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CGTO 33-1-37-2 JOINT OIL ANALYSIS

PROGRAM MANUAL

VOLUME II SPECTROMETRIC AND PHYSICAL TEST LABORATORY OPERATING REQUIREMENTS

AND PROCEDURES

DISTRIBUTION STATEMENT A. Approved for public release; distribution is unlimited. Requests for this document shall be referred to Director, Joint Oil Analysis Program Technical Support Center, 85 Millington Avenue, Pensacola, FL 32508-5010.

DESTRUCTION NOTICE - For unclassified, limited documents, destroy by any method that will prevent disclosure of contents or reconstruction of the document.

Published b under the authority of the Joint Oil Analysis Program Regulation.

AFI 21-131(I)/AR 700-132/OPNAVINST 4731.1B

This publication supersedes Army TM 38-301-2 dated 1 July 2005. y direction of Commander, Naval Air Systems Command

12 Sept 2008

0817LP1082309

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LIST OF EFFECTIVE PAGES Dates of issue for original and changed pages are: Original .......... 0 ............ 12 Sept 08

IRACs 1 through 4 incorporated. Total number of pages in this volume is 265 consisting of the following: Page 1 Change No. No. Title ................................................. 0 A ...................................................... 0 Flyleaf-1 .......................................... 0 Flyleaf-2 Blank ............................... 0 i -iv .................................................. 0 1-1 .................................................... 0 1-2 Blank ......................................... 0 2-1 - 2-10 ......................................... 0 3-1 - 3-20 ......................................... 0 4-1 - 4-6 ........................................... 0 5-1 - 5-49 ......................................... 0 5-50 Blank ....................................... 0 6-1 - 6-26 ......................................... 0 6-27 Blank……………… .............. 0

Page 1 Change No. No. 7-1 - 7-20 ......................................... 0 8-1 - 8-19 ......................................... 0 8-20 Blank ....................................... 0 9-6....... ............................................. 0 9-7 Blank ......................................... 0 A-1 - A-12 ....................................... 0 B-1-B-35 ......................................... 0 C-1 ................................................... 0 C-2 Blank ........................................ 0 D-1 ................................................... 0 D-2 Blank ........................................ 0 E-1 ................................................... 0 E-2 Blank ........................................ 0 F-1 ................................................... 0

Page 1 Change No. No. F-2 Blank ......................................... 0 G-1-G-5 ........................................... 0 G-6 Blank……… ............................ 0 H-1 ................................................... 0 H-2 Blank ........................................ 0 I-1 - I-2 ............................................ 0 J-1 .................................................... 0 J-2 Blank ......................................... 0 K-1 ................................................... 0 K-2 Blank ........................................ 0 L-1 - L-4 .......................................... 0 M-1 - M-2 ........................................ 0 N-1 - N-4 ......................................... 0 O-1 - O-3 ......................................... 0 O-4 Blank ........................................ 0

1 Zero in this column indicates an original page.

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By Order of the Secretary of the Army:

GEORGE W. CASEY, JR. General, United States Army

Chief of Staff Official:

JOYCE E. MORROW Administrative Assistant to the

Secretary of the Army 0832414

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TABLE OF CONTENTS Section Page I. INTRODUCTION ...................................................................................................................................... 1-1 1-1. Purpose .................................................................................................................................... 1-1 1-2. Applicability .............................................................................................................................. 1-1 1-3. Manual Change Procedures ................................................................................................... 1-1 II. SPECTROMETRIC LABORATORY OPERATING REQUIREMENTS .................................................. 2-1 2-1. Introduction .............................................................................................................................. 2-1 2-2. Facilities ................................................................................................................................... 2-1 2-3. Staffing Requirements ............................................................................................................. 2-1 2-4. JOAP Training ......................................................................................................................... 2-1 2-5. JOAP Laboratory Instruments ................................................................................................. 2-2 2-6. Other JOAP Instrumentation ................................................................................................... 2-3 2-7. Instrument Requirements ........................................................................................................ 2-4 2-8. Laboratory Supplies Required................................................................................................. 2-4 2-9. Forms Required ....................................................................................................................... 2-9 2-10. Publications Required ............................................................................................................. 2-9 III. SPECTROMETRIC LABORATORY OPERATING PROCEDURES ..................................................... 3-1 3-1. Introduction .............................................................................................................................. 3-1 3-2. Sample Processing .................................................................................................................. 3-1 3-3. Disposal of Oil Sample Bottles and Caps ............................................................................... 3-1 3-4. Spectrometer Preparation and Operation ............................................................................... 3-1 3-5. Data Recording, Processing and Warehousing ..................................................................... 3-3 3-6. Analytical Data Evaluation ....................................................................................................... 3-7 3-7. Response to Customers .......................................................................................................... 3-7 3-8. Transfer of Oil Analysis Records ............................................................................................ 3-11 3-9. Disposal of Oil Analysis Records ............................................................................................ 3-12

3-10. Contingency Operations .......................................................................................................... 3-12 3-11. Requests for Spectrometer Maintenance ............................................................................... 3-13 3-12. Spectrometer Protection During Shutdown Periods ............................................................... 3-14 3-13. JOAP Certification and Correlation Programs ........................................................................ 3-14

IV. PHYSICAL TEST LABORATORY OPERATING REQUIREMENTS ..................................................... 4-1 4-1. General .................................................................................................................................... 4-1 4-2. Laboratory Operating Requirements ...................................................................................... 4-1 4-3. Laboratory Testing Requirements (Army) .............................................................................. 4-3 4-4. U.S. Air Force Special Tests ................................................................................................... 4-6 V. PHYSICAL TEST LABORATORY OPERATING PROCEDURES ......................................................... 5-1 5-1. Total Acid Number (TAN) ........................................................................................................ 5-1 5-2. Blotter Spot Test ...................................................................................................................... 5-2 5-3. Ferrographic Analysis Procedures………………………………………………… .................. 5-4 5-4. Fourier Transform Infrared (FT-IR) Analysis .......................................................................... 5-11 5-5. Fuel Dilution Determination in Used Lubricating Oils ............................................................. 5-15 5-6. Microscopic Analysis ............................................................................................................... 5-21

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Section Page 5-7. Particle counter Testing ........................................................................................................... 5-22 5-8. Viscosity Measurements of Used Lubricating Oils……………………………………………… 5-23 5-9. Water Contamination Tests………………………………………………………………. .......... 5-35 VI. US NAVY DIELECTRIC COOLANT TESTING…………………………………………………………… .. 6-1 6-1. General .................................................................................................................................... 6-1 6-2. Coolant Testing Procedures .................................................................................................... 6-2 6-3. Moisture Analysis..................................................................................................................... 6-6 6-4. Flash Point Analysis ................................................................................................................ 6-15 6-5. Contamination Analysis Kit ...................................................................................................... 6-16 6-6. Navy (ships) Physical Properties Procedures ........................................................................ 6-23 VII. US AIR FORCE B-2 COOLANT TESTING PROCEDURES …… ........................................................ 7-1 7-1. Introduction .............................................................................................................................. 7-1 7-2. General .................................................................................................................................... 7-1 7-3. Equipment ................................................................................................................................ 7-1 7-4. Test Sequence ......................................................................................................................... 7-1 7-5. Laboratory Safety .................................................................................................................... 7-2 7-6. Testing ..................................................................................................................................... 7-2 7-7. Appearance ............................................................................................................................. 7-2 7-8. Dielectric Strength ................................................................................................................... 7-3 7-9. Particulate Contamination ....................................................................................................... 7-5 7-10. Volume Resistively .................................................................................................................. 7-10 7-11. Water Content .......................................................................................................................... 7-13 VIII. Contamination Testing of coolant in operating systems ethylene glycol/water (EGW) …… ............... 8-1 8-1. Introduction .............................................................................................................................. 8-1 8-2. General .................................................................................................................................... 8-1 8-3. Equipment ................................................................................................................................ 8-2 8-4. Test Sequence ......................................................................................................................... 8-3 8-5. Laboratory Safety .................................................................................................................... 8-3 8-6. Testing ..................................................................................................................................... 8-3 8-7. Appearance ............................................................................................................................. 8-3 8-8. Dielectric Strength ................................................................................................................... 8-4 8-9. Particulate Contamination ....................................................................................................... 8-6 8-10. Refractive index ....................................................................................................................... 8-11 8-11. Specific Gravity ........................................................................................................................ 8-14 8-12. Accelerated Stability ................................................................................................................ 8-15 8-13. NaMBT Content……………………………………………………………………………………. 8-15 IX. CONTAMINATION OF TURBOJET ENGINES WITH AUTOMOTIVE OIL……………………………….. 9-1 9-1. Introduction. ............................................................................................................................. 9-1 9-2. General……………………………………………………………………………………………… 9-1

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LIST OF FIGURES

Number Title Page

3-1. Oil Analysis Record (DD Form 2027) ............................................................................ 3-6 3-2. Sample Message Format for Reporting Correlation Results ........................................ 3-17 4-1. Typical Physical Test Laboratory Layout ...................................................................... 4-2 4-2. Nonaeronautical Equipment Lubricant Sample Analysis Requirements Guide ............ . 4-4 6-1. Coolant Identification Label.…………………………………………………………………. 6-3 6-2. Coolant Analyis Report................................ ................................................................. 6-5

LIST OF TABLES

Number Title Page

2-1. Quantities of Electrodes and Bottle Caps for Six (6) Months Operations ..................... 2-6 3-1. Correlation Elements and Score Weighting Scheme .................................................... 3-18 3-2. JOAP Fluids .................................................................................................................. 3-19 5-1. Viscosity Guidelines for MIL-L-2104 Lubricating Oil ..................................................... 5-25 5-2. Brookfield Viscometer Quality Assurance Chart...... ..................................................... 5-29 5-3. Brookfield Spindle Factors..... ....................................................................................... 5-30 5-4. Specific Gravity for Type Oil.... ...................................................................................... 5-31 5-5. Spindle/Range Information............................................................................................ 5-34 5-6. Fuse Ratings for Selected Voltage..... .......................................................................... 5-37 5-7. Settings for Type Oil.... .................................................................................................. 5-42 6-1. Specific Testing Sequence ........................................................................................... 6-4 6-2. Aquatest VIII Replacement Parts .................................................................................. 6-7 6-3. Solvents and Chemicals ................................................................................................ 6-11 6-4. Contamination Analysis Kit Replacement Parts ........................................................... 6-13 6-5. Maintenance Advisories ................................................................................................ 6-22 7-1. SEBD Coolant Test Requirements ............................................................................... 7-2 8-1. EGW Coolant Test Requiements...... ............................................................................ 8-2 A-1. Analytical Sample Record ............................................................................................. A-3 A-2. Analytical Sample Record Deletion ............................................................................... A-6 A-3. Analytical Sample Record Change ............................................................................... A-8 A-4. Maintenance Feedback Record .................................................................................... A-9 A-5. Maintenance Feedback Deletion .................................................................................. A-11 A-6. Maintenance Feedback Record Change ...................................................................... A-12

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APPENDICES Number Title A Non-automated Laboratory Data Submission B Type Equipment Codes C Major Command Codes D JOAP Laboratory Codes/Spectrometer Codes E Data Index Codes F Reason for Sample Codes G Laboratory Recommendations Codes H Action Take Codes I Discrepant Item Codes J How Malfunctioned Codes K How Found Codes L Sample Message Format, Diagnostic Data and Request for Assistance M DA Form 3254-R, Oil Analysis Recommendation and Feedback and Preparation Instructions N Army Requirements for Certification of Laboratory Personnel O Ferrogram Analysis Report Sheet

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SECTION I

INTRODUCTION 1-1. Purpose. The purpose of Volume II is to standardize Joint Oil Analysis Program (JOAP) operating procedures and provide standardization guidance for JOAP laboratories. 1-2. Applicability. The provisions of this manual apply to all activities of the Departments of the Army, Navy, and the Air Force participating in the JOAP and to laboratories operating under contract or mutual assistance agreements. 1-3. Manual Change Procedures. Detailed procedures for manual changes are contained in Volume I.

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SECTION II

SPECTROMETRIC LABORATORY OPERATING REQUIREMENTS 2-1. Introduction. This section contains information and instructions regarding space and staffing requirements, and equipment and consumable supplies that are recommended for operation of a JOAP laboratory performing spectrometric analysis. Additional information for laboratories performing physical property testing is contained in Section IV. 2-2. Facilities. Laboratory square footage space requirements have been omitted for fixed land based laboratories since operational requirements, work loading, service directive specifications, and facility availability vary so widely between service activities. Activities experiencing problems with space requirements should refer inquiries to the appropriate service oil analysis program manager.

a. Shipboard Laboratories. The optimum shipboard laboratory should have 200 square feet of working area to allow for semi-permanent spectrometer shock mounting with adequate bulkhead clearance to allow access to equipment for required maintenance and servicing and to provide adequate space for administrative/records filing and storage of supplies and spare parts. The area must be free of explosive/corrosive fumes, provided with positive ventilation and exhaust, and should be environmentally controlled with respect to both temperature and humidity.

b. Mobile Laboratory. A mobile laboratory should have at least 200 square feet of floor space, be completely self contained (equipment, supplies and work space) and capable of deployment. The spectrometer should be shock mounted and the facility should be capable of air transport without any disassembly. All environmental control features should be built-in, with only external grounding and power plug-in required for immediate operational capability. 2-3. Staffing Requirements. See Section IV for physical testing manpower requirements.

a. The number of personnel required for a laboratory will vary depending on the assigned workload, the utilization of civilian or military personnel, the utilization of manual or automated data recording and the type and location of the laboratory. These requirements are to be used as guidelines only and are calculated based solely on spectrometric analysis. Additional staffing may be necessary for physical testing manpower requirements. In general, the number of personnel required for spectrometric analysis may be computed as follows:

(1) Automatic Recording, P = W/1100 (2) Manual Recording, P = W/865

P = number of personnel required W = estimated workload in samples per month

b. A certified evaluator must be present during all hours of laboratory operations. All Army laboratories must

employ two certified evaluators full-time. Army requirements for certification of laboratory evaluators are in Appendix N. 2-4. JOAP Training. a. Training Courses Available

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(1) Defense Joint Oil Analysis Program Training Courses available: Title Course No.

Atomic Emission Spectrometer J3AZP2A752-000

Physical Properties Testing J3AZP2A752-003

Ferrography Testing J3AZP2A752-004

NOTE

The Air Force Non Destructive Inspection (NDI) course, J3ABP2A732-000 (or equivalent), includes evaluator training and operation/maintenance of the Model M spectrometer equivalent to training provided in course J3AZP2A752-000.

(2) A model M spectrometer maintenance training course is available from Spectro, Inc.

NOTE

It is highly recommended that personnel scheduled for spectrometer maintenance training posses an electronics background.

b. Training Requests

(1) Army/Air Force - submit training requirement(s) in accordance with established service procedures. (2) US Navy/US Marine personnel: Ms. Sheila Nelson Naval Station Norfolk Naval Personnel Development Command DSN 564-2996 ext 3223 COMM 757-444-2996 ext 3223 US Coast Guard: AETCM Dukes Training Quota Management Center Chesapeake Va COMM 757-366-6582 2-5. JOAP Laboratory Instruments. The following atomic emission rotrode instruments are approved for use in the

JOAP and are eligible for JOAP certification when enrolled and operated by DOD laboratory personnel.

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a. Baird A/E35U-3. This fluid analysis spectrometer has been the standard instrument for the JOAP. The dash 3" is configured for the detection of up to 20 elements. It should be operated in a temperature and humidity controlled laboratory environment. This instrument is no longer being manufactured/procured and is being replaced by newer JOAP approved instrumentation.

b. Baird A/E35U-3A. Also known as the "FAS-2C", this spectrometer is an updated version of the A/E35U-3. It has essentially the same characteristics as the "dash 3". This instrument is no longer being manufactured/procured and is being replaced by newer JOAP approved instrumentation

c. Baird MOA. This Multielement Oil Analyzer is a bench top portable spectrometer designed for both mobility and laboratory use. It has many of the same features and internal parts as the A/E35U-3 and -3A spectrometers. this spectrometer can be used in harsher environments. If standardization must be repeated periodically while deployed under adverse conditions, standardization is made simple through computer assistance. The spectrometer is configured for the fifteen JOAP elements.

NOTE

The MOA II is not an approved JOAP instrument.

d. Spectroil Plus. Spectro, Inc. modified the Spectroil Jr. spectrometers to what we now refer to as the "Jr. plus" or "Plus". The Plus is also a bench top spectrometer designed for both laboratory and mobility use. This spectrometer can be used in harsh environments. If standardization must be repeated periodically while deployed under adverse conditions, standardization is made simple through computer assistance. The spectrometer is configured for the fifteen JOAP elements. This instrument is no longer being manufactured/procured and is being replaced by newer JOAP approved instrumentation.

e. Spectro, Inc. Model M. The "M" has many of the features of the "Plus". Additionally, it has many built-in safety features for power applications and routine operation. It also was designed for both laboratory and mobility use. It also has computer assisted standardization capability. The spectrometer is configured for the fifteen JOAP elements.

f. Spectro, Inc. Model M/N. The "M/N" is essentially the same as the "M". The "M/N has electromagnetic Interference (EMI) protection that meets the requirements of the US Navy. Additionally, the "M/N" has a convenient port for measuring the source frequency. Adjustment of the source frequency is made with a control that has been placed in the burn chamber. 2-6. Other JOAP Instrumentation

a. Fourier Transform Infrared (FT-IR) Oil Analyzer Spectrometer. The FT-IR spectrometer system quantitatively measures fuel, coolant, water, and monitors oxidation, oil additive depletion, lubrication degradation, and incorrect fluid contamination. The FT-IR spectrometer technology provides a means to evaluate a variety of fluid conditions that lead to component failures in oil lubrication systems.

b. Ferrography Automated. Personal computer application for debris and wear particle analysis trending that has software capability in trending evaluation techniques. Ferrography is used in support of fine filtration equipped components to identify abnormal component failures through enhanced diagnostic techniques. Ferrography detection ranges from 8 to 200 microns size wear particles. Iron (Fe) is the primary element evaluated for types of wear such as spalling, rubbing, and cutting wear particles.

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2-7. Instrument Requirements.

a. Environmental controls. If possible, temperature and humidity should be controlled to 75 +3°F and approximately 50 percent or less relative humidity. If no controls are available, spectrometer standardization will be more frequent. If a computer is used or is an integral part of the instrument, problems may occur if excessive heat is encountered. For spectrometers designed for mobility purposes, these requirements are not necessary. However, for efficient computer operation and to prevent frequent standardization, it is advisable to have some control over the environment, even in a mobility environment.

b. Power requirements. Refer to the spectrometer manufacturer's information concerning the application power to the instrument as the requirements vary from instrument to instrument and country to country. Ensure that all measures are taken to set up the instrument for the correct voltage and frequency (Hz) before applying power. If a multimeter is available, ensure the voltage is constant and within specifications.

c. Exhaust vent. Fumes from the spectrometer must be vented to the outdoors to protect the operator. If you are operating the spectrometer outdoors with mobility equipment, vent the exhaust away from the operator to a sufficient distance to avoid inhalation of fumes. 2-8. Laboratory Supplies Required.

a. Spectrometric Oil Standards. The same standards are used for the standardization of atomic emission and atomic absorption spectrometers.

(1) Description. The D-12 standards contain the same weight of each of 12 elements (aluminum, chromium, copper, iron, lead, magnesium, nickel, silicon, silver, sodium, tin, and titanium). The D-3 standards contain the same weight of each of 3 elements (boron, molybdenum, and zinc). The D19-0 PPM standard is a base oil with no elements added. In the manufacture of the D-12 and D-3 standards, soluble complex metallo-organic compounds are blended in hydrocarbon base oil with a stabilizing agent. All standards have a minimum flash point of 340°F (171.1°C) and a viscosity of approximately 245 centistokes at 100°F (37.6°C). (2) Ordering Standards. The D19-0 PPM, D-12, and D-3 standards are available in 8 ounce bottles through normal supply sources as stock numbered items. The D19-0 PPM and D-12 standards are manufactured by the Joint Oil Analysis Program Technical Support Center, Pensacola, Florida, and are distributed to all users through the Item Manager, the Defense Supply Center Richmond, 80 Jefferson Davis Highway, Richmond, VA 23297-5864. (a) Standards available. Available Designation ***Elements Concentrations Shelf Life

D-19 None 0 *30 months

D-3 B, Mo, Zn 100 *12 months

D-12 Fe, Al, Cr, Cu, Pb, Na **5, 10, 30 *30 months MG, Ni, Si, Ag, Sn, Ti 50, 100 ,300

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* Shelf/service life assigned to Spectrometric Oil Standards is finite with no extensions allowed.

Standards reaching service life shall be locally disposed of in accordance with applicable service regulations.

NOTE

Up to 2 bottles of expired oil standards, normally referred to as "slop oil", may be retained for use for warm-up burns. Higher concentrations of expired standards such as 50, 100 or 300 ppm are best for this purpose. These slop oil bottles must be clearly marked on the label as slop oil - “for warm-up burns only" to ensure that they are not used for standardization of the spectrometer.

** The 5 PPM concentration is not applicable to AOAP laboratories. *** JOAP elements and their symbols are as follows:

Element Aluminum Barium Boron Cadmium Chromium Copper Iron Lead Magnesium Manganese Molybdenum

Symbol

Al Ba B

Cd Cr Cu Fe Pb Mg Mn Mo

Element Nickel Silicon Silver Sodium Tin Titanium Zinc

Symbol

Ni Si Ag Na Sn Ti Zn

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(b) Applicable stock number for the zero PPM, D-3 and D-12 standards are as follows:

PPM Concentration

0 5 10 30 50

100 (D-3) 100 (D-12)

300

National Stock Number 1RM 9150-00-179-5137-SX 1RM 9150-01-307-3343-SX 1RM 9150-00-179-5145-SX 1RM 9150-00-179-5144-SX 1RM 9150-00-179-5143-SX 1RM 9150-01-283-0249-SX 1RM 9150-00-179-5142-SX 1RM 9150-00-179-5141-SX

(3) Stocking Standards. Due to shelf life control requirements of spectrometer oil standards, local

supply departments are prohibited from maintaining standards in stock. Standards ordered through local supply activities will be forwarded from the Navy Inventory Control Point stocking point. Therefore, it is recommended that laboratories frequently inventory standards on hand, maintain no more than 6 months usage level on hand, and order replacement stock 30 to 45 days in advance of anticipated requirements.

b. Electrodes. Both disc and rod electrodes listed below are operating activity expense items and must be

ordered through normal supply channels from Defense General Supply Center, Richmond, VA 23297. A suggested 6-month supply is listed in table 2-1. For a list of JOAP tested and approved electrodes, e-mail a request to: [emailprotected]

Electrode

Rod (6 inches long) Disc (0.200 inch thick)

P/N

M8971-2-2 M8971-1-2

Unit of Issue

Box (50 ea) Box (500 ea)

NSN

5977-00-464-8433 5977-00-464-8496

TABLE 2-1. QUANTITIES OF ELECTRODES AND BOTTLE CAPS FOR SIX (6) MONTHS

Expected Number of Samples per Month

Disc

Electrodes Rod

Bottle Caps

Up to 1000 1000 to 3000 3000 to 5000

16 boxes 40 boxes 64 boxes

6 boxes 16 boxes 26 boxes

8,000 20,000 32,000

NOTE

Shipboard and mobile laboratories should order sufficient electrodes to last a full deployment. Six-inch rod electrodes normally provide for 25 to 30 analyses; disc electrodes are for one time use only. Individual packages of electrodes should not be opened until needed, and different manufacturer's electrodes should not be intermixed (see paragraph 3-3).

c. Oil Sample Containers.

