CHAPTER 1 INTRODUCTION - TM-1-1500-204-23-2_11
CHAPTER 2 PNEUDRAULICS GENERAL
Mechanical Advantage.
Figure 2-3. Pascal's Law
Uses of Hydraulic Systems in Army Aircraft.
Figure 2-4. Mechanical Advantage
Fluid Contamination. - TM-1-1500-204-23-2_17
Fluid Contamination. - TM-1-1500-204-23-2_18
CHAPTER 3 HYDRAULIC SHOP OPERATIONS
Equipment safety.
Maintenance of Shop Equipment.
Hydraulic Test Stand. Fixed.
Figure 3-2. Typical Gasoline Engine-Driven Hydraulic Test Stand
Periodic inspection
Tube-Bending Machine, Hand-Operated.
Periodic inspection.
Hydraulic Fluid Dispenser, Aircraft,
Handling of Hydraulic Fluid in 55-Gallon Drums. - TM-1-1500-204-23-2_29
Handling of Hydraulic Fluid in 55-Gallon Drums. - TM-1-1500-204-23-2_30
CHAPTER 4 HYDRAULIC MAINTENANCE PRACTICES
Figure 4-1. Printed - Symbol identification Tape.
Use of fusible alloy for bending tubing.
Figure 4-4. Bending Tube with Bending Machine
Table 4-1. Bend Radii for Conduit and Fluid Lines
Preparing flaring tool for flaring.
Figure 4-6. Tube Bend Data Drawing
Figure 4-7. Dimensions for Single-Flared Tubing
Figure 4-10. Flaring Tool
Figure 4-12. Beading Large Tubing
Figure 4-13. Bead Dimensions
Figure 4-14. Tube and Fitting Alignment
Figure 4-16. Installed Low-Pressure Hose
Table 4-3. Hose Clamp Tightening, Fingertight-Plus Turns Method, Beaded Tubing
Flareless Fittings.
Figure 4-18. MS Flareless Fittings
Bulkhead fitting installation.
Figure 4-21. MS Turns and Torque Values
Figure 4-24. Bulkhead Flareless Fitting Installation
Theory of pipe thread seal.
Table 4-5. Torque Values for MS21921 Coupling Nut Based on Lubrication Method, - TM-1-1500-204-23-2_51
Table 4-5. Torque Values for MS21921 Coupling Nut Based on Lubrication Method, - TM-1-1500-204-23-2_52
Figure 4-25. Installation of MS33514 Fitting End
Table 4-8. Torque Values for AN924 Jamnut Used on Fittings
Figure 4-27. Combination Bulkhead and Universal Fitting Assembly
Table 4-9. AN Flared Fitting Identification
Figure 4-28. AN Flared Fittings
Figure 4-29. Damaged Fittings
Figure 4-31. Tubing End Clearance for Low-Pressure Tubing Repair
Table 4-10. Hose Clamp Tightening, Fingertight-Plus Turns Method
Figure 4-33. Repairing High-Pressure Tubing
Flexible Hose Assemblies.
Table 4-11. Determining Tube Thickness and Burst Pressure
Determining Tube Thickness and Burst Pressure -cont
Markings.
