AIRCRAFT HYDRAULIC SYSTEM

• Hydraulics is the branch of science which deals with the behavior of the
fluids at rest and at motion.
ADVANTAGES OF HYDRAULIC SYSTEM
1. Hydraulics provides smoother and steadier movement.
2. Hydraulic power is confined to pipelines and components, which avoids the
extra strengthening of airframe structure required for mechanical
operations
3. Hydraulics systems have a higher Power/weight ratio than mechanical
systems, particularly on large transport aircraft.
4. Installation of hydraulic equipment is simpler. Pipelines between
components for example, can be routed around obstructions and structure,
whereas to solve this problem mechanically requires the use of levers,
guides, bell-cranks and pulleys to change direction of mechanical pushrods
and cables.
5. Variation in speed of operation can be achieved without the use of complex
gearing.
6. Finally, hydraulic actuation normally obtains its power from the aircraft
engines, which relieves the pilot of unnecessary fatigue when operating a
service.

HYDRAULIC FLUIDS
DESIRABLE PROPERTIES OF HYDRAULIC FLUIDS
• The hydraulic fluids must wet the surface when it comes in contact with it.
• It should not corrode the metal which comes in contact with it.
• Fluid that is used in an aircraft hydraulic system must be as incompressible
as practical.
• It must have a low viscosity so it will flow through the lines with a
minimum of friction.
• It must be chemically stable.
• It should have good lubricating properties so the pump and system
components will not wear excessively.
• It must not foam in operation.
• It must be compatible with the metal in the components and with the elastic
materials of which the seals are made.
• It must have a high flash point.
• It must have a high fire point.
 • It should have high boiling point.
• Have a wide operating temperature range.
o (Flash point is the temperature at which a liquid gives off vapor in
sufficient quantity to ignite momentarily or flash when a flame is
applied. A high flash point is desirable for hydraulic liquids because it
indicates good resistance to combustion and a low degree of
evaporation at normal temperatures.)
o (Fire point is the temperature at which a substance gives off vapor in
sufficient quantity to ignite and continue to burn when exposed to a
spark or flame. Like flash point, a high fire point is required of
desirable hydraulic liquids.)

TYPES OF HYDRAULIC FLUIDS USED IN AVIATION

VEGETABLE BASE HYDRAULIC FLUID
• This type of hydraulic fluid is essentially castor oil and alcohol and is dyed
blue for identification.
• The common flushing agent used to flush the hydraulic system which
contains this type of hydraulic fluid is alcohol.
• Natural rubber seals are used in the systems which uses vegetable base
hydraulic fluids.
• This type of hydraulic fluids is flammable.
MINERAL BASE HYDRAULIC FLUID
• MIL-H-5606 is the most commonly used hydraulic fluid today.
• Mineral base hydraulic fluid is basically a kerosene type petroleum product.
• This type of hydraulic oil has good lubricating property.
• This type of hydraulic oil has additives to inhibit foaming and prevent
corrosion formation.
• It is quite stable chemically.
• It has very little viscosity change with temperature.
• Mineral base hydraulic fluids are dyed red for identification.
• The hydraulic systems using mineral base hydraulic fluids may be flushed
with Naptha, Varsol or Staddard solvent.
• Neoprene seals and hose may be used with 5606 hydraulic fluids.
• Mineral base hydraulic fluid is also flammable.
SYNTHETIC BASE HYDRAULIC FLUIDS
• The most commonly used fluid of this type is MIL-H-8446, commonly
known as Skydrol-500A.
• Synthetic base hydraulic fluid (skydrol-500A) is coloured purple
• While the other fluids of this type are coloured green and amber.
• Skydrol-500A is slightly heavier than water.
• Skydrol-500A has a wide range of operating temperature from somewhere
around -65°F to over 225°F for sustained operation.
• These fluids are quite susceptible to contamination by water from the
atmosphere and must be kept tightly sealed.
• These fluids attack polyvinyl chloride and must not be allowed to drip onto
electrical wiring, as it will break the insulation.
• This fluid will also lift the finish from an aircraft.
• The hydraulic systems using synthetic base hydraulic fluids may be flushed
with trichloroethylene..