(1) Bottle caps NSN 6640-01-042-6583, with nomenclature of Cap, Screw, Bottle & Jar, P/N24-3600, 24 MM size 24, white urea linerless plastic will be used for performing sample analysis when a JOAP approved cap is not provided with the oil analysis bottle. They may be obtained either through normal supply channels or by open purchase. A suggested six-month supply is listed in table 2-1.

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(2) Reusable fluid holders (aluminum boats) are used for daily standardization and daily standardization checks of atomic emission rotrode spectrometers and are available through normal supply channels under NSN 6650-00-086-1571.

d. Miscellaneous Supplies. (1) Atomic Absorption Spectrophotometer Equipped Laboratories.

Item

Cleaning Compound Towel, Paper 40 Sq In. Disk, Filter 47 mm 100's Diluter Disc, Bacterial Filtering Acetylene, Technical Cylinder Cylinder Gas Nitrous (250 gal) Cylinder Gas Nitrous (2000 gal) Nitrous Oxide (250 gal) Nitrous Oxide (2000 gal) Filter, Disc Acetone, Technical Methyl Isobutyl Ketone (MIBK) Xylene Syringe, Hypodermic, 5 ml Syringe, Hypodermic, 20 ml Test Tube 13 x 100 MM Tubing, 0.023 I.D. x 0.038 O.D.

Unit of Issue

QT BX (16,800 ea) BX (1,350 ea) EA PG CF EA EA EA EA EA CN (5 gal) GL GL EA EA PG (125 ea) EA

National Stock No.

6850-00-227-1887 7920-00-721-8884 7920-00-965-1709 American Scientific Prod. P/N P4927-11 6640-00-299-8692 6830-00-270-8216 8120-00-130-1921 8120-00-130-1941 6505-00-130-1920 6505-00-130-1940 6640-00-299-8691 6810-00-184-4796 6810-00-286-3785 6810-00-598-6600 6515-00-754-0406 6515-00-380-4300 6640-00-443-3750 Perkins-Elmer P/N 4710-PPE-801S

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(2) Atomic Emission Spectrometer Equipped Laboratories.

Item

Cleaning Compound Paper Towel Disk Filter Stop Watch TBI Ultrasonic Cleaner (BF) Optical Alignment Fixture Adjustment Fixture Electrode Sharpener

Unit of Issue

QT 40 Sq In. 47 mm 100's EA EA EA EA EA

National Stock No.

6850-00-227-1887 7920-00-721-8884 7920-00-965-1709 6645-00-250-4680 4940-00-164-8997 6650-00-119-9412 6650-00-119-9413 6650-00-498-8182

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(3) Electron solvent has been approved for use in the JOAP program as a replacement for

Trichloroethane. See paragraph 3-4.b (2) for units of issue and NSN’s 2-9. Forms Required. a Oil Analysis Record (DD Form 2027) is required for those laboratories performing manual recording of oil analysis data and is available through normal forms distribution channels.

b. Oil Analysis Request (DD Form 2026) may be required by the laboratory to replace damaged or oil soaked copies for analysis results entry and return to customer activities (as required by service policy). c. Oil Analysis Recommendation and Feedback Form, DA Form 3254-R (Army laboratories). 2-10. Publications Required. The following publications are required for daily operational reference guides for oil analysis laboratories as indicated. a. All Oil Analysis Laboratories. (1) Message Address Directory: Army DA Pamphlet 25-11, Navy USN PLAD 1, as appropriate.

(2) Joint Oil Analysis Program Manual, NAVAIR 17-15-50, TM 38-301, T.O. 33-1-37. All laboratories should have Volumes I, II and III. Laboratories providing support for nonaeronautical equipment should have Volume IV.

(3) ADP System Users Guide (as applicable). b. Laboratories Using A/E35U-3.

(1) Technical Manual, Operation Instructions/Maintenance Instructions, Fluid Analysis Spectrometer, Type A/E35U-3, Air Force T.O. 33A6-7-24-1, Navy NAVAIR 17-15BF-62.

(2) Technical Manual, Illustrated Parts Breakdown, Fluid Analysis Spectrometer, Type A/E35U-3, Air Force T.O. 33A6-7-24-4, Navy NAVAIR 17-15BF-63. (3) Maintenance Manual Supplement, NAVAIR 17-15BF-62.1. (Army and Navy) (4) Technical Manual, Periodic Maintenance Requirements Manual Fluid Analysis Spectrometer A/E35U-3/-3A/FAS-2C, NAVAIR 17-600-131-6-2. (Navy only) c. Laboratories using FAS-C2 spectrometers.

(1) Operation and Maintenance Instructions, Fluid Analysis Spectrometer A/E35U-3A (FAS-2C), Air Force T.O. 33A6-7-24-11, Army TM 9-6650-306-14, Navy NAVAIR 17-15BF-92.

(2) Illustrated Parts Breakdown, Fluid Analysis Spectrometer A/E35U-92.3A (FAS-2C), Air Force T.O. 33A6-7-24-14, Army TM 9-6650-306-24P, Navy NAVAIR 17-15BF-92.1. d. Laboratories using Baird MOA spectrometers.

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Baird User’s Guide for Multielement Oil Analyzer. (Manufacturer's manual, no number assigned). e. Laboratories using Spectro, Inc. Spectroil Jr. Plus spectrometers. Spectro, Inc. Spectroil Jr. Plus Instruction Manuals. Operation and Maintenance Manual. Volume II is Detailed Maintenance. (Manufacturer's manual, no number assigned.) f. Laboratories using Spectro, Inc. Model M and M/N spectrometers.

(1) Spectro, Inc. Model M/N Operation and User Maintenance Manual, Air Force T.O. 33B4-2-29-1 US Navy NA 17-15BF-95.

g. Army Oil Analysis laboratories. (Additional publications required.) (1) The Army Material Maintenance Policies, AR 750-1, in the Maintenance Management UPDATE. (2) Aeronautical Equipment Army Oil Analysis Program (AOAP), TB 43-0106. (3) The Army Maintenance Management System, DA PAM 738-750, in the Maintenance Management

UPDATE. (4) Oil Analysis Standard Interservice System Users Manual.

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SECTION III

SPECTROMETRIC LABORATORY OPERATING PROCEDURES 3-1. Introduction. This section provides general instructions concerning laboratory operating procedures, laboratory reports, requests for spectrometer maintenance, requests for technical assistance and contingency operations.

3-2. Sample Processing.

a. Processing and evaluation priority shall be as follows:

(1) Special aeronautical. (2) Routine aeronautical.

(3) Special nonaeronautical.

(4) Routine nonaeronautical.

b. Each laboratory shall process samples, evaluate results, and transmit recommendations to the

customer as soon as possible during normal working hours on a non-reimbursable basis. Aeronautical samples shall be processed within 24 clock hours of receipt and nonaeronautical samples within 72 clock hours of receipt, weekends and holidays excluded. Equipment specific variations to these time requirements are noted in the specific equipment tables in volumes III and IV.

c. If delays are expected in processing priority samples, the laboratory shall notify the customer as

soon as possible.

d. The laboratory shall normally request a special sample for verification of analysis prior to a recommendation for maintenance action.

3-3. Disposal of Oil Sample Bottles and Caps. All oil sample bottles (glass and plastic); bottle caps, plastic tubing and unused oil shall be segregated for disposal and disposed of in accordance with local base requirements.

3-4. Spectrometer Preparation and Operation. All spectrometers require preliminary preparation prior to operational use. Daily standardization checks in accordance with procedures identified in the manuals for each spectrometer shall be performed once each day prior to operation. If the daily standardization check is out of allowable tolerances, a complete standardization shall be performed in accordance with the applicable spectrometer manual. A complete standardization shall be accomplished at least once each week. Correct frequency, or breaks per half cycle, is essential for repeatable results. Those spectrometers that do not have any automatic frequency adjustment shall be checked at least once every 2000 burns. Periodic standardization checks shall be made throughout the operational period. At a minimum, these checks will be made when switching from analysis of aeronautical to non-aeronautical samples (or vice versa) and whenever the spectrometer has not been operated for 30 minutes or more. The following instructions also apply:

a. All Laboratories. Personnel shall not smoke, eat, or drink in close proximity to oil analysis

equipment, sample preparation areas, or ADP equipment.

b. Atomic Emission Laboratories.

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(1) Electrodes. An analysis obtained on a sample using one manufacturer’s electrodes will frequently vary from results obtained on the same sample when using electrodes from another manufacturer. Therefore, when a change is made from one manufacturer’s to another manufacturer’s electrodes (either rod, disc, or both), or a change in lot or batch number of the same manufacturer occurs, a daily standardization check must be performed using the new electrodes before continuing operations. Also, ensure that the operator performs a disc-offset procedure if this procedure is required for the spectrometer in use (typically Spectro, Inc. Model M and M/N). Refer to the spectrometer manual.

(a) Rod electrodes should be resharpened only on one end after each burn. The sharpening process must remove all contamination from the previous burn. Contamination is readily visible as stains/discolorations on the flat face and the sides of the electrode and must be completely removed in order to preclude contamination of subsequent analysis burns. The resharpened end should have a smooth, polished appearance and the slight point on the sharpened end must be geometrically centered. Rod electrodes must not be handled by the sharpened end in order to avoid contamination.

(b) Disc electrodes are for one time use only and must be discarded after each sample

analysis. Electrodes should not be picked up or touched with the hands but should always be handled with a tissue to avoid the possibility of contamination. Discs should not be poured out in an open container, but should be left in the original container until ready for use. Dropped or spilled electrodes should be discarded due to the possibility of contamination.

(2) Sample Holders. Aluminum boats (NSN 6650-00-086-1571) shall be used for standardization

of the JOAP atomic emission rotrode spectrometer and for daily standardization checks. Aluminum boats are also used for any other special check or process performed prior to the analysis of used fluids; for example disk/rod offset checks and optical profiling when required. White caps (NSN 6640-01-042-6583) will be used as sample holders for all sample analyses except when analyzing low flash point fluids. Low flash point fluids shall be analyzed using the aluminum boat with cover (NSN 6650-01-011-3472). If an insufficient amount of fluid is available for analysis to fill a cap, an aluminum boat may be used for the analysis. Aluminum boats and covers must be thoroughly cleaned before reuse. Electron is the primary fluid recommended for cleaning the aluminum boats and covers. Any solvent that dissolves the oil may be used, but the solvent must have no metallic content to contaminate the boats and covers and present no serious health risk to the user or the environment. The solvent must also not affect the sample stand components when used for cleaning the sample stand. No cleaner may be used that has a flash point below 140 degrees F or one which is considered an ozone depleting substance. Consult with your local environmental personnel to ensure that any fluid that is used is completely safe and that correct usage and disposal procedures are in effect. Here is information for obtaining electron: Unit of Issue NSN

55 gallons drum 6850-01-375-5555 6 gallons 6850-01-375-5553 1 gallon 6850-01-375-5554 Aerosol spray (12 cans per box) 6850-01-371-8048 Pump spray (12 per box) 6850-01-371-8049

(3) Sample Excitation Stand Cleaning. The excitation stand area must be kept clean in order to

obtain accurate analyses. Dirt and oil, in addition to distorting sample results, may also cause high-voltage arcing, which may result in damage to the instrument. All personnel must adhere to the cleaning procedures and schedules given in the applicable instrument owner’s manual. Refer to pages 2-9 and 2-10 of this volume for the applicable manual numbers.

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3-5. Data Recording, Processing, and Warehousing

a. The US Army data is processed and warehoused by the US Army Program Management office at Redstone Arsenal, Huntsville, AL. The US Navy data is processed and warehoused by the US Navy Program Management office at Pensacola NAS, Pensacola, FL. The US Air Force data is processed and warehoused by the JOAP-TSC at Pensacola NAS, Pensacola, FL.

(1) Laboratories shall submit data to their respective service database as directed by the Service Program Manager or as contained in Volume I, page 4-9.

(2) Each Service Program manager is responsible for routine data transfer to the other services.

NOTE

JOAP laboratory personnel are responsible for ensuring that all processed oil analysis results are entered into the applicable service database. This includes assigned, temporarily assigned, transient, and deployed assets. The analysis information shall be supplied to the owning organization or home base location for database entry or update of records as applicable. Retain a copy of the analysis data until receipt is confirmed to ensure that no analysis data is lost.

Army only: The AOAP Program Manager will provide technical assistance and initiate corrective software program changes to the Oil Analysis Standard Interservice System (OASIS) laboratory operating system. If OASIS software support is required, contact the AOAP Manager as follows:

COMMANDER ATTN AMXLS LA BLDG 3627 USAMC FIELD SUPPORT ACTIVITY PROVISIONAL REDSTONE AL 35898-7466 AOAP Hot Line DSN: 645-0869 / (256) 955-0869 Data Facsimile: 746-9344 / (256) 876-9344 DDN address: [emailprotected]

(3) Data Reports. Routine reports are produced from laboratories and from the service database. Examples of some of the reports available are included in Volume I in appendices C and D (D is Army only)

b. Automated laboratories. Detailed information concerning automated systems to access the computer

file data and for entry of variable sample data into the computer files. Entry of sample analysis data on the DD Form 2026 by the laboratory is not required unless required by individual service policy for return of the DD Form 2026 to the customer.

(1) The DD Form 2026 is used as a source document for basic information to access the computer file data and for entry of variable sample data into the computer files. Entry of sample analysis data on the DD Form 2026 by the laboratory is not required unless required by individual service policy for return of the DD Form 2026 to the customer.

(2) DD Form 2027 is not normally used by automated laboratories unless required for backup or

temporary records in the event of automated system failure.

(3) The requirements for assignment of sample numbers by service activities is the same as that specified in paragraph 3-5.c. for non-automated laboratories.

c. Non-Automated Laboratories. The following information is for use by those non-automated

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laboratories required to transmit manually accumulated data into the JOAP database and may be directed for use by other service program managers for their automated laboratories experiencing ADP equipment failure.

(1) DD Form 2026 is used as a source document to locate existing DD Form 2027 and complete the variable data section or to initiate new DD Form 2027. The DD Form 2026 is also used by Air Force non-automated laboratories for submission of data for entry into the JOAP data base (see Appendix A for specific Air Force data submission instructions), and may be directed for use by other service program managers in appropriate circ*mstances.

(2) DD form 2027, (figure 3-1), is used as an historical record of equipment monitored. Non-Air

Force activities that are not designated to transfer data to the data base shall complete DD Form 2027 using information from the DD Form 2026 and laboratory analysis data and retain DD Form 2027 on file as the historical record for each item of equipment monitored. These laboratories may use either coded or plain language data entries, whichever is locally desired. Laboratories will comply with individual service directives for sending non-automated data into the JOAP database.

(3) Data from the DD Form 2026 are transferred to the DD Form 2027 as follows:

(a) Permanent Data Section: The information for this section is provided by the oil analysis

request (DD Form 2026). This data, once entered on the DD Form 2027, rarely changes but should be verified at the time of each subsequent data entry.

NOTE

When instructions for a data entry item specify, “leave blank”, laboratory personnel may use these data entry blocks for any purpose desired locally. Each laboratory supervisor will determine which, if any, of the data entry blocks will be used locally and for what purpose.

1. Component Control Number (CCN) - leave blank.

2. Equipment Model/APL - enter the equipment/component model name from DD

Form 2026 and/or the appropriate model code from Appendix B.

3. Equipment Serial Number - enter the equipment/component serial number being monitored (Engine, Gearbox, etc. that was sampled).

4. Type Equipment Code - leave blank.

5. Customer - enter the major command listed on the DD Form 2026 or the appropriate code from Appendix C.

6. Customer Identification - enter the activity’s name and unit identification code (UIC). (USAF-enter base code.)

7. Lab - enter your laboratory name or JOAP code from Appendix D as appropriate.

8. End Item Model/Hull Number - enter End Item Model/Hull number as given on

DD Form 2026 and/or the appropriate code from Appendix B.

9. End Item Serial Number - enter end item serial/bureau number.

10. Type Oil - leave blank.

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(b) Variable Data Section: The information for this section is also provided by the oil

analysis request (DDForm 2026) but changes with each sample processed and recorded.

1. Sample Number - Army laboratories shall enter sample number. Air Force and Navy laboratories shall enter sample number. Air Force and Navy laboratories shall enter the sample number assigned by the customer and listed on the DD Form 2026.

a. If no customer sample number is assigned, Air Force and Navy laboratories will assign a temporary control number, process the sample in the normal manner and contact the customer by appropriate means, depending upon customer location and request a sample number. The omission of a sample number shall not delay the processing of a sample or the customer notification of analysis results.

b. The monthly reporting period shall be the first through the last day of each

month. The first digit of the sample number will be monthly designator identified as follows:

1 - Jan 4 - Apr 7 - Jul O - Oct 2 - Feb 5 - May 8 - Aug N - Nov 3 - Mar 6 - Jun 9 - Sep D - Dec

c. The second part of the sample number shall be composed of three numerical

digits and will follow the monthly designator. Sequence numbers will be assigned in ascending order beginning with 001 each month, e.g., 234th sample submitted in Feb will be reflected as sample number 2234.

2. Data Index - USN leave blank. USAF leave blank for routine documentation. For file maintenance actions, see Appendices A and E.

3. Date Sample Analyzed - enter Julian date sample analyzed.

4. Response/Turn Around Time - enter the number of days in transit as calculated by

subtracting the date the sample was taken from the date the sample was analyzed. Air Force laboratories will enter the total sample response time in whole hours to include elapsed hours from the time that the sample was taken to the time that the laboratory completed sample processing and issues laboratory recommendation. (Army laboratories - leave blank.)

5. Last Lab Recommendation - leave blank.

6. Hours/Miles Since Overhaul - enter the number of hours/miles since new or

7. Overhauled as applicable.

8. Hours/Miles Oil Change - enter the number of hours/miles since oil change.

9. Reason for Sample - enter the appropriate reason sample submitted code from

Appendix F.

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Figure 3-1. Oil Analysis Record (DD Form 2027)

Figure 3-1. Oil analysis Record (DD Form 2027)

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NOTE

If the DD 2026 reports that oil was added since the last sample data was submitted, use wear-metal columns Ba, Cd, and Mn to record the unit of measurement in Ounces (O), Pints (P), Quarts (Q), or Gallons (G), the numerical quantity of oil added, and the oil consumption rate in unit quantity per hour. (For example, Q1-0.5; i.e., 1 quart of oil added and a consumption rate of 0.5 quarts per hour.) To determine the oil consumption rate, compute the operating hours between oil additions by subtracting previously reported oil addition time since oil change (TSOC) or time since overhaul (TSO) from latest oil addition TSOC or TSO. Divide the reported quantity of oil added by the operating hours calculated above for the oil consumption rate per operative hour. The oil consumption rate trend provides additional information to aid the laboratory evaluator and maintenance personnel in evaluating equipment condition. The individual taking the sample must ensure that all oil added since the last sample (regardless of the number of hours between samples) is documented on the DD2026, including oil added after the current sample is taken so that the rate of oil usage can be correctly determined. For example, over the course of 100 hours between samples, oil has been added 8 times and added after the current sample for a total amount of 1 quart.

(d) Post Analysis Data:

1. Validation - this block is normally left blank. However, it may be used to identify the laboratory operator/evaluator for laboratory management purposes.

2. Laboratory Recommendation - after laboratory evaluation of sample results, enter the

appropriate recommendation code from Appendix G.

(e) Feedback Data (if applicable):

1. Action Taken - enter the appropriate action taken code from Appendix H. 2. Discrepant Item - enter the appropriate discrepant item code from Appendix I.

3. How Malfunctioned - enter the appropriate how malfunctioned code from Appendix J.

4. How Found - enter the appropriate how found code from Appendix K.

3-6. Analytical Data Evaluation. Techniques for evaluating analytical results, evaluation criteria, and the methodology for establishing criteria are contained in Volumes III and IV. 3-7. Response to Customers.

a. Response Requirements. Each laboratory is required to provide analysis results, recommendations,

and additional information, when applicable, to customers as shown below. Shorter laboratory response time requirements than those specified in paragraph 3-2 may be assigned by parent program management offices since response time requirements vary according to type equipment, operational and mission differences and individual service requirements. Equipment specific variations to these time requirements are noted in the specific equipment tables in volumes III and IV.

(1) Army and Navy. Upon receipt, laboratory personnel shall stamp the DD Form 2026 with a sample number and the date received.

(2) The Army requires the processed DD Form 2026/DA Form 5991-E, Oil Analysis Request, to

be returned to the submitting Army unit personnel.

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(a) Laboratory personnel shall circle in red all incomplete or obviously incorrect entries on

DD Form 2026 submitted with samples and a copy of the incorrect or incomplete DD 2026 shall be returned to the customers OA for corrective action. Laboratories shall return the processed DD Form 2026 stamped with either PROCESSED (date) NORMAL RESULTS” or “PROCESSED (date) ABNORMAL RESULTS” to all customers. The laboratory shall annotate the DD Form 2026 with the laboratory recommendation and if the recommendation is other than normal with enough information to identify what was abnormal. For example. “High iron” or “low viscosity.” At a minimum. DD Form 2026 will be returned once a week.

(b) Each laboratory is required to provide information to customers that will enable the

customer to ensure that all samples taken were received and analyzed by the laboratory. For samples with normal results, return of the processed DD Form 2026 will serve as notification of completion of sample analysis. For samples with abnormal results, the laboratory shall advise the owning unit of the laboratory recommendation either in person or by telephone within 24 clock hours of sample receipt for aeronautical samples and within 72 clock hours of sample receipt for nonaeronautical samples, weekends and holidays excluded. Navy laboratories shall maintain a log of all telephone calls, message traffic, and/or personal contacts made because of recommendations made on equipment with abnormal oil analysis results.

(c) Laboratories shall provide units with Oil Analysis Standard Interservice System reports as

required. Navy laboratories, at a minimum, shall issue the following reports: Monthly: Report Subsystem Distribution Monthly Activity Aeronautical Squadron Components Enrolled Aeronautical Squadron Ship Ship Ground Company Workload Summary Aeronautical Wing or CAG Ship Squadron Ground Battalion or Base Weekly: Report Subsystem Distribution Received and Processed Ship Ship

At a minimum, Army laboratories shall provide the Components enrolled in AOAP and the Resample and Type Recommendation Reports monthly to all using units.

(d) Army Only. Requests for samples and oil changes shall be made on DD Form 2026. recommendations for maintenance actions shall be made on DA Form 3254-R, Oil Analysis Recommendation and Feedback. Once initial contact is made in person or by telephone, the laboratory shall follow up with a DA Form 3254-R for all on-post units and for off-post nonaeronautical Reserve and National Guard units. For aeronautical Reserve and National Guard units and for off-post active Army units (aeronautical and non-aeronautical) the laboratory shall follow up initial contact with a priority message confirming initial contact and a DA Form 3254-R by mail. The DA Form 3254-R shall be forwarded within 24 clock hours following the initial contact. A DA Form 3254-R and instructions for laboratory preparation of the form are in Appendix M.

