PD07WRGBZOENF10.pdf

PD07WRGBZOENF10

CAGE: 98752

29 October 2009

Distribution Statement A. Approved for public release; distribution is unlimited. FSC 4920

Inch-Pound

PD07WRGBZOENF10

29 October 2009 Superseding None

Purchase Description Universal Hydraulic Test Stand (UHTS) - Dual system, trailer-mounted

1. SCOPE

1.1 Scope. This specification covers the requirements of a dual hydraulic system universal hydraulic test stand (UHTS) driven by a diesel engine or an electric motor used to provide hydraulic fluid pressure and flow for testing hydraulic systems on multiple air frames.

1.2 Classification. The UHTS consists of the following types. When a section references the UHTS in the general nature, the requirement is applicable to both type I and type II. However, when a section references a specific type, that requirement is only applicable to the specific type. The type of UHTS is to be furnished as specified (see 6.2).

1.2.1 Types. The types of UHTS are as follows:

Type I - diesel engine Type II - electric motor

2. APPLICABLE DOCUMENTS

2.1 General. The documents listed in this section are for guidance and information.

2.2 Government documents.

2.2.1 Specifications, standards, and handbooks. The following specifications, standards, and handbooks of the exact revision listed below form a part of this document to the extent specified herein.

AMSC N/A FSC 4920

Comments, suggestions, or questions on this document should be addressed to U.S. Air Force Logistic Center, WR-ALC ATTN: 642 CBSG/GBEA, 460 Richard Ray Blvd Ste 200, Robins AFB, GA 31098-1640. Since contact information can change, you may want to verify the currency of this address information using the ASSIST Online database at www.dodssp.daps.mil.

FEDERAL STANDARD

FED-STD-595 Color

COMMERCIAL ITEM DESCRIPTION

A-A-50271 Plate, Identification A-A-52550 Pintle Assembly, Towing, Manual Release A-A-52464 Coupler, Drawbar, Ring A-A-59494 Wheels and Hubs for Industrial Pneumatic Tires

MILITARY SPECIFICATIONS

MIL-PRF-23377 Primer Coatings: Epoxy, High-Solids MIL-PRF-26915 Primer Coatings: For Steel Surface MIL-PRF-85285D Coating: Polyurethane, Aircraft and Support Equipment DODI 6055.11 Protection of DoD Personnel from Exposure to Radiofrequency

Radiation and Military Exempt Lasers

MILITARY STANDARDS

MIL-STD-130N Identification Marking of US Military Property MIL-STD-461E Department of Defense Interface Standard, Requirements for the

Control of Electromagnetic Interference Characteristics of Subsystems and Equipment

MIL-STD-810F Environmental Test Methods & Engineering Guidelines MIL-STD-1472F Human Engineering MIL-STD-1474 Noise Limits for Military Materiel MIL-HDBK-1784 Mobility, Towed and Manually Propelled Support Equipment MIL-PRF-5606 Hydraulic Fluid, Petroleum Base, Aircraft, Missile, and Ordnance

MIL-F-5504B Filters And Filter Elements, Fluid Pressure, Hydraulic Micronic Type

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

MIL-PRF-87257 Hydraulic Fluid, Fire Resistant; Low-temperature, Synthetic Hydrocarbon Base, Aircraft and Missile

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

MS 27228 90 Deg Flange Assembly, Adapter, Hose to Tube, Reusable, Hydraulic, Fuel and Oil Lines

MS27265 Connector, Plug, Electrical-Ramp Power, 416/240 Volts, Male

DEPARTMENT OF DEFENSE HANDBOOK

MIL-HDBK-759 Human Engineering Design Guidelines

MIL-HDBK-808 Finish, Materials and Processes for Corrosion Prevention and Control in Support Equipment

MIL-HDBK-1791 Designing for Internal Aerial Delivery in Fixed Wing Aircraft MIL-HDBK-781A Reliability Test Method, Plans, and Environments for Engineering

Development, Qualification, and Production DOD-HDBK-743A Anthropometry

(Copies of these documents are available online at http://assist.daps.dla.mil/quicksearch/ or www.dodssp.daps.mil or from Standardizations Documents Order Desk, 700 Robbins Avenue, Building 4D, Philadelphia, PA 19111-5094.)

2.2.2 Other government documents, drawings, and publications. The following other government documents, drawings, and publications form a part of this document to the extent specified herein. Unless otherwise specified, the issues are those cited in the solicitation.

SD-14 Listings of Toxic Chemicals, Hazardous and Ozone-Depleting Chemicals

AF DWG 7347073 Coupling, Male, 12 inch Duct AF DWG 55C6182 Connectors- 440 Volt / 416 Volt Power Cable

(Copies of the above drawings are available from the contracting officer listed in block 7 on page 1 of this solicitation; Technical Orders are available online at http://www.robins.af.mil/library/technicalorders.asp)

2.3 Non-government publications. The following documents form a part of this document to the extent specified herein. Unless otherwise specified, the issues of these documents are those cited in the contract.

AIA/NAS 1638 Cleanliness Requirements of Parts Used in Hydraulic Systems

(Copies of these documents are available from AIA/ Aerospace Industries Association of America, Inc 1250 Eye Street, NW Suite 1100, Washington DC 20005 Phone (202) 371-8400.)

