres-
sure (10,000 ±250 psi) to the swage tool. Keep the
(d) Join lower die/holder assembly to top of power unit, fitting, and tube in the positions described
power unit. (See Figure 4-79) (Note that this assembly in steps (g)1and (h)3 of 6.2.
will fit on power unit only one way.)
(4) Remove Tooling.
(e) Connect one end of hydraulic hose to
portable hydraulic pump. Make sure pump delivers (a) Release the pressure to allow the dies to
10,000 250 psi. open. After the dies halves have opened, slide the head
assembly out of the power unit. The two pads do not
(f) Connect other end of hydraulic hose to require much pressure to separate.
power unit.
(b) Remove the head assembly from the
(g) Position Fitting On Tube. swaged fitting/tube.

Change 4 4-95
TM 1-1500-204-23-2

Table 4-39.1. Power Unit, Head Assembly, Die End Plates & Screw

Tube Fitting
OD Size Power Unit Head Assembly Die
1/4” -04 DLT06MAPW0000 DLT05PSHA3004 DLT06PSDI3004
3/8” -06 DLT10MAPW0000 DLT10PSHA3006 DLT10PSDI3006
1/2” -08 DLT20MAPW0000 DLT20PSHA3008 DLT20PSDI3008
5/8” -10 DLT20MAPW0000 DLT20PSHA3010 DLT20PSDI3010
3/4” -12 DLT30MAPW0000 DLT30PSHA3012 DLT30PSDI3012
1” -16 DLT40MAPW0000 DLT40PSHA3016 DLT40PSDI3016

Fitting End Plates

Size
Inboard Upper Inboard Lower Outboard Upper Outboard Lower Screw, Socket, Head, Flat
-04 DLT05PSEU3004 DLT05PSEL3004 DLT05PSFU3004 DLT05PSFL3004 MS24671-1
-06 DLT10PSEU3006 DLT10PSEL3006 DLT10PSFU3006 DLT10PSFL3006 MS24671-1
-08 DLT20PSEU3008 DLT20PSEL3008 DLT20PSFU3008 DLT20PSFL3008 MS24671-1

-10 DLT20PSEU3010 DLT20PSEL3010 DLT20PSFU3010 DLT20PSFL3010 MS24671-1

-12 DLT30PSEU3012 DLT30PSEL3012 DLT30PSFU3012 DLT30PSFL3012 MS24671-1

-16 DLT40PSEU3016 DLT40PSEL3016 DLT40PSFU3016 DLT40PSFL3016 MS24671-1

Figure 4-79. Head Assembly, Lower Die Block assembly and Power Unit

4-96 Change 4
 TM 1-1500-204-23-2

e. Inspection of Swaged Connections. Com- (2) Place inspection gage over swaged end of
plete the following steps: fitting. Ensure internal shoulder of gauge contacts end
of fitting. (See Figure 4-81)
NOTE
Outside diameter of fitting must be smaller than
Inspect swage fittings for wear, chaffing, cuts, ID of gauge. Part of the die marks on fitting must be
splits and leaks. Inspect entire length for proper visible outside of gauge.
routing of the hydraulic tubing. Inspect adjacent
structure for damage. Inspect swaged fittings NOTE
only with inspection gages supplied by Deutsch
Metal Components — use no other method. To If inspection gauge does not fit properly over
verify dimensions of inspection gauges, see Ta- the swaged fitting, reswage the fitting. If dimen-
ble 4-39.2. sions of swaged fitting are still not satisfactory,
contact Deutsch Metal Components represen-
(1) Select inspection gage, based on size of fit- tative for assistance.
ting. (See Table 4-39.2 & Figure 4-80).
(3) Rotate gauge 90°, and repeat step (2)
Swage fittings must be inspected after swaging. above.
This action verifies the fitting has been compressed ac-
curately.

Table 4-39.2. lnspection Gauge (0-3000 psi max)

Gauge
Inside Inside Length
Fitting Diameter “A” “B" ±.003
Size Permaswage No. NSN ±.002 (inches) (inches)
-04 12-9892-04 5220-00-005-5636 .315 .460
-06 12-9892-06 5210-00-005-5638 .3447 .584
-08 12-9892-08 5210-00-004-4912 .606 1.020
-10 12-9892-10 5210-01-251-3823 .735 1.020
-12 12-9892-12 5210-00-004-4914 .863 1.020
-16 12-9892-16 5220-00-882-7951 1.144 1.160

Figure 4-80. lnspection Gauge

Change 6 4-97
TM 1-1500-204-23-2

Figure 4-81. Using lnspection Gauge

f. Tube Repair Techniques. Four basic types of required, and the distance between cuts exceeds 0.30",
tubing system failures lend themselves to permanent re- use repair TYPE 2.)
pair using Permaswage techniques. The failure types
and recommended repair procedures (one per page) are Cut the tube only after checking to assure enough space
as follows: is available to operate the swage tod.

(1) Type 1 – Small Hole or Short Crack in (b) Replace removed section of tube with a
Tube. compatible Permaswage® union fitting.

(a) Make one or two cuts as necessary to al-

low removal of damaged tube section. (If two cuts are

Figure 4-82. Type 1 Repair

4-98 Change 4
 TM 1-1500-204-23-2

(2) Type 2 – Lengthwise Crack in Tube (Crack (b) Use a tube splice and two compatible
Longer Than 0.30 Inches). Permaswage® union fittings to recreate the section of
tubing which was removed. Assemble these parts into
(a) Make two cuts to allow removal of dam- the line being repaired before you swage the fittings.
aged section of tube. Cut the tube only after checking to
assure enough space is available to operate the swage (c) Swage each end of the fittings.
tool.

Figure 4-87. Type 2 Repair, Crack is longer than 0.30"

(3) Type 3 – Leaking Tube or Fitting (b) Swage tube splices to a compatible Per-
Associated with Elbow, Tee or Cross. maswage® elbow, tee, or cross fitting. Do this to recre-
ate section of tubing system which was removed.
(a) Cut out defective elbow, tee, or cross. Cut
the tube only after checking to assure enough space is (c) Swage each leg (tube) of this assembly
available to operate the swage tool. to the tubing being repaired. Use Permaswage® union
fittings.

Change 4 4-99
TM 1-1500-204-23-2

Figure 4-88. Type 3 Repair

(4) Type 4 – Damaged Tube or End Fitting (b) Replace the removed fitting with a com-
(flareless female). patible Permaswage® D10007 flared deem and D10006
coupling nut. (Insert the end of the tube being repaired
(a) Cut off the flared end of the tube as shown into the flared sleeve as for as possible before swaging.
in Figure 4-89. Refer to Table 4-39.2 to determine the This will duplicate the original overall length of the as-
cutoff length ("L”). Use of these cutoff lengths permits sembly.)
repair of the line without splicing new tubing into the line.

4-100 Change 4
 TM 1-1500-204-23-2

Figure 4-89. Type 4 Repair

Table 4-39.3. lnspection Gauge (0-3000 psi max)

Tube
Size Fitting
(inches) Size “L” (±.010)
1/4” -04 .541
3/8” -06 .508
1/2” -08 .588
5/8” -10 .600
3/4” -12 .628
1” -16 2.110

Change 4 4-100.1
TM 1-1500-204-23-2

g. Frequently Asked Questions.

1. Is it OK to swage a fitting more than once?

YES. It is OK to swage a fitting more than once — just be sure that you’re using the correct die set. And be sure that your
hydraulic pump is delivering the right amount of pressure to the swage tool.
2. If a joint is weeping or leaking, should the fitting be swaged again?
If a Permaswage® joint begins to weep or leak, the leakage will often be stopped by swaging the fitting again.
3. How many fittings can be swaged into a line?
As many as will fit. Allow a minimum distance of one tube diameter between fittings.
4. Is it OK to glue fittings onto tube?
NO. Do not glue at any time.

Refer any questions to your Deutsch Metal Components representative (web address: www.deutschco.com)

h. Basic Maintenance. This paragraph covers Parts of this tooling are subjected to extremely
regular inspections, cleaning, and stowage of the equip- high forces – the following procedures must be
ment. Also covered is how to replace the cutter wheel performed as often as specified to ensure safe
of the tube cutter. and successful operation.

NOTE

Inspections and Cleaning of Tooling

Procedure Performed How Often

Check All Components
If any deep scratches, gouges, dimples or abnormalities appear, Before each use
discontinue use and contact Deusch Metal Components
Check Die Sets
Upper and lower halves must be a serialized set. They must be clean. Before each use
Apply Deutsch Swage Lube to the heads and dieblocks prior to installing
the dies.
Check Connection Paths
Components must be clean in all areas where they contact each other Each time components are
connected.
Check Tube Cutter
Cutting wheels must be sharp. Rollers must be parallel and not wobbly. Before each use.
Lubricate Tube Cutter
Lubricate ratchet, rollers and cutter wheel with light oil. As required to ensure ease o9f
operation.

4-100.2 Change 4
 TM 1-1500-204-23-2

(1) Storing Equipment After Use. Replace tightened by a wrench. The union nut must be tightened
protective caps over all connectors before storing until it can no longer rotate.
equipment. Storing the equipment without replacing the
protective caps can cause the equipment to fail. b. Inspection. The quick-disconnect coupling will
be inspected as follows:
(2) How to Replace Cutter Wheel of Tube Cut-
ter (Figure 4-77). The cutter wheel in the tube cutter (1) Inspect union nut for tightness and security.
should be replaced whenever it becomes too dull to cut
efficiently. It should also be replaced if it becomes dam- (2) Inspect coupling for leaks when pressure is
aged in any way. applied.

4-10. QUICK-DISCONNECT COUPLINGS. Quick- (3) Actuate affected component to ensure free
disconnect couplings of the self-sealing type are used at flow through the coupling.
various points in all hydraulic systems. These couplings
are installed at locations where frequent uncoupling of 4-11. HYDRAULIC system reservoir holds enough
lines is required for inspection and maintenance. Each fluid for use in operation of the system and to replace
coupling assembly consists of two halves held together fluid lost through minor leakage or evaporation. Reser-
by a union nut. Each half contains a valve which is held voirs may also be installed to provide a space for in-
open when the coupling is connected, allowing fluid to crease in fluid volume over the original amount, such
flow in either direction through the coupling. When the as that which might occur through thermal expansion or
coupling is disconnected, a spring in each half closes foaming. They also provide a place of escape for air
the valves, preventing loss of fluid and entrance of air. trapped in the system.
The union nut has a quick-lead thread which permits the
coupling to be connected or disconnected by turning the a. Types of Reservoirs Used in Hydraulic Sys-
nut. Various types of union nuts are used in hydraulic tems. Two types of reservoirs are used in aircraft hy-
systems. For one type, a quarter-turn on the union draulic systems: the in-line and the integral type.
nut locks or unlocks the coupling. For another type, a
full turn is required. Some couplings require wrench (1) In-line. The in-line reservoir, seen in figure
tightening; others are connected and disconnected by 4-91, has its own housing, is complete within itself, and
hand. Some installations require that the coupling be is connected with other components in the system by
secured with safety wire; others do not require any tubing or hose. The in-line type is most common in Army
form of safetying. Because of these differences, all aircraft, and is covered in this manual.
quick disconnects must be installed in accordance with
the instructions in the applicable maintenance manual.
(2) Integral. The integral reservoir consists
However, following are general guidelines for installa-
merely of a space set aside within a major component
tion and inspection.
for the purpose of holding a supply of operational fluid.
An example of this kind of reservoir is an automotive
a. Installation. When installing a coupling, the brake master cylinder.
coupling can be fully connected by hand. The external
shape of the union nut sleeve is such that it can be

Change 4 4-101
TM 1-1500-204-23-2

reservoir at a level below the pump. In this case, the

weight of the fluid obviously deters, rather than aids,
the flow of fluid into the pump. A reservoir so located
has to have the fluid it contains under greater than
atmospheric pressure to force the fluid upward into the
pump. Another reason for pressurizing reservoirs is to
enable aircraft to fly at very high altitudes. Since atmo-
spheric pressure decreases as altitude increases and
at very high altitudes become too low to force enough
fluid into a pump, the reservoir has to be pressurized.
Two general methods of pressurizing reservoirs are
employed. One method employs fluid, the other air.

(a) Fluid-pressurized reservoir. This

method makes use of fluid pressure bled from the
pressure lines of the system in which the reservoir is
incorporated. The reservoir is designed in such a way
as to develop a relatively low pressure on the supply
fluid contained in the reservoir by use of a stream of fluid
fed into the reservoir at a much higher pressure. Such
Figure 4-91. Reservoir with Baffles, Fins and a reservoir is commonly called an airless reservoir.
Finger Strainer

b. Theory of Operation. A space is provided in Construction.Figure 4-92 shows the construction and
the reservoir above the normal level of the fluid for fluid operation of a typical reservoir pressurized in this man-
expansion and for escape of trapped air. Most reservoirs ner. The major parts of the assembly are a cylindrical
are designed so they cannot be serviced completely to housing that has three fluid ports and a polished bore, a
the top. This is done by locating the filler neck some- housing tube which terminates in a head, and a piston
what below the top of the reservoir. On most reservoirs, and piston tube assembly. The piston and piston tube
a dipstick or glass sight gauge is provided so that fluid assembly are free to slide back and forth relative to the
level can be easily and accurately checked. All reser- housing. The housing tube and head are stationary.
voirs are either vented or closed to the atmosphere and
pressurized.
Operation.In operation, as shown in figure 4-93, fluid
(1) Vented reservoirs. In vented reservoirs, at- pressure admitted to the housing tube at system op-
mospheric pressure and gravity are the forces which erating pressure—of example, at 3,000 psi—enters the
cause fluid to flow out of the reservoir and into the pump. space formed between the piston and the housing tube
In order to supply a pump with fluid, a vented reservoir head. This pressure tends to force the piston and hous-
must be positioned at a higher location than the pump. If ing tube head in opposite directions. However, since the
the reservoir and the pump were at the same level, grav- housing tube head cannot move and the piston can, the
ity would have no effect on fluid flow. If the reservoir was piston moves toward the right, pushing against the sup-
at a level below the pump, fluid would tend to run out of ply fluid on its right
the pump and into the reservoir. Most hydraulic system
reservoirs of current Army aircraft are vented.

(2) Pressurized reservoirs. In the hydraulic

systems of some aircraft, it is necessary to mount the

4-102 Change 4
 TM 1-1500-204-23-2

and thus developing pressure in the fluid. The surface of pump will not be without fluid even if the filter element
the housing tube is exposed to 3,000 psi pressure within becomes clogged. This valve is normally held closed
a space that is one-sixtieth as large in area as the piston by a spring that would be opened by the stronger partial
surface that contacts the supply fluid. This means that vacuum that would develop if the element became badly
a pressure of 50 psi (3,000 psi + by 60) is built up in the clogged.
supply fluid.
g. Standpipes. Some aircraft have emergency
(b) Air-pressurized reservoir. Pressurizing hydraulic systems that take over if the main system fails.
with air is done by forcing air into the reservoir above In many such cases, the pumps of both systems obtain
the level of the fluid. The amount of pressure kept in fluid from a single reservoir. Under such circumstances,
an air-pressurized reservoir is usually around 15 psi. fluid for the emergency pump is drawn from the bottom
No attempt is made to keep the air and fluid separated. of the reservoir and the main system draws its fluid
In most cases, the initial source of air pressure in the through a standpipe located at a higher elevation. With
compressor section of the aircraft engine. Since pres- this arrangement, operation of the emergency system
sure within the engine compressor is normally about is ensured should the main system fail.
100 psi, it has to be reduced before being delivered to
the reservoir. This is accomplished by passing the air h. Air Cylinders. Air cylinders are the pneumatic
through an air pressure regulator. reservoirs in an aircraft pneumatic system, which serves
as an emergency source of pressure for the hydraulic
c. Baffles and Fins. Baffles and/or fins are used in system. These cylinders are made of steel and may
most reservoirs to prevent the fluid within the reservoir have a cylindrical or a spherical shape (see figure 4-95).
from swirling and surging. These conditions could cause Cooling of the high-pressure air in the storage cylinders
fluid to foam and air to enter the pump along with the fluid will cause some condensation to collect in them. To
(see figure 4-93). ensure positive operation of systems, storage cylinders
must be purged of moisture periodically. This is done by
d. Finger Strainers. Many reservoirs have strain- slightly cracking the moisture drain fitting located on the
ers in the filler neck to keep foreign matter from enter- cylinder manifold.
ing when the filler cap is off. These strainers are made
of fine gauze and are called finger strainers because of i. Maintenance of Reservoirs. A typical reservoir
their shape. Finger strainers should never be removed consists essentially of a reservoir shell assembly which
or punctured as a means of speeding up the pouring of houses a filter element, relief valve, and required gas-
fluid into the reservoir (see figure 4-93). kets, seals, and O-ring packings.

e. Filter Elements. Filter elements are incorpo-

rated in some reservoirs either to filter air before it
enters the reservoir or to filter fluid before it leaves the
reservoir. Figure 4-94 shows these filters installed. Degreasing solvent, MIL-PRF-680, is com-
When an air vent filter element is used, it is located bustible and toxic to eyes, skin and respiratory
in the upper part of the reservoir above the fluid level. tract. Wear protective gloves and goggles/face
When a fluid filter element is used, it is located at or shield. Avoid repeated or prolonged con-
near the bottom of the reservoir. Fluid returning to tact. Use only in well ventilated areas (or use
the reservoir surrounds the filter element and flows approved respirator as determined by local
through the wall of the element. This leaves any fluid safety/industrial hygiene personnel). Keep
contaminant on the outside of the element. The fluid away from open flame other sources of ignition.
filter elements commonly used in aircraft reservoirs are
made of treated cellulose formed into accordion-like (1) Wash all parts and flush inside of tank
pleats. This construction exposes the fluid to the maxi- with degreasing solvent, MIL-PRF-680. Dry with com-
mum amount of filter surface within a given space. pressed air.

f. Filter Element Bypass Valve. Reservoirs hav-

ing filter elements have a bypass valve to ensure that the

Change 4 4-103
TM 1-1500-204-23-2

Figure 4-92. Fluid-Pressurized Reservoir (Unpressurized)

Figure 4-93. Fluid-Pressurized Reservoir (Pressurized)

4-104
 TM 1-1500-204-23-2

Figure 4-95. Spherical Air Cylinder

capability, but many later model aircraft have 5-micron

filters; and two-stage filters, one element of which has
a 3-micron capability, are found in some recent models.
They are intended primarily to safeguard the operation
of certain important units by filtering out foreign parti-
cles generated by wear and tear of parts in the system.
Figure 4-94. Reservoir with Filter Elements They cannot handle large quantities of foreign matter
from outside the system.

a. Uses of Filters in Hydraulic Systems. Filters

The use of any alcohol in cleaning components are sometimes used in reservoirs. In addition, they may
which contact hydraulic fluids is prohibited. For- be located in the pressure line, in the return line, or in
mation of a polymeric residue can result which any other location where they are needed to safeguard
could impair mechanical operation of the com- the system against foreign particles in the fluid. How-
ponent. ever, filters are not normally used in system supply lines.
There are many models of filters, the variation being ne-
(2) Replace filter element when signs of cracks cessitated by the location of the filter within the particular
or tears are noted. Replace filter screens that show aircraft.
signs of deterioration.
b. Theory of Operation. The size and shape of
(3) Refer to the applicable aircraft maintenance each element depend on its use and installation; how-
manual for detailed assembly and maintenance require- ever, all line filter assemblies are made up of three basic
ments. units: filter head, filter case, and filter element. Figure
4-96 shows a typical line filter assembly in which the dif-
4-12. HYDRAULIC SYSTEM FILTERS. Practically all ferential pressure indicator is located in the top of the
foreign particles found in hydraulic fluid can be removed filter head assembly (in some designs the indicator is
by filters. The degree of filtration needed depends on the located on the side of the filter head assembly). Also lo-
acceptance level desired. Most high pressure hydraulic cated within the head is a bypass valve assembly which
systems use filters having a 10- to 15-micron routes hydraulic fluid directly from the inlet to the

4-105
TM 1-1500-204-23-2

outlet port if the filter element becomes clogged with for-

eign matter. The filter case is the housing that holds the
element to the head assembly and is the part that is re-
moved during replacement of the filter element.

(1) Normal flow. Figure 4-97 shows a filter in

normal flow. Hydraulic fluid enters the filter through the
inlet port in the body and flows around the element inside
the filter bowl. Filtering takes place as the fluid passes
through the filtering element at the hollow core, leaving
the dirt and impurities on the outside of the filter element.
Filtered fluid then flows from the hollow core to the outlet
port in the body and into the system.

(2) Clogged filter. Figure 4-98 shows a filter

that is clogged. The bypass pressure relief valve in the
body allows the fluid to bypass the filter element and
pass directly through the outlet port. In most filters on
this type, the relief valve is set to open if the pressure
drop exceeds 50 psi; for example, if the pressure at the
filter inlet port was 70 psi and the pressure at the outlet
port dropped below 20 psi, the relief valve would open.

(3) Differential pressure indicator. Filters with

a differential pressure indicator operate on the principle Figure 4-97. Fluid Filter (Normal Fluid)
of difference in pressure entering the element and pres-
sure after it leaves the element.

Figure 4-96. Fluid Filter Assembly

Figure 4-98. Fluid Filter (Clogged)

4-106
 TM 1-1500-204-23-2

(a) Operation. Figures 4-99 and 4-100 show c. Filter Elements. The filtering elements in fluid
the indicator during normal flow and during bypass. As filters are normally made of paper or of stainless steel.
contaminating particles collect on the outside of the filter Paper elements are used mostly in low pressure sys-
element, the differential pressure across the element in- tems and are thrown away when removed. Stainless
creases. When this increased pressure reaches a spe- steel elements are used in both high pressure and low
cific value, inlet pressure forces the spring-loaded mag- pressure systems and may be reused.
netic piston downward breaking the magnetic attach-
ment between the indicator button and the magnetic pis- (1) Paper elements. A typical fluid filter with a
ton. This allows the red indicator to pop out, showing paper element is designed to remove 99 percent of all
that the element must be cleaned. Because increased particles 10 microns (0.000394 inch) in diameter and
fluid viscosity at low temperatures might cause a false larger. This element, like those used in the reservoir,
indication of contamination, a low-temperature lockout is made of specially treated cellulose paper formed in
of the differential pressure indicator prevents actuation accordion-like pleats to present the maximum filtering
at low temperatures. surface to the fluid.

(b) Bypass. If the filter element is not re- (a) Replacement criteria. Paper filter ele-
placed when the indicator shows contamination, the ments are replaced on a scheduled basis, depending on
filter element will continue to collect foreign particles the needs of the specific aircraft system. Unscheduled
and the pressure differential between the inlet and out- replacement of filter elements is also required following
let ports will increase until the bypass valve opens and removal of certain components.
directs fluid through the filter element bypass. The use
of a nonbypassing-type filter eliminates the possibility (b) Removal and replacement. The follow-
of contaminated fluid passing the filter element and ing procedure for removing and replacing paper filter el-
contaminating the entire system. This type of filter will ements is typical of most Army aircraft.
minimize the need for flushing the entire system and
will lessen the chance for failure of pumps and other 1 Relieve system pressure by operating
components in the power system. the main system bypass valve or by actuating a hydrauli-
cally operated unit.

Figure 4-99. Differential Pressure Indicator

(Normal Flow)

Change 4 4-107
TM 1-1500-204-23-2

7 Before installing the new filter, clean the

filter head and the filter case and inspect them for dam-
age; replace all damaged parts.

8 Replace all O-ring packings.

9 Fill the filter bowl with new fluid before

attaching it to the filter housing head. Filling the bowls
helps to stop the injection of air into the system.

10 Install the filter in its case and screw

the case into the filter head. The correct torque is usually
handtight plus one-eighth of a turn, but always check
the specific maintenance manual for the specific torque
Figure 4-100. Differential Pressure Indicator value.
(Clogged Filters)
11 Pressurize the hydraulic system and
2 Depressurize reservoir (if necessary). inspect the filter assembly for leaks. If the assembly
is Satisfactory, replace the lockwire between the filter
3 Cut lockwire. case and the head assembly.