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(2) Air Force laboratories and Navy non-aviation samples do not require the processed DD Form

2026 to be returned. They should ensure that the customer is notified of the receipt and processing of all samples. due to message traffic restrictions, this may normally be accomplished by telephone or personal contact. Navy laboratories shall also be responsible for providing adequate analysis information to the customer, as directed by responsible authority, to enable the customer to comply with the requirement imposed by OPNAVINST 4790.2G to maintain records of oil analysis results to highlight equipment trends.

(3) Interservice Response Requirements. Laboratories performing interservice fluid analysis service shall comply with the requirements of the customer’s parent service regarding sample response unless alternate response procedural agreements between services are reached.

(4) Samples Requiring Amplified Response. All laboratories must provide sample analysis results,

including laboratory recommendation information when applicable, to the customer activity for all types of samples listed below:

(a) All special samples.

(b) All samples for which the analysis indicates possible discrepancy.

(c) All samples suspected to be invalid.

(d) All samples for which response is specifically requested by the operating activity in

special circ*mstances.

b. Content and Terminology. Each response shall contain the following information:

(1) Equipment Model and Serial Number and End Item Model and Serial Number. This information is provided by the customer on the Oil Analysis Request (DD Form 2026).

(2) Sample Analysis. The sample analysis shall be reported as normal, marginal, high, or abnormal

for individual metal content. (3) Date Sample Taken. As provided on DD Form 2026.

(4) Recommendations. Each response shall contain the complete recommendation description

corresponding to the applicable recommendation code.

NOTE Laboratory recommendations are indeed only recommendations. It is the customer’s responsibility to take appropriate corrective action. If a disagreement between the laboratory and customer arises concerning corrective action, the discrepancy should be entered in the equipment forms by laboratory personnel and corrective action taken, if any, entered by the customer.

c. Method of Response. Each laboratory response shall be prepared and delivered as follows:

(1) Results Involving Operational/Flight Safety. Whenever analysis of any sample results in a laboratory determination that operational/flight safety is affected, the laboratory shall immediately provide detailed Information to the customer by telephone, when possible, followed by priority message (or memorandum for on base responses if desired) for confirmation of results and recommendations.

(2) Results Not Involving Operational/Flight Safety. Whenever analysis of a sample results in a recommendation requiring the customer to take action, but does not involve operational/flight safety, reports shall be made verbally followed by a memorandum report for on base/post customers (except in cases where Information copies of official notification correspondence are required by higher commands) and by message,

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speed letter or letter, as appropriate for off base/post customers.

(3) Message Format. A recommended format for a priority message for use in reporting analysis results Involving operational/flight safety follows:

FROM: LABORATORY TO: CUSTOMER

INFO: SERVICE OIL ANALYSIS PROGRAM MANAGEMENT OFFICE COGNIZANT FIELD ACTIVITY (USN) /ITEM MANAGER (USAF)

(Engine/component removal recommendations only)

TYCOM (USN) /MAJOR COMMAND (USA, USAF) (Engine/component removal recommendations only)

OTHER INFO ADDRESSEES (as directed by individual service requirements)

UNCLAS SUBJ: JOAP OIL SAMPLE ANALYSIS REPORT

REF: (A) NA 17-15-50/TM 38-301/T.O. 33-1-37 1 IAW REF (A) FOLLOWING REPORT SUBMITTED a. SAMPLE NUMBER (if assigned) AND TYPE (routine/ Special). b. DATE SAMPLE TAKEN. c. END ITEM IDENTIFICATION (serial/indent number). d. EQUIPMENT MODEL AND SERIAL NUMBER. e. SAMPLE ANALYSIS RESULTS (normal, marginal, high, Abnormal for specific

elements). f. RECOMMENDATIONS (use plain language corresponding to specific

recommendation codes) RECOMMEND DO NOT FLY, DO NOT CHANGE OIL, SUBMIT CHECK SAMPLE ASAP, ETC.

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(4) Laboratory responses to contractor customers requiring oil analysis support in support of a contract with a component of DOD shall contain the same information as responses made to military operating activity customers. 3-8. Transfer of Oil Analysis Records. Any time that an oil analysis customer relocates, either deployed or permanently, and oil analysis services are required at the new location, the transfer of workload and provision of services shall be handled through the normal chain of command in order to ensure orderly transfer of support. unusual problems encountered should be referred to the appropriate service oil analysis program management office for resolution.

a. Transient Equipment Records. Transient customers are responsible for obtaining complete oil analysis records for their equipment from the losing laboratory and for delivery of the records to the gaining laboratory at the new operating site. If sufficient time is not available to comply with these procedures prior to departure, the customer shall notify the losing laboratory concerning the relocation and the losing laboratory shall mail all required oil analysis records to the gaining laboratory.

b Permanent Relocation/Temporary Deployment. Whenever the oil analysis workload is transferred from one laboratory to another due to customer transfer, the following instructions apply:

(1) Transferring Activity (Customer). The customer activity is responsible for notifying the home base (supporting) oil analysis laboratory concerning transfer/deployment schedules in advance of departure. advance notice is required in order to provide the laboratory sufficient time for orderly processing of records for transfer to the new supporting laboratory to avoid disruption in equipment oil analysis monitoring schedules.

(2) Transferring/Losing Laboratory. The losing laboratory will forward equipment oil analysis records directly to the gaining laboratory unless directed otherwise by competent authority. The losing laboratory shall ensure that each equipment record transferred is complete, accurate and legible.

(a) When both the losing and gaining laboratories are equipped with appropriate automated systems the record transfer may be accomplished using ADP products in accordance with instructions provided by the appropriate service program management office.

(b) When only one or neither laboratory is equipped with an automated data system, a copy

of records must be made for transfer. Either a hardcopy computer record printout or copies of DD Form 2027, refer to figure 3-1, may be used, depending upon the losing laboratory capabilities.

(c) The following actions will be taken by transferring/losing laboratories:

1. Customer Temporary Deployment.

a. Retain original oil analysis records.

b. Forward copies of records to gaining laboratories.

c. Update or replace original records upon return of customer/equipment and

notify deployment site laboratory of records receipt.

NOTE

In cases where equipment will be deployed for lengthy periods exceeding normal laboratory equipment data retention periods, losing laboratories may elect to transfer the original records and retain copies only for the

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normal retention period.

2. Customer Permanent Transfer.

a. Retain copies of oil analysis records.

a. Forward original records.

c. Destroy copies retained either upon notification of receipt of records by the gaining laboratory or at the expiration of the normal record retention period as desired.

(3) Gaining laboratory. The historical records for gained equipment will provide a baseline for evaluations and recommendations when providing service to the new customer. Problems encountered in data transfer should be immediately referred to the appropriate program management office. The gaining laboratory will take the following actions upon receipt of newly gained equipment oil analysis records:

(a) Notify losing laboratory when oil analysis records have been received and screened for

completeness, accuracy, and legibility.

(b) Initiate new records if required.

(c) If deployed customer, forward original of records accumulated during deployment to the customers home base supporting laboratory upon completion of deployment. Format of records for transfer will be determined by ADP capabilities of both laboratories involved. Retain data/copies of records until notified of records receipt by customer’s home base supporting laboratory.

(4) Lost oil analysis records. In the event copies of oil analysis records are lost during transfer, either the customer or the gaining laboratory, as appropriate, should request new copies of the oil analysis records from the losing laboratory.

NOTE

The above procedures also apply to an operating activity that is reassigned to another service’s laboratory.

3-9. Disposal of Oil Analysis Records. The original copy of an oil analysis record may be destroyed by the originating laboratory 12 calendar months after receipt of the last sample from the item of equipment involved. laboratories with ADP capability will utilize normal purge routines specified by parent service. 3-10. Contingency Operations. Whenever a JOAP laboratory becomes inoperative, the following procedures apply.

a. If operational capability cannot be restored within a reasonable time consistent with operational safety, as determined by the appropriate program manager or the on-site commander for deployed units, the laboratory shall contact their program management office and the back-up laboratory listed in the JOAP Directory (or as directed by the applicable program manager) and provides the following information:

(1) Estimate of duration of laboratory downtime.

(2) Number of samples backlogged.

(3) Average number of samples received daily.

(4) Method of transporting samples to back-up laboratory.

b. Temporary additional staffing, TAD/TDY of personnel from an inoperative laboratory for the

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reassignment of workloads may be necessary. The two laboratories shall negotiate staffing requirements and coordinate with local management as required. (At those bases/posts having no government or contract laboratories, US govemment personnel shall negotiate workload transfers and personnel support for the laboratories.) Staffing problems not settled between affected laboratories shall be referred to the appropriate OAP management office for resolution.

c. If the laboratory supports customers of more than one service, the disposition of backlogged

samples shall be coordinated between the appropriate service program management offices.

3-11. Requests for Spectrometer Maintenance.

a. Army Laboratories. After exhausting local capabilities for repair, Army laboratories shall forward diagnostic data to the JOAP-TSC. The diagnostic data may be forwarded in message format as shown in Appendix L or in comparable format by telephone. If troubleshooting, consulting, and advisory support by the JOAP-TSC is unsuccessful, the JOAP-TSC will refer the laboratory to the Army program management office for further action. The program director is responsible for coordination of all on-site maintenance/service visits by the spectrometer manufacturer’s representatives.

b. Navy Laboratories. After exhausting local capabilities for repair, Navy laboratories shall contact the Navy Oil Analysis Program Office for assistance. (1) East coast laboratories (ISSC Cherry Point, ISSC Jacksonville, NAS Corpus Christi, NAS Key West, NAS Oceana, NAS Patuxent River, NAS Sigonella, FRC Mayport, MID ATLANTIC LAB Norfolk, Bagram Air Base, Al Asad Iraq and Atlantic Fleet ships should contact the NOAP East Coast Tech Rep. (2) West coast laboratories NAS Lemoore Ca, NAS Fallon, NAS Whidbey Island WA, MCAS Yuma, NAVSHIPYD and IMF Pearl Harbor, Camp Pendleton CA, SWRMC San Diego, NAF Atsugi, MCAS Iwakuni and Pacific Fleet ships should contact the NOAP West Coast Tech Rep.

(1) East coast laboratories (NADEP Cherry Point, NADEP Jacksonville, Corpus Christi NAS Truax FieldNAS Key West, NAS Oceana, NAS Sigonella, SIMA Mayport, MID ATLANTIC LAB Norfolk and Atlantic Fleet ships will address messages to NATEC DET MIRAMAR CA //3.7BD//, NATEC DET OCEANA VA //3.7BD// and NAVOAPROGMGR PENSACOLA FL //3.2//.

(2) West coast laboratories NAS Lemoore Ca, NAS Meridian, NAS Fallon, NAS Whidbey WA,

MCAS Yuma, USS INCHON, NAVSHIPYD Pearl Harbor, SIMA San Diego and Pacific Fleet ships operating off the west coast or in the vicinity of Hawaii will address their messages to NATEC PAC SAN DIEGO CA //3.7/VA1//, with info copies to NATEC DET MIRAMAR CA //3/7BD//, NATEC SAN DIEGO CA//3.7.4//, and NAVOAPROGMGR PENSACOLA FL //3.2//.

(3) NAF Atsugi, USS ESSEX, USS KITTY HAWK and ships deployed to the WESTPAC and Indian Ocean area will forward their messages to NATEC PAC SAN DIEGO CA//3.7BA1//, NATEC DET ATSUGI JA//3.7BD//, NATEC DET MIRAMAR CA//3.7BD// with info copies to NATEC SAN DIEGO CA//3.7.4//, NAVOAPROGMR PENSACOLA FL //3.2//.

(4) NATEC LANT NORFOLK and NATEC PAC SAN DIEGO will coordinate spectrometer

maintenance support in their respective areas. If support capabilities are exhausted and if additional support is required, request for contractor support from the NAVOAPROGMGR PENSACOLA FL //3.2//.

c. Air Force Laboratories. After exhausting local maintenance capabilities, Air Force laboratories shallcontact the spectrometer manufacturer for additional telephonic troubleshooting assistance. If the problem still cannot be resolved, Air Force laboratories shall contact the Program Management Office, OC-ALC TIEO, 4750 Staff Drive, Tinker AFB, OK 73145-3317 for contractor on-site support.

d. The JOAP-TSC will provide troubleshooting, consulting, and advisory maintenance support as

requested. If unsuccessful, the JOAP-TSC will refer the laboratory to the appropriate service program management office for coordination of on-site assistance visits if required. Direct liaison is encouraged between

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the JOAP-TSC, PMEL, NATEC and laboratory activities. Since local availability of spare parts is limited, diagnostic data must be accurate and complete.

e. Army and Navy laboratories located near Air Force bases may negotiate with Air Force PMEL

personnel for spectrometer maintenance. Support will be at the discretion of the Air Force Major Command involved. 3-12. Spectrometer Protection during Shutdown Periods. During in port shutdown periods in excess of two weeks and during shutdown periods when spectrometer protection is required, such as shop renovation or shipyard repair, laboratory managers shall ensure that laboratory personnel protect the spectrometer from contamination (dust, paint chips, moisture, etc.). A plastic covering, taped to form a complete barrier is recommended for this purpose. 3-13. JOAP Certification and Correlation Programs. The JOAP Certification and Correlation Programs are primary elements of the JOAP quality assurance initiative to ensure standardization of procedures and quality of oil analysis by the JOAP laboratories. Follow the specific spectrometer operators’ manual for any additional special standardization recommendations/requirements prior to the analysis of correlation samples such as optical alignment or a check of the source frequency using a test meter or an oscilloscope. Participation in these programs is mandatory for all atomic emission rotrode spectrometer oil analysis laboratories, organic or under contract to a US military service for analyzing used oils from US government equipment.

a. Certification Program. Based upon laboratory facilities, personnel qualifications, and JOAP Correlation Program performance, laboratory spectrometers are categorized as certified or uncertified.

(1) Certified laboratories are authorized to provide oil analysis support to all authorized and approved customers, intraservice and interservice, as well as other DoD authorized customers. Uncertified laboratories are prohibited from providing oil analysis services to any customers unless the appropriate service program. Management office grants a waiver. This waiver must be in writing and shall normally limit the laboratory to intraservice support. A waiver granting authority for interservice support shall be supported by written concurrence of the program manager of the other supported service(s) on file with the program management office granting the waiver.

(2) The JOAP Certification Program is described in detail in Volume I.

b. Correlation Program.

(1) If a laboratory receives damaged correlation samples or does not receive samples by the 15th of the month, the laboratory shall notify the TSC of the problem immediately by telephone or e-mail.

(2) Perform complete spectrometer standardization. Immediately following the standardization,

perform a daily standardization check with at least three standards prior to correlation samples analysis to ensure that the standardization was successful. If the results are not within the required tolerances, repeat the complete spectrometer standardization until the daily standardization checks are acceptable.

NOTE Correlation printouts, including all standardization data, shall be retained for three months. This information is vital for troubleshooting instruments that score low in the program. The Program Managers may also request printouts as a quality assurance check.

(3) Ensure that the samples are analyzed on the spectrometer whose serial number is on the mailing label. Follow the specific spectrometer operators manual for any additional special standardization recommendations/requirements prior to the analysis of correlation samples such as optical alignment or a check

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of the source frequency using a test meter or an oscilloscope.

(4) Shake each correlation sample vigorously for one minute by hand just prior to analysis.

(5) Analyze each sample three (3) times and average the results.

(6) Report results on the results card, e-mail, or message to the nearest whole PPM. Examples: 5.5 PPM = 6, 4.4 PPM = 4.

(7) Record “0” if a zero reading is obtained.

(8) Record R/M if one or more elements are inoperative.

(9) Leave elements not analyzed blank.

(10) Submit results to the TSC as soon as possible after receipt of the samples. Current month

results are to be submitted by the 21st of the month. There is no late penalty for late submission. However, your results will not be used to help calculate the trimmed mean. JOAP certified laboratories should ensure that results from the previous month are received prior to submitting current month results. If a low score is achieved, then the problem can then be hopefully resolved prior to submitting additional results. Results can be sent by e-mail, regular mail, message traffic and facsimile. E-mailing the correlation data to [emailprotected] is preferred as the data can then be downloaded directly into the correlation database. A receipt confirmation will be sent. If regular mail, message, or facsimiles are used for sending data, be sure to use two of these methods to ensure receipt by the TSC. If sending data by e-mail, be sure to attach the data using the standard form supplied by the TSC. An example of the message format is in Figure 3-2.

Phone: DSN 922-5627, ext 115 or 121 Commercial (850) 452-5627, ext 115 or 121

FAX: DSN 922-2348 Commercial (850) 452-2348

(11) Comply with any other special instructions received with the correlation samples.

(12) Score Computation.

(a) General. Correlation scores for all participating laboratory spectrometers are based on reproducibility 1 and reproducibility 2 results. A correlation test results report is sent each month for all spectrometers enrolled in the program. If either reproducibility 1 (R1) or reproducibility 2 (R2) fails the criteria for any of the required elements, points are subtracted as provided below. Each sample pair accounts for 50 possible points for a total of 100 points. Results are rounded off (i.e., one R1 failure equals 3.33 points for a JOAP instrument, 96.67 equals 97 percent score). Table 3-1 lists the 15 JOAP elements and points assigned for the types of spectrometers.

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(b) Late Results.

1. Non-submission (NS). If the score sheet sent by the JOAP-TSC indicates N/S for

the current month and results were submitted, contact the TSC as soon as possible and send in the results by the best and quickest means available. Be aware that all means of transmittal are subject to not actually arriving at the TSC. That is why it is recommended to send the data via at least two methods unless you receive an e-mail confirmation of receipt. If results were not submitted, please submit them as soon as possible. For JOAP Certified labs, non-submission of data can jeopardize JOAP certification.

2. Reported Maintenance (RM). Laboratories unable to analyze their correlation

samples due to an inoperative spectrometer should report this fact to the JOAP-TSC prior to the data submission cutoff date. The JOAP-TSC will place these laboratories in an RM status for that month. RM status laboratories must ensure repairs are expedited and that results are submitted as soon as the spectrometer is operational. Table 3-2 lists all JOAP fluids currently used in equipment monitored in the JOAP.

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SAMPLE MESSAGE FORMAT FOR REPORTING CORRELATION RESULTS FROM: LABORATORY TO: DIRJOAP TSC PENSACOLA FL

UNCLAS SUBJ: CORRELATION TEST RESULTS FOR (Month)

1. DATE RECEIVED AND DATE ANALYZED (4 FEB 04/7 FEB 04)

2. SAMPLE 1 2 3 4

Fe 21 17 9 10

AG 14 12 1 2

Al 47 40 1 1

Cr 16 13 9 8

Cu 20 16 5 4

Mg 15 13 1 1

Na 53 49 15 12

Ni 30 25 8 7

Pb 5 4 3 2

Si 7 6 3 3

Sn 7 6 3 3

Ti 19 16 0 0

B 4 3 3 3

Mo 5 5 10 11

Zn 7 6 4 3

(Round off results to nearest whole PPM)

3. SPECTROMETER MODEL AND SERIAL NO. (FAS-2C O015)

4. STANDARDS USED FOR STANDARDIZATION/EXP DATE (i.e. 0 PPM NWL165 /D12-100 JUN 06 100 PPM CES584 MAY 06 / D3-100 PPM NCW503 JUN 04)

5. DISC ELECTRODE MFG AND LOT/BATCH NUMBER: (i.e. CARBON OF AMERICA 241-00-17)

6. ROD ELECTRODE MFG AND LOT NUMBER: (i.e. BAY CARBON LOT 0400 BATCH 331)

7. OPERATOR AND SUPERVISOR: (i.e. SSGT RAY JOHNSON / MSGT MIKE WILLIAMS)

8. COMMENTS: (list any pertinent comments)

Figure 3-2. Sample Message Format for Reporting Correlation Results

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NOTES

If a laboratory is unable to conduct analysis for one or more elements for a given month due to instrument malfunction and appropriate maintenance corrective actions have been initiated and reported to the JOAP-TSC, an RM code will be entered in place of the score(s) that would normally be entered for the element(s). Laboratories are prohibited from analyzing oil samples for operational equipment for the element(s) for which the spectrometer was placed in an RM status. (See Vol I for additional information concerning RM status.) The JOAP-TSC will coordinate closely with the service program managers to resolve possible adverse affects on certification status and interservice support. A message request for maintenance help to the JOAP-TSC or some other agency, with info copy to the TSC, does not constitute requesting R/M status unless a specific request for R/M status is included in the message. Either call the TSC or send an e-mail specifically requesting R/M status and try to provide the TSC with a “get well” date.

TABLE 3-1. CORRELATION ELEMENTS AND SCORE WEIGHTING SCHEME

Element Symbol No Data or Fails Reproducibility 1 or 2

Iron Silver Aluminum Chromium Copper Magnesium Sodium Nickel Lead Silicon Tin Titanium Boron Molybdenum Zinc

Fe Ag Al Cr Cu Mg Na Ni Pb Si Sn Ti B Mo Zn

JOAP AE Rotrode

3.33 3.33 3.33 3.33 3.33 3.33 3.33 3.33 3.33 3.33 3.33 3.33 3.33 3.33 3.33

AA/ICP/etc.

