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AEROSPACE AS5440 REV. A

STANDARD
Issued 1998-04
Revised 2011-01

Superseding AS5440

(R) Hydraulic Systems, Military Aircraft, Design and Installation, Requirements For

RATIONALE

AS5440 has been updated to Revision A for the following reasons:

a. Minor technical changes have been made

b. The references called up in the document have been updated

c. Editorial changes have been made to improve the readability of the document

TABLE OF CONTENTS

1.  SCOPE .......................................................................................................................................................... 4 

1.1  Classification ................................................................................................................................................. 4 
1.1.1  Types ............................................................................................................................................................ 4 
1.1.2  Classes ......................................................................................................................................................... 4

2.  REFERENCES.............................................................................................................................................. 4 
2.1  Applicable Documents .................................................................................................................................. 4 
2.1.1  SAE Publications........................................................................................................................................... 4 
2.1.2  US Government Publications ........................................................................................................................ 7 
2.1.3  NAS Publications .......................................................................................................................................... 9 
2.2  Definitions ..................................................................................................................................................... 9 
2.2.1  Utility System ................................................................................................................................................ 9 
2.2.2  Flight Control System .................................................................................................................................. 10 
2.2.3  Combined Flight Control Utility System ...................................................................................................... 10

3.  REQUIREMENTS ....................................................................................................................................... 10 

3.1  Materials ...................................................................................................................................................... 10 
3.2  Design ......................................................................................................................................................... 10 
3.3  Hydraulic Fluid ............................................................................................................................................ 10 
3.4  Hydraulic Seals ........................................................................................................................................... 11 
3.4.1  Gland Design .............................................................................................................................................. 11 
3.4.2  O-ring and Seal Assemblies ....................................................................................................................... 11 
3.4.3  Backup rings ............................................................................................................................................... 11 
3.5  Functional Simulator ................................................................................................................................... 11 
3.6  General System Design .............................................................................................................................. 12 
3.6.1  Fluid Temperature Limitations .................................................................................................................... 12 
3.6.2  Fire Hazards................................................................................................................................................ 12 
3.6.3  Surge Pressure ........................................................................................................................................... 12 
3.6.4  Strength ....................................................................................................................................................... 16 
3.6.5  Reservoir Pressurization ............................................................................................................................. 16 
__________________________________________________________________________________________________________________________________________
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SAE reviews each technical report at least every five years at which time it may be reaffirmed, revised, or cancelled. SAE invites your written comments and suggestions.
Copyright © 2011 SAE International
All rights reserved. No part of this publication may be reproduced, stored in a retrieval system or transmitted, in any form or by any means, electronic, mechanical,
photocopying, recording, or otherwise, without the prior written permission of SAE.
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Tel: +1 724-776-4970 (outside USA) on this Technical Report, please visit
Fax: 724-776-0790 http://www.sae.org/technical/standards/AS5440A
Email: [email protected]
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SAE AS5440A Page 2 of 44

3.6.6  Fluid Velocity Limitations ............................................................................................................................ 16 

3.6.7  Subsystem Isolation .................................................................................................................................... 16 
3.6.8  Ground Service Provisions ......................................................................................................................... 16 
3.6.9  Removal of Entrapped Air ........................................................................................................................... 17 
3.6.10  Power Pumps .............................................................................................................................................. 18 
3.6.11  Pump Supply Shutoff Valves ...................................................................................................................... 18 
3.6.12  Special Tools............................................................................................................................................... 18 
3.6.13  System Pressure Indication ........................................................................................................................ 19 
3.6.14  Fluid Sampling Valves ................................................................................................................................ 19 
3.6.15  Automatic Diagnostic Monitor System ........................................................................................................ 19 
3.7  Utility System Design .................................................................................................................................. 19 
3.7.1  Wheel Brake Systems ................................................................................................................................. 20 
3.8  Flight Control System Design ..................................................................................................................... 20 
3.8.1  System Isolation .......................................................................................................................................... 20 
3.8.2  Hydraulic Power Failures ............................................................................................................................ 20 
3.8.3  System Separation ...................................................................................................................................... 21 
3.8.4  Subsystems Pressure ................................................................................................................................. 21 
3.8.5  Flight Control Power Sources ..................................................................................................................... 21 
3.8.6  System Temperature .................................................................................................................................. 21 
3.9  Emergency System Design for Utility System ............................................................................................ 21 
3.9.1  Emergency System Types .......................................................................................................................... 21 
3.9.2  Emergency Line Venting ............................................................................................................................. 22 
3.10  Components ................................................................................................................................................ 22 
3.10.1  Standard Components ................................................................................................................................ 22 
3.10.2  Fixed Orifices .............................................................................................................................................. 22 
3.10.3  Actuators Essential to Safe Operation of the Aircraft ................................................................................. 22 
3.11  Component Design and Installation ............................................................................................................ 22 
3.11.1  Design Practice and Installation.................................................................................................................. 22 
3.11.2  Accumulators .............................................................................................................................................. 23 
3.11.3  Actuating Cylinders ..................................................................................................................................... 23 
3.11.4  Manual Bleed Valves .................................................................................................................................. 23 
3.11.5  Brake Valves ............................................................................................................................................... 23 
3.11.6  Check Valves .............................................................................................................................................. 23 
3.11.7  Directional Control Valves ........................................................................................................................... 23 
3.11.8  Pressure Regulating Valves........................................................................................................................ 24 
3.11.9  Filters .......................................................................................................................................................... 24 
3.11.10  Fittings ......................................................................................................................................................... 25 
3.11.11  Flow Dividers............................................................................................................................................... 26 
3.11.12  Flow Regulators .......................................................................................................................................... 26 
3.11.13  Protective Devices ...................................................................................................................................... 26 
3.11.14  Snubbers ..................................................................................................................................................... 26 
3.11.15  Manually Operated Pumps ......................................................................................................................... 26 
3.11.16  Flexible Connections ................................................................................................................................... 27 
3.11.17  Lock Valves ................................................................................................................................................. 27 
3.11.18  Motors ......................................................................................................................................................... 28 
3.11.19  Power Pump Variable Delivery ................................................................................................................... 28 
3.11.20  Power Pump Fixed Displacement ............................................................................................................... 28 
3.11.21  Relief Valves, System and Thermal Expansion .......................................................................................... 28 
3.11.22  Reservoirs ................................................................................................................................................... 28 
3.11.23  Restrictor Valves ......................................................................................................................................... 30 
3.11.24  Self-Sealing Couplings ................................................................................................................................ 30 
3.11.25  Shuttle Valves ............................................................................................................................................. 31 
3.11.26  Pressure Switches ...................................................................................................................................... 31 
3.11.27  Swivel Joints ............................................................................................................................................... 31 
3.11.28  Tubing ......................................................................................................................................................... 31 
3.11.29  Design of System Installations .................................................................................................................... 34 
3.12  Workmanship .............................................................................................................................................. 35 
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4.  QUALITY ASSURANCE PROVISIONS ...................................................................................................... 35 

4.1  Responsibility for Inspection ....................................................................................................................... 35 
4.1.1  Responsibility for Compliance..................................................................................................................... 35 
4.2  Inspection .................................................................................................................................................... 35 
4.2.1  Vibration Prior to First Flight ....................................................................................................................... 35 
4.2.2  Ground and Flight Tests ............................................................................................................................. 36 
4.3  Cleaning of Parts and Systems................................................................................................................... 36 
4.3.1  System Contamination Level forPproduction Aircraft ................................................................................. 36 
4.4  Hydraulic System Information ..................................................................................................................... 36 
4.4.1  Hydraulic System Analysis and Design Study ............................................................................................ 36 
4.4.2  Developmental and Preproduction Study ................................................................................................... 36 
4.4.3  Hydraulic System Production Study............................................................................................................ 36 
4.4.4  Hydraulic System Design ............................................................................................................................ 37 
4.4.5  Hydraulic System Nonstandard Component Cross-Sectional Assembly Drawings ................................... 37 
4.4.6  Functional Simulator Design and Test Program ......................................................................................... 37 
4.4.7  Vibration Test Plan ...................................................................................................................................... 37 
4.4.8  Consideration of Data Requirements.......................................................................................................... 37

5.  PREPARATION FOR DELIVERY ............................................................................................................... 38

6.  NOTES ........................................................................................................................................................ 38 

6.1  Intended Use ............................................................................................................................................... 38 
6.2  MIL-H-5440 ................................................................................................................................................. 38 
6.3  Qualified Products Lists .............................................................................................................................. 39 
6.4  Document Change Identification ................................................................................................................. 39

APPENDICIES

APPENDIX A CERTIFICATION/DATA REPORT TECHNICAL CONTENT REQUIREMENTS ....................................... 40 

APPENDIX B TEST REPORT TECHNICAL CONTENT REQUIREMENTS..................................................................... 44

TABLES

TABLE 1 SYSTEM PEAK PRESSURE ...................................................................................................................... 12 

TABLE 2 HYDRAULIC PRESSURE .......................................................................................................................... 13 
TABLE 3 HYDRAULIC LINE SUPPORT SPACING, U.S. CUSTOMARY ................................................................. 32 
TABLE 4 HYDRAULIC LINE SUPPORT SPACING, METRIC................................................................................... 33 
TABLE 5 DATA REQUIREMENTS ............................................................................................................................ 38 
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1. SCOPE

This specification covers the design and installation requirements for Types I and II military aircraft hydraulic systems.

1.1 Classification

Military aircraft hydraulic systems shall be of the following types and classes, as specified:

1.1.1 Types

Type I Maximum fluid operating temperature +160 °F (+71 °C).

Type II Maximum fluid operating temperature +275 °F (+135 °C).

1.1.2 Classes

The class of operating pressure shall consist of the following:

a. Class 1500. 1500 psi (10 342 kPa) nominal operating pressure

b. Class 3000. 3000 psi (20 684 kPa) nominal operating pressure

c. Class 4000. 4000 psi (27 579 kPa) nominal operating pressure

d. Class 5000. 5000 psi (34 473 kPa) nominal operating pressure

e. Class 8000. 8000 psi (55 158 kPa) nominal operating pressure

For variable pressure level systems, such as 5000 psi and 3000 psi, the highest pressure shall determine the pressure
class. The pressure class shall be annotated with a “V” to indicate variable pressures (example: class 5000V)

2. REFERENCES

The following publications form a part of this document to the extent specified herein. The latest issue of SAE publications
shall apply. The applicable issue of the other publications shall be the issue in effect on the date of the purchase order. In
the event of conflict between the text of this document and references cited herein, the text of this document takes
precedence. Nothing in this document, however, supersedes applicable laws and regulations unless a specific exemption
has been obtained.

2.1 Applicable Documents

2.1.1 SAE Publications

Publications are available from SAE International, 400 Commonwealth Drive, Warrendale, PA 15096-0001, Tel: 877-606-
7323 (inside USA and Canada) or 724-776-4970 (outside USA), www.sae.org.

ARP584 Coiled Tubing, Corrosion Resistant Steel, Hydraulic Applications, Aerospace

ARP598 Aerospace Microscopic Sizing and Counting of Particulate Contamination for Fluid Power Systems

AS603 Impulse Testing of Hydraulic Hose, Tubing, and Fitting Assemblies

AS604 Hose Assembly, Polytetrafluoroethylene, Metallic Reinforced, 3000 psi, 400 °F, Heavyweight, Hydraulic

AS614 Hose Assembly, Polytetrafluoroethylene, Metallic Reinforced, 4000 psi, 400 °F, Heavy Duty, Hydraulic
and Pneumatic
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ARP994 Recommended Practice for the Design of Tubing Installations for Aerospace Fluid Power Systems

ARP1192 Procedure for Calibration and Verification of a Liquidborne Particle Counter: An Absolute Standard

AS1290 Graphic Symbols for Aircraft Hydraulic and Pneumatic Systems

AS1300 Port - Ring Locked Fluid Connection Type, Standard Dimensions For

AS1339 Hose Assembly, Polytetrafluoroethylene, Metallic Reinforced, 3000 psi, 400 °F, Lightweight, Hydraulic
and Pneumatic

ARP1383 Impulse Testing of Aerospace Hydraulic Actuators, Valves, Pressure Containers, and Similar Fluid
System Components

AS1975 Hose Assembly, Polytetrafluoroethylene, Para-Aramid Reinforced, 3000/4000 psi, 275 °F, Standard Duty,
Hydraulic, Aircraft Systems

AMS3216 Fluorocarbon (FKM) Rubber, High-Temperature- Fluid Resistant Low Compression Set 70-80

AMS3218 Fluorocarbon (FKM) Rubber, High-Temperature- Fluid Resistant Low Compression Set 85-95

AIR4057 Secondary Filters For Fluid System Reliability

AS4059 Aerospace Fluid Power-Cleanliness Classification For Hydraulic Fluids

AMS4081 Aluminum Alloy Tubing, Hydraulic, Seamless, Drawn, Round, 1.0Mg - 0.60Si - 0.28Cu - 0.20Cr (6061-
T4), Solution Heat Treated and Naturally Aged

AMS4083 Aluminum Alloy Tubing, Hydraulic, Seamless, Drawn, Round, 1.0Mg - 0.60Si - 0.28Cu - 0.20Cr (6061-
T6), Solution and Precipitation Heat Treated

ARP4146 Coil Tubing, Titanium Alloy, Hydraulic Applications, Aerospace

AS4201 Port-Ring Locked Fluid Connection Type 8000 psi - Design Standard

AS4251 Coupling Assemblies, Non-Locking Probe Style, Self-Aligning, Self-Sealing, Disconnects