4 Unscrew the filter case and remove it (2) Stainless steel elements. Stainless steel
from the filter head, using a slight rocking and downward filter elements are used in most modern aircraft. Filter
pull on the case after the case threads are free from the element surfaces of this type usually have a corru-
filter. gated stainless steel mesh construction. Such filters
are usually rated from 5- to 10-micron nominal flow
5 Extract the retaining ring and remove and at 25-micron absolute flow. This means about 95
the filter element from the cases. percent of 5- to 10-micron particles and 100 percent of
25-micron particles will be filtered from the fluid. The
6 After ensuring that a replacement filter curved passages of the filter element limit the length of
element is available, cut the filter element. the particles that pass through the filter.

4-108 Change 4
 TM 1-1500-204-23-2

(a) Wash filter element in degreasing solvent,

MIL-PRF-680, using a soft lint-free cloth. Allow to drain,
Degreasing solvent, MIL-PRF-680, is com- and dry with low pressure compressed air.
bustible and toxic to eyes, skin and respiratory
tract. Wear protective gloves and goggles/face (b) Replace filter element when cracks,
shield. Avoid repeated or prolonged con- tears, and other signs of deterioration are noted.
tact. Use only in well ventilated areas (or use
approved respirator as determined by local d. Two-Stage Fluid Filters. Two-stage line-type
safety/industrial hygiene personnel). Keep hydraulic system filters are being used in some recent
away from open flame other sources of ignition. aircraft models. The typical two-stage filter has two
filter elements, two bypass valves, and two differential
pressure indicators. The first-stage element can filter
out smaller particles than the second-stage element
can. Normally, the fluid passes through both elements,
Under no condition shall a wire brush be used flowing first through the first stage element. As long as
in cleaning filter element. Failure to comply will the first stage element is unclogged and functioning,
result in possible failure of equipment. there will be no foreign matter left for the second-stage
element to remove. However, if the first-stage element
becomes clogged, its bypass valve opens and fluid
goes directly from the filter inlet port to the second-stage
The use of any alcohol in cleaning components element, which then takes over the job of filtering out
which contact hydraulic fluids is prohibited. For- foreign particles. Although the second-stage element
mation of a polymeric residue can result which is not capable of filtering out the very small particles,
could impair mechanical operation of the com- it can be safely used until the first-stage element is
ponent. unclogged.

Change 4 4-108.1/(4-108.2 blank)

 TM 1-1500-204-23-2

e. Air Filters. An air filter is usually located in the hydraulic fluid. Aircraft systems use engine-driven
line leading into the system supply source. Additional power pumps for this purpose. Hand pumps are also
filters may be located at various points in the system provided as emergency equipment and for ground
lines to remove any foreign matter that may enter the checking the hydraulic system. Hydraulic motors in
system. Like hydraulic filters, air filters have a remov- Army aircraft perform such functions as landing gear
able element and a built-in relief valve. The relief valve retraction and extension and operating cargo ramps,
is designed to open and bypass the air supply around doors, and winch hoists.
the filter element in case the element becomes clogged.
Some air filters are equipped with a paper-type element a. Power Pumps. The primary energizing unit of
which must be replaced periodically. Others have a the hydraulic system is the power pump. It is the unit that
screen mesh-type which requires periodic cleaning. The normally delivers hydraulic fluid under pressure to the
screeen mesh-type may be returned to the system after actuators. Power pumps may be driven by an electric
being cleaned and dried. motor, a turbine unit, or the aircraft engine; however,
engine-driven pumps are used in all Army aircraft at this
f. Servicing Filters. Filters should be serviced in time. The piston type power pumps used in modern
accordance with schedules and procedures contained hydraulic systems run at a rated speed of about 1 1/2
in technical manuals pertaining to the specific aircraft in- times engine crank-shaft speed. In the drive shafts of all
volved. However, the following general guidelines apply power pumps, there is a thinned portion that provides for
to the servicing of all aircraft hydraulic system filters: a shearing action. If the pump seizes, the shaft will break
at this point, thus preventing damage to the engine or
(1) Handle filters carefully. A hole no larger the transmission.
than a pinprick will permit large foreign particles to pass
through the element. (1) Bent-axis constant-volume pumps. Con-
stant-volume piston-type pumps put out a constant flow
(2) Service filters in a clean area; this will help of fluid for any given rpm. The pistons (usually seven or
keep dirt and other foreign particles from entering the nine in number) are fastened by universal linkage to the
system while the filter is being serviced. drive shaft, as shown in figure 4-101. The universal link
(2) in the center drives the cylinder block (4). This block
(3) Do not leave a disassembled filter housing is held at an angle to the drive shaft (1) by the housing.
unprotected because this may cause contamination. Pumps are available with different angles between
the drive shaft and the cylinder block; a large angle
(4) Remove wrappings from a replacement el- provides more output volume per revolution because
ement only when the element is to be inspected or in- the larger angle increases the piston stroke.
stalled.
(a) Theory of operation. Figure 4-102 illus-
(5) The filter bowl should only be handtightened trates the theory of operation. As the drive shaft (1) ro-
to the head. Always safety the bowl and head together. tates the cylinder block (4) and the piston assemblies,
all the pistons are always the same distance from their
(6) Be sure that a popped-out indicator button is points of attachment (3) on the drive shaft. Although the
indicating the need to service the filter. Push the button pistons appear to move within the cylinders, it is actually
back in with the system at normal operating pressure. If the cylinders that move back and forth around the pis-
the button pops out again, the filter needs servicing; if it tons as the block and piston assembly rotates. Figure
stays in, the filter is not clogged. 4-103 shows a pump with pistons on intake and pres-
sure strokes. Piston (1) is at the top of its cylinder,
4-13. PUMPS AND MOTORS. The hydraulic pump is
the mechanism for transferring and pressurizing aircraft

4-109
TM 1-1500-204-23-2

having just completed its pressure stroke and ready to (6), which in turn is attached to the compensator (7).
being its intake stroke. As the block starts to rotate from An increase in pressure moves the compensator to
this point, the piston becomes aligned with the intake the right. Decreased pressure allows it to move to
port (3). When the block has turned one-half of a revo- the left because of the valve spring tension. As the
lution, the piston reaches the bottom of the cylinder (4). pistons travel to the left, fluid drawn from the inlet port
The cylinder space formerly occupied by the piston is (12) passes through the open center of the cylinder
now full of fluid . As the block continues to rotate, the block and then into the cylinders (13). At this point,
piston becomes aligned with the outlet port (2). Having hydraulic fluid fills the center of the pistons. Some
now moved through the last 180 degrees of rotation, it fluid will continue to flow out through the cross-drilled
has exhausted all fluid from the cylinder and is ready to holes and on to the pump return port (2) on the drive
make another cycle. Since several pistons are operat- end of the pump. As the pistons are forced to the right
ing as described and since the cylinder block and piston by the cam (3), the cross-drilled hole of each piston
assembly rotate rapidly, there are always pistons some- is blocked off by its sleeve. About the time that the
where between the upper and lower positions. This en- cross-drilled passage is blocked off, the supply annulus
sures a constant intake and output of fluid. (8) that surrounds the cylinder is also blocked off. This
condition traps the fluid in the piston and cylinder. As
(b) Cooling and lubrication. The pis- the piston continues on to the right, pressure builds
ton-type pump uses case pressure for cooling and up against the check valve (10). Fluid under pressure
lubrication. Fluid seeps by the pistons in the cylinder goes out the check valve into the pressure chamber
block and fills all the space inside the pump. This (9) and through the outlet port (11). When the piston
fluid cannot escape through the drive end of the pump moves as far right as possible, the cycle starts all over
because of a seal around the drive shaft. Excess case again. This cycle is the same for all nine pistons
pressure within the housing is routed back to the intake
side of the pump. This is done through a relief valve 1 Zero flow. (See figure 4-106). As pres-
called a foot valve (figure 4-104). This valve prevents sure rises in the pressure outlet line, it is also felt in
the case pressure from rising above approximately 15 the passageway (14). This pressure acts on the com-
psi. Drilled passageways through the universal link pensator (7), forcing it to the right. This compresses
rods help to keep the rod ball end lubricated. the spring and carries the spider and sleeves (6 and
5) with the compensator. The more the sleeves move
(2) Variable-volume pumps. A variable-vol- to the right, the farther each piston travels before the
ume pump has some advantages. One is that its use cross-drilled passage is covered. This means that less
does away with the need for a pressure regulator or an fluid is trapped by the right end of the piston for output
unloading valve. Integral flow control valves regulate to the pressure manifold. The maximum setting of the
the pressure according to the demands made on the compensator is all the way to the right. Then the output
system. A second advantage is that pressure surges to the pressure manifold drops to zero, as shown in fig-
are reduced. Accumulators are not needed to smooth ure 4-106. In this condition, all intake of the pump goes
out surges with systems using variable-volume pumps, out the return port (2). Rotation of the cam draws fluid
but they are retained to aid the pump when peak loads through the pump for cooling and lubrication. There is
occur. always fluid being pumped through the inlet port. But
fluid will not be pumped through the outlet port until sys-
(a) Stratopower effective stroke tem pressure drops low enough to demand it. Always
pumps. As shown in figure 4-105, the drive shaft connect the proper lines to the ports marked IN, OUT,
(1) rotates the cam (3). This cam causes the nine and RETURN.
spring-loaded pistons (4) to move back and forth
in their cylinders, which are in a stationary cylinder 2 Pressure regulation. The strato-power
block. In operation, each piston is forced into and pump does not require a pressure regulator. The com-
removed from the cylinder once for each revolution pressor serves nearly the same purpose. Pressure can
of the cam. The pistons are held in contact with the be increased by turning the adjusting screw (15, fig-
cam by piston springs, which also return the pistons ure 4-106) clockwise or decreased by turning it coun-
after each forward or power stroke. Each piston has terclockwise.
a half-ball bearing surface which acts like a universal
linkage. The flat side contacts the cam during all (b) Vickers stroke-reduction pump. (See
angle changes. The pistons have fairly large hollow figure 4-107). The Vickers stroke-reduction pump oper-
centers, connected with cross-drilled holes. Around ates somewhat like the constant volume piston-
each piston there is a sleeve (5) attached to a spider

4-110
 TM 1-1500-204-23-2

Figure 4-101. Bent-Axis Constant Volume Pump

Figure 4-102. Constant Volume Pump (Piston Installation)

4-111
TM 1-1500-204-23-2

Figure 4-103. Constant Volume Pump (Piston Operation)

Figure 4-104. Constant Volume Pump Foot Valve

4-112
 TM 1-1500-204-23-2

1. DRIVE SHAFT 8. SUPPLY ANNULUS

2. RETURN PORT 9. PRESSURE CHAMBER
3. CAM 10. CHECK VALVE
4. PISTON 11. OUTLET PORT
5. SLEEVE 12. INLET PORT
6. SPIDER 13. CYLINDER
7. COMPENSATOR 14. PASSAGEWAY

Figure 4-105. Stratopower Effective Stroke Pump (Full Flow)

2. RETURN PORT 7. COMPENSATOR

5. SLEEVE 14. PASSAGEWAY
6. SPIDER 15. PRESSURE ADJUSTING SCREW

Figure 4-106. Stratopower Effective Stroke Pump (Zero Flow)

4-113
TM 1-1500-204-23-2

Figure 4-107. Vickers Stroke Reduction Pump (Zero Flow)

type pump. The main difference between the two types They simply rotate with the cylinder block without mov-
is the angle between the drive shaft and the cylinder ing back and forth.
block. In the constant-volume pump, this angle is fixed;
in the Vickers pump, the angle varies automatically to 2 Full flow. As the pressure in the system
satisfy the pressure-volume demands of the system. starts to drop, its force on the pilot valve is reduced.
When this happens, the spring under the pilot valve
1 Zero Flow. (See figure 4-107). In the moves it upward. This reduces the opening to the
stroke-reduction pump, the drive shaft (11), the pistons passageway and cuts down the pressure on the pres-
(7), and the cylinder block (6) are all supported by the sure control piston so that its spring pushes it to the
bearing (10) and they all rotate. A yoke (8) contains the right. Now the yoke swivels downward, causing the
cylinder block, which swivels around the pivot pin (9). stroke of the pistons to increase. The pressure and
Before the pump builds up any pressure, the yoke is volume output again start to increase until the system’s
held by the spring in the pressure control piston (3) in demands are met (see figure 4-108). The action of the
the position shown in the full-flow illustration (see figure pressure control valve (12) stabilizes the position of the
4-106). When outlet pressure is at maximum, the yoke cylinder block (6). Its angle adjusts to meet the system
is held in the position shown in figure 4-107. As long as demands. Notice that the hollow center of the pressure
there is no pressure in the system, the cylinder block and control piston is vented to the inside of the case (14) so
yoke are in the extreme angle position. System pressure that fluid trapped inside the piston can escape to the
entering the connecting line (1) acts on the pilot valve case. A foot valve (not shown) prevents case pressure
(2), pushing it down against the spring toward the zero from becoming too high.
flow position. This opens the passageway (4), sending
pressure against the rod side of the pressure control 3 Pressure regulation. Pressure is in-
piston (3). As the piston moves to the left, its spring creased or decreased by turning the adjusting screw
is compressed. This force, which is transmitted through (13, figure 4-108). An internal relief valve prevents
the valve plate (5), causes the yoke to swivel upward damage in case the pressure control valve fails to
so that the cylinder block moves toward a zero angle. If function properly.
the cylinder block reaches the extreme zero flow point,
there is no fluid output to the system. This is because (c) Kellogg stroke-reduction pump. The
the pistons have no stroke in the cylinder block. Kellogg pump shown in figure 4-109, is made up of two

4-114
 TM 1-1500-204-23-2

major component groups: the rotating group and the end of the inlet annulus. Further rotation forces the pis-
pressure-compensating group. The rotating group con- ton to the right and aligns the cylinder with the annulus
sists of the drive shaft (2), the cylinder barrel (4), nine connected to the outlet port (9) and to the compensator
pistons (3) with their piston shoes and locking plates (1). valve (8). In this position, fluid is forced from the pis-
The pressure-compensating group consists of a cam ton. This discharge stroke lasts until the cylinder and
plate (6), a compensator valve (8), and a control pis- piston reach the bottom position and are ready to begin
ton (7). The cylinder barrel is supported in the housing another intake stroke. At the same time, there are eight
by a roller bearing (5). The drive shaft passes through other pistons on the intake and discharge strokes, all
— but does not touch — the inclined cam plate to rotate doing the same thing. Their pumping action continues
the cylinder barrel unit. Pistons of the rotating group are until the fluid needs of the system are satisfied.
actuated by tilting the nonrotating cam plate. The con-
tact is a universal action type, consisting of hydraulically
balanced shoes and locking plates. The length of pis- 2. Zero Flow. When a subsystem actuator completes its
ton stroke is determined by the angle of the cam plate: travel, the need for pump output is reduced to zero. The
maximum pump output requires a high angle; zero pump pump senses the end of the actuator travel because the
output requires a flat angle setting. unused output causes a sudden increase in discharge
pressure. As this pressure reaches the setting of the
compensator valve, it pushes the valve to the right (see
1. Fuel Flow. In figure 4-109, the lower piston is shown figure 4-110). The pressure then pushes on to the con-
near the beginning of the intake stroke. As the cylinder trol piston, causing it to move to the left and decreasing
unit is rotated, the piston moves to the left in its cylin- the angle of the cam plate. This action decreases the
der. For nearly one-half of a revolution, the face port effective length of the piston stroke, thus decreasing the
of this cylinder is aligned with the annulus connected volume of fluid delivered to the system. In actual oper-
to the fluid inlet (10). Hydraulic fluid is sucked into the ation, the cam
cylinder as the piston in withdrawn just after passing the

6. CYLINDER BLOCK
12. PRESSURE CONTROL VALVE
13. PRESSURE ADJUSTING SCREW
14. PRESSURE CONTROL PISTON VENT

Figure 4-108. Vickers Stroke Reduction Pump (Full Flow)

4-115
TM 1-1500-204-23-2

1. PISTON SHOE AND LOCKING PLATE

2. DRIVE SHAFT
3. PISTON
4. CYLINDER BARREL
5. ROLLER BEARING
6. CAM PLATE
7. CONTROL ARM
8. COMPENSATOR VALVE
9. OUTLET PORT ANNULUS
10. FLUID INLET ANNULUS
11. OUTLET CHECK VALVE

Figure 4-109. Kellogg Stroke Reduction Pump Assembly

4-116
 TM 1-1500-204-23-2

Figure 4-110. Kellogg Stroke Reduction Pump (Reduced Output)

plate assumes various angles to maintain the proper containing a piston (3) and two spring loaded check
system pressure. It will meet all fluid demand conditions valves (5 and 4). When the piston moves to the right,
within the rating of the pump. A pump check valve in- the piston check valve (4) is held closed by the spring.
stalled in the pump outlet line prevents return flow into The piston forces the fluid in the right chamber (5) out
the pump during operation of the system with a portable into the pressure line through the check valve. At the
test stand. Reverse flow of hydraulic fluid would motor- same time, the suction effect created in the left chamber
ize the pump. (2) by the moving piston draws fluid through the inlet
line check valve (1), thus filling that chamber. When the
b. Maintenance of Power Pumps. Repair and piston moves to the left, the inlet line check valve is held
overhaul of hydraulic power pumps is done at depots. closed by the pressure of the fluid in the left chamber.
This work requires special tools and equipment. The space available for the fluid in the right chamber
is now less than the space in the left chamber. This
c. Hand Pumps. Hand pumps serve as replace- is caused by the piston rod displacement in the right
ments for power pumps during emergencies in flight and chamber; the excess fluid under pressure is driven out
as sources of power for checking the hydraulic system through the discharge port of the system.
when the aircraft is on the ground. They are piston-type
pumps and may be either single or double action; how- (2) Maintenance. Maintenance of hand pumps
ever, most are the double-action type. Such pumps de- consists of disassembly, inspection, reassembly and
liver fluid under pressure on both the fore and aft strokes testing.
of the piston.

(1) Description. The hand pump shown in fig-

ure 4-111 consists essentially of a cylinder assembly

4-117
TM 1-1500-204-23-2

1. INLET CHECK VALVE 4. CHECK VALVE

2. PUMP CHAMBER 5. CHECK VALVE
3. PISTON

Figure 4-111. Double-Action Hand Pump

(a) Disassembly. Carefully disassemble the

pump and thoroughly clean all parts with degreasing sol-
Degreasing solvent, MIL-PRF-680, is com- vent, MIL-PRF-680. Dry with clean, dry compressed air.
bustible and toxic to eyes, skin and respiratory
tract. Wear protective gloves and goggles/face (b) Inspection. Inspect all parts for nicks,
shield. Avoid repeated or prolonged con- cracks, scratches, and corrosion. Inspect threaded
tact. Use only in well ventilated areas (or use surfaces for damaged threads and piston shaft and
approved respirator as determined by local springs for distortion. Check the valve poppets for
safety/industrial hygiene personnel). Keep proper seatting.
away from open flame other sources of ignition.
(c) Reassembly. Replace all non-repairable
parts and natural or synthetic rubber items, such as
O-rings or packings. Remove minor scratching or corro-
The use of any alcohol in cleaning components sion by polishing with crocus cloth . If necessary, clean
which contact hydraulic fluids is prohibited. For- internal and external threads with the appropriate size
mation of a polymeric residue can result which tap or die. Coat all internal parts with the appropriate
could impair mechanical operation of the com- type hydraulic fluid prior to assembly.
ponent.

4-118 Change 4
 TM 1-1500-204-23-2

(d) Testing. After the pump has been re- (2) Operation. When the hydraulic system is
assembled, test it for proof pressure and leakage. pressurized, fluid pressure is put on the pistons of the
Figure 4-112 illustrates a simplified setup for testing the cylinder block. Pressure must also go to the closed
hand pump. starting valve of the motor. Normal system pressure
will sustain cylinder and generator rotation, but higher
1 Proof pressure. To test for proof pres- pressure is needed to start the rotation.
sure, pump fluid through the circuit with the pump con-
nected and the shutoff valve open. This bleeds all air (a) Starting. Starting is accomplished by the
from the system. Next, close the shutoff valve and op- starting valve (6). When system pressure builds up to
erate the pump to obtain the required proof pressure. 1,800-2,200 psi, the starting valve is moved to the right
Proof pressure is approximately 1-1/2 times normal op- as shown. This action permits fluid under pressure to
erating pressure. Control the strokes so that the final move the control piston (9). The control piston moves
stroke will leave the piston in the retracted position, af- the bottom of the wobbler plate (8) to the right with sud-
ter which pressure should be maintained for a specified den force. Movement of the wobbler kicks the upper
time (usually 2 to 5 minutes). Repeat the preceding step, and lower pistons (7) to give the cyliner block an ini-
this time controlling the strokes so that the final stroke tial spin. Thereafter, system pressure maintains rotation
will leave the piston in the extended position. of the cylinder block. As hydraulic pressure continues
to increase, motor speed increases. As the rotational
2 Leakage test. For the leakage test, use speed increases, the governor flyweights (3) begin to
the pump to pressurize the circuit to the normal oper- pivot outward, moving the governor control valve (4) pro-
ating pressure (the shutoff valve is closed during this portionately to the left. This movement gradually block
check). The pressure must hold for a specified period the pressure to the control piston. When the passage
of time (approximately 2 minutes). There should be no is completely blocked, pressure is no longer put on the
piston creep, and the pressure drop should not exceed control piston and motor speed ceases to increase. This
the specified amount (usually 50 to 100 psi). is referred to as an on-speed condition.

3 Completion of testing. After completion (b) Load control. The load imposed on the
of testing, relieve the pressure and remove the pump motor varies with the electrical load on the generator.
from the test circuit. Drain the pump to the drop point. To meet the changing demands, the motor must vary its
Then refill it with the specified preservative fluid to about torque to maintain its normal operating speed. Let us
90 percent of its capacity. Plug all ports and closures assume that the motor tends to overspeed.
and mark the rubber parts cure date of the pump.
1 Overspeed. The overspeeding causes
d. Hydraulic Motors. Motors operate on the same the governor flyweights (3) to move outward, pulling the
principle as power pumps, but in reverse. governor control valve (4) a little bit to the left. Move-
ment to the left from the blocked position vents the con-
(1) Applications. Figure 4-113 shows a vari- trol piston (9) passage to return system pressure. This
able-displacement, axial-piston, rotating-cylinder-block reduces the force acting on the control piston. Now sys-
unit. It delivers a minimum of 16.6 horsepower at tem pressure acting on the upper piston (7) is greater
8,000 rpm. This particular motor is used to drive than the return system pressure on the control piston.
an ac-dc generator at a constant rpm. Since an ac The result is that the upper piston in the rotating cylinder
generator or alternator must put out the same num- block moves the wobbler plate (8) toward the right, thus
ber of cycles per second under all load conditions, a reducing the angle of the wobbler plate. The reduced
very sensitive flyweight governor is required on the angle reduces the torque output and consequently the
motor. For components where the rpm is not critical, speed of the motor.
a constant-displacement-type hydraulic motor would
probably be used.