5.55 5.55 5.55 5.55 5.55 5.55

- 5.55

- 5.55

- 5.55

-

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TABLE 3-2. JOAP FLUIDS The following fluids are the types now used in the Joint Oil Analysis Program for all JOAP engines, transmissions and components. STOCK NUMBER 9150-01-152-7060 9150-00-985-7232 9150-01-113-2045 9150-01-080-5961 9150-00-111-6255 9150-01-131-3325 9150-00-223-4134 9150-01-290-2943 9150-00-149-7431 9150-00-235-9061 9150-00-942-9343 9150-01-177-3988 9150-01-178-4726 9150-00-189-6730 9150-00-188-9864 9150-01-178-4725 9150-01-048-4593 9150-01-313-2191 9150-01-035-5393 9150-00-111-3199 9150-00-111-0209 9150-01-293-7696 9150-00-111-0211 9150-00-168-6889 9150-00-985-7099 9150-00-186-6682 9150-00-186-6689 9150-01-278-1356 9150-01-177-2762 9150-01-177-2763 9150-00-402-2372 9150-LP-000-1012 9150-00-782-2627 9150-01-209-2684 9150-01-210-1938 9150-00-181-8229 9150-00-664-4449

PRODUCT LUB OIL HYDRAULIC FLUID HYDRAULIC FLUID HYDRAULIC FLUID HYDRAULIC FLUID YELLOW HYDRAULIC FLUID RED HYDRAULIC FLUID PETRO HYDRAULIC FLUID HYDRAULIC FLUID LUB OIL COMPOUND LUB OIL STEAM LUB OIL ENG 10 GRADE LUB OIL ENG 30 GRADE LUB OIL ENG 40 GRADE LUB OIL ENG 50 GRADE LUB OIL ENG 15W/40 LUB OIL GEAR 75 LUB OIL GEAR 80/90 LUB OIL GEAR 85/140 LUB OIL PRESERV. LUB OIL PRESER. 30 LUB OIL PRESER. 15-40 LUB OIL PRESER. 50 LUB OIL A/C LUB OIL A/C LUB OIL ENG 10 GRADE LUB OIL ENG 30 GRADE LUB OIL ENG S/30 LUB OIL ENG 10/30 LUB OIL ENG 15/40 LUB OIL ENG OIL LUB (1100 GR) LUB OIL A/C TURBINE LUB OIL HELO LUB OIL HELO LUB OIL SHIP OIL COMPRESSOR XC 20/50 PHILLIPS

SPECIFICATION ASTO750

MIL-H-17672 MIL-H-19457 MIL-H-22072 MIL-H-46170 MIL-H-46170 MIL-H-5606 MIL-H-6083 MIL-H-83282 MIL-L-15019 MIL-L-17331 MIL-L-2104 MIL-L-2104 MIL-L-2104 MIL-L-2104 MIL-L-2104 MIL-L-2105 MIL-L-2105 MIL-L-2105 MIL-L-21260 MIL-L-21260 MIL-L-21260 MIL-L-21260 MIL-L-22851 MIL-L-23699 MIL-L-46152 MIL-L-46152 MIL-L-46152 MIL-L-46152 MIL-L-46152 MIL-L-46167 MIL-L-6082 MIL-L-7808 MIL-L-85734 MIL-L-85734 MIL-L-9000 W-L-825

NATO H573 H580 H579 H544 H544 H515 C635 0250 0Z37 0238 N/C 01236 0186 0226 0228 C640 C642

644 0128 056 0183 0113 0148 0278 0283

TYPE S

S S S S S

S M M M M M M M M

M S M M M M M M M S S S M M

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TABLE 3-2. JOAP FLUIDS (Cont) Correlation Fluid Identification *Type MIL-L-9000 Mobil Jet 254 Phillips XC 20/50 VV-L-825

*M - Mineral *S - Synthetic

Diesel engine lubricating oil Coast Guard turbine engine oil Aircraft piston engine lubricating oil Refrigerant compressor lubricating oil

M

S

M

M

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SECTION IV

PHYSICAL TEST LABORATORY OPERATING REQUIREMENTS 4.1 GENERAL.

a. Purpose. This section outlines the requirements for physical property testing of used lubricant from engines, transmissions and hydraulic systems. Physical property testing is a diagnostic tool used to determine the physical condition of used lubricants. It is not intended to replace normal maintenance practices.

b. Scope. Physical property tests described in this manual are designed to determine whether used oil

is contaminated or deteriorated by testing the oil for the following: viscosity, moisture/water content, flash point (fuel dilution), acidity, dispersancy, insolubles/total solids and particles/debris. The physical test requirements in this section are applicable to activities operating nonaeronautical equipment as directed by appropriate authority within the individual services and may also be applicable to selected items of aeronautical equipment as directed. The physical test may be used individually or in conjunction with spectrometric oil analysis as directed by appropriate authority within the individual services. 4.2 Laboratory Operating Requirements. The following paragraphs contain information regarding space and staffing requirements, as well as equipment recommended for operation of a JOAP laboratory performing physical property tests.

a. Laboratory Space Requirements. Recommended space requirements shown in figure 4-1 are to be used as guidelines only, since operational requirements and facility availability vary widely among service activities. The area required for a spectrometric testing facility is not included in figure 4-1. Activities experiencing problems with space requirements should contact the appropriate oil analysis program manager.

b. Laboratory Environmental Requirements. Each laboratory shall be environmentally controlled for

operational efficiency. Proper ventilation and exhaust capabilities (for crackle, water (KF), and flash point) shall be provided to conform to safety requirements. Physical property test equipment is designed to operate over a wide range of environmental conditions. Refer to equipment operation, maintenance manuals and local base policies for specific equipment requirements. A portable fire extinguisher shall be readily accessible in all testing areas.

c. Staffing Requirements.

(1) Number of Personnel. The number of personnel required for a laboratory will vary depending on assigned workload, use of civilian or military personnel, use of manual versus automated data recording, and the type and location of the laboratory. In general, one full-time employee is required for every 800 analyses per month with automated data recording (this includes spectrometric and physical property testing). All Army laboratories must employ two certified evaluators full-time. One full time certified AOAP evaluator must be present at all times during the operation of the laboratory.

(2) Training. All laboratory personnel performing the duties of operator and/or evaluator for

nonaeronautical equipment must receive appropriate training as determined by the appropriate service oil analysis program manager. The training may be obtained through attendance at service-approved courses and/or on the job training (OJT). Certification of physical testing operators/evaluators is an individual service prerogative in accordance with applicable service guidelines. Army requirements for certification of laboratory personnel are in Appendix N.

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NOTE 1: THE BALANCE, KF EQUIPMENT VISCOMETER, PATCH TEST (PARTICLE COUNT) EQUIPMENT, ETC., ARE POSITIONED ON BENCH-TOPS OF LABORATORY FURNITURE. SUPPLIES, EQUIPMENT, ETC., MAY BE STORED BENEATH WHEN NOT IN USE. ALSO, ABOVE THIS EQUIPMENT ARE WALL CABINETS FOR STORAGE OF SUPPLIES, ETC. NOTE 2: SPACE FOR A SPECTROMETRIC TESTING FACILITY IS NOT INCLUDED ON THIS LAYOUT.

LEGEND 1 CRACKLE TEST 2 FLASH POINT 3 2 EA 36" X 18", STORAGE

CABINETS FOR PARTS, SUPPLIES, ETC.

4 DESK AND CHAIR 5 BLOTTER/TOTAL SOLIDS 6 CHAIRS OR STOOLS

Figure 4-1. Typical Physical Test Laboratory Layout

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4.3 Laboratory Testing Requirements (Army). Figure 4-2 outlines the Army sample analysis requirements to be followed for engines, transmissions, and hydraulic system samples.

a. Engines. The laboratory shall conduct at least the following screening tests on engine samples.

(1) Spectrometric analysis - Spectrometric results shall be reviewed to determine whether a critical condition requiring maintenance action or a non-critical condition, such as oil contamination, exists. In either case, a resample shall be requested for verification. A critical condition may be discovered by high wear-metal concentrations or abnormal trend indications. A non-critical condition could be detected by high silicon concentrations indicating contamination of the oil by dust/dirt. Spectrometric values may also be reviewed for additive levels for elements such as zinc, boron, copper, and magnesium.

(2) Viscosity.

(3) Blotter.

(4) Water test, Crackle or Karl Fischer (KF).

(5) Fourier Transform Infrared (FT-IR) Oil Analysis Spectrometer.

b. Transmissions. The laboratory shall conduct the following screening tests on transmission samples:

(1) Spectrometric analysis. (2) Viscosity.

(3) Water test, -Crackle or Karl Fischer.

(4) Fourier Transform Infrared (FT-IR) Oil Analysis Spectrometer.

c. Hydraulic Fluids. The following tests are provided as a means of screening hydraulic fluid samples

taken from equipment and may be used as directed by the appropriate service program manager.

(1) Spectrometric analysis. (2) Viscosity.

(3) Water by Karl Fischer Titration. If water contamination exceeds the guidelines, the laboratory

shall recommend flushing the system and replacing the fluid.

(4) Water by Crackle Test. If water is present, the laboratory shall recommend flushing the system and replacing the fluid.

(5) Automatic Electronic Particle Counting. If the particle count exceeds published guidelines, the

laboratory shall recommend flushing the system and replacing the fluid.

(6) Fourier Transform Infrared (FT-IR) spectrometric analysis. If water contamination, oil additive depletion levels, or lubrication degradation exceed the specified guideline, the laboratory will recommend flushing the system and replacing the fluid to include servicing/replacing the oil filter.

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NONAERONAUTICAL EQUIPMENT LUBRICANT SAMPLE

ANALYSIS REQUIREMENT GUIDE* I. ENGINES

A. Spectrometric

1. Pass - Go to I.B. 2. Fail - See wear-metal guidelines for specific equipment.

a.Critical - Resample to verify. (1) Wear Metals - abnormal or high range. (2) Oil contamination by dirt or dust - Si increase.

b.Noncritical - Resample to verify, then change oil. (1) Oil contamination by dirt or dust - Si increase. (2) Additive depletion - Zn, Mg, or Cu decrease. (3) Coolant Problem - B or Na increase by 20 PPM or more.

B. Viscosity

1. Pass - Go to I.C. 2. Fail - See viscosity guidelines.

a. Low - Fuel dilution or wrong oil. Verify by flash point test and change oil. If repeat problem, make maintenance recommendation for fuel dilution. b. High - Soot, sludge, water or wrong oil. Verify by blotter and water tests and change oil.

C. Blotter

1. Pass - Go to I.D. 2. Fail – Refer to paragraph 5-2.b.

a. Contaminated oil - Soot or water is present. Verify by water (crackle or KF) test and change oil.

b. Additive depletion - Spot has poor dispersency. Verify by spectrometric analysis (large decrease in Zn, Mg, or Cu) and change oil.

D. Crackle Test for Water

1. Pass - Go to I.E. if quantitative degree of water content required (optional). 2. Fail – Refer to paragraph 5-9.a.

a. Free water - Change oil. b. Coolant leak - Verify by spectrometric (B or Na increase by 20 PPM or more) and change oil. c. Dissolved water - Verify by KF test and consult guidelines.

E. Karl Fischer Test for Water

1. Pass 2. Fail – Refer to paragraph 5-4.b.

F. Fourier Transform Infrared (FT-IR) Spectrometric Analysis Results

1. Pass 2. Fail - See FT-IR method number guidelines and analysis readings. Refer to paragraph 5-4.

a. Free water - Change oil and service filters. b. Contaminated oil - Soot, Oxidation, Glycol, and Fuel Readings exceed established guidelines,

recommend oil changes or inspect and initiate repairs of faulty systems.

Figure 4-2. Nonaeronautical Equipment Lubricant Sample Analysis Requirement Guide (Sheet 1 of 2)

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II. TRANSMISSIONS

A. Spectrometric 1. Pass - Go to II.B. 2. Fall - See wear-metal guidelines for specific equipment.

a.Critical - Resample to verify.

(1) Wear Metals - abnormal to high range. (2) Oil contamination by dirt or dust - Si Increase.

b. Noncritical - Resample to verify, then change oil.

(1) Oil contamination by dirt or dust - SI Increase. (2) Additive depletion - Zn, Mg, or Cu decrease. (3) Water or moisture condensation - Na increase.

B. Viscosity 1. Pass - Go to II.C. 2. Fail - See viscosity guidelines.

a. Low - Wrong oil, change oil. b. High - Sludge, water or wrong oil. Verify by water test and change oil.

C. Water test - Crackle or Karl Fischer 1. Pass 2. Fail – Refer to paragraph 5-9.

D. Fourier Transform Infrared (FT-IR) Spectrometric Analysis Results 1. Pass 2. Fail - See FT-IR method number guidelines and component analysis warnings. Refer to

paragraph 5-4. a. Submitting unit to correct the faulty system initiate Critical - Recommend corrective

maintenance actions. b. Non-critical - Change oil and service filter.

(1) Oil contamination by dirt or dust. (2) Additive depletion. (3) Water or moisture condensation - Sodium (Na) increase.

Ill. HYDRAULIC SYSTEMS

The following tests are approved methods of testing hydraulic fluid condition and may be directed by services as required. These tests may be performed singly or in combination as required. (Army laboratories shall use spectrometric, viscosity and water testing as a minimum.)

A. Spectrometric B. Viscosity C. Water testing, Crackle or Karl Fischer Method D. Electronic Particulate Count E. Colorimetric Patch Testing F. Fourier Transform Infrared (FT-IR) Spectrometric analysis for additive depletion and lubrication

degradation contaminants in the components servicing the oil system. Refer to paragraph 5-4. 1. Pass 2. Fail - See prescribed guidelines for specific components.

a. Water: Change oil and service or replace component filters. b. Chlorine: Change oil and service or replace component filters.

*Sequence of test provided as a guide, not as mandatory requirements.

Figure 4-2. Nonaeronautical Equipment Lubricant SampleAnalysis Requirement Guide (Sheet 2 of 2)

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(7) Patch test contamination analysis. If the test results exceed the class level allowed for the type equipment, the laboratory shall recommend cleaning the system and replacing the fluid.

d. Grease. The laboratory shall perform ferrographic analysis of samples taken from AH-1 series helicopter swashplates and scissors and sleeve assemblies. Samples from other components may be analyzed as directed by the AOAP Program Manager.

4-4. U.S. Air Force SpeciaI Tests.

a. The following instructions apply to suspected problems with jet engine oil. Common problems are contamination from let fuel, hydraulic fluid, water or loss of viscosity.

(1) Ensure samples are taken properly.

(2) Send two 5 dram oil sample bottles. If possible, retain a larger sample bottle for possible further testing requirements. Ensure they are tightly sealed, taped and adequately packed. Include a DD Form 2026 with all pertinent information. Give reason for test(s) and point of contact with DSN number. If analysis requirement is immediate, send by overnight express. If not, send first class to the following address:

WL POSL ATTN DR ROBERT WRIGHT BLDG 490 AREA B 1790 LOOP ROAD N WRIGHT PATTERSON AFB OH 45433-7103 DSN: 785-4230

Commercial: (937) 255-4230

b. The following instructions apply to suspected problems with hydraulic fluid. Common problems are contamination from particulates, water and other fluids.

(1) Refer to MIL-HDBK-200 for area laboratory locations.

(2) If further information is required, a point of contact is WL-POSL at the numbers provided above.

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SECTION V

PHYSICAL TEST LABORATORY OPERATING PROCEDURES 5.1 Total Acid Number

a. Scope. This method, based on ASTM-D974, determines Total Acid Number (TAN) in petroleum products due to processes such as oxidation.

b. Summary of Method. In the procedure, a weighed amount of lubricant sample is dissolved in a mixture of toluene and isopropyl alcohol and p-Naptholbenzein indicator added. The mixture is then titrated with potassium hydroxide of known normality, until a color, change is observed. The acidity, or Total Acid Number (TAN), of the sample is then calculated based on the milliliters of potassium hydroxide required to neutralize the known of sample.

c. Equipment/Apparatus/Material (1) Balance (2) Erlenmeyer Flasks: 250 ml capacity (Fischer Scientific, S63271 or equivalent). (3) Auto Zero Burette 25 milliliter capacity (Digitrate) (4) Toluene, TT-T-548, 6810-00-281-2002, 1 Gal (5) Isopropyl alcohol, O-C-265, 6810-00-227-0410, ACS Grade, 1 Gallon (6) P-Naptholbenzein, 6810-00-070-7611, 25 grams (7) 100 ml graduated cylinder, MS35943-7, 6640-00-420-0000 (8) 0.1 N Alcoholic potassium hydroxide (KOH) (9) Laboratory apron, 021-758, 8415-00-634-5023 (10) Goggles, industrial, chemical splash, not vented, ANSIZ87.1-1989,4240-00-190-6432 (11) Nitrile Laboratory gloves, 8415-01-492-0179 (small), 8415-01-492-0179 (Medium),

8415-01-492-0178 (Large), 8415-01-492-0180 (Extra-Large).

d. Operation/Procedures (1) Prepare titrating solvent. Mix together 500 ml of Toluene, 495 ml of Isopropyl Alcohol

and 5 ml of water. Add 0.50 grams of p-Naptholbenzein. (2) Tare an Erlenmeyer flask by placing it on the balance and adjusting the readout to

zero. (3) Add sample to the flask until approximately 20 grams of sample has been added. If

sample is dark, use less of the sample. Sample size may be decreased to as small as two (2) mL for dark samples. Some POE oils have leak-detecting dye in them and require a smaller sample.

(4) Record the weight of the sample to two decimal places. (5) Add 100 ml of the toluene/isopropyl alcohol titrating solvent and mix by swirling the

sample to ensure the sample is completely dissolved. The mixture should appear orange and hom*ogeneous at this point

(6) Fill the automatic burette with the 0.1n alcoholic potassium hydroxide (KOH) solution. (7) Ensure the KOH solution is at the zero line of the burette. (8) Add the KOH solution in small increments to the sample mixture. Swirl the flask after

each addition and note the color of the mixture. Add in decreasing increments as green swirls start to appear. (9) STOP when a distinct color changes from orange to green that lasts for 15 seconds is

observed. Color should be a grass green, possibly overlaid with brown but not a yellow brown (10) Record the amount of KOH used. (11) Prepare a blank by adding 100 ml of titrating solvent to another. (12) Titrate the blank following steps 5 through 10. (13) Record the ml of KOH required to obtain a color change in the blank. (14) Calculate TAN as follows:

(a) Subtract the ml of KOH required to titrate the blank in step 12 from the ml of KOH required to titrate the sample recorded in step 10. Record this number as NET ML of KOH.

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then dividing the result by the gra of sample.

(15) Record the TAN and enter into OASIS/LARA.

-2. Blotter Spot Test

(b) Compute TAN by multiplying net ml of KOH by 5.61ms of sample. TAN (mg KOH gm) = (net ml KOH) x 5.61 grams

5

tive test for amount of insoluble contaminants and/or dispersant ability of used lubricants from diesel engines.

es, and the resulting spot is evaluated for total contaminants, coolant contaminants, and dispersant effectiveness.

c. Definitions.

ants keep contaminants suspended in the oil rather than allowing them to be deposited on engine surfaces.

ful to the

equipment. Some examples are fuel, oxidation products, soot, dust, wear debris, water and coolant.

a. Equipment/Apparatus/Materials.

(1) Filter paper (circles or sheets).

) Wire. Approximately 1/16 inch diameter wire (paper clip).

ire size is not critical, it is important that the same size wire is used each time to drop the oil on the filter paper.

f. Operation/Procedures.

) Shake sample vigorously to ensure hom*ogeneity.

) Using a suitable wire, place one drop of the oil sample in the center of the filter paper.

) Allow 15 minutes for the oil spot to spread and dry.

the oil spot for the following characteristics: solids contamination, dispersancy, and coolant contaminants.

g. References/Guidelines.

re or in the case of solids “drop out”, a recommendation to change the oil and the oil filter should be

sued.

a. Scope. This method provides a qualita

b. Summary of Method. After vigorous shaking, one drop of the used lubricant is placed in the center of filter paper. The oil spot is allowed to develop for 15 minut

(1) Dispersancy. Dispersancy is a measure of the ability of the oil to support debris. Dispersancy

additives in most modern lubric

(2) Contaminants. Contaminants are soluble and insoluble materials that accumulate in used oils from

many sources and, that if allowed to accumulate beyond recommended guidelines, may become harm

th(2

b. Standards/Standardization/Calibration. It is recommended that the operator prepare blotter spots of new

oils to become familiar with normal spot sizes and patterns. Although w

(1 (2 (3 (4) Evaluate

(1) Solids Contamination. Distinctive patterns develop after placing the oil on the filter paper.

Evaluation of solids contamination becomes obvious after experience is gained for a given type of equipment. Solids contamination is evaluated as being light, medium, or heavy. Care should be exercised if solids suddenlydisappear and an oil or oil filter change has not been reported. This condition can indicate a loss of dispersion and a “drop out” of solids that cannot be detected by any of the available test methods. When heavy solids aconfirmedis

(2) Dispersancy, Dispersancy is evaluated as good, fair, or poor. The spots for oils with good dispersion are characterized by fuzzy or lacy patterns, with solids carried well out in the paper. Generally, the greater the size of the spot and spread of the solids as compared with the initial spot, the better the dispersion. As the oil’s dispersion is reduced, the spot becomes smaller. The spots for oils with poor dispersion have sharp and

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distinct peripheries and the spots after 15 minutes are not much larger than the initial spots. A recommendation to

oolant contaminants will reduce or destroy dispersant additives. Spots that form are similar to those described for the dispersion guidelines. In addition, these spots will

e dry. h.

(2) Coolant Contaminants - (1) Not Detected, (2) Present.

oil would be rated 1,1,1, while the worst possible case is 3,2,3. When numerical coding is used, it is not necessary to save the actual blotter spot record, since data can still be trended.

change oil should be issued if dispersion is poor. (3) Coolant Contaminants. Water and other c

often appear to be wet long after normal spots ar

Reports. Record test results as follows.

(1) Total Contaminants - (1) Light, (2) Medium, (3) Heavy.

Dispersion- (1) Good, (2) Fair, (3) Poor.

Using the numerical codes above, the best quality

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5-3. Ferrographic Analysis Procedures Army CH-47D Helicopter Swash plate/Scissors and Sleeve Assemblies

a. Scope. This procedure is used to determine the size, shape and type of wear-metal particles being generated by a piece of equipment as well as the mode of wear (e.g. spalling, rubbing and cutting) producing the particles.

b. Summary of Method. The grease sample is diluted with a fixer solution to break down the bonding

material of the grease. The liquid is then allowed to flow across a substrate mounted over a magnetic field gradient. The magnetic field aligns the particles in strings along the slide and the fixer solution is passed across the substrate to remove the residual grease. After drying, the substrate is analyzed under a Ferroscope. Laboratory grease evaluation procedures are contained in volume III.

c. Equipment/Apparatus/Materials. The equipment required is the analytical Ferrograph and Ferroscope. d. Standards. None e. Operation/Procedures

WARNING

Repeated or prolonged contact with liquid tetrachloroethylene or inhalation of vapors can cause skin and eye irritation, dermatitis, narcotic effects, and liver and kidney damage. After prolonged skin contact, wash the contacted area with soap and water. Remove contaminated clothing. If vapors cause irritation, get to fresh air. For prolonged over-exposure, get medical help. When handling liquid in vapor-degreasing tanks with hinged cover and air exhaust, or at air-exhausted workbench, wear approved gloves and goggles if contact with liquid is likely. When handling liquid at open, unexhausted workbench, wear approved respirator, gloves, and goggles. Dispose of liquid-soaked rags in approved metal containers.

(1) Measure 1 cubic centimeter (cc) of grease and place it into a 16 x 150 millimeter (mm) test tube.

Add approximately 7 milliliters (ml) of tetrachloroethylene and shake until thoroughly dissolved.

(2) Remove the glass substrate from the package. With the dot in the lower left hand corner, position the substrate so that the top edge is elevated and resting on top of the magnet assembly. The drain tube supports the bottom edge of the substrate.

(3) Cut a 4 inch long piece of Tygon tubing and two pieces of turret tubing, one piece 2 inches long and

one piece 8 inches long. Cut both ends of the turret tubing at a 45 degree angle and insert an end of each piece into the Tygon tubing. Place the 2 inch long piece of turret tubing in the delivery arm with the 45-degree angle open end facing the drain tube.

(4) The sample and rinse vials are supported at least 3 ½ inches above the peristaltic pump. The pump

itself is not used. The end of the 8-inch piece of turret tubing is inserted into the sample vial, supported by a double-notched stopper (one notch for the turret tube and one to equalize pressure).

(5) A screw clamp is placed on the Tygon tubing. A slight suction is applied at the delivery arm end of

the tubing and the clamp is loosened long enough to allow the sample to flow halfway through the tube. The clamp is tightened, the suction removed, and the delivery arm is lowered until the exit end of the turret tube touches the substrate. The delivery arm is then backed off slightly.

