GROUP NAME : THE COBAIN (GROUP 1)

NAME : LEONG WEI JIE

53106114010
: KURT COBAIN LIM
53106114365
: MOHAMAD ADEEB FARAHI BIN MOHAMAD BUKHAREE
53106114047
: KAHVINESH A/L PALAS SUPARMANIAM
53106114300
: AMER ASYRAF BIN AZRUELL AZLAN
53106114443
CLASS : 3 AEM 2
SUBJECT : HYDRAULICS & PNEUMATICS SYSTEM
SUBJECT CODE : AJD 20603
LECTURER : AMIR HAKIMIN HASHIM
TITLE : Hydraulic Systems A and B Return Filter Module and
Components Removal / Installation

1
 Index

No. Topic Page

1. Introduction To Hydraulics 34
2. Introduction To Return Filters 5
3. Return Filter Module Components 68

4. Removal of Return Filter Element 9 11

5. Installation of Return Filter Element 12 18
6. Removal of Return Filter Module 19 23
9, Installation of Return Filter Module 24 25

10. Functional / Operational Test 26 - 29

11. Safety Precautions 30
12. Appendix 31 33
13. Reference 34

2
 Introduction To Hydraulics
Aircraft Hydraulics Definition

Aircraft Hydraulics is a means of transmitting energy or power from one place to

another efficiently.

What is a hydraulics system?

It is a system where liquid under pressure is used to transmit this energy. Hydraulics
systems take engine power and converts it to hydraulic power by means of a
hydraulic pump. This power can be distributed throughout the airplane by means of
tubing that runs through the aircraft. Hydraulic power may be reconverted to
mechanical power by means of an actuating cylinder, or turbine.

1. A hydraulic pump convers mechanical power to hydraulic power

2. An actuating cylinder converts power to mechanical power
3. Landing Gear
4. Engine Power (Mechanical HP)

If an electrical system were used instead of a hydraulic system, a generator would

take the place of the pump and a motor would take the place of the actuating
cylinder.

Advantages of Hydraulic Systems

(over other systems for aircraft use)

1. It is lighter in weight than alternate existing systems.

2. It is dead beat, that is, there is an absence of sloppiness in its response to

demands placed on the system.

3. It is reliable; either it works or doesn't.

4. It can be easily maintained.

5. It is not a shock hazard; it is not much of a fire hazard.

6. It can develop practically unlimited force or torque.

Example: A gun turret must be able to change direction almost instantaneously.

This is what is accomplished by this hydraulic system. In an electrical system, the
rotating armature must come to full stop and then reverse direction or else the
armature will burn out. This doesn't happen with a hydraulic system because there is
no need for a motor in the hydraulic system.

Example: In a landing gear the hydraulic motor can produce enough power to
pull up the landing gear system without trouble even though air loads act on the
system and the slip stream air is impinging against it.

3
 The actuating cylinder can change hydraulic power to linear or rotating motion. It
has a reduction gear in it to reduce rotating motion to that amount which is needed.
Previously, systems used to control motion by using steel cables connected by
pulleys between the controlling mechanism (such as the pedals) and the controlled
surface (such as the rudder). The cables were affected by expansion rates of the
cables due to temperature changes. Hydraulic systems can control motion without
worrying about the effect of temperature since it is a closed system (not open to the
atmosphere) compared to a cable system. This means better control of the plane
and less lag time between the pilot's movement to control the plane and the
response by the control surface.

Some Devices Operated by Hydraulic Systems in Aircraft

1. Primary control boosters

2. Retraction and extension of landing gear

3. Sweep back and forth of wings

4. Opening and closing doors and hatchways

5. Automatic pilot and gun turrets

6. Shock absorption systems and valve lifter systems

7. Dive, landing, speed and flap brakes

8. Pitch changing mechanism, spoilers on flaps

9. Bomb bay doors and bomb displacement gears

4
 Introduction To Return Filter

Almost every hydraulic system uses a return line filter. It's designed to mount directly
onto the tank cover. Therefore, you can easily replace filter elements when needed.
It's perfect for easy maintenance. Select your return line filter based on the maximum
flow of the hydraulic system.
Characteristics of a return line filter:
1. Low cost
2. Very easy servicing
3. No downtime because it incorporates duplex filters
4. Grade of filtration: Fine Filtration
a. 40 to 90 m, using stainless steel filter mesh
b. 10 m, using filter paper
c. 10 to 25 m, using glass fibre
5. Equipped with a bypass check valve that opens a 2 bars (maximum)
To prevent the hydraulic oil from foaming in the tank - in all operating conditions - the
return flow must come from below the fluid level in the tank. As a general rule, the
distance between the bottom of the tank and the end of the pipeline should be more
than 2 to 3 times the pipe diameter.