AS4330 Tubing, Flared, Standard Dimensions For, Design Standard

ARP4378 Aerospace - Accumulator, Hydraulic, Welded Bellows, Factory Precharged

ARP4386 Terminology and Definitions for Aerospace Fluid Power, Actuation and Control Technologies

AS4395 Fitting End, Flared, Tube Connection, Design Standard

AS4396 Fitting End - Bulkhead Flared Tube Connection, Design Standard

ARP4553 Aerospace, Hydraulic, Accumulator, Self Displacing

AS4716 Gland Design, O-Ring and Other Elastomeric Seals

ARP4835 Valves, Aircraft, Hydraulic, Thermal Expansion Relief

AMS4945 Titanium Alloy Tubing, Seamless, Hydraulic, 3Al - 2.5V, Controlled Contractile Strain Ratio Cold Worked,
Stress Relieved

ARP4946 Aerospace - Valves, Check, Hydraulic, Aircraft and Missile

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AS5202 Bosses, Fluid Connection-Internal Straight Thread

AMS5561 Steel Tubing, Welded and Drawn, 9.0Mn-20Cr-6.5Ni-.28N High Pressure Hydraulic

AS5586 Aerospace – General Requirements for Hydraulic System Reservoirs

AS5781 Retainers (Backup Rings), Hydraulic and Pneumatic, Polytetrafluoroethylene Resin, Single Turn, Scarf-
Cut, for Use in AS4716 Glands

AS5782 Retainers (Backup Rings), Hydraulic and Pneumatic, Polytetrafluoroethylene Resin, Solid, Un-Cut, For
Use in AS4716 Glands

AIR5829 Air in Aircraft Hydraulic Systems

AS5891 Achieving Cleanliness Standards for Aircraft Hydraulic Systems During Manufacture

AS5994 Pump Units, Hydraulic, Electric Motor Driven, Variable Delivery

AMS-T-6845 Tubing, Steel, Corrosion Resistant (530400), Aerospace Vehicle Hydraulic System, 1/8 Hard Condition

AMS7259 Rings, Sealing, Fluorocarbon (FKM) Rubber, High-Temperature- Fluid Resistant Low Compression Set 85-95

AMS7276 Rings, Sealing, Fluorocarbon (FKM) Rubber, High-Temperature- Fluid Resistant Low Compression Set 70-80

AS7997 Motors, Aircraft Hydraulic, Constant Displacement, General Specification For

AS8775 Hydraulic System Components, Aircraft and Missiles, General Specification for

AS19692 Pumps, Hydraulic, Variable Flow, General Specification For

AS33583 Tubing End - Double Flare, Standard Dimensions For

AS33584 Tubing End - Standard Dimensions for Flared

AS33611 Tube Bend Radii

AS50881 Wiring, Aerospace Vehicle

AMS-P-83461 Packings, Preformed, Petroleum Hydraulic Fluid Resistant, Improved Performance at 275 °F (135 °C)

AMS-P-83461/1 Packing, Preformed, Petroleum Hydraulic Fluid Resistant, Improved Performance at 275 °F (135 °C)
Sizes and Tolerances

AMS-P-83461/2 Packing, Preformed, Petroleum Hydraulic Fluid Resistant Improved Performance at 275 °F (135 °C)
For Use In Boss Fittings, Sizes and Tolerances

AMS-R-83485 Rubber Fluorocarbon Elastomer Improved Performance at Low Temperatures

AS85421 Fittings, Tube, Fluid Systems, Separable, Beam Seal, 3000/4000 psi, General Specification For

AS85720 Fittings, Tube, Fluid Systems, Separable, High Pressure Dynamic Beam Seal, 5000/8000 psi, General
Specification For

AS94900 Aerospace - Flight Control Systems-Design, Installation and Test of Piloted Aircraft, General Specification For
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2.1.2 US Government Publications

Available from the Document Automation and Production Service (DAPS), Building 4D, 700 Robbins Avenue,
Philadelphia, PA 19111-5094, Tel: 215-697-9495, https://assist.daps.dla.mil/quicksearch/.

2.1.2.1 Active Specifications

MIL-PRF-5503 Actuators: Aeronautical Linear Utility, Hydraulic, General Specification For

MIL-DTL-5508 Fuses, Aircraft Automatic Quantity-Measuring, Hydraulic

MIL-J-5513 Joints, Hydraulic, Swivel

MIL-B-8584 Brake Systems, Wheel, Aircraft Design Of

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

MIL-DTL-9395 Switches Pressure (Absolute, Gage and Differential), General Specification For

MIL-DTL-25427 Coupling Assembly, Hydraulic, Self Sealing, Quick Disconnect, General Specification For

MIL-DTL-25579 Hose Assembly, Tetrafluoroethylene, High Temperature, Medium Pressure, General Specification For

MIL-DTL-27267 Hose, Polytetrafluoroethylene, 450 Degrees F, Medium Pressure

MIL-DTL-27272 Fittings, Polytetrafluoroethylene Hose, High Temperature, Medium Pressure, General Requirements For

MIL-V-29592 Valve, Air Vent, Automatic, Hydraulic, Low Pressure Type II Systems, General Specification For

MIL-PRF-46170 Hydraulic Fluid, Rust Inhibited, Fire Resistant, Synthetic Hydrocarbon base

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

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

MIL-PRF-83282 Hydraulic Fluid, Fire Resistant, Synthetic Hydrocarbon Base, Aircraft, Metric, NATO Code Number H-537

MIL-DTL-83296 Fittings, Corrosion Resistant Steel, High Temperature, High Pressure (3000 PSI), Hydraulic and
Pneumatic, General Specification for

MIL-DTL-83298 Hose, Conductive, Polytetrafluoroethylene Tube, High Temperature, High Pressure (3000 PSI),
Hydraulic And Pneumatic

MIL-F-83300 Flying Qualities of Piloted V/STOL Aircraft

MIL-DTL-85052 Clamp, Loop, Cushion, General Specification For

MIL-DTL-85052/1 Clamp, Loop, Tube, 17-7 PH CRES, 275 °F, Fuel and Petroleum Based Hydraulic Fluid Resistant

MIL-DTL-85052/3 Clamp, Loop, Tube, 17-7 PH CRES, 500 °F

MIL-V-85245 Valve, Relief, Hydraulic, High Response, Type II Systems, General Specification For

MIL-H-85800 Hose Assemblies, Polytetrafluoroethylene Aramid Fiber Reinforced, 5000 and 8000 psi, General
Specification For
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MIL-PRF-87257 Hydraulic Fluid, Fire Resistant; Low Temperature, Synthetic Hydrocarbon Base, Aircraft and Missile

2.1.2.2 Inactive Specifications

The following publications are provided for information purposes only and are not a part of this SAE Aerospace Technical
Report. The procuring agency may use these documents as guidance or invoke them as necessary.

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

MIL-V-5519 Valves, Regulating Fluid Pressure

MIL-V-5525 Valves, Aircraft Power Brake

MIL-V-5530 Valves, Aircraft Hydraulic Shuttle

MIL-P-5954 Pump Unit, Hydraulic, Electric Motor Driven, Fixed Displacement

MIL-DTL-8348 Gage Assemblies, Air Pressure, Dial Indicating Chuck Type, Self-Contained

MIL-T-8504 Tubing, Steel, Corrosion-Resistant (304), Aerospace Vehicle Hydraulic Systems, Annealed, Seamless
and Welded

MIL-V-8566 Valves; Aircraft Hydraulic Flow Regulator

MIL-H-8891 Hydraulic Systems, Manned Flight Vehicles, Type III Design, Installation and Data Requirements For,
General Specification For

MIL-V-19067 Valves, Check, Controllable, Hydraulic, Aircraft, Type II Systems

MIL-DTL-19068 Valve, Shuttle, Hydraulic, Aircraft, Type II Systems

MIL-PRF-25675 Valves, Check, Miniature, Hydraulic, Aircraft and Missile

2.1.2.3 Cancelled Specifications

The following publications are provided for information purposes only and are not a part of this SAE Aerospace Technical
Report. The procuring agency may use these documents as guidance or invoke them as necessary.

MIL-P-7858 Pump, Hydraulic, Power Driven, Fixed Displacement

2.1.2.4 Active Standards

MIL-STD-464 Electromagnetic Environmental Effects Requirements for Systems

FED-STD-791 Lubricants, Liquid Fuels and Related Products; Methods of Testing

MIL-STD-1472 Human Engineering

MIL-STD-1797 Flying Qualities of Piloted Aircraft

MIL-HDBK-2069 Aircraft Survivability

MIL-HDBK-2089 Aircraft Survivability Terms

MIL-STD-5522 Test Requirements and Methods for Aircraft Hydraulic and Emergency Pneumatic Systems

MIL-STD-7179 Finishes, Coatings, And Sealants For The Protection Of Aerospace Weapons Systems
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MIL-F-8815/4 Filter, Fluid, Pressure, Hydraulic Line, 3000 PSI, Absolute 5 Micron, Style A, Bypass, -65 °F to
+275 °F

MIL-F-8815/5 Filter, Fluid, Pressure, Hydraulic Line 3000 PSI, Absolute 5 Micron, Style B, Non Bypass, -65 °F to
+275 °F

MIL-F-8815/6 Filter Elements, Noncleanable, Fluid Pressure, Hydraulic Line, 3000 PSI, 5 Micron Absolute -65 °F to
+275 °F

2.1.2.5 Inactive Standards

The following publications are provided for information purposes only and are not a part of this SAE Aerospace Technical
Report. The procuring agency may use these documents as guidance or invoke them as necessary.

AN929 Cap Assembly, Pressure Seal Flared Tube Fitting

MIL-STD-1247 Markings, Functions and Hazard Designations of Hose, Pipe, and Tube Lines for Aircraft, Missile, and
Space Systems

MS14169 Circular Spline and Adapter Details Engine Driven Accessories

MS14184 Nonmetallic Shaft-Coupling Details, Engine Driven Accessories

MS21344 Fitting, Installation of Flared Tube, Straight Threaded Connectors, Design Standard For

2.1.2.6 Navy Department Technical Manuals

Copies of documents are available from the Navy Aviation Supply Office, Code 03443, 5801 Tabor Avenue, Philadelphia,
PA 19120-5099.

NAVAIR 01-1A-17 Aviation Hydraulics Manual

NAVAIR 01-1A-20 Aviation Hose and Tube Manual

2.1.3 NAS Publications

Publications are available from Aerospace Industries Association, 1000 Wilson Boulevard, Suite 1700, Arlington, VA
22209-3928. Tel: 703-358-1000, www.aia-aerospace.org.

NASM85449 Clamp Assembly, Saddle-Type, Cushion, General Specification For

NASM85449/1 Clamp Assembly, Saddle-Type, Cushioned, NBR Rubber, 321 CRES, 275 °F, Fuel Resistant, General
Purpose

NASM5449/3 Clamp Assembly, Saddle-Type, Cushioned, Silicone Fabric, Reinforced, 321 CRES, 500 °F, General
Purpose

2.2 Definitions

General definitions for terminology used within this document may be found in ARP4386. The following definitions are
unique to this document.

2.2.1 Utility System

The hydraulic system that supplies power for the normal operation of any services on the aircraft, excluding the operation
of the aircraft primary flight control system surfaces.
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2.2.2 Flight Control System

The hydraulic system that supplies power for primary flight control systems used to actuate such surfaces as ailerons,
rudders, elevators, stabilizers, or combined function surfaces.

2.2.3 Combined Flight Control Utility System

The hydraulic system that supplies a portion of the power required for primary flight control and also supplies power to the
utility services.

3. REQUIREMENTS

3.1 Materials

Materials used in the manufacture of hydraulic systems in military aircraft shall conform to applicable Government
specifications. The use of contractor specifications in lieu of an applicable Government specification requires the approval
of the procuring agency.

Use of aluminum materials in flight control components in 5000 psi (34 473 kPa) systems and above, require special
precautions to ensure conformance to the fatigue requirements for production configuration parts. The use of aluminum
alloy parts for 5000 psi and greater is not encouraged and shall not be used unless approved by the contracting activity.

Contractor’s specifications must be accepted by the Government and contain provisions for tests. The use of contractor’s
specifications will not constitute waiver of Government inspection.

3.2 Design

The hydraulic systems and components shall be designed to operate under all conditions that the aircraft may encounter
within the structural limitations of the aircraft, including forces or conditions caused by:

a. Acceleration or deceleration

b. zero gravity (g), negative g, or any flight attitudes obtainable with the aircraft

c. structural deflection

d. vibration

e. other environmental conditions.

The hydraulic systems shall be configured such that failure of any two fluid systems resulting from combat or other
damage which cause loss of fluid or pressure will not result in complete loss of flight control.

Fixed wing aircraft shall maintain level one (1) flying qualities of MIL-STD-1797 with one fluid system failure (including the
power source) and level three (3) flying qualities including carrier landing, with two fluid system failures.

Rotary wing aircraft shall meet MIL-F-83300 flying qualities with two fluid system failures for return to the intended landing
area (including shipboard areas and land).

General aircraft combat survivability guidelines are provided in MIL-HDBK-2069 and MIL-HDBK-2089.

3.3 Hydraulic Fluid

Fluid conforming to MIL-PRF-83282 and MIL-PRF-87257 shall be used for hydraulic systems and associated ground
equipment. Other hydraulic fluid may be used when specified by the contracting activity. Hydraulic fluids containing
barium (i.e., MIL-PRF-46170) shall not be used.
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3.4 Hydraulic Seals

AS4716 shall be used for gland design and seal assembly installation. O-rings with cross-sectional diameters of 0.070
(1.778 mm) inch or less, or their equivalent proprietary seals, shall not be used as external seals.