4-119
TM 1-1500-204-23-2

Figure 4-112. Hand Pump Test Circuit

1. GOVERNOR SPRING 6. STARTING VALVE

2. PREACT PISTON 7. PISTON
3. GOVERNOR FLYWEIGHT 8. WOBBLER PLATE
4. GOVERNOR CONTROL VALVE 9. CONTROL PISTON
5. BACK PRESSURE VALVE 10. FEEDBACK LINE

Figure 4-113. Hydraulic Motor

4-120
 TM 1-1500-204-23-2

2 Activation of flyweight governor. Move- pointer to move to a correspondingly higher reading on

ment of the wobbler plate also momentarily activates the the dial. As hydraulic system pressure decreases, the
preact piston (2) of the flyweight governor. This prevents Bourdon tube curls back toward its original shape by a
over-travel of the governor control valve and hastens the corresponding amount. This causes the pointer to fall
motor’s response to changes in load. The preact pis- back to a correspondingly lower dial reading. Pressure
ton acts when the wobbler plate moves to the right and gauge snubbers are usually used with hydraulic pres-
the control piston moves to the left. This action forces sure gauges to dampen oscillations of the pointer.
fluid in the feedback line (10) into the chamber on the
left side of the preact piston. When fluid moves into (2) Remote-indicating gauges. In the remote-
this chamber, the preact piston moves to the right, in- indicating gauge, the gauge transmitter contains a Bour-
creasing tension on the governor spring (1) and oppos- don tube diaphragm, or bellows, to which hydraulic sys-
ing movement on the governor control valve to the left. tem pressure is admitted through a connecting line. The
Motor speed decreases and the fluid in the preact pis- Bourdon tube diaphragm reacts to pressure changes
ton chamber bleeds off through the restrictor bleed. The in a manner similar to that of the direct-reading type
governor control valve moves back to the right, blocking gauge. Movements of the diaphragm produce electrical
the control piston passage and holding the wobbler plate signals that are transmitted through connecting wiring to
in its new position. These events occur almost instantly the indicator unit, where they cause the indicator pointer
to match torque requirement with the load. to move. Some aircraft systems have a direct-reading
gauge in a location in the system in addition to a re-
3 Back pressure valve. A back pressure mote-indicating gauge. In the event a remote-indicating
valve (5) is installed in the discharge line of the lower gauge indicates a possible problem, always check the
piston to prevent the piston from floating and chattering. direct-reading gauge to confirm whether the gauge or
If this valve were not in the return line, return pressure the system is at fault.
would exist on both sides of the lower pistons. Under
this condition, the pistons would tend to float. The back b. Pressure Switches. A pressure switch is de-
pressure valve puts 100 psi over return pressure load signed to open or close an electrical circuit in response
on the back side of the lower pistons. This load holds to a predetermined hydraulic pressure entering the
them against the wobbler plate and prevents chattering. switch from a connected source. Piston-type and
diaphragm-type pressure switches are the types com-
(3) Maintenance. Repair and overhaul of hy- monly used in Army aircraft.
draulic motors are done at depots. This work requires
special tools and equipment. (1) Piston-type. The piston-type pressure
switch shown in figure 4-115 consists of a rectangu-
4-14. DEVICES FOR REGULATING PRES- lar-shaped housing, a cylinder bore and piston, an
SURE. Devices for regulating pressure in aircraft adjustable spring for loading the piston, a microswitch,
hydraulic systems include pressure gauges, pressure and a linkage for transmitting movement of the piston to
switches, relief valves, and pressure reducing valves. the microswitch. The housing has a port for connecting
the switch to a system pressure line and an electrical
a. Pressure Gauges. Hydraulic pressure gauges receptacle for connecting the switch with an electrical
indicate the amount of pressure in a hydraulic system. circuit.
Gauge dials are calibrated to display this pressure in
pounds—per square inch (psi). Direct-reading and re- (2) Diaphragm-type. The diaphragm-type pres-
mote-indicating gauges are the types used. sure switch consists of a cylindrical-shaped housing, a
diaphragm, an adjustable spring to load the diaphragm,
(1) Direct-reading gauges. The direct-reading a microswitch, and linkage for transmitting movements
gauge shown in figure 4-114 consists essentially of a of the diaphragm to the microswitch. The housing has
Bourdon tube, a pointer, a dial, and a raintight case. a port at one end for connecting the switch to a system
The Bourdon tube and the pointer are interconnected pressure line and an electrical receptacle for connecting
by gearing to cause them to move together. Pressure the switch with an electrical circuit at the other end.
within the hydraulic system is admitted into the Bour-
don tube through a connecting line. As hydraulic sys- (3) Operation. The operation described here
tem pressure increases, it causes the Bourdon tube to covers the piston-type pressure switch. However, the
straighten to a corresponding degree. The change in diaphragm switch operates on essentially the same
curvature of the tube reacts on the gearing, causing the

4-121
TM 1-1500-204-23-2

principles. Fluid pressure entering the port of the (a) Description. A typical main system relief
pressure switch acts on the face of the piston to move valve and a breakdown of its component parts is shown
it against the resistance of the piston return spring. in figure 4-116. The relief valve consists of a cylindri-
When the fluid pressure acting on the piston becomes cal housing containing a poppet valve and a piston as-
great enough to overcome the force of the piston return sembly. Each end of the housing is made to include a
spring, movement of the piston causes the pivoted lever wrench-holding surface and a threaded port for instal-
of the connecting linkage between the piston and the lation of a hydraulic fitting. The housing is stamped to
micro-switch to rotate. The movement of the pivoted identify the ports as PRESS (pressure) and RET (re-
lever is transmitted through the idler spring to the actu- turn). The poppet valve (1), which is located just inside
ating button of the microswitch. When the microswitch the pressure port, is seated over a passage through the
actuating button has moved a sufficient amount, the valve.
micro-switch contacts move into the pressure-induced
position. Some pressure switches are designed so (b) Operation. When fluid pressure at the
that their contacts remain open until closed by the pressure port reaches 3,650 psi, the pressure forces
action of fluid pressure against the switch position. the piston (2) to depress the load spring (3) and to move
Such switches are specified as NORMALLY OPEN clear of the poppet valve. Thus, the passage through
(NO). Other switches are designed for their contacts the piston is opened, and fluid flows through the valve
to remain closed until opened by the reaction of fluid into the return line. When pressure at the pressure
pressure against the switch piston. These are specified port is reduced to 3,190 psi, the coil spring reseats the
as NORMALLY CLOSED (NC). piston against the poppet valve and fluid flow through
the relief valve ceases. Should the pressure at the
(4) Uses. Pressure switches on Army aircraft outlet port exceed the pressure at the inlet port, the
serve two purposes. One is to close the circuit of a poppet valve will unseat and fluid from the return line
warning light that shows low pressure in a system. The will flow through the valve into the pressure line.
other is to affect the circuits of solenoid valves in aircraft
having dual hydraulic boost control systems in such a (2) Thermal relief valves. Thermal relief valves
manner that operating pressure to one boost system are usually smaller than system relief valves. They are
cannot be shut off unless the other boost system is pro- used in systems where a check valve or a selector valve
vided with enough operating pressure to fly the aircraft. prevents pressure from being relieved through the main
Some pressure switches are designed with two sets of system relief valve. As pressurized fluid in the line in
contacts so as to provide control for both the warning which it is installed builds up to an excessive amount, the
light and the solenoid valve. valve poppet is forced off its seat and the excess pres-
surized fluid flows through the relief valve to the reser-
(5) Maintenance. Maintenance of hydraulic voir. When system pressure decreases to a preset pres-
pressure switches is limited to testing, removal, and sure, spring tension overcomes system pressure and
replacement. forces the valve poppet to the closed position.

c. Pressure Relief Valves. Relief valves are (3) Maintenance. Relief valve maintenance is
safety devices used to prevent pressure from building limited to adjusting the valve for proper relief pressure
up to a point where it might blow seals and thus burst or and checking the valve for leakage. If it is thought that
otherwise damage the container in which it is installed. a relief valve is leaking internally, a flexible hose may
Relief valves are installed in aircraft hydraulic systems be connected to the return port of the valve and the
to relieve excessive fluid pressure caused by thermal drippings, if any, caught in a container. The opening
expansion, pressure surges, and the failure of a hy- and closing pressure of the valve may also be checked
draulic pump compensator or other regulating devices. in this manner provided an external source of power is
used.
(1) System relief valves. Main system relief
valves are set to open and close at pressure determined d. Pressure Reducing Valves. Pressure reduc-
by the system in which they are installed. In systems ing valves are used in hydraulic systems where it is
made to operate at 3,000-psi normal pressure, the relief necessary to lower the normal system operating pres-
valve might be set to be completely open at 3,650 psi sure to a specified amount.
and to reseat at 3,190 psi. These pressure ranges
may be different from one aircraft to another. When
the relief valve is in the open position, it sends excess
pressurized fluid to the reservoir return line.

4-122
 TM 1-1500-204-23-2

system operation. The accumulator can supplement

the pump output when the pump is under a peak load,
and the stored energy in an accumulator can be used to
actuate a unit in case the normal hydraulic system fails.

Before removing valve core from a bleeder-type

air valve assembly, ensure that all air has been
exhausted by loosening air valve approximately
one-fourth turn. Failure to comply may result in
personnel injury as the valve may separate with
explosive force. Eye protection must be worn.

a. Types. The two types of hydraulic accumulators

used are the cylindrical type (see figure 4-118), using
the floating pistons and seals, and the spherical type
(see figure 4-119), using a diaphragm. Both types have
a high pressure air valve installed for servicing the air
side of the accumulator. A new high pressure valve core
should be installed when the accumulator

Figure 4-114. Pressure Gauge

(1) Operation. In figure 4-117, system pressure

is being ported to a subsystem through the shuttle
sleeve assembly. Subsystem pressurized fluid on the
large flange area of the shuttle, causing the shuttle
to move to the left after reaching a set pressure and
thus closing off the normal system. The valve will stay
in this position until subsystem pressure is lowered.
The shuttle will then move to its prior position, allowing
the required amount of pressurized fluid to enter the
subsystem.

(2) Relief function. During normal operation of

the subsystem, the pressure reducing valve continu-
ously meters fluid to the system. The pressure reducing
valve is also designed to act as a relief valve. When
pressurized fluid builds up to an excess amount within
the subsystem, the shuttle assembly overcomes spring
tension and moves farther to the left. This movement
causes a passage to be opened to the return line, and
all excess fluid is relieved. When pressure is lowered
to an acceptable amount, the shuttle assembly returns
to a balanced position.

4-15. ACCUMULATORS. An accumulator is used

in a hydraulic system to store a volume of fluid under
pressure. It acts as a cushion against pressure surges
Figure 4-115. Piston-Type Pressure Switch
caused by pulsating fluid delivery from the pump or from

4-123
TM 1-1500-204-23-2

air pressure has been exhausted through the valve core able. When liquid fluid escapes from the air
or the valve core has been removed from the air valve valve, excessively worn seals or a scored
assembly. The hydraulic system pressure gauge will in- piston are indicated, and replacement of the
dicate the approximate accumulator air pressure when accumulator is necessary.
the hydraulic hand pump has been operated for a pe-
riod of time starting with zero pressure on the hydraulic • On spherical type accumulators any indica-
system. tion of fluid at the air valve shall be cause for
replacement of the accumulator, as this is an
b. Accumulator Operation. Spherical and cylin- indication of deterioration or rupture of the di-
drical accumulators operate in essentially the same aphragm.
manner. In operation, the compressed-air chamber is
charged to a pressure somewhat lower than the system (3) Check the preload pressure on the accumu-
operating pressure. This initial charge is referred to as lator by depleting the fluid pressure. This may be done
the accumulator preload. When a preload is introduced by operating the controls of a system of which the ac-
in an accumulator, the hydraulic system pressure will cumulator is a part until all reserve pressure has been
be zero. As the system is subsequently pressurized used.
and overcomes the preload pressure, the air will be
compressed in the accumulator. When use of hydraulic (4) Ensure that the air preload is completely ex-
units lowers system pressure, the compressed air will hausted before disassembling the accumulator.
then force fluid from the accumulator into the system
to satisfy system demands. Many aircraft have several 4-16. FLOW CONTROL UNITS. Numerous valving
accumulators in the hydraulic system. There may be an devices are used in aircraft hydraulic systems to control
accumulator for the main and emergency systems, and the flow of fluid within the system. These devices per-
there may be auxiliary accumulators located in various form such functions as controlling direction, sequence,
unit systems. and priority of flow; transforming fluid pressure into
mechanical energy; holding loads in position against
c. Maintenance. Maintenance of accumulators at feedback-induced forces; and preventing leaks. The
the organizational and intermediate maintenance levels devices that perform these functions are selector valves,
primarily consists of inspection and servicing. Some in- control valves, check valves, sequence valves, prior-
termediate maintenance activities may have the respon- ity valves, shuttle valves, actuating cylinders, ratchet
sibility for overhaul or repair, but this primarily rests with valves, servos, irreversible valves, and fuses.
the depot maintenance units. Inspection and servicing
procedures are as follows: a. Selector Valves. The purpose of a selector
valve is to control the direction of movement of an
(1) Visually inspect accumulators for indications actuating unit. It does this by providing pathways for
of external hydraulic leaks. pressure and return fluid into and out of an actuating
unit, and by providing the means for immediately and
NOTE conveniently switching the directions of the pressure
and return fluid (necessary for reversing the direction
Use only dry air or nitrogen when pressurizing of movement of the actuating unit). Selector valves
accumulator. are classified as closed-center and open-center types.
These classifications are based on what happens to the
(2) Test for internal leaks by momentarily de- flow of fluid when the selector valve is placed in the off
pressing the valve core. position. When a closed-center selector valve is placed
in the off position, its pressure passage is blocked to the
NOTE flow of fluid and no fluid can pass through its pressure
port. When an open-center selector valve is placed in
• On cylindrical type accumulators, a slight
amount of atomized hydraulic fluid is permiss-

4-124
 TM 1-1500-204-23-2

the off position, its pressure passage and return pas- poppet to the return line. In figure 4-123, the selector
sage become interconnected and fluid can flow into the valve control has been placed in the opposite direction.
pressure port and out of the return port. Selector valves Fluid pressure is forcing the actuating cylinder piston
may be further classified on the basis of design charac- outward, and fluid from the actuating cylinder flows
teristics as cam-operated, in-line, radial, and compound. through the other unseated poppet to the return line.

(1) Closed-center selector valves. The (b) Radial cam-operated selector valve
four-way, closed-center type selector valves are the (poppet-type). In the typical poppet-type radial selec-
ones most commonly used in aircraft hydraulic systems. tor valve shown in figure 4-124, the cam in the center is
Rotor and spool type valving devices are used in these attached to a control handle. Moving the control handle
valves. The valves operate in one off position and in two causes the cam to rotate and moves the poppets on or
on positions. Figure 4-120 shows a typical four-way, off their seats. In the position shown here, poppets A
closed-center rotor-type selector valve. This valve is in and C are seated and poppets B and D are unseated.
the off position: all the valve ports are blocked, and no Fluid entering the inlet pressure port flows around
fluid can flow into or out of the valve. poppet B and to the actuator unit through the cylinder
1 port. Fluid returning from the actuator unit enters
(2) Open-center selector valves. Figure 4-121 through the cylinder 2 port, flows around poppet D, and
illustrates an open-center, spool-type selector valve. exits through
This valve is in the off position, and as can be seen, the
center seat provides an interconnection between the
pressure port and the drilled passage in the spool. This
permits fluid to enter the pressure port and pass freely
through the valve and out of the return port.

(3) Cam-operated selector valves. Pop-

pet-type and ball-type selector valves are operated by
cams that lift the poppet or ball off its seat. Purpose,
use, and operation of the two types are the same: one
controls fluid flow by the use of poppets; the other
employs a ball-shaped valve. The piston-type selector
valve may also be cam-operated. In this case, flow is
directed by the sliding action of a piston, which is a
spool-shaped plunger within a housing.

(a) In-line cam-operated selector valve

(poppet-type). The poppets of an in-line selector
valve are similar to the pistons of an in-line aircraft
engine. In the neutral position, all four poppets are
closed. With this type of valve, a pressure rise caused
by an increase in temperature in either cylinder line can
unseat an upper poppet. This will relieve the pressure 1. POPPET VALVE
into the return line. An integral temperature relief valve,
relieving from the pressure manifold into the return line 2. PISTON
is used in several models of the valve. Figure 4-122 3. LOAD SPRING
shows a condition in which fluid pressure is forcing the
actuating cylinder piston inward, permitting fluid to flow
from the actuating cylinder through the lower unseated Figure 4-116. System Relief Valve

4-125
TM 1-1500-204-23-2

the return line. If the cam is rotated 90 degrees, poppets pounded into one unit. Each selector valve is controlled
A and C will unseat and poppets B and D will seat. Fluid independently, but only one connection is needed for
entering the inlet pressure port then passes around pop- the pressure line and one for the return line.
pet A and to the actuator unit through the cylinder 2 port.
Fluid returning from the actuator unit flows to the return b. Control Valves. For Army aircraft, the term
line by entering the selector valve through the cylinder control valve refers to a valve that controls direction
1 port, flowing around poppet C, and exiting through the of flow through alternate channels. Although similar in
return port. If the cam is rotated 45 degrees from the principle to a selector valve, a control valve functions
position shown in the schematic, all poppets are seated more like a shutoff valve. Some control valves are actu-
and the selector valve is in a neutral position. ated manually; others, electrically. Electrical actuation
may be by means of either a solenoid or a motor. A
(4) Compound selector valve. To conserve solenoid-actuated valve is shown in figures 4-125 and
space and make installation easy when banks of units 4-126. The
are to be controlled, several selector valves are com-

Figure 4-117. Pressure Reducing Valve

Figure 4-118. Cylindrical Accumulator

4-126
 TM 1-1500-204-23-2

valve device is spring-loaded to one position and sole- free flow of fluid in one direction, while allowing limited
noid-actuated to the other position. operation speed through restricted flow of fluid in the
opposite direction. An orifice-type check valve is shown
c. Check Valves. For hydraulic components and in figure 4-128. The operation of the orifice-type check
systems to operate as they should, the flow of fluid must valve is the same as that of the simple-type except for
be rigidly controlled. Fluid must be made to flow accord- the restricted flow allowed when closed. This is accom-
ing to needs of the system. Many kinds of valve units plished by having a second opening in the valve seat.
are used for exercising such control. One of the sim- This second opening is never closed and is the means
plest and most commonly used is the check valve. The by which some reverse flow can take place through the
check valve allows free flow of fluid in one direction, but valve. The second opening is much smaller than the
no flow or a resticted flow in the other direction. There opening in the valve seat. As a rule, this opening is a
are two types of in-line check values: simple and orifice. specified size in order to maintain close control over the
rate at which fluid can flow through the valve in reverse.
(1) Simple-type. Simple-type check valves
shown in figure 4-127 are used when a free flow of (3) Marking of valves. The direction of fluid flow
fluid is desired in only one direction. Fluid entering the through in-line check valves is indicated by stamped ar-
inlet port of the check valve forces the valving device row markings on the housing as shown in figures 4-127
off its seat against the spring. This permits fluid to flow and4-128. On the simple-type in-line check valve, a sin-
through the passageway thus opened. The instant that gle arrow shows the direction in which fluid can flow.
fluid stops moving in this direction, the valving device The orifice-type in-line check valve is usually marked
is returned to its seat by the spring. This blocks the with two arrows. One arrow is more pronounced than
opening in the valve seat, thus blocking the flow of fluid the other, and indicates the direction of unrestricted flow.
through the valve. The other arrow is either smaller than the first or of bro-
ken-line construction and points in the direction of re-
stricted reverse fluid flow.

d. Sequence Valves. The purpose of sequence

valves (sometimes called timer check valves) is to set
up a sequence of operation. In Army aircraft, these
valves are used in such mechanisms as landing gear
doors; landing gear uplocks and downlocks; cargo
doors, ramps, and locks; and ejection seats to cause
hydraulic operations to occur in a specific order. Two
major types are used: mechanically-actuated and pres-
sure-actuated.

(1) Mechanically-actuated sequence

valves. The mechanically-actuated sequence valve
is the type commonly used in Army aircraft. A typical
valve of this type (shown in figure 4-127) consists of
a housing in which there are two ports, a ball valving
device, two springs, a plunger that extends through
one end of the housing, and the necessary seals to
prevent leakage. The input pressure line is connected
as shown to the actuating cylinder and to sequence
valve B. Since sequence valve B is now closed, fluid
Figure 4-119. Spherical Accumulator cannot pass through it. When the door is opened, the
door actuating cylinder piston rod extends far enough to
(2) Orifice-type. The orifice-type check valve contact and depress the plunger of sequence valve B.
(sometimes called a damping valve) is used to allow This opens sequence valve B and allows fluid pressure
normal operating speed of a mechanism by providing to pass through to the

4-127
TM 1-1500-204-23-2

Figure 4-120. Rotary-Type, Closed Center Selector Valve

Figure 4-121. Spool-Type, Open Center Selector Valve (Closed)

4-128
 TM 1-1500-204-23-2

Figure 4-122. In-Line Cam-Operated Selector Valve (Actuator Retracting)

Figure 4-123. In-Line Cam-Operated Selector Valve (Actuator Extending)

4-129
TM 1-1500-204-23-2

valve A while the landing gear is still retracted and the

sequence valve is still open.

(2) Pressure-actuated sequence valves. The

typical pressure-actuated sequence valve consists of
a three-port housing, a spool-type valving device, and
an adjustable spring. Operation of the pressure-actu-
ated sequence valve shown in figure 4-130 is dependent
upon movement of the spring-loaded spool. Unlike the
mechanically-operated type, no mechanical contact with
any other unit is necessary to operate a pressure-actu-
ated sequence valve. When the selector valve is posi-
tioned, fluid pressure is directed to the pressue inlet port
of the sequence valve and passes through the valve to
the first unit to be actuated. The pressure necessary
to operate this unit is less than that required to move
the spool against the restraint of its spring. After oper-
ation of the first unit is completed and flow to it ceases,
pressure in the passage between the pressure inlet port
and the first unit port increases. This pressure is con-
Figure 4-124. Radial Cam-Operated Selector Valve ducted through a special passage to the underside of
the pilot piston on the lower end of the spool, forcing the
spool upward until the passage between the pressure
down side of the landing gear actuating cylinder, thus inlet port and the port to the second unit becomes un-
extending the gear. Return fluid from the door actuat- blocked. Fluid then flows into the second unit, causing
ing cylinder is routed to the reservoir through sequence it to operate.

Figure 4-125. Solenoid-Actuated Control Valve (Energized)

4-130
 TM 1-1500-204-23-2

Figure 4-126. Solenoid-Actuated Control Valve (De-energized)

Figure 4-127. Simple Check Valve

Figure 4-128. Orifice Check Valve

4-131
TM 1-1500-204-23-2

Figure 4-129. Landing Gear System Using Mechanically Actuated Sequence Valves

e. Priority Valves. Priority valves are installed in is unrestrained. When system pressure drops below
hydraulic systems to provide adequate fluid flow to units normal, the priority valve automatically reduces the rate
requiring immediate completion of action. Figure 4-131 of flow to the unit not requiring immediate completion of
illustrates the operation of a priority valve. The priority action. Priority valves are used in hydraulic systems to
valve is installed in the line between an actuating unit in give operating priority to such units as brakes, landing
gear, and flaps.

f. Shuttle Valves. In some cases, two sources of

operating pressure are connected to a single component
or system. One of the pressure sources will be reserved
for emergency use. Provisions are usually

Figure 4-130. Pressure-Actuated Sequence Valve

Figure 4-131. Priority Valve

which completion of action can be delayed and its
source of operating pressure. As long as system pres-
sure is normal, the flow of fluid to the delayable unit

4-132
 TM 1-1500-204-23-2

made in such cases to eliminate any possible transfer of g. Actuating Cylinders (Actuators). Actuating
fluid from one pressure source to the other. This is done cylinders transform energy in the form of fluid pressure
by means of shuttle valves. Army aircraft equipped with into mechanical force so that the energy can perform
dual brake systems use shuttle valves to isolate the pi- work. They impart powered linear motion to some mov-
lot and copilot master cylinders from each other so as able object or mechanism. A typical actuating cylinder
to allow optional operation of the brakes by either set is made of a cylinder housing, one or more pistons
of master cylinders. Also, Army aircraft having com- and piston rods, and the necessary seals to prevent
pressed-air equipment for emergency operation of land- leakage between the piston rods and the end of the
ing gears and wheel brakes use shuttle valves to iso- cylinder. The cylinder housing contains a polished bore
late the system hydraulic fluid from the compressed air in which the piston operates and one or more ports
or other authorized gas used in emergency operation. through which fluid enters and leaves the bore. Actu-
Two types of shuttle valves are used in Army aircraft: ating cylinders come in two major types: single-action
the floating-piston type, and the detent-type. and double-action.