ASTM C1036 Standard Specification for Flat Glass

(Copies of these documents are available from ASTM/ American Society for Testing & Materials, 100 Bar Harbor Drive, West Conshohocken, PA 19428-2959 Phone (610) 832-9500)

AMERICAN SOCIETY OF MECHANICAL ENGINEERS (ASME)

ASME Boiler and Pressure Vessel Code, Section VIII, Div 1

(Copies of these documents are available from www.asme.org or ASME Information Central Orders/Inquiries, P.O. Box 2300, Fairfield, NJ 07007-2300.)

NATIONAL ELECTRICAL CONTRACTORS ASSOCIATION (NEMA)

MG-1 Motors and Generators MG-2 Safety Standard and Guide for Selection, Installation, and Use of Electric Motors and Generators

(Copies of these documents are available from www.nema.org or from National Electrical Contractors Association, 1300 North 17th Street, Suite 1847, Rosslyn, VA 22209)

NATIONAL FIRE PROTECTION ASSOCIATION (NFPA)

NFPA No. 70H National Electrical Code.

NFPA T2.24.1 National Fluid Power Assoc. Zero Leakage

(Copies of these documents are available from www.nfpa.org or from National Fire Protection Association, Battery March Park, Quincy, MA 02269.)

SOCIETY OF AMERICAN ENGINEERS

SAE ARP 4943 Ground Support Equipment Hydraulic Systems, Design and Installation, General Requirements SAE AS8090 Mobility, Towed Aerospace Ground Equipment, General Requirements SAE ARP1247C Aerospace Ground Support Equipment Motorized and Nonmotorized, General Requirements SAE-AIR1375 Minimum Safety Requirements for Special Purpose Airline Ground

Support Equipment SAE/ARP 1232 Gland Design, Elastomeric O-Ring seals, Static Radial SAE/ARP 1234 Gland Design, Elastomeric O-Ring Seals, Static Axial, Without Back-Up

Rings SAE/J2013 Military Tire Glossary SAE/AS 4716 Gland Design, O-ring and Other Elastomeric Seals SAE AS 35411B Fittings, Lubrication SAE AS 5756 Cable, Power, Electrical, Portable General Specification For

(Copies of these documents are available from www.sae.org or from Society of American Engineers, 400 Commonwealth Drive, Warrendale, PA 15096-0001)

AWS American Welding Society

(Copies of these documents are available from http://www.awspubs.com/ or from American Welding Society, 550 N.W. LeJeune Road, Miami, Florida 33126)

2.4 Order of precedence. In the event of a conflict between the text of this document and the 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.

3. REQUIREMENTS

3.1 First article. For purposes of this solicitation/contract and purchase description, the terms “first article” and “preproduction unit” are synonymous and are used interchangeably. In accordance with the solicitation/contract, the contractor shall provide two units of each type for preproduction unit testing in accordance with 4.2 of this purchase description. The contractor shall be responsible for performing contractor-testing and aircraft compatibility testing on the units. Subsequent to government approval of the two contractor-tests, the contractor shall submit the units to the government who shall conduct user’s operational testing.

3.2 Materials. The materials of construction are the responsibility of the contractor. All materials shall be suitably treated to resist corrosion due to electrolytic decomposition and any other atmospheric conditions that may be encountered during operational use or storage. The materials shall be of sufficient capability to meet all operational and environmental requirements in accordance with 3.7.

3.2.1 Recycled, recovered, or environmentally preferable materials. Recycled, recovered, or environmentally preferable materials should be used to the maximum extent possible provided that the material meets the operational and maintenance requirements, and promotes economically advantageous life cycle costs. However, used, rebuilt, or refurbished items shall not be provided.

3.2.2 Prohibited materials. The use of any refrigerant requiring recovery by a recovery system or the use of any ozone depleting compounds (ODCs) are prohibited for any operation, maintenance, repair, or troubleshooting action for the UHTS.

3.2.3 Metals containing hydraulic fluid and fuel. Any metals which react with hydraulic fluids of the UHTS or can interfere or degrade the hydraulic fluids shall be prohibited. Any metals which can react with fuels used on the UHTS or can interfere or degrade the fuel shall be prohibited.

3.2.4 Additional prohibited materials. The following materials shall not be used in the construction of the units:

Magnesium. The use of magnesium and magnesium-alloys shall be prohibited.

Black iron and galvanized pipe. Black iron and galvanized pipe shall be prohibited.

Cadmium plated parts. Cadmium plating shall not be used on parts which may come in contact with aircraft components being tested, fuel, and hydraulic fluids.

3.2.5 Green procurement program. Green procurement program (GPP) is a mandatory federal acquisition program that focuses on the purchase and use of environmentally preferable products and services. GPP requirements apply to all acquisitions using appropriated funds, including services and new requirements. Federal acquisition regulation (FAR) 23.404(b) applies and states the GPP requires 100% of environmental protection agency (EPA) designated product purchase that are included in the comprehensive procurement guidelines (CPG) list that contains recovered materials, unless the item cannot be acquired: a) competitively within a reasonable timeframe; b) meet appropriate performance standards, or c) at a reasonable price. The prime contractor is responsible for ensuring that all subcontractors comply with this requirement.

3.3 Design. The UHTS shall consist of a self contained, enclosed, four wheel, towable, trailer mounted test stand that produces hydraulic power as specified herein. The UHTS shall be able to be moved, maneuvered, parked and positioned on a specific location by three persons between 5th percentile female and 95th percentile male in accordance with DOD- HDBK-743A with no additional equipment required. The UHTS type I shall be powered by a diesel engine. The UHTS type II shall be powered by an electric motor. The drive systems shall be the only primary difference that distinguishes the diesel version from its electric counterpart and parts commonality shall be maximized between the two types. The UHTS shall withstand the stress, shock, and vibration incident to operation, shipment, towing, and lifting by forklift. The UHTS shall be designed to provide the minimum practical loss of time for maintenance, repair, and service. The UHTS design shall ensure safe, efficient, and economical operation. Where applicable, the UHTS shall meet the requirements of SAE ARP1247. The UHTS shall be designed to operate for at least 20,000 hours over a service life of 20 years.

