Model 525B Maintenance Manual (Rev 22)

29-10-00-0 (Rev 17)

MAIN HYDRAULIC POWER - DESCRIPTION AND OPERATION

1. General
A. The main hydraulic power is supplied by two engine driven pumps and is the main supply of the airplane's normal hydraulic
systems. Pressurizing the main hydraulic power system can be done by connecting an external ground service unit to the
system.
B. This section includes those hydraulic components which store fluid, generate pressure and fluid flow, filter impurities,
control and direct the flow of fluid under pressure for operation of the airplane's actuating systems.
C. General personnel and technical safety precautions are outlined, which maintenance personnel must familiarize
themselves with before work is done work on the Model 525B hydraulic systems. In addition to the precautions outlined
herein, obey local safety directives.
D. The Model 525B hydraulic system uses fire resistant, synthetic hydrocarbon base, hydraulic fluid (MIL-PRF-83282). It is
NOT COMPATIBLE with phosphate ester (Skydrol/Hyjet) fluids. Refer to Chapter 12 for servicing the airplane with
hydraulic fluid.
CAUTION: The Model 525B hydraulic system is designed for use with MIL-PRF-83282 hydraulic fluid. The seals,
packings, O-rings and some metallic components are NOT COMPATIBLE with phosphate ester
(Skydrol/Hyjet) type hydraulic fluid. If phosphate ester hydraulic fluid is introduced into the system,
rapid deterioration of all seals, packings and O-rings will occur. This will cause multiple leaks, and
require overhaul or replacement of all components that contain such seals. Additionally, particles of
deteriorated seals, packings and O-rings may be deposited within the orifices or valves from which they
are dislodged, which will cause failure of the component during operation.
2. Personnel and Technical Safety Precautions
A. Personnel Safety Precautions.
NOTE: Before any maintenance is done on the hydraulic systems, personnel must read and fully
understand safety precautions.
(1) Wash hands fully with soap and water before work is done on open hydraulic systems.
(2) Wear eye goggles anytime there is a possibility of hydraulic fluid splash or when you pressure test
components/systems.
(3) If fluid splashes into the eyes, treat the eyes immediately by irrigating with clean cool water. Report the incident.
(4) Make sure that system pressure is completely depleted before you attempt to open, or disconnect, a hydraulic line or
component.
(5) Make sure all personnel are clear of all actuating systems (i.e., landing gear during retraction/extension, flight
surfaces, etc.) prior to pressurizing the hydraulic system.
3. Hydraulic System Contamination
A. External Source Contamination.
(1) When a hydraulic line or fitting is opened, the potential for contamination of the hydraulic system is high. Caps and or
plugs must be inserted immediately to stop contaminants from entering the system. Hands and tools must be free of
dirt and grease. If the point of entry of the contaminant is downstream of the pressure filter, but upstream of an
actuating component, the contaminants may cause damage to or failure of the component. If the point of entry is a
return line, the hydraulic fluid will possibly contaminate the valves of the hydraulic manifold.
(2) Dirty quick disconnect fittings on a hydraulic ground servicing unit will introduce dirt/contamination into the hydraulic
system. This dirt may lodge in solenoid valves or other components in the hydraulic system, causing a failure of the
component in which the dirt becomes trapped.
(3) If a non-compatible hydraulic fluid is introduced into the system, it will be necessary to remove and overhaul all
hydraulic actuators, valves, pumps, reservoirs, accumulators and replace all seals, packing and O-Rings. The filters
will not give protection for the system in case of incompatible fluid introduction. In addition, all lines must be thoroughly
flushed to make sure of complete removal of all contaminated fluid.
B. System Introduced Contamination.
(1) Wear in the hydraulic pumps is the chief source of system introduced contamination. Periodic examination of the
pressure filter will let you to detect an impending pump failure. Metallic particles trapped in the filter are an indication
of pump failure.

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 Model 525B Maintenance Manual (Rev 22)
29-10-00-0 (Rev 17)