(1) Floating-piston type. In the floating-piston (1) Single-action. The single-action (single
type shown in figure 4-132, fluid entering the shuttle port) actuating cylinder causes movement in one direc-
valve from pressure source 1 moves the piston to block tion only. Operation of this type of cylinder is controlled
the flow from pressure source 2 so that fluid flows to the by a three-way control valve. In this single-action cylin-
unit being actuated from pressure source 1 only. Con- der shown in figure 4-133, fluid under pressure enters
versely, fluid entering from source 2 would reposition the the port at the left and pushes against the face of the
piston to block the flow from source 1; fluid would then piston, forcing the piston to the right. As the piston
flow to the unit being actuated from pressure source 2 moves, air is forced out of the spring chamber through
only. The piston is restrained against random movement the vent and the spring is compressed. When pressure
by the slight drag of the O-ring against the cylinder walls. on the fluid is released to a point less than the force in
the compressed spring, the spring pushes the piston
toward the left. As the piston moves to the left, fluid
is forced out of the fluid port and air enters the spring
chamber through the vent.

(2) Double-action. The double-action (two-

port) actuating cylinder causes movement in two di-
rections. Operation of this type of cylinder is usually
controlled by a four-way selector valve. Placing the
selector valve in the on position (see figure 4-134),
admits fluid pressure to the left-hand chamber of the
actuating cylinder, thus forcing the piston to the right.
As the piston moves to the right, it pushes return fluid
out of the right-hand chamber and through the selector
valve to the reservoir. When the selector valve is placed
in its other on position (see figure 4-135), fluid pressure
enters the right-hand chamber and forces the piston
to the left. As the piston moves to the left, it pushes
return fluid out of the left-hand chamber and through
the selector valve to the reservoir. Besides having the
ability to move a load into position, a double-action
Figure 4-132. Floating-Piston Shuttle Valve cylinder can hold a load in position in opposition to any
force which may tend to displace it. This capability
exists because, when the selector valve used to control
(2) Detent-type. The detent-type shuttle valve
operation
operates on the same general principles as the float-
ing-piston type, with the exception that a spring-loaded
detent ball holds the piston in the position dictated by
the pressure source.

4-133
TM 1-1500-204-23-2

of the actuating cylinder is placed in the off position, fluid (a) To reduce excessive wear and possible
is trapped in the chambers on both sides of the actuating failure of hydraulic cylinder packing rings, exposed part
cylinder piston. This locks it against movement in either of piston rod shall be cleaned as follows:
direction.
1 Remove foreign materials by wip-
(3) Allowable leakage. The seepage of some ing with a clean cloth saturated with hydraulic fluid,
fluid past shaft end seals and bearings is necessary for MIL-H-5606 or MIL-H-83282.
their lubrication. However, through normal wear, seep-
age develops into leakage. Moderate leakage at piston 2 If extreme foreign materials are encoun-
rod end bearings and seals during operation is normal tered, clean before and after each flight.
in actuating cylinders which have been in use for some
time. There are established limits as to the amount of 3 If operating in freezing temperature,
leakage permitted at such points. The general military cleaning is accomplished easier immediately after land-
specification for allowable external leakage at each shaft ing.
seal and bearing is one drop per 25 cycles of operation
(25 full or partial strokes in each direction). This specifi- (b) Replace hydraulic cylinders when the rod
cation is applicable except where a different leakage lim- becomes scratched, nicked, or dented deep enough to
itation is specifically stated in publications for the equip- cause leakage.
ment concerned.
(c) When overhauling hydraulic cylinders, all
(4) Maintenance. Care of hydraulic actuating ferrous metal parts will be magnetic particle-inspected
cylinders shall be as specified in applicable aircraft for cracks and flaws. Inspection will be accomplished in
maintenance manual. Typical troubleshooting data is accordance with TM 55-1500-335-23, and TM 55-1500-
outlined in table 4-40. 204-23-7. Parts will be marked properly after inspection.

Figure 4-133. Single-Action Actuating Cylinder

4-134
 TM 1-1500-204-23-2

Figure 4-134. Double-Action Actuating Cylinder (Extension)

Figure 4-135. Double-Action Actuating Cylinder (Retraction)

4-135
TM 1-1500-204-23-2

Table 4-40. Troubleshooting Actuators

Trouble Probable Cause Remedy

Leakage from operating end of Packing around piston rod is Disassemble cylinder and
piston leaking replace packing, if worn
External leakage around head and Lockring holding gasket is not Tighten
base right
Gasket is worn Replace with new gasket
Leakage from one side of piston to Packing on piston is worn or Disassemble and replace
the other scored packing
Packing inside piston is worn or Disassemble and replace
scored packing
Piston is not securely fastened to Tighten nut holding piston on
piston rod piston rod
Smooth finish on barrel is Overhaul
scratched or scored

h. Ratchet Valve. Hydraulic ratchet valves are i. Hydraulic Servos. Many situations exist in
used as companion devices to double-action actuating which powered movements must be consistently made
cylinders. The purpose of a ratchet valve is to aid with accuracy within thousandths of an inch; such exact
an actuating cylinder in holding a load in the position control cannot be effected by an actuating cylinder
into which it has been moved by operation of a hand merely connected with a selector valve. Hydraulic ser-
pump. The ratchet valve insures that there will be vos perform this function. Hydraulic servos are used in
trapped fluid on each side of the actuating cylinder both airplanes and helicopters to multiply the physical
piston. This is necessary for the actuating cylinder effort expended by personnel in operating the aircraft.
to lock a load against movement in either direction, Servos enable a pilot to use fingertip force in controlling
and is especially vital should the selector valve which the actions of a flight control system that may actually
controls the actuating cylinder be left in the on piston require hundreds of pounds of force to actuate.
or have internal leakage. The ratchet valve does not
affect actuating cylinder piston movements that are (1) Design. In effect, a hydraulic servo is a com-
intentionally produced by means of system operating bination of an actuating cylinder and a selector valve
pressure. Ratchet valves are optional equipment and in a single unit. The servo selector valve is manually
are used only in cases where locking a load in position opened by the operator and is automatically closed by
is of great importance. In figure 4-136, the ratchet valve the servo’s movement. The spool-shaped valving de-
is shown with no pressure applied (selector valve off ). vice of the servo selector valve is commonly referred
The piston is centered in its bore, and both check valves to as a pilot valve. Servos are made in two general
(balls A and B) are closed. This locks the actuating designs. In one design, the servo cylinder housing is
cylinder in position by trapping all fluid in the cylinder. stationary and the piston rod moves. In the other de-
The ratchet valve is shown in figure 4-137 with pressure sign, the piston rod is stationary and the cylinder hous-
applied to port 1. This forces the piston to the right ing moves. For convenience, a servo in which the
where it unseats ball check B. Pressure entering port 1
unseats ball check A on the left side. Fluid then flows
through the ratchet valve, and the piston moves to the
right, unseating ball check B.

4-136
 TM 1-1500-204-23-2

cylinder housing is stationary and the piston moves is is now stopped, the piston will travel no
used for the following explanation of basic servo opera- farther.
tion and of servo sloppy links and bypass valves. Such
a servo is shown in figure 4-138. j. Irreversible Valves. Irreversible valves assist
hydraulic servos in a manner similar to that in which
(2) Operation. To exemplify servo operation, let ratchet valves assist actuating cylinders. Both ratchet
us assume that the servo pilot valve has been moved valves and irreversible valves provide defense against
a given distance to the right from the off position and is movement of the unit by an externally applied force.
to be held there. If the given distance is 0.250 inch, the Irreversible valves are used with hydraulic servos in
following will result: a helicopter flight control system to block the travel of
feedback forced from their point of origin in the rotor
• Fluid under pressure will flow through head and blades to the control stick. Figure 4-139
the now unblocked selector valve cylin- illustrates basic operation of the irreversible valve. The
der port and will enter the left chamber check valve in this mechanism allows fluid from the
of the servo cylinder housing. pump to flow in the normal direction as shown by the
arrows. However, feedback force tends to move the
• The piston will be forced to the right and servo piston in the opposite direction to the pump-pro-
will carry the selector valve housing with duced pressure. This tends to force fluid backward
it since that housing is welded to the through the irreversible valve. The check valve blocks
piston rod. this rearward flow of fluid and keeps the servo piston
from yielding to feedback force. The relief valve serves
• When the piston has moved to the right as a safety device to limit the pressure produced by
exactly 0.250 inch, the selector valve feedback-induced movement of the servo piston. It
housing will have moved to the right over opens to allow fluid to bypass to the return line if the
the now stationary pilot valve. This will feedback-produced pressure exceeds a preset safe
result in returning the selector valve to limit.
the off position. Since the flow of fluid

Figure 4-136. Ratchet Valve (Static)

4-137
TM 1-1500-204-23-2

Figure 4-137. Ratchet Valve (Moving)

Figure 4-138. Hydraulic Servo

4-138
 TM 1-1500-204-23-2

return spring, and a metering plate. The housing has a

port at each end; one pressure, the other, return. The
sleeve is attached to the housing and is centered on the
axis of the housing. It has a polished bore in which the
piston operates. Holes in the end of the sleeve nearest
the outlet port open the bore of the sleeve to a space
between the sleeve and the housing. The metering
plate divides whatever fluid enters the fuse into streams
of unequal size. The larger streams flow around the
outside of the sleeve; the smaller streams, through the
inside.

Figure 4-140. Hydraulic Fuse Assembly

Figure 4-139. Irreversible Valve
(1) Normal flow. Whenever the fuse is not
k. Hydraulic Fuses. Fuses are incorporated in transmitting fluid, its piston is pulled to the inlet end of
hydraulic systems to prevent continued loss of fluid in the fuse by the piston return spring as shown in figure
cases of serious leakage. Fuses are strictly safety de- 4-141. As soon as fluid begins flowing through the fuse,
vices. They are not needed for operation of the system. the stream of fluid that enters the sleeve reacts against
Hydraulic fuses are usually installed in lines that are run the piston. This causes a slow movement of the piston
in hazardous locations or that conduct fluid to compo- toward the outlet end of the sleeve. Meanwhile, the
nents located in such places. They can only be used in stream of fluid that flows on the outside of the sleeve
lines through which fluid flows in one direction but not passes through the communication holes in the sleeve
continuously or in lines through which flow is reversed and then out of the fuse outlet port. As long as the
at intervals. A hydraulic fuse is designed to permit only quantity of fluid passing through the fuse is equal to or
a limited quantity of fluid to pass through it. When this less than the rated flow capacity of the fuse, the piston
limit is reached, the fuse automatically shuts off further travels less distance within the sleeve than its travel
flow. The typical fuse shown in figure 4-140 consists limit.
essentially of a housing, a sleeve, a piston, a piston

Change 4 4-139
TM 1-1500-204-23-2

(2) Blocked flow. If the flow of fluid through the the fuse (see figure 4-142). The piston is held in the
fuse becomes greater than its rated flow capacity, the blocking position until the pressure is relieved. When
increased pressure causes the piston to travel until the the pressure is relieved, the piston return spring retracts
needle on its end plugs the opening at the outlet end the piston and fluid again flows through the fuse.
of the housing, thus blocking further fluid flow through

Figure 4-141. Hydraulic Fuse (Full Flow)

Figure 4-142. Hydraulic Fuse (Blocked Flow)

cles of foreign matter lodged in assemblies will cause

leakage or improper operation of the valve. Wash
all parts, except solenoids, with degreasing solvent,
Degreasing solvent, MIL-PRF–680, is com- MIL-PRF-680, and dry with compressed air.
bustible and toxic to eyes, skin and respiratory
tract. Wear protective gloves and goggles/face 4-17. TYPES OF PNEUDRAULIC SYSTEMS. The
shield. Avoid repeated or prolonged con- arrangement of components within the hydraulic sys-
tact. Use only in well ventilated areas (or use tems varies among the different types of aircraft.
approved respirator as determined by local However, all aircraft hydraulic systems incorporate the
safety/industrial hygiene personnel). Keep components described in paragraph 4-16 . The hy-
away from open flame other sources of ignition. draulic system may be an open-center or a closed-cen-
ter type and may be interconnected with a pneumatic
l. Maintenance of Hydraulic Flow Control system that serves as an emergency pressure source
Units. Extreme cleanliness is essential. Small parti- in case the main system fails.

4-140 Change 4
 TM 1-1500-204-23-2

a. Open-Center Hydraulic System. An open- ter passage of these valves. Since no restrictions exist
center hydraulic system has hydraulic fluid flow but in the system, there is no pressure in the system other
no pressure until some actuating unit is operated. A than that caused by friction.
typical basic open-center system such as the one
shown in figure 4-143 consists primarily of a reservoir, (2) Operation of system with one selector
a constant-delivery type pump, a relief valve, one or valve in on position. With one selector valve in the
more selector valves, and one or more actuating units. operating position, as shown in figure 4-144, fluid flows
This system does not require a pressure regulator. The under pressure to the actuating unit. As the actuat-
system relief valve limits system pressure when the ing unit moves, it forces residual fluid from the piston
selector valve is in an on position and an actuating unit through the open selector valve and back to the reser-
is operating. voir. At the end of the stroke of the actuating unit, fluid
flow becomes blocked and pressure increases within
(1) Operation of system with selector valves the system. Eventually, the pressure builds up to the
in off position. Fluid flows from the reservoir into the setting of the relief valve, at which point it is bypassed to
pump and from the pump into the main pressure line. the return line and back to the reservoir. This condition
Because all selector valves are in the off position, the exists until the selector valve is returned to the neutral
fluid passes back to the reservoir through the open-cen- (off) position.

Change 4 4-140.1/(4-140.2 blank)

 TM 1-1500-204-23-2

Figure 4-143. Open-Center Hydraulic System (Valve Closed)

Figure 4-144. Open-Center Hydraulic System (Valve Open)

b. Closed-Center Hydraulic System. A closed- leading from the selector valve to each side of the piston
center hydraulic system is sometimes called a di- in the actuating unit. Thus, the fluid cannot move in any
rect-pressure system because the hydraulic fluid is direction. This holds the piston in a locked position, and
under pressure throughout the system when the pump any attached mechanism will be held in a fixed position.
is operating. A basic closed-center hydraulic system
consists primarily of a reservoir, a pump, a relief valve, (2) Selector valve B. In figure 4-146, the rotor
one or more selector valves, and one or more actuating of selector valve B is positioned so as to direct the fluid
units. In figures 4-145 through 4-147, each of the three flow from the selector valve to the face of the piston in
selector valves controls a different actuating unit and the actuating unit. This pressure forces the piston to
each valve is in a different position. Hydraulic fluid is move outward, causing any mechanism attached to the
drawn from the reservoir to the pump, which forces the piston rod to function. Fluid moving out of the actuating
fluid on to the selector valves A, B, and C with results unit as the piston moves outward flows into the return
as described in the following paragraphs. line to the reservoir.

(1) Selector valve A. In figure 4-145, the rotor (3) Selector valve C. In figure 4-147, the rotor
of selector valve A is positioned so that the valve ports of selector valve C is positioned to direct the fluid flow to
are closed. The hydraulic fluid is trapped in the lines the rod side of the piston, forcing the piston to move

4-141
TM 1-1500-204-23-2

Figure 4-145. Selector Valve A Closed

Figure 4-146. Selector Valve B Open

Figure 4-147. Selector Valve C Open

4-142
 TM 1-1500-204-23-2

inward. Fluid moving out of the actuating unit as the pis- two identical subsystems that can be operated indepen-
ton moves inward flows into the return line to the reser- dently of each other to provide separate braking action
voir. for the landing gear on each side of the aircraft. Each
subsystem is operated by a toe plate (brake pedal) that
c. Pneumatic System. Aircraft pneumatic sys- is hinge-mounted to the top of the aircraft rudder pedal.
tems are mostly used as an emergency source of Since each brake pedal can be operated independently,
pressure for hydraulically operated subsystems. The the brakes can be used for steering the aircraft. A list
pneumatic power system usually consists of one or of components, which may be found in varying combi-
more high pressure air cylinders, pressure gauges, and nations to make up the different wheel brake systems,
pressure warning lights. Since the pneumatic power includes the following: master cylinder (or a power
source does not replenish itself during flight, the com- brake control valve), wheel brake assemblies, deboost-
pressed-air supply is good for only a certain number of ers, parking brake valves, shuttle valves, accumulators,
operations. connecting lines, and bottles charged with compressed
air. The minimum number of parts which could be used
(1) Construction. High pressure pneumatic to perform the function of a simple wheel brake system
systems are constructed to operate in much the same are a master cylinder (or a power brake control valve),
manner as hydraulic systems. A shuttle valve connects a wheel brake assembly, and connecting lines.
the pneumatic system to the hydraulic system. This
allows the use of the same tubing and units for both sys- (1) Master cylinders. Master cylinders are used
tems. The shuttle valve separates the normal hydraulic in some wheel brake systems as the means of trans-
system from the pneumatic system. Pneumatic system forming force applied by the of the operator foot into fluid
selector valves control the air to the subsystems. Each pressure; the greater the force applied to the pedal, the
subsystem is connected to the high pressure air source higher the fluid pressure. Master cylinders fall into three
through a pressure regulator and relief valve assembly general classifications: simple, compound, and power-
and a selector valve. Since pneumatic selector valves boost. Within these classifications, there are many vari-
are installed in parallel, air pressure is immediately ations in shape, size, and design, depending on the
available to all subsystems for instant operation. Con- manufacturer and on how the cylinder functions in the
nected in this manner, more than one system can be brake system. Brake systems incorporating simple and
operated at the same time. compound master cylinders operate independently of
any other hydraulic system within the aircraft and are
(2) Servicing. The air cylinders are charged sometimes called independent brake systems. In brake
through a ground test filler connection by a portable systems using a power boost master cylinder, some of
nitrogen cart or a high pressure air compressor. All the power needed for braking is supplied by a power-
nitrogen or air is filtered by a filter in the service line. driven pump.

4-18. AIRCRAFT BRAKE SYSTEMS. All hydraulic (a) Simple master cylinder. Some simple
brake systems operate on the same basic principle. cylinders have integral reservoirs; others are connected
When the operator moves a brake pedal or other brake with in-line reservoirs by means of a hose. In some
operating control, the movement is transmitted to a designs, a push rod actuates the piston; in others a
master cylinder or to a power brake control valve from pull rod performs this function. The design shown in
which fluid pressure is delivered through connecting figure 4-148 has an integral reservoir, and the piston is
lines to a brake assembly connected to a wheel or shaft actuated by a push rod. Note that the illustration shows
whose movement is to be braked. The fluid pressure the cylinder in released position, with the compensating
acting on the brake assembly pushes brake linings into valve open. This allows any thermally expanded fluid
contact with surfaces of a rotating disc. The resulting within a connected wheel brake assembly to pass freely
friction slows—and finally stops— the continued rota- into the reservoir and from the reservoir back into the
tion of the wheel or shaft to which the disc is connected. assembly to replace fluid that may have been lost due
When the brake pedal or brake control is returned to the to minor leakage. When the brake pedal is depressed,
off position, brake operating pressure is relieved, the the first few thousandths of an inch of travel of the mas-
brake lining loses contact with the disc, and the wheel ter cylinder push rod closes the compensating valve,
or shaft is free to turn again. thus trapping the fluid that lies between the underface
of the piston and the wheel brake assembly. Further
a. Wheel Brake Systems. Aircraft wheel brake depression of the brake pedal moves the piston within
systems are dual in nature in that they are composed of its bore and forces fluid out of the master cylinder

4-143
TM 1-1500-204-23-2

Figure 4-148. Simple Master Cylinder

into the wheel brake assembly. Releasing the brake assembly and opens a passage between the large cylin-
pedal retracts the master cylinder push rod, allowing der bore and the reservoir, thus allowing any fluid dis-
the piston spring to open the compensating valve and played by the large piston to flow without resistance into
to hold it open until the pedal is depressed again. the reservoir. The small cylinder bore remains open to
the passage within the master cylinder through which
(b) Compound master cylinder. Some air- fluid is delivered to the wheel brake assembly. As force
craft require wheel brake systems that operate with applied to the brake pedal is increased so as to push
more fluid flow and higher fluid pressure than is within the linings into hard contact with the brake disc, the two
the capability of a simple master cylinder. In some types pistons move slightly farther into their bores. Since any
of aircraft, a compound master cylinder is used for this fluid displaced out of its bore by the large piston is flow-
purpose. This type of master cylinder can deliver a large ing to the reservoir without resistance, practically all the
quantity of fluid at low pressure by means of relatively force exerted on the brake pedal is applied to the small
short pedal travel. It can also develop high operating piston.
pressure by means of moderate pedal pressure. This
dual capability is achieved by means of two pistons: 2 Brakes released. Upon release of the
a large one for producing a large fluid flow with short brake pedal, the spool of the transfer valve returns to
travel; and a small one for developing high pressure its spring-loaded position, the pistons return to their
from a lightly applied force. Figure 4-149 shows a released position, the compensating valves open, and
compound master cylinder in a released position, which the fluid that was forced into the wheel brake assembly
means that the compensating valves of both pistons when the brake was applied returns to the master
are open to the reservoir. cylinder.

1 Brakes applied. As the brake pedal is (c) Power-boost master cylinder. Some air-
depressed, both compensating valves close and the pis- craft land at speeds too great to permit control of the
tons are forced ahead in their cylinder bores. The fluid aircraft by a brake system powered entirely by an op-
displaced jointly by the two pistons flows into the wheel erator’s foot and leg muscles. The brake systems of
brake assembly, where it moves the linings into con- such aircraft require power produced by a power-driven
tact with the disk. A slight additional movement of the pump. In some aircraft, the pump-produced power does
brake pedal and pistons raises the pressure in the sys- the job alone and is merely controlled by the operator.
tem by a few pounds. This slight rise in pressure moves In other aircraft, the pump-produced power is used as a
a spring-loaded spool in the transfer valve within the supplement (or boost) to the power supplied by the mus-
master cylinder. The new position of the spool blocks cles of the operator; the power-boost master cylinder is
the flow of fluid from the large cylinder to the wheel brake used in these brake systems. In the event of

4-144
 TM 1-1500-204-23-2

1 Design. Figure 4-150 shows a typical

power-boost master cylinder. Note that two intercon-
nected chambers make up the cylinder body. The up-
per chamber houses a spring-loaded sleeve and slide
and the pressure and return ports for the main system
lines. The lower chamber contains a spring-loaded pis-
ton and poppet and the port to the brake line. This cham-
ber also serves as a reservoir for the fluid that energizes
the brake when pressure is applied. An actuating lever
and two slide actuating springs are mounted on top of
the cylinder. One end of the actuating lever is secured
to the aircraft; the other end, to the cylinder housing. It
should be noted that the master cylinder described here
has a piston rod that is pulled outward of the housing as
the brake is applied. However, there is another design in
which applying the brake pushes the piston rod inward.

2 Fluid pressurization. Applying pressure

to the brake pedal creates a pull on the piston rod that
results in downward movement of the piston. When
sufficient movement of the piston occurs to release the
poppet extension from its contact with the housing, the
poppet seats, thereby closing the compensating valve.
Fluid trapped between the underside of the piston and
the wheel brake assembly then becomes pressurized.
This fluid pressure, acting with force exerted by the pis-
ton retracting spring, creates a downward pull on the
master cylinder housing. When the pull becomes suf-
ficiently great, it causes the pivoted actuating lever to
move from its previously angled position. The new po-
sition of the actuating lever forces the attached slide ac-
tuating springs to retract the slide, thereby causing the
slide to block the return port and to open the pressure
port. This allows pressure from the system pump to
Figure 4-149. Compound Master Cylinder pass through the pressure port and the slide and to en-
ter the chamber above the piston. This pressure exerts
loss of pump-produced power to the master cylinder, a downward push on the piston, which aids the mus-
some brake application by muscle power alone is possi- cle (operator) produced pull on the piston in develop-
ble. However, considerably more force than normal has ing brake application pressure within the lower cham-
to be applied to the brake pedal to achieve the neces- ber and the connected wheel brake assembly. What-
sary braking action. In heavy aircraft the most vigorous ever pressure is present in the chamber above the pis-
manual application is still completely inadequate and an ton is also present within the slide and tends to force the
emergency source of boost pressure, such as an accu- slide upward against the resistance of the slide actuat-
mulator or a compressed-air bottle, has to be provided. ing springs. When the pressure-produced force

4-145
TM 1-1500-204-23-2

cation is under complete control of the operator and is

determined by the amount of pressure he applies to the
brake pedal.