CAUTION:
These fluids are not compatible with each other and must never be mixed, or
used to replace each other.

HYDRAULIC FLUID CONTAMINATION CHECK

• Whenever it is suspected that a hydraulic system has become contaminated,
or the system has been operated at temperatures in excess of the specified
maximum, a check of the system should be made.
• The filters in most hydraulic systems are designed to remove most foreign
particles that are visible to the naked eye.
• Hydraulic liquid which appears clean to the naked eye may be
contaminated to the point that it is unfit for use.
• Thus, visual inspection of the hydraulic liquid does not determine the total
amount of contamination in the system.
• Large particles of impurities in the hydraulic system are indications that
one or more components in the system are being subjected to excessive
wear.
• Isolating the defective component requires a systematic process of
elimination.
• Fluid returned to the reservoir may contain impurities from any part of the
system.
• To determine which component is defective, liquid samples should be taken
from the reservoir and various other locations in the system.
• Samples should be taken in accordance with the applicable manufacturer’s
instructions for a particular hydraulic system.
• Some hydraulic systems are equipped with permanently installed bleed
valves for taking liquid samples, whereas on other systems, lines must be
disconnected to provide a place to take a sample.
• In either case, while the fluid is being taken, a small amount of pressure
should be applied to the system.
• This ensures that the liquid will flow out of the sampling point and thus
prevent dirt from entering the hydraulic system.
• Some contamination test kits have hypodermic syringes for taking samples.
• Various test procedures are used to determine the contamination level in
hydraulic liquids.
• The filter patch test provides a reasonable idea of the condition of the fluid.
o This test consists basically of filtration of a sample of hydraulic
system liquid through a special filter paper.
o This filter paper darkens in degree in relation to the amount of
contamination present in the sample, and is compared to a series of
standardized filter disks which, by degree of darkening, indicate the
various contamination levels.
o The equipment provided with one type of contamination test kit is
illustrated in figure.
o When using this type of contamination test kit, the liquid samples
should be poured through the filter paper, and the test filter paper
should be compared with the test patches supplied with the test kit.
o More expensive test kits have a microscope for making this
comparison.
o To check liquid for decomposition, pour new hydraulic liquid into a
sample bottle of the same size and color as the bottle containing the
liquid to be checked.
o Visually compare the color of the two bottles.
o Liquid which is decomposed will be darker in color.
o At the same time the contamination check is made, it may be
necessary to make a chemical test.
o This test consists of a viscosity check, a moisture check, and a flash
point check.
 o However, since special equipment is required for these checks, the
liquid samples must be sent to a laboratory, where a technician will
perform the test.

CONTAMINATION CONTROL
• Filters provide adequate control of the contamination problem during all
normal hydraulic system operations.
• Control of the size and amount of contamination entering the system from
any other source is the responsibility of the people who service and
maintain the equipment.
• Therefore, precautions should be taken to minimize contamination during
maintenance, repair, and service operations.
• Should the system become contaminated, the filter element should be
removed and cleaned or replaced.
• As an aid in controlling contamination, the following maintenance and
servicing procedures should be followed at all times:
 o Maintain all tools and the work area (workbenches and test
equipment) in a clean, dirt-free condition.
o A suitable container should always be provided to receive the
hydraulic liquid that is spilled during component removal or
disassembly procedures.
o Before disconnecting hydraulic lines or fittings, clean the affected area
with dry cleaning solvent.
o All hydraulic lines and fittings should be’ capped or plugged
immediately after disconnecting.
o Before assembly of any hydraulic components, wash all parts in an
approved dry cleaning solvent.
o After cleaning the parts in the dry cleaning solution, dry the parts
thoroughly and lubricate them with the recommended preservative
or hydraulic liquid before assembly. Use only clean, lint-free cloths to
wipe or dry the component parts.
o All seals and gaskets should be replaced during the re-assembly
procedure. Use only those seals and gaskets recommended by the
manufacturer.
o All parts should be connected with care to avoid stripping metal
slivers from threaded areas. All fittings and lines should be installed
and torqued in accordance with applicable technical instructions.
o All hydraulic servicing equipment should be kept clean and in good
operating condition.