3.4.1 Gland Design

Seal gland dimensions shall conform to the requirements of AS4716. Nonstandard glands for specialized seal assemblies
shall be used only with the approval of the contracting activity. For system pressure levels above class 3000, the
diametral clearance gaps of AS4716 may be reduced from the minimum of 0.003 inch (0.076 mm) to improve seal life and
aid in preventing seal assembly extrusion. Care shall be taken to prevent binding and interference at the most adverse
temperature extremes. Standard clearance may be used for system pressure levels greater than 3000 psi (20 684 kPa) if
proprietary-type seal assemblies and high modulus backup ring materials are used.

3.4.2 O-ring and Seal Assemblies

O-rings shall conform to AMS-P-83461, AMS7276, AMS7259, AMS3216, AMS3218 or AMS-R-83485 Seal assembly
configurations other than O-ring may be used in standard glands if design permits. For AS5202 and AS1300 ports, use
AMS-P-83461/1 and AMS-P-83461/2, as applicable.

3.4.3 Backup rings

AS5781 and AS5782 back up rings shall be used in AS4716 seal glands. Solid backup rings shall conform to AS5782.
Scarf-cut backup rings conforming to AS5781 may be used on dynamic applications where minimum seal friction is
required for satisfactory operation or where access to the gland prevents installation of AS5782. If AS5782 solid backup
rings are used on dynamic piston applications, friction due to pressure entrapment between the backup rings must be
considered in the design of the device.

Extra care, training and drawing notes should be implemented to prevent backup rings designed for AS4716 grooves from
being inadvertenly used in MIL-G-5514 grooves and vice versa. Note that backup rings per AS5781 and AS5782 are color
coded to help prevent incorrect installation into MIL-G-5514 glands.

Nonstandard backup rings may be used for system pressure levels greater than class 3000 (20 684 kPa), subject to the
approval of the contracting activity. AS5781 and AS5782 provide alternate backup ring material recommendations for
pressure applications higher than 3000 psi.

3.5 Functional Simulator

A functional simulator(s) for the hydraulic system shall be constructed to determine system performance.

As required, separate simulators may be constructed for utility functions such as landing gear, wing fold, steering and
brakes. However, all components required for flight control must be on one simulator. The utility functions not on the
flight control simulator must be reproduced with hydraulic loads and valves necessary to functionally control this load in
the system. Arrangement shall be made for the application of simulated flight loads.

Tubes, fittings, and tube material for all simulators shall be identical to those installed in the first flight aircraft. Tubing
installations shall match line length and total bend angle for each functional leg installed in the aircraft. Line to line
connections where no change in tube size or flow direction occurs may be eliminated.

Prototype components or laboratory models may be used for systems development testing. However, before first flight,
testing shall be accomplished on the simulator with all components and simulated loading incorporated. This safety of
flight testing shall simulate a mission profile to duplicate actual aircraft flight conditions. All functions shall operate in
sequence for a check on unusual back pressure, surges, temperature, pump pulsation, and vibration. They shall simulate
start-up, flight-control checkout, door closing, braking, steering, flap retraction, gear retraction, and power flight control
under takeoff, cruise, approach, landing, and taxi conditions. All emergency modes and system failure conditions as
required by section 3.2 shall be demonstrated.
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The simulator shall be maintained beyond the development and test phase to be used to evaluate significant changes to
the system during production of the aircraft.

3.6 General System Design

Hydraulic systems shall be as simple and foolproof as possible and in accordance with design, operation, inspection, and
maintenance objectives specified in the aircraft design requirements. For Navy aircraft, the hydraulic system shall be
designed to accommodate the maintenance procedures described in NAVAIR 01-1A-17 and NAVAIR 01-1A-20 manuals.

Each hydraulic system shall be separated from all other systems and fluid shall not be transferred between systems such
that one reservoir level would increase and another reservoir level decrease.

3.6.1 Fluid Temperature Limitations

The hydraulic system, with MIL-PRF-83282 fluid shall be capable of starting and operating at fluid temperatures between
–40 °F (-40 °C) and the upper limit of the operating envelope.

Fluid temperatures shall not exceed +160 °F (+71 °C) for Type I systems and +275 °F (+135 °C) for Type II systems at
any point in the system. Operation at these temperatures shall not result in any degradation of the system. With MIL-
PRF-87257 fluid, the low temperature limit shall be –65 °F (-54 °C).

3.6.1.1 Climate Extremes

Ground operation, flight operation and storage climatic extremes shall be in accordance with the weapon system
procurement specification.

3.6.2 Fire Hazards

The hydraulic system shall be so designed and installed with other systems that it will eliminate or isolate the system(s)
from fire hazards caused by proximity of combustible gases, heat sources, bleed-air ducts or electrical ignition sources.
Hydraulic lines and equipment located in the vicinity of heat and ignition sources that may cause spontaneous ignition or
sustained fire of hydraulic leakage from these lines or equipment shall be protected by devices such as fire walls,
shrouds, or equivalent means that will prevent fluid ignition.

Rotating components that fail and continue to rotate shall be disconnected from their driving source or stopped to prevent
heat generation and the possibility of fire.

3.6.3 Surge Pressure

Peak pressure resulting from any phase of the system operation shall not exceed the percent value shown in Table 1 for
the main system, subsystem, or return system pressures when measured with electronic or other test equipment.

TABLE 1 - SYSTEM PEAK PRESSURE

Pressure Class, Psi (kPa) Peak Pressure

1500, 3000, 4000, and 5000 135% of system nominal operating pressure
(10 342, 20 684, 27 579 and 34 473)
8000 (55 158) 120% of system nominal operating pressure.

3.6.3.1 Pressure Limitations

Pressure limitations shall be in accordance with Table 2.

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TABLE 2 - HYDRAULIC PRESSURE

Component or Pressure (See Note 1) Remarks

Characteristic
Class 5000 Class 8000
(34 473 kPa) & (55 158 kPa)
below
Pump Pressures
1. Pump pressure at 100% 100% System design
zero flow pressure
2. Pump minimum 100% -150 psi 100% -150 psi
pressure at full flow
(100% -1034 kPa) (100% - 1034 kPa)
Relief Valve Pressure Settings
1. System relief valve See Para 3.11.21
maximum pressure
100% + 850 psi 100% + 850 psi
at rated flow
(100% + 5860 kPa) (100% + 5860 kPa)

2. Thermal relief valve 100% + 1000 psi 100% + 1000 psi

cracking pressure
(100% + 6895 kPa) (100% + 6895 kPa)
Proof Pressures (minimum)
1. Lines, fittings, Proof pressures values
hoses and for hoses to be in
couplings accordance with the
applicable specification
(a) Pressure circuits 200% 200%

(b) Return and case 100% 100%

drain circuits
2. Accumulators 200% 200% See para. 3.11.21
3. Low pressure side
of reservoir & pump
suction line for the
following reservoir
types:
(a) Bootstrap reservoir 150% of reservoir
operating pressure

(b) Gas pressurized 200% of reservoir

reservoirs operating pressure
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TABLE 2 - HYDRAULIC PRESSURES (CONTINUED)

Component or Pressure (See Note 1) Remarks

Characteristic
Class 5000 Class 8000
(34 473 kPa) & (55 158 kPa)
below
Proof Pressures (minimum)
4. Components under 150% 150%
system pressure
5. Components under 100% 100% Except for hoses which
return pressure shall be 125% of
only system pressure
6. Heat exchangers 150% 150% 150% of maximum
operating pressure
7. Complete System
(a) Pressure side 150% 150% Aircraft installed
systems only
(b) Return side 75% 75%
Burst Pressures (minimum)
1. Lines, fittings,
hoses and Burst pressures values
couplings for hoses to be in
accordance with the
(a) Pressure circuits 400% 300% applicable specification
but not less than this
(b) Return and case 200% 150% table
drain circuits
2. Accumulators 400% 400%
3. Low pressure side
of reservoir & pump
suction line for the
following reservoir
types:

(a) Bootstrap reservoir 300% of reservoir 300% of reservoir

operating pressure operating pressure

(b) Gas pressurized 400% of reservoir 400% of reservoir

reservoirs operating pressure operating pressure
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TABLE 2 - HYDRAULIC PRESSURES (CONTINUED)

Component or Pressure (See Note 1) Remarks

Characteristic
Class 5000 Class 8000
(34 473 kPa) & (55 158 kPa)
below
Burst Pressures (minimum)
4. Components under 250% 200%
system pressure

5. Components under 150% 150% Except for hoses which

return pressure only shall be 125% of
system pressure
6. Heat exchangers 250% of maximum
operating pressure
7. Collapse pressure 50 psid (345 Kpa) 50 psid (345 Kpa)
of parts subject to external external
suction

Note 1: Percentage of supply pressure, pressure in psi or as otherwise noted.

3.6.3.2 Back Pressure

The system shall be so designed that proper functioning of any unit such as internal actuator locks or brakes will not be
affected by the maximum back pressure in the system. The system or systems shall also be so designed that
malfunctioning of any unit in the system will not render any other subsystem, emergency system, or alternate system
inoperative because of back pressure.

3.6.3.3 Brakes

Back pressure resulting from the operation of any unit while the aircraft is on the ground shall create no greater back
pressure at the brake valve return port than 90 percent of that pressure which will cause contact of braking surfaces. In
addition, supply pressure to the brake system shall not drop below the maximum brake-operating pressure during the
operation of any other subsystem in the aircraft during taxiing, landing, or takeoff.

3.6.3.4 Pressure Regulation

System pumps shall use an internal pressure regulating device to limit excessive pressure and to maintain constant
pressure at varying flow demands. An independent safety relief valve shall also be incorporated into each system.

3.6.3.5 Variable Pressure Systems

Systems that vary the pump operating pressure as power demand varies shall provide hydraulic power with pump(s)
failed at the high or low pressure setting to maintain flying qualities set forth in paragraph 3.2. All design factors and
pressure ratings cited in this document shall be applied at the maximum pump discharge pressure.

3.6.3.6 Return System

As a minimum, lines, fittings, and equipment in return circuits shall be designed for 1/2 the system pressure, with the
exception of some components as noted in Table 2.
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3.6.4 Strength

3.6.4.1 Additional Loads

All hydraulic systems and components which are subjected, during operation of the aircraft, to structural or other loads
which are not of hydraulic origin shall withstand such loads when applied simultaneously with appropriate proof pressure
as specified in Table 2 without exceeding the material yield point at the maximum operating temperature.

3.6.4.2 Loads Due to Aircraft Acceleration

All components and their attached lines and fittings, subjected to loads resulting from airframe accelerations, shall be
designed and tested on the basis of a pressure equal to the maximum pressure that will be developed, at the maximum
operating temperature. This operation shall not exceed the material yield point.

3.6.5 Reservoir Pressurization

The reservoir shall be designed so that the hydraulic fluid is completely separated from the atmosphere during normal
functioning of the system. The reservoir pressure shall be adequate to provide pump full flow performance at –20 °F (-29 °C).

3.6.6 Fluid Velocity Limitations

Tubing size and maximum fluid velocity for each system shall be determined considering, but not limited to, the following:

a. Allowable pressure drop at minimum required operating temperatures.

b. Pressure surges caused by high fluid velocity, rapid closure of valves, and rapid actuator piston deceleration.

c. Back pressure in return lines, as it may affect brakes and pump-case drain lines.

d. Pump inlet pressure, as affected by long suction lines, and a high response rate variable-delivery pump.
Consideration should be given to both pressure surges and cavitation.

3.6.6.1 Fluid Flow Effects

The systems shall be so designed that malfunctioning of any unit or subsystem will not occur because of reduced flow,
such as created by single-pump operation of a multiple-pump system, or reduced engine speed. The systems shall also
be designed such that increased flow will not adversely affect the proper functioning of any unit or subsystems; examples
include increased flow rate caused by accumulator operation or units affected by the operation with aiding loads.

3.6.7 Subsystem Isolation

Two or more subsystems pressurized by a common pressure source, one of which is essential to flight operation and the
other not essential, shall be so isolated so that the system essential to flight operation will not be affected by any damage
to the nonessential system.

3.6.8 Ground Service Provisions

Each hydraulic system shall include a set of self-sealing couplings for attachment of ground power sources. System
ground service provisions shall be so designed that pressurization of any hydraulic system in the aircraft is not necessary
in order to test another hydraulic system. A central ground servicing station shall be provided for each system that
includes connections for attachment of ground service equipment for system checkout and flushing, reservoir bleeding,
reservoir fill, and accumulator nitrogen charging.
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3.6.8.1 Ground Service Connections

A set of self-sealing couplings consisting of bulkhead halves and protective caps shall be provided at a convenient
location in the aircraft, easily accessible from the ground, for attachment of ground service equipment. The aircraft
bulkhead halves shall mate with the ground cart hose halves without the use of adapters. The self-sealing coupling shall
be in accordance with MIL-DTL-25427 and its applicable specification sheets.

Electric motor-driven pumps used in emergency or auxiliary systems shall not be used for ground test purposes unless
the motor is designed for continuous operation.

3.6.8.1.1 Reservoir Supercharging Connection

When reservoirs are normally pressurized by either compressed air or nitrogen, a ground supercharging connection shall
be provided and shall consist of a fitting end in accordance with AS4395-4 or AS4396 for attachment to a ground
supercharging unit. A protective cap in accordance with AN929 with a safety chain shall be provided to protect the end
connection when not in use.