4 Brake release. Release of pressure on

the brake allows the piston spring to retract the piston,
which results in reopening the compensating valve (see
figure 4-151). This allows the actuating lever to return
to its angled position, thereby permitting the slide to re-
turn to the position, thereby permitting the slide to re-
turn to the position in which it blocks the pressure port
and opens the return port. Fluid that was forced into the
wheel brake assembly during brake application can then
return to the chamber on the underside of the piston and
thus release the brake.

(2) Power control valves. In aircraft that land at

high speed, power brake control valves are used instead
of master cylinders to provide the wheel brake assem-
blies with fluid pressure. The main difference between
a power brake control valve and a master cylinder lies
in the pressure source. A power brake control valve
produces no pressure. It is, pressure to a wheel brake
assembly. Since the power brake control valve does
not produce pressure, a brake system using this type
of valve must be supplied with an emergency source of
input pressure, such as an air bottle, for use in the event
that the regular pressure source fails.

(a) Brake application. When the brake pedal

Figure 4-150. Power-Boost Master Cylinder (Brake is depressed, the plunger moves toward the left as
Applied) shown in figure 4-152. This movement is transmitted
to the spool by the spool pressure spring, causing the
spool to move toward the left. If the brake pedal is
acting on the slide becomes slightly greater than the depressed only a minimum amount, the spool’s leftward
force exerted by the slide actuating springs, the slide movement is just enough to barely unblock the pressure
moves upward to the extent that it blocks both the pres- port. This movement of the spool interconnects the
sure and return ports. pressure and brake lines and isolates the brake line
from the return line. As a result fluid flows out of the
3 Pressure maintenance. Since no pres- brake port into the brake assembly, thus raising the
sure can then be relieved or increased within the cham- pressure in the wheel brake assembly and causing the
ber above the piston, brake application remains con- brake to be applied. The rise in pressure in the wheel
stant as long as the operator does not change the force brake assembly takes place gradually because of the
applied to the brake pedal. The degree of brake appli- very small opening between the spool and the pressure

4-146
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of force in the spool pressure spring at that time. Since

the amount of force exerted by the spool pressure
spring is in proportion to the distance the brake pedal is
depressed, the degree of pressure with which the brake
is applied depends on how far the pedal is depressed.

(b) Pressure maintenance. Once a given

degree of braking effort has been obtained by depress-
ing the pedal a given distance, it will remain unchanged
as long as the pedal is not moved. This is because
the movement of the spool to the right in blocking the
pressure port leaves the brake line isolated from both
the pressure and the return lines. Thus, no fluid can
enter or leave the wheel brake assembly and change
the amount of pressure therein unless the position of
the spool is changed by moving the pedal. When the
brakes are in this static condition, the operator may ex-
perience the illusion that he is still applying the brakes.
The reason for this is that the fluid pressure within the
spool that tends to move the spool toward the right is
transmitted back to the brake pedal through the spool
pressure spring and the plunger. This results in a push
of the pedal against the operator’s foot, giving him the
feeling that he is applying the brakes.

(c) Brake release. As shown in figure 4-153,

releasing the brake causes the plunger spring to move
the plunger toward the right. This releases pressure on
the spool pressure spring and permits the spool return
spring to move the spool toward the right. Under these
conditions the pressure port is blocked and the brake
line and the return line are interconnected. The fluid
Figure 4-151. Power-Boost Master Cylinder (Brake that was forced into the wheel brake assembly when the
Released) brake was applied now returns to the reservoir.

b. Wheel Brake Assemblies. The wheel brake

port. Whatever amount of pressure is present in the assembly is that portion of a wheel brake system that re-
wheel brake assembly at any given moment is also ceives pressure from a master cylinder or a power brake
present in the hollow of the spool, having entered the control valve and converts the pressure into a retarding
spool through a cross-drilled hole. This pressure within force that stops wheel rotation.
the spool tends to move it toward the right. This is in
opposition to the force exerted by the spool pressure (1) Disc brakes. A typical disc assembly is
spring and reblocks the pressure port. The amount of shown in figure 4-154. In a disc assembly, one or two
fluid pressure that has to be present at any given time steel discs are generally used, depending on the type
in the wheel brake assembly and in the spool to cause
reblocking of the pressure port depends on the amount

4-147
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Figure 4-152. Power Brake Control Valve (Brakes Applied)

Figure 4-153. Power Brake Control Valve (Brakes Released)

4-148
 TM 1-1500-204-23-2

and size of the aircraft on which the brakes are installed. this first movement of the piston. However, to obtain full
These discs are keyed to the wheel and rotate with the braking friction between the rotating disc and the lining
wheel. The brake piston housing, which is securely "pucks", the piston must move farther to the left. The
bolted to the torque plate of the aircraft landing gear, disc must be firmly pinched between the lining "pucks".
contains from one to four brake actuating pistons, the The spring guide is already contacting the face of the
number depending on the type and size of the aircraft. adjusting pin, and the adjusting pin is held firmly by the
Depressing a brake pedal forces hydraulic fluid through friction of the adjusting pin grip (9). However, pressure
connecting lines to the wheel brake assembly and into on the piston provides enough force to overcome this
each piston cavity. This forces the piston and the out- friction, allowing the piston and pin to move farther to
board brake lining against the brake disc. Since the disc the left. If the brakes are held in this applied position,
is free to move from side to side along the lugs in the the lining wears away. The pin continues to move in-
wheel, it is forced against the inboard brake lining. The ward slowly to compensate for the small amount of lin-
friction that results from this clamping of the rotating disc ing wear.
between a pair of linings retards the continued rotation
to the disc and of the wheel to which it is attached. 2 Release. Each time the brakes are re-
leased, the piston backs away from the outboard lining
(a) Single-disc. Figure 4-155 shows a cross- block. It can move until the back of the piston head con-
section of a single-disc brake. This brake, like most hy- tacts the face of the adjusting pin. The piston always re-
draulically operated disc brakes, is self-adjusting. The leases to give the same running clearance. The self-ad-
illustration shows a cutaway of only one piston cavity. justing pin grip prevents the pin from moving to the right.
However, all piston assemblies of this type of brake are
nearly identical. (b) Dual-disc. Dual-disc brakes, which are
always multiple piston types, are used on aircraft re-
1 Application. Application of the single- quiring more braking friction at lower pressure than
disc brake occurs when hydraulic fluid under pressure single disc brakes provide. Pressure applied to the pis-
enters the fluid port (7). This pressure forces the pis- tons of this type of brake pushes their attached linings
ton (5) to the left against spring pressure until the spring against the brake disc nearest the pistons. That disc is
guide (6) contacts the flanged side of the adjusting pin then forced against the brake linings on its side of the
(8). In moving this distance, the piston has forced the center carrier assembly. This forces the center carrier
outboard brake lining (4) against the steel disc (3), which assembly and its second set of brake linings against
in turn moves sideways on its keys and contacts the the second disc. The second disc is then forced against
the brake linings in the anvil. In this manner, each
brake disc receives equal braking action on both sides
when the brake is operated. When brake pressure is
released, the return springs within the self-adjusting
mechanism in each cavity retract the pistons.

(2) Parking brake valves. Parking brake valves

are used on some aircraft wheel brake systems as a
means of trapping fluid pressure in the wheel brake as-
semblies to keep the brakes applied for parking. Individ-
ual and dual type valves are commonly used. Because
the dual type is basically a combination of two individual
valves, this explanation of the dual valve will illustrate
the operation of both types.

(a) Operation. The typical dual parking brake

valve shown in figure 4-156 incorporates two spring-
loaded pistons in compensator cylinders, which provide
Figure 4-154. Disc Brake Assembly an automatic means of compensating for changes in hy-
draulic oil volume caused by temperature
inboard brake lining (2) supported by the backing plate
(1). The brake running clearance is thus taken up by

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TM 1-1500-204-23-2

1. BACKING PLATE
2. INBOARD BRAKE LINING
3. DISC
4. OUTBOARD BRAKE LINING
5. PISTON
6. SPRING GUIDE
7. FLUID PORT
8. ADJUSTING PIN
9. ADJUSTING PIN GRIP

Figure 4-155. Disc Brake Assembly Cross Section

changes or minor leakage. During normal braking of charged, the pistons become partially retracted, and
the aircraft by pedal actuation, the lever of the park- the springs become partially compressed. Spring ten-
ing brake valve is held in the off position by means of sion on the spring-loaded pistons maintains constant
a spring. The camshaft to which the lever is attached braking pressure by compensating for volume changes
holds the two outer poppets of the valve unseated as produced by changes in temperature and by minor
shown here. This permits fluid pressure from the mas- leaks.
ter cylinder or power brake control valve to pass straight (c) Brakes locked. After the parking brake
through the parking brake valve to the wheel brake as- has been set in the park position, the brake pedals are
semblies. In this position, the inner poppets are seated released. The parking brake lever then becomes locked
and the spring-loaded pistons are inoperative. in the park position by means of a locking pin, which
(b) Setting parking brakes. To set the is extended to the locking position by a spring. The
brakes for parking, the parking brake valve is left in locking pin is retracted, permitting release of the lever
the off position until the brake pedals are depressed by fluid pressure, when the brake system is pressurized
(see figure 4-157). While the brake pedals are still by operating the brake pedals.
depressed, the parking brake control handle is pulled c. Helicopter Rotor Brake Systems. Rotor brake
to the park position. This rotates the camshaft of the systems are installed on some helicopters as a means
valve, causing the outer poppets to seat as shown in of shortening the time required to bring their rotor as-
figure 4-158; fluid pressure is now locked within the semblies to rest after power has been shut off. They
wheel brake assemblies. At the same time, the rotating also prevent the rotor assemblies of parked helicopters
camshaft unseats the inner poppets, thereby opening from windmilling. A basic hydraulic rotor brake system
the compensator cylinders to the wheel brake assem- is shown in figure 4-159. Newer helicopters have more
blies. As a result, the compensator cylinders become complex systems, but the same basic principles apply.

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 TM 1-1500-204-23-2

of brake cylinders to move toward each other. This pro-

duces a clamping action on the rotor brake disc which
stops its rotation. The master cylinder handle is auto-
matically locked in the brake on position for parking the
aircraft by means of a spring-loaded latch.

(2) Brake release. To release the brake, the

spring-loaded latch has to be pulled outward to disen-
gage it from the handle. A spring-loaded detent helps
to hold the handle in the released position.

d. Maintenance of Brake Systems. Proper func-

tioning of the aircraft brake system is of utmost impor-
tance. Failure of any component within the system could
result in destruction of equipment and loss of life.

(1) Inspection. Inspections must be conducted

Figure 4-156. Dual Parking Brake Valve
at frequent intervals, and maintenance work which
might be indicated must be performed promptly and
carefully. The system should be under operating pres-
sure when it is being checked for leaks, but loose fittings
must be tightened with the pressure off. All flexible
hoses should be carefully checked for swelling, crack-
ing, and soft spots and should be replaced if evidence
of deterioration is noted. The proper fluid level must be

Figure 4-157. Dual Parking Brake Valve (Off)

(1) Brake application. To apply the rotor brake,

the master cylinder handle is slowly pushed downward
and forward. This results in a movement of the master
cylinder piston that forces fluid out of the master cylin-
der and into the rotor brake cylinders. Movement of the Figure 4-158. Dual Parking Brake Valve (On)
fluid causes the pistons and brake linings of each pair

4-151
TM 1-1500-204-23-2

maintained at all times to prevent brake failure or the bleeder valves on the brake assembly. As shown in fig-
introduction of air into the system. Air in the system is ure 4-161, a bleeder hose is attached to the bleeder
indicated by a spongy action of the brake pedals. If air is valve and the free end of the hose is placed in a con-
present in the system, it must be removed by bleeding. tainer holding enough hydraulic fluid to cover the end of
the hose. The air-laden fluid is then forced from the sys-
(2) Bleeding. There are two general methods of tem by applying the brakes. If the brake system is part
bleeding brake systems: pressure bleeding, and gravity of the main hydraulic system, a portable hydraulic test
bleeding. The method used usually depends on the type stand may be used to supply the pressure. If the sys-
and design of teh brake system, but may be dictated by tem is an independant master cylinder system the mas-
availability of required equipment. Specific instructions ter cylinder will supply the necessary pressure. In either
are found in the aircraft technical manual. case, each time the brake pedal is released, the bleeder
valve must be closed; otherwise air will be drawn back
(a) Pressure bleeding. In the pressure into the system. Bleeding should continue until no more
method, shown in figure 4-160, air is expelled through air bubbles come through the bleeder hose into the con-
the brake system reservoir or a bleeder valve located tainer.
somewhere within the system. Pressure is supplied by
a pressurized hydraulic fluid dispenser. Pressurized (3) Troubleshooting. Table 4-41 lists common
fluid flows completely through the system, unit all air is troubles found in wheel brake systems, and table 4-42
expelled. describes those found in helicopter rotor brake systems
used on Army aircraft.
(b) Gravity bleeding. In the gravity method,
the air is expelled from the system through one of the

Figure 4-159. Rotor Blade Brake System

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 TM 1-1500-204-23-2

1. HYDRAULIC RESERVOIR 4. PRESSURE BLEEDER TANK

2. TUBE ASSEMBLY 5. CONTAINER
3. BLEEDER VALVE 6. FLEXIBLE HOSE

Figure 4-160. Bleeding Brake Hydraulic System

Figure 4-161. Gravity Method for Brake Bleeding

4-153
TM 1-1500-204-23-2

Table 4-41. Troubleshooting Wheel Brake Systems

Trouble Probable Cause Remedy

Brakes do not hold Air in system. Bleed system.
Leaks in system. Check for leaks and tighten all
fittings.
Worn brake linings. Replace brake linings as
necessary.
Oil or grease on brake linings. Replace brake linings as
necessary.
Leak in master cylinder or power Replace master cylinder or power
brake control valve. brake control valve and bleed
system.
Brakes grab Stones or other foreign matter Clean brake disc brake linings.
locking brake disc.
Warped or bent brake disc. Replace brake disc.
Brakes will not release Parking brake stuck. Replace parking valve and bleed
system.
Blockage in master cylinder or Replace master cylinder or power
power brake control valve. brake control valve and bleed
system.
Dragging brakes Warped disc. Replace disc.
Automatic adjusting mechanism Replace adjusting mechanism or
faulty. brake assembly.
Excesssive force required on brake Power-boost master cylinder Replace power boost master
pedals of power-boost brake system inoperative. cylinder and bleed system.
to apply brakes
Excessively worn brake linings. Replace brake linings.
Failure of main or utility hydraulic Check main or utility hydraulic
system pressure. system and correct defect.
Parking brake will not hold Air in system. Bleed brakes.
Defective parking brake valve. Replace parking brake valve and
bleed system.

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Table 4-41. Troubleshooting Wheel Brake Systems — Continued

Trouble Probable Cause Remedy

Pedals bottom, no brakes Broken or leaking brake line. Replace damaged line and bleed
system.
Master cylinder or power brake Replace master cylinder or power
control valve defective brake control valve and bleed
system.
Excessively worn brake linings. Replace brake linings.
Air in system. Bleed brakes.
Solid pedal and no brakes Too little fluid in system Replenish supply and bleed
brakes.
Excessively worn brake linings or Replace brake linings.
grease on brake linings.
Spongy brakes Air in system. Bleed brakes.
Low hydraulic fluid level. Replenish supply.
Unable to hold pressure Leak in brake system. Visually check entire system for
evidence of leaks.
Master cylinder or power brake Replace master cylinder or power
control valve defective. brake control valve and bleed
system.
Uneven braking Worn brake linings. Replace brake linings.
Worn brake disc. Replace brake disc.
Air in system. Bleed system.
Leaking line connection. Tighten connection and bleed
system.
Worn or damaged pressure relief Replace pressure relief valve and
valve. bleed system.
Weak braking Air in system. Bleed system.
Master cylinder or power brake Replace master cylinder or power
control valve defective. brake control valve and bleed
system.
Insufficient supply of hydraulic fluid. Replenish supply.

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TM 1-1500-204-23-2

Table 4-42. Troubleshooting Rotor Brakes Systems

Trouble Probable Cause Remedy

Brake does not hold. Brake cylinders improperly adjusted. Adjust cylinders
Leakage in lines. Repair or replace as necessary.
Defective accumulator. Check air pressure; replace
accumulator if necessary.
Accemulator air pressure escaping Service accumulator and bleed air
into brake lines (brake off over a out of brake lines.
prolonged period).
Internal or external leakage in Replace master cylinder.
master cylinder.
Low oil level in utility reservoir. Service reservoir.
Brake does not release (lining drags Improper internal adjustment of Replace brake cylinder.
on disc). brake cylinder.
Brake disc warped. Replace disc.
Clutch pump operates with rotor brake Defective rotor brake limit switch. Check prime power source and
on. continuity; replace switch if
necessary.
Open circuit breaker. Reset circuit breaker.
Defective clutch control relay. Replace relay.
Spongy brake. Air in lines. Bleed air at master cylinder and/or
brake cylinders.
Brake cylinders improperly adjusted. Adjust brake cylinders.
Master cylinder handle does not lock Defective latch. Replace master cylinder.
in parked position (when not made
inoperative by latch).
Master cylinder handle does not Defective latch. Replace handle.
release.

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4-19. DAMPENING AND ABSORBING 2 Nose landing gear damper. The nose
UNITS. Dampening and absorbing units retard the landing gear of an aircraft has a tendency to shimmy
motion of moving objects to which they are attached. when the aircraft is taxiing at any appreciable speed. A
These units perform this function by removing some of damper is used as shown in figure 4-164 to eliminate
the energy of motion and converting it to heat. The heat wheel shimmy without interfering with the normal steer-
is then dissipated into the atmosphere. Dampening ing movements on the nose wheel.
and absorbing units used in Army aircraft are hydraulic
dampers, shock struts, and liquid springs. 3 Rotor blade damper. Piston-type
dampers are used on helicopter rotor head assemblies
a. Hydraulic Dampers. A damper is a device for and on tail rotor hub assemblies to control lead-lag
controlling the speed of relative movement between movements of rotor blades. Note in figure 4-165 how
two connected objects. Usually, one end of the damper the dampers are connected. Lead-lag movements of
is connected to a fixed member; the other end, to a rotor blades occur in cases in which there are three or
movable part. The reacting parts of the damper move more blades in a set and the blades are hinged to the
against considerable resistance. This resistance slows rotor head.
the speed of relative movement between the objects.
Hydraulic dampers used in Army aircraft operate either (b) Vane damper. A typical vane-type
by displacing fluid or by shearing fluid. damper is shown in figure 4-166. This type of damper
consists basically of a cylindrical housing having a pol-
(1) Displacement-principle dampers. Dis- ished bore with two stationary vanes (called abutments)
placement-principle dampers used in Army aircraft are and having a shaft supporting two movable vanes. To-
of two types—piston and vane. Though different in gether the four vanes split the cylinder bore lengthwise
construction, both types have the same basic design into four chambers as shown in figure 4-167. The two
characteristics—a sturdy metal container with a size- stationary vanes are attached to the damper housing.
able inner space divided into two or more chambers. The two movable vanes, along with the shaft, make
The chambers vary in size according to the position up a unit called a wing shaft. The wing shaft rotates
of parts within the damper. The chambers must be between the abutments. One end of the wing shaft is
completely filled with fluid in order to operate properly. splined and protrudes through the damper housing. A
lever arm, attached to the splined end, is the means of
(a) Piston damper. A typical piston damper rotating the wing shaft.
is shown in figure 4-162. Note in figure 4-163 that the
piston and rod assembly divides the space within the 1 Operation. The damper chambers are
damper housing into two chambers. Seal rings on the completely filled with fluid , and at any instant of damper
piston prevent fluid leakage between the chambers. An motion the fluid is subjected to forced flow. As the wing
orifice permits fluid to pass with restricted flow from one shaft rotates, fluid flow between the chambers takes
chamber to the other. A filler port (not shown) provides place through an opening within the wing shaft, which in-
for servicing the damper with fluid. terconnects the four chambers. Thus a restraining force
is developed in the damper, dependent on the velocity
1 Operation. As the piston is forced to of fluid flow through the orifice. Slow relative movement
the right, chamber 2 decreases in proportion to the dis- between the wing shaft and the damper housing causes
tance the piston is moved. Simultaneously, chamber 1 a low velocity flow through the opening and little resis-
increases by a comparable size. The hydraulic fluid dis- tance to damper arm rotation. More rapid motion of the
placed from chamber 2 flows through the restricting ori- wing shaft increases the speed of fluid flow and thus in-
fice into chamber 1. When the piston is moved toward creases resistance to damper arm rotation. The timing
the left, reverse changes occur in the chamber sizes and rate of vane-type dampers can be adjusted by a tim-
in the direction of fluid flow. The restriction of the fluid ing adjustment centrally located in the exposed end of
flow by the orifice shows the rate of speed at which a the wing shaft. This adjustment (not shown) sets the
given amount of force can move the damper piston. The effective size of the opening through which fluid flows
rate at which a damper moves in response to a force is between chambers and thus determines the speed of
called damping rate or timing rate. In some dampers, movement with which the damper will respond to an ap-
the opening is of fixed size and timing rate is not ad- plied force.
justable. In other dampers, the orifice size is adjustable
to allow for timing adjustments.

4-157
TM 1-1500-204-23-2

Figure 4-162. Piston Damper

Figure 4-163. Piston Damper Cross Section Figure 4-164. Nose Landing Gear with Piston
Damper
2 Nose landing gear damper. Vane-type
dampers, such as the one shown in figure 4-168, are Theory of operation. In a shear-principle
used on the nose landing gear of some aircraft to elimi- damper, two reacting parts are free to slide or rotate
nate the shimmy tendency. past each other as the damper operates. The surfaces
facing each other are relatively smooth, and between
3 Stabilizer bar damper. Some heli- them there is a preset gap of a few thousandths of an
copters have vane-type dampers, such as the one inch. This gap is filled with a highly viscous fluid. As
shown in figure 4-169, that serve to control the de- the parts of the damper move relative to each other,
gree of sensitivity with which a helicopter responds the film of fluid in the gap between them shears into
to movement made by the pilot on the flight controls. two thinner films. Each film adheres to and moves
These dampers are mounted on a bracket attached along with one of the parts. It is the friction within the
to the helicopter mast (main shaft). The damper arms fluid itself that causes resistance to movement of the
are interconnected with other parts of the flight control parts to which the films adhere. To better understand
system. this principle, imagine a puddle if syrup spilled on a
relatively smooth table top. A sheet of paper placed on
(2) Shear-principle dampers. In dampers op- top of the puddle would move with considerable drag.
erating on the shear principle, fluid is not forced out of This is very much like what happens between the parts
one space and into another within the damper as in the of a shear-principle damper as the damper operates.
case of displacement dampers. Instead, action on the
fluid involves tearing (shearing) a thick film of highly vis-
cous fluid into two thinner films that move with resistance
in opposite directions. A highly viscous fluid is thick bod-
ied, syrupy, and sticky.