3.4 Weight. The UHTS maximum dry weight shall not exceed 8000 lbs. Dry weight is defined as with the engine serviced and the hydraulic system and fuel tank drained.

3.5 Dimensions. The UHTS shall not exceed 120 inches in length (tow bar up/stowed), 78 inches in width, and 96 inches in height (tow bar up/stowed).

3.6 Safety. The hydraulic system's component operation and arrangement shall minimize operational, safety, and fire hazardous conditions. The UHTS shall meet the requirements of

SAE-AIR1375.

3.6.1 Automatic shutdown. The system controls shall automatically shut-down the stand whenever any hazardous abnormal condition exists on the UHTS during operations. Any hazardous abnormal condition shall immediately cause the UHTS to place all controls and equipment in a safe-mode to protect the operator, aircraft, and the UHTS in a steady-state shut-down condition.

3.6.2 Alarm. The system controls shall automatically initiate a visual and audio alarm on the control panel whenever any abnormal condition exists on the UHTS during operations.

3.6.3 Emergency manual shutdown. The control panel shall have an emergency shut-down button on the control panel. When activated, the switch shall instantaneously remove power from all systems and sub-systems. Actuation of the emergency shutdown switch shall require a maintenance action to reset. The switch shall be located in the upper right hand corner of the control panel and be of the mushroom type configuration.

3.6.4 Fire prevention, safety, design & construction practices. Best commercial practices shall be employed. The danger to personnel from fire and explosion shall be avoided by separation of hazardous substances from heat sources, suitable vents and drains, and other fire prevention measures. All fastening devices and other parts which may cause hazardous conditions shall be secured or shall have other approved locking means applied. The use of safety wire as a securing method is not allowed. Mechanical or electrical parts that are of such nature or so located as to become a hazard to operating or maintenance personnel shall be enclosed or properly guarded. Suitable guards shall be provided for all exposed moving parts or mechanisms that might snag clothing or cause injury to personnel. Guards shall be designed to permit inspections and maintenance mechanisms without removal of guard, wherever possible. A safety relief system shall be provided such that excessive pressure shall be released automatically.

3.7 Performance conditions.

3.7.1 Operating environments. The UHTS shall be capable of startup and full operation at the operating temperature range of -40 °F to 125 °F at sea level. The UHTS shall operate in a humid environment of 125°F and 20% relative humidity. The UHTS shall be capable of startup without the aid of auxiliary equipment at ambient temperatures down to -25 °F with exception of the UHTS type I being allowed the equipment as specified in Appendix A, paragraph 3.3.2. The engine is required to operate, but not start at -26 to -40 degrees Fahrenheit. The contractor shall provide cold weather auxiliary equipment as required with each UHTS as part of this contract.

3.7.2 Altitude. The UHTS shall be capable of operation from sea level to a minimum of 7,000 feet. Non-operational altitude range shall be sea level to 40,000 feet. In altitude conditions from sea level to 3,000 feet the UHTS shall provide rated pressure and flow while operating in 125 degree Fahrenheit conditions. In altitude conditions from 3,001 to 5,000 feet the UHTS shall provide rated pressure and flow while operating in 125 degree Fahrenheit conditions. In altitude conditions from 5,001 to 7,000 feet the UHTS shall provide rated pressure and flow while operating in 105 degree Fahrenheit conditions. Derating of the UHTS is allowed at temperatures and elevations exceeding the above listed conditions. Example: derating is allowed while operating in a 130 degree Fahrenheit 3,500 feet above sea level environment, but not allowed in a 125 degree Fahrenheit 3,500 feet above sea level environment.

3.7.3 Operating and storage environments. The performance capability of the UHTS shall not be affected by operation or storage under the following environments:

a. Low pressure (altitude). The UHTS shall not be damaged by operation or storage at altitudes as specified in 3.7.2.

b. High temperature storage/operation. The UHTS shall not be damaged by storage at a temperature of 160°F or operation at a temperature of 125°F.

c. Low temperature storage/operation. The UHTS shall not be damaged by storage at a temperature of -65°F or operation at a temperature of -40°F.

d. Solar radiation. The UHTS shall not be damaged by exposure to solar radiation such as encountered in tropical, subtropical climates and desert environments.

e. Rain. The UHTS shall be able to withstand exposure to rainfall (operational and non-operational) at the rate of 4 in/hr at an angle from vertical to 45 degrees with 45 mph winds.

f. Humidity. The UHTS assembly shall not be damaged by operation or storage in a warm, humid environment and environments in which high levels of humidity occur in accordance with Table 1.

g. Fungus. The UHTS shall not be damaged by exposure to moist fungus growth such as encountered in tropical and subtropical climates.

h. Salt fog. The UHTS shall not be damaged by operation or storage in an atmosphere containing salt-laden moisture such as encountered near bodies of salt water and in transportation on shipboard.

i. Sand and dust. The UHTS shall be able to withstand exposure to small-particles dust (≤ 149 μm) and blowing sand (150 to 850 μm particles size) (operational and non-operational) at a temperature of 125°F and 20% relative humidity.

j. Vibration forces. The UHTS shall not be damaged by vibration forces that will typically be encountered during its transportation in aircraft, railroad car, ship, or truck.

k. Snow and ice. The UHTS shall be capable of storage and operation during snow and ice accretion up to 2-inches per hour for at least 12 hours. Particular note shall be made with regard to provisions to prevent accumulation of dirt, snow, ice, etc., which may hinder servicing and operation.