Table 4-12. Maximum Distance between Supports for Fluid Tubing
Figure 4-35. Nonself-Sealing, Aromatic and Heat-Resistant Hose
Internal inspection
Figure 4-39. Knife for Cutting Flexible Hose
Table 4-14. Hose Cutoff Factor, MIL-H-8788 or MIL-8790 Hose (in Inches)
Hose Cutoff Factor, MIL-H-8788 or MIL-8790 Hose (in Inches)-CONT - TM-1-1500-204-23-2_71
Hose Cutoff Factor, MIL-H-8788 or MIL-8790 Hose (in Inches)-CONT - TM-1-1500-204-23-2_72
Hose Cutoff Factor, MIL-H-8788 or MIL-8790 Hose (in Inches)-CONT - TM-1-1500-204-23-2_73
Hose Cutoff Factor, MIL-H-8788 or MIL-8790 Hose (in Inches)-CONT - TM-1-1500-204-23-2_74
Figure 4-40. Determining Hose Assembly Length
Figure 4-41. Field Fabrication of High-Pressure Hose Assemblies
Table 4-15. Operating, Proof, and Burst Test Pressures for MS28759 and MS28762 Hose Assemblies
Table 4-16. Operating, Proof, and Burst Test Pressures
Table 4-17. Operating, Proof, and Burst Test Pressures
Table 4-18. Operating, Proof, and Burst Test Pressure
Table 4-19. Operating, Proof, and Burst Test Pressures
Table 4-20. Proof Test Torque Values MS Flared Swivel Nut Fittings (Reference and 10064)
Figure 4-42. Identification Tags for Field Fabricated Hose Assemblies
Figure 4-43. Assembly of Medium and Low-Pressure Hose Assemblies
Table 4-21. Tetrafluoroethylene Hose MIL- F-27272 (in Inches)
Identification.
Internal Inspection.
Figure 4-45. Field Disassembly of Teflon Hose
Figure 4-46. Nipple Assembly Surface
Hose assemblies.
Figure 4-48. Medium-Pressure Teflon Hose Assembly Procedure (Sheet 1 of 3)
Figure 4-48. Medium-Pressure Teflon Hose Assembly Procedure (Sheet 2 of 3)
Figure 4-48. Medium-Pressure Teflon Hose Assembly Procedure (Sheet 3 of 3)
Table 4-22. Teflon Hose Cutoff Factors (in Inches)
Proof test procedures.
Table 4-23. Proof Test Pressures, Medium-Pressure Teflon Hose Assemblies
Figure 4-49. Teflon Hose Installation Procedures, Right and Wrong
Table 4-24. Support Clamp Sizes (For Use with MIL-H-27267 Hose of Teflon)
Assembly procedure for high pressure Teflon hose
Figure 4-50. Field Assembly of High-Pressure Teflon Hose
Table 4-26. Tetrafiouroethylene Hose MIL-H-38360 (In Inches)
Table 4-28. Proof Test Pressures, High-Pressures Teflon Hose Assemblies
Table 4-29. Support Clamp Sizes (For use with MIL-H-38360 Hose of Teflon)
Table 4-30. Coupling Bulge, MIL-H-7061 Hose Assembly
Sealing with plugs, caps, and seals.
Instructions for Field Assembly of Lightweight Rubber Hose Assembly
Installation of Flexible Nose.
Hose Installation.
Figure 4-50A. Field Assembly of Lightweight Rubber Hose .
Table 4-32. Minimum Bend Radii of Hose for Fuel, Oil, and Coolant Systems
Table 4-34. Hose End Fitting And Coupling Nut Installation Torque In Inch-Pounds
Hydraulic Packings and O-Rings.
Figure 4-57. Hose Line Installation Aids for All Types of Hoses
Figure 4-59. O-Ring Identification
Figure 4-62. Internal O-Ring Removal (Wedge- Type Extractor)
Figure 4-65. External O-Ring Removal (Spoon- Type Tools)
Backup Rings
Figure 4-69. External O-Ring Installation
Figure 4-72. Stretching Teflon Backup Ring
Swaged Tubing Repairs.
Figure 4-75. Single Backup Ring Installation
Figure 4-77. Installation of Leather Backup Rings
Tube End Preparation.
Table 4-35. Permaswage Repair with D10000 Series Tooling
Figure 4-79. Failure Modes and Recommended Repair Methods
Figure 4-80. Marking Tube Prior to Cutting
Table 4-36. Additional Marking Distance
Table 4-37. Tube Insertion Band Location
Figure 4-85. Checked Swaged Joint with D9892 Inspection Gauge
Table 4-38. Troubleshooting Guide for Inspection Checking
Table 4-39. Fitting Dimensions After Swaging
Figure 4-87. Utilzing 0.300 Inch Tube End Gap Tolerance with Standard Union Fittings
Figure 4-90. Tube Insertion Limits when Using Standard Union Fittings
Quick-Disconnect Couplings
Hydraulic Reservoirs.