4-158
 TM 1-1500-204-23-2

Figure 4-167. Vane Damper Cross Section

Figure 4-165. Main Rotor Assembly with Piston

Dampers

Figure 4-166. Vane Damper

b. Shock Struts. A shock strut can be thought of

as a combination suspension unit and shock absorber.
The shock strut performs functions in an aircraft sim-
ilar to those performed in an automobile by the chas- Figure 4-168. Nose Landing Gear with Vane
sis spring and the shock absorber. There are two ma- Damper
jor types of shock struts, the classification depending
on construction and operation. In the mechanical type, (1) Simple shock strut. The basic parts of a
a rubber or spring mechanism performs the cushioning simple shock strut are two telescoping tubes: a piston
operation. In the pneudraulic type, air and hydraulic fluid and a cylinder. A simple shock strut is installed in an air-
accomplish this. craft as shown in figure 4-170 with the piston uppermost
and with the cylinder filled with fluid. An orifice in the
piston head permits fluid to pass from one chamber to
the other. When a shock strut has sufficient fluid above
the piston head, the space above the fluid is filled with
air. When the aircraft is landing and the shock strut

4-159
TM 1-1500-204-23-2

the unanchored end of the metering pin is located in

the orifice when the shock strut is fully extended. The
large diameter of the pin at this end provides a high re-
sistance to fluid flow, a condition that is required during
landing. The small diameter portion of the metering pin
is located within the orifice when the shock strut is in its
taxi position (partially compressed). This provides the
low resistance to fluid flow that is required for taxiing.
The portion of the metering pin nearest is anchored end
lies within the orifice when the shock strut is completely
compressed. The large diameter of the metering pin at
this end provides increased resistance to fluid flow. The
design of the pin at this end ensures against bottoming
of the shock strut during unusually hard landings. The
gradual increase in the diameter of the pin toward the
anchored end prevents a sudden change in resistance
to fluid flow.

(b) Plunger. Some complex shock struts are

mounted on the aircraft with their cylinders uppermost
as shown in figure 4-172. In such a unit, a plunger an-
chored in the cylinder extends downward into the pis-
ton. The plunger forces fluid out of the piston and into
Figure 4-169. Stabilizer Bar with Vane Dampers the cylinder during compression of the shock strut. The
plunger is hollow, and fluid enters and leaves its interior
is compressing, fluid is forced through the orifice into through an orifice and through holes in its walls.
the piston. The movement of fluid through the orifice,
together with the compression of the air, absorbs the (c) Floating piston. In some shock struts,
energy of motion of the descending aircraft. When the the air charge is carried at the bottom of the shock
load on the shock strut is lightened, the shock strut ex- strut instead of at the top. Since air normally rises to
tends. This extension is caused by the force exerted by the top of a liquid, some means must be provided to
the compressed air in the shock strut and, during takeoff, keep the air below the liquid. A floating piston serves
by the weight of the lower tube and the attached land- this purpose. In the floating-piston type shock strut,
ing gear. When the shock strut is extending, fluid in the the upper chamber of the strut decreases in size as
piston passes through the orifice from the piston into the the strut compresses as shown in figure 4-173. This
cylinder. is because compression of the shock strut forces fluid
downward out of the upper chamber into the lower
(2) Complex shock strut. Complex shock fluid chamber. The increase in size of the lower fluid
struts work in essentially the same manner as simple chamber, necessary for accommodating the inflow of
ones. However, they contain, in addition to two tele- fluid, is obtained by downward movement of the floating
scoping tubes, a number of parts that make for more piston. Thus, in addition to holding the air below the
effective damping action than is possible with simple fluid, the floating piston contributes to the movement of
struts. Design features found singly or in combination fluid through the orifice as the shock strut compresses
in complex shock struts are metering pins, plungers, and extends.
and floating pistons.
(3) Uses of shock struts. Shock struts support
(a) Metering pin. The metering pin is a the static load of the aircraft, cushion jolts during taxiing
means of changing the effective size of the orifice so or towing, and absorb the shock of landing.
as to vary the rate of fluid flow from one chamber of the
shock strut to the other. The diameter of the metering (a) Supporting static loads. The normal
pin varies along its length, being almost equal at the load of a parked aircraft is static; that is, the force
ends and smaller in the middle. Note in figure 4-171 present is fixed. The pressure of the air and fluid
that within a shock strut tends to keep the shock strut fully
extended. However, air pressure in a shock strut is not
enough to keep the strut fully extended while supporting
the static load

4-160
 TM 1-1500-204-23-2

Figure 4-170. Simple Shock Strut

of an aircraft. Therefore, a shock strut gives under load aircraft must be stopped. To perform this task, the shock
and compresses until the air pressure builds enough to strut must remove a great amount of energy from the
support the aircraft. downward movement of the aircraft. The impact force
is very great compared to the force exerted by the mere
(b) Cushioning during taxiing. As an air- weight of the aircraft. The shock strut removes some of
craft taxies, the unevenness of the runway surface the energy of motion—and thus some impact force—by
causes the aircraft to bob up and down as it moves converting energy into heat and dissipating the heat into
forward (sometimes air currents contribute to this ef- the atmosphere. The resistance to fluid flow offered by
fect). The inertia of the aircraft fuselage in opposition the orifice is the principal means of developing the heat.
to such up-and-down movements causes the force of Also, the temperature of the air inside the strut rises as
the taxi load to fluctuate. This bouncing motion is held the air is compressed.
within limits by the damperlike action of the shock strut.
1 Strut extension. The speed of a de-
This dampening results from resistance created by the scending aircraft while landing causes over-compres-
back-and-forth flow of fluid through the orifice as the sion of the air in the shock strut. As a result, the air
shock strut extends and compresses. pressure is greater than that needed to support the
static load of the aircraft. The excess pressure tends to
(c) Reducing shock during landing. The extend the shock strut and to bounce the aircraft back
aircraft will continue to descend at a high rate when into the air. For reasons of comfort and control of the
landing, even after the wheels touch the ground. In aircraft, this rebound has to be held to the lowest level
the few remaining inches that the fuselage can move possible. The most common means of counteracting
toward the ground after the wheels touch, the descent rebound involves
of the

4-161
TM 1-1500-204-23-2

Figure 4-172. Complex Shock Strut (Plunger)

2 Strut retraction. Compression of the

shock strut forces fluid from the annular space back
into the piston. Transfer of fluid into or out of the
Figure 4-171. Complex Shock Strut (Metering Pin) annular space takes place through transfer passages
in the wall of the piston. The fluid moves with some
resistance, the resistance varying with the size of the
the use of a shock strut annular space. The annular transfer passages. In simple shock struts, the transfer
space is a chamber that surrounds the polished pis- passages are merely holes. In many complex shock
ton surface that lies within the cylinder. The annular struts, the passages are provided with a snubber valve
space has no definite volume. The volume depends on or a rebound control valve. Such a valve allows fluid to
the amount the shock strut is extended or compressed. flow more
The annular space is at minimum size when the shock
strut is completely extended and at maximum size when
the strut is completely compressed. As the shock strut
extends, fluid passes from the piston into the annular
space.

4-162
 TM 1-1500-204-23-2

cleaned frequently with a clean, lint-free cloth moistened

with hydraulic fluid. Specific instructions for servicing
with hydraulic fluid and air pressure are stamped on the
nameplate of the shock strut and are given in the appli-
cable aircraft manual. With a few exceptions, a single
port in the shock strut serves as a filler hole for both hy-
draulic fluid and air. An air valve assembly screws into
the port.

(5) Shock strut high-pressure air valve

cores. The following paragraphs provide general in-
formation relative to high-pressure air valve cores
(AN809-1) used in hydraulic systems and shock struts.

(a) Identification. High-pressure air valve

cores may be recognized by the symbol H stamped on
the core head.
NOTE
Some early valve cores incorporated lead plug
seats which are now unsatisfactory. Use only
valve cores incorporating synthetic rubber plug
seats.

1 Types. There are two types of valve

cores that are approved for all weather high-pressure
usage. Sample cores are shown in figure 4-174.
Figure 4-173. Floating Piston Shock Strut
2 Use. Air valve cores used in hydraulic
systems or shock struts shall be high-pressure type.
freely into the annular space during shock strut com- Low-pressure cores such as used in tires and tubes will
pression than it flows out during extension. not be used in hydraulic installations.

(b) Installation. Procedures for installing

high-pressure air valve cores are described in the fol-
Always be sure to release the air pressure be- lowing paragraphs.
fore attempting to remove the air valve core of
the air valve assembly. Rock the aircraft and NOTE
depress the valve core several times with a suit- Use a drop of hydraulic fluid, MIL-H-5606 , on
able metal tool to ensure that all pressure is re- plug seat before installation of valve core in hy-
leased. Air pressure could blow out the air valve draulic installations.
assembly or the valve core when they are loos-
ened, resulting in damage to equipment or injury 1 Core installation. Valve cores are in-
to personnel. stalled with valve repair tool, MIL-T-4873, shown in fig-
(4) Servicing shock struts. Shock struts ure 4-174. This tool is also used when it becomes nec-
should be frequently checked for leakage, proper air essary to remove core, smooth down a damaged cap
pressure, security of attachment, and cleanliness. The seat, rethread damaged inside thread of valve stem, or
exposed portion of the shock strut piston should be rethread damaged cap threads.

4-163
TM 1-1500-204-23-2

Figure 4-174. High-Pressure Air Valve Cores

4-164
 TM 1-1500-204-23-2

proper type are not available or when aircraft involved is

needed for tactical or other urgent use.

4 Core cap. Install a low temperature

valve core cap, part No. MS20813. These caps are
painted yellow for identification as low temperature
caps.

c. Liquid Springs. The liquid spring contains hy-

draulic fluid under pressure. The cushioning effect of
the spring is produced by effecting a slight compression
in the fluid. Note in figure 4-175 that the piston rod fits
into the inner space of the cylinder and that a gland seal
is provided to prevent fluid leakage as the piston rod
moves into and out of the housing. The housing is at-
tached to a stationary part of the aircraft, and the piston
rod is connected to a movable part of the landing gear.
A typical installation of a liquid spring on a tail landing
gear of an Army aircraft is shown in figure 4-176.

(1) Uses. The liquid spring performs the same

functions as the shock struts just discussed, but there
are differences in operation. The manner in which the
liquid spring performs these functions is described in the
following paragraphs.

(a) Supporting static loads. The weight of

the parked aircraft tends to move the housing of the liq-
uid spring downward over the piston rod. The inward
movement of the piston rod decreases the space oc-
cupied by the fluid. This compresses the fluid, thus in-
creasing its pressure. The movement continues until
Figure 4-175. Liquid Spring fluid pressure puts a force on the shaft equal to the force
tending to move the shaft inward. When this point is
2 Core removal. Valve cores shall not be reached, no further inward movement of the shaft takes
removed from valve body unless it will be replaced with place and the aircraft is held in a stationary position.
a new core, nor will it be removed or loosened from hy-
draulic accumulators or shock struts to exhaust pressure
and then be reinstalled (figure 4-174).

NOTE

In case a core is reinstalled, it shall be seated

tightly and examined for leaks.

3 Core installation. Valve cores shall not

be reinstalled when removed from hydraulic pressure
accumulators or shock struts, except when cores of

Figure 4-176. Tailwheel Liquid Spring

4-165
TM 1-1500-204-23-2

(b) Cushioning during taxiing. The liquid a. Safety. Prior to use of a test stand, it is essen-
spring controls the bouncing motion of the aircraft in tial that the personnel responsible for its operation are
much the same way as the shock strut does. As the completely familiar with procedures and operation of the
piston in the liquid spring moves inward and outward in equipment.
relation to its housing, there is a back-and-forth move-
ment of fluid through an orifice in the piston. This fluid
flow restrains the rate at which the piston moves, thus
dampening the up-and-down movements of the aircraft
fuselage. •Always wear ear protection when noise pro-
duced by test stand engines exceeds estab-
(c) Reducing shock during landing. In the lished limits. Failure to comply will result in se-
liquid spring, the resistance to fluid flow necessary to rious injury to personnel.
convert motion energy to heat energy is effected by
means of a check valve in the piston. As the liquid •Do not connect or disconnect any hoses with
spring compresses, fluid flows through the check valve the fluid bypass valve closed and the test stand
in addition to flowing through the orifice. During ex- in operation. High pressure contained in the
tension, the check valve closes and fluid then passes hose may injure personnel.
through the orifice only. The additional restraint that
is set up to the movement of fluid from one side of b. Procedures. General operating procedures are
the piston to the other provides rebound control during as follows:
landing.
(1) Set the parking brake to secure the test
(2) Servicing. The liquid spring can be serviced stand in position.
as follows:
(2) Perform the operator inspection of the test
(a) The exposed portion of the liquid spring stand.
shaft should be cleaned by using a clean, lint-free cloth
moistened with hydraulic fluid. (3) Connect the test stand coupling halves to
(b) When the liquid spring is serviced to the the corresponding outlets on the aircraft. Keep unused
correct level with the proper type of hydraulic fluid , the couplings capped at all times.
fluid is under pressure. A special gun, which looks like
a hand grease gun, is used to force the fluid inside the (4) Open the fluid bypass valve.
spring.
NOTE (5) Start the engine in accordance with applica-
ble operating procedures.
Specific servicing instructions are stamped on
the nameplate of the spring and are also in- (6) Adjust the pump delivery for requirements of
cluded in the manual for the aircraft. the aircraft under test.
4-20. USE OF TEST STANDS. The purpose of the
aircraft hydraulic test stand is to perform the following
test operations on aircraft hydraulic systems: flush or
fill the system with micronically filtered hydraulic fluid,
•Do not connect or disconnect any hoses with
provide a source of hydraulic pressure for testing air-
the fluid bypass valve closed and the test stand
craft hydraulic systems without the necessity of operat-
in operation. High pressure contained in the
ing the aircraft engine, and test all components of the
hose may injure personnel.
aircraft hydraulic systems, including aircraft with pres-
surized reservoir systems. The appropriate aircraft and
equipment technical manuals must be consulted prior to (7) Slowly close the fluid bypass valve.
use of any test stand. This manual contains only gen-
eral guidelines for their use.

4-166
 TM 1-1500-204-23-2

(8) Adjust the pressure relief valve to relieve and tests show that MIL-H-83282 extinguishes itself
pressure at approximately 200 psi above the system when the external source of flame or heat is removed.
pressure of the system under test. MIL-H-83282 is compatible with all materials used in
systems presently employing hydraulic fluid MIL-H-5606
(9) Open the flow control valves and proceed and may be combined with the latter fluid with no ad-
with the test in accordance with the applicable aircraft verse effect except a degradation of its fire resistant
technical manual. properties. However, the presence of MIL-H-5606 in
amounts exceeding 3 percent by volume will compro-
(10) Following the test procedure, open the by- mise the fire resistant performance of MIL-H-83282.
pass valve. Although MIL-H-83282 exceeds the performance of
MIL-H-5606 at normal temperatures, the viscosity of
(11) Close the flow control valves. MIL-H-83282 increases at low temperatures; therefore,
use of MIL-H-83282 must be within the limitations set
(12) Allow the engine to cool as required by the forth in paragraph 4-21f.
specific operating procedures.
c. Applications of MIL-H-83282. The fire haz-
(13) Shut down test stand in accordance with ards of MIL-H-5606 are greatest in flight control systems
applicable operating procedures. which are under high pressure and which have a rel-
atively large volume of fluid. The aircraft hydraulic
(14) Disconnect couplings from aircraft and cap systems and components shown in table 4-43 will be
immediately to prevent contamination. converted from MIL-H-5606 to MIL-H-83282.

(15) Release parking brake and tow test stand d. Non-Applicability of MIL-H-83282 . The com-
from work area. ponents shown in table 4-44 will retain MIL-H-5606 hy-
draulic fluid. These components cannot be readily ser-
viced by field personnel or have not been tested for
4-21. CONVERSION OF AIRCRAFT TO FIRE-RE-
MIL-H-83282. In the event that the temperature limi-
SISTANT HYDRAULIC FLUID. Following are gen-
tations in paragraph b above are exceeded, field per-
eral guidelines for conversion of Army aircraft from
sonnel will be unable to change these components from
MIL-H-5606 to MIL-H-83282 hydraulic fluid .
MIL-H-83282 back to MIL-H-5606 .
a. Hydraulic Fluid MIL-H-5606. MIL-H-5606 is a
e. Conversion Procedures. Procedures will be
petroleum base hydraulic fluid and is presently speci-
performed at Direct Support or higher levels of main-
fied for use in some Army rotary wing and fixed wing
tenance unless otherwise directed by reference to a
aircraft. Because of its relatively low flashpoint of 200°F
specific maintenance manual. Refer to the applicable
(93°C), it has been considered a safety hazard. In an
aircraft Technical Manual or to 55-1500-334-25 for
effort to remove the vulnerability of aircraft systems and
specific conversion procedures.
related support equipment to accidental or combat-in-
curred fires, hydraulic fluid MIL-H-83282 has been de-
veloped as a directly interchangeable fluid which is sig- f. Operating Temperature Limitations. Although
nificantly less susceptible to fire, with a flashpoint of MIL-H-83282 operates well under normal temperatures,
400°F (204°C). the viscosity of the fluid increases as the temperature
decreases. Therefore, the minimum ambient operat-
ing temperatures shown in table 4-45 have been estab-
b. Hydraulic Fluid MIL-H-83282. MIL-H-83282
lished for the use of MIL-H-83282. These temperatures
consists of a synthetic hydrocarbon base and contains
are based on a clold soak of the hydraulic fluid at low
additives which provide superior anti-wear characteris-
temperatures. Aircraft that are sheltered or pre-heated
tics and inhibit oxidation and corrosion. MIL-H-83282
prior to engine start should not have any problems with
has an operational high temperature limit of 400°F
stiff or sluggish flight controls. Unless the sheltered ar-
(204°C) as compared to 275°F degrees (135°C) for
eas are at or below the temperatures in table 4-45, the
MIL-H-5606. These factors should provide significantly
viscosity of MIL-H-83282 will not create any difficulty.
improved reliability. Flashpoint, fire point, and spon-
Once the aircraft is started and warm, the hydraulic fluid
taneous ignition temperatures of MIL-H-83282 exceed
should stabilize within normal operating limits.
that of MIL-H-5606 by greater than 200°F (93°C),

4-167
TM 1-1500-204-23-2

Table 4-43. Applications of MIL-H-83282

Aircraft Application
OH-58A Flight Control System
UH-1/H Flight Control System
Armament System M6
Additional Armament Systems for UH-1B, M16 and
M21
UH-1/M Hydraulic Systems 1 and 2
Armament Systems M6, 16, 21
AH-1 Series Hydraulic Systems 1 and 2
Armament Turret System
CH-47 C/D Flight Control Systems 1 and 2
Utility Hydraulic System
OV-1 Main Hydraulic System
UH-60A Hydraulic Systems 1, 2, and 3
Servicing Equipment
MK-1 D6, MSU-1 AGPU Hydraulic dispensers and test stands will be
converted to MIL-H-83282 to provide ground support
to converted aircraft.

4-168
 TM 1-1500-204-23-2

Table 4-44. Non-Applicability of MIL-H-83282

Aircraft Component
UH-1/H/M Stabilizer Bar Dampers
AH-1 Series Pylon Dampers
CH-47 C/D Lag Dampers
Landing Gear Shock Struts
OV-1 Propellor Control System and Landing
Gear
Pneudraulic Struts

OH-6 Landing Gear Struts

UH-60A
AH-64A Landing Gear Shock Struts Brake System

Table 4-45. Operating Temperature Limitations of MIL-H-83282

Aircraft Minimum temperature

UH-1 -30°F (-35°C)
OH-58 -25°F (-32°C)
CH-47 -50°F (-46°C)
OV-1 -40°F (-40°C)
AH-1 -50°F (-46°C)
AH-64 -25°F (-32°C)
UH-60A -40°F (-40°C)
Servicing Equipment
D5A, D5B, D6 -20°F (-29°C)
MSU-1 -25°F (-29°C)

Change 2 4-169/(4-170 blank)

 TM 1-1500-204-23-2
APPENDIX A
REFERENCES

AR 385-10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . The Army Safety Program

AR 385-30 . . . . . . . . . . . . . . . . . . . . . . . . . . . . Safety Color Code Markings and Signs
AR 385-32 . . . . . . . . . . . . . . . . . . . . . . . . . . . . Protective Clothing and Equipment
FM1-509 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fundamentals of Aircraft Pneudraulics
FM 10-69 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Petroleum Supply Point Equipment and Operations
H4/H8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Commercial and Government Entity (CAGE)-Name to CAGE
NAVPERS 16193 . . . . . . . . . . . . . . . . . . . . . . Basic Hydraulics
55-1500-334-25 . . . . . . . . . . . . . . . . . . . . . . . Conversion of Aircraft to Fire-Resistant Hydraulic Fluid
TM55-1510 Series . . . . . . . . . . . . . . . . . . . . . Operator’s, direct support, general support and depot maintenance man-
uals (fixed wing)
TM55-1520 Series . . . . . . . . . . . . . . . . . . . . . Operator’s, direct support, general support and depot maintenance man-
uals (rotary wing)
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Industrial Hydraulics Manual, Vickers Inc, Troy, Michigan

A-1/(A-2 blank)
 TM 1-1500-204-23-2
GLOSSARY
AC (AIR CORPS) Flared tube fittings. Now obsolete.

AN (ARMY-NAVY) Flared tube fittings.

AXIAL Pertaining to an axis; commonly refers to flow of fluid or air through a component
parallel to that component’s lengthwise axis.

BOURDON TUBE Tube in an instrument that tends to straighten when fluid or air pressure acts upon
it, thereby acting on an indicating needle.

BUNAN Synthetic rubber compound with excellent resistance to petroleum products; used
as material for flexible hose.

CHAMFER A beveled edge.

COLD FLOW Deep, permanent impressions in flexible hose produced by pressure from hose
clamps or supports.

FIRE POINT Temperature at which fluid gives off vapor in sufficient quantity to ignite and continue
to burn when exposed to a spark or flame.

FLASH POINT Temperature at which fluid gives off vapor in sufficient quantity to ignite momentarily
or flash when exposed to a spark of flame.

GASKET Hydraulic seal used in applications where there is no relative motion.

MICRON .0000394 inch or 1/1000th millimeter.

MONEL High-strength nickel steel used for rivets and other materials used in high-heat ap-
plications.

MS (MILITARY STANDARD) Designation of certain materials used in aircraft maintenance.

PACKING Hydraulic seal used in areas of relative motion.

PERMASWAGE Repair technique for permanent installation of fittings squeezed onto hydraulic tub-
ing under very high pressure.

PHENOLIC Cotton fabric filled with a phenolic resin to form a hard material suitable for fairleads,
supports, etc.

SAE (SOCIETY OF Standards for thread sizes, metal identification numbers, etc.
AUTOMOTIVE ENGINEERS)

Glossary-1
TM 1-1500-204-23-2

SOLENOID Switch using an electromagnetic field to hold it is one position.

SWAGING Process of installing a fitting on tubing by squeezing it under very high pressure.

TETRAFLUOROETHYLENE Compound commonly known as Teflon used in flexible hose, backup rings, gaskets,
etc.

VISCOSITY A fluid’s internal resistance to flow.

