MSG-3 MAINTENANCE MANUAL

COMBINED AND FLIGHT POWER SYSTEMS — SERVICING

1. Combined / Flight Hydraulic System Reservoir — Filling Procedures
A. General
This procedure is used to service and bleed the combined or flight system reservoirs.
B. Preparation
SPECIAL TOOLS AND TEST EQUIPMENT
Container, Skydrol resistant ................................................................................................ Standard
Hydraulic reservoir fluid servicing cart ................................ GSE2900161 or equivalent (see Note)
Hydraulic test stand ............................................................. GSE2900149 or equivalent (see Note)
Power supply ....................................................................... GSE2400434 or equivalent (see Note)
NOTE: See Hydraulic Servicing, 12-01-05, System Description for approved hydraulic fluid.
Hydraulic reservoir fluid servicing cart requirements:
• Ground servicing pump for filling reservoir
• Use approved / compatible phosphate ester fluid
• Supply pressure of at least 65 psi to overcome aircraft system return pressures
• 3 micron filtration system (compatible to aircraft system)
• Integral relief valve, set to relieve at 100 psi
• Quick disconnects (Aeroquip Part No. 015567-S5-6D) for bypass / fill and 3/8 inch
high pressure lines (3000 psi)
Hydraulic test stand requirements:
• Use approved / compatible phosphate ester fluid
• 0 - 3000 psi / 0 - 22 gpm variable flow rate
• 3 micron filtration system (compatible to aircraft system)
• Integral relief valve set to relieve at 100 psi
• Quick disconnects for the ground service / test panel:
– Part No. 015567-S5-6D bypass / filler coupling hose attachment (3/8 inch line size) -
3000 psi
– Part No. 015567-S5-12D pressure coupling hose attachment (3/4 inch line size) -
3000 psi
– Part No. 015567-S5-16D suction coupling hose attachment (1 inch line size) - 3000
psi
Electrical power cart minimum requirements:
• AC - 3 phase, 115V, 400hz, 30kva
• DC - 28V, 1000 amps
(1) Reference(s)
• Hydraulic Servicing, 12-01-05, System Description
• External Electrical Power Application - Maintenance Practices, 20-20-10, Maintenance
Practices
• External Hydraulic Power Application, 20-30-10, Maintenance Practices
C. Procedure
NOTE: The following procedures are provided:
• 1.C1. Servicing Reservoir with Ground Support Equipment
• 1.C2. Servicing Reservoir with Engines Running

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• 1.C3. Servicing Reservoir with Onboard Replenisher