5
 Return Filter Module Components
1. Consist of 2 hydraulics system; hydraulics system A and hydraulics system B
2. Each hydraulics system got their own respective reservoir which is labeled as
Hydraulic System A Reservoir and Hydraulics System B Reservoir.
3. Both of the hydraulics system does not combine and is separated as 2
different system.
4. Both of this system are located under the fuselage of and aircraft. It is located
in the main landing gear wheel well of the aircraft to be more specific.
5. Refer to the picture below for a better understanding of the placing for the
Hydraulics System A and B return filter module and component.

6
 Structure of Return Filter Module (Hydraulics System A)

1. Consist of a few important parts such as differential pressure indicator, filter

module, filter bowl, filter element, lock ring etc.
2. A few minor component such as reducer, union, nut and washers, bolt, etc.
3. Refer to the picture below to understand the construction of the Return Filter
Module (Hydraulics System A) for a better understanding.

7
Structure of Return Filter Module (Hydraulics System B)
1. A bit different from the return filter module for hydraulics system B.
2. Contains High Pressure Bypass Valve as a precautions steps for carrying a
high pressure hydraulics liquid.
3. Most of the part is the same as Return filter module for hydraulics system A.
4. Below is the diagram for the Return Filter Module (Hydraulics System B).

8
 Removal of Return Filter Element
References
Reference Title
29-09-00-860-802 Hydraulic Reservoirs Depressurization
29-11-00-860-805 Hydraulic System A and B Power Removal

Location Zones

9
Zone Area
133 Main Landing Gear Wheel Well, Body Station 663.75 to Body Station 727.00
Left
134 Main Landing Gear Wheel Well, Body Station 663.75 to Body Station 727.00
Left

Preparation of Removal
Remove hydraulic power from the applicable system. To do this task:
Hydraulic System A or B Power Removal, refer to Task 29-11-00-860-805.
1. Tools and Equipment
Referenc Description
e
COM-163 Portable Hydraulic Cart, Systems Test, Capable of 3000 PSI and
a minimum flow of 30 GPM.
SPL- Adapter Ground Service Disconnect
12499

2. Location Zones
Zone Area
131 Center Section Wing Box, Body Station 540.00 to Body Station
663.75 Left
132 Center Section Wing Box, Body Station 540.00 to Body Station
663.75 Right
211 Flight Compartment Left
212 Flight Compartment Right

3. Access Panels
Number Name/Location
192BL ECS Ram Air Inlet Mixing Duct Panel
Forward
192BR ECS Ram Air Inlet Mixing Duct Panel
Forward

4. Hydraulic System Power Removal

A. Removal from a Portable Hydraulic Cart
i. Adjust the pressure portable hydraulic cart,
ii. Disconnect the pressure and return lines of the portable
hydraulic cart, Com-163 from the pressure and return
connections of the ground service disconnect module.
iii. Disconnect the pressure and return lines of the portable
hydraulic cart, COM-163 from the adapter, SPL-12499
a) Disconnect the adapter, SPL-12499 from the pressure
and return connections of the ground service disconnect
module.

10
 iv. Install caps on the pressure and return connections of the
ground service disconnect module.
v. Close ECS Ram Air Inlet Mixing Duct Panel Forward, for both
Number 192BL & 192 BR
B. Removal hydraulic power from an Electric Motor-Driven Pump (EMDP)
i. Set this switch on the forward overhead panel, P5, to the off
position:
a) For the hydraulic System A; HYD PUMPS A ELEC 2
b) For the hydraulic System B, HYD PUMPS B ELEC 1
C. Removal hydraulic Power from an Engine Driven Pump (EDP)
i. Stop the applicable engine. TASK 71-00-00-700-819-F00
ii. Keep the HYD PUMPS ENG switch for the applicable hydraulic
system in the ON position.
a) The HYD PUMPS ENG switches should be left in the ON
position. This will increase the life of the depressurization
solenoid which becomes energized when the HYD
PUMPS ENG switch is put it in the OFF position.