Table 1

3.8 Accessibility. Compartment access and handles shall reflect compatibility with the clothing and personal equipment (C/PE) of personnel using and maintaining equipment, under the environmental conditions specified herein, having space allocations commensurate with the restrictions imposed on performance by C/PE. The UHTS shall be in accordance with the service and access requirements of 3.4.3 of SAE ARP1247C.

3.8.1 Component accessibility. Components shall be arranged for maximum ease of operation and maintenance consistent with the versatility and efficiency required to conform to the requirements specified herein. Flow control, diverting valves, direction control valves, relief valves, pressure control valves, temperature and pressure sensors, transducers, cartridge valves, flow meters, and other porting devices shall be arranged for the highest reliability and maintainability possible within the given envelope of space. All components shall be identified (or keyed) to avoid installation errors. The arrangement of components shall be such that any single fault/failure shall not affect the operation of the remainder of the entire stand with the exception of the prime mover (engine/motor). The UHTSs shall be operable, maintainable, and supportable by 5th percentile female through the 95th percentile male personnel wearing full mission oriented protective posture (MOPP) level IV chemical protective clothing and equipment or arctic clothing or both.

3.8.2 Personal protective equipment (PPE) requirement. The UHTS shall permit performance of mission-essential operations, maintenance, and decontamination tasks by trained and acclimatized personnel when clothed in battle dress uniform (BDU), airman battle uniform (ABU) cold-wet weather protective clothing, artic clothing, and the protective ensembles for MOPP level IV. Operational inspections and servicing (fuel, oils, etc.) shall be performed by the 5th percentile female through the 95th percentile male personnel without requiring the removal of other components or access panels, including in extreme cold conditions while wearing protective gloves. Inspections and servicing shall be accomplished from a standing position using normal motions such as leaning, reaching, bending, or squatting.

3.8.3 Inspection and servicing provisions.

a. Routine servicing tasks and pre-use inspections shall require no hand tools.

b. Drain plugs and filters shall be directly accessible and oriented to have unimpeded drainage to a catch pan.

c. The UHTS shall be designed with maximum usage of sealed lifetime lubrication bearings.

The UHTS shall be designed so that oils and coolant levels can be checked while the unit is running as well as while it is non-operational.

3.8.4 Human engineering criteria. The use of night-vision goggles by the operator shall be considered in the layout and light intensities of displays. Special emphasis shall be given, but not limited to, visual displays, control/display integration, controls, labeling, anthropometry, design for maintainability, and hazard and safety criteria, as applicable. MIL-HDBK-759 may be used for information and guidance on human factors engineering, and MIL-STD-1472 may be used as a source for anthropomorphic data.

3.8.4.1 Human factors. The design shall foster effective performance of operating procedures, an effective personnel safety and health environment, and minimize factors that contribute to increased operator error. The design shall incorporate protection from toxic, electrical, thermal, mechanical, and other potential hazards. The design shall also reflect efficient arrangement of equipment and components; and feature characteristics that ensure a rapidity, safety, ease, and economy of use. The equipment shall represent the simplest design consistent with functional requirements.

3.9 UHTS function.

3.9.1 Dual system supply. The UHTS shall have two independent hydraulic systems. Each system shall be pressure and flow independent and capable of delivering the following flow and pressure combinations: 0-53 gallons per minute (gpm) @ 250-3000 pounds per square inch (psi), 0-40 gpm @ 250-4000 psi, 0-32 gpm @ 250-5000 psi. Each system shall be capable of delivering pressure and flow requirements without exceeding the system’s maximum flow velocity as defined in 3.11.12. The UHTS shall permit the two systems (both the supply and return lines) to be connected (manifolded) to allow for both systems to be ported into single input and output connections. The manifolded systems shall have the capability to generate minimum total flow rates of 0-106 gpm @ 250-3000 psi, 0-80 gpm @ 250-4000 psi, 0-64 gpm @ 250-5000 psi, without exceeding the system’s maximum flow velocity as defined in 3.11.12.

The UHTS shall have a minimum controllable flow of 1.5 gpm in each individual system and 3 gpm when the systems are manifolded.

3.9.2 Flow measurement. Two flow meters shall be provided and be visible from the control panel, one in each independent return line. Each shall have the ability to measure a minimum of 60 gpm, and shall have the ability to accurately measure flow in 0.5 gpm graduations or less.

The flow meters shall be accurate within +/- 1.0% of reading. The flow meters shall be easily removable for cleaning without affecting calibration. The UHTS shall have a means for in place calibration of the flow indicators without requiring removal from the UHTS. If turbine meters are used with digital indicators, they shall have a verifiable minimum operational life of 10,000 hours.

3.9.3 Pressure measurement. Pressure measuring/indicating devices shall be provided and shall be located on the control panel. The indicators shall provide a minimum recommended operational range of 0 to 5000 psi. The indicators shall be accurate to within 1.0% full scale from 0-5000 psi. The low pressure measurement shall be accurate to within 1.0% full scale range from 30 inches HG vacuum to 500 psig. The indicators shall be designed for operation from -40o F to +200o F. Pressure measuring/indicating devices shall be provided as a minimum at system outlet, system return, main pump inlet, boost pump, fill pump, and back pressure.

