Beruflich Dokumente
Kultur Dokumente
13 March 1963
Final Report
Qualfie
:--~C'ter,3 inari
obtain copicc o" this -
13 Maroh 1963
Prepred by
Prepared . roinsen Approved by K.W. Dubois
li~dro-Meg h. SectionChe
Hydro-Keoh. Seation
Approved by
Hydro-Mech. Seotion
Test Group Engineer
L.0 ASTRAVT
A. A survey of hydraulic fluid contamination was made
in which 79 airplanes, plus several test stands,
were sampled. The results are presented in tabular
and graphical form.
B. An analysis of the data of the survey leads to the
conclusion that substantially cleaner systems can
be maintained with no great Increase In cost.
0, Recommendations are made concerning the maximum
permissible level of contamination, and procurement
of components which will operate reliably at the
fluid contamination levels to which they will be
subjected.
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DOUGLAS AIRCRAFT COMPANY. INC.
1.0 SUMMARY
2.0 TABLE OF CONTENTS
3.0 INTRODUCTION
4.0 FIELD SURVEY OF HYDRAULIC FLUID CONTANDITION
4.1 Data Obtained and Procedures Used.
4.2 Systems Tested.
4.3 Tabulation and Analysis of.Results.
4.3.1 Tabulation
4.3.2 Analysis
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DOUGLAS AIRCRAFT COMPANY. INC.
7.0 DISCUSSION
7.1 Maintenance Practices
7.2 System Flushing
7.3 Filter Servicing Policy
7.T Filter Performance in a System
7.5 Contamination Teats.
8.0 CONCLUSIONS
9.0 REFERENCES
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DOUGLAS AIRCRAT COMPANY. INC.
APPENDIX
Sampling Prooedure and Zquipment
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DOUGLAS AIRCRAFT COMPANY, INC.
3.0 INTRODUCTION
This test program was undertaken by Douglas Aircraft
Company under Navy contract NOw 62-0297t, Task Order 62-2.
Stated objectives of the contract are as follows:
1. Investigate actual contamination levels in service
aircraft.
2. Determine minimum contamination level which can be
consistently maintained in service.
3. Establish methods and procedures which can be used to
insure that system components will be sufficiently
contaminant resistant to operate in contaminated fluid
without performance degradation or loss of reliability.
The handbook of maintenance instructions for each aircraft
contains instructions for maintaining the hydraulic system
in a clean condition. Most maintenance personnel have no
clear conception of the nature of the contaminants most
prevalent in hydraulic system, and are satisfied if the
components, the filter elements, and the oil, look clean.
Figure 1 shows some typical particle sizes related to
filter ratings, valve clearances, etc.
While hydraulic fluid contamination has long been known to
adversely affect some components, notably hydraulic pumps,
failures usually occurred gradually, and could be detected
before they became catastrophic.
The advent of hydraulically powered control systems, and
more recently, the use of electro-hydraulic servo-control
valves with these control systems, has made hydraulic fluid
cleanliness vital to the satisfactory function of the
aircraft and to the performance of its mission. Much
attention has been focused on this area in recent yearss
so much so, that malfunctions traceable to other causes
are sometimes blamed upon fluid contamination.
This contamination survey and analysis are intended,
therefore, to answer the questions, (1) how clean are the
hydraulic systems now? (2) how clean can we make them,
economically? and (3) how can system reliability be
assured at the contamination levels which it is practical
to maintain?
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DOUGLAS AIRCRAFT COMPANY, INC.
Contamination vs Viscosity
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DOUSLAS NUCRAP COMPAY. MC.
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DOUW"am coo., sc
a
4
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DOUGLAS AICRAFT COMPAly. INC.
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INC.
DOUGLAS AIRCRAFT COAMPANY
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DOUGLAS AIRCRAFT COMPANY. INC.
__________________________________________________
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DOUGLAS MAICRAFT COMPANY. 04C.
A
,1p.
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DOULU AIRCRAFT COMPANY. INC.
7.0 DISCUSSION
7.1 Maintenance Practices
The majority of maintenance personnel contacted
during the contamination survey had some awareness
of the importance of hydraulic system cleanliness
and made an attempt to keep their systems clean.
They have little idea of the degree of cleanliness
required, as evidenced by the fact that one squadron,,
informed in advance of the contamination survey,
had obtained some fruit jars into which to draw
oil samples. The jars were carefully wiped out
with a clean rag.
Most maintenance officers stated that they had
little or no hydraulic contamination trouble.