3.6.8.1.2 Reservoir Filling Connection

Reservoirs shall be filled by low-pressure replenishment methods. The reservoir filling connection shall be a check valve
and a self-sealing coupling for attachment to ground filling equipment. Direct pouring of fluid into the reservoir (including
in-flight fluid replenishment provisions) shall not be provided. When the reservoir level is not readily visible from the fill
connection, a remote indicator shall be provided at that point.

3.6.8.2 Ground Service Information

The following information shall be attached in a permanent manner on the aircraft near the ground service connections:

Set ground service reservoir pressurizing valve to __________ psi (kPa).

Set ground service stand relief valve to __________ psi (kPa).
Set ground service stand volume output to __________ gpm (lpm).
Set ground service stand pressure compensator to __________ psi (kPa).
Use hydraulic fluid conforming to __________.
Ground service stand output filter shall be __________ microns absolute.
(Any other precautions or information considered necessary.)

The contractor shall fill in the values of the blank underline.

3.6.9 Removal of Entrapped Air

Each hydraulic system shall be equipped with an air removal device to vent undissolved air from the system automatically
without operator intervention. The automatic bleed valves shall be in accordance with MIL-V-29592 and shall be so
designed that in case of failure in the open position, leakage of fluid shall be minimal. In the most adverse case of flight
duration, pressure and temperature, the leakage shall not exceed the emergency reserve capacity of the reservoir.

Each system shall also be equipped with a manual bleed valve. Bleed valves shall be accessible without exposing
personnel to undue hazards.

See AIR5829 for discussion of sources of air and design for air reduction and elimination in hydraulic systems.

3.6.9.1 On-Board Deaeration Equipment

When the need is recognized, consideration shall be given to the use of on-board deaeration equipment that will remove
both dissolved and undissolved air from the hydraulic oil and systems.
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3.6.10 Power Pumps

The hydraulic pump(s) shall be compatible with the installed aircraft system and shall not cause abnormal or undesirable
effects on the installed aircraft system. Primary pump applications designed for continuous duty shall be provided with at
least two qualified pump designs from separate manufacturing sources unless this requirement is waived by the
contracting activity. All pumps qualified for a given application shall be physically and functionally interchangeable and
shall be compatible with the system and each other to allow mixed use in multiple pump systems.

The pump drive couplings shall be designed to include non-metallic spline bushings to minimize wear. The spline
bushings shall be designed in accordance with MS14169 or MS14184 and shall be supplied with the gearbox.

3.6.10.1 Emergency Power Pumps

Hydraulic power pumps designed to provide emergency power to flight critical systems or brakes shall not be used for any
other functions.

3.6.10.2 Multiple Pumps

Multiple engine aircraft shall have pumps directly driven by at least two engines. The hydraulic systems shall have a
sufficient number of engine pumps, augmented if necessary by pumps powered by other separate sources, to provide
power to all systems critical for safe operation of the air vehicle. This requirement shall be met with any combination of
engines operating to maintain flight or to be used while taxiing.

3.6.10.3 Pump Pulsation

For all power generating components (engine pumps, power packages, transfer units, etc), pump pulsations shall be
controlled to a level which does not adversely affect the aircraft system tubing, components, and supports installation.
The contractor shall determine by test the effect of pump pulsations (pump ripple) on the hydraulic system. Initial tests
shall be conducted on the functional simulator, with recording equipment, and shall cover the complete speed range from
zero revolutions per minute (rpm) to the maximum speed, pressures, and flows that the pump will be subjected to when
installed in the aircraft. Adverse effects including induced resonant vibrations shall be eliminated. Results of the
functional simulator tests for pump ripple effects shall be documented, forwarded to the contracting activity, and shall be
verified on the first aircraft, and any additional corrections required shall be made prior to the first flight.

3.6.10.4 Pump Rotation Reversal

For equipment not designed to withstand reverse rotation, the system and components shall be designed so that no
single failure will permit reverse rotation.

3.6.10.5 Attenuators

The harmful effects of pump cavitation resulting from system failure or air ingestion from improper maintenance shall be
considered in the design of each hydraulic system. Where appropriate, as determined upon review by the contracting
activity, attenuators shall be installed to minimize these harmful effects.

3.6.11 Pump Supply Shutoff Valves

Pump supply (suction) shutoff valves shall be provided if the fire protection requirements of the particular model aircraft
specify the need for such equipment in other systems, such as fuel or lubricating oil systems, or both. These valves,
when required, shall not be located on the engine side of fire walls or flame-tight diaphragms but shall be located as close
as the design will permit to these members. However, the valves shall be so removed from the engine that the loss of the
engine from the attaching structure will not impair the operation of the valve. These valves shall be operable from the
cockpit, to both the closed and open positions.

3.6.12 Special Tools

Hydraulic systems shall be so designed that special tools will not be required for installation or removal of components.
Where special tools are absolutely necessary, they shall require approval by the contracting activity.
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3.6.13 System Pressure Indication

Pressure indicating equipment shall be provided to indicate the system pressure in hydraulic systems or subsystems.
This pressure indication may be displayed to the flight crew in conjunction with other information on a multifunction,
multiplexed display. For the emergency conditions of decreasing or fluctuating pressure, the pressure indication shall be
displayed immediately to the flight crew.

On engine driven multiple pump systems, pressure indicating equipment shall be provided for each pump to enable the
flight crew to check for proper operation of each pump without shutdown of any engine.

3.6.13.1 System Low-Pressure Warning Light

In addition, but not as a substitute for the requirement of 3.6.13, a warning light shall be installed in the cockpit in a
conspicuous location to warn the pilot of low hydraulic system pressure. The light shall be actuated by a pressure switch
in the system. There shall be a separate warning light for each hydraulic system. The warning light, or lights, shall not be
actuated by any combination of normal flight-control operations. A momentary flicker of the warning light during ground
checkout only is permissible, provided such condition is described in the appropriate aircraft operation and maintenance
manuals and provided such condition does not occur during flight unless a system malfunction exists.

3.6.13.2 Maintenance check Gages and Indicators

Pressure gages and indicators that require a preflight, postflight, or daily check shall not require workstands or platforms
in order to read the gages or indicators.

3.6.14 Fluid Sampling Valves

A fluid sampling valve, conforming to MIL-V-81940, shall be provided in the system return line that is common to all
actuating circuits and shall be located upstream of the main return line filter. The sampling valve(s) shall be located in a
readily accessible area and shall allow convenient use of sampling containers. Fluid sampling valves shall also be
provided in other portions of the system if considered necessary by the procuring activity. The sampling valve shall allow
representative fluid samples to be taken while the system is fully pressurized. Contamination generated by the operation
of the valve shall not adversely affect the fluid sample. The valve nozzle shall include a protective cap, and the cap shall
also prevent external leakage in the event of valve malfunction. The cap shall be provided with a security chain, or
equivalent, to prevent loss of the cap.

3.6.15 Automatic Diagnostic Monitor System

Integral with each hydraulic system, a diagnostic system shall be provided to continuously monitor the system and
components and detect out-of-tolerance conditions. These out-of-tolerance conditions shall be detected during flight
operations and give indication of a failed or failing component and indicate maintenance actions needed such as filter
replacement, accumulator recharging and over temperature indication. The information shall be stored during flight. At
the completion of the flight, the information shall be displayed upon demand at a central location on the aircraft readily
accessible to ground maintenance personnel without the use of work stands, platforms, or any other ground support
equipment. Sensors installed in the hydraulic system to accomplish this monitoring shall not degrade the safety of the
hydraulic system. Design of the system shall enable the integrity of the sensors and sensor circuits to be checked. At a
minimum, the system shall monitor the following components and conditions and record the conditions indicating
maintenance required and conditions indicating component deterioration leading to failure: main system hydraulic pumps,
accumulators, filters, reservoir fluid levels, reservoir fluid temperature, and system free air (see 4.4.8).

3.7 Utility System Design

All hydraulically operated services (excluding flight controls covered by 3.2) that are essential to the accomplishment of
the basic aircraft mission (weapon-bay doors, in-flight refueling, etc) or essential to land and stop the aircraft (landing
gear, brakes, excluding Types I and IV brakes of MIL-B-8584) shall have provisions for emergency actuation. No failure
of the utility system shall result in loss of the aircraft or damage that would prevent safe flight and safe landing of the
aircraft.
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3.7.1 Wheel Brake Systems

Wheel brake systems shall be in accordance with MIL-B-8584.

3.8 Flight Control System Design

Flight control systems as defined in paragraph 6.2, which require hydraulic power for operation shall conform to AS94900.

When multiple hydraulic systems are used for flight control, the hydraulic systems shall be so designed that ground
service equipment may be connected to either one of the flight control systems and that system may be operated without
adverse effects on the unpressurized system, such as overflow of the system or failure of any part thereof. In order to
accomplish this objective, automatic bypass of the fluid in the unpressurized system from one side of the actuator piston
to the other side may be provided.

3.8.1 System Isolation

Whenever hydraulic power is required for primary flight controls, a completely separate, integral hydraulic system shall be
provided to supply only the primary flight controls. This hydraulic system shall not be used to supply any other system or
component in the aircraft, unless approval is obtained from the contracting activity. This hydraulic system shall contain a
minimum number of components. Dual actuator systems may employ the combined flight control and utility system
function for one-half of the power, in which case the flight control function shall be given pressure priority.

3.8.1.1 Hydromechanical Components Built-In-Test (BIT) Function

All primary flight control hydromechanical components shall be monitored for failure conditions and fully integrated into
the BIT routines of the flight control system.

3.8.2 Hydraulic Power Failures

In aircraft, where direct mechanical control is unable to obtain aircraft controllability and the emergency requirements of
MIL-STD-1797 cannot be accomplished following hydraulic power failures, an emergency power source shall be designed
to provide controllability.

3.8.2.1 Emergency System Application

The means of engaging the emergency power system shall be either manual or automatic; however, they shall be of the
simplest and most reliable nature possible, consistent with the requirements of the aircraft. Manual engagement of the
emergency power system shall not be used unless specifically approved by the contracting activity.

If the aircraft has a single engine, the emergency power source shall be independent of the operation of this engine. On
multiple engine aircraft, the emergency source of power shall be on a different engine than the primary source of power.

In some cases, it is permissible to utilize the utility hydraulic system as the emergency source of power, if it is
accomplished in such a way that there is no interconnection with the flight control power system. No single failure can
cause loss of both flight control and utility systems.

Consideration shall be given to the possibility of landings wherein none of the engines are operating. Because some
engines will not windmill sufficiently to provide flight control power during landing, it may be necessary to provide
emergency power sources not dependent upon engine operation. In aircraft which are capable of being landed without
engine power, this condition shall not be considered an emergency, and provisions shall be made for landings with one of
the power systems failed while out of fuel. When designing for this condition, extreme care must be exercised not to
reduce the reliability of the power systems. The flight control power system shall return to normal operation upon
correction of the emergency condition. Where a ram air turbine is used as the source of emergency power, it shall be
capable of extension and operation under any flight conditions. The ram air turbine shall be capable of retraction if the
flight control system returns to normal operation.
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3.8.2.2 Disengagement and Bypass

Where direct mechanical control is utilized following primary hydraulic system failure, provisions shall be made for
automatic, direct bypass of the fluid from one side of the primary flight control actuator piston to the other side. Where the
actuator can be disengaged from the system, bypass will not be required. For dual actuator systems, the failed system
shall provide automatic bypass. Bypass damping may be required on stiffness-critical actuator designs.

3.8.3 System Separation

Hydraulic systems shall be separated as far as the design will allow to be less vulnerable and survivable to gunfire or
engine fires. Where design permits, multiple hydraulic systems should be on opposite sides of the fuselage, the wing
spar, or similarly separated. The systems necessary for safe flight shall be separated a minimum of 18 inches unless
survivability and vulnerability analyses show that less separation is satisfactory. Where it is deemed necessary for these
systems to come together, as in a dual tandem surface actuator, the actuator shall be protected from the threat to a
degree specified by the contracting activity.

3.8.4 Subsystems Pressure

Subsystems and branch circuits which use a pressure lower than the full system pressure shall be designed to withstand
and operate under full system pressure or shall have a relief valve installed downstream of the pressure reducing valve.
This relief valve may be incorporated into the same housing as the pressure reducer, provided the relief valve mechanism
is independent of the pressure reducer mechanism. The relief valve shall be capable of handling the full flow of the
pressure reducer. Bypass of the relief valve shall cause an external indicator to signal a failed pressure reducer.

3.8.5 Flight Control Power Sources

Aircraft primary flight control hydraulic systems shall have engine driven pumps as their source of power. Helicopter
primary flight control systems shall have transmission driven pumps as a source of power so that power will be available
during auto rotation.

3.8.6 System Temperature

The hydraulic flight control actuators shall provide the required actuation rates under minimum and maximum in-flight fluid
and ambient temperatures. The flight critical components shall not bind or jam under any combination of in-flight fluid and
ambient temperature conditions including single undetected failures, such as relief valves, worn pumps, failed valves and
other heat generating failures. The effects of differential fluid temperature in tandem units shall also be demonstrated
during actuator qualification testing.

3.9 Emergency System Design for Utility System

3.9.1 Emergency System Types

Where emergency devices are required in hydraulic systems, the emergency systems shall be completely independent of
the main system up to, but not necessarily including, the shuttle valve, the actuating cylinder, or motor. The system shall
be so designed that failure of an actuator in one subsystem shall not prevent the operation of or cause the failure of both
normal and emergency actuation of another subsystem. These emergency systems shall utilize hydraulic fluid,
compressed gas, gas generating devices, direct mechanical connection, or gravity. Mechanical connections may include
electromechanical units.