(2) Other hydraulically operated components have a lesser probability of introducing contaminants into the hydraulic fluid,
but any particles which might be produced are routed through the main return filter.
4. Tools and Equipment
A. For tools and equipment, refer to Hydraulic Power - General.
5. Recommended External Leakage Limits for Hydraulic System Components
A. Dynamic Seals - Applies to seals which contact parts that slide or turn, such as actuator shaft seals, control valve shaft
seals and so forth.
(1) Actuate the component through several full travel cycles to exercise the seal before you do the check. This is very
important during extremely cold weather because seal resiliency and seal capability are reduced under such
conditions. Sufficient actuation to warm the system fluid is often beneficial under this condition.
(2) The following recommended limits apply with the unit under full or partial system pressure.
(a) After overhaul limit - one drop in five minutes, maximum.
(b) In-service limit - one drop-per-minute or one drop in five complete cycles, maximum.
B. Static Seals - Applies to static seals at parting surfaces, boss seals under tube fittings, static gland seals, etc.
NOTE: Low torque on fittings and nuts bearing upon static seals will often result in a leak which can be
stopped by a correctly retorqued fitting or nut. Relief is often temporary, however, due to packing
damage during operation with the low fitting- or nut torque. All seals which leak or were leaking
must be replaced as soon as possible.
(1) The recommended limits that follow apply with the unit under full or partial pressure:
(a) Seepage, that causes no perceptible dripping, is acceptable.
(b) Leaks that drip from accessible static seals require seal replacement. Leaks that drip from inaccessible seals
that cannot be reduced to one drop in ten minutes require removal of the leaking unit.
6. Description/Operation
A. The main hydraulic system is an open-center-type system. The two engine-driven pumps (one on each engine) supply a
continuous flow of hydraulic fluid as long as the engine(s) are operating. A hydraulic manifold, installed forward of the
hydraulic reservoir, inboard of fairing access panel 166A, includes sections for system control, as well as gear, speed
brake, and flap control.
(1) The system control portion of the hydraulic manifold includes a solenoid operated loading valve which controls the
open center operation of the system. In a no-pressure-demand condition, the loading valve is de-energized open,
letting the fluid free-flow from pressure to return. In a pressure demand condition, the loading valve is energized
closed and pressure is routed to a selected system/component.
(2) A relief valve limits the hydraulic system pressure to 1500 PSI (10,342 kPa). The relief valve is installed in parallel
with the loading valve in the system portion of the hydraulic manifold. A reservoir, installed on the right side of the
airplane, stores fluid for the various hydraulically operated components and is accessed by opening fairing panel
access door 166BA. The reservoir is pressurized with pneumatic pressure from the airplane's pneumatic regulator to
give positive hydraulic fluid pressure to the engine driven hydraulic pumps. The relief valve, which begins to relieve
pressure at 28 PSI, +2 or -2 PSI (193 kPa, +14 or -14 kPa), is installed in the pressurization line, downstream of the
reservoir to prevent overpressurizing the system.
B. Other main system components include one pressure filter, found between the pump outlets and the manifold inlet and two
return filters that are found between the manifold outlet and the reservoir. Remove fairing access panel 166BB to get
access.
(1) Two firewall hydraulic shutoff valves, installed on the forward side of the aft engine carry-thru beam, are motorized
electrically closed or opened. Either shutoff valve may be closed during an engine fire, stopping the flow of fluid to the
engine pump selected. Ground service connections are below the hydraulic reservoir behind the hydraulic access
door 166BA.
C. For Airplanes -0001 thru -0056 and -0058 thru -0450, a flow switch/check valve (ST021, left or ST020, right) is
incorporated in each pressure line on the forward side of the aft engine carry-thru beam. The check valves stop fluid flow
from one engine pump to the other. The flow switches give an indication on the annunciator panel when flow from an
engine pump is interrupted.
D. For Airplanes -0057 and -0451 and On, a flow switch/check valve (ST021, left or ST020, right) is incorporated in each

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 Model 525B Maintenance Manual (Rev 22)
29-10-00-0 (Rev 17)

pressure line on the forward side of the aft engine carry-thru beam. The check valves stop fluid flow from one engine pump
to the other. The flow switches give a HYD FLOW LOW L-R crew alerting system (CAS) message on the primary flight
display when flow from an engine pump is interrupted.
E. For system layout and component location, refer to Figure 1.
7. Hydraulic System Reservoir Fluid Level
A. The main system hydraulic reservoir includes a sight glass to show fluid level. The sight glass is marked at FULL and ADD
levels. Fluid level is to be measured with the landing gear extended and speed brakes and flaps retracted. The reservoir
capacity at the FULL level is 187 cubic inches (3.06 l). When the gear is retracted, an additional 27 cubic inches (0.44 l) of
hydraulic fluid flows into the reservoir. With the gear extended and all hydraulically actuated components extended, a
properly serviced reservoir will contain 156 cubic inches (2.55 l)

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Retain printed data for historical reference only. For future maintenance, use only current data. Print Date: Wed Jul 03 01:09:33 CDT 2019
 Model 525B Maintenance Manual (Rev 22)
29-10-00-0 (Rev 17)

Figure 1 : Sheet 1 : Hydraulic System Component Location

A32159

FIREWALL SHUTOFF
VALVE (VT004)
FLOW SWITCH/CHECK VALVE
(ST020)
FLOW SWITCH/CHECK
VALVE (ST021)

G FIREWALL
RESERVOIR SHUTOFF
PRESSURIZATION VALVE
LINE RELIEF (VT003)
VALVE
D
RETURN
F
FILTER

C
B PRESSURE FILTER

HYDRAULIC SYSTEM
RESERVOIR ENGINE−DRIVEN
HYDRAULIC PUMP
RETURN
FILTER
HYDRAULIC DETAIL A
MANIFOLD AIRPLANES −0001 THRU −0022
6310T1072
A6317T1017

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Retain printed data for historical reference only. For future maintenance, use only current data. Print Date: Wed Jul 03 01:09:33 CDT 2019