BASIC HYDRAULIC SYSTEM

• As aircraft have become more complex, the demand for hydraulically
operated equipment has increased.
• The following services are operated using hydraulic system, which depends
upon the design and the type of the aircraft.
o Retractable landing gear
o Wing flaps
o Engine cowl flaps
o Passenger doors and stairs
o Wind shield wipers
BASIC HYDRAULIC SYSTEM
A simple hydraulic system essentially consists of
four basic components such as a vented reservoir,
a hand operated pump with a check valve at its
both inlet and outlet, a selector valve and an
actuator.

BASIC HYDRAULIC SYSTEM USING SINGLE ACTING

ACTUATOR
The actuator in this system is a simple single action unit that uses hydraulic fluid
to force the piston out, but a spring returns the piston when the fluid is released
back into the reservoir.

BASIC HYDRAULIC SYSTEM USING DOUBLE ACTING ACTUATOR

HAND PUMP SYSTEM

• The first of the basic components, the reservoir, stores the supply of
hydraulic fluid for operation of the system. It replenishes the system fluid
when needed, provides room for thermal expansion, and in some systems
provides a means for bleeding air from the system.
• A pump is necessary to create a flow of fluid. The pump shown in figure is
hand operated; however, aircraft systems are, in most instances equipped
with engine-driven or electric motor driven pumps.
• The selector valve is used to direct the flow of fluid. These valves are
normally actuated by solenoids or manually operated, either directly or
indirectly through use of mechanical linkage.
 • An actuating cylinder converts fluid pressure into useful work by linear or
reciprocating mechanical motion, whereas a motor converts fluid pressure
into useful work by rotary mechanical motion.

POWER PUMP SYSTEM

• The given figure shows a basic system with
the addition of a power-driven pump and filter,
pressure regulator, accumulator, pressure gage,
relief valve, and two check valves.
• The filter removes foreign particles from
the hydraulic fluid, preventing dust, grit, or
other undesirable matter from entering the
system.
• The pressure regulator unloads or relieves
the power-driven pump when the desired
pressure in the system is reached. Thus, it is
often referred to as an unloading valve. When
one of the actuating units is being operated and
pressure in the line between the pump and
selector valve builds up to the desired point, a
valve in the pressure regulator automatically
opens and fluid is bypassed back to the
reservoir. This bypass line is shown in figure
leading from the pressure regulator to the
return line.
• Many hydraulic systems do not use a
pressure regulator, but have other means of
unloading the pump and maintaining the
desired pressure in the system. These methods
are described in this chapter.
• The accumulator (refer figure) serves a
two fold purpose:
o It acts as a cushion or shock absorber by maintaining an even pressure
in the system, and
o It stores enough fluid under pressure to provide for emergency
operation of certain actuating units. Accumulators are designed with a
compressed air chamber which is separated from the fluid by a
flexible diaphragm or movable piston.
 • The pressure gage (refer figure) indicates the amount of hydraulic pressure
in the system.
• The relief valve is a safety valve installed in the system to bypass fluid
through the valve back to the reservoir in case excessive pressure is built
up in the system.
• The check valves allow the flow of fluid in one direction only. Check valves
are installed at various points in the lines of all aircraft hydraulic systems.
• In figure given one check valve prevents power-pump pressure from
entering the hand-pump line; the other prevents hand-pump pressure from
being directed to the accumulator.