3.9.1.1 High Lift Devices

Where safe operational landings cannot be accomplished without the use of hydraulically operated high lift devices, they
shall be powered by dual actuator hydraulic systems or shall be provided with an emergency system.
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3.9.2 Emergency Line Venting

The emergency line from the shuttle valves shall be vented to the reservoir or to a low pressure (15 psi gage maximum,
above reservoir pressurization) nonsurging return line when the emergency system is not in use. When shuttle valve
leakage is not critical, the line may be vented to the atmosphere. Provisions shall be made to bleed the compressed gas
to the atmosphere rather than back to the reservoir after actuation of the emergency system.

3.10 Components

All components used in the system(s) shall conform to AS8775, and the appropriate detailed specifications, except the
requirements shall be upgraded to agree with Table 2 with respect to operating and test pressures. All components used
shall meet the impulse testing requirements as specified in AS603 or ARP1383. All protective finishes shall be in
accordance with MIL-STD-7179.

3.10.1 Standard Components

Standard components shall be used in preference to nonstandard components. Where no applicable AN, MS, or industry
standard exists, a uniquely designed component compatible with the performance, installation, and inspection, and
maintenance requirements shall be used.

3.10.2 Fixed Orifices

Orifices larger than 0.005 inch (0.127 mm) diameter but smaller than 0.070 inch (1.778 mm) diameter shall be protected
by adjacent integral strainer elements (last chance screens) having screen openings one-third to two-thirds of the
diameter of the orifice being protected. Orifices smaller than the 0.005 inch diameter are prohibited. Multiple-orifice fixed
restrictors are recommended as a means of increasing the orifice diameter and allowing the use of coarser strainer
elements, minimizing the risk of clogging. Orifice and strainer elements, in combination, shall be strong enough to absorb
system design flow and pressure drop without rupture or permanent deformation.

3.10.3 Actuators Essential to Safe Operation of the Aircraft

Where two or more independent hydraulic systems are utilized to power services essential for safe flight (e.g., primary
flight controls), the actuation and control devices shall be designed and constructed (either parallel or series
configuration) so that no single structural or hydraulic failure may cause loss of more than one hydraulic system or allow
transfer of fluid from one system to another. Aluminum shall not be used as a barrel material for actuators essential to
safe operation (flight control and landing gear).

3.11 Component Design and Installation

If a fluid, which is different from the specified fluid, is used for component testing and shipping, it shall be drained and
flushed with the specified fluid prior to the installation of the component in the aircraft.

3.11.1 Design Practice and Installation

The hydraulic system component installation requirements specified in the following subparagraphs are considered to be
good design practice, however, it is recognized that variations from these practices will, in many cases, be necessary due
to specific installation requirements. All installation of standard parts or components shall be designed to accommodate
the worst dimensional and operational conditions permitted in the applicable part or component specification of AN or MS
standards. All components shall be installed and mounted to withstand all expected acceleration loads, wrench loads,
and vibration effects.

3.11.1.1 Reverse Installation

All system components shall be designed so that reverse installation cannot occur. Nonstandard components shall be
used, if necessary, to conform to these requirements.
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3.11.2 Accumulators

Accumulators shall be installed with the utmost consideration given to the protection of crew members and flight essential
systems in case of rupture resulting from gun fire. Hydraulic accumulators shall be in accordance with ARP4553 (self-
displacing hydraulic accumulators), or ARP4378 (maintenance-free hydraulic accumulators).

3.11.2.1 Measurement of Accumulator Gas Pressure

When accumulator gas charge is critical to the functioning of the hydraulic system or subsystem, a permanent pressure
indicating device shall be attached to the gas side of the accumulator. The pressure indicating device shall not be used to
indicate equivalent hydraulic pressure to the crew members.

3.11.2.2 Accumulator Accessibility

In accumulator installations that require gas charging in the field, adequate access shall be provided around the gas
charging valve for use of a MIL-DTL-8348 high-pressure, gas-testing gage assembly and for standard fitting connections
to charge accumulators.

3.11.2.3 Accumulator Instructions

If the accumulator is rechargeable in the field, instructions for servicing the accumulator with gas pressure with the
accumulator oil chamber discharged shall be provided adjacent to the accumulator. Information shall be included to
indicate the proper gas preload pressure throughout the temperature range for which the accumulator will be serviced.

3.11.2.4 Gas Requirements

Accumulators shall be charged with inert gas only, such as dry nitrogen or helium.

3.11.3 Actuating Cylinders

Hydraulic actuating cylinders shall be so installed that they shall not interfere with the adjacent structure and are readily
accessible for maintenance and inspection. If design permits, the cylinder shall be installed in a protected area, or if
exposed, they shall be protected from flying debris during landing and takeoff. Actuating cylinders other than those used
for primary flight control shall conform to MIL-PRF-5503. For higher pressure systems, MIL-PRF-5503 shall be used
except the performance pressures shall be per Table 2.

3.11.4 Manual Bleed Valves

Manual bleed valves shall conform to MIL-V-81940 and shall be so located that they can be operated without removal of
other aircraft components. Such installations shall permit attachment of a flexible hose so that fluid bleed off may be
directed into a container (see 3.6.9).

3.11.5 Brake Valves

Brake valves shall be installed in accordance with MIL-B-8584 and shall conform to MIL-V-5525.

3.11.6 Check Valves

Check valves shall conform to MIL-PRF-25675, MIL-V-19067, or ARP4946.

3.11.7 Directional Control Valves

The installation of directional control valves shall be compatible with the control valve performance such that the system
operation may not be affected by back pressure, internal flow, or pressure surges which might tend to cause the valves to
open or move from their setting or cause them to transfer fluid from one system to the other. Hydraulic control valves
shall not be installed in the pilot’s cockpit or compartment.
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3.11.7.1 Directional Control Valve Handle Installation

All installations of directional control valve handles shall conform to MIL-STD-1472. Valve installation shall incorporate
internal or external stops capable of withstanding limit loads generated by the application of 75 lbs (334 N) on the handle
grip without detrimental effects.

3.11.7.2 Multiple Control Valve Systems

In systems which incorporate two or more directional control valves, provision shall be made to prevent fluid from being
transferred inadvertently, at any possible valve setting, from the cylinder ports of one valve into the cylinder ports of
another valve.

3.11.7.3 Control Valve Actuation

Control valve operation may be direct, such as push-pull rods, cable control, or indirect, such as electrically operated
controls. Push-pull rods shall require a minimum or no adjustment. Sheathed flexible controls shall not be used. Cable
control shall be designed to provide minimum adjustment and positive control. All controls shall be designed to prevent
overtravel or undertravel of the valve control handle by use of external or internal stops. Electrically operated valves shall
be provided with mechanical override control mechanisms.

3.11.7.4 Control Valve Wiring

Electrically operated control valves shall be wired in accordance with AS50881.

3.11.8 Pressure Regulating Valves

Valves that reduce pressure for utility circuits shall conform to MIL-V-5519.

3.11.9 Filters

Filters in accordance with MIL-F-8815 with an element collapse pressure of 150% of operating pressure shall be provided
in all hydraulic systems. These filters shall be used to filter all circulating fluid in the system. The pump pressure line filter
shall be located downstream from the ground servicing connection point, otherwise, an additional filter shall be required to
filter fluid entering the aircraft from the ground servicing unit.

All vent openings or fluid exposed to breathing action through vents shall be protected by filters.

Line filters installed in the aircraft system in close proximity to an accumulator, shall be, if design permits, installed
upstream from the accumulator.

When a secondary or last chance type filter screen is used internal to or in close proximity to a component, provisions
shall be made for removal and replacement of the screen.

Sintered metal powder type elements shall not be used in hydraulic systems. These types of filters may be used only as
air vent filters.

The system filter condition shall be monitored electronically.

3.11.9.1 Aircraft Filters

All filters installed in the hydraulic system(s) shall be in accordance with the requirements of MIL-F-8815/4, MIL-F-8815/5,
and MIL-F-8815/6 as applicable. All filter elements shall be capable of maintaining the particulate contamination level
equal to or better than the following: Class 8 per AS4059 in accordance with Method 3009 of FED-STD-791, with
automatic particle counter calibrated per ARP1192 or microscopic particle counts per ARP598.

Fluid samples for contamination tests shall be obtained from sampling valves specified in 3.6.14.
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3.11.9.2 Filter Locations

Filters shall be provided in the following locations as a minimum requirement.

3.11.9.2.1 Pressure Filter Installation

A non-bypass-type filter shall be installed in the system pressure circuit and shall be so located that all fluid from the
aircraft pump will be filtered prior to entering any major equipment or components of the system. In multiple pump
systems, each pump shall have a separate filter installation.

3.11.9.2.2 Return Filter Installation

A bypass-type filter shall be installed in the return circuit. All fluid entering the return circuit shall be circulated through the
filter prior to entering the return line to the pump(s) and reservoir.

3.11.9.2.3 Reservoir Fill Filter Installation

A non-bypass-type filter shall be installed to filter all fluid entering the system through the reservoir fill connection. The
main system return filter or the pump case drain filter may also be used for this function provided check valves are
installed in the system to prevent back flow to components. Also, the fill fluid flow rate shall be limited to prevent opening
of the filter housing bypass valve.

3.11.9.2.4 Pump-Case-Drain Filter Installation

Each pump-case-drain line shall have a bypass-type filter installed.

3.11.9.2.5 Pump Suction Filter Installation

Filters shall not be installed between the system reservoir and the pump suction port.

3.11.9.3 Hydraulic Sequencing

Where hydraulic sequencing is critical, and where contamination can prevent proper sequencing, each sequence valve
shall be protected from contamination in each direction of flow by a screen-type filter element. This element may be
included as a part of the sequence valve assembly.

3.11.9.4 Ground Support Equipment Filtration

All ground support equipment hydraulic filters shall be qualified to MIL-PRF-81836.

3.11.10 Fittings

As much as design permits, tube fittings shall be of the permanent type employing no screw threads. Threaded,
reconnectable type fittings shall be used for component installation, production break points, and at other points
consistent with the maintenance plan of the aircraft.

Repair and replacement methods involving failed tubing and fittings shall be established for each aircraft model and shall
be included in the applicable aircraft publications.

Fittings with threaded connections shall conform to AS85421 for Class 4000 pressure (27 579 kPa) or less and AS85720 for
greater than Class 4000. For installation in the aircraft, no lubrication or bonding material shall be applied to the threads of
reconnectable fittings except for the fluid specified in paragraph 3.3. Any other lubricating material necessary for the correct
installation of the fitting is specified in the fitting specification and is permanently applied to the fittings (see 4.4.8).
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3.11.10.1 Boss Fittings

Ring locked type boss fittings shall be used in all components. Ports for these fittings shall conform to the requirement of
AS1300 for Class 5000 systems (34 473 kPa) and below and AS4201 for Class 8000 systems (55 158 kPa) and below.
These ring locked fittings shall mate to either AS85421 or AS85720 fittings. For Class 4000 systems (27 579 kPa) and
below, AS5202 port may be used if design permits.

3.11.11 Flow Dividers

Flow dividers shall not be used if the effect of a malfunction of the flow divider would result in an unsafe flight condition.

3.11.12 Flow Regulators

Flow regulators may be installed in the hydraulic system to limit the rate of fluid flow. They shall conform to MIL-V-8566 for
Type I systems. The direction and rate of fluid flow shall be clearly indicated on the flow regulator and the adjacent structure.
Regulators used under continuous dynamic conditions shall not adversely affect the operation of the hydraulic system.

3.11.13 Protective Devices

Hydraulic fuses, circuit breakers, reservoir level sensors, or other similar devices may be used to meet survivability
requirements. Premature or inadvertent shutoff or any other malfunction of such devices shall not occur during any flow
or pressure variations or any conditions of system operation. The function and reliability of such devices shall be
demonstrated in the functional mock-up and simulator.

Hydraulic fuses for Type I systems shall conform to MIL-DTL-5508 (see 4.4.8).

3.11.13.1 Second Tier Screens

It is recommended that second tier screens, as defined by AIR4057 should, when fully clogged, withstand a proof
pressure test without collapse, rupture, or permanent deformation.

3.11.14 Snubbers

Pressure snubbers shall be used with all hydraulic pressure transmitters, hydraulic pressure switches, and hydraulic
pressure gages as required. Snubbers may be an integral part of the pressure transmitter switch or gauge. Pneumatic
pressure gages are excluded from this requirement.

3.11.15 Manually Operated Pumps

Where a manually operated pump is required, either a hand- actuated or foot-actuated pump shall be selected, based on
trade-off studies. In installations where a pump can be operated by personnel in a standing position, strong consideration
shall be given to a foot pump to minimize physical exertion.

3.11.15.1 Manually Operated Pump Suction Line

No screen or filter shall be used in the suction line of the pump. The suction line shall be of a diameter and length to
insure priming a dry pump and obtaining full rated flow at –40 °F (-40 °C) temperature within 12 complete cycles at a rate
of 20 cycles per minute. The pump circuit shall be capable of full priming and rated flow in flight at the highest altitude at
which pump operation is essential and intended.

3.11.15.2 Manually Operated Pump Check Valve

A standard check valve shall be provided in the pump pressure line.