Remove pressure from the applicable hydraulic reservoir. To remove it,

do this task: Hydraulic Reservoirs Depressurisation, refer to Task 29-09-
00-860-802.
1. Location Zones
Zone Area
131 Main Landing Gear Wheel Well, Body Station 663.75 to Body Station
727.00 - Right
A. Remove hydraulic power supplied to the airplane
B. Remove pressure from the pneumatic system
C. Put a container below the air charging valve to catch any trapped
hydraulic fluid which may come out of the system
D. Remove the dust cap from the air charging valve
i. Put a rag around the air charging valve to catch spray of
hydraulic fluid. Do not get hydraulic fluid in your mouth, eyes,
skin or on the airplane. It can cause injuries to persons and
damage to equipment.
E. Cover the air charging valve with a rag to help prevent a spray of
hydraulic fluid when you release the pressure.
F. Slowly turn the swivel nut on the air charging valve (1 to 2-1/4 turns) to
the fully open position to release the pressure in the reservoirs.
G. Make sure the reservoir air pressure gauge shows 0 psi.
H. Turn the swivel nut on the air charging valve to the fully closed position.
I. Reinstall the dust cap to the air charging valve.
Procedures of Removal
Removal for Airplanes with V-Band Clamp Filter Module
1. Remove the nut [10] from the damp [9]
i. Put a container below the filter bowl to catch hydraulic fluid.
2. Remove the clamp [9]

11
3. Remove the filter bowl [11]
4. Remove the filter element [15]
i. Shut off valve will close when the filter element is removed.
ii. Discard the filter element [15]
iii. Remove and the discard packings [14] and [16]
iv. Fully clean the filter bowl [11]

Removal for Airplanes With Threaded Filter Module

1. Put a container below the filter bowl [11] to catch hydraulic fluid.
2. Removing of the filter bowl [11]
i. Pull the lock ring [9] down and rotate it to the disengaged position.
ii. Loosen the filter bowl [11]
a) The shutoff valve in the filter head will close as the filter
bowl [11] is loosened.
b) Remove the filter bowl [11]
3. Discard the filter element [15]
4. Remove and discard packings [14] and [16]
5. Fully clean the filter bowl [11]

Installation of Return Filter Element

1. Reference
a. Hydraulic Reservoir Servicing (P/B 301)
b. Supply Electrical Power (P/B 201)
c. Hydraulic Reservoirs Pressurization (P/B 201)
d. Hydraulic System A or B Pressurization (P/B)
2. Consumable Materials
Referenc Descriptions Specification

12
 e s
D00054 Fluid Hydraulic Assembly Lubricant MCS
352B (Formerly Monsanto MCS 352B)
D000153 Fluid Hydraulic Fluid, Fire Resistant BMS3-11
(Interchangeable and Intermixable with BMS 3- Type
11 Type V)

3. Expendables/Parts
AMM Item Description AIPC Reference AIPC Effectivity
14 Packing 29-11-61-01-044 MLI 001-039
29-11-61-01-205 MLI 001-039
29-11-61-01-544 MLI 001-039
29-11-61-01-705 MLI 001-039
29-11-61-02-100 MLI 040-084, 101-131
29-11-61-02-145 MLI 040-092, 101-131, 134-
141, 143-999
29-11-61-02-600 MLI 040-064, 101-131
29-11-61-02-645 MLI 040-092, 101-131, 134-
141, 143-999
15 Filter 29-11-61-01-048 MLI 001-039
Element
29-11-61-01-195 MLI 001-039
29-11-61-01-546 MLI 001-039
29-11-61-01-695 MLI 001-039
29-11-61-02-065 MLI 040-092, 101-131, 134-
141, 143-999
29-11-61-02-110 MLI 040-092, 101-131, 134-
141, 143-999
29-11-61-02-565 MLI 040-092, 101-131, 134-
141, 143-999
29-11-61-02-610 MLI 040-092, 101-131, 134-
141, 143-999
16 Packing 29-11-61-01-049 MLI 001-039
29-11-61-01-049 MLI 001-039
29-11-61-01-200 MLI 001-039
29-11-61-01-548 MLI 001-039
29-11-61-01-700 MLI 001-039
29-11-61-02-095 MLI 040-092, 101-131, 134-
141, 143-999
29-11-61-02-140 MLI 040-092, 101-131, 134-
141, 143-999
29-11-61-02-595 MLI 040-092, 101-131, 134-
141, 143-999
29-11-61-02-640 MLI 040-092, 101-131, 134-
141, 143-999