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(6) The clamp is released very slowly allowing the sample to flow evenly down the substrate. When the

volume in the sample bottle reaches approximately ¼ inch, the Tygon tube is clamped and the end of the turret tube is placed in the rinse vial. The clamp is then released and the substrate rinsed with fixer solution. Allow several air gaps in the turret tube by opening and closing the clamp several times to ensure that the oil does not back up into the rinse.

(7) Allow the substrate to dry. Remove the substrate by lifting upon the exit end and pulling it straight

out of the holder so as not to break the completed Ferrogram. Number the Ferrogram and the Ferrogram cover with the component serial number and sample number. This can be done using thin typewriter correction tape or a glass-marking pen.

(8) The Ferrogram is then analyzed using the Ferroscope. The wear-metal debris is compared to the

guideline photographs for degrees of severity. The results are recorded on the Ferrograph worksheet (see Appendix O), and filed by component serial number along with the substrate. Worksheets and substrates will be kept on file for a minimum of one year.

Supplemental Ferrographic Oil Analysis Procedures (Army).

This is a supplemental procedure used by the Army in the analysis of suspect aeronautical oil samples. Suspect oil samples are defined as those for which one or more of the following diagnostic indicators are observed: chip light; vibration; metal on screens or filters; oil of unusual color, odor, or high solids content; and oil samples having abnormal spectrometric trends or wear-metal content.

a. Scope. This procedure captures information relative to the size, shape, and types of wear-metal particles

and debris too large to be detected by spectrometric analysis.

b. Summary of Method. The oil sample is diluted with a fixer solution to increase the rate of flow. The sample is then analyzed using the Direct Reading (DR) Ferrograph and appropriate guidelines, to quantify both large and small wear particles. If the established DR guidelines are exceeded, the development of a Ferrogram and its examination under the Ferroscope is required.

c. Equipment/Apparatus/Materials. The equipment required is the DR Ferrograph, analytical Ferrograph or

Ferrograph Machine III (FMIII), and the Ferroscope. d. Standards. None. e. Operation/Procedures.

WARNING

Both the fixer reagent and filtered oil contain a nonflammable chlorinated hydrocarbon. Its vapor however is harmful if breathed. Ensure adequate ventilation. Avoid contact with skin. Do not take internally. Serious injury may result if these cautions are not followed.

f. Direct Reading (DR) Ferrograph.

(1) Press the on/off switch on the rear of the DR unit to the on position. At this time the “INSERT TUBE LED” lights, and both windows display 0.0. This is a standby state during which the DR warms up. NOTE: The DR should be turned on at least 30 minutes before testing is begun.

(2) Heat the sample oil to approximately 149° F (65° C) and vigorously shake the sample in the original

container until all sediment is hom*ogeneously suspended in the oil. (3) Turn the drain pump knob so that the white indicators line up.

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(4) Using the dispenser assembly on the fixer reagent bottle, pump exactly 2 ml of fixer reagent/solvent

into a new test vial.

(5) Using a pipette dispenser, add exactly 1 ml of sample lubricant to the same test vial and mix thoroughly.

(6) Place the vial in the holder and prepare the DR for testing by:

(a) Remove the precipitator tube from its shipping bag. (b) Carefully raise the clamp assembly and place the glass section of the precipitator tube in the

groove provided. Be sure not to touch the glass tube with your fingers. This could interfere with zeroing the instrument (see paragraph (9)). As you slide the tube in, note the small lever at the rear as you position the tube (you will hear a slight click).

(c) When the precipitator tube is correctly positioned the “INSERT TUBE LED” goes off and the

“PRIME LED” lights: Gently lower the clamp to lock the tube into position on the magnet. (d) Place the Tygon end of the tube on the inlet nipple. (e) Run the opposite length of the tube around the tube guide at the left of the DR. It fits behind

a lip. (f) Run the tube through the two spring supports up to the sample vial. It is better to have the

excess length near the vial and a relative length down to the guide. (g) Place the opposite end of the tube into the vial. This should touch the bottom of the vial so

that the entire sample will be drawn out during the test. (h) Make sure that the waste bottle is placed in the well, and place the drain tube permanently

attached to the outlet nipple into the waste bottle.

(7) Confirm that the “INSERT TUBE LED” is off, and that the “PRIME LED” is on. If the opposite occurs, readjust the precipitator tube against the actuator arm.

(8) Press the PRIME pushbutton. This action causes the PRIME LED to go off and both the DL ZERO

and DS ZERO LEDS to come on for approximately 2 seconds (at this time the DR circuitry automatically zeros on the empty precipitator tube). When zeroing is complete, the DS LED goes off, and only the DL LED is on, indicating the DR is functioning correctly.

(9) Create a suction in the precipitator tube by slowly turning the drain pump knob in a clockwise

direction. This action draws the mixed fluid from the sample vial. When the fluid level is drawn at a level below the sample vial, the siphoning action takes over, and the oil flows by itself. Stop turning when the white line on the knob lines up with the other line of the DR. When the fluid passes the second light path in the test area, the auto-zero sequence is initiated. Again, both the DL and DS LEDS are on. When the DR has zeroed on the sample, the 2 LEDS go off; the windows display 0.0; and the RUN LED lights. This indicates that the test is in progress and typically requires about 5 minutes to complete. As the solution flows over the test area, the display increments from 0.0, indicating that residual wear particles are dropping into the 2 light paths. When the liquid stops flowing, record the readings.

(10) Turn the drain pump knob slowly in a clockwise direction after all the oil has passed over the test

area. This action empties the pumping system into the waste bottle. (11) Remove the precipitator tube from the test area.

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(12) Discard the precipitator tube, sample vial, and pipette tip before doing another test.

g. Ferrogram preparation. There are three different methods of preparing ferrogams; the standard method,

the fast method that employs the older model Analytical Ferrograph, and the new method that employs the newer model FMIII. h. The Standard Method.

(1) Remove the Ferrogram substrate from the sealed bag and protective envelope.

CAUTION

Avoid touching the surface of the substrate with the fingers. Always handle the substrate by the edge.

(2) Install the substrate in the substrate-holding fixture by retracting the spring-loaded positioning pin and inserting the substrate into the holding fixture as far as possible. When positioning the substrate, make sure that the black dot appears in the lower left-hand corner.

(3) Remove the turret tube from the sealed bag and cut one end at a 45 degree angle. This will

become the exit end of the tubing. (4) Press the exit end of the turret tube with the 45 degree angle facing the operator into the delivery

arm holding groove. Notice the index mark on the delivery arm and observe the distance from the index mark to the end of the arm. Now extend the turret tube an equal distance beyond the end of the delivery arm.

(5) Press the turret tube into the exit notch on the downstream side of the pump. (6) Release the pump turret arm locking screw by turning the knurled nut counterclockwise. Open the

pump turret arms, thread the tube around the turret and then partially close the turret arms. (7) Press the turret tube into the pump entry tube clamp on the upstream side of the pump and secure

it by turning the knurled eccentric clamp lever counterclockwise. Tighten the turret arms. (8) Inspect the drain tube to make sure no sections of it are liquid filled. Draw out any liquid with a

cotton swab. (9) Insert the drain tube into the drain tube holder and rotate the drain tube holding fixture

counterclockwise until it is centered on the substrate. (10) Lower the notched end of the drain tube until the tip touches the substrate. (11) Prepare the sample by first heating it to 149°F (65°C) and then shaking vigorously until all sediment

is hom*ogeneously suspended in the oil. (12) Discharge 5 ml of fixer reagent into a sample vial (to be used as a wash), and place the vial in the

rack slot nearest the magnet assembly. (13) Discharge 1 ml of fixer reagent into a second sample vial and place it in one of the empty vial rack

slots. Add 3 ml of oil sample to the vial containing 1 ml of fixer reagent and mix thoroughly. This can be done with a mechanical shaker or by hand if care is taken to cover the mouth of the vial with a non-contaminating material or stopper.

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(14) Place the sample vial back into the rack. Because of the influence of the field strength of the

magnet, place the vial containing the sample mixture in the position farthest away from the magnet assembly. (15) Install the spring clip assembly on the oil sample vial.

(16) Insert the suction end of the turret tube into the bottom of the sample vial and press the tube into the spring clip.

(17) Lower the delivery arm until the exit end of the tube touches the substrate. Then, back off the

delivery arm approximately 1 mm so that the liquid does not drip, but flows freely onto the substrate. (18) Place the power switch to the ON position, set the timer to 15 minutes, and depress the red timer

START button to start the sample cycle. (19) When the sample vial is empty, reset the timer to 10 minutes and depress the red timer START

button to start the wash cycle. (20) Remove the spring clip and turret tube from the empty vial and transfer both to the vial containing

the fixer reagent wash solution. (21) Introduce three air gaps into the flow in the turret tube by removing the end of the turret tube

momentarily from the wash solution and then reinserting it back into the solution. This prevents the oil from diffusing back into the wash solution.

(22) Immediately after the pump shuts off, lift the turret tube off of the ferrogram by raising the delivery

arm. (23) When flow through the drain tube has stopped (approximately 1 minute) lift the drain tube holder

with the drain tube in it, and rotate it 90 degrees clockwise. (24) Allow sufficient time for the ferrogram to dry; do not remove the ferrogram until all of the fixer

reagent has evaporated. (25) Release the spring-loaded positioning pin and lift the ferrogram up vertically.

CAUTION

Do not drag the ferrogram across the magnet as this could disturb the particles on the ferrogram. (26) Label the ferrogram and ferrogram cover with the component serial number and sample number.

This can be done using typewriter correction tape or a glass marking pen. (27) Discard the turret tube and the sample and fixer reagent vials.

i. The Fast Method. (1) Measure 5 ml of sample and place into a 16x150 mm test tube. Add approximately 7 ml of fixer

reagent/solvent and shake until thoroughly mixed.

(2) Follow steps (3) through (4) of the Standard Method above.

(a) Follow step (2) from the standard method above.

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(b) Cut a 4” long piece of Tygon tubing, a 2” long piece of turret tubing, and an 8” piece of turret

tubing. Cut the ends of the turret tubing at a 45° angle to the axis of the tubing. Insert an end of each piece of turret tubing into the Tygon tubing. Place the 2” long piece of turret tubing into the delivery arm with the 45° angle open end facing the operator.

(c) Follow step (4) from the standard method above.

(3) The sample and rinse vials are supported 3 ½ inches above the peristaltic pump. The pump itself is

not used. The free end of the turret tubing is inserted into the sample vial, supported by a double-notched stopper (one notch for the turret tube and one to equalize the air pressure).

(4) A screw clamp is placed on the Tygon tubing section. A slight suction is applied at the delivery arm

end of the tubing and the clamp is loosened long enough to allow the sample to flow halfway through the tube. The clamp is tightened, the suction removed, and the delivery arm is lowered until the exit end of the turret tube touches the substrate. The delivery arm is then backed off slightly.

(5) The clamp is initially released very slowly allowing the sample to establish a path down the

substrate. Once the path is established, the sample is allowed to flow at a faster rate. When the volume in the sample vial reaches approximately ¼ inch, the tube is clamped and the end of the turret tube is placed in the rinse vial. The clamp is then released and the substrate rinsed with the fixer solution. Allow several air gaps in the turret tube by opening and closing the clamp several times. This will ensure that the oil does not back up into the rinse.

(6) Follow steps (25) through (27) for the Standard Method above.

j. New Method (FMIII). Automatic Cycle: The automatic cycle button initiates the flow of liquid across the

ferrogram at a controlled rate and will automatically switch to a rinse cycle and a drying cycle to give you a properly prepared ferrogram. Machine set up instructions and the semi-automatic and fixer cycles are described in the manufacturers users manual.

NOTE

The instructions provided below describe the processing of a single sample. The design of the FMIII provides the ability to process two samples simultaneously if desired.

(1) Using the dispenser assembly on the fixer reagent bottle, pump exactly 1 ml of fixer reagent into a

new test vial. (2) After heating the sample to 149°F (65°C), using a pipette dispenser, remove slightly more than 1ml

of sample lubricant from a sample bottle. (3) Add exactly 1 ml of sample lubricant to the same sample vial. (4) Repeat steps (2) and (3) until you have a total of 3 ml of sample lubricant in the sample vial. (5) Mix these solutions thoroughly. (6) Place the sample vial under the sample head assembly and seal it into position by pushing the

bottom of the vial into the detente. Swing the delivery arm/sensor assembly outward over the magnet assembly cover.

(7) Place the notched end of the FMIII sample tube through the sample head assembly all the way to

the bottom of the vial.

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(8) Place the other end of the FMIII sample tube through the delivery arm/sensor assembly until the

sample tube bottoms out onto the surface of the magnet assembly cover. This will properly locate the right height for the FMIIII sample tube when being placed into operating position.

(9) Unpack a glass substrate from its protective envelope.

(10) are fully holding the substrate by the edges, place the entry end of the substrate on the lip of the

magnet assembly cutout with the exit end resting on the vacuum drain assembly (the exit end is defined by the black dot).

NOTE

The black dot viewed on the left hand side indicates the substrate is in the proper position for sample lubricant to flow down the non-wetting barrier.

(11) Push down the vacuum drain assembly into operating position. (12) Swing the delivery arm/sensor assembly over the glass substrate and center it by the detente for

proper position. (13) Press the auto cycle button. This action causes the SEMI-AUTOMATIC CYCLE LED switch to go

off and the SAMPLE LED to go on initiating the pumping action in the sample vial. Soon the sample lubricant will go through the sample tube and deposit wear debris on the glass substrate with the excessive fluid and fumes being vacuumed away by the vacuum drain assembly. Once all the sample fluid is gone indicated by our sensor, the pumping action will still occur removing any residual sample lubricant for about two minutes. The FIXER LED will come on indicating fixer is now washing the glass substrate for about 8 minutes.

NOTE

The delay time and fixer cycle can be adjusted. See manufacturers users manual. Afterwards, the fixer wash will stop and the vacuum drain will still be on, removing any residual fixer and fumes until the ferrogram is dry. The COMPLETE CYCLE LED and the sound of beeper indicate this.

(14) Check to make sure that the ferrogram is dry by swinging the delivery arm/sensor assembly

outward, and visually inspecting the ferrogram for any remaining fixer. (15) Carefully pull the vacuum drain assembly upwards. Position your fingers so that you are controlling the ferrogram by the edges and carefully lift straight up.

NOTE

Do not move ferrogram side-to-side near the magnetic field. This may relocate the wear debris and give misleading information.

(16) Place the ferrogram into its protective envelope and mark with the component serial number and sample numbers.

(17) Remove the FMIII sample tubing and the sample vial from the FMIII and discard them.

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k. Evaluation. At this point the ferrogram is ready for optical examination using the Ferroscope

operating instructions for the Ferroscope are found in the manufacturers users manual. The sample has already been determined to be suspect based on spectrometric results and DR readings. The evaluation process then is primarily concerned with determining the size, shape, and type of wear being generated. Techniques and guidelines for the ferrogram evaluation process are found in the Wear Particle Atlas prepared for the Advanced Technology Office, Support Equipment Engineering Department, Naval Air Engineering Center, Lakehurst, NJ. A copy of the Wear Particle Atlas is furnished with each ferrograph system.

l. Recording Results. The results are recorded on the ferrograph worksheet (Appendix O) and filed by

component serial number along with the substrate. Worksheets and substrates will be kept on file for a minimum of 1 year.

m. Ferrography is performed on aeronautical fine filtration equipped components or when units report debris

found during routine inspection. Also, if abnormal wear particle analysis readings are obtained from the oil sample then further testing is required.

n. Oil analysis of the servicing oil is the first step in the analysis process using the atomic emission

spectrometer wear particle readings that are noted on the component historical record. The second step is to prepare a ferrogram for which the oil has been pre-heated to 60 degrees Centigrade, using a pipette and dispenser to withdraw 1 ml of the component’s oil sample, which is then diluted, with 1 ml of Fixer oil. Using a 100 ml glass vial, shake vigorously. Procedures for Direct Read (DR) III instrument are prescribed in the instrument’s manual. Enter the component results on the DR Analysis Report Register Appendix ‘O’ and the unit’s submitted DD Form 2026/DA Form 5991-E, Oil Analysis Request. The component analysis results from the spectrometric and AR analysis readings are used to determine if further ferrographic tests are necessary. If no further ferrographic test is deemed necessary, evaluation is based on spectrometric and physical property test results.

5-4. Fourier Transform Infrared (FT-IR) Analysis. a. Scope. FT-IR or Fourier transform infrared spectroscopy is an analytical measurement method used to

characterize and identify the structure and relative quantity of organic lubricant molecules. The FT-IR can detect water, fuel, anti-freeze, by-products formation (oxidation, nitration, sulfates), foreign fluid contamination, lubricant breakdown and additive depletion.

b. Summary of Method. Oil is drawn by vacuum into a transmission cell that is transparent to infrared (IR)

light. As the infrared light beam is transmitted through the cell, the oil and its contaminants absorb some of the light; the remaining light exits to a detector producing an infrared transmission spectrum. The instrument software creates an absorption spectrum to classify specific and repeatable peaks corresponding to the molecular bonding characteristics of the oil. This software extracts information for each lubricant.

c. Equipment/Apparatus. The BIO-RAD Oil Analyzer is currently used for FT-IR analyses in the JOAP.

Refer to the BIO-RAD Oil Analyzer Operator’s Manual and the Win-IR Software Quick Reference Guide for operation and maintenance of the FT-IR spectrometer.

d. Materials.

(1) Wash beaker with wash solvent (n-heptanes or hexane) (2) Wash bottle with wash solvent (3) Waste beaker

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e. Standards/Standardization/Calibration. Use the calibration function in the oil analysis mode to check alignment, voltages, cleanliness, water vapor, and cell path-length. The software will issue warnings for any parameter out of limit. If any function is beyond preset limits, instrument operation cannot continue until the condition is corrected.

Following are the recommended Win-IR timing parameters for oil analyzers with and without the auto sampler:

AUTOSAMPLER SPECIFIC PARAMETERS

Maximum Load Time (seconds) 90

Wash Time (seconds) 12

Drying Time (seconds) 20

Fill-to-Scan Delay Time 0

Maximum Retries 2

Consistent Loads 2

Auto start Wash/Dry 0

GENERAL PARAMETERS

Number of Scans 20

Rescan Background (Minutes 2

Right Monitor Window (Wave numbers) 3000

Left Monitor Window (Wave numbers) 1500

Start Scanning at Absorbance 1.4

Valid Sample (Absorbance) 2.1

Cell Clean (Absorbance) 3

Background Clean (Absorbance) 2 f. Operation/Procedures. The sample is taken directly from the sample container. The JOAP FTIR-instruments running all versions of the BIO-RAD Win-IR software are configured to run 10 analysis methods that correspond to different oil classes and/or oil applications with different limits. The methods are listed below:

Method Name Lubricant Type (example)

Run_All_Test Unknown Petroleum_Ground Diesel Crankcase (Mil-L-2104) Synthetic_Turbine Polyol Ester (Mil-L-23699) Syn-Ground_Hyd Ground Equipment Synthetic Hydraulic (Mil-H-6083)

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Syn_Ground_Hyd (M1) Fire Retardant Hydraulic (Mil-H-46170) Petroleum_Hydraulic (10W) Ground Equipment Petroleum Hydraulic (Mil-L-2104, 10W) Syn_Aero_Hyd Aircraft Hydraulic (Mil-H-83282) Mil-L-17331 Steam Turbine (Mil-L-17331) Mil-L-9000 Marine Diesel Crankcase (Mil-L-9000) Syn_Aero_Hyd (350) Aircraft Hydraulic (Mil-H-83282, 350 PPM limit for water)

The Petroleum Diesel Engine Oil FT-IR method is called “petroleum ground”. It is designed primarily for analyzing Mil-L-2104 type lubricants. Many diesel engine lubricants and some gear oils (Mil-L- 2105) and transmission oils fit this application. Polyalphaolefins (PAO) and synthetic/petroleum blends should be analyzed using this method. A similar method is used to analyze marine diesel crank case Mil-L-9000 fluid but with different limits. The Gas Turbine Oil FT-IR method is called “synthetic_turbine”. This method is designed primarily for Mil-L-23699, Mil-L-7808 and DoD-L-85734 type lubricants. These lubricants are polyol esters. Listed below are the methods developed for hydraulic fluids along with the primary fluid and examples of equipment use:

Method Name Primary Fluid Equipment Example

Syn-Ground_Hyd Mil-H-6083 M109 A6 Syn_Ground_Hyd (M1) Mil-H-46170 M1A1 Petroleum_Hydraulic (10W) Mil-L-2104, 10W M578, 113A3 Syn_Aero_Hyd Mil-H-83282 Helicopter hydraulic systems Mil-L-17331 Mil-l-17331 Steam Turbine Syn_Aero_Hyd (350) Mil-H-83282 UH60 hydraulic systems

(1) Turn on the instrument and allow it to warm up for 30 minutes.

(2) Open the Win-IR software, the default screen is the “Used Oil” User Mode.

(3) Calibrate the instrument at the beginning of each work day/shift. (Note: The pump must be running to calibrate. This is to remove any oil/solvent that may have run back into the cell.) Press “Calibrate”. The system will check the calibration, alignment, cell cleanliness, take a background, ensure background integrity, and measure the cell path-length. Once completed, the screen will display the results. The following is a typical screen display.

Calculated Cell Path-length: _______ (typically 0.1mm, range 0.09 to 0.14mm)

Signal voltage: _______ (typically -6 volts, range -5 to -7 volts)

Alignment Quality: _______ (typically 15%, range 10% to 50%)

CH Absorbance Intensity: _______ (typically less than 0.2, range 0 to 0.2) Results should be within the limits specified. Keep a log of these results. If the cell is dirty, a message will appear: “Warning - Cell Requires Cleaning!” Clean cell and “Calibrate” again. If problems continue to occur, check with the supervisor. See “Operator Mode Error Messages and Actions” in the Bio-Rad Oil Analyzer Operator’s Guide for the Hardware and Software for other problems. (4) After internal calibration, click on “OK”. The original User screen returns. Now click on

“Analyze”. A final check of the cell will be made and then the “Sample Information Entry Form” appears.

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Laboratory ID Number: _ _ _ _ _

TEC:_ _ _ _

Component Model #: Undefined

Component Serial Number: _ _ _ _ _ _ _ _ _ _ _

End Item: Undefined

End Item Serial Number: _ _ _ _ _ _ _ _ _

Fluid Type: Undefined

Time Since Fluid Change: _ _ _ _

Check Info Cancel Fill in the items with the spaces by clicking on them or press the Tab key to move down the screen. Do not press Enter. The other items will auto-fill when “Check Info” is pressed (if the TEC code is valid.) If the TEC is unknown, type YYYY for the TEC. A screen will occur asking you to chose the correct lubricant type e.g. synthetic aeronautical. If known, arrow down to the correct fluid and hit Enter. If unknown, the “scan and search” may be chosen. In this mode, the FT-IR scan will be performed. After the scan, a library of spectra will be searched to find the best match. The name of the lubricant matched will be given on the report along with the quality of the match presented as a percentage. (5) The “Sample Information Entry Form” screen will re-display once. “Check Info” is pressed, with

an extra button “Analyze Sample”:

Check Info Analyze Sample Cancel

Check all the entered information against the sample submission one more time, then either use the mouse to click on the “Analyze Sample” button or just hit Return. The system will now wait for the sample to appear in the cell.