3.11.15.3 Hand Pump Handle Length

The effective operating handle length of hand pumps shall be such that the handle load shall not exceed 67 pounds (298
N). The length of this handle travel at the handgrip shall not exceed 18 inches (45.7 cm).
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3.11.16 Flexible Connections

Whenever relative motion exists between two points, metal coiled tubing in accordance with ARP584 or ARP4146 shall
be used unless hoses, extension units, or swivels are demonstrated to be superior in the application and the environment.
Hoses are preferred over extension units and swivels and shall be selected according to the following paragraphs.

3.11.16.1 Hose Assemblies

Hose assemblies shall not be subjected to torsional deflection (twisting) when installed, or during system actuation. No
hose clamp type installation shall be used in hydraulic systems.

Class 1500 (10 342 kPa) polytetrafluoroethylene hose assemblies shall conform to MIL-DTL-25579. These hose
assemblies shall have permanent type end fittings and their installation shall allow space to permit replacement with
spares conforming to MIL-DTL-27267 and MIL-DTL-27272.

Class 3000 (20 684 kPa) polytetrafluoroethylene hose shall conform to AS604 and AS1339.

Class 4000 (27 579 kPa) polytetrafluoroethylene hose shall conform to AS614 and AS1975. Installations shall permit
replacement with MIL-DTL-83298 and MIL-DTL-83296 hose assemblies.

Class 5000 (34 473 kPa) and Class 8000 (55 158 kPa) aramid fiber hoses shall conform to MIL-H-85800.

3.11.16.2 Hose Support

The support of a flexible line shall be such that it will not tend to cause deflection of the rigid lines under any possible
relative motion that may occur. Flexible hose between two rigid connections may have excessive motion restrained where
necessary but shall not be rigidly supported as by a tight rigid clamp around the outside diameter of the flexible hose.
Extreme care should be used in the selection and placement of the supports to assure that the flexible line is not
restricted and does not rub on structure or adjacent members during any portion of its excursion. Clamping of aramid
fiber hoses is not permitted unless absolutely necessary to prevent chafing. Extreme caution must be used in clamping
these hoses to prevent any damage to the chafe guard or underlying fibers.

3.11.16.3 Hose Bend Radii

The minimum radius of bend for hose assemblies shall be a function of hose size and flexing range to which the hose
installation will be subjected. The minimum bend radius as installed for hoses shall be in accordance with the applicable
hose specification.

3.11.16.4 Hose Protection

Hose shall be protected against chafing where necessary to preclude damage to the hose and to the adjoining structure,
tubing, wiring, and other equipment.

3.11.16.5 Provisions for Hose Elongation and Contraction

Hose assemblies shall be so selected and installed that elongation and contraction under pressure, within the hose
specification limits, shall not be detrimental to the installation either by causing strains on the end fittings or excessive
binding or chafing of the hose.

3.11.17 Lock Valves

Where lock valves are used, provisions shall be made for fluid expansion and contraction throughout the temperature
range. Where several actuating cylinders are mechanically tied together, only one lock valve shall be used to
hydraulically lock all actuators so tied together (see 4.4.8).
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3.11.18 Motors

All constant-displacement motors shall be in accordance with AS7997 and they shall be accessible for maintenance and
inspection. Case flow connections shall be provided using a check valve in the case drain line. All case drain lines
should be connected to the system return line upstream of the reservoir provided the return steady state pressure is lower
than the motor case pressure. Connection of case drain lines to actuator return lines is prohibited. Shaft seal drain shall
be vented overboard.

3.11.19 Power Pump Variable Delivery

Variable delivery pumps shall be in accordance with AS19692. The pressure differential between the pump-case cooling
port and the reservoir shall be such as to permit the pump to maintain cooling flow in any pump flow condition including
zero flow.

3.11.19.1 Electric Motor Driven Pumps

Electric motor driven hydraulic pumps in accordance with MIL-P-5954 or AS5994 may be used, as necessary, for either
normal, emergency, or auxiliary operation of hydraulic systems.

3.11.20 Power Pump Fixed Displacement

Fixed displacement pumps shall be in accordance with the procuring agency specifications. MIL-P-7858 can be used as a
reference for the development of a fixed displacement pump specification. Fixed displacement power pumps shall not be
used as the main source of fluid power in any system.

3.11.21 Relief Valves, System and Thermal Expansion

The system relief valves shall be designed as safety devices to prevent bursting or other damage to the system if the
normal pressure regulation device malfunctions, a blocked line condition occurs, or overload forces are generated on
actuating units.

Excessive system pressure caused by thermal expansion of the fluid shall be relieved through the thermal expansion
relief valves.

Relief valves are to be used as safety devices and not as pressure regulating devices.

3.11.21.1 System Relief Valves

Relief valves shall conform to MIL-V-8813 or MIL-V-85245.

System pressure relief valves shall relieve excessive pressure through bypass of fluid from the pressure to the return side
(see Table 2). The valves shall have a capacity equal to or greater than the rated flow of the largest pump when two or
more pumps have a common pressure line. The systems shall be designed so that the fluid flowing through the system
relief valves does not exceed the temperature of 160 °F (+71 °C) for Type I systems or 275 °F (+135 °C) for Type II
systems.

3.11.21.2 Thermal Expansion Relief Valves

Thermal expansion relief valves shall conform to ARP4835. For subsystems isolated from the system relief valve, local
relief valves shall be installed to prevent excessive pressure rise and system damage resulting from thermal expansion of
hydraulic fluid. The valve shall relieve fluid to the return side of the system. Internal valve leakage shall not be
considered an acceptable method of providing thermal relief (see Table 2 for relief valve setting).

3.11.22 Reservoirs

Hydraulic reservoirs shall be designed in accordance with AS5586.

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When a hydraulic emergency system is used in any military aircraft, except trainer types, a separate emergency reservoir
shall be provided. The emergency reservoir shall be located as remote as design permits from the main reservoir to
minimize the effect of gunfire damage. Both the main and emergency reservoirs shall be serviceable through a common
filler port unless the system or the reservoir design does not permit it.

The fill and vent lines for all hydraulic reservoirs shall be designed so that rupture of any reservoir, fill, or vent lines will not
cause fluid exchange between reservoirs or loss of sufficient fluid from any other reservoir to impair system operation.

Reservoirs shall be protected from failure when rapid discharge of the main or emergency system into the reservoirs is
encountered.

Protection from overpressurization resulting from overfilling shall be incorporated into the reservoir subsystem.

Pressurized reservoir installations shall include a depressurization valve for maintenance purposes.

3.11.22.1 Reservoir Location

It is desired that the reservoir shall be so located that the following conditions will be obtained:

a. A static head of fluid is supplied to the hand pump and the power-driven pump or pumps in all normal flight attitudes
of the aircraft

b. The length of suction line to the pump is a minimum

c. The best available temperature and pressure is utilized, but must not be installed in engine compartments

d. There is maximum protection from combat damage

e. Suction lines shall be so routed as to prevent breaking of the fluid column caused by gravity after engine shutdown
and during the parking period. Where such routing is not possible, provisions shall be installed to maintain the fluid
column to the pump after engine shutdown. A swing gate type check valve in the suction port of the reservoir should
normally maintain the fluid column to the pump.

f. If routing of the pump bypass cannot be accomplished so that breaking of the fluid column by gravity after engine
shutdown is prevented, check valves shall be incorporated in the lines.

3.11.22.2 Gas Pressurized Reservoirs

The inert gas pressure shall be controlled by an externally nonadjustable pressure-regulating device to control the gas
pressure in the reservoir. A relief valve shall also be connected to the airspace to protect the reservoir and pump from
excessive pressure. If the air pressure regulator and relief valve are combined into one housing, a single failure in that
unit shall not permit overpressurization of the reservoir.

3.11.22.3 Reservoir Air Pressurization Moisture Removal Equipment

When engine bleed air is used for reservoir pressurization, a moisture removal unit shall be installed at a location to
protect the pressure regulation lines and equipment. Bleed line components shall be installed to minimize the effects of
trapped moisture. A filter shall be provided.

3.11.22.4 Reservoir Fluid Level Indication

Reservoir fluid level indication shall be provided both on the reservoir itself as required in AS5586 and also in the cockpit.
Both fluid level indications shall be temperature compensated for the correct volume for any temperature as specified in
paragraph 3.6.1.1 of this document. Cockpit indicator fluid level markings shall correspond to the direct- reading fluid
level indicator markings provided on the reservoir and shall be lighted in accordance with applicable cockpit lighting
requirements. A warning light shall also be provided to signal the pilot of a low fluid level condition. The cockpit fluid level
indicator shall not eliminate the requirement for the direct-reading fluid level indicator on the reservoir itself, as this is
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required for reservoir servicing with power off. The reservoir level monitoring and branch circuit isolation shall be
accomplished electronically.

3.11.22.5 Bootstrap Reservoir Pressurization

In the event that normal system pressure is lost for any reason, bootstrap reservoir pressurization shall be maintained to
help prevent pump cavitation and assist in the purging of free air from the pump. This may be accomplished by placing
the accumulators and check valves in the bootstrap circuit. Provision for depleting this trapped pressure and
depressurizing the reservoir for ground maintenance shall be incorporated into the circuit.

See AIR5829 for discussion of sources of air and design for air reduction and elimination in hydraulic systems.

3.11.23 Restrictor Valves

Adjustable orifice restrictor valves may be used in experimental aircraft, but only fixed orifice restrictor valves shall be
used in service test and production aircraft. One-way restrictors shall be designed with different port sizes on each end to
prevent installation in the wrong flow direction. The direction of restricted and unrestricted flow shall be indicated on the
restrictor. (For fixed orifice filtration requirements, see 3.10.2.)

3.11.24 Self-Sealing Couplings

Self-sealing couplings shall conform to MIL-DTL-25427.

Hydraulic systems shall be provided with self-sealing couplings for each engine driven pump and so located that the
pump can be readily removed for servicing. A coupling shall be used in each line going to each pump.

Self-sealing couplings shall also be provided on all hydraulically operated brake installations where it is necessary to
disconnect the brake line in order to remove the wheel. The self-sealing coupling shall be attached to the brake, and it
shall be possible to remove the wheel without damaging the coupling.

Self-sealing couplings shall also be provided at all other points in the hydraulic system which require frequent
disassembly or, where convenient, to isolate parts of the system as in jacking and servicing one landing gear only. If
required, provisions for connecting couplings with trapped pressure in the hydraulic system shall be incorporated in the
coupling design.

Clearance shall be provided around the coupling to permit connection and disconnection. Self-sealing couplings installed
adjacent to each other shall be of different size or be otherwise so designed that inadvertent cross connection of the lines
cannot occur.

3.11.24.1 Airframe Break Points

When self-sealing couplings are provided at airframe break points, especially in flight control systems, and where
disconnection of such a coupling or couplings will adversely affect the operation of any of these systems, the coupling
design shall prevent inadvertent disconnection. The design shall also provide an indication when a coupling connection is
incomplete. If the means of preventing inadvertent disconnection are not absolutely positive, the system shall be so
designed that a hydraulic lock resulting from an inadvertent coupling disconnection will not be the cause of an aircraft
accident.

3.11.24.2 Component, Modular Quick Disconnects

When self-sealing couplings are used to mount components, they shall conform to AS4251 except at specified pressure.
The design shall provide deflection and separation forces. Locating pins may be used to aid installation as specified in
the procurement document.
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3.11.25 Shuttle Valves

Shuttle valves shall conform to MIL-V-5530 for Type I systems and MIL-DTL-19068 for Type II systems. Shuttle valves
shall not be used in installations in which a force balance can be obtained on both inlet ports simultaneously which may
cause the shuttle valve to restrict flow from the outlet port. Where shuttle valves are necessary to connect an actuating
cylinder with the normal and emergency systems, the shuttle valve unit shall be built into the appropriate cylinder head,
using component parts of applicable AN or MS approved shuttle valves in a cartridge. Where the above installation
cannot be made, a standard shuttle valve may be located at the actuator port and shall be tested to the same
requirements as the actuator. In the event neither of the above installations is possible, a length of rigid line is
permissible between the cylinder port and the shuttle valve, provided the rigid line and shuttle valve are firmly attached to
the actuating cylinder. Hoses shall not be used between the actuating cylinder port and the shuttle valve.

3.11.26 Pressure Switches

Pressure switches may be installed in hydraulic systems where the regulation of hydraulic pressure is required by
controlling an electric motor driven pump. Precautions shall be taken to prevent chatter or cutoff. Pressure switches shall
conform to the requirements of MIL-DTL-9395.

3.11.27 Swivel Joints

Swivel joints shall be designed in accordance with MIL-J-5513 except all pressure-to-atmosphere dynamic seals shall be
dual unvented. Hoses and coiled tubes have superior in-service life and should be used in place of swivel joints where
design permits. Where lines or fittings are used to drive swivel joints, they shall be supported and strong enough to
ensure proper operating installation.

3.11.28 Tubing

3.11.28.1 Tubing Materials

Tubing shall be either corrosion resistant steel conforming to AMS-T-6845, MIL-T-8504, AMS5561, or titanium alloy
conforming to AMS4945. Aluminum alloy tubing per AMS4081 or AMS4083 may be used in pump suction lines and drain
lines only. The minimum wall thickness in any alloy or tube size shall be 0.020 inch.

3.11.28.2 Tube Ovality and Bends

Bends shall be uniform and shall be in accordance with AS33611. Tubing ovality shall not exceed 3% for titanium alloys,
5% for corrosion resistant steels, and 10% for aluminum alloys. These ovality limits apply to tubing as installed in the air
vehicle.