Provisions for in-place calibration and isolation of pressure measuring/indicating devices shall be incorporated and shall minimize leakage during calibration (to the level specified herein). All pressure gauges used in support of the system and sub-systems shall be located on the control panel and provide a means of calibration, as required, without removal of the gauge.

3.9.4 Temperature measurement. Temperature indicators shall be provided on the control panel to indicate the hydraulic fluid temperature at the supply to the high pressure pumps. The range of the indicators shall be at least -30o F to +200o F and shall indicate to within +/- 2o F. The accuracy of the indicators shall not be affected by continued exposure to the climatic extremes specified herein.

3.9.5 Aircraft fluid filling. A system incorporating an electric-motor-driven pump, filter, push-button-type fill valves, and relief valves shall be provided to allow filling or adding hydraulic oil to the aircraft’s sub-systems. The filling pump shall be a low-pressure hydraulic pump with weather-proof enclosure, having a capacity of a least 2 gpm at 150 psi that is driven by a direct-current motor, for the UHTS type I, powered by the engine battery. The UHTS type I shall permit the operation of the fill pump and all system controls for a 15 minute period from auxiliary power/battery without the diesel engine operating, and still retain sufficient battery power to start and operate the diesel engine and systems. For the UHTS type II, the fill pump shall be AC powered. Valve and tubing size shall be not less than 3/8 inch. A variable relief valve shall be provided, but not mounted on the control panel. The valve shall be adjustable throughout a pressure range from 5 to 200 psi and capable of relieving the total volume discharged by the fill pump. The valve shall have a locking device so that vibration cannot change the pressure setting. Each relief valve shall be set for 200 psi. Check valves shall be provided in the fill system. A 3 micron absolute filter suitable for 150 psi minimum operating pressure shall be provided in the fill system. The filter element housing shall be capable of withstanding a minimum proof pressure of 2.5 times the operating pressure and a minimum burst pressure of 4.00 times the maximum operating pressure under all conditions, environments, and hydraulic fluids specified.

3.9.6 Fluid purification. The UHTS shall provide a continuous flow process for purification of hydraulic fluids contained within the UHTS and the aircraft. Purification shall be accomplished without the use of any external equipment. The purification portion of the UHTS shall be operated and monitored from the control panel of the UHTS. The purification process shall be able to be deactivated and reactivated at the control panel. The UHTS shall have additional external supply and return connections and have the ability to purify hydraulic fluid from a 55 gallon drum or legacy mule utilizing government supplied adapters for the drum and legacy mule reservoir. The UHTS purification unit shall also be able to pull hydraulic fluid from a drum, purify the fluid and fill the reservoir on the UHTS with that fluid. Purification of the hydraulic fluid shall consist of the removal of free air, air in solution, water, chlorinated solvents and particulates. Systems which use desiccants or which degrade the hydraulic fluid properties in the purification process shall not be acceptable. All purification processes and equipment require approval from the Air Force Petroleum Agency, Science and Technology Division (HQ AFPET/AFTT). Approval requires successful completion of a 1500-hour pump wear test as performed by the HQ AFPET/AFTT in-house pump test facility. (see Appendix C for test plan.)

As part of this test, a stand alone purification unit emulating the exact process and components to be contained in the UHTS, must be submitted to the Air Force Petroleum Agency, Science and Technology Division (HQ AFPET/AFTT) for testing. The purifier shall be a separate isolated system from the two hydraulic systems. Failure of any purifier component shall not inhibit function of the two UHTS hydraulic systems or other sub-systems.

The UHTS purification system shall provide the following capabilities for decontaminating (purifying) hydraulic fluids within the total UHTS/aircraft hydraulic system while operating in open loop and have the capability of decontaminating (purifying) hydraulic fluids within each of the two aircrafts systems while operating in closed loop. While purifying in closed loop, the UHTS shall provide a way to select between each aircraft system and purify a single system at a time:

a. Particulates levels shall be removed down to NAS 1638 class 5 [ISO code 13/11] or better from the UHTS and the aircraft hydraulic fluids.

b. The UHTS shall de-aerate all hydraulic fluid within its own systems and that of the aircraft systems (100% free, 80% dissolved) to less than eight (8) percent dissolved air content at 0 psig at 70o F +/- 30o F.

c. The UHTS shall remove water (100% Free, and < 150 ppm total for MIL-PRF 83282 and MIL-PRF-87257, and < 100 ppm for MIL-PRF-5606) from all hydraulic fluid in its own system and sub-systems and the aircraft systems. A water sensor with red and green (no go/go) global control system panel indicator lights and a panel readout (in ppm of water) shall be provided which indicates the required water purity level has been reached.

d. The UHTS shall remove chlorinated solvents (degreasers) from all hydraulic fluids in its own system and sub-systems and the aircraft.

e. The UHTS shall have the ability purify all the hydraulic fluid in the UHTS and the aircraft systems while the UHTS is under normal operation as well as without use of the UHTS main hydraulic pumps and the primary pump drives (except as necessary to momentarily cycle the aircraft components to push or force contaminated hydraulic fluid out of the aircraft components and into the aircraft piping system where it can then be picked up by the UHTS’s purification system).