(6) Load the sample cell by pressing the pump rocker switch to the right position, marked FILL/RINSE,

place the sample bottle under the sample probe (tubing) such that the end is completely immersed below the level of the oil sample.

When the cell is filled, the system will “Beep” twice and the message “Stop Pumping” will appear. (Or

stop when oil exits the bottom tubing.) NOTE: For aeronautical synthetic lubricants with low viscosity, release the pressure on the pump or keep the sample probe in the oil sample bottle. The backpressure on the pump will continue to sip the oil through even though the pump is turned off.

(7) Allow the FT-IR to collect data. The number of scans will count down in the bottom right hand corner of the screen and the name of the sample will appear at the top of the screen. Once the system has acquired and signal averaged the spectrum, a message “Please Empty Cell” will appear.

(8) Press the rocker pump switch to the left “EMPTY” position. Hold the waste beaker under the

sample probe. Once the cell is empty, the system will “Beep” twice and the message “Please Clean Cell” will occur.

(9) Rinse the sample probe with solvent from the wash bottle while still holding the waste beaker

underneath.

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(10) Now press the rocker pump switch to the right “FILL/RINSE” position. Rinse the sample probe (tubing) with wash solvent and pull the solvent through the system. Continue rinsing until the solvent exiting the bottom tubing appears clean. Leave the pump running to pull air through the system. The solvent should be exiting into a waste container. NOTE: Viscous fluids e.g. ground equipment, will clean faster and easier with an air/solvent mixture to “scrub” the walls of the tubing rather than just plain solvent.

(11) Observe the display in the bottom left corner of the screen and continue the cleaning process until

the displayed absorbance is less than 0.30. The system will continuously check the cell cleanliness. Once clean, the system will return to the “Sample Information Entry” screen.

(12) Repeat steps (6) through (11) for additional samples. (13) Shut down the system by clicking the button labeled “Cancel” in the “Sample Information Entry”

screen.

(14) Release the pressure on the pump tubing to extend the tubing life.

(15) Shut off the pump (center position). The screen will go blank after 10 minutes.

(16) Do not turn off power to the FT-IR. The heat from the system will assist in keeping the internal KBr beam splitter from fogging and extend the life of the desiccant.

g. Safety Precautions. The solvent, N-heptane, is flammable. Store in a flammable locker and dispose of

the oil/solvent waste according to local regulations. (N-heptane is a petroleum distillate.) Gloves and lab coat should be worn, especially for any oil spill cleanup.

5-5. Fuel Dilution Determination in Used Lubricating Oils. a. Scope. This method covers the determination of oil dilution by diesel fuel or gasoline in engines and is to

be conducted when screening tests indicate the presence of fuel contamination. Two methods are available for determining fuel dilution, the flashpoint method and the fuel sniffer method.

b. Summary of Methods.

(1) The Setaflash Tester low/high temperature, closed cup models, is used to determine fuel dilution of

used lubricating oils in diesel or gasoline fueled engines by measuring flashpoint depression.

(2) The Fuel Sniffer measures fuel dilution by using a surface acoustic wave sensor to determine the percent fuel in the sample by analyzing the air in the top of the sample bottle.

c. Equipment/Apparatus/Materials.

(1) Flashpoint method

Setaflash Testers. One of the following is used, depending on oil tested.

(a) Model 01SF Lo Temperature, closed cup, used for measuring fuel dilution in lubricating oils of gasoline engines.

(b) Model 03SF, Hi Temperature, closed cup, used for measuring fuel dilution in lubricating oils

of diesel engines.

(2) Fuel Sniffer, manufactured by Spectro, Inc.

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d. Standards/Standardization/Calibration. Prepare calibration standards of diesel fuel or gasoline in

MIL-L-2104 (OE 30 weight) or in MIL-L-9000 (grade 9250) oil at concentrations of 0, 5.0, and 10.0 percent by volume. Fuel standards should be made of the same fuel available to the majority of customers of the oil lab. Standards should be prepared a minimum of once each month and stored in tightly capped glass bottles.

e. Preparation of Sample. No special sample preparation is required; however, particulate matter should be

allowed to settle as much as possible and syringe needle should be immersed in top part of sample in an effort to prevent syringe plugging from large particulates.

f. Operating Instructions.

(1) Setaflash method

NOTE

Detailed instructions are also found in ASTM Test Method D-3828.

(a) Filling Gas Supply System. It is recommended that the Setaflash tester be connected to the

laboratory gas supply wherever possible.

SAFETY NOTE

Connection to the laboratory gas supply must NOT be made with flexible tubing. Connect ONLY with stainless steel or copper tubing and permanent attachments.

(b) The following applies only when liquefied petroleum gas (LPG) must be used.

1. Fully charge the tank ONLY when the instrument is at ambient temperature. Do not

recharge the tester tank with the pilot test jet lit nor in the vicinity of any ignition source.

CAUTION

The Setaflash Tester contains LPG which may present a safety hazard unless directions are followed explicitly.

2. Shake the container of LPG to make sure it contains fuel. If empty, it will exhaust the

remaining fuel from the Setaflash tester integral tank. Hold the cylinder with the valve nozzle straight down. The valve nozzle requires an adapter that is supplied with the container. Do not twist or bend the nozzle on the cylinder as this may damage its main valve.

3. Press the nozzle firmly into the valve of the Setaflash integral tank. A hissing sound

indicates that fuel is entering the tank. 4. When the tank is full, a spray-back occurs. Remove the container from the tank valve

immediately. 5. Wipe off excess fuel from the tank or adjacent areas with absorbent paper. 6. Regular laboratory gas may be used with an adapter - SEE SAFETY NOTE ABOVE.

(c) Determination of flashpoint by FLASH/NO FLASH method.

1. Inspect sample well and lid/shutter for cleanliness, and freedom from contamination.

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2. Switch instrument to SUPPLY. 3. Turn the temperature dial fully clockwise causing the RED signal light to glow. 4. When the thermometer reads approximately 295°F (140°C), slowly return the

temperature dial to the point at which the signal light is just extinguished. 5. The sample well temperature is stable when the signal light slowly cycles ON/OFF.

Slight adjustments may be necessary to obtain precise temperature. Numbered divisions are used as a guide to temperature settings.

6. Charge the syringe with 4 ml of sample, transfer to the filling orifice, taking care not to

lose any sample. 7. Set the timer by rotating the knob clockwise to its fullest extent. DO NOT FORCE

AGAINST THE STOP. 8. Meanwhile, open the gas control valve and light the pilot/test flame. Adjust the test

flame size with the pinch valve to match the 4mm dial gauge ring. 9. When the time has elapsed, slowly and uniformly open and close the slide completely

over a period of 2 ½ seconds - watch for flash at 300°F (150°C). Report results as less than or more than 300°F (150°C) as applicable.

10. Close the Gas Control Valve. 11. To prepare for the next test, unlock the lid and shutter assembly. Lift to hinge stop.

Soak up sample with tissues to remove any traces of contamination (if necessary use moistened tissues). Allow the sample well to cool below 212°F (100°C) before using moistened tissue. Clean the underside of the lid and filling orifice. A pipe cleaner may be of assistance in cleaning the orifice.

12. Any further cleaning necessary may be carried out by complete removal of the lid and

shutter assembly. To remove this, disconnect the silicon rubber gas tube and slide the assembly to the right. Unscrewing the retaining nut by hand and removing the plunger assembly should also clean the syringe.

(2) Fuel Sniffer

(a) Scope. The Fuel Sniffer offers a new capability for engine condition monitoring. It can be used in the laboratory or in the field to give rapid and accurate measurements of fuel contamination in engine oils. The Fuel Sniffer is a non-destructive test that requires only a small oil sample. The results of the analysis are reported in percent dilution.

(b) Summary of Method. Oil samples should be collected in glass or plastic bottles. The

quantity of oil collected should be a representative sample and at least 25 ml. The sample should remain capped and properly labeled before use. It is important that the type of fuel being used in the engine is noted, as this will affect the calibration standard used. The Fuel Sniffer is menu driven. Interaction with the Fuel Sniffer software, LCD and sample inlet is accomplished through the control panel. The sample inlet is a 1/8-inch Swagelok compression fitting. The tubing that connects the Fuel Sniffer to the sample bottle attaches at this location using a 1/8-inch Swagelok nut provided on the tubing assembly. Turn clockwise to attach the tubing.

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CAUTION

Do not over-tighten. The fluid is drawn into the unit, and a measurement of percent fuel from 0 to 10% is provided.

(c) Equipment/Apparatus/Materials. Spectro, Inc manufactures the Fuel Sniffer. They can be

reached at:

Spectro, Inc., 160 Ayer Road, Littleton, MA. Ph (978) 486-0123, Facsimile (978) 486-0030, e-mail: [emailprotected]

Fuel Sniffer Specifications

Dimensions: 9 cm x 20 cm x 28 cm (3.5" x 8" x 11")

Weight: 2.7 Kg (6 pounds)

External Power: 85 to 265 VAC, 47 to 440 Hz

Sensor: SAW Chemical Microprocessor

Display: LCD, with LED backlight

Serial Output: RS232C @ 9600 Baud

Measurement Range: 0 to 10% fuel dilution

Measurement Time: 60 seconds

Accuracy: +/- 0.2%

Data Log Memory: 500 measurements

The Fuel Sniffer is designed for general-purpose laboratory use. The Fuel Sniffer is not designed for use in areas containing explosive atmospheres and should not be operated in these environments. It is recommended that a clean and dedicated circuit be provided in an earth ground configuration to power the Fuel Sniffer. A 110 or 220V power cord is supplied for this purpose.

CAUTION

Always connect the IEC plug into the back of the Fuel Sniffer before plugging into the main power source.

(d) Standards/Standardization/Calibration. To perform a calibration of the Fuel Sniffer, a calibration standard must be prepared. It is recommended to calibrate the Fuel Sniffer on a daily basis to ensure accurate results. The Fuel Sniffer requires only one reference calibration point due to the SAW sensor linear response. The standard concentration must be prepared at the 5% level, which is the midpoint of the dynamic range. The Fuel Sniffer does not allow the user to use any other value. If any other level of dilution is used above or below this standard, the instrument will either over or under estimate actual readings respectively.

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WARNING WARNING

The oil sample bottle should be approximately ¾ full. Do not fill the sample bottle to the top. There must be a headspace between the sample and the top of the bottle for a proper measurement and to avoid the possibility of contaminating and damaging the Fuel Sniffer’s sensor with the sample.

The oil sample bottle should be approximately ¾ full. Do not fill the sample bottle to the top. There must be a headspace between the sample and the top of the bottle for a proper measurement and to avoid the possibility of contaminating and damaging the Fuel Sniffer’s sensor with the sample.

NOTE NOTE To ensure a representative calibration sample, the standard should be mixed and allowed to equilibrate for at least one hour for diesel fuel and at least four hours for more volatile gasoline fuel or jet fuel. To ensure a representative calibration sample, the standard should be mixed and allowed to equilibrate for at least one hour for diesel fuel and at least four hours for more volatile gasoline fuel or jet fuel.

CAUTIONCAUTION

Using a standard immediately after preparation will cause the instrument to under report values.

The flask should remain uncapped during the equilibration period to ensure a representative calibration sample. This is done to “off gas” the light end hydrocarbons that are present in fresh fuel samples. This is consistent with an actual engine oil sample, since it would have been exposed to heat during operation that drives off the light end gases. Hence using a standard immediately after preparation will cause the instrument to under report actual measured values because the light end gases have been included in the standard calibration. The following sequences of LCD screens illustrate the calibrate fuel dilution mode. The sample bottle clamp and seal must be connected by way of the sample tube to the “Sample Connect” before starting a measurement. By pressing the start button, the analysis cycle will begin, and the red calibrate LED will illuminate. CALIBRATE FUEL DILUTION PRESS START OR ⇓⇑ CALIBRATE FUEL DILUTION CALIB, IN PROGRESS, WAIT CALIBRATION SATISFACTORY PRESS SELECT TO CONTINUE Upon a successful calibration, the calibrate LED will turn off and the user must press “Select” to return to the main menu choices.

(e) Operation/Procedures. Basic operation is covered here. Please refer to the manufacturer’s

manual for more detailed information concerning theory of operation, accessories, data transfer, parts, maintenance, and troubleshooting.

1. Software Overview. The Fuel Sniffer is a menu driven instrument. The LCD display

presents a series of menus, which allow operation of the instrument. The software prompts the user through each step to make a successful measurement analysis. There are four pushbuttons on the front panel, “Select”, “Down Arrow”, “Up Arrow”, and “Start” which are used to input information. Each menu function is discussed in detail.

2. Start-Up Screens. Upon power up, the LCD will indicate the following displays: MICROSENSOR SYSTEMS INC. FDM METER VERSION 3.1.5

AUTOTEST UNDERWAY PLEASE WAIT

AUTOTEST SATISFACTORY PRESS SELECT TO CONTINUE

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Upon successful completion of the power-up, the Fuel Sniffer will respond with a series of five tones and the front panel LED’S will each flash from top left to bottom right sequence with each audible tone. By pressing the “Select” button, the Fuel Sniffer will respond with the following main operating menu.

PROGRAM SELECTION PRESS ⇓⇑ FOR MENU

By pressing either “arrow” button, the Fuel Sniffer will display the menu selections. The primary Fuel Sniffer menus are below.

MEASURE FUEL DILUTION PRESS START OR ⇓⇑ CALIBRATE FUEL DILUTION PRESS START OR ⇓⇑ TRANSFER DATA TO OUTPUT PRESS START OR ⇓⇑

SET TIME AND DATE PRESS START OR ⇓⇑

3. Measuring fuel dilution.

a. Basic information. This mode allows the measurement of fuel dilution in oil samples. The results are reported in percent fuel dilution on the LCD. Each sample analysis requires 60 seconds to complete. The Fuel Sniffer must be in position on its stand with the sample inlet tubing connected to the tubing connector on the control panel. The Fuel Sniffer should be allowed to warm up and stabilize for at least 15 minutes after the power On/Off toggle switch has been turned to On.

b. Procedure. Loosen the two screws that hold the sample bottle diameter

adjustment bar and reposition so that the sample bottle is centered on the platform. Tighten the screws to hold the bar in position. Set the sample platform to the correct height by loosening the two captive adjustment screws. Set the table so that the sample bottle just clears the bottom of the sample cover with the sample bottle lever in the up position (towards the Fuel Sniffer). Tighten the adjustment screws. Place the sample bottle in position on the sample table. Move the sample bottle lever into the down (towards the operator) position. There should be some resistance as the lever is moved into the down position such that the sample bottle will be locked in place.

c. Analysis start. By pressing the start button, the analysis cycle will begin and the

green measure LED will illuminate. The Fuel Sniffer will begin a pumping sequence to first purge the headspace, then reverse flow pulling the headspace sample into the detector and then reversing the flow purging the detector expelling the sample in preparation for the next measurement.

d. Results. The results will be reported in percent fuel dilution over the calibrated

range of 0 to 10%. The user must acknowledge the result and push “Select” to begin the next measurement cycle. The following sequences of LCD screens illustrate the measure fuel dilution mode.

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MEASURE FUEL DILUTION PRESS START OR ⇓⇑ MEASURE FUEL DILUTION MEAS. IN PROGRESS, WAIT 0.0% FUEL DILUTION PRESS SELECT TO CONTINUE MEASURE FUEL DILUTION PRESS START OR ⇓⇑

Please refer to the complete Spectro, Inc. “System Description and Operations Manual” which comes with each unit or is available through e-mail by request from the JOAP-TSC at: [emailprotected]

The information contained in this manual was included with the permission of Spectro, Inc. 5-6. Microscopic Analysis

a. Scope. This method covers the microscopic examination of debris filtered from suspect spectrometric oil samples to determine the significance of debris with respect to wear, contamination, and component condition. Currently, this method is applicable to all US Army aircraft but may be specified for use on other equipment by the appropriate service oil analysis program manager. A precise methodology for the characterization and classification and the importance or implications of results of insoluble debris analysis has not been established.

b. Summary of Method. A measured quantity of the suspect oil sample is mixed with solvent and filtered

through a 0.45-micrometer membrane filter. The insoluble debris and filter membrane are carefully rinsed with solvent to remove oil and then allowed to air dry. The dry membrane is transferred to a petri slide and the debris examined under a low-power microscope. The debris observed are characterized and related to the component’s condition with respect to wear and contamination.

c. Definitions.

(1) Suspect Oil Sample. An oil sample from equipment for which one or more of the following diagnostic

indicators are observed: chip-light, vibration, metal on screens or filter, oil of unusual color, odor, or solids contents, and oil having an abnormal spectrometric trend or level.

(2) Insoluble Debris. Refers to insoluble solid materials filtered from suspect oil samples that may

consist of wear debris, corrosion products, and non-metallic debris generated by the component, or contaminants from external sources.

d. Equipment/Apparatus/Materials.

(1) Millipore Filtering Equipment Set.

(2) Microscopic Equipment Set (3) Solvent. Biotek Hisolv or other high flash solvent is used as the solvent depending on local

availability. Before use, the solvent shall be filtered through a 0.45-micrometer membrane filter.

e. Operation/Procedures.

(1) Loosen the cap on the suspect oil sample bottle and place the bottle in an oven at 65± 5 °C (149° ± 9 °F) for 30 minutes. (2) Prepare the vacuum filtering apparatus by installing a 0.45 micron membrane filter and start vacuum.

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(3) Remove the warm sample from the oven, tightly cap, and shake vigorously. Pour 10 ml of the

sample into a 100 ml graduated cylinder with a stopper. Add 90 ml of pre-filtered solvent, install stopper and mix well.

(4) With the vacuum still applied, carefully remove the spring clamp and upper section of the filter funnel

carefully wash the edges of the filter membrane with a gentle stream of solvent using care not to wash debris off the filter membrane. Continue wash until membrane and debris are free of oil. Allow the membrane to dry. Transfer the membrane to a petri slide.

(5) Inspect the debris using the microscope, identify the metal or alloy and record the findings. 5-7. Particle Counter Testing

a. Scope. The information concerning hydraulic fluid testing contained in this section is applicable to aircraft and other equipment hydraulic systems using MIL-H-5606, MIL-H-83282 and MIL-H-46170 hydraulic fluid. These instructions may require modifications, including sample dilution for equipment using higher viscosity hydraulic fluids. During normal operation, hydraulic systems may become contaminated with metallic and nonmetallic particles. Particulate contamination may result from internal wear, failure of system components,or incorrect maintenance and servicing operations. Hydraulic system contamination analysis provides a method of determining the particulate contamination level of a hydraulic system and detecting the presence of free water or other foreign substances.

b. Summary of Methods.

(1) The two primary methods of analyzing hydraulic fluids currently in service use are the patch test method, using the Contamination Analysis Kit P/N 571-414 (08071) and the automatic electronic particle counting method, using electronic particle counters such as the HIAC 8000 Contamination Test Center. Both the HIAC 8000 Contamination Test Center and the Contamination Analysis Kit P/N 571-414 (08071) have been approved for Navy fleet use and may be authorized for Army and Air Force use by proper authority.

(2) Due to differences in their basic method of operation, test results obtained using automatic particle

counters and the Contamination Analysis Kit P/N 571-414 (08071) may not always be in precise agreement. Although both pieces of equipment are authorized for use and either may be utilized, it is important that the reasons for differing test results be fully understood.

(3) Automatic particle counters optically sense particles contained in the fluid sample and electronically

size and count them. Most particle counters are calibrated so that the smallest particle counted will have an effective diameter of 5 microns. Particles smaller than 5 microns, although always present, will not affect the particle count.

(4) The contamination Analysis kit, P/N 571-414, uses a patch test method in which the fluid sample is

filtered through a test filter membrane, causing it to discolor proportional to the particulate level. The test filters used have a filtration rating of 5 microns absolute however, they will also retain a large percentage of those particles less than 5 microns in size. The contamination standards provided with the contamination analysis kit are representative of test indications that will result if the fluid sample has a particle size distribution (number of particles versus size) typical of that found in the average military aircraft. Samples from aircraft having typical particle size distributions will, therefore, show good correlation if tested using both particle count and patch test methods.

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(5) Some operating hydraulic systems may, as a result of peculiar design characteristics, produce a

particle size distribution different from that normally found in typical aircraft. Fluid samples from this equipment generally contain an abnormally large amount of silt-like particles smaller than 5 microns in size. Experience has shown this condition is usually the result of inadequate system filtration or the use of hydraulic components having abnormally high wear rates. It is fluid samples of this type that may produce different results when tested using both particle counting and patch test methods. The differing test results are caused by the particle counter not counting those particles smaller than 5 microns, whereas many of them will be retained by the patch test filter membrane and cause it to discolor a proportional amount.

(6) When conflicting test results are encountered due to the reasons discussed, the equipment tested

shall be considered unacceptable if it fails either test method. The equipment should then be subjected to decontamination. It is important to recognize, however, that the differing test results may be indicative of system deficiencies and justification for requesting an engineering investigation of the equipment. Poor correlation between particle counts and patch tests can also result from improper sample taking procedures, incorrect particle counter calibration, or faulty test procedure. These possibilities must be carefully investigated should a correlation problem be encountered.

c. HIAC Contamination Test Center, Model 8000 is approved for use in accordance with NAVAIR 01-1A-17.

Operators of this equipment are required to have copies of operators manuals furnished with the equipment. NAVAIR 17-20SX-146 provides calibration procedures for the HIAC Contamination Test Center. Periodic calibration is required in accordance with NAVAIR 01-1A-17 or after repairs which could affect the calibration (see operators manual, calibration procedures).

d. Colormetric Patch testing using the Contamination Analysis Kit P/N 571-414. The Contamination Analysis

Kit, P/N 571-414 (08071), is the principal equipment currently used for determining contamination levels in military aircraft hydraulic systems and hydraulic ground support test and servicing equipment. The contamination analysis kit equipment employs a “Patch Test” method in which a hydraulic fluid sample of known volume is filtered through a filter membrane of known porosity. All particulate matter in excess of a size determined by the filter characteristics is retained on the surface of the membrane, causing it to discolor an amount proportional to the particulate level of the fluid sample. Refer to NAVAIR 17-15E-52 and NAVAIR 01-1A-17 for additional information concerning the contamination analysis kit.

5-8.Viscosity Measurements of Used Lubricating Oils a. Nametre Method.

(1) Scope. This method is used by the Army and is performed on all non-aeronautical engine,

transmission, and hydraulic samples. (2) Summary of Method. Used oil samples are allowed to stabilize at room temperature. The

viscometer’s transducer tip is then immersed in the sample to the level indicating line, and when the reading stabilizes, the viscosity is read directly from the digital readout panel. The used lubricant quality is then determined by comparison with viscosity guidelines for lubricants of the same type and grade or results from the analysis of the first sample after oil change for the specific item of equipment.

(3) Equipment/Apparatus/Materials.

(a) Viscometer, Nametre Model 7.006 Direct Readout Viscometer. (b) Thermometer, ASTM 28F.

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(4) Standards/Standardization.