3.11.28.2.1 Tubing Pre-Stress (autofrettage)

For tube flatness greater than the limits of AS33611, tubing pre-stress (autofrettage) may be used to reduce the flatness
to meet the requirements of AS33611 for tube assemblies.

3.11.28.3 Installation of Small Size Tubing

If tubing in sizes smaller than 3/8-inch outside diameter (-6 size) is used in hydraulic systems, particular care shall be
taken to properly install, support, and protect it, and it must be shown that proper operation of the service in which such
tubing is used will be possible at –40 °F (-40 °C) temperature.

3.11.28.4 Straight Tubing

Straight tubing between two rigid tubing end connections shall not be used.
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3.11.28.5 Tubing and Fitting Identification

All hydraulic fluid lines shall be permanently marked using identification markings which are in accordance with MIL-STD-
1247. Hoses do not have to be marked if the adjacent tubing or component identify the function. Hydraulic lines shall be
marked in conspicuous locations throughout the aircraft in order that each run or line may be traced. This marking shall
indicate the unit operated and the direction of flow, such as LANDING GEAR UP ----------> or FLAPS DOWN ---------->.
These markings shall be repeated as often as necessary, particularly on lines entering and emerging from closed
compartments, to facilitate maintenance work. Where fittings are located in members, such as bulkheads and webs, each
fitting location shall be identified (placarded) as to system function, using the same terminology as on its connecting line.

3.11.28.6 Tubing Support

All hydraulic tubing shall be supported from rigid structure by MIL-DTL-85052 (MIL-DTL-85052/1 or MIL-DTL-85052/3)
loop type cushion clamps, NASM85449 (NASM85449/1 or NASM85449/3) saddle type cushion clamps, or line block
clamps. Supports shall be placed as closely as design permits to the start of the bend to minimize tube overhang.
Maximum spacings between supports are specified in TABLE 3 and TABLE 4, except that where tubes support fittings
such as unions and tees, spacings should be reduced approximately 20 percent. When the required spacing cannot be
met, analysis shall be provided to substantiate that the line natural frequency falls outside of any excitation frequency
band within the region of interest. Where tubes of different diameters are connected together, spacing of the smallest
tube diameter shall be used. Provisions shall be made in support locations to accommodate change in tubing length
caused by expansion and contraction. In order to facilitate inspection and repair, tubing shall not be bundled together.

TABLE 3 - HYDRAULIC LINE SUPPORT SPACING, U.S. CUSTOMARY

Dash Nominal Maximum Length Between Support Centers

Size Tube OD (measured along tube)
(inches)
Aluminum
Titanium (inches) Steel (inches)
alloy (inches)
(1) (2) (1) (2)

-3 0.188 13 7 14 8 12
-4 0.250 15 8 16 10 13.5
-5 0.313 16 9 18 11 15
-6 0.375 17 10 20 12 16.5
-7 0.438 18.5 11 21.5 13 18
-8 0.500 20 12 23 14 19
-9 0.563 21 12.5 24.25 15 20.5
-10 0.625 22 13 25.5 15 22
-11 0.688 23 14 25.5 15 22
-12 0.750 24 15 27.5 16 23
-13 0.813 25 15.5 28 17 24
-14 0.875 26 16 28.5 17 25.25
-15 0.938 27 16.5 29 17.5 25.25
-16 1.000 28 17 30 18 26.5
-20 1.250 31 19 31.5 19 28.5
-24 1.500 34 21 32.5 19.5 29.5
(1) Normal vibration environment.
(2) Severe dynamic environment – nacelle, landing gear, pump pressure line to the filter.
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TABLE 4 - HYDRAULIC LINE SUPPORT SPACING, METRIC

Maximum Length Between Support Centers

Dash Nominal
Size Tube OD (measured along tube)
(millimeters) Titanium Steel Aluminum
alloy
(centimeters) (centimeters)
(centimeters)
(1) (2) (1) (2)

-3 4.78 33.0 17.8 35.6 20.3 30.5

-4 6.35 38.1 20.3 40.6 25.4 34.3
-5 7.95 40.6 22.9 45.7 27.9 38.1
-6 9.53 43.2 25.4 50.8 30.5 41.9
-7 11.13 47.0 27.9 54.6 33.0 45.7
-8 12.70 50.8 30.5 58.4 35.6 48.3
-9 14.30 53.3 31.8 61.6 38.1 52.1
-10 15.88 55.9 33.0 64.8 38.1 55.9
-11 17.48 58.4 35.6 64.8 38.1 55.9
-12 19.05 61.0 38.1 69.9 40.6 58.4
-13 20.65 63.5 39.4 71.1 43.2 61.0
-14 22.23 66.0 40.6 72.4 43.2 64.1
-15 23.83 68.6 41.9 73.7 44.5 64.1
-16 25.40 71.1 43.2 76.2 45.7 67.3
-20 31.75 78.7 48.3 80.0 48.3 72.4
-24 38.10 86.4 53.3 82.6 49.5 74.9
(1) Normal vibration environment.
(2) Severe dynamic environment – nacelle, landing gear, pump pressure line to the filter.

3.11.28.7 Location of Hydraulic Tubing

Hydraulic lines shall not be installed in the cockpit or cabin and shall be remote from personnel stations. In addition,
hydraulic lines shall be located remotely from exhaust stacks and manifolds, electrical, radio, oxygen, and equipment
lines, and insulating materials. In all cases, the hydraulic lines shall be routed below these items to prevent fire from line
leakage. Hydraulic lines shall not be grouped with lines carrying other flammable fluids in order to prevent inadvertent
cross connection of different systems. Hydraulic drain and vent lines shall exhaust in areas where the fluid cannot be
blown into the aircraft, collect in pools in the structure, or be blown onto or near exhaust stacks, manifolds, or other
sources of heat. Tubing shall be located so that damage cannot occur from being stepped on, used as handholds, or by
manipulation of tools during maintenance. Components and lines shall be so located that easy accessibility for
inspection, adjustment, and repair is possible. Hydraulic tubing shall not be used to provide support of other aircraft
installations, such as wiring, other aircraft tubing, or similar installations. Attachment of so-called marriage clamps for
spacing of such installations is likewise prohibited. Marriage or butterfly clamps may be used where required to maintain
clearances between hydraulic tubing runs, but not for support of such tubes.
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3.11.28.8 Tubing Flares and Assembly

Tubing flares shall conform to AS33583 or AS4330 and shall be used only in drain or vent lines. When installing tube
connections, care must be exercised to keep the wrench torque used to assemble each joint within the limits specified on
MS21344.

3.11.29 Design of System Installations

The installation practices of ARP994 should be used as a guide.

3.11.29.1 Component Lines

Two or more lines attached to a hydraulic component shall be designed so as to prevent incorrect connection to the
component.

3.11.29.2 Drain lines

Drain or overboard vent lines coming from the pump, reservoir, or other hydraulic components shall not be connected to
any other line or any other fluid system in the aircraft in such manner as to permit mixture of the fluids at any of the
components being drained or vented.

3.11.29.3 Mounting Lightweight Components

Lightweight components that do not have mounting provisions may be supported by the tubing installation, provided the
component is rigidly installed and does not result in destructive vibration or cause other adverse conditions to the tubing
installation. Clamps or similar devices may be used to support such units to structure, provided that nameplates, flow-
direction arrows or markings, or other data is not obscured and that the supporting members do not affect the operation of
the unit. If the unit cannot be supported by a clamp, the tubes on each side of the components shall be clamped to
structure within two inches of the component.

3.11.29.4 Electrical Bonding, Grounding, and Lightning Protectors

The aircraft hydraulic system components, tubing, and distribution elements shall be bonded to the aircraft in accordance
with MIL-STD-464. All electrically conductive components shall have a mounting point to structure resistance not
exceeding 2.5 miliOhms.

3.11.29.5 Vibration

The complete hydraulic system, including lines and components, shall be designed to withstand the effect of vibration,
pump pulsation, and shock loads encountered during service operation of the aircraft. Care shall be taken to ensure that
main pump pressure discharge lines, clamps and components can withstand the most adverse conditions of pump
cavitation, pulsation, and vibration. Aramid fiber braid hose per MIL-H-85800 and AS1975 and wire braid hose per
AS1339 shall not be used in pump discharge lines due to the hose’s low vibration-tolerant construction.

3.11.29.6 Tubing Clearance

Where tubing is supported to structure or other rigid members, a minimum tube to structure clearance equal to the tube
clamp thickness shall be maintained with such member. A minimum clearance of 0.25 inch (6.35 mm) shall be
maintained with adjacent structure, tubing, or other installations. In areas where relative motion of adjoining components
exists, a minimum clearance of 0.25 inch shall be maintained under the most adverse conditions that may be
encountered. It is an objective that tube replacement or repair be accomplished without removing adjacent tubes.
ARP994 provides data on tool clearances required for installation and repair of tubes using various approved fittings.
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3.11.29.7 Pump Ssuction Line Design

The pump suction line shall be designed to provide flow and pressure at the pump inlet port. This requirement shall
include operating the pump at the maximum output flow and shall include all ground and flight conditions the aircraft will
encounter. Zero g and negative g conditions and low temperature start and operation shall also be included in the above
requirement.

3.11.29.8 Flight Control Actuators

Consideration should be given to the clearance between moving flight control system components and structure or other
components to ensure that no possible combination of temperature effects, airloads, or structural deflections can cause
binding, rubbing, or jamming of any portion of the primary flight control system.

3.12 Workmanship

Workmanship shall be of such quality as to assure that the hydraulic systems furnished under this specification are free of
defects that compromise, limit or reduce performance or intended use.

4. QUALITY ASSURANCE PROVISIONS

4.1 Responsibility for Inspection

Unless otherwise specified in the contract or purchase order, the contractor is responsible for the performance of all
inspection requirements (examinations and tests) as specified herein. Except as otherwise specified in the contract or
purchase order, the contractor may use his own or any other facilities suitable for the performance of the inspection
requirements specified herein, unless disapproved by the Government. The Government reserves the right to perform
any of the inspections set forth in this specification where such inspections are deemed necessary to ensure supplies and
services conform to prescribed requirements.

4.1.1 Responsibility for Compliance

All items shall meet all requirements of sections 3. The inspection requirements set forth in this specification shall
become a part of the contractor’s overall inspection system or quality program. The absence of any inspection
requirements in the specification shall not relieve the contractor of the responsibility of ensuring that all products or
supplies submitted to the Government for acceptance comply with all requirements of the contract. Sampling inspection,
as part of manufacturing operations, is an acceptable practice to ascertain conformance to requirements; however, this
does not authorize submission of known defective material, either indicated or actual, and does not commit the
Government to accept defective material.

4.2 Inspection

The hydraulic system installation of one of the first complete experimental and production aircraft shall be subject to
inspection for conformance to the requirements of this specification by engineering representatives of the contracting
activity. It is expected that this inspection will be performed at the contractor’s plant concurrently with similar engineering
inspections of other systems of the aircraft. Detailed arrangements for the inspection will be the subject of
correspondence between the contracting activity and the contractor.

4.2.1 Vibration Prior to First Flight

The hydraulic system of the first flight aircraft shall be tested prior to first flight to determine if any destructive vibration
occurs as the result of any and all combinations of engine and hydraulic pump speed, and hydraulic pump flows and
pressures. Hydraulic lines, hoses and their supports, fittings, and all components shall be checked. Corrective action
shall be taken if required.
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4.2.2 Ground and Flight Tests

The ground and flight test requirements for the testing of aircraft hydraulic systems designed in accordance with this
specification shall be as specified in MIL-STD-5522.

4.3 Cleaning of Parts and Systems

To assure that the hydraulic system is free of contamination, all parts of the hydraulic system shall be thoroughly cleaned
prior to installation. Specification ARP5891 provides discussion of solid contamination removal and gives effective
procedures for system clean-up. Each new hydraulic system shall be operated at least 10 times in order to ensure
filtration of all circulating fluid. Ground equipment which is used for this cleaning process shall be provided with filters
specified in 3.11.9.4. Dead-end lines in the system shall be properly connected with jumpers to completely clean such
lines. If the filter element in the hydraulic system is used during this operation, it shall be replaced. Chlorinated solvents
shall not be used to clean hydraulic components, lines or fittings.

4.3.1 System Contamination Level forPproduction Aircraft

A minimum of two contamination tests (see requirements 3.11.9.1) shall be performed on each major system, separated by a
minimum of 2 flight hours and a determination made that a stable or decreasing particulate level has been achieved.
Particulate contamination level shall be below the level specified in 3.11.9.1. The level of water in each hydraulic system
shall be less than 250 parts per million at delivery. The level of chlorine shall be less than 100 parts per million at delivery.
The method used to measure chlorine shall be x–ray fluorescence or equivalent. The method shall be capable of detecting
10 ppm or greater total chlorine in oil based samples with a level of precision of ± 10 percent at the 100 ppm level.

4.4 Hydraulic System Information

To obtain approval of the hydraulic system, the information in the following subparagraphs shall be included.

4.4.1 Hydraulic System Analysis and Design Study

This study shall be done on proposed new aircraft during the preliminary design and definition phases of research,
experimental, or prototype aircraft (see 4.4.8 and APPENDIX A).

4.4.2 Developmental and Preproduction Study

This study shall be done during the development phase of the hydraulic system (see 4.4.8 and APPENDIX A).

4.4.2.1 Component Tests

Tests shall be made on components other than those specified in APPENDIX B, 30.1 when analysis suggests that these
tests are required (see 4.4.8 and APPENDIX B).

4.4.3 Hydraulic System Production Study

This study applies if there are any changes in the hydraulic system after the development phase (see 4.4.8 and
APPENDIX A).