The UHTS type I purifying unit shall be able to be powered by the operation of the diesel engine and have the additional ability to be plugged into a 115volt 20 amp (max) external circuit for operation. UHTS type II purifying unit shall be able to be powered by the main 3-phase electrical connection and have the additional ability to be plugged into a 115volt 20 amp (max) external circuit for operation. The diesel and electric versions shall each be functionally self-contained.

f. The UHTS shall purify the hydraulic fluid from the aircraft in accordance with Table 2. This requirement for purification of the fluid from the aircraft shall be accomplished by providing the circulation flows through the aircraft by the main pump into the UHTS’s purification system. The time required to purify 50 gallons of hydraulic fluid, from the initial level to the final purity level as listed in Table 2, shall be 4 hours or less.

NOTE: SEE PARAGRAPH 4.18.19 FOR MORE INFORMATION

REGARDING THE HYDRAULIC PURIFICATION SYSTEM.

Table 2

INITIAL LEVEL FINAL PURITY LEVEL

600-800 part per million (ppm) water

100 ppm water (<150 ppm dissolved for MIL-PRF 87257 and MIL-PRF-83282, and < 100 ppm for MIL- PRF-5606 and 100% Free)

20/16 particulate level, NAS class 11

ISO code 13/11 or better particulate level, NAS class 5

Air (approx. 12%) Removal of all air (100% free, <8% dissolved)

g. The UHTS’s hydraulic fluid purification system shall entrap and hold solid impurities in a sealed sump tank which can be serviced without the removal of the system from the stand. Any venting of impurities from the system shall not result in a safety hazard to operating personnel.

3.9.7 System compatibility. The UHTS hydraulic system design shall be completely compatible with all single and dual system aircraft hydraulic systems in the Air Force. The UHTS shall operate without error through the entire range specified herein. When connected to an aircraft’s hydraulic system in aircraft reservoir (closed loop) mode, the UHTS shall have minimal affect on the hydraulic fluid level of the aircraft’s reservoir(s) except during the intentional fill operations. Each of the return systems shall have a loader valve capable of being adjusted from 25 to 250 psi back pressure so the bootstrap reservoir will not dump into the UHTS when operating in “stand reservoir (open loop) position”.

3.10 UHTS control system. The control and maintenance of the entire UHTS shall be performed through manual controls, micro-electronic controls, keypad, or a combination thereof. Any single system component failure, excluding major components, shall not prevent the functional operation of the remainder of the stand. During normal UHTS operations, it shall not be possible to over-pressurize the aircraft’s hydraulic systems or the UHTS. The relief valve settings shall be adjustable to allow a setting of 5 psi to 75 psi below the maximum allowable pressure for any given test.

3.10.1 Self-diagnostics. To assure proper operation, the UHTS shall have the capability to perform an on-board error diagnostic routine. This routine shall be internally initiated at start-up and able to be manually initiated by the operator during operation of the UHTS. The self-diagnostics program shall verify (at a minimum) the proper operation, performance, and safety-features of the unit. All automated monitoring devices and measurement gauges shall be interrogated as part of this routine to assure all readings are within nominal values. Errors discovered through the self-diagnostics routine shall be clearly displayed to the operator, along with any associated recommended corrective actions. The UHTS shall auto-initiate this self-diagnostics program at start-up (triggered by the “power on” switch). An illuminated “power on” indicator shall indicate all systems are functional and battery power is available to the engine and control circuits. In addition, the UHTS control system shall have the capability when manually activated of sequentially displaying all, or selected temperatures, pressures, flow and liquid levels, flow/pressure/safety control valve positions, and all safety alarms without the engine / electric motor operating. A revolving buffer error log shall be resident on the UHTS and shall store the last 100 error conditions. The error log shall be accessible to the operator via the primary UHTS operator interface display. A method shall be provided for the error log to be reset/cleared by the maintenance technician.

3.10.2 Manual control. The manual controls for the UHTS shall permit the operator to monitor and control all stand and system parameters, including flow, pressure, back-pressure, system configuration for aircraft or UHTS reservoir (closed or open loop), system safety monitoring, and all engine/motor control and operating indicators/monitors and sensors.

3.11 Hydraulic system. As a minimum, the hydraulic system shall have the capacity to perform continuous and intermittent pressure/flow functional testing on the systems and sub-systems which comprise the aircraft’s hydraulic systems in open (stand reservoir) or closed (aircraft reservoir) loop mode selectable at control panel. The hydraulic system shall be designed and installed in accordance with SAE ARP 4943.

3.11.1 Fluid compatibility. The unit shall be capable of operating with any of the following hydraulic fluids with a maximum time period of 20 minutes required for the complete changing of fluid in the unit as performed by a 5 level journeyman. These fluids are: MIL-PRF-5606, MIL-PRF-83282, and MIL-PRF-87257.

3.11.2 Flow control. The UHTS shall provide individual pumps (main / boost) and controls for each hydraulic system. Reverse flow to the high-pressure pumps shall be prevented. The control panel shall control the flow from each pressure outlet up to operating flows and pressures in accordance with 3.9.1. The UHTS shall accurately meter the flow in each system throughout the volume range in accordance with 3.9.1. The controls shall control the flow within +/- 0.50 gpm.

3.11.3 Pressure control. The system shall allow for regulating the pressure at a constant flow over the operating range as specified herein.

3.11.3.1 Startup/shutdown pressure. The hydraulic control system functions shall provide the ability to start and stop the UHTS’s hydraulic systems and sub-systems with pressure automatically set at a very low pressure (adjustable from 300 to 500 psig) to reduce or eliminate the shock loading of the hydraulic sub-systems.

