Model 525 Maintenance Manual (Rev 26)

29-10-00-0 (Rev 10)

MAIN HYDRAULIC POWER - DESCRIPTION AND OPERATION

1. General
A. The main hydraulic power is generated by two engine driven pumps and is the heart of the airplane's normal hydraulic
systems. 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. Also,
pressurizing the main hydraulic power system can be accomplished by connecting an external ground service unit to the
system.
B. General personnel and technical safety precautions are outlined below which maintenance personnel should familiarize
themselves with prior to performing work on the Model 525 hydraulic systems. In addition to the precautions outlined
herein, adhere to local safety directives.
C. The Model 525 hydraulic system utilizes 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 525 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 Skydrol is introduced into the system, rapid deterioration of
all seals, packings and o-rings will take place causing multiple leaks, and also requiring the
overhaul or replacement of all components containing such seals. Additionally, particles of
deteriorated seals, packings and o-rings may be deposited within the orifices or valves from which
they are dislodged causing failure of the component during operation.
2. Personnel and Technical Safety Precautions
A. Personnel Safety Precautions.
NOTE: Prior to performing any maintenance on the hydraulic systems, personnel should read and
thoroughly understand the following precautions.
(1) Wash hands thoroughly with soap and water before working on open hydraulic systems.
(2) Wear eye goggles anytime there is a possibility of hydraulic fluid splash or when pressure testing
components/systems.
(3) If fluid splashes in the eyes, treat eyes immediately by irrigating thoroughly with clean cool water. Report the incident.
(4) Ensure and verify that system pressure is completely depleted before attempting to open (disconnect) a hydraulic line
or component.
(5) Verify personnel are clear of all actuating systems (landing gear during retraction/extension, thrust attenuators, 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 prevent 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 ground servicing cart 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, packings and O- rings. The filters
will not provide any protection for the system in case of incompatible fluid introduction. In addition, all lines must be
thoroughly flushed to ensure complete removal of all contaminated fluid.
B. System Introduced Contamination.
(1) Wearing hydraulic pumps are the chief source of system introduced contamination. Periodic examination of the
pressure filters will allow the detection of an impending pump failure by noting the presence of metallic particles
trapped in the filters.

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 Model 525 Maintenance Manual (Rev 26)
29-10-00-0 (Rev 10)

(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. Refer to Hydraulic Power - General for tools and equipment.
5. Recommended External Leakage Limits for Hydraulic System Components
A. Dynamic Seals - Applies to seals which contact sliding or rotating parts such as actuator shaft seals, control valve shaft
seals, etc.
(1) Actuate component through several full travel cycles to exercise the seal prior to performing the check. This is
particularly important during extremely cold weather since seal resiliency and, therefore, seal capability are reduced
under such conditions. Sufficient actuation to warm up 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
eliminated by correctly retorquing the fitting or nut. Relief is often temporary, however, due to
packing damage during operation with the low fitting or nut torque. Therefore, a follow-up at the
earliest possible time should be instituted to replace all seals which leak or were leaking
(1) The following recommended limits apply with the unit under full or partial pressure.
(a) Seepage, causing no perceptible dripping, is acceptable.
(b) Dripping leaks from accessible static seals should be cause for seal replacement. Dripping leaks from
inaccessible seals that cannot be reduced to one drop in ten minutes should be cause for unit removal.
6. Description/Operation
A. The main hydraulic system is an open center type system. 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 under fairing access panels 192B and 192C incorporates sections for system control, as well as gear,
speed brake, flap and thrust attenuator control. The system control portion of the hydraulic manifold incorporates 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, allowing the fluid to 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. A relief
valve limits the hydraulic system pressure to 1500 PSI. 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. The reservoir is pressurized using pneumatic pressure from the airplane's pneumatic
regulator to provide positive hydraulic fluid pressure to the engine driven hydraulic pumps. A relief valve,which begins to
relieve 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 two pressure filters, one located in the left engine pump pressure line and one in
the right pump pressure line. The pressure filters are mounted on the forward side of the aft engine carry thru beam. A
third, return, filter is located in the return line to the hydraulic reservoir. Access may be gained by removing access panel
192C. 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 located below the hydraulic reservoir behind the hydraulic access
door.
C. A flow switch/check valve is incorporated in each pressure line just downstream of the pressure filters. The check valves
prevent fluid flow from one engine pump to the other. The flow switches provide an indication on the annunciator panel
when low/no-flow occurs from the respective engine pump.
D. Refer to Figure 1 for a system layout and component location.
7. Hydraulic System Reservoir Fluid Level
A. The main system hydraulic reservoir incorporates a sight glass to indicate fluid level. The sight glass is marked at FULL
and ADD levels. Fluid level is to be measured with the landing gear extended; thrust attenuators, speed brakes and flaps

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 Model 525 Maintenance Manual (Rev 26)
29-10-00-0 (Rev 10)

retracted. The reservoir capacity at the FULL level is 125 cubic inches (2 l). Retracting the gear will cause an additional 25
cubic inches (0.4 l) of hydraulic fluid to flow into the reservoir. With the gear extended and all hydraulically actuated
components extended, a properly serviced reservoir will contain 100 cubic inches (1.6 l)

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 Model 525 Maintenance Manual (Rev 26)
29-10-00-0 (Rev 10)

Figure 1 : Sheet 1 : Hydraulic System Component Location

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 Model 525 Maintenance Manual (Rev 26)
29-10-00-0 (Rev 10)

Figure 1 : Sheet 2 : Hydraulic System Component Location

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Retain printed data for historical reference only. For future maintenance, use only current data. Print Date: Tue Jul 02 13:35:48 CDT 2019