G-2
 TM 1-1500-204-23-2
INDEX

Paragraph
Figure, Table
Subject Number

Absorbing Units, Dampening and . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-19

Acceptable and Unacceptable Tube Bends . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-5
Accumulator, Cylindrical . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-118
Accumulator, Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1 5b
Accumulator, Spherical . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-119
Accumulators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-15
Accumulator Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-15b
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-15c
Types . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-15a
Actuating Cylinder, Double-Action (Extension) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-134
Actuating Cylinder, Double-Action (Retraction) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-135
Actuating Cylinder, Single-Action . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-133
Actuating Cylinders (Actuators) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-16g
Actuators, Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . T4-42
Adjuster Valve, Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-157
After Swage Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-86
Air Cylinder, Spherical . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-95
Air Cylinders, Hydraulic Reservoirs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-11h
Air Filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-12e
Air Valve Cores, High-Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-174
Aircraft Brake Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-18
Brake Deboosters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-18c
Helicopter Rotor Brake Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-18d
Maintenance of Brake Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-18e
Wheel Brake Assemblies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-18b
Wheel Brake Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-18a
Alignment, Tube and Fitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-14
Alignment, Tubing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-20
Aluminum Protective Dust Plug and Moisture Seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-54
AN Flared Fitting Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . T4-9
Application of Mechanical Advantage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F2-5
Application of Swaged Tubing Repairs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9a
Applications of MIL-H-83282 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-21 c, T4-43
Aromatic And Heat-Resistant Hose, MIL-H-6000 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-35
Aromatic, Flame, and Oil-Resistant Hose, MIL-H-7938 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-36
Aromatic-Resistant Hose, Flame and MIL-H-8794 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-34
Aromatic-Resistant Hose, Nonself-Sealing, MIL-H-5593 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-37
Aromatic-Resistant Hose, Self-Sealing, MIL-H-7061 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-38
Assembly Clearance, Nipple . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-47
Assembly of High-Pressure Tetrafluoroethylene (Teflon)
Hose Assemblies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5j
Assembly of Medium-and Low-Pressure Hose Assemblies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-43
Assembly of Medium-Pressure Tetrafluoroethylene (Teflon)
Hose Assemblies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5i
Assembly Surface, Nipple . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-46

Index-1
TM 1-1500-204-23-2
Assembly, V-Ring Packings in Various Positions of . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-71

Backup Ring Installation, Double . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-76

Backup Ring Installation, Single . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-75
Backup Ring, Teflon, Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-73
Backup Ring, Teflon, Reversing Spiral of . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-74
Backup Ring, Teflon, Stretching . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-72
Backup Rings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8
Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8a
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8b
Backup Rings, Leather, Installation of . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-77
Baffles and Fins . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-11c
Baffles, Fins, and Finger Strainer, Reservoir with . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-91
Ball Size, Inspection, Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . T4-13
Band Identification, Solid Color . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-2
Band Location, Tube Insertion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . T4-37
Basic Swage Tool Assembly Showing Lower Die Block
Assembly and Position of Fitting Locator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-84
Bead Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-13
Beaded Tubing Joints . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2h
Beading Large Tubing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-11
Bend Radii for Conduit and Fluid Lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . T4-1
Bend Radii of Hose for Fuel, Oil, and Coolant Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . T4-32
Bending Machine, Bending Tube with . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-4
Bending Tube with Bending Machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-4
Bending Tubing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2e
Bends, Installation of Flexible Hose . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2c
Bent-Axis Constant-Volume Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-101
Bleeding Brake Hydraulic System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-160
Blocked Flowing Hydraulic Fuse . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-142
Boss Installation, Torque Valves for . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . T4-7
Brake Assembly, Disc . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-151
Brake Assembly, Disc, Cross Section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-152
Brake Bleeding, Gravity Method for . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-161
Brake Hydraulic System, Bleeding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-160
Brake System, Rotor Blade . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-159
Brake Systems, Aircraft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-18
Bulge, Coupling, Low-and Medium-Pressure Hose Assemblies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-44
Bulge, Coupling, MIL-H-7061 Hose Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . T4-30
Bulkhead and Universal Fitting Assembly, Combination . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . T4-27

Index-2
 TM 1-1500-204-23-2
C

Chafing, Installation of Flexible Hose . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6f

Check Valve, Orifice . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-128
Check Valve, Simple . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-127
Check Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-16c
Checking Swaged Joint with D9892 Inspection Gauge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-85
Chipless Cutter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-81
Clamp Sizes, Support (For Use with MIL-H-38360 Hose of Teflon) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . T4-29
Cleaning (of 55-Gallon Drums) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3b
Cleaning Tubing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2b
Clogged Filters in Differential Pressure Indicator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-100
Clogged Fluid Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-98
Closed Center Hydraulic System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-17b
Combination Bulkhead and Universal Fitting Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-27
Complex Shock Strut (Metering Pin) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-171
Complex Shock Strut (Plunger) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-172
Components, MS Fitting and . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-17
Compound Master Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-149
Computation of Force, Area, and Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1b
Computation of Volume, Area, and Length of Stroke . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1c
Computing Force, Pressure, and Area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F2-1
Computing Volume, Length, and Area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F2-2
Conduit and Fluid Lines, Bend Radii for . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . T4-1
Connections, Tubing-to-Tubing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-22
Constant-Volume Pump, Bent-Axis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-101
Constant Volume Pump Foot Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-104
Constant Volume Pump (Piston Installation) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-102
Constant Volume Pump (Piston Operation) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-103
Consumable Materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
Contamination, Fluid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4
Contamination Prevention . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4c
Control Units, Flow . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-16
Control Valve, Power Brake (Brake Applied) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-152
Control Valve, Power Brake (Brake Released) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-153
Control Valve, Solenoid-Actuated (De-energized) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-126
Control Valve, Solenoid-Actuated (Energized) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-125
Control Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-16b
Conversion of Aircraft to Fire-Resistant Hydraulic Fluid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-21
Applications of MIL-H-83282 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-21c
Conversion Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-21e
Hydraulic Fluid MIL-H-5606 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-21a
Hydraulic Fluid MIL-H-83282 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-21b
Non-Applicability of MIL-H-83282 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-21d
Operating Temperature Limitations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-21f
Conversion Procedures (MIL-H-5606 to MIL-H-83282) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-21e
Coupling Bulge, Low-and Medium-Pressure Hose Assemblies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-44
Coupling Bulge, MIL-H-7061 Hose Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . T4-30

Index-3
TM 1-1500-204-23-2
Couplings, Quick-Disconnect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10
Cross Section, Piston Damper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-163
Cross Section, Vane Damper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-168
Cutoff Factor, MIL-H-8788 or MIL-H-8790 (in Inches) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . T4-15
Cutoff Factors, MIL-H-38360 Hose (in Inches) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . T4-27
Cutoff Factors, Teflon Hose (in Inches) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . T4-22
Cutter, Chipless . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-81
Cutting Flexible Hose, Knife for . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-39
Cutting, Marking Tube Prior to . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-46
Cutting, Tube with Tube Cutter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-3
Cutting Tubing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2d

Damaged Fittings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-29

Dampening and Absorbing Units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-19
Hydraulic Damper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-19a
Liquid Springs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-19c, F4-174
Shock Struts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-19b
Damper, Piston . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-162
Damper, Vane . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-166
Data Drawing, Tube Bend . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-6
Detecting Fluid Contamination . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4a
Determining Hose Assembly Length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-40
Determining Tube Thickness and Burst Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . T4-11
Devices for Regulating Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-14
Pressure Gauges . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-14a
Pressure Reducing Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-14d
Pressure Relief Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-14c
Pressure Switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-14b
Differential Pressure Indicator (Clogged Filters) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-99
Differential Pressure Indicator (Normal Flow) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-100
Dimensions, After Swage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-86
Dimensions, Beading . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-13
Dimensions for Double-Flared Tubing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-8
Dimensions for Single-Flared Tubing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-7
Disc Brake’ Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-154
Disc Brake Assembly Cross Section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-155
Distance Between Supports for Fluid Tubing, Maximum . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . T4-12
Double Backup Ring Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-76
Double Lap Flare, Tubing with . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-11
Double-Action Actuating Cylinder (Extension) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-134
Double-Action Actuating Cylinder (Retraction) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-135

Index-4
 TM 1-1500-204-23-2
Double-Action Hand Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-111
Double-Flared Tubing, Dimensions for . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-8
Dual Internal O-Ring Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-64
Dual Parking Brake Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-156
Dual Parking Brake Valve (Off) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-157
Dual Parking Brake Valve (On) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-158
Dust Cap (AN-SAE Friction), Plastic Protective . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-56
Dust Cap, Plastic Protective . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-55
Dust Cap, Steel Protective . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-53
Dust Plug and Moisture Seal, Aluminum Protective . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-54
Dust Plug and Moisture Seal (AN-SAE Threaded) Plastic Protective . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-51
Dust Plug and Moisture Seal, Steel Protective . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-52

Ease of Installation (of Hydraulic Systems) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2c

Ease of Operation (of Hydraulic Systems) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2b
Efficiency (of Hydraulic Systems) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2a
Elliptical Rings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7b, F4-70
External O-Ring Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-69
External O-Ring Removal (Spoon-Type Tools) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-65
External O-Ring Removal (Wedge-Type Tools) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-66

Failure Modes and Recommended (Permaswage) Repair Methods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-79

Field Assembly of High Pressure Teflon Hose, MIL-H-38360 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-50
Field Disassembly of Teflon Hose . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-45
Field Fabrication of High-Pressure Hose Assemblies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-41
Filter Element Bypass Valve, Hydraulic Reservoirs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-11f
Filter Elements, Hydraulic Reservoirs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-11e
Filter Elements, Hydraulic Systems Filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-12c
Filter Elements, Reservoir with . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-94
Filter, Fluid, Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-96
Filters, Hydraulic System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-12
Finger Strainers, Hydraulic Reservoirs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-11d
Fingertight-Plus Turns Methods, Hose Clamp Tightening . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . T4-10
Fingertight-Plus Turns Methods, Hose Clamp Tightening, Beaded Tubing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-3
Fitting Dimensions After Swaging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . T4-39
Fittings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3
Flared Fittings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3g
Flareless Fittings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3a
Oxygen System Tapered Pipe Thread . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3b

Index-5
TM 1-1500-204-23-2
Rosan Fluid Fittings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3f
Straight Pipe Thread . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3c
Universal Fittings AN 832, AN 833, and AN 834, High Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3e
Universal Fittings AN 832, AN 833, and AN 834, Low Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3d
Fittings, Damaged . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-29
Fittings, Tubing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-15
Flame and Aromatic Resistant Hose, MIL-H-8794 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-34
Flame, Aromatic, and Oil-Resistant Hose, MIL-H-7938 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-36
Flared Fitting Identification, AN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . T4-9
Flared Fittings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3g
Flareless Fitting Installation, Bulkhead . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-24, T4-4
Flareless Fittings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3a
Flareless Fittings, MS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-18
Flaring Tubing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2f
Flexible Hose Assemblies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Assembly of High-Pressure Tetrafluoroethylene (Teflon) Hose Assemblies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5j
Assembly of Medium-Pressure Tetrafluoroethylene (Teflon) Hose Assemblies . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5i
Identification of Flexible Hose . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5a
Identification Tags for Field Fabricated Hose Assemblies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5g, F4-42
Instructions for Assembly of High-Pressure (3000 psi)
Hose Assemblies MS28759 and MS28762 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5e
Instructions for Assembly of Medium-Pressure, MS28741, and
Low-Pressure, AN6270, Hose Assemblies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5h
Instructions for Repair of Flexible Rubber Hose . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5d
Proof Testing of Flexible Hose Assemblies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5f
Replacement of Flexible Hose . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5c
Self-Sealing Hose for Aromatic Fuel, MIL-H-7061 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5k
Storage of Hose and Hose Assemblies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5b
Use of Dust Plugs, Dust Caps, and Moisture Seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-51
Flexible Hose, Installation of . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6
Floating Piston Shock Strut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-173
Floating Piston Shuttle Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-132
Flow Control Units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-16
Actuating Cylinders (Actuators) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-16g
Check Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-16c
Control Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-16b
Hydraulic Fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-16k
Hydraulic Servos . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-16i, F4-138
Irreversible Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-16j, F4-139
Maintenance of Hydraulic Flow Control Units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-161
Priority Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-16e
Rachet Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-16h
Selector Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-16a
Sequence Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-16d

Index-6
 TM 1-1500-204-23-2
Shuttle Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-16f
Fluid Contamination . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4
Contamination Prevention . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4c
Detecting Fluid Contamination . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4a
System Flushing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4b
Fluid Dispenser, Hydraulic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F3-6
Fluid Filter Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-96
Fluid Filter (Clogged) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-98
Fluid Filter (Normal Flow) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-97
Fluid-Pressurized Reservoir (Pressurized) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-93
Fluid-Pressurized Reservoir (Unpressurized) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-92
Full Flow in Hydraulic Fuse . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-141
Fuse Assembly, Hydraulic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-140

Gasket Installation, MS Fitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-19

Gauge, Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-114
General Hydraulic Maintenance Practices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
General Shop Rules (Hydraulic Shop) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
Responsibility . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1a
Shop Housekeeping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1b
Shop Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1d
Shop Tools and Materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1c
Gravity Method for Brake Bleeding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-161

Hand Pump Test Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-112

Hand Pumps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-13c
Handling of Hydraulic Fluid in 55-Gallon Drums . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3b
Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3a
Transporting Fluid to Aircraft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3d
Withdrawing Fluid from Drum . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3c
Helicopter Rotor Brake Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-18d
High-Pressure Air Valve Cores . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-174
High-Pressure Hose Assemblies, Field Fabrication of . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-41
High-Pressure Teflon Hose, MIL-H-38360, Field Assembly of . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-50
High-Pressure Tubing, Repairing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-33
Hose Assemblies, Flexible . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5
Hose Assembly Length, Determining . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-42
Hose Clamp, in Installation of Flexible Hose . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6i
Hose Clamp Tightening, Fingertight-Plus Turns Method . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . T4-10
Hose Clamp Tightening, Fingertight-Plus Turns Method, Beaded Tubing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . T4-3
Hose Clamp, Tightening, With Socket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-32

Index-7
TM 1-1500-204-23-2
Hose Connections to Engines, Installation of Flexible Hose . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6h
Hose Cutoff Factor, MIL-H-8788 or MIL-H-8790 Hose (in Inches) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . T4-14
Hose Cutoff Factors, MIL-H-38360 Hose (in Inches) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . T4-27
Hose End Fitting and Coupling Nut Installation Torque in Inch-Pounds . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . T4-34
Hose Installation, Flexible Hose . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5b
Hose Line Installation Aids for All Types of Hoses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-57
Hose Markings, and Installation of Flexible Hose . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6j
Hose, MIL-F-27272, Tetrafluoroethylene (in Inches) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . T4-21
Hose, MIL-H-38360, Tetrafluoroethylene (in Inches) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . T4-27
Hose Restrictions, Installation of Flexible Hose . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6d
Hydraulic Dampers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-19a
Hydraulic Filler and Bleeder Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2a
Hydraulic Fluid (Fire Resistant), Conversion of Aircraft to . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-21
Hydraulic Fluid in Army Aircraft, Types . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
Hydraulic Fluid in 55-Gallon Drums, Handling of . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
Hydraulic Fluid MIL-H-5606 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-21a
Hydraulic Fluid MIL-H-83282 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-21b
Hydraulic Fuse Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-140
Hydraulic Fuse (Blocked Flow) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-142
Hydraulic Fuse (Full Flow) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-141
Hydraulic Hose Testing Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2d
Hydraulic Hose Testing Unit, Typical . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F3-3
Hydraulic Maintenance Practices, General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
Hydraulic Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-113
Hydraulic Motors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-13d
Hydraulic Packings and O-Rings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7
Elliptical Rings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7b, F4-70
O-Rings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7a
V-Ring Packings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7c
Hydraulic Reservoirs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-11
Air Cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-11h
Baffles and Fins . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-11c
Filter Element Bypass Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-11f
Filter Elements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-11e
Finger Strainers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-11d
Maintenance of Reservoirs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-11i
Standpipes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-11g
Theory of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-11b
Types of Hydraulic Reservoirs Used in Hydraulic Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-11a
Hydraulic Servos . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-16i, F4-138
Hydraulic System Filler and Bleeder, Typical . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F3-1
Hydraulic System Filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-12
Air Filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-12e
Filter Elements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-12c
Servicing Filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-12f
Theory of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-12b

Index-8
 TM 1-1500-204-23-2
Two-Stage Fluid Filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-12d
Uses of Filters in Hydraulic Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-12a
Hydraulic System, Open-Center (Valve Closed) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-143
Hydraulic System, Open-Center (Valve Open) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-144
Hydraulic Systems in Army Aircraft, Use of . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
Hydraulic Test Stand, Fixed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2b
Hydraulic Test Stand, Portable, Gasoline Engine-Driven . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2c
Hydraulic Test Stand, Typical Gasoline Engine-Driven . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F3-2

Identification of Backup Rings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8a

Identification of Flexible Hose . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5a
Identification of O-Rings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-63
Identification Tags for Field Fabricated Hose Assemblies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5g, F4-42
Identification Tape, Printed-Symbol . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-1
In-Line Cam-Operated Selector Valve (Actuator Extending) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-123
In-Line Cam-Operated Selector Valve (Actuator Retracting) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-122
Inspection
of Quick Disconnect Coupling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10b
of Swaged Joint . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9g
Inspection Ball Size Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . T4-13
Inspection Checking (of Swaging), Troubleshooting Guide for . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . T4-38
Installation
Hose . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6b
of Backup Rings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8b
of Beaded Tubing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2j
of Flared Tubing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2i
of Flexible Hose . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6
of Quick-Disconnect Couplings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10a
Installation Aids, Hose Line, for all Types of Hose . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-57
Installation of Flexible Hose . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6
Bends . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6c
Chafing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6f
Hose Clamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6i
Hose Connections to Engines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6h
Hose Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6b
Hose Markings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6j
Hose Restrictions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6d
Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6a
MS Flared Swivel Connections Torquing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6k
Support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6e
Temperature Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6g
Installation of Leather Backup Rings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-77
Installation of MS33514 Fitting End . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-25

Index-9
TM 1-1500-204-23-2
Installation Procedures, Teflon Hose, Right and Wrong . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-49
Installation Torque Values MS Flared Swivel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-25
Installation Torque Values MS Flared Swivel Nut Fittings
(Reference AND 100064) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . T4-33
Installed Low-Pressure Hose . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-16
Installing Teflon Backup Ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-73
Instructions
for Assembly of High Pressure (3000 psi) Hose Assemblies
MS28759 and MS28762 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5e
for Assembly of Medium-Pressure, MS28741, and
Low-Pressure, AN6270, Hose Assemblies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5h
for Repair of Flexible Rubber Hose . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5d
Internal O-Ring Installation (Metallic Sleeve) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-68
Internal O-Ring Installation (Paper Cover) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-67
Internal O-Ring Removal (Pull-Type Extractor) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-61
Internal O-Ring Removal (Push-Type Extractor) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-63
Internal O-Ring Removal (Wedge-Type Extractor) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-62
Introduction
Consumable Materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
Purpose . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
Scope . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
Irreversible Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-16j, F4-139

Jamnut (AN924) Used on Fittings, Torque Values for . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . T4-8

Kellogg Stroke Reduction Pump Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-109

Kellogg Stroke Reduction Pump (Reduced Output) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-110
Knife for Cutting Flexible Hose . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-39

Landing Gear System Using Mechanically Actuated Sequence Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-129

Large Tubing, Beading . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-12
Liquid Spring, Tailwheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-176
Liquid Springs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-19c, F4-175
Low-Pressure Hose, Installed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-16
Low-Pressure Tubing, Repair of . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-30
Low-Pressure Tubing Repair, Tubing End Clearance for . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-31
Lubricant Selection, Packing and . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . T4-6

Index-10
 TM 1-1500-204-23-2
Lubrication (during Installation of Flexible Hose) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6a
Lubrication (of Hydraulic Systems) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2e

Main Rotor Assembly with Piston Dampers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-168

Maintenance of Accumulators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-15c
Maintenance of Brake Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-18e
Maintenance of Power Pumps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-13b
Maintenance of Reservoirs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-11i
Maintenance of Shop Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
Hydraulic Filler and Bleeder Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2a
Hydraulic Hose Testing Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2d
Hydraulic Test Stand, Fixed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2b
Hydraulic Test Stand, Portable, Gasoline Engine-Driven . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2c
Master Gauge Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2f
Tube Bending Machine, Hand-Operated . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2e
Marking MS Fittings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-23
Marking, Tube End . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-83
Marking with Permaswage Marking Tool, D9862-S, M, and L . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-82
Master Cylinder, Compound . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-149
Master Cylinder, Power-Boost (Brake Applied) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-150
Master Cylinder, Power-Boost (Brake Released) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-151
Master Cylinder, Simple . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-148
Master Gauge Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2f
Master Gauge Unit, Typical . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F3-5
Maximum Distance Between Supports for Fluid Tubing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . T4-12
Mechanical Advantage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1e, F2-4
Mechanical Advantage, Application of . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F2-5
Medium-and Low-Pressure Hose Assemblies, Assembly of . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-45
Medium-Pressure Teflon Hose Assembly Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-48
MIL-H-83282, Applications of . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-43
MIL-H-83282, Non-Applicability of . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-21d, T4-44
MIL-H-83282, Operating Temperature Limitations of . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . T4-45
Minimum Bend Radii of Hose for Fuel Oil, and Coolant Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . T4-32
Motor, Hydraulic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-113
Motors, Pumps and . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-13
MS Fitting and Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-17
MS Fitting Gasket Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-19
MS Fittings, Marking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-23
MS Flared Swivel Connectors Torquing, and Installation of
Flexible Hose . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6k
MS Flareless Fittings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-18
MS Turns and Torque Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-21
MS21921 Coupling Nut, Torque Values for . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . T4-5
MS33514 Fitting End, Installation of . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-25

Index-11
TM 1-1500-204-23-2
N

Nipple Assembly Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-47

Nipple Assembly Surface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-46
Non-Applicability of MIL-H-83282 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-21 d, T4-44
Nonself-Sealing, Aromatic and Heat-Resistant Hose, MIL-H-6000 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-35
Nonself-Sealing, Aromatic-Resistant Hose, MIL-H-5593 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-37
Normal Flow in Differential Pressure Indicator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-99
Normal Flow in Fluid Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-97
Nose Landing Gear with Piston Damper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-164
Nose Landing Gear with Vane Damper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-168
Nut Installation Torque in Inch-Pounds, Hose End Fitting and Coupling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . T4-34

O-Ring Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-59

O-Ring Installation, External . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-69
O-Ring Installation, Internal (Metallic Sleeve) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-68
O-Ring Installation, Internal (Paper Cover) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-69
O-Ring, Removal of . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-60
O-Ring Removal, Dual Internal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-64
O-Ring Removal, External (Spoon-Type Extractor) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-65
O-Ring Removal, External (Wedge-Type Extractor) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-66
O-Ring Removal, Internal (Pull-Type Extractor) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-61
O-Ring Removal, Internal (Push-Type Extractor) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-63
O-Ring Removal, Internal (Wedge-Type Extractor) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-62
O-Rings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7a
Open-Center Hydraulic System (Value Closed) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-143
Open-Center Hydraulic System (Value Open) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-144
Operating Pressure (psi) for MIL-H-7061, Proof Test and . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . T4-31
Operating, ’Proof, and Burst Test Pressures for AN6270 Hose
Assembly using MIL-H-5593 Low Pressure Hose . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . T4-19
Operating, Proof, and Burst Test Pressures for MIL-H-83796
Medium Pressure Hose Assembly, Lightweight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . T4-17
Operating, Proof, and Burst Test Pressures for MIL-H-83797
Medium Pressure Hose . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . T4-18
Operating, Proof, and Burst Test Pressures for MS28741 Medium
Pressure Hose Assemblies, using Single Wire Braid Hose,
Military Specification MIL-H-8794 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . T4-16
Operating, Proof, and Burst Test Pressures for MS28759 and
MS28762 Hose Assemblies using MIL-H-8788 High Pressure Hose . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . T4-15
Operating Temperature Limitations (of Hydraulic Fluid) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-21f
Operating Temperature Limitations of MIL-H-83282 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . T4-45
Orifice Check Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-128
Oxygen System Tapered Pipe Thread . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3b