Baffles and Fins.
Figure 4-92. Fluid-Pressurized Reservoir (Unpressurized)
Figure 4-94. Reservoir with Filter Elements
Figure 4-96. Fluid Filter Assembly
Figure 4-99. Differential Pressure Indicator (Normal Flow)
Two-Stage Fluid Filters.
Pumps and Motors.
Zero flow
Figure 4-101. Bent-Axis Constant Volume Pump
Figure 4-104. Constant Volume Pump Foot Valve
Figure 4-106. Stratopower Effective Stroke Pump (Zero Flow )
Figure 4-107. Vickers Stroke Reduction Pump (Zero Flow)
Figure 4-108. Vickers Stroke Reduction Pump (Full Flow)
Figure 4-109. Kellogg Stroke Reduction Pump Assembly
Figure 4-110. Kellogg Stroke Reduction Pump (Reduced Output)
Figure 4-111. Double-Action Hand Pump
Hydraulic Motors.
Figure 4-112. Hand Pump Test Circuit
Devices for Regulating Pressure
Pressure Relief Valves
Figure 4-114. Pressure Gauge
Accumulator Operation.
Figure 4-116. System Relief Valve
Control Valves.
Check Valves.
Figure 4-120. Rotary-Type, Closed Center Selector Valve
Figure 4-122. In-Line Cam-Operated Selector Valve (Actuator Retracting)
Figure 4-124. Radial Cam-Operated Selector Valve
Figure 4-126. Solenoid-Actuated Control Valve (De-energized)
Figure 4-129. Landing Gear System Using Mechanically Actuated Sequence Valves
Figure 4-132. Floating-Piston Shuttle Valve
Allowable leakage
Figure 4-134. Double-Action Actuating Cylinder (Extension)
Table 4-40. Troubleshooting Actuators
Figure 4-136. Ratchet Valve (Static)
Figure 4-137. Ratchet Valve (Moving)
Figure 4-139. Irreversible Valve
Figure 4-141. Hydraulic Fuse (Full Flow)
Figure 4-143. Open-Center Hydraulic System (Valve Closed)
Figure 4-145. Selector Valve A Closed
Aircraft Brake Systems
Figure 4-148. Simple Master Cylinder
Figure 4-149. Compound Master Cylinder
Figure 4-150. Power-Boost Master Cylinder (Brake Applied)
Figure 4-151. Power-Boost Master Cylinder (Brake Released)
Figure 4-152. Power Brake Control Valve (Brakes Applied)
Figure 4-154. Disc Brake Assembly
Figure 4-155. Disc Brake Assembly Cross Section
Figure 4-156. Dual Parking Brake Valve
Troubleshooting.
Figure 4-161. Gravity Method for Brake Bleeding
Table 4-41. Troubleshooting Wheel Brake Systems
Troubleshooting Wheel Brake Systems - cont - TM-1-1500-204-23-2_188
Troubleshooting Wheel Brake Systems - cont - TM-1-1500-204-23-2_189
Dampening and Absorbing Units.
Figure 4-163. Piston Damper Cross Section
Figure 4-165. Main Rotor Assembly with Piston Dampers
Figure 4-169. Stabilizer Bar with Vane Dampers
Figure 4-170. Simple Shock Strut
Figure 4-171. Complex Shock Strut (Metering Pin)
Figure 4-173. Floating Piston Shock Strut
Figure 4-174. High-Pressure Air Valve Cores
Figure 4-175. Liquid Spring
Reducing shock during landing
Conversion of Aircraft to Fire-Resistant Hydraulic Fluid
Table 4-43. Applications of MIL-H-83282
Table 4-44. Non-Applicability of MIL-H-83282
APPENDIX A REFERENCES - TM-1-1500-204-23-2_203
GLOSSARY - TM-1-1500-204-23-2_204
GLOSSARY -cont - TM-1-1500-204-23-2_205
CHAPTER 2 PNEUDRAULICS GENERAL
Mechanical Advantage.