4. Location Zones
13
 Zone Area
133 Main Landing Gear Wheel Well, Body Station 663.75 to Body Station
727.00 Left
134 Main Landing Gear Wheel Well, Body Station 663.75 to Body Station
727.00 Right

Installation For Airplanes With V-Band Clamp Filter Module

1. Apply MCS 352B fluid, D00054 or hydraulic fluid, D00153 to the new
packing [14] and to new packing [16].
2. Install the new packing [14] and new packing [16] on the head of the
filter bowl [11].
3. Put the filter element [15] in the filter bowl [11].
4. Install the filter bowl [11] in the filter head.
5. Install the clamp [9] around the filter bowl [11] and the filter head.
i. Note for System A return filter module only: Position the clamp
so that the opening of the clamp is inboard and the nut is
accessible, providing maximum clearance from the System A
electric motor-driven pump (EMDP) pressure hose.
6. Install the nut [10] on the clamp [9]
7. Tighten the nut [10] on the clamp [9] to 120-144 pound inches (13.55-
16.26 Newton meters) (for filter assembly from Aircraft Porus Media
Manufacturer) or 60-70 pound-inches (6.77-7.9 Newton meters) (for
filter assembly from Purolator manufacturer).
8. Push the differential pressure indicator if it is necessary.
9. If it is necessary, perform Hydraulic Reservoir Servicing.

Installation for Airplanes with Threaded Filter Module

1. Apply MCS 352B fluid, D00054 or hydraulic fluid, D00153 to the new
packing [14] and packing [16].
2. Install the new packing [14] and new packing [16] on the head of the
filter bowl [11].
3. Put the filter element [15] in the filter bowl [11]
4. Do these steps to install the filter bowl [11] in the filter head:
i. Rotate the lock ring [9] and move it up to the engaged position.
ii. Install the filter bowl [11].
iii. Tighten the filter bowl [11] by hand.
a) Note: The lock ring [9] engages the filter head when the
filter bowl is tight.
5. Push the differential pressure indicator if it is necessary.
6. If it is necessary, perform Hydraulic Reservoir Servicing.

Labelled Parts For Hydraulics System A and B Return Filter Module and
Components

14
15
16
17
18
Removal Of Return Filter Module

19
 Location of this return filter module can be found at zone number 133 which is
near the main landing gear wheel well, body station 663.75 to 727.00 at the
left side. Another area this EMDP can be found is at zone 134 that have the
same body station number of zone 133 which is from body station 663.75 to
727.00, but at the right side.

Removal preparation of return filter module (figure 401)

First of all, before anything, we need to remove the hydraulic power from the
applicable system. Do this task Hydraulic System A and B Power Removal,
(TASK 29-11-00-860-805)

In order for us to remove the hydraulic power, we need to refer TASK 29-11-00-860-
805. This task is all about stopping hydraulic pumps or portable hydraulic cart when
the hydraulic pressure is not necessary.

TASK 29-11-00-860-805

20
Location for this task is at zone 131 which is at the Centre Section Wing Box that is
at Body Station 540.00 to 663.75 which is at the left side, zone 132, same as the
area of zone 131 but at the right side, zone 211 which is at the left side of the Flight
Compartment and also zone 212, same area of zone 211 but at the right side.

There are three source of power that will be remove when installing or removing
some component of the aircraft. There are power from the Portable Hydraulic Cart,
Electric Motor-Driven Pump (EMDP) and also the Engine Driven Pump (EDP).