C1. Servicing Reservoir with Ground Support Equipment
NOTE: The following procedure is used in conjunction with Figure 301 and Figure 302.
This procedure is performed with engines shut down.
(1) Configure aircraft as follows:
CAUTION: FAILURE TO ENSURE CORRECT ORIENTATION OF THE OVERBOARD
RELIEF VALVE COULD RESULT IN DAMAGE TO THE RESERVOIR AND
SURROUNDING COMPONENTS.
(a) Prior to filling reservoir, verify overboard relief valve (located in tail compartment) is
installed correctly.
NOTE: The arrow should be pointing away from the reservoir (direction of drain flow)
and the port marked IN should be on the reservoir end of the valve.
(b) Aircraft may be on jacks or on ground.
(c) Landing gear extended and all gear doors closed.
(d) Flaps - any position.
(e) All other surfaces / systems in clean flight configuration.
(2) Service reservoir as follows:
WARNING: MANY OF THE MATERIALS SPECIFIED HAVE SIGNIFICANT
OCCUPATIONAL SAFETY, HEALTH OR ENVIRONMENTAL
REQUIREMENTS RELATED TO THEIR USE. SAFETY DATA SHEETS
SHALL BE CONSULTED FOR ALL MATERIALS TO DETERMINE THE
MANUFACTURERS RECOMMENDATIONS CONCERNING
OCCUPATIONAL EXPOSURE PRECAUTIONS. IT IS THE SOLE
RESPONSIBILITY OF THE USER TO ENSURE PROTECTION FROM
INJURY OR EXPOSURE, SAFE APPLICATION OF MATERIALS AND
COMPLIANCE WITH ANY FEDERAL, STATE OR LOCAL REGULATIONS
REGARDING THE USE OF ANY OF THE MATERIALS SPECIFIED.
CAUTION: SKYDROL TYPE IV PHOSPHATE ESTER HYDRAULIC FLUID SHALL
DAMAGE PAINTS, RUBBER AND PLASTIC MATERIALS. FAILURE TO
REMOVE RESIDUAL SKYDROL FROM EXPOSED SURFACES MAY RESULT
IN DAMAGE TO AIRCRAFT OR EQUIPMENT.
(a) Connect hydraulic test stand / ground servicing cart filler, suction and pressure quick
disconnect couplings to the appropriate ground service / test panel connections.
CAUTION: AT NO TIME SHALL THE FLOW OF HYDRAULIC FLUID THROUGH
THE OVERBOARD DRAIN BE USED AS A METHOD TO DETERMINE
RESERVOIR FLUID LEVELS / QUANTITY.
NOTE: During the following procedures the reservoir sight gage of the system being
serviced must be monitored.
If the reservoir has been drained, some fluid must be put in prior to
pressurizing the system.
(b) With the hydraulic test stand / ground servicing cart selected to AIRCRAFT /
RESERVOIR SUPPLY, pressurize the respective system to 3000 psi.

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NOTE: If the STAND reservoir position is used, the aircraft system reservoir will be
drained.
(c) While monitoring the reservoir sight gage, fill the reservoir to just above FULL (for
servicing / bleeding purposes only).
(d) With a clean container (approximately 3 - 5 gallons) placed under the overboard drain
(left side), depress manual bleeder valve on top front end of reservoir. Keep bleeder
valve depressed until fluid flow into the container becomes clear, not foamy
(nonaerated).
NOTE: Do not bleed the reservoir below the REFILL mark on the reservoir sight gage.
The drained fluid may be filtered through a 3 micron filter and returned to the
hydraulic test stand / ground servicing cart at a later date.
(e) Replenish reservoir fluid level to FULL mark on sight gage.
NOTE: Do not fill above the FULL mark.
Operate lateral flight controls and speedbrakes slowly to avoid air cavitation or
overboard porting of fluid of the unpressurized hydraulic system. If available,
the use of two hydraulic test stand / ground servicing carts with combined and
flight systems pressurized will prevent this.
WARNING: FAILURE TO ENSURE ALL PERSONNEL AND EQUIPMENT ARE
CLEAR OF FLIGHT CONTROL SURFACES BEFORE OPERATING
FLIGHT CONTROLS MAY RESULT IN SERIOUS INJURY OR DEATH.
(f) Slowly operate flight controls, 6 - 8 cycles per minute, for approximately 2 minutes.
WARNING: FAILURE TO INSTALL ALL LANDING GEAR AND LANDING GEAR
DOOR SAFETY DEVICES BEFORE WORKING IN ANY WHEEL WELL
MAY RESULT IN SERIOUS INJURY OR DEATH.
CAUTION: DO NOT PULL PIN ON DOOR CONTROL VALVE WITH PRESSURE ON
HYDRAULIC SYSTEM.
(g) Operate each landing gear door 3 - 5 full cycles, returning doors to closed.
NOTE: If on jacks, operate landing gear doors approximately 5 - 10 cycles.
(h) Bleed reservoir again. See Step 1.C1.(2)(d) and Step 1.C1.(2)(e).
(i) Verify sight gage fluid quantity level agrees with fluid quantity displayed on EICAS and
service panel gages.
NOTE: Variations in readings may be cause to troubleshoot the indicator system.
(j) Remove hydraulic power from aircraft. See External Hydraulic Power Application,
20-30-10, Maintenance Practices.
(k) Remove electrical power from aircraft. See External Electrical Power Application -
Maintenance Practices, 20-20-10, Maintenance Practices.
NOTE: The service panel and cockpit hydraulic quantity indicators may go above the
FULL mark when system is depressurized.
(l) Proceed to Step 1.D.(1).
C2. Servicing Reservoir with Engines Running
NOTE: The following procedure is used in conjunction with Figure 301 and Figure 302.