(a) Standards required for viscometer calibration and daily standardization checks are:

Cannon Standard Number Nominal Viscosity at 771 °F (250 °C)

S-6 6.75 centipoises x g/cm3

S-60 93.40 centipoises x g/cm3

S-200 430.00 centipoises x g/cm3

They are available from Cannon Instrument Co., P.O. Box 16, 2139 High Tech Road, State College, PA 16804-0016; phone numbers are 1-800-676-6232 or 1-814-353-8000.

(b) On receipt of standards, the laboratory shall provide the Joint Oil Analysis Program

Technical Support Center (JOAP-TSC) with information from the standard bottle label. The JOAP-TSC will then provide the laboratory with a table of viscosity values expected for that particular standard at a range of temperatures.

CAUTION

The transducer tip is a sensitive and delicate device and should be treated with care. The tip should be cleaned with soft absorbent paper between determinations and with a standard safety; solvent after the final measurement is made.

(5) Calibration.

(a) When the viscometer is in use, it will be calibrated daily using Cannon S-6, S-60, and S-

200 standards. A quotient index (QI) shall be calculated by dividing the measured value for the standard by the table value for the standard at room temperature. If the Q1 is between 0.95 and 1.05, no adjustment is required for that standard; if not, the instrument requires calibration.

(b) Separate daily calibration logs for each standard shall be maintained by the laboratory. The

room temperature, measured value, table value, QI, and date of analysis shall be entered on these logs. (c) Standardization Check. Once the viscometer is calibrated, only standardization checks are

required throughout the day. When the viscometer is unused for a portion of the day or when switching between different weight oils, a sample of the Cannon standard with the viscosity that most nearly matches that of the samples to be analyzed shall be analyzed to verify that the viscometer is still calibrated correctly. If the QI for the standardization check sample is out of limits, the viscometer must be recalibrate.

(d) Preparation of Sample. Sample should be at room temperature 75° ± 2°F or 24° ± 1°C).

Agitate the sample of used oil in the original container until all sediment is hom*ogeneously suspended in the oil. Make sure all air bubbles caused by agitation have been removed from the sample before making the viscosity measurement.

(e) Analysis. Immerse transducer tip in oil up to the line on the sheath. When the digital

readout stabilizes, record the viscosity in centipoises xg/cm3.

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(f) Guidelines. Table 5-1 shows the viscosity guideline limits for various grades of used MIL-L-

2104 lubricating oils. Samples with viscosities below the minimum guidelines require testing for flash mint for fuel dilution. Samples with viscosities above the maximum guidelines require blotter and water testing.

TABLE 5-1. VISCOSITY GUIDELINES FOR MIL-L-2104 LUBRICATING OIL

Nm Units: Centipoises Xg/cm3

Temp, Grade 10 Grade 30 Grade 50* Grade 15W-40

°F Nm Min Nm Max Nm Min N Max Nm Min Nm Max Nm Min Nm Max

65 108 307 124 349 296 845 141 344

66 105 299 121 341 289 824 136 333

67 103 292 119 333 282 803 133 321

68 100 284 116 325 276 783 129 311

69 98 277 114 318 270 764 125 300

70 96 270 112 311 263 745 121 290

71 94 263 109 304 257 726 118 281

72 91 256 107 297 251 708 115 272

73 89 250 105 290 245 691 111 263

74 87 244 102 283 240 673 108 254

75 85 238 100 277 234 657 105 246

76 83 232 98 271 229 640 103 238

77 81 226 96 264 223 624 100 231

78 79 220 94 258 218 609 97 224

79 77 214 92 253 213 594 94 217

80 75 209 90 247 208 579 92 210

81 74 204 88 241 203 565 89 204

82 72 199 86 236 198 551 87 197

83 70 194 84 230 194 537 85 191

84 69 189 83 225 189 524 83 186

85 67 184 81 220 185 511 81 180

86 65 179 79 215 181 498 78 175

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87 64 175 78 210 176 486 76 170

88 62 170 76 205 172 473 75 165

89 61 166 74 201 168 462 73 160

90 60 162 73 196 164 450 71 155

91 58 158 71 192 161 439 69 151

92 57 154 70 187 157 428 67 147

93 55 150 68 183 153 418 66 143

94 54 146 67 179 150 407 64 138

95 53 142 65 175 146 397 63 135

96 52 139 64 171 143 387 61 131

97 50 135 63 167 139 378 60 127

98 49 132 61 163 136 368 68 124

99 48 128 60 159 133 359 57 120

100 47 125 59 156 130 350 56 117

* Grade 50 oil is being phased out of the DoD inventory and is being replaced with Grade 15W40.

b. Brookfield Method using Small Sample Adapter with #18 spindle (see paragraph c. below for operation without the Small Sample Adapter).

(1) Scope. This method is used by the US Navy and is performed on various non-aeronautical equipment fluid samples.

(2) Summary of Method. The Syncro-Lectric Viscometer is a rotational viscometer which measures

torque necessary to overcome the immersed element, which is a spindle attached to a beryllium copper spring. The degree to which the spring is wound is proportional to the viscosity of the fluid at the test temperature for any given speed and spindle.

(3) Apparatus. Viscometer, Brookfield Syncro-Lectric-Models LVF, LVDV-E, LVDV-1+, LVDV-2+, small

sample adapter with the #18 spindle, and water bath capable of temperatures between 10 degrees Celsius and 60 degrees Celsius.

(4) Standards. The standard recommended for viscometer calibration, Fluid #50, is available from

Brookfield Engineering Labs, Inc., 11 Commerce Blvd., Middleboro, Massachusetts, 02346, U.S.A., 800-628-8139.

(5) Procedure

(a) Assemble the Model A laboratory stand. Place the upright rod into the base (refer to assembly instructions in the manufacturer’s manual). The rack gear and clamp assembly should face the front of the base. The upright rod is held in place with the jam nut, which is attached from the bottom of the base. Tighten this nut with a suitable wrench. Attach leveling feet.

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(b) Insert the mounting handle on the back of the viscometer into the hole on the clamp assembly. Be sure that the clamp screw is loose.

(c) Tighten the clamp screw. Adjust the viscometer to be as close to level as possible while tightening the clamp screw.

(d) Level the viscometer. The level is adjusted using the three leveling screws on the base. Adjust so that the bubble level on top of the viscometer is centered within the circle. Check level periodically during use.

(e) Ensure water bath is filled to the level recommended by the manufacturer.

(f) Connect the tubing from the water bath to the inlet and outlet connectors on the water jacket of the small sample adapter.

(g) Adjust the water bath temperature.

(6) Instrument Start-up. (LVDV-E, LVDV-1+, LVDV-2+)

NOTE

Before a reading can be taken, the viscometer must be auto-zeroed. This action is performed each time the power switch is turned on. The display window on the viscometer displays a guide through the procedure.

(a) Turn the power switch (located on the rear panel) to the ON position. This will result in the

following screen display:

BROOKFIELD RV VISCOMETER

The model type will be displayed in the upper right-hand corner of the screen ( DV-1+, DV-2+, etc.. After a few seconds, the following screen appears:

BROOKFIELD VERSION 5.0

(b) After a short time the viscometer will instruct you to remove the spindle and that any key be

pressed. The viscometer will begin to auto-zero itself.

NOTE Ensure that the viscometer is level before initiating auto-zero.

(c) After the viscometer has completed it’s auto-zeroing, follow the directions to replace the spindle and press any key. Pressing any key at this point will result in the display of the default screen.

CP 0.0 S01 0.0RPM % 0.0

The display will vary slightly depending upon the status of the last spindle entry.

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1. Pressing the SELECT Spindle key will cause the characters on the top line of the display

to begin to blink. 2. By pressing the up or down arrow keys, the characters will start to cycle through the

different types of spindles. When the desired spindle is reached, press the Select Spindle key once again. This will cause the characters to stop blinking and the new spindle will be accepted for use in the viscometer calculations.

(d) Speed Selection can be accomplished by pressing the Select Speed key. Once the key is

depressed, scroll through the different speeds by pressing the Up or Down arrows. Pressing the Select Speed key again after the desired speed was reached will allow the viscometer to accept the new speed for it’s calculations.

(7) Calibration Procedure.

NOTE

The laboratory shall annotate on the viscosity standard bottle a 1-year shelf life, expiration date effective the day the standard is initially opened. At the 1-year expiration date, the laboratory shall discard the outdated standard in accordance with local directives and replace it with a more current one.

(a) Warm up the viscometer in accordance with the Instrument Start-up procedure. (b) Put the proper amount of standard (8 ml) in the sample chamber, allowing the fluid to cover

the spindle with chamber in place. (c) Place the number 18 spindle on the viscometer and attach the extension link, coupling nut,

and free hanging spindle. (d) Ensure the temperature of the water bath is at the temperature at which the standard’s

known viscosity was determined. (e) Place the sample chamber into the water jacket.

CAUTION

The coupling shaft is a left-hand thread, and proper care must be taken in order not to damage the viscometer bearings.

(f) Allow 3 minutes for the viscosity standard, sample chamber and spindle to reach test

temperature. (g) Measure the viscosity and annotate the viscometer’s reading on the QA chart (see Table 5-

2). The factor of the spindle and fluid accuracy determines the total tolerance of the fluid. Table 5-3 provides the various factors for spindles.

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NOTE

Instrument tolerance is equal to spindle factor. If the spindle factor is 10, then the viscometer’s tolerance will be 10.

BROOKFIELD VISCOMETER QUALITY ASSURANCE CHART

DATE TEMPERATURE VISCOMETER MODEL MANUFACTURER: BROOKFIELD PART NUMBER LOT NUMBER CERTIFIED VISCOSITY EXPIRATION DATE: ( 1 YEAR AFTER OPENING)

SPINDLE LV 1

RPM FACTOR

% TORQUE

MIN ACCEPT

ACTUAL READING IN Cp

MAX ACCEPT

INTRUMENT ACCURACY

FLUID ACCURACY

TOTAL TOLERANCE

30 2 12 5 6 10

SPINDLE LV 2

RPM FACTOR

% TORQUE

MIN ACCEPT

ACTUAL READING IN Cp

MAX ACCEPT

INTRUMENT ACCURACY

FLUID ACCURACY

TOTAL TOLERANCE

30 10 12 25 6 50

SPINDLE 18

RPM FACTOR

% TORQUE

MIN ACCEPT

ACTUAL READING IN Cp

MAX ACCEPT

INTRUMENT ACCURACY

FLUID ACCURACY

TOTAL TOLERANCE

30 1 12 2.5 6 5

TABLE 5-2

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SPINDLE FACTOR

SPINDLE NUMBER

RPM 18 LV1 LV2 LV3 LV4

60 0.5 1 5 20 100

30 1 2 10 40 200

12 2.5 5 25 100 500

6 5 10 50 200 1M

3 10 20 100 400 2M

1.5 20 40 200 800 4M

0.6 50 100 500 2M 10M

0.3 100 200 1M 4M 20M

TABLE 5-3

Example: Spindle factor for spindle 18 at 30 rpm is 1 and fluid accuracy is +/- 1% of the known viscosity (for Standard at 45 centipoise, fluid accuracy is +/- .45 cp). Total tolerance would equal +/- 4.5 cp of standards known viscosity. ( 1 + .45 = 1.45 )

CAUTION

The spindle must rotate at least five (5) times before readings are taken.

(8) Sample Procedure.

(a) Preparation of Sample. Agitate the used oil sample in the original container until all sediment

is hom*ogeneously suspended in the oil. NOTE Ensure that the viscometer speed is at 12 rpm for all testing. (b) Warm up the viscometer in accordance with the Instrument Start-up procedure. (c) Put the proper amount of used oil (8 ml) in the small sample chamber, which will allow the

spindle to be completely immersed in the oil. (d) Put the number 18 spindle in the used oil and attach the extension link, coupling nut and free

hanging spindle. (e) Adjust water bath temperature to 104 degrees Fahrenheit. (f) Allow 3 minutes for the viscosity standard, sample chamber and spindle to reach test

temperature. (g) Place the sample chamber in the water jacket.

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CAUTION

Protect alignment by taking care to avoid putting side thrust on the shaft.

(h) Measure the viscosity and record the viscometer reading.

NOTE

On LVF model viscometers, multiply the dial reading by the spindle factor to obtain the centipoises of the fluid. Centipoise = dial reading * spindle factor

355cp = 35 (DR) * 10 (SF)

CAUTION

The spindle must rotate at least five (5) times and torque value must be above 10% before readings can be taken.

(i) If desired, convert centipoise to centistokes by dividing by specific gravity:

Centistokes = Centipoise/Specific Gravity

The average specific gravity of in-service diesel lubricating oil is approximately 0.92; synthetic gas turbine oil is 1.0. Refer to TABLE 5-4 below for the specific gravity of various oils used.

SPECIFIC GRAVITY OIL TYPE

0.92 MIL-L-9000G MS-9250

0.880 MIL-L-17331 MS-2190 TEP

1.0 MIL-L-23699

0.880 MS- 2075TH

0.863 MS-2110TH

0.867 MS-2135TH

0.859 MIL-H-5606

0.834 MIL-H-83282

1.40 MIL-H-19457 FYRQUEL

TABLE 5-4

(9) Cleaning. Clean the small sample chamber with cleaning solvent and wipe dry with a non-abrasive cloth.

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CAUTION

Electron should be used with adequate ventilation. Prolonged breathing of vapors should be avoided. The solvent should not be used near open flame or heat, as the products of decomposition are toxic and very irritating.

NOTE

The black insulating bottom of the sample chamber should not be exposed to strong solvents such as methanol, toluene, ammonia, and 111-trichloroethylene. Do not totally immerse the chamber in any cleaning solution. Improper cleaning may result in separation of the black insulation from the chamber.

c. Brookfield Method without Small Sample Adapter.

(1) Scope. This method is used by the US Navy and is performed on various non-aeronautical equipment fluid samples. (2) Summary of Method. The Syncro-Lectric Viscometer is a rotational viscometer which measures the

torque necessary to overcome the immersed element, which is a spindle attached to a beryllium copper spring. The degree to which the spring is wound is proportional to the viscosity of the fluid at the test temperature for any given speed and spindle. (3) Apparatus. Viscometer, Brookfield Syncro-Lectric-Models LVF, LVDV-E, LVDV-1+, LVDV-2+, Small

Sample Adapter with the #1 and 2 spindle, 100 ml beaker, oven and a digital thermometer capable of temperature ranges between –40 to 250 degrees Fahrenheit. (4) Standards. The standard recommended for viscometer calibration, Fluid #50, is available from

Brookfield Engineering Labs, Inc., 11 Commerce Blvd., Middleboro, Massachusetts, 02346, U.S.A., 800-628-8139. (5) Procedure

(a) To assemble the Model A laboratory stand, place the upright rod into the base (refer to

assembly instructions in manufacturer’s manual). The rack gear and clamp assembly should face the front of the base. The upright rod is held in place with the jam nut, which is attached from the bottom of the base. Tighten this nut with a suitable wrench. Attach the leveling feet.

(b) Insert the mounting handle on the back of the viscometer into the hole on the clamp

assembly. Be sure that the clamp screw is loose. (c) Tighten the clamp screw. Adjust the viscometer to be as close to level as possible while

tightening the clamp screw. (d) Level the viscometer. The level is adjusted using the three leveling screws on the base.

Adjust so that the bubble level on top of the viscometer is centered within the circle. Check level periodically during use.

NOTE

Before a reading can be taken, the viscometer must be auto-zeroed. This action is performed each time the power switch is turned on. The display window on the viscometer displays a guide for the procedure. Refer to Paragraph 5-8.b. (6) for complete instructions.

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(6) Calibration Procedure.

NOTE

The laboratory shall annotate on the viscosity standard bottle a 1-year shelf life, expiration date effective the day the standard is initially opened. At the 1-year expiration date, the laboratory shall discard the outdated standard in accordance with local regulations and replace it with a more current one.

(a) Warm up the viscometer in accordance with the Instrument Start-up procedure. (b) Place the number 1 or 2 spindle on the viscometer. In order to use the smaller beaker, the

spindle guard cannot be used. Take care not to bump the spindle.

CAUTION

The coupling shaft is a left-hand thread, and proper care must be taken in order not to damage the viscometer bearings.

(c) Put the proper amount of standard in a 100 ml beaker allowing the fluid to reach the groove

imbedded on the spindle. (d) Allow the fluid to reach the temperature at which the standard’s known viscosity was

determined. (e) Measure the viscosity and annotate the viscometer’s reading on the QA chart (Table 5-2).

The factor of the spindle and fluid accuracy determines the total tolerance of the fluid. Table 5-3 shows the various factors for spindles.Example: Spindle factor for spindle 18 at 30 rpm is 1 and fluid accuracy is +/- 1% of the known viscosity (for Standard at 45 centipoise, fluid accuracy is +/- .45 cp). Total tolerance would equal +/- 5.5 cp of standards known viscosity ( 1 + .45 = 1.45 ).

CAUTION

The spindle must rotate at least five (5) times before readings are taken.

(7) Sample Procedure

(a) Warm up the viscometer in accordance with the Instrument Start-up procedure.

(b) Place the number 1 or 2 spindle on the viscometer. To determine the proper spindle, a known range of viscosity should be determined for the fluid (see TABLE 5-5).

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NOTE

Ensure the spindle speed is set at 60 RPM.

SPINDLE RANGE

LV-1 15-20K

LV-2 50-100K

SCV4-18 1.2-30K

TABLE 5-5

CAUTION

The coupling shaft is a left-hand thread, and proper care must be taken in order not to damage the viscometer bearings.

(c) Put the proper amount of used oil with in the container, allowing the fluid to reach the groove

imbedded on the spindle.

(d) Place the sample in the oven and allow the fluid to reach 104 degrees Fahrenheit. (e) Measure the viscosity and annotate the viscometer’s reading.

CAUTION

The spindle must rotate at least five (5) times before readings are taken.

(f) Convert centipoise to centistokes by dividing by specific gravity, and record the viscosity of

the sample.

NOTE

On LVF model viscometers, multiply the dial reading by the spindle factor to obtain the centipoises of the fluid.

Centipoise = dial reading * spindle factor 355cp = 35 (DR) * 10 (SF) Centistoke= Centipoise/Specific Gravity

The average specific gravity of in-service diesel lubricating oil is approximately 0.92; synthetic gas turbine oil is 1.0. Refer to TABLE 5-4 for the specific gravity of various oils used.

(8) Cleaning. Clean the spindle with cleaning solvent and wipe dry with a non-abrasive cloth.

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CAUTION

Electron should be used with adequate ventilation. Prolonged breathing of vapors should be avoided. The solvent should not be used near open flame or heat, as the products of decomposition are toxic and very irritating.

5-9 Water Contamination Tests a Crackle Test

(1) Scope of Test: The crackle-test is a simple test used to identify the presence of free and emulsified

water that is suspended in oil. Water contamination refers to the presence of free water in used lubricating oils, and is usually performed on non-aeronautical samples. The crackle test indicates whether water is present. If the exact amount of water is desired, the Karl Fischer test for water shall be conducted.

(2) Equipment/Apparatus/Materials:

(a) Hot Plate thermostatically controlled. (Shall be explosion proof, variable temperature for use onboard ships)

(b) (Thermolyne, Model Number HP11515B, NSN 6640-01-125-3765 or equivalent) (c) Thermometer, Surface (PTC Instruments, Direct Contact Spot Check Model 572FM (Basic

Thermometer with magnet and leaf spring, Open purchase, Phone #: 310-312-0826, http://wwww.ptc1.com) (d) Oil dropper tube or lab syringe

(3) Applicable Standards: None

(4) Summary of Method: Water held in suspension by emulsifiers becomes audible (crackles) and visible as

bubbles and steam when drops of oil are place on a heated surface of 300 deg F. (a) The method is non-quantitative. (b) Hot plate temperatures above 300 degrees F induce rapid scintillation that may be undetectable. (c) The method does not measure the presence of chemically dissolved water.

(5) Safety Considerations:

(a) Protective eyewear is suggested. (b) Long sleeves are suggested. (c) Testing must be performed in a well-ventilated area or inside of a fume hood.

WARNING

Persons performing test must wear protective goggles and clothing and avoid direct contact with hot

plate surface.

(6) Interferences: (a) Refrigerants and other low boiling-point suspensions may interfere. (b) Different base stocks, viscosities, and additives will exhibit varying results. (c) Certain synthetics, such as esters, may not produce scintillation.

b Operation/Procedures:

(1) Achieve surface temperature on a hot plate of 300 degrees F (135 degrees C). Always use the same temperature.

(2) Violently agitate oil sample to achieve hom*ogenous suspension of water in oil. (3) Using a clean dropper, place a drop of oil on the hot plate. (4) Observe the drop of oil:

(a) Record the reaction as positive (1), meaning bubbles were present; or negative (0), meaning bubbles were not present.

c Applicable Standards: None

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b. Karl Fischer Water Test (KF) With the Aquatest 2010

(1) Scope. Karl Fisher (KF) titration is an accurate method of measuring moisture that utilizes the

quantitative reaction of water with iodine, which can be measured electrolytically at the anode. One molecule of iodine reacts quantitatively with one molecule of water. Consequently, 1 mg of water is equivalent to 10.71 coulombs. Based on this principle, the water content in the sample can be determined by the quantity of electricity required for the electrolysis.

(2) Summary of Method. After the instrument is prepared for use, operation is accomplished in three

quick steps: 1) depress the FILE key and verify all the parameters are set in accordance with Table 5-3 and the weight of oil being tested. (2) introduce a measured quantity of sample; and (3) wait for the results of the sample to be displayed and/or printed with the amount of moisture present.

(3) Equipment/Apparatus/Materials.

(a) Aquatest 2010

Manufacturer:

Photovolt Instruments Inc. 6325 Cambridge St. Suite 3 Minneapolis, MN 55416 Phone: (800) 222-5711

(b) Syringes. Ten milliliter capacity syringes are used for replacing titrator solutions and one

microliter or ten microliter syringes are used for sample induction with a 4 ½ inch needle.

(4) Preparation of Sample. No special sample preparation is required; however, particulate matter should be allowed to settle as much as possible and syringe needle should be immersed in top portion of sample in an effort to prevent syringe plugging from large particles.

(5) Operation/Procedures. Aquatest 2010 analysis for detection of water in oil.

(a) Proper Use.

1. Do not use this product for any purpose other than for which it was intended. 2. When storing or moving the instruments refer to operating manual for proper storing of

this equipment.

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3. Use only those accessories recommended by the manufacturer in order to avoid risk of

fire, shock, or other hazards 4. Unplug all equipment exposed to rain, moisture, or strong impact and have the

instrument inspected by qualified service technician before use. 5. Disconnect all equipment from the line power source during a lightning storm or before

leaving unused for extended periods of time. 6. Unplug all equipment before cleaning. Then use a clean, dry, chemically untreated

cotton cloth to wipe the unit. Use no cleaning fluids, aerosols or forced air that could over spray or soak into the unit and cause electrical shock.

(b) Setting up for operation.

1. The AQUATEST 2010 has Type T line voltage fuses in series with the power supply. These fuses are located on the rear panel. To replace the fuses, unplug the line cord and remove the fuse cover from the power-input module. Remove the fuse/selector cover. Do not remove or change the setting of the voltage selector. Pull out each fuse drawer and replace both fuses with two of the identical rating. Always change both fuses.