Figure 2-3. Pascal's Law
Uses of Hydraulic Systems in Army Aircraft.
Figure 2-4. Mechanical Advantage
Fluid Contamination. - TM-1-1500-204-23-2_17
Fluid Contamination. - TM-1-1500-204-23-2_18
CHAPTER 3 HYDRAULIC SHOP OPERATIONS
Equipment safety.
Maintenance of Shop Equipment.
Hydraulic Test Stand. Fixed.
Figure 3-2. Typical Gasoline Engine-Driven Hydraulic Test Stand
Periodic inspection
Tube-Bending Machine, Hand-Operated.
Periodic inspection.
Hydraulic Fluid Dispenser, Aircraft,
Handling of Hydraulic Fluid in 55-Gallon Drums. - TM-1-1500-204-23-2_29
Handling of Hydraulic Fluid in 55-Gallon Drums. - TM-1-1500-204-23-2_30
CHAPTER 4 HYDRAULIC MAINTENANCE PRACTICES
Figure 4-1. Printed - Symbol identification Tape.
Use of fusible alloy for bending tubing.
Figure 4-4. Bending Tube with Bending Machine
Table 4-1. Bend Radii for Conduit and Fluid Lines
Preparing flaring tool for flaring.
Figure 4-6. Tube Bend Data Drawing
Figure 4-7. Dimensions for Single-Flared Tubing
Figure 4-10. Flaring Tool
Figure 4-12. Beading Large Tubing
Figure 4-13. Bead Dimensions
Figure 4-14. Tube and Fitting Alignment
Figure 4-16. Installed Low-Pressure Hose
Table 4-3. Hose Clamp Tightening, Fingertight-Plus Turns Method, Beaded Tubing
Flareless Fittings.
Figure 4-18. MS Flareless Fittings
Bulkhead fitting installation.
Figure 4-21. MS Turns and Torque Values
Figure 4-24. Bulkhead Flareless Fitting Installation
Theory of pipe thread seal.
Table 4-5. Torque Values for MS21921 Coupling Nut Based on Lubrication Method, - TM-1-1500-204-23-2_51
Table 4-5. Torque Values for MS21921 Coupling Nut Based on Lubrication Method, - TM-1-1500-204-23-2_52
Figure 4-25. Installation of MS33514 Fitting End
Table 4-8. Torque Values for AN924 Jamnut Used on Fittings
Figure 4-27. Combination Bulkhead and Universal Fitting Assembly
Table 4-9. AN Flared Fitting Identification
Figure 4-28. AN Flared Fittings
Figure 4-29. Damaged Fittings
Figure 4-31. Tubing End Clearance for Low-Pressure Tubing Repair
Table 4-10. Hose Clamp Tightening, Fingertight-Plus Turns Method
Figure 4-33. Repairing High-Pressure Tubing
Flexible Hose Assemblies.
Table 4-11. Determining Tube Thickness and Burst Pressure
Determining Tube Thickness and Burst Pressure -cont
Markings.