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(1) Configure aircraft as follows:

(a) Aircraft on ground and landing gear doors closed.
(b) Flaps - any position.
(c) All other surfaces / systems in clean flight configuration.
(2) Service reservoir as follows:
WARNING: MANY OF THE MATERIALS SPECIFIED HAVE SIGNIFICANT
OCCUPATIONAL SAFETY, HEALTH OR ENVIRONMENTAL
REQUIREMENTS RELATED TO THEIR USE. SAFETY DATA SHEETS
SHALL BE CONSULTED FOR ALL MATERIALS TO DETERMINE THE
MANUFACTURERS RECOMMENDATIONS CONCERNING
OCCUPATIONAL EXPOSURE PRECAUTIONS. IT IS THE SOLE
RESPONSIBILITY OF THE USER TO ENSURE PROTECTION FROM
INJURY OR EXPOSURE, SAFE APPLICATION OF MATERIALS AND
COMPLIANCE WITH ANY FEDERAL, STATE OR LOCAL REGULATIONS
REGARDING THE USE OF ANY OF THE MATERIALS SPECIFIED.
CAUTION: SKYDROL TYPE IV PHOSPHATE ESTER HYDRAULIC FLUID SHALL
DAMAGE PAINTS, RUBBER AND PLASTIC MATERIALS. FAILURE TO
REMOVE RESIDUAL SKYDROL FROM EXPOSED SURFACES MAY RESULT
IN DAMAGE TO AIRCRAFT OR EQUIPMENT.
(a) Connect service / test cart filler hose quick disconnect to the appropriate ground service
/ test panel connection.
(b) While monitoring reservoir sight gage, fill reservoir to just above FULL (for servicing /
bleeding purposes only).
WARNING: FAILURE TO ENSURE ALL PERSONNEL AND EQUIPMENT ARE
CLEAR OF FLIGHT CONTROL SURFACES BEFORE OPERATING
FLIGHT CONTROLS MAY RESULT IN SERIOUS INJURY OR DEATH.
CAUTION: NEVER FILL ABOVE FULL TO THE POINT THAT INDICATOR IS NO
LONGER VISIBLE IN THE RESERVOIR SIGHT GAGE.
(c) Slowly operate the flight controls 6 - 8 cycles per minute, for approximately 2 minutes.
WARNING: FAILURE TO INSTALL ALL LANDING GEAR AND LANDING GEAR
DOOR SAFETY DEVICES BEFORE WORKING IN ANY WHEEL WELL
MAY RESULT IN SERIOUS INJURY OR DEATH.
(d) Operate each landing gear door 3 - 5 full cycles returning, doors to closed.
(e) With a clean container (approximately 3 - 5 gallons) under overboard drain (combined
- left / flight - right), depress manual bleeder valve on top front end of the reservoir.
Keep bleeder valve depressed until fluid flow into container becomes clear, not foamy
(nonaerated).
NOTE: Do not bleed the reservoir below the REFILL mark on the reservoir sight gage.
Drained fluid may be filtered through a 3 micron filter and returned to the
hydraulic service / test cart at a later date.
(f) Replenish reservoir fluid level to FULL mark on sight gage.
NOTE: Do not fill above the FULL mark.

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Do not operate aircraft with the hydraulic reservoir overserviced.