For Hydraulic System Power Removal from a Portable Hydraulic Cart

Access Panel involved:

Panel number 192BL (ECS Ram Air Inlet Mixing Duct Panel)
Forward.
Panel number 192BR (ECS Ram Air Inlet Mixing Duct Panel)
Forward.

Removal From A Portable Hydraulic Cart:

First we need to adjust the pressure of the portable hydraulic cart,
COM-163 to zero.
Then, disconnect the pressure and return lines of the COM-163 from
the pressure and return connections of the ground service disconnect
module.
After that, disconnect the pressure and return line of the COM-163 from
the adapter, SPL-12499 and right after that, disconnect the adapter
from the pressure and return connections of the ground service
disconnect module.
Then, install caps on the pressure and return connection of the ground
service disconnect module.
Lastly, close all the applicable access panel 192BL and 192BR.
Removal from Electric Motor-Driven Pump
We only need to set this switch on the forward overhead panel , P5 , to
the OFF position for the hydraulic system A ; HYD PUMP A ELEC 2
and for hydraulic system B ; HYD PUMP B ELEC 1.

(PICTURE OF EMDP)

21
Hydraulic System Power removal from Engine Driven Pump (EDP)

Firstly, we need to stop the applicable engine by following the normal Engine
Stop procedure. Can be found in TASK 71-00-00-700-819-F00.
Then we need to make sure the HYD PUMP ENG switch for the applicable
hydraulic system is in ON position.
This is because, it will increase the life of the depressurization solenoid which
becomes energized when the HYD PUMP ENG is at OFF position

These are the basics and normal procedure for hydraulic system power removal.
Before we install anything or remove anything from the aircraft regarding of the
hydraulic section, we need to remove the power first. Power is supplied from the
Portable Hydraulic Cart, EMDP and EDP.

Then, after removing the hydraulic power, we need to release the pressure
from the applicable hydraulic reservoir, do this task: Hydraulic Reservoir
Depressurization, TASK 29-09-00-860-802.

Hydraulic Reservoir Depressurization (TASK 29-09-00-860-802)

First, we need to remove hydraulic power supplied to the airplane:

The main hydraulic system A and B
The standby hydraulic system
Then, we need to remove pressure from the Pneumatic System by
referring to (TASK 36-00-00-860-806)
Next, we need to put a container below the air charging valve to catch any
trapped hydraulic fluid that may come out from the system

22
 Remove the dust cap of the air charging valve
Cover the air charging valve with a rag to help prevent spray of hydraulic
fluid when you release the pressure
Turn the swivel nut on the air charging valve slowly which is about 1 to 2
-1/4 turns to the fully open position to release the pressure in the reservoir
We have to make sure that the reservoir air pressure gauge shows 0 psi
Then turn the swivel nut on the air charging valve to the fully closed
position
Lastly, Re-install the dust cap on the air charging valve.

Procedure Of Removal Of Filter Module

To remove system A filter module [8],
Disconnect the hydraulic line [3], hydraulic line [4] and
disconnect the port 1 union [5] from the hydraulic line.
To remove system B filter module [13],
Disconnect the hydraulic line [12], and disconnect union [5] from
the port 1 hydraulic line.
Next is, install plugs in the disconnection hydraulic lines.
Then, drain the hydraulic fluid into a container
If it is necessary, do this task: Clean (Wet wash) the External Surfaces
of the Airplane (TASK 12-40-00-100-801)
Remove the bolts [1] and the washers [2]
Remove the filter module [8] or filter module [13]

23
24
 Installation Of Return Filter Module

Reference(s)
Hydraulic Reservoir Servicing (P/B 301) TASK 12-12-00-601-801
Lockwire, Cotter Pins, and Lockrings installation (P/B 401) TASK 20-
10-44-400-801
Hydraulic Reservoir Pressurization(P/B 201) TASK 29-09-00-860-801
Hydraulic System A and B pressurization(P/B 201) TASK 29-11-00-860-
801

Expendables or Parts
Packing (AMM item 7)
Filter Module (AMM item 8)
Filter Module (AMM item 13)
Zone location:
Zone 133 Main Landing Gear Wheel Well , Body Station from
663.75 to Body Station 727.00 Left
Zone 134 - Main Landing Gear Wheel Well , Body Station from
663.75 to Body Station 727.00 Right

Procedure of the installation of return filter module

Install the filter module.