Packing and Lubricant Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . T4-6

Index-12
 TM 1-1500-204-23-2
Packings and O-Rings, Hydraulic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7
Parking Brake Valve, Dual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-156
Parking Brake Valve, Dual (Off) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-157
Parking Brake Valve, Dual (On) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-158
Pascal’s Law . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1d, F2-3
Permaswage Fittings, Typical Styles of . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-78
Permaswage Marking Tool, D9862-S, M, and L, Marking with . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-82
Permaswage Repair with D10000 Series Tooling-Tube
Material and Maximum Operating Pressure Limitations (psi) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . T4-35
Petroleum-Base Fluid (Hydraulic) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3b
Pipe Thread, Straight Thread and . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-26
Piston Damper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-162
Piston Damper Cross Section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-163
Piston Damper, Nose Landing Gear with . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-164
Piston Dampers, Main Rotor Assembly with . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-165
Piston-Type Pressure Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-115
Plastic Protective Dust Cap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-55
Plastic Protective Dust Cap (AN-SAE Friction) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-56
Plastic Protective Dust Plug and Moisture Seal (AN-SAE Threaded) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-51
Pneudraulic Systems, Types of . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-17
Closed-Center Hydraulic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-17b
Open-Center Hydraulic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-17a
Pneumatic System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-17c
Pneudraulics Theory and Basic Principles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
Computation of Force, Area, and Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1b
Computation of Volume, Area, and Length of Stroke . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1c
Mechanical Advantage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1 e, F2-4
Pascal’s Law . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1d, F2-3
Qualities of Hydraulic Fluid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1a
Use of Air in Hydraulic Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1f
Pneumatic System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-17c
Power Brake Control Valve (Brake Applied) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-152
Power Brake Control Valve (Brake Released) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-153
Power Pumps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-13a
Power-Boost Master Cylinder (Brake Applied) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-150
Power-Boost Master Cylinder (Brake Released) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-151
Precautions
for Hydraulic Fluid Selection and Contamination . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3d
for Repair of Tubing Assemblies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4a
Pressure Gauge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-114
Pressure Gauges . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-14a
Pressure Reducing Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-14d
Pressure Relief Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-14c
Pressure Switch, Piston-Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-115
Pressure Switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-14b
Pressure-Actuated Sequence Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-130

Index-13
TM 1-1500-204-23-2
Pressure-Reducing Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-117
Pressures, Proof Test, High-Pressure Teflon Hose Assemblies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . T4-30
Pressures, Proof Test, Medium-Pressure Teflon Hose Assemblies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . T4-23
Printed-Symbol Identification Tape . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-1
Priority Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-131
Procedures, for Use of Test Stands . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-20b
Proof Test and Operating Pressure (psi) for MIL-H-7061 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . T4-31
Proof Test Pressures, High-Pressure Teflon Hose Assemblies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . T4-28
Proof Test Pressures, Medium-Pressure Teflon Hose Assemblies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . T4-23
Proof Test Torque Values MS Flared Swivel Nut Fittings
(Reference AND 10064) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . T4-20
Proof Testing of Flexible Hose Assemblies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5f
Properly Burred Tube . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-9
Pump Assembly, Kellogg Stroke Reduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-109
Pump, Constant Volume, Bent-Axis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-101
Pump, Constant Volume, Foot Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-104
Pump, Constant Volume, (Piston Installation) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-102
Pump, Constant Volume, (Piston Operation) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-103
Pump, Hand, Double-Action . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-111
Pump, Hand, Test Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-112
Pump, Kellogg Stroke Reduction (Reduction Output) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-110
Pump, Stratopower Effective Stroke (Full Flow) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-105
Pump, Stratopower Effective Stroke (Zero Flow) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-106
Pump, Vickers Stroke Reduction (Full Flow) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-108
Pump, Vickers Stroke Reduction (Zero Flow) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-107
Pumps and Motors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-13
Hand Pumps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-13c
Hydraulic Motors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-13d
Maintenance of Power Pumps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-13b
Power Pumps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-13a
Purpose (of Manual) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1

Qualities of Hydraulic Fluid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1a

Quick-Disconnect Couplings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10b
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10a

Rachet Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-16h

Rachet Valve (Moving) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-137
Rachet Valve (Static) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-136
Radial Cam-Operated Selector Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-124
Recommended (Permaswage) Repair Methods, Failure Modes and . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-79

Index-14
 TM 1-1500-204-23-2
Regulating Pressure, Devices for . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-14
Relief Valve, System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-116
Repair
of High-Pressure Tubing Assemblies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4c
of Low-Pressure Tubing Assemblies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4b
of Tubing Assemblies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4
Repair of Low-Pressure Tubing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-30
Repair of Tubing Assemblies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4
Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4a
Repair of High-Pressure Tubing Assemblies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4c
Repair of Low-Pressure Tubing Assemblies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4b
Template . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4d
Repairing High-Pressure Tubing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-33
Replacement of Flexible Hose . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5c
Reservoir, Fluid-Pressurized (Pressurized) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-93
Reservoir, Fluid-Pressurized (Unpressurized) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-92
Reservoir with Baffles, Fins and Finger Strainer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-91
Reservoir with Filter Elements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-94
Reservoirs, Hydraulic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-11
Responsibility (for Hydraulic Shop Rules) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1a
Reversing Spiral of Teflon Backup Ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-74
Rings, Backup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8
Rotary-Type, Closed-Center Selector Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-120
Rotor Blade Brake System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-159

Safety (in Use of Test Stands) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-20a

Scope (of Manual) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
Selector Valve A Closed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-145
Selector Valve B Open . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-146
Selector Valve C Open’ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-147
Selector Valve, In-Line Cam-Operated (Actuator Extending) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-123
Selector Valve, In-Line Cam-Operated (Actuator Retracting) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-122
Selector Valve, Radial Cam-Operated . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-124
Selector Valve, Rotary-Type, Closed-Center . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-120
Selector Valve, Spool-Type, Open-Center (Closed) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-121
Selector Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-16a
Self-Sealing, Aromatic-Resisting, Hose MIL-H-7061 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-38
Self-Sealing, Hose for Aromatic Fuel, MIL-H-7061 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5k
Separable Fittings, Utilizing 0.150 Tube End Gap Tolerance on . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-89
Sequence Valve, Landing Gear System Using Mechanically Actuated . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-129

Index-15
TM 1-1500-204-23-2
Sequence Valve, Pressure-Actuated . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-130
Sequence Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-16d
Servicing Filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-12f
Shaped Fittings, Utilizing 0300 Inch Tube End Gap Tolerance on . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-92
Shock Strut, Complex (Metering Pin) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-171
Shock Strut, Complex (Plunger) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-172
Shock Strut, Floating Pin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-173
Shock Strut, Simple . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-170
Shock Struts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-19b
Shop Equipment, Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
Shop Housekeeping (Hydraulic Shop) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1b
Shop Rules, General (Hydraulic Shop) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
Shop Safety (Hydraulic Shop) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1c
Shop Tools and Materials (Hydraulic Shop) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1d
Shuttle Valve, Floating-Piston . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-132
Shuttle Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-16f
Simple Check Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-127
Simple Master Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-148
Simple Shock Strut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-170
Single Backup Ring Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-75
Single Flared Tubing, Dimensions for . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-7
Single-Action Actuating Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-133
Size (of Hydraulic Systems) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2d
Solenoid-Actuated Control Valve (De-energized) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-126
Solenoid-Actuated Control Valve (Energized) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-125
Solid Color Band Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-2
Spherical Accumulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-119
Spherical Air Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-95
Spool-Type, Open-Center, Selector Valve (Closed) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-121
Stabilizer Bar with Vane Dampers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-169
Standard Union Fittings, Tube Insertion Limits when Using . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-90
Standard Union Fittings, Utilizing 0300 Inch Tube End Gap Tolerance with . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-87
Standpipes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-11g
Steel Protective Dust Cap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-53
Steel Protective Dust Plug and Moisture Seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-52
Storage of Hose and Hose Assemblies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5b
Storage (55-Gallon Drums) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3a
Straight Pipe Thread . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3c
Straight Thread and Pipe Thread . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-26
Stratopower Effective Stroke Pump (Full Flow) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-105
Stratopower Effective Stroke Pump (Zero Flow) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-106
Stretching Teflon Backup Ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-72
Support Clamp Sizes (for Use with MIL-H-27267 Hose of Teflon) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . T4-24
Support Clamp Sizes (for Use with MIL-H-38360 Hose of Teflon) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . T4-29

Index-16
 TM 1-1500-204-23-2
Support, of Flexible Hose . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6e
Swage Tool Assembly Showing Lower Die Block Assembly and
Position of Fitting Locator, Basic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-84
Swaged Joint, Checking, with D9892 Inspection Gauge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-85
Swaged Tubing Repairs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9
Application . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9a
Inspection of Swaged Joint . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9g
Swaging Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9f
Technique . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9b
Tube Cutting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9c
Tube Deburring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9d
Tube End Preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9e
Swaging, Fitting Dimensions After . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . T4-39
Swaging Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9f
Synthetic-Base Fluid MIL-H-83282 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3c
System Flushing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4b
System Relief Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-116
Systems and Repairs, Tubing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2

Tailwheel Liquid Spring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . T4-176

Technique, Swaged Tubing Repairs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9b
Teflon Hose Assembly Procedure, Medium-Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-48
Teflon Hose Cutoff Factures (in Inches) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-23
Teflon Hose, Field Disassembly of . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-47
Teflon Hose Installation Procedures, Right and Wrong . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-49
Temperature Protection and Installation of Flexible Hose . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6g
Template for Repair of Tubing Assemblies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4d
Test Pressures, Operating, Proof, and Burst, for AN6270 Hose
Assembly using MIL-H-5593 Low Pressure Hose . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . T4-19
Test Pressures, Operating, Proof, and Burst, for MIL-H-83796
Medium Pressure Hose Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . T4-17
Test Pressures, Operating, Proof, and Burst, for MIL-H-83797
Medium Pressure Hose . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . T4-18
Test Pressures, Operating, Proof, and Burst, for MS28741 Medium
Pressure Hose Assemblies, using Single Wire Braid Hose,
Military Specification MIL-H-8794 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . T4-16
Test Pressures, Operating, Proof, and Burst, for MS28759 and
MS28762 Hose Assemblies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . T4-15
Test Stands, Use of . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-20
Tetrafluoroethylene Hose MIL-F-27272 (in Inches) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . T4-21
Tetrafluoroethylene Hose MIL-H-38360 (in Inches) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . T4-26
Theory and Basic Principles of Pneudraulics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
Theory of Operation, Hydraulic Reservoirs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-11b
Theory of Operation, Hydraulics System Filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-12b

Index-17
TM 1-1500-204-23-2
Tightening Hose Clamp with Socket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-32
Tool, Flaring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-10
Torque Values for AN924 Jamnut Used On Fittings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . T4-8
Torque Values for Boss Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . T4-7
Torque Values for MS21921 Coupling Nut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . T4-5
Torque Values, Hydraulic Tubing B-Nut (AN818) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . T4-2
Torque Values, Installation, MS Flared Swivel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . T4-25
Torque Values, MS Flared Swivel Nut Fittings (Reference
AND 0064), Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . T4-33
Torque Values, MS Flared Swivel Nut Fittings (Reference
AND 0064), Proof Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . T4-20
Torque Values, MS Turns and . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-21
Transporting Fluid to Aircraft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3d
Troubleshooting Actuators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . T4-40
Troubleshooting Guide for Inspection Checking (of Swaging) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . T4-38
Troubleshooting Wheel Brake Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . T4-41
Tube and Fitting Alignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . T4-13
Tube Bend Data Drawing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-6
Tube Bending Machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F3-4
Tube Bending Machine, Hand-Operated . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2e
Tube Bends, Acceptable and Unacceptable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-5
Tube Cutter, Cutting Tube with . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-3
Tube Cutting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9c
Tube Deburring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9d
Tube End Marking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-83
Tube Insertion Band Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . T4-37
Tube Insertion Limits when Using Standard Union Fittings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-90
Tube Material and Maximum Operating Pressure Limitations (psi)
for Permaswage Repair with D1 0000 Series Tooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . T4-35
Tube, Properly Burred . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-9
Tube Thickness and Burst Pressure, Determining . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . T4-11
Tubing Alignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-20
Tubing Assemblies, Repair of . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4
Tubing Damage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2c
Tubing End Clearance for Low-Pressure Tubing-Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-31
Tube Fittings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-15
Tubing Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2b
Tubing Repairs, Swaged . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9
Tubing Systems and Repairs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
Beaded Tubing Joints . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2h
Bending Tubing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2e
Cleaning Tubing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2g
Cutting Tubing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2d
Flaring Tubing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2f
Installation of Beaded Tubing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2j
Installation of Flared Tubing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2i
Tubing Damage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2c

Index-18
 TM 1-1500-204-23-2
Tubing Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2b
Types . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2a
Tubing with Double Lap Flare . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-11
Tubing-to-Tubing Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-22
Two-Stage Fluid Filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-12d
Types of Accumulators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-15a
Types of Hydraulic Fluid Used in Army Aircraft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
Petroleum-Base Fluid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3b
Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3d
Synthetic-Base Fluid MIL-H-83282 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3c
Vegetable-Base Fluid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3a
Types of Hydraulic Reservoirs Used in Hydraulic Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-11a
Types of Pneudraulic Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-17
Types of Tubing Systems and Repairs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2a
Typical Gasoline Engine-Driven Hydraulic Test Stand . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F3-2
Typical Hydraulic Hose Testing Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F3-3
Typical Hydraulic System Filler and Bleeder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F3-1
Typical Master Gauge Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F3-5
Typical Styles of Permaswage Fittings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-78

Universal Fittings AN832, AN833, AN834 High Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3e

Universal Fittings AN832, AN833, AN834 Low Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3d
Use of Air in Hydraulic Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1f
Use of Dust Plugs, Dust Caps, and Moisture Seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-51
Use of Test Stands . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-20
Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-20b
Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-20a
Uses of Filter in Hydraulic Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-12a
Uses of Hydraulic Systems in Army Aircraft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
Ease of Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2c
Ease of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2b
Efficiency . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2a
Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2e
Size . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2d
Utilizing 0.150 Inch Tube End Gap Tolerance on Separable Fittings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-89
Utilizing 0.300 Inch Tube End Gap Tolorance on Shaped Fittings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-88
Utilizing 0.300 Inch Tube End Gap Tolorance with Standard Union Fittings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-87
V-Ring Packings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7c
V-Ring Packings in Various Positions of Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-71
Valve A, Closed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-145
Valve B, Open . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-146
Valve C, Open . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-147
Valve, Pressure-Reducing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-117
Valve, Priority . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-131
Valve, Rachet (Moving) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-137

Index-19
TM 1-1500-204-23-2
Valve, Rachet (Static) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-136
Valve, Priority . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-131
Vane Damper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-166
Vane Damper Cross Section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-167
Vane, Dampers, Nose Landing Gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-168
Vane, Dampers, Stabilizer Bar . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-169
Vegetable-Base Fluid (Hydraulic) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3a
Vickers Stroke Reduction Pump (Full Flow) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-108
Vickers Stroke Reduction Pump (Zero Flow) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-107
Volume, Length, and Area, Computing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F2-2

Wheel Brake Assemblies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-18b

Wheel Brake Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-18a
Wheel Brake Systems, Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . T4-41
Withdrawing Fluid from Drum . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . T3-3c

Index-20
 These are the instructions for sending an electronic 2028
The following format must be used if submitting an electronic 2028. The subject line must be
exactly the same and all fields must be included; however only the following fields are
mandatory: 1, 3, 4, 5, 6, 7, 8, 9, 10, 13, 15, 16, 17, and 27.
From: “Whomever” [email protected]
To: [email protected]
Subject: DA Form 2028
1 From: Joe Smith
2 Unit: home
3 Address: 4300 Park
4 City: Hometown
5 St: MO
6 Zip: 77777
7 Date Sent: 19-OCT-93
8 Pub no: 55-2840-229-23
9 Pub Title: TM
10 Publication Date: 04-JUL-85
11 Change Number: 7
12 Submitter Rank: MSG
13 Submitter FName: Joe
14 Submitter MName: T
15 Submitter LName: Smith
16 Submitter Phone: 123-123-1234
17 Problem: 1
18 Page: 2
19 Paragraph: 3
20 Line: 4
21 NSN: 5
22 Reference: 6
23 Figure: 7
24 Table: 8
25 Item: 9
26 Total: 123

27 Text:
This is the text for the problem below line 27.
 Use Part II (reverse) for Repair Parts and DATE
Special Tool Lists (RPSTL) and Supply
RECOMMENDED CHANGES TO PUBLICATIONS AND
BLANK FORMS
Catalogs/ Supply Manuals (SC/SM) 8/30/02
For use of this form, see AR 25--30; the proponent agency is ODISC4.

TO: (Forward to proponent of publication or form)(Include ZIP Code) FROM: (Activity and location)(Include ZIP Code)
Commander, U.S. Army Aviation and Missile Command MSG, Jane Q. Doe
ATTN: AMSAM--MMA--NP 1234 Any Street
Redstone Arsenal, AL 35898 Nowhere Town, AL 34565
PART 1 - ALL PUBLICATIONS (EXCEPT RPSTL AND SC/SM) AND BLANK FORMS
PUBLICATION/FORM NUMBER DATE TITLE Organizational, Direct Support, And
TM 9-1005-433-24 16 Sep 2002 General Support Maintenance Manual for
Machine Gun, .50 Caliber M3P and M3P
Machine Gun Electrical Test Set Used On
Avenger Air Defense Weapon System
ITEM PAGE PARA- LINE FIGURE TABLE
NO. NO. GRAPH NO. * NO. NO. RECOMMENDED CHANGES AND REASON

1 WP0005 2 Test or Corrective Action column should identify a different WP number.

PG 3

L E
P
A M
E X
* Reference to line numbers within the paragraph or subparagraph.
TYPED NAME, GRADE OR TITLE TELEPHONE EXCHANGE/ SIGNATURE
AUTOVON, PLUS EXTENSION

MSG, Jane Q. Doe, SFC 788-1234

DA FORM 2028, FEB 74 REPLACES DA FORM 2028, 1 DEC 68, WHICH WILL BE USED. USAPA V3.01
TO: (Forward direct to addressee listed in publication) FROM: (Activity and location) (Include ZIP Code) DATE
Commander, U.S. Army Aviation and Missile Command MSG, Jane Q. Doe 8/30/02
ATTN: AMSAM-MMA-NP 1234 Any Street
Redstone Arsenal, AL 35898 Nowhere Town, AL 34565

PART II - REPAIR PARTS AND SPECIAL TOOL LISTS AND SUPPLY CATALOGS/SUPPLY MANUALS
PUBLICATION NUMBER DATE TITLE

TOTAL NO.
PAGE COLM LINE NATIONAL STOCK REFERENCE FIGURE ITEM OF MAJOR
ITEMS RECOMMENDED ACTION
NO. NO. NO. NUMBER NO. NO. NO.
SUPPORTED

L E
P
M
PART III - REMARKS (Any general remarks or recommendations, or suggestions for improvement of publications and
blank forms. Additional blank sheets may be used if more space is needed.)

A
E X
TYPED NAME, GRADE OR TITLE TELEPHONE EXCHANGE/AUTOVON, SIGNATURE
PLUS EXTENSION
MSG, Jane Q. Doe, SFC 788-1234
USAPA V3.01
 Use PartII(reverse) for Repair Parts and DATE
Special Tool Lists (RPSTL) and Supply
RECOMMENDED CHANGES TO PUBLICATIONS AND Catalogs/ Supply Manuals (SC/SM)
BLANK FORMS
For use of this form, see AR 25--30; the proponent agency is ODISC4.

TO: (Forward to proponent of publication or form)(Include ZIP Code) FROM: (Activity and location)(Include ZIP Code)
Commander, U.S. Army Aviation and Missile Command ATTN:
AMSAM-MMA-NP Redstone Arsenal, AL 35898

PART 1 --ALL PUBLICATIONS (EXCEPT RPSTL AND SC/SM) AND BLANK FORMS
PUBLICATION/FORM NUMBER DATE TITLE

ITEM PAGE PARA- LINE FIGURE TABLE

NO. NO. GRAPH NO. * NO. NO. RECOMMENDED CHANGES AND REASON

* Reference to line numbers within the paragraph or subparagraph.

TYPED NAME, GRADE OR TITLE TELEPHONE EXCHANGE/ SIGNATURE
AUTOVON, PLUS
EXTENSION

DA FORM 2028, FEB 74 REPLACES DA FORM 2028, 1 DEC 68, WHICH WILL BE USED. USAPA V3.01
TO: (Forward direct to addressee listed in publication) FROM: (Activity and location) (Include ZIP Code) DATE
Commander, U.S. Army Aviation and Missile Command
ATTN: AMSAM-MMA-NP Redstone Arsenal, AL
35898

PART II --REPAIR PARTS AND SPECIAL TOOL LISTS AND SUPPLY CATALOGS/SUPPLY MANUALS
PUBLICATION NUMBER DATE TITLE

TOTAL NO.
PAGE COLM LINE NATIONAL STOCK REFERENCE FIGURE ITEM OF MAJOR
ITEMS RECOMMENDED ACTION
NO. NO. NO. NUMBER NO. NO. NO.
SUPPORTED

PART III --REMARKS (Any general remarks or recommendations, or suggestions for improvement of publications and blank forms.
Additional blank sheets may be used if more space is needed.)

TYPED NAME, GRADE OR TITLE TELEPHONE EXCHANGE/AUTOVON, SIGNATURE

PLUS EXTENSION

USAPA V3.01
 The Metric System and Equivalents

Linear Measure Liquid Measure

1 centimeter = 10 millimeters = .39 inch 1 centiliter = 10 milliters = .34 fl. ounce

1 decimeter = 10 centimeters = 3.94 inches 1 deciliter = 10 centiliters = 3.38 fl. Ounces
1 meter = 10 decimeters = 39.37 inches 1 liter = 10 deciliters = 33.81 fl. ounces
1 dekameter = 10 meters = 32.8 feet 1 dekaliter = 10 liters = 2.64 gallons
1 hectometer = 10 dekameters = 328.08 feet 1 hectoliter = 10 dekaliters = 26.42 gallons
1 kilometer = 10 hectometers = 3,280.8 feet 1 kiloliter = 10 hectoliters = 264.18 gallons

Weights Square Measure

1 centigram = 10 milligrams = .15 grain 1 sq. centimeter = 100 sq. millimeters = .155 sq. inch
1 decigram = 10 centigrams = 1.54 grains 1 sq. decimeter = 100 sq. centimeters = 15.5 sq. inches
1 gram = 10 decigram = .035 ounce 1 sq. meter (centare) = 100 sq. decimeters = 10.76 sq. feet
1 decagram = 10 grams = .35 ounce 1 sq. dekameter (are) = 100 sq. meters = 1,076.4 sq. feet
1 hectogram = 10 decagrams = 3.52 ounces 1 sq. hectometer (hectare) = 100 sq. dekameters = 2.47 acres
1 kilogram = 10 hectograms = 2.2 pounds 1 sq. kilometer = 100 sq. hectometers = .386 sq. mile
1 quintal = 100 kilograms = 220.46 pounds
1 metric ton = 10 quintals = 1.1 short tons

Cubic Measure
1 cu. centimeter = 1000 cu. millimeters = .06 cu. Inch
1 cu. decimeter = 1000 cu. centimeters = 61.02 cu. Inches
1 cu. meter = 1000 cu. decimeters = 35.31 cu. feet

Approximate Conversion Factors

To change To Multiply by To change To Multiply by

inches centimeters 2.540 ounce-inches Newton-meters .007062

feet meters .305 centimeters inches .394
yards meters .914 meters feet 3.280
miles kilometers 1.609 meters yards 1.094
square inches square centimeters 6.451 kilometers miles .621
square feet square meters .093 square centimeters square inches .155
square yards square meters .836 square meters square feet 10.764
square miles square kilometers 2.590 square meters square yards 1.196
acres square hectometers .405 square kilometers square miles .386
cubic feet cubic meters .028 square hectometers acres 2.471
cubic yards cubic meters .765 cubic meters cubic feet 35.315
fluid ounces milliliters 29,573 cubic meters cubic yards 1.308
pints liters .473 milliliters fluid ounces .034
quarts liters .946 liters pints 2.113
gallons liters 3.785 liters quarts 1.057
ounces grams 28.349 liters gallons .264
pounds kilograms .454 grams ounces .035
short tons metric tons .907 kilograms pounds 2.205
pound-feet Newton-meters 1.356 metric tons short tons 1.102
pound-inches Newton-meters .11296

Temperature (Exact)

°F Fahrenheit 5/9 (after Celsius °C

temperature subtracting 32) temperature
PIN: 070461-000