Overboard porting of fluid may result during operation.
(g) Verify sight gage fluid quantity level agrees with fluid quantity displayed on EICAS and
service panel gages.
NOTE: Variations in readings may be cause to troubleshoot the indicator system.
(h) Remove hydraulic power from aircraft. See External Hydraulic Power Application,
20-30-10, Maintenance Practices.
(i) Remove electrical power from aircraft. See External Electrical Power Application -
Maintenance Practices, 20-20-10, Maintenance Practices.
(j) Close and secure ground service panel door.
(k) Proceed to Step 1.D.(1).
C3. Servicing Reservoir with Onboard Replenisher
NOTE: The following procedure is used in conjunction with Figure 301, Figure 302 and Figure
303.
(1) Configure aircraft as follows:
(a) Aircraft on ground and landing gear doors closed.
(b) Flaps - any position.
(c) All other surfaces / systems in the clean flight configuration.
(2) Service reservoir as follows:
WARNING: MANY OF THE MATERIALS SPECIFIED HAVE SIGNIFICANT
OCCUPATIONAL SAFETY, HEALTH OR ENVIRONMENTAL
REQUIREMENTS RELATED TO THEIR USE. SAFETY DATA SHEETS
SHALL BE CONSULTED FOR ALL MATERIALS TO DETERMINE THE
MANUFACTURERS RECOMMENDATIONS CONCERNING
OCCUPATIONAL EXPOSURE PRECAUTIONS. IT IS THE SOLE
RESPONSIBILITY OF THE USER TO ENSURE PROTECTION FROM
INJURY OR EXPOSURE, SAFE APPLICATION OF MATERIALS AND
COMPLIANCE WITH ANY FEDERAL, STATE OR LOCAL REGULATIONS
REGARDING THE USE OF ANY OF THE MATERIALS SPECIFIED.
CAUTION: SKYDROL TYPE IV PHOSPHATE ESTER HYDRAULIC FLUID SHALL
DAMAGE PAINTS, RUBBER AND PLASTIC MATERIALS. FAILURE TO
REMOVE RESIDUAL SKYDROL FROM EXPOSED SURFACES MAY RESULT
IN DAMAGE TO AIRCRAFT OR EQUIPMENT.
(a) Set selector valve for onboard hydraulic replenisher to desired reservoir to be serviced.
(b) While monitoring reservoir sight gage, pump handle on hydraulic replenisher.
NOTE: Reservoir must be serviced sufficiently so sight gage indicator does not move
below the full mark with 3000 psi applied.
If gages on ground service panel are to be used for monitoring reservoir
servicing, dc power must be applied to aircraft.
(c) Fill reservoir above FULL (for servicing / bleeding purposes only).

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(d) Apply electrical power to aircraft. See External Electrical Power Application -
Maintenance Practices, 20-20-10, Maintenance Practices.
(e) Apply hydraulic power to aircraft. See External Hydraulic Power Application, 20-30-10,
Maintenance Practices.
(f) With a clean container (approximately 3 - 5 gallons) placed under overboard drain (left
side), depress manual bleeder valve on top front end of reservoir. Keep bleeder valve
depressed until fluid flow into container becomes clear, not foamy (nonaerated).
NOTE: Do not bleed the reservoir below the REFILL mark on the reservoir sight gage.
(g) If reservoir sight gage has been bled below full mark, repeat Step 1.C3.(2)(b) thru Step
1.C3.(2)(f) until reservoir registers FULL with 3000 psi hydraulic pressure.
(h) Remove hydraulic power from aircraft. See External Hydraulic Power Application,
20-30-10, Maintenance Practices.
(i) Remove electrical power from aircraft. See External Electrical Power Application -
Maintenance Practices, 20-20-10, Maintenance Practices.
(j) Set selector valve for onboard hydraulic replenisher to neutral (center) position.
(k) Refill onboard replenisher with hydraulic fluid at filler port as required.
(l) Verify sight gage fluid quantity level agrees with fluid quantity displayed on EICAS and
service panel gages.
(m) Close and secure ground service panel door as required.
D. Follow On
(1) Inspect the work area for foreign objects and damage.
(2) Record all maintenance actions in accordance with current governing authority.

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Combined System Reservoir

Figure 301

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Flight System Reservoir

Figure 302

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Onboard Hydraulic System Replenisher

Figure 303

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