Table 4-12. Maximum Distance between Supports for Fluid Tubing
Figure 4-35. Nonself-Sealing, Aromatic and Heat-Resistant Hose
Internal inspection
Figure 4-39. Knife for Cutting Flexible Hose
Table 4-14. Hose Cutoff Factor, MIL-H-8788 or MIL-8790 Hose (in Inches)
Hose Cutoff Factor, MIL-H-8788 or MIL-8790 Hose (in Inches)-CONT - TM-1-1500-204-23-2_71
Hose Cutoff Factor, MIL-H-8788 or MIL-8790 Hose (in Inches)-CONT - TM-1-1500-204-23-2_72
Hose Cutoff Factor, MIL-H-8788 or MIL-8790 Hose (in Inches)-CONT - TM-1-1500-204-23-2_73
Hose Cutoff Factor, MIL-H-8788 or MIL-8790 Hose (in Inches)-CONT - TM-1-1500-204-23-2_74
Figure 4-40. Determining Hose Assembly Length
Figure 4-41. Field Fabrication of High-Pressure Hose Assemblies
Table 4-15. Operating, Proof, and Burst Test Pressures for MS28759 and MS28762 Hose Assemblies
Table 4-16. Operating, Proof, and Burst Test Pressures
Table 4-17. Operating, Proof, and Burst Test Pressures
Table 4-18. Operating, Proof, and Burst Test Pressure
Table 4-19. Operating, Proof, and Burst Test Pressures
Table 4-20. Proof Test Torque Values MS Flared Swivel Nut Fittings (Reference and 10064)
Figure 4-42. Identification Tags for Field Fabricated Hose Assemblies
Figure 4-43. Assembly of Medium and Low-Pressure Hose Assemblies
Table 4-21. Tetrafluoroethylene Hose MIL- F-27272 (in Inches)
Identification.
Internal Inspection.
Figure 4-45. Field Disassembly of Teflon Hose
Figure 4-46. Nipple Assembly Surface
Hose assemblies.
Figure 4-48. Medium-Pressure Teflon Hose Assembly Procedure (Sheet 1 of 3)
Figure 4-48. Medium-Pressure Teflon Hose Assembly Procedure (Sheet 2 of 3)
Figure 4-48. Medium-Pressure Teflon Hose Assembly Procedure (Sheet 3 of 3)
Table 4-22. Teflon Hose Cutoff Factors (in Inches)
Proof test procedures.
Table 4-23. Proof Test Pressures, Medium-Pressure Teflon Hose Assemblies
Figure 4-49. Teflon Hose Installation Procedures, Right and Wrong
Table 4-24. Support Clamp Sizes (For Use with MIL-H-27267 Hose of Teflon)
Assembly procedure for high pressure Teflon hose
Figure 4-50. Field Assembly of High-Pressure Teflon Hose
Table 4-26. Tetrafiouroethylene Hose MIL-H-38360 (In Inches)
Table 4-28. Proof Test Pressures, High-Pressures Teflon Hose Assemblies
Table 4-29. Support Clamp Sizes (For use with MIL-H-38360 Hose of Teflon)
Table 4-30. Coupling Bulge, MIL-H-7061 Hose Assembly
Sealing with plugs, caps, and seals.
Instructions for Field Assembly of Lightweight Rubber Hose Assembly
Installation of Flexible Nose.
Hose Installation.
Figure 4-50A. Field Assembly of Lightweight Rubber Hose .
Table 4-32. Minimum Bend Radii of Hose for Fuel, Oil, and Coolant Systems
Table 4-34. Hose End Fitting And Coupling Nut Installation Torque In Inch-Pounds
Hydraulic Packings and O-Rings.
Figure 4-57. Hose Line Installation Aids for All Types of Hoses
Figure 4-59. O-Ring Identification
Figure 4-62. Internal O-Ring Removal (Wedge- Type Extractor)
Figure 4-65. External O-Ring Removal (Spoon- Type Tools)
Backup Rings
Figure 4-69. External O-Ring Installation
Figure 4-72. Stretching Teflon Backup Ring
Swaged Tubing Repairs.
Figure 4-75. Single Backup Ring Installation
Figure 4-77. Installation of Leather Backup Rings
Tube End Preparation.
Table 4-35. Permaswage Repair with D10000 Series Tooling
Figure 4-79. Failure Modes and Recommended Repair Methods
Figure 4-80. Marking Tube Prior to Cutting
Table 4-36. Additional Marking Distance
Table 4-37. Tube Insertion Band Location
Figure 4-85. Checked Swaged Joint with D9892 Inspection Gauge
Table 4-38. Troubleshooting Guide for Inspection Checking
Table 4-39. Fitting Dimensions After Swaging
Figure 4-87. Utilzing 0.300 Inch Tube End Gap Tolerance with Standard Union Fittings
Figure 4-90. Tube Insertion Limits when Using Standard Union Fittings
Quick-Disconnect Couplings
Hydraulic Reservoirs.