If packings and fittings are not installed on the filter module , Do this step:

For system A filter module [8] :

o Apply the MCS 352B fluid, D00054 or hydraulic fluid, D00153 to the
new packings [7], unions [5] and reducer [6]
o Then, install new packing [7] and union [5] in port 1, new packing [7]
and reducer [6] in port 2, and new packing [7] and union [5] in port 3.
o Install lockwire on reducer [6] in port 2 and on union on port 3. To
install, Do this task: Lockwire, Cotter Pins and Lockrings Installation,
TASK 20-10-44-400-801.
For system B filter module [13]:
o Apply MCS 352B Fluid , D00054 or hydraulic fluid, D00153 to the new
packings [7], union [5] and port 2 plug [17]
o Install new packing [7] and union [5] in port 1, new packing [7] and
union [5] in port 3, and new packing [7] and plug [17] in port 2.

25
 o Then, install lockwire on plug [17] in port 2 and on union [5] in port 3.
To install it, , Do this task: Lockwire, Cotter Pins and Lockrings
Installation, TASK 20-10-44-400-801.
Then, attach the filter module [8] or filter module [13] to the structure with
bolts[1] and washers [2]
After that, remove the plugs from the hydraulic lines.
For filter module [8], connect the hydraulic line [3] to the port 3, connect the
hydraulic line [4] to port 2 and connect the union 5 in port 1 to the hydraulic
line.
For filter module [13] however, connect the hydraulic line [12] to port 3 and
connect the union [5] in port 1 to the hydraulic line.
For the system A filter module [8] only :
o Firstly, loosen the nut [10] from the clamp [9]
o Then position the clamp [9] so that the opening of the clamp is inboard
and the nut [10] is accessible, providing the maximum clearance from
the system A EMDP pressure hose.
o Lastly, tighten the nut [10] on the clamp [9] to 120-144 pound inches
(for filter assembly from Aircraft Porus Media manufacturer) or 60-70
pound inches (for filter assembly from Purolator manufacturer).

Functional / Operational Checks

Return Filter Element and Module Installation Test

1. Pressurize the applicable hydraulic reservoir. To pressure it, do this
task: Hydraulic Reservoirs Pressurization, Task 29-09-00-860-801.
i. Reservoir Pressurization with Pneumatic System Pressurized
a) Make sure the downlock pins are installed on all the
landing gear. Without the downlock pins, the landing gear

26
 could retract and cause injuries to persons and damage
the equipment.
b) Get access to the air charging valve manifold assembly in
the right main landing gear wheel well.
o Make sure the air charging valve is fully closed
and a dust cap is installed on the valve stem.
c) To pressurize the pneumatic crossover manifold, perform
either of these tasks:
o Supply pressure to the Pneumatic System with
one or both engines.
o Supply pressure to the Pneumatic System with the
APU.
o Supply pressure to the Pneumatic System with an
External Ground Air Source.
d) Make note of the reservoir pressure indication on the air
pressure gauge in the right main landing gear wheel well,
and the duct pressure indication on the bleed air pressure
gauge in the flight compartment (P5-10 panel).
e) Make sure the pressure difference between the reservoir
air pressure gauge and the bleed air pressure gauge is
not more than 10 psi.
o Note: A pressure difference greater than 10 psi
may be an indication of an air leak in the reservoir
pressurization system. Normal reservoir pressure
should be 45-50 psi. However, the approximate
operating range can vary between 12-65 psi
depending on pneumatic source available and
aircraft operation.
f) Make sure the reservoir air pressure indication remains
stable and does not decrease.
o Note: If the pressure decrease, there may be an
air leak in the reservoir pressurization system.
ii. Reservoir Pressurization with an External Air Source
a) Make sure the downlock pins are installed on all the
landing gears.
b) Make sure the pneumatic system is depressurized
(engines, APU, and external air sources are off).
c) Get access to the air charging valve manifold assembly in
the right main landing gear wheel well.
o Remove the dust cap from the valve stem on the
air charging valve.
d) Connect the external ground 0-50 psi dry filtered
regulated air source. STD 77 to the valve stem on the
air charging valve.
e) Turn the swivel nut on the air charging valve to the fully
open position (1 to 2 turns).