OPEN CENTER HYDRAULIC SYSTEM

• An open center system is one having fluid flow, but no pressure in the
system when the actuating mechanisms are idle.
• The pump circulates the fluid from the reservoir, through the selector
valves, and back to the reservoir.
• The open center system may employ any number of subsystems, with a
selector valve for each subsystem.
• Unlike the closed center system, the selector valves of the open center
system are always connected in series with each other.
• In this arrangement, the system pressure line goes through each selector
valve.
• Fluid is always allowed free passage through each selector valve and back
to the reservoir until one of the selector valves is positioned to operate a
mechanism.
• When one of the selector valves is positioned to operate an actuating
device, fluid is directed from the pump through one of the working lines to
the actuator.
• With the selector valve in this position, the flow of fluid through the valve to
the reservoir is blocked.
• The pressure builds up in the system to overcome the resistance and moves
the piston of the actuating cylinder; fluid from the opposite end of the
actuator returns to the selector valve and flows back to the reservoir.
• Operation of the system following actuation of the component depends on
the type of selector valve being used.
• Several types of selector valves are used in conjunction with the open
center system.
• One type is both manually engaged and manually disengaged.
 • First, the valve is manually moved to an
operating position.
• Then, the actuating mechanism reaches
the end of its operating cycle, and the pump
output continues until the system relief valve
relieves the pressure.
• The relief valve unseats and allows the
fluid to flow back to the reservoir.
• The system pressure remains at the relief
valve set pressure until the selector valve is
manually returned to the neutral position.
• This action reopens the open center flow
and allows the system pressure to drop to line
resistance pressure.
• The manually engaged and pressure
disengaged type of selector valve is similar to
the valve previously discussed.
• When the actuating mechanism reaches the end of its cycle, the pressure
continues to rise to a predetermined pressure.
• The valve automatically returns to the neutral position and to open center
flow.

CLOSED-CENTER HYDRAULIC SYSTEMS

• In the closed-center system, the fluid is under pressure whenever the
power pump is operating.
• The three actuators are arranged in parallel and actuating units B and C are
operating at the same time, while actuating unit A is not operating.
• This system differs from the open-center system in that the selector or
directional control valves are arranged in parallel and not in series.
• The means of controlling pump pressure varies in the closed-center system.
If a constant delivery pump is used, the system pressure is regulated by a
pressure regulator.
• A relief valve acts as a backup safety device in case the regulator fails.
• If a variable displacement pump is used, system pressure is controlled by
the pump’s integral pressure mechanism compensator.
• The compensator automatically varies the volume output. When pressure
approaches normal system pressure, the compensator begins to reduce the
flow output of the pump.
 • The pump is fully compensated (near zero flow) when normal system
pressure is attained.
• When the pump is in this fully compensated condition, its internal bypass
mechanism provides fluid circulation through the pump for cooling and
lubrication.
• A relief valve is installed in the system as a safety backup.
• An advantage of the open-center system over the closed-center system is
that the continuous pressurization of the system is eliminated.
• Since the pressure is built up gradually after the selector valve is moved to
an operating position, there is very little shock from pressure surges.
• This action provides a smoother operation of the actuating mechanisms.
• The operation is slower than the closed-center system, in which the
pressure is available the moment the selector valve is positioned.
• Since most aircraft applications require instantaneous operation, closed-
center systems are the most widely used.

HYDRAULIC POWER PACK SYSTEM

• A hydraulic power pack is a small unit that consists of an electric pump,
filters, reservoir, valves, and pressure relief valve.
• The advantage of the power pack is that there is no need for a centralized
hydraulic power supply system and long stretches of hydraulic lines, which
reduces weight.
• Power packs could be driven by either an engine gearbox or electric motor.
• Integration of essential valves, filters, sensors, and transducers reduces
system weight, virtually eliminates any opportunity for external leakage,
and simplifies troubleshooting.
• Some power pack systems have an integrated actuator.
• These systems are used to control the stabilizer trim, landing gear, or flight
control surfaces directly, thus eliminating the need for a centralized
hydraulic system.

• When the selector lever is operated the pressure from the

accumulator starts to move the actuator.
• As the accumulator ram moves up, the switch operating collar moves
away from the motor switch and the pump commences it’s pumping
cycle.
• The actuator will extend until full travel is reached.
• Further pump action will recharge the actuator until the fully charged
position is reached and the switch operating collar will operate the
motor switch and stop the pump.