Baffles and Fins.
Figure 4-92. Fluid-Pressurized Reservoir (Unpressurized)
Figure 4-94. Reservoir with Filter Elements
Figure 4-96. Fluid Filter Assembly
Figure 4-99. Differential Pressure Indicator (Normal Flow)
Two-Stage Fluid Filters.
Pumps and Motors.
Zero flow
Figure 4-101. Bent-Axis Constant Volume Pump
Figure 4-104. Constant Volume Pump Foot Valve
Figure 4-106. Stratopower Effective Stroke Pump (Zero Flow )
Figure 4-107. Vickers Stroke Reduction Pump (Zero Flow)
Figure 4-108. Vickers Stroke Reduction Pump (Full Flow)
Figure 4-109. Kellogg Stroke Reduction Pump Assembly
Figure 4-110. Kellogg Stroke Reduction Pump (Reduced Output)
Figure 4-111. Double-Action Hand Pump
Hydraulic Motors.
Figure 4-112. Hand Pump Test Circuit
Devices for Regulating Pressure
Pressure Relief Valves
Figure 4-114. Pressure Gauge
Accumulator Operation.
Figure 4-116. System Relief Valve
Control Valves.
Check Valves.
Figure 4-120. Rotary-Type, Closed Center Selector Valve
Figure 4-122. In-Line Cam-Operated Selector Valve (Actuator Retracting)
Figure 4-124. Radial Cam-Operated Selector Valve
Figure 4-126. Solenoid-Actuated Control Valve (De-energized)
Figure 4-129. Landing Gear System Using Mechanically Actuated Sequence Valves
Figure 4-132. Floating-Piston Shuttle Valve
Allowable leakage
Figure 4-134. Double-Action Actuating Cylinder (Extension)
Table 4-40. Troubleshooting Actuators
Figure 4-136. Ratchet Valve (Static)
Figure 4-137. Ratchet Valve (Moving)
Figure 4-139. Irreversible Valve
Figure 4-141. Hydraulic Fuse (Full Flow)
Figure 4-143. Open-Center Hydraulic System (Valve Closed)
Figure 4-145. Selector Valve A Closed
Aircraft Brake Systems
Figure 4-148. Simple Master Cylinder
Figure 4-149. Compound Master Cylinder
Figure 4-150. Power-Boost Master Cylinder (Brake Applied)
Figure 4-151. Power-Boost Master Cylinder (Brake Released)
Figure 4-152. Power Brake Control Valve (Brakes Applied)
Figure 4-154. Disc Brake Assembly
Figure 4-155. Disc Brake Assembly Cross Section
Figure 4-156. Dual Parking Brake Valve
Troubleshooting.
Figure 4-161. Gravity Method for Brake Bleeding
Table 4-41. Troubleshooting Wheel Brake Systems
Troubleshooting Wheel Brake Systems - cont - TM-1-1500-204-23-2_188
Troubleshooting Wheel Brake Systems - cont - TM-1-1500-204-23-2_189
Dampening and Absorbing Units.
Figure 4-163. Piston Damper Cross Section
Figure 4-165. Main Rotor Assembly with Piston Dampers
Figure 4-169. Stabilizer Bar with Vane Dampers
Figure 4-170. Simple Shock Strut
Figure 4-171. Complex Shock Strut (Metering Pin)
Figure 4-173. Floating Piston Shock Strut
Figure 4-174. High-Pressure Air Valve Cores
Figure 4-175. Liquid Spring
Reducing shock during landing
Conversion of Aircraft to Fire-Resistant Hydraulic Fluid
Table 4-43. Applications of MIL-H-83282
Table 4-44. Non-Applicability of MIL-H-83282
APPENDIX A REFERENCES - TM-1-1500-204-23-2_203
GLOSSARY - TM-1-1500-204-23-2_204
GLOSSARY -cont - TM-1-1500-204-23-2_205