27
 o Do not use more than 70 psig pressure. If you use
too much pressure, damage to the equipment can
occur.
f) Supply and adjust the pressure of the external ground 0-
50 psig dry filtered regulated air source, STD 77 to
pressurize the reservoirs to 45-50 psi.
o Make sure the reservoir air pressure gauge in the
right main landing gear wheel well shows
approximately 45-50 psi.
g) Turn the swivel nut on the air charging valve to the fully
closed position (1 to 2 turns).
o Make sure the reservoir air pressure gauge
indication is stable at approximately 45-50 psi.
h) Disconnect the external ground 0-50 psig dry filtered
regulated air source, STD 77 from the valve stem on
the air charging valve.
i) Reinstall the dust cap to the valve stem on the air
charging valve.

2. Then, supply Electrical Power

3. Pressurize the applicable hydraulic system. To pressurize the system,
perform Hydraulic System A or B Pressurization, Task 29-11-00-860-
801.
i. Hydraulic System A or B Pressurization with a Portable
Hydraulic Cart
a) Make sure the hydraulic reservoirs are depressurized.
b) Make sure the ground lock assemblies are installed in the
nose gear and main landing gears.
c) Open these applicable access panels:
o 192BL ECS Ram Air Inlet Mixing Duct Panel
Forward
o 192BR ECS Ram Air Inlet Mixing Duct Panel
Forward
d) Relieve head pressure prior to connecting the portable
hydraulic cart, COM-163.
e) Connect the portable hydraulic cart, COM 163 to the
ground service disconnect:
o Connect the pressure line of the portable hydraulic
cart, COM 163 to the pressure connection of the
ground service disconnect module.
o Connect the return line of the portable hydraulic
cart, COM 164 to the return connection of the
ground service disconnect module.
Do not use a hydraulic cart with a back flow
return pressure that is more than the limit.
Damage to the hydraulic system equipment
could occur.

28
 f) Make sure that the back flow return pressure on the
portable hydraulic cart, COM 163 is not more than 65
psi (448 kPa).
o Use the manufacturers instructions to make the
adjustment.
o If you cannot adjust the pressure to the limit, you
could over-service the hydraulic system(s) or
cause hydraulic fluid to drain from the drain mast.
g) Connect the portable hydraulic cart, COM 163 to the
ground service disconnect:
o Connect the adapter SPL 12499 to the pressure
connection of the ground service disconnect
module.
o Connect the pressure line of the portable hydraulic
cart, COM 163 to the adapter, SPL 12499.
o Connect the adapter SPL 12499 to the return
connection of the ground service disconnect
module.
o Connect the return line of the portable hydraulic
cart, COM 163 to the adapter, SPL 12499.
h) Pressurize the aircraft hydraulic reservoirs.
o Use a close loop hydraulic cart.
i) Disconnect the return line and the pressure line form the
hydraulic cart.
j) Operate the portable hydraulic cart, COM 163 to
pressurize the hydraulic system.
o Do not operate the EDPs or EMDPs with the
portable hydraulic cart return and pressure lines
connected. This may prevent the pumps from
receiving enough hydraulic fluid from their
respective reservoirs and cavitate the pump.
ii. Hydraulic System Pressurization with an Electric Motor-Driven
Pump (EMDP)
a) Make sure the ground lock assemblies are installed in the
nsoe gear and main landing gears.
b) Supply electrical power.
c) For the hydraulic System A make sure Circuit Breaker at
Power Distribution Panel Number 2, P92, Row C, Column
8, Number C00767 ELEC HYD PUMP CONTROL SYS
A is switched off.
d) For the hydraulic System B, make sure Circuit Breaker at
Power Distribution Panel Number 1, P91, Row C, Column
8, Number C00768 ELEC HYD PUMP CONTROL SYS
B is switched off.
e) Do not operate the EMDP for more than 2 minutes unless
the applicable fuel tank has a minimum 1675 lbs (760 kg)
of fuel in it. If you operate the EMDP for 2 minutes without