4.4.3.1 Functional Test Specification

This is a specification incorporating the necessary functional tests of the hydraulic system of production aircraft (see 4.4.8
and APPENDIX B).

4.4.3.2 Schematic Diagram

The schematic diagram should be such as to present the system in a clear and easily readable form, with complete
subsystems grouped and labeled accordingly (see 4.4.8 and APPENDIX A).
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4.4.3.3 Schematic Diagram of the Mechanical to Hydraulic Systems

This is a schematic diagram linking the mechanical system with the hydraulic system (see 4.4.8 and APPENDIX A).

4.4.3.4 Schematic Diagram for Electrical Wiring

This is a schematic diagram of the electrical portion of the hydraulic system (see 4.4.8 and APPENDIX A).

4.4.4 Hydraulic System Design

The design information shall be gathered prior to or with the final schematic diagram (see 4.4.8 and APPENDIX A).

4.4.5 Hydraulic System Nonstandard Component Cross-Sectional Assembly Drawings

The nonstandard component cross-sectional assembly drawings shall contain information for an evaluation to determine
whether the nonstandard component should be used (see 4.4.8 and APPENDIX A).

4.4.6 Functional Simulator Design and Test Program

A general design for the functional simulator shall be made 30 days prior to construction of the simulator (see 4.4.8 and
APPENDIX A).

4.4.7 Vibration Test Plan

A hydraulic system vibration test plan shall be written for first flight aircraft (see 4.4.8 and APPENDIX A).

4.4.8 Consideration of Data Requirements

The data requirements in TABLE 5 should be considered when this specification is applied on a contract. The applicable
Data Item Descriptions (DID’s) should be reviewed in conjunction with the specific acquisition to ensure that only essential
data are requested/provided and that the DID’s are tailored to reflect the requirements of the specific acquisition. To ensure
correct contractual application of the data requirements, a Contract Data Requirements List (DD Form 1423) must be
prepared to obtain the data, except where DOD FAR Supplement 227.405-70 exempts the requirement for a DD Form 1423.
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TABLE 5 - DATA REQUIREMENTS

Reference Para. DID Number DID Title Suggested

Tailoring
3.6.15 DI-NDTI-80809A Test/Inspection Reports Contracting activity
approval prior to
finalization of sys-
tem design
3.11.10 DI-NDTI-80809A Test/Inspection Reports Contracting activity
approval prior to
installation
3.11.13 DI-NDTI-80809A Test/Inspection Reports Specific application
subject to approval
of the contracting
activity
3.11.17 DI-NDTI-80809A Test/Inspection Reports Selection of lock
valve for design
subject to approval
of contracting act-
ivity
4.1.1 DI-NDTI-80809A Test/Inspection Reports 10.2.7
3.12.1, 3.12.2 DI-MISC-80678 Certification/Data Report -
and 3.12.3
3.12.2.1 and DI-MISC-80603A Test Reports Delete 10.2a
3.12.3.1
3.12.3.2 thru DI-MISC-80678 Certification/Data Report -
3.12.7

The above DID’s were those cleared as of the date of this specification. The current issue of DoD 5010.12-L, Acquisition
Management Systems and Data Requirements Control List (AMSDL), must be researched to ensure that only current,
cleared DID’s are cited on the DD Form 1423.

5. PREPARATION FOR DELIVERY

The section is not applicable to this specification.

6. NOTES

6.1 Intended Use

The design and installation requirements covered by this specification are intended for use in aircraft hydraulic systems,
such as the utility system, the flight control system, various subsystems, and with component installation procedures for
temperatures from –65 °F (-54 °C) to 275 °F (+135 °C). Type III systems, -65 °F (-54 °C) to 450 °F (+232 °C), are
covered by MIL-H-8891.

6.2 MIL-H-5440

The initial SAE publication of this document was taken directly from U.S. Military Standard MIL-H-5440H. This SAE
Standard may retain the same part numbers established by the original military document.
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6.3 Qualified Products Lists

Any requirements associated with Qualified Products Lists (QPL) may continue to be mandatory for DoD contracts.
Requirements relating to QPLs have not been adopted by the SAE for this standard and are not part of this SAE
document.

6.4 Document Change Identification

A change bar (|) located in the left margin is for the convenience of the user in locating areas where technical revisions,
not editorial changes, have been made to the previous issue of this document. An (R) symbol to the left of the document
title indicates a complete revision of the document, including technical revisions. Change bars and (R) are not used in
original publications, nor in documents that contain editorial changes only.

PREPARED BY SAE A-6A2 MILITARY AIRCRAFT PANEL OF

COMMITTEE A-6 AEROSPACE ACTUATION, CONTROL AND FLUID POWER SYSTEMS
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APPENDIX A - CERTIFICATION/DATA REPORT TECHNICAL CONTENT REQUIREMENTS

A.1 SCOPE

This appendix covers information that shall be included in the certification/data report when specified in the contract or
order. This appendix is mandatory only when data item description DI-MISC-80678 is cited on the DD Form 1423.

A.2 APPLICABLE DOCUMENTS

This section is not applicable to this appendix.

A.3 DATA SUBMITTAL

A.3.1 Hydraulic System Analysis and Design Study Report

The data listed in this paragraph should be submitted for evaluation of design studies of a proposed new aircraft during
the preliminary design and definition phases of a research, experimental, or prototype aircraft. The contractor should
submit a report covering such design studies and analyses as are required to establish the design parameters of the
hydraulic system of the proposed aircraft. The design analysis should show that the hydraulic system fulfills the needs
imposed by the weapon system requirements. This report should include the following information and data:

a. Pressure and flow rates versus time for each mission profile along with the power load analysis

b. A thermal analysis with temperature-versus-time curves for fluid temperature for typical missions and for ground
operations. This analysis shall include the highest and lowest temperatures expected in flight including the maximum
temperatures due to single failures such as worn pumps and relief valve bypass.

c. Fluid selection. Nonflammable (or less flammable) hydraulic fluids should be considered in the interest of reducing
the potential fire hazard in a combat environment. The fluid selection should be based on a trade study to insure that
specific improvements in safety and survivability are realized without excessive penalty in hydraulic system
performance, operational capability, or cost of the aircraft. The trade study should consider reliability and all logistic
aspects over the expected life of the aircraft including supply and maintenance as well as impact on support and
service equipment on the flight line, in repair shops, and overhaul facilities.

d. Analyses or trade studies should include the following:

1. Optimum approach to permanent tube joining

2. Optimum separable tube fitting design

3. Whether tubing materials having a strength-to-weight ratio higher than that of AMS-T-6845 can be used
successfully, consistent with (1) and (2) alone, and be available within the time constraints of the program
schedule.

A.3.2 Developmental and Preproduction Data Report

The following data should be submitted for approval during the development phase of the hydraulic system and should be
for use as production procurement data:

a. A hydraulic system ground and flight test report in accordance with MIL-STD-5522.

b. Detail specifications, test procedures and test reports for the following components:

1. Pumps and motors

2. Flight-control actuators

3. Valves and switches

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4. Flexible connectors including hoses (if nonstandard)

5. Packings and packing installations (if nonstandard)

6. Fluids (if nonstandard)

7. Fittings and tubings (if nonstandard)

8. Hydraulic power transfer units (if used)

NOTE: Other components that may require surveillance, in view of the criticality of the particular item to the proper
functioning of the weapon system, may be specified after the hydraulic system schematic diagrams have been reviewed.
The list of surveillance items will be established during the service-contractor conference (see 3.5.1).

c. Analyses of failures and malfunctions affecting performance and safety.

A.3.3 Production Data Report

Where changes have been made in the hydraulic system over the developmental hydraulic system, the developmental
data required in 30.2 should be submitted.

A.3.4 Schematic Diagram Report

The schematic diagram should consist of one copy of the conventional size and one copy approximately 11 inches in
height. The arrangement of the schematic diagram should be such as to present the system in a clear and easily
readable form, with complete subsystems grouped and labeled accordingly. Emphasis should be placed on simplicity and
clarity of presentation, with location in the aircraft being of secondary importance. Nomenclature of each unit should be
made adjacent to or in the vicinity of each unit. In addition, the schematic diagram should contain the following
information:

a. Operating pressure of all systems and subsystems.

b. All relief valve reseat and full flow pressures.

c. Initial gas pressure of accumulators and their normal gas and fluid capacities.

d. Pressure range of pressure regulators.

e. Diameter, wall thickness, and material of tubing.

f. Total and reserve fluid capacities of the reservoir, or reservoirs, and the system; reservoir pressure; and method of
pressurization.

g. Displacement of fluid in cubic inches of each actuating cylinder for both extension and retraction.

h. Actuating cylinder piston head diameter, rod diameter, effective piston area, total and working stroke of each cylinder.

i. Displacement per revolution and number of required revolutions of hydraulic motors for each half-cycle of operation
and the torque load required for each unit.

j. Type of power-driven pump and displacement, including flow rate curve showing engine and pump rpm, for all phases
of flight such as takeoff, climb, cruise, and landing.

k. Indicated fluid flow direction through all hydraulic lines.

l. Reservoir pressurizing system source, operating pressure, and schematic diagram of plumbing.
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m. Name and part number of all units. Standard part numbers should be indicated where applicable. Nonstandard units
should also include name of manufacturer and the manufacturer’s part number.

n. Connections for testing with auxiliary or ground test power system should be indicated.

o. Tubing and hose lines should be identified in accordance with AS1290.

p. Hydraulic components should be shown in simple schematic form. Multiple position units, such as selector valves,
should clearly indicate internal fluid porting. Flow path of selector valves should be shown for each position of the
valves. Hydraulic components should be shown in accordance with AS1290.

q. Maximum and normal system temperature (estimated). In estimating maximum and normal system temperatures, the
following conditions should be specified:

1. Location of temperature

2. Altitude

3. Ambient temperature

4. Compartment temperature

5. Engine power setting

6. Time duration of flight and time duration limitations for ground operation at maximum system temperature

r. Pressure and temperature pickup locations to be installed for instrumentation purposes in accordance with MIL-STD-
5522 should be indicated on the copies of the schematic diagrams submitted to the contracting activity.

s. Hydraulic system block diagram. (This may be a separate sheet of the schematic diagram).

A.3.5 Mechanical to Hydraulic System Schematic Diagram

This is a simple schematic diagram of linkage showing mechanical disconnects, downlocks, and unlocks, and other data
to tie the mechanical system to the hydraulic system for analysis.

A.3.6 Electrical Wiring Schematic Diagram

This is a simple schematic wiring diagram of the electrical portion of the hydraulic system giving current loads and
describing functions. (This diagram and data may be on a separate drawing).

A.3.7 Hydraulic System Design Report

The hydraulic system design report should be submitted prior to or with the final schematic diagram. The report should
incorporate sufficient design calculations and data to verify that the hydraulic system design complies with all design
requirements. A hydraulic system temperature survey (minimum through maximum) should be included considering the
location of the hydraulic system in the aircraft. The time of flight at maximum system temperature and conditions under
which this temperature occurs should be included. Compartment temperatures should be estimated. For primary flight
control systems, peak and average flow rates and the power spectrum should be indicated. Duration of peak flow rates
should also be indicated. The minimum temperature at which full performance occurs should be determined by the
contractor and submitted for approval.
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A.3.8 Hydraulic System Nonstandard Component Cross-Sectional Assembly Drawings Report

The cross-sectional assembly drawings for each nonstandard hydraulic component shall contain information in order that
an evaluation of the unit can be made. Such information shall include the applicable specification, the material protective
finish of each part, and bearing load and life data for the application. This information may appear as a written addition to
the drawing. Reason for the use of a nonstandard component, where a standard exists, should be submitted with the
component drawing.

A.3.9 Functional Simulator Design and Test Program Report

A report describing the general design of the functional simulator, as described in paragraph 3.5.1, and the anticipated
test program should be submitted to the contracting activity for approval no later than 30 days prior to beginning
construction of the simulator in order that any modification to the simulator or revision of the test program recommended
by the contracting activity may be included.

A.3.10 Vibration Test Plan Report

A test plan for the vibration test in 4.2.1 should be submitted to the contracting activity for approval within 30 days prior to
the start of the test.
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APPENDIX B - TEST REPORT TECHNICAL CONTENT REQUIREMENTS

B.1 SCOPE

B.1.1 Scope

This appendix covers information that shall be included in the test reports when specified in the contract or order. This
appendix is mandatory only when data item description DI-MISC-80653 is cited on the DD Form 1423.

B.2 APPLICABLE DOCUMENTS

This section is not applicable to this specification.

B.3 COMPONENT AND FUNCTIONAL TEST REPORTS

B.3.1 Contractor Proposed Component Tests

The following procedure should be adopted by the contractor for components not listed under 30.2(b) in APPENDIX A:

a. The contractor should certify, upon completion of validating tests, that the hydraulic component conforms to the
applicable military or contractor-prepared specifications approved by the contracting activity and is satisfactory for
use in the particular aircraft weapon system and hydraulic system.

b. The test reports, as well as the specifications and other applicable engineering data covering the hydraulic system
components, other than those specified in APPENDIX A, 30.2(b) should be retained by the contractor and should be
available to the contracting activity upon request, with the exception that all the cross-sectional assembly drawings
should be submitted for information.

c. The contractor should list, in a status of equipment list, those components that are contractor- certified for data
availability and compliance with the applicable Government-approved specifications.

B.3.2 Functional Test Specification Report

A specification incorporating the necessary functional tests of the hydraulic system of production aircraft should be
submitted to the contracting activity for approval.