3.11.3.2 Transient pressure and recovery. The hydraulic power supply system shall limit the maximum transient pressure during cutout to not more than 133 percent of selected pressure.

The adjustment range of the pressure compensator shall be from 250 to 5000 psi. All variable volume controls and pressure controls shall be mounted on the control panel. The pump response time interval between the instant when an increase (or decrease) in discharge pressure change initiates, and the subsequent instant when the discharge pressure reaches its first maximum (or minimum) value, shall not exceed 0.100 second.

3.11.3.3 Hydraulic pumps. Each pump pressure shall stabilize to a steady state value within 10 seconds after initial startup of the pump. Each pump shall limit the maximum transient pressure during cutout. Each pump shall have the following operating characteristics: Each pump shall have an adjustable pressure compensation control for regulating the pressure at a constant value with the flow varying from zero to maximum. The adjustment range of the pressure compensator shall be as required to control the pump over the operational range specified herein. The moving parts of the hydraulic pump shall be inherently balanced and shall not vibrate in such a manner as to cause failure of any part of the pump or drive mechanism at speeds up to and including 125% of the rated speed. The pump output pulsations in the system shall not exceed +/- 1% of rated operating pressure. All pump models when operating at rated inlet temperature at rated speed and in a circuit whose system is defined herein for response tests, shall have a response time of 0.100 seconds maximum unless otherwise specified. All pumps under any operating condition within the limits established (and at any speed greater than 50% of rated speed), after being disturbed from steady state operation by a change in flow demand or a change in pump speed shall recover to steady state operation (other than permissible pressure pulsations as specified herein) in not more than 1 second after the initial response to that change in flow demand. The alarm visual indicator for the faulty system or sub-system shall remain illuminated after the motor stops. Before restarting the faulty system or sub-system, it shall be necessary to manually reset the safety device. The reset mechanism device shall be on the face of the control panel.

3.11.4 Fluid temperature control. The hydraulic UHTS shall maintain the hydraulic fluid temperature of the systems and sub-systems below 160°F when operating at the systems’ maximum pressures and flows in accordance with 3.9.1 with an outside air ambient temperature of 125°F. Adjustable thermoswitches shall sound the warning horn when the oil inlet temperature to any high-pressure pump exceeds 165°F. The thermoswitches shall have an adjustable range from 150°F to 200°F. The unit shall function in pump unloaded mode when fluid temperature reaches 170°F.

3.11.4.1 Heat exchanger. The heat exchanger(s) shall be hydrostatic proof tested at 150% of the maximum operating pressure (shell and tubes) and operate in the 150% range without leakage or permanent distortion. The heat exchanger(s) shall be provided with a bypass valve for use in cold weather operation. The heat exchanger shall be positioned with respect to the control panel for safety and operator effectiveness.

3.11.5 Fluid filtration. High and low pressure filtration systems shall be incorporated for each system. These systems shall consist of the filter element housing, filter element, and differential pressure indicator. The filter units shall be an in-line type with replaceable elements. The filter units shall have features necessary to promote ease of inspection, servicing and replacement of parts and elements. The filter element housing shall be capable of withstanding a minimum proof pressure of 2.5 times the operating pressure and a minimum burst pressure of 4.00 times the maximum operating pressure under all conditions, environments, and hydraulic fluids specified. The flow entering the housing shall not impinge on the filter element. The filter element and housing for the high pressure system shall be certified and acceptance qualified to MIL-PRF-81836. The filter element and housing for low pressure systems shall be certified and acceptance qualified to MIL-F-5504. The filter assemblies shall be capable of withstanding 1000 hours of operation at 275° F fluid and ambient temperature with no degradation in performance. When the pressure drop across the high pressure filter unit exceeds the pre-determined differential pressure of 100 +/- 15 psi (adjustable), an alarm indication, both audio and visual, shall be activated. Once actuated, this indicator shall remain activated until manually reset. Indicators shall be mounted on the stand control panel to simultaneously indicate the pressure on both sides of the filter in the fill system and boost pump systems. The indicators shall have a range from 0 to 200 psi.

3.11.6 Air bleed. The UHTS shall have a system to allow the operator to remove air from any system supply or return line without inferring with or otherwise affecting any other system. Free air may be extracted from the UHTS and the aircraft hydraulic fluids by manually bleeding air from an air trap reservoir (filter canisters, etc.) at the UHTS control panel. The main pumps and all other components shall be operated to flush trapped air from the aircraft to the air trap reservoir(s) on the UHTS. A means shall be provided for the operator to observe at the control panel, whether or not free air exists in the hydraulic fluid.

3.11.7 Run-around capability. A run-around block for each of the systems shall be installed in a convenient and accessible location on the UHTS so that the high-pressure and return hoses may be attached to it when they are not connected to an aircraft. The run-around block shall be ported to allow running the UHTS in a run-around position. The run-around blocks shall be color coded to match the control panel.

3.11.8 Fluid sampling. A fluid sampling valve(s) shall be provided to allow the operator of the stand to remove samples of hydraulic fluid from either hydraulic system/sub-system, or fluid fill supply or return line without affecting any other system of the stand. The sample valves should be located on unit control panel to facilitate ease of sampling.