29
 fuel in the tank. Let the reservoir go back to ambient
temperature before you continue with the test. If you
continue to operate the EMDP, the hydraulic fluid can get
too hot.
f) Set these switches on the forward overhead panel, P5, to
the ON position:
o Hydraulic System A: HYD PUMPS A ELEC 2
o Hydraulic System B: HYD PUMPS B ELEC 1
iii. Hydraulic System A or B Pressurization with an Engine-Drive
Pump (EDP)
a) Make sure the ground lock assemblies are installed in the
nose gear and main landing gears.
b) Supply Electrical Power.
o Do not operate the EDP for more than 2 minutes
unless the applicable fuel tank has a minimum of
1675 lbs (760 kg) of fuel in it.
c) Set this switch on the forward overhead panel, P5, to the
ON position:
o Hydraulic System A: HYD PUMPS A ENG 1
o Hydraulic System B: HYD PUMPS B ENG 2
d) Operate or motor the applicable engine to keep the
hydraulic system pressurized.
e) Make sure the hydraulic pressure becomes stable
between 2800 and 3200 psig.
4. Examine the filter module and hydraulic line connections for leaks.
5. If it is necessary, perform Hydraulic Reservoir Servicing.

Safety Precautions

Most hydraulic fluids are flammable and can cause skin irritation if prolonged
contact occurs. Change clothing immediately if drenched with hydraulic fluid and
wash thoroughly.
Hydraulic fluid becomes a hazard if it is sprayed, heated to its flash point, or
otherwise subjected to conditions that cause vaporization. Hydraulic fluid must never
be stored in a missile stowage, testing, or maintenance area. Do not
handle hydraulic fluid in the presence of electrical sparks or open flames. Hydraulic

30
fluid should be kept in closed metal containers. Bulk supplies should be stored only
in approved and authorized areas.
Spilled fluids make a surface slippery. Wipe up spilled or leaking fluid
immediately. Oily rags and clothing should be stored in a closed metal container to
avoid a potential fire hazard. They should be properly disposed of at the first
opportunity
PERSONNEL SAFETY PRECAUTIONS
When working with high-pressure equipments, you must wear approved
safety glasses or face shields. Do not direct high-pressure air against the deck,
workbench, or other equipments. Low-pressure air may be used for certain specified
maintenance-related cleaning or drying tasks. Always obtain permission to use low-
pressure air for these purposes. Never direct any pressurized air jet toward your (or
a shipmate's) body.
During any GMLS equipment operation, keep all parts of the body clear of any
component that moves as a result of pneumatic or hydraulic pressure.
Safety precautions must be observed and common sense used all the time.
Do not think that once you have learned all the applicable safety rules you can sit
back and relax. Review them periodically, particularly for those jobs seldom
performed. Try to improve upon any rules in effect. Safety is everyone's
responsibility, not just those who drew up the regulations. Many accidents are
caused by personnel who are so familiar with their jobs they think they can take
shortcuts. Personnel who do not know the applicable safety precautions often are
the cause of accidents. We also cannot forget the many tragic accidents caused by
practical jokers. However, in the majority of instances, plain carelessness is the
biggest threat.

Appendix

31
Picture 1: Real Life Hydraulics System

Picture 2: Return Filter

32
Picture 3: Portable Hydraulic Cart

Picture 4: ECS Ram Air Inlet

33
Picture 4: Electric Motor Driven Pump (EMDP)

Picture 5: Engine Driven Pump (EDP)

34
 Reference
1. Aircraft Maintenance Manual, Boeing 737-600/700/800/900
a. Chapter 29 Hydraulic Power
2. FAA Handbooks & Manual, Airframe Handbook
a. Chapter 12 Hydraulic and Pneumatic Power Systems
3. Wikipedia, Hydraulics Drive System
a. https://en.wikipedia.org/wiki/Hydraulic_drive_system
4. Flight Learnings, Aircraft Hydraulics System
a. http://www.flightlearnings.com/2010/04/13/aircraft-hydraulic-
systems/
5. Skybrary, Hydraulics System
a. http://www.skybrary.aero/index.php/Hydraulic_Systems

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