Several were concerned that the hydraulic fluid
in shock struts became dark and apparently more
viscous.
It appears that system cleanliness must be inherent
in the system design, the design of the ground
support equipment and the prescribed servicing
practices. Although there should be a continuous
effort to acquaint maintenance personnel with the
importance of hydraulic system cleanliness,
"better maintenance" alone will do little to
achieve it.
7.2 System Flushing
Apparently flushing of hydraulic systems is rarely
practiced. None of the squadrons visited ever
flushed a hydraulic system unless a complete
failure of a hydraulic pump occurred. One 0 & R
facility changes oil in airplanes undergoing
repair, provided an oil sample is shown to be
excessively contaminated by the SAE-ARP 598
procedure. One airplane was checked during its
first engine run after completing this procedure
(Figure 4, Sample No. 51) and found to be little
cleaner than other airplanes of this model. The
small particle count (5 to 15 microns) was
substantially lower however. This system had
been pronounced satisfactory by the 0 & R
laboratory. Conclusions to be drawn from this
example are:
A. A hydraulic system should be drained immediately
after an engine run, so the maximum amount of
dirt-will be in suspension in the fluid.
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DOUGLAS NARCRAT COMPANY. INC.
I little value.
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DOUGLAS ARCIAFT COMPANY. INC.
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DOUGLAS AIRCAFT COPANY, INC.
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DOIULAS AICRAFT COMPANY. INC.
8.0 CONCLUSIONS
1. Approximately one-fourth of the hydraulic systems
in Naval aircraft are contaminated beyond the
maximum level recommended for reliable, trouble-
free operation. (Class 5)
2. Filter elements of 25 micron absolute rating woven
wire mesh, per specification MIL-F-25682 or
equivalent, are only marginally acceptable or
are unsatisfactory in many applications.
3. Existing systems can be maintained in a cleaner
condition by employing better test stand
filtration, better filling stand filtration and
periodic system flushing. In some aircraft
systems, the use of additional filters or a
different filter media may be justified.
'4. Cleaning and reuse of MIL-F-5504 paper filters
should be discontinued, except as an emergency
measure. Cleaning of metal filters at squadron
level should be discontinued.
5. The number and sizes of filters in new systems
should be in proportion to system complexity
rather than maximum pump flow.
6. Special flushing and fluid reconditioning stands
being contemplated will be unnecessary if use
is made of the improved filter media which has
become available (MIL-F-8815 and MIL-P-27656).
7. No great improvement in contaminant-resistance
of hydraulic system components appears likely.
No procurement specification changes are
recommended, except a minimum contamination
level for life-testing servo-control valves.
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DOUGLAS AIRCRAFT COMPANY. INC.
9.0 REFEENCES
(A) Report ES 29862 - Evaluation of Contamination
Tolerance of Servo Valves and Contamination
Levels in Hydraulic Systems, Aircraft Division
Douglas Aircraft Company.
(B) Report ES 40348 - Servo Valves, Comparative Test
of the Effect of Contamination on Performance,
Aircraft Division, Douglas Aircraft Company
(C) Report P49AE-32-1 - Evaluation of 2-15 Micron
Filter Element in the A4D-2N Utility Hydraulic
System, Service Test Division, Naval Air Test
Center - 6-13-61
(D) Contamination Control for Cleaner, More Reliable
Pumps - by J. H. Ballantoni and A. B. Billet,
Aviation Age (Periodical) January 1958, Page 138
(E) Specification MIL-P-19692A (WEPS) - Pumps,
Hydraulic, Variable Delivery, General Specifi-
cation for - 12-1-60
(F) Specification MIL-V-27162 (USAF) - Valves Servo
Control, Electro-Hydraulio, General Specification
for - 10-6-59
(0) Specification MIL-H-8775B - Hydraulic System
Components, Aircraft and Missiles, General
Specification for - 11-8-61
(H) Society of Automotive Engineers Technical Paper
575B - Commercial Jets - Hydraulic System
Contamination versus Airline Maintenance - by
R. H. Lesser - October 1962
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OOUG&AbAMCL COWAWM,Wic KLEGIIO CMSO IL UMOUCD,CALUeOWN.
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FIGURE 8
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DOUGLAS AInCRAFT COMPANY. INC.
APPENDIX A
4a0r.4Nv0 4 N
1.4-14. V 0_t4 r V -:0.10-4
04043
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II
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DOUCILASAMAD1 COMDAN. NC. Kt VIGUNCO DiVION It SEUNDO. CAAJFNWI
FIGURE A2
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