3.11.9 Fluid leakage. Total external leakage of the UHTS fittings shall not exceed 2 drops per hour at any flow or pressure specified herein and as defined by NFPA T2.24.1. All fittings and threaded bosses in the hydraulic circuits and components shall be “zero-leakage/zero-weepage” type. All 5000 psi pressure fittings shall be corrosion resistant steel, titanium, or electroless nickel plated steel. Bulkhead-type, high-pressure fittings shall use a locknut with a backup gasket. Fittings shall reseal repeatedly with no degradation in seal performance. The reservoir and hydraulic systems shall not permit leakage or spillage of hydraulic fluid from the system during air shipment with the reservoir filled with hydraulic fluid.

3.11.10 Hydraulic fluid reservoir. A corrosion-resistant hydraulic fluid reservoir shall be mounted within the UHTS housing. The reservoir fluid shall be sealed and isolated from ambient atmosphere and pressurizing gasses during normal operations. The reservoir shall be of sufficient capacity to supply at least 60 gallons of operational fluid to the systems when inclined 8.5° from vertical in any direction. It shall have additional space for a 3 gallon expansion above the normal full level and at least a 2 gallon space below the outlet to the system for collecting moisture and impurities. The reservoir shall be elevated above the hydraulic pumps. The reservoir shall ensure removal of air from the hydraulic system. The reservoir shall withstand

200% of maximum operational return pressure with no deformation under testing. The reservoir shall conform to design requirements of the Boiler and Pressure Vessel Code, Section VIII, Div 1, with regards to obstruction of flow, structural design, shell, seams, structural strength, baffles, fluid connections, sump, drain return line inlet, scuppers, filler unit, finish, and filling time.

Closed and open loop operation for each system is required on the UHTS. Closed loop operations isolate the UHTS’s reservoir from the flow loop while an open loop would allow the UHTS’s fluid reservoir to be in the loop.

3.11.10.1 Fluid level gage. A gauge shall be mounted on the control panel to indicate the quantity of available fluid in the reservoir to within +/- 1 gallon of actual quantity.

3.11.10.2 Reservoir drain valve. The UHTS shall be equipped with a reservoir drain valve to remove water and contaminants from the bottom of the hydraulic reservoir. The valve shall be accessible by the operator standing outside the UHTS. Piping shall carry the drainage from the reservoir to the outside of the stand housing.

3.11.11 Outlets and connections.

3.11.11.1 Hose and fitting connections. A manifold block may be utilized for consolidating the high pressure controls and valves for higher reliability and reduced in-line piping controls. All high pressure plumbing shall be maintained to a minimum. Two pressure and two return outlets, and one each manifolded pressure and manifolded return port shall be provided on the UHTS.

Supply and return ports shall also be provided for connecting external hydraulic systems or reservoirs to the purifier system (see 3.9.6). The outlets shall not be located where leakage of fluid from the outlet could fall on the trailer tires or within the housing of the UHTS.

3.11.11.2 High pressure connections. All connections, tubing, valves, etc., used in the pressure side of the hydraulic systems and sub-systems shall be sized as specified herein, and to allow not more than 180 psi pressure drop from the high pressure pump discharge to the end of each pressure hose with 30 gpm flow. Each pressure outlet connection on the UHTS shall terminate with an SAE male 37° flared fitting.

3.11.11.3 Return connections. Independent return connections shall be provided for each system. Each return connection on the unit shall terminate with an SAE male 37° flared fitting.

The pressure drop from the end of the return hose to the suction of the boost pump shall not exceed 40 psi at 30 gpm flow.

3.11.11.4 Seals, gland design, packings, backup-rings. Seal materials shall be compatible with all specified fluids. For static applications, o-ring packing squeeze shall be a minimum of 10% at the most adverse tolerance conditions. Seal gland dimensions shall conform to the requirements of AS4716 and shall consider the recommendations of ARP 1234A and ARP 1232A. Care shall be taken to prevent binding and interference at the most adverse temperature extremes. For system high pressure levels above 3000 psi, the clearance gaps may be reduced to improve seal life and aid in preventing packing extrusion. O-ring packings and backup rings shall be manufactured from compounds specifically approved through Industry Standards Testing for their function and placement.

3.11.11.5 Hose assemblies. The hose assemblies specified in Table 3 shall be provided with the UHTS first production (first article) units only for use during testing and equipped as specified.

Dust and foreign matter protection shall be provided for all open hydraulic fittings and connections. All protection devices shall be secured to the hose end or the UHTS first production (first article) units to prevent loss. Production UHTS units shall be shipped without hydraulic hoses. All hydraulic system circuits shall terminated at the bulkhead and each system opening shall be capped and protected from dust and foreign matter during shipment of the production units.

TABLE 3

3.11.11.6 Couplings. Couplings shall be provided with the UHTS first production (first article) units only for use during testing and equipped as specified. All couplings shall be Aeroquip 145/155 Series Soft Sealing couplings or equivalent and be approved for use at the rated pressures and shall not leak or discharge any fluid (except for normal surface wetting) when disconnected. A sufficient quantity of hose end and bulk head style couplings for use on the runaround blocks, as well as all necessary adapters, shall be supplied with each UHTS first production unit to configure the UHTS with a -12 supply (5000 psi working pressure minimum) and -16 return (1000 psi working pressure minimum) as well as a -16 supply (5000 psi working pressure minimum) and -24 return (1000 psi working pressure minimum). Plug assemblies with retention chain and cap assemblies with retention chain shall be provided for all couplings.

3.11.12 Pressure safety factors. The high pressure portion of the system shall be rated for 5000 psi (minimum) operating pressures. The low pressure portions of the systems that are subjected to boost pump pressures shall be rated for 250 psi (minimum) operating pressures.