IMPORTANT NOTE The AQUA TEST 2010 is shipped without fuses installed. Prior to applying power, verify that the appropriate fuses are installed and that the voltage selection switch is set to the correct voltage.

WARNING

For protection against fire, replace both fuses with two of identical rating. Refer to Table 5-6 for proper fuse ratings for the selected voltage.

Voltage Rating Fuse Description

100/115 Type T, 0.4 amp. 250V, Slow Blow UL Listed 220/240 Type T, 0.2 amp 250V, Slow Blow IEC Approved

Table 5-6

2. The AQUATEST 2010 is designed to operate at nominal line voltages of

100/115/220/240 VAC, depending upon the setting of the voltage selection switch located on the back of the instrument. The red notch on the voltage selection switch indicates the selected operating voltage. To change the voltage, first unplug the line cord. Open the fuse drawer and check the fuse ratings compared to the desired voltage setting. Change the fuses if necessary. If the voltage is being changed from 110/115V to 220/240V or 220/240V to 110/115V, the fuses must be changed. Both fuses must be replaced together.

3. Using a flat bladed screwdriver, move the rotary dial so that the new voltage is

indicated on the switch.

(c) Assembling the Titration Cell. The titration cell for the AQUATEST 2010 consists of a titration vessel, generator cartridge, sensing electrode, injection port, vent tube, stir bar, and gas port stopper. The titration cell is assembled as follows:

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IMPORTANT NOTE Before assembling the titration cell, all part must be properly lubricated with Photo volt Sealant to prevent seizing of parts to the generator vessel.

1. Place the stir bar into the vessel. 2. Lubricate the ground glass portion of the sensing electrode and insert into the proper

port on vessel. 3. Place a septum inside the 2-pice injection port assembly and gently tighten the

threaded portions. 4. Lubricate the ground glass portion of the gas port stopper and the rounded sides of

the sample injection port. 5. The injection port can occupy one of two positions on the titration vessel. Select the

preferred position for the injection port and insert the stopper into the remaining port. 6. Fill the vent tube with silica gel desiccant. A plug of glass wool may be used under

and over the desiccant. Lubricate the slotted stopper and the ground glass joint at the bottom of the tube. Insert the vent tube into the proper port on the vessel. Insert the slotted stopper into the vent tube.

NOTE

The silica gel desiccant must be replaced periodically. If the blue indicating beads are no longer blue through more than 50% of the tube, replace the desiccant.

7. Remove the generator cartridge from the packing. Remove the foam insert.

Lubricate the solid stopper and ground glass joint on the body of the generator. Assemble the pieces and insert into the proper port on the vessel.

WARNING

Proper personal protective equipment (PPE) should be used with all hazardous chemicals. Refer to the MSDS for the hazards involved with each chemical being used.

(d) Filling the vessel with KF Reagents. Selection of reagents is an important factor in the

overall performance of a coulometric titration. Photovolt provides reagents designed to provide optimal performance in the analysis of the wide variety of materials. Photovolt Pyridine Free KF Reagent is the most popular reagent currently in use. Pyridine is replaced by a proprietary amine, which has a reduced odor and toxicity compared to pyridine.

WARNING

Dispose of Karl Fischer reagents, solvents and cleaning solutions in a proper manner. Refer to the MSDS sheets for the chemicals to identify chemical hazards. Follow all applicable regulations regarding disposal of chemical waste.

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1. Remove the stopper from the gas tube port of the vessel and pour approximately 150

ml of Photovolt Coulometric KF vessel solution into the cell using a large polyethylene funnel supplied. Replace the stopper.

NOTE

Take care to avoid getting water into the vessel when filling with the reagents. Make sure the vessel is free from water.

2. Remove the stopper from the top of the generator. 3. Carefully crack the top off one 5 ml ampoule of Photovolt Coulometric KF generator

solution. 4. Pour the full contents of the ampoule into the generator using the small polyethylene

funnel supplied with the reagent. 5. Replace the stopper.

NOTE

For best results, maintain the level of the solution in the generator well below the level of the solution in the vessel.

6. Set the slide lever on the left side of the instrument approximately half way through

its range to achieve a moderate rate of stirring. Avoid setting the lever to high to reduce “tumbling”. This action could damage the electrode.

7. When facing the AQUATEST 2010, connect the sensing electrode to the BNC connector on the right denoted by the letter D for detector. Connect the generator to the BNC connector on the left denoted by the letter G for generator.

(e) Achieving Set Point. Generally, after filling the vessel with solution, the AQUATEST

2010 will need to be equilibrated before beginning analysis of samples or standards. This process is referred to as “bringing to set point.” In most cases, the AQUATEST 2010 will come to set point in less than 10 minutes. The exact amount of time required for the process, generally depends upon how “wet” the vessel solution is during filling. A very small amount of water present in the vessel, before the addition of reagent, can add a great deal of time to the process. For this reason, it is best to ensure that the components of the vessel are reasonably free of moisture before assemble.

WARNING

The AQUA TEST 2010 sensing electrode can be damaged by exposure to high heat. DO NOT place the sensing electrode in an oven.

1. Turn on the power switch. The following message should be displayed:

###### S T B Y

Where the # # are present indicates potential.

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NOTE

If the potential shows a negative value, this indicates that the vessel solution contains a large amount of free iodine. Excess iodine may be present in the vessel solution as a result of the reagent manufacturing process. If this is observed, add approximately 2 uL of pure water until the potential becomes positive.

2. Press the [STANDBY] key. The display indicates the titration rate (ug H2O/sec),

current demand sign (*), status and total moisture, for example:

12 . 5 * WET 765 .8 ug

After titration of residual moisture from filling the vessel with the solutions, the titration stops, the beeper will sound three times and the following will be displayed:

END

After a few seconds and if the background is above 0.1 ug H2O/sec., the display will read:

RDY

If the background is below 0.1 ug H2O/sec., the display will read:

DRY

If the indicated titration rate (background) is 0.2 (ug H2O/sec) or higher, moisture is still present or remains on the inner walls of the vessel. In this case press the [STANDBY] key again to stop the electrolysis and set the stirrer speed to zero. Lift the vessel and swirl it gently to mix any moisture in the vessel with the reagent. Do not shake the vessel hard enough to cause the solution to exit through the vent tube. After swirling, replace the titration cell, adjust the stirrer speed, and press [STANDBY] to restart electrolysis. Repeat this procedure a few times if necessary. Again wait for display to indicate [ RDY ].

NOTES

When the titration rate falls below 0.2 (ug H2O/sec), the AQUA TEST 2010 is ready for analysis of most samples or standards. Testing should not be conducted before this. The performance of the AQUA TEST 2010 can be verified through the injection of a small amount of pure water ( 2 ul of pure water injected from a 5 ul syringe is suggested).

(f) Programming the Aquatester for variety of oils. The conditions under which a sample

measurement is performed can be selected through use of the [ FILE ] key. A sequential menu of setting will be displayed by pressing this key. Eight files can be programmed into the AQUATEST 2010 to perform test on a variety of oils.

1. Pressing [FILE] key will give the following display:

FILE#: X

Where X is the number of the presently active analysis file. To begin using a different file for a sample measurement, enter a number from 1 to 8 using the keypad. Press [ESCAPE] if the new file is not to be altered before analyzing a sample. To check the contents of the new file, press the [ENTER] key to display each of the settings. Pressing the [ENTER] key allows viewing of the contents of a file without changing

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them. Entering a number into a field then pressing [ENTER] will change that setting. For a complete list of settings for each type of oil commonly used in the Navy refer to Table 5-7.

A/C Reefer

oils

23699 2190 2135 2110 Mil-h-5606

MIL-H-83282

MIL-H-19456

QA Check

File * * * * * * * * * Delay .2 .2 .2 .2 .2 .2 .2 .2 .2 Min

Time Blank Blank Blank Blank Blank Blank Blank Blank Blank

Stop Time

Blank Blank Blank Blank Blank Blank Blank Blank Blank

End Point

.1 .1 .1 .1 .1 .1 .1 .1 .1

Print Form

2 2 2 2 2 2 2 2 1

Calc Form

3 3 3 3 3 3 3 3 0

Units

1(%) 2 (PPM)

2 (PPM)

1 (%)

1 (%)

1 (%)

1 (%)

1 (%)

Prod

* * * * * * * * *

Test * * * * * * * * *

Blank

Blank Blank Blank Blank Blank Blank Blank Blank Blank

Volume

1

.25 1 1 1 1 1 1

Density 1 1 0.88 0.867 0.863 0.859 0.834 1.4

Table 5-7

*=Any entry 1 to 99 can be entered.

2. Delay. A titration delay time is used when a sample requires an extraction time period

in the vessel solution before it can be analyzed. It is also used to allow time for moisture to be carried into the vessel from the optional vaporizer accessory. After pressing the [START/STOP] key, the titration sequence will not begin until the selected time has elapsed.

3. Min. Time (Minimum Titration Time). The titration will proceed for a minimum time

equal to this value regardless of the status of the sensing electrode circuit. This setting is used in the analysis of samples having only a trace of moisture where the peak moisture value may not exceed the detection threshold of the AQUATEST 2010.

4. Stop Time (Titration Maximum Stop Time). The titration will be forced to stop at the

selected time regardless of the status of the sensing electrode circuit. By bypassing the normal endpoint detection algorithm, this function can be used to terminate a titration at a selected time,. The titration will stop if the detection algorithm senses that all of the moisture has been titrated before the stop time is reached.

5. End Point ( End point Sensitivity). This setting is used to determine the endpoint of

titration through the sensing electrode circuit. The sensitivity is increased. If the endpoint sensitivity is set at zero,

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the AQUATEST 2010 will continue to titrate indefinitely or until the Titration Stop Time is reached or until the Start/Stop key is depressed.

6. Print FRM ( Print Format). There are four different print formats possible for reports generated by the AQUATEST 2010. As the value set for print format increases so does the information that the printout generates. A zero value for print format deactivates the printer and no printout will be generated. To printout a completed history with the average of all samples conducted since last time the test number has been reset to 1, press [MEMORY] and [PRINT] keys.

7. Calc. FRM ( Calculation Report Form). Many calculations can be performed on the

measured data to yield a final concentration value. The selection of calculation format determines how the final value will be calculated. A zero value entered into the calculation format setting forces all data to be presented in total ug H2O only. To get a complete list of Calculation values refer to Manufacturer’s manual. It is recommend that moisture content when a liquid sample is taken by volume. (Calc Form 3).

8. Units. If an appropriate calculation formula is selected for the “ Calc FRM” parameter,

the AQUATEST 2010 will automatically prompt the user for units. Units determine whether the final value will be given in PPM (parts per million) or percent. Depending on the type of oil units 1 and 2 will most commonly be used.

9. Samples. The AQUATEST 2010 can accept and use information about the samples to

be measured. Sample information is entered before starting a titration or after completed a measurement. Press [SAMPLE] key and the following should be displayed:

PROD: X

The product code number can be used to identify the sample being tested. It is printed on the analysis report when print format 2, 3 or 4 is selected. A product code number can be any number between 1 and 9999.

10. Test Number. The AQUATEST 2010 has a memory capacity for up to 99 sample

measurements. The 99 measurements can split in any fashion among a series of product code numbers. Each product code number may have a different number of sample results.

11. Blank. The AQUATEST 2010 will display an upper case “B” when a blank value is to

be entered. The blank value will be subtracted from the final result of moisture test. This is used to compensate for moisture that is introduced into the vessel from sources other than the sample. (For example, when using a cleaning solvent to dissolve a sample, the solvent usually contributes a small amount of moisture that must be subtracted from the final result).

12. Sample Volume. The AQUATEST 2010 will display:

VOLUME:

If liquid volume rather than mass are measured, the AQUATEST 2010 will prompt you to enter a volume in liters. Enter the value using the number keys then press [ENTER].

13. Specific Gravity (Or Density). Density must be entered in order for the AQUATEST

2010 to determine the end result. For a complete list of Navy oil specific gravity refer to Table 5-1 in the physical testing procedure for viscosity.

14. Set Clock. The “set clock” function allows the time and date to be set. Press [OPTION]

key once followed by the right arrow key twice. The following message will be displayed:

SET CLOCK

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Press enter key and the current date will be displayed in the following format:

DATE:YYYY/MM/DD

Use the number keys to change the date. Press the right arrow [>] key to past the slash mark or press the minutes (-) symbol. Press the [ENTER] key to set the value into the instrument clock.

15. Reagent Use. The AQUATEST 2010 maintains a running count of the amount of

water that has reacted with the reagents in the vessel. This count is maintained even when the power is interrupted. The “reagent use” function should be reset each time that the reagents are changed. Press the [OPTION] key once, followed by the right arrow [>] key until the following display:

REAGENT USE

Press the enter key to view the current reagent usage. The display will read:

REAG USE: VVV-GGG

The ( VVV) is the consumption value in mg H2O for the vessel solution and (GGG) is the consumption value of H2O for the generator solution.

a. When replacing both solutions press the [CLEAR] key to reset both values. b. When replacing the vessel solution only. Enter zeros for the digits of the first value

and press the [ENTER ] key. c. When replacing the generator solution only, use the arrow [>] key to the digits of

the second number and enter zeros.

Refer to manufacturer’s specifications for the capacity data of the solutions.

(6) Standards/Standardization/Calibration

(a) A calibration check that verifies the accuracy of titration of the instrument and reagent can be performed, as needed, using de-ionized (DI) water.

(b) Place the Aquatest 2010 in the proper file for Q.C. verification (paragraph f., items 1-15). (c) Setup sample, first press the [SAMPLE] button. Next enter the serial number for the product.

Enter 1 for test and press [ENTER]. (d) Use a 50 micro-liter (ul) syringe. Clean the syringe by drawing 50 ul of test fluid. Discharge

the fluid into a suitable waste container. (e) Draw 50ul test fluid past the 50ul mark on the syringe. Place the needle in the upward

position allowing the bubble to float to the top of syringe chamber. Discharge all air bubbles until fluid has reached the 50ul mark on the syringe.

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NOTE

Do not inject fluid with visible bubbles. Start each injection when the display says that the titration rate is 0.20 or less.

(f) Press start on the Aquatest 2010 and inject 2ul into the generator vessel. Repeat step 3

times for a total 3 injections. NOTE

An injection of 2ul should get a result of 1000 +/- 50ug. If erratic readings occur, replace generator and vessel solution after you place Aqua tester in standby.

(g) Print a data report and average of the 3 injections by pressing the [MEMORY] and then the

[PRINT] button.

(7) Sample testing procedure.

(a) Condition syringe by drawing 1cc of oil into a 5cc syringe (for 23699 samples draw 0.5cc of sample into a 1cc syringe). Discharge oil into a suitable waste container. Repeat step “a” no less than 3 times to flush last oil residue from syringe.

(b) Draw 1.25cc of sample (for 23699 draw 0.5cc) into syringe. Invert syringe and ensure air

bubbles rise to the top of syringe. With syringe inverted depress plunger to the 1cc mark (for 23699 depress to the .25cc mark) to remove air and excess oil. Wipe oil from end of needle.

(c) When the machine displays “RDY” press the “START” button, insert syringe below the

solution level and inject sample. Remove syringe. When test is completed the results will be printed.

(8) Maintenance

(a) The Aquatest 2010 has been designed to provide years of operation under normal laboratory use. The appearance and operation of your Aquatest 2010 can be maintained by providing proper routine care.

1. Spills of reagents or sample on the outer surface of the case should be removed quickly using a slightly damp cloth. In the event of a large spill, immediately unplug the instrument until the excess liquid can be removed.

2. The desiccant in the vent tube should be changed when more than 50% of the blue

indicting beads are no longer blue. 3. The injection port septum should be changed whenever it has been pierced to the

extent that it will no longer maintain a good moisture tight seal. 4. Check the ground glass joints of the titration cell at least once a week by trying to

rotate them. If they do not move smoothly, clean the joint and reseal with sealing grease. 5. When replacing reagents, always lubricate the ground glass joints with sealing

grease.

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6. If the instrument will not be used for an extended period of time (more than 3 to 4

weeks), the solutions should be removed and the titration cell rinsed with methanol. Never allow the reagents to evaporate totally from the titration cell.

(b) Maintaining the printer unit. The printer should be cleaned of paper dust periodically. Use a

soft brush or clean compressed air to remove dust particles from the printer mechanism. Any accumulation of material in the printer housing can be removed with a vacuum.

NOTE

Do not insert sharp objects into the printer unit. Portions of the mechanism may fail to operate properly if they are scratched or cut.

(c) Cleaning the titration cell. The titration cell can be cleaned with methanol or ethanol to

remove waste material. If samples are greasy, exolene, octanol, chloroform, or other solvents can be used as degreasing agents before final cleaning.

WARNING

Proper personal protective equipment (PPE) should be used with all hazardous chemicals. Refer to the MSDS for the hazards involved with each chemical being used.

It is not generally necessary to remove all traces of waste material from the cell. The Coulometric titration method can be used in the presence of many foreign substances. Wiping waste material with a soft paper towel should clean the sensing electrode. It can be rinsed with solvents.

NOTE Never heat the sensing electrode or place it in a drying oven. The sealed glass envelope may crack.

(d) Cleaning and maintaining the generator. Over a period of time, contaminants may

accumulate in the frit of the generator cartridge. Many of the contaminants can be removed by periodically rinsing the frit with dry reagent grade methanol or other solvents. When the contaminants build up to the extent that they begin to impair the performance of the Aquatest 2010, the instrument may display an error message.

(e) Reagents and equipment for cleaning the generator.

1. Alcohols. Methanol or ethanol, reagent grade, should contain a low amount of water.

Alcohols are used to rinse the frit after nitric acid cleaning and water rinsing.

NOTE

Ketones such as acetone, aldehydes and very acidic or basic solvents should not be used to clean the components of the titration vessel. Some of these solvents can interfere with the Karl Fischer reaction when present at elevated levels.

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2. Other solvents. A wide variety of solvents may be used to remove sample build up on

the frit. Oils can best be removed with petroleum solvents – xylenes, toluene, chloroform, methylene chloride, etc. With other samples, the analyst is usually aware of solvents in which their samples are soluble. Use these solvents to remove any build up on the frit. Rinse the frit with water to remove the solvents before cleaning with nitric acid. The frit material and the platinum anode and cathode are relatively inert to most solvents and acids. Strong alkalis should be avoided especially when hot, for they may damage the frit.

3. Nitric acid. ACS reagent grade nitric acid is suggested for thorough cleaning of the frit.

Technical grades can be used if ACS reagent grade is not available. Nitric acid is preferred to other acids and can be obtained from any chemical supply house.

4. Containers for cleaning the generator. Any acid and solvent resistant glassware or

plastic-ware may use. Glass or polyethylene containers are suitable. 5. Vacuum apparatus. Some means of drawing a slight vacuum on the generator

cartridge is necessary. The PHOTOPHOLT titration cell cleaning kit (part number 4091004), is quite useful for providing a sufficient vacuum. A plug for the vent hole is included with the kit.

6. Explosion proof oven. An oven can be used to dry the generator cartridge after rinsing

with alcohol. Maintain the oven at 40-60 degrees Celsius. Use of a drying oven is optional.

(f) Cleaning procedure.

1. The Aquatest 2010 should be in [STANDBY] mode or the power should be turned off before unplugging the generator cartridge from the instrument.

2. Remove the generator cartridge and siphon or pour off the generator solution. 3. Rinse the generator cartridge with methanol followed by clean water to remove any

remaining Karl Fischer solutions. 4. Insert a plug into the vent hole on the generator cartridge if vacuum is to be used to aid

in the cleaning process. 5. Immerse the generator cartridge in a small container of 75% nitric acid and 25% water.

Draw about 5-10 ml of acid into the generator cartridge. It will probably come through the frit very dark brown due to iodine’s and other containments. Discard the darkened acid and draw more acid through the frit until it comes through clear.

6. Replace the acid container with one containing water and repeat the process of

drawing water through the frit. Draw up enough water to completely remove all traces of the nitric acid. 7. Replace the water container with one containing the driest alcohol available (methanol

is preferred) and repeat the process of drawing alcohol through the frit. 8. Place the generator cartridge in an explosion proof oven to dry.

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WARNING

Dispose of Karl Fischer reagents, solvents and cleaning solutions in a proper manner. Refer to the MSDS sheets for the chemicals to identify chemical hazards. Follow all applicable regulations regarding disposal of chemical waste.

c. Distillation Test for Water in Petroleum Products and Bituminous Materials. (ASTM-D95)

(1) Scope. This test method covers the determination of water in petroleum products, tars, and other bituminous materials by the distillation method.

(2) Summary of Method. The material to be tested is heated under reflux with a water-immiscible

solvent, which co-distills with the water in the sample. Condensed solvent and water are continuously separated in a trap, the water settling in the graduated section of the trap and the solvent returning to the still.

(3) Equipment/Apparatus/Materials. The apparatus consists of a glass or metal still, a heater, a reflux

condenser, and a graduated glass trap. For detailed equipment requirements, refer to ASTM-D95, Section 6. (4) Standards/Standardization/Calibration. Standardization of a given assembly of apparatus is

accomplished when accurate readings are obtained from the addition of known amounts of water from a calibrated buret or pipet to a clear hydrocarbon oil, which is then tested in accordance with ASTM-D95, Section 9.

(5) References/Guidelines:

(a) ASTM-D86 Method for Distillation of Petroleum Products.

(b) ASTM-D1796 Test Method for Determination of Water and Sediment in Fuel Oils by the Centrifuge Method (Laboratory Procedure).

(c) ASTM-D4006 Test Method for Water in Crude Oil by Distillation. (d) ASTM-D4007 Test Method for Water and Sediment in Crude Oil bj the Centrifuge Method

(Laboratory Procedure).

(e) ASTM-E123 Specification for Apparatus for Determination of Water by distillation.

d. Pall TD513 Series Water Sensor (1) Scope. This test method covers the determination of the total of dissolved water in hydraulic,

transmission, and electronic cooling system fluids. (2) Summary of Method. The Pall Water Sensor is a small portable device that provides an electronic

display reading of percent dissolved water through the use of in-system, bottle, or dipstick probes.

(3) Equipment/Apparatus/Materials.

(a) Water Sensor (b) Probes

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(c) Battery Charger (d) Isopropyl alcohol is required to clean the probes.

(1) Standards/Standardization/Calibration. A calibration validation procedure is used to ensure that the

unit is operating properly and within calibration tolerances. (2) References/Guidelines: Pall TD513 Water Sensor Manual (3) Quick Use Instructions to monitor fluid water content.

(a) Charge Unit. Plug power adapter into a 110V wall outlet for 24 hours (see battery, page 6 of the manual).

(b) Connect sensor. Attach the sensor to the display cable by rotating the outer ring

clockwise. Measure?

Yes Next (c) Press “PWR” to turn unit “on”.

(d) Press “YES” to accept measurement mode. I.D.# Next Yes No

(e) Press “YES” to continue without entering a sample identification number.

73F H-83282 218

1. Press “FLUID TEMP” to select a different fluid to be measured.

Use PRF-87252? Yes No Next

2. Press “NEXT WATER” to change fluid type.

Fluid Selected 3. Press “YES” to accept the fluid type. or

73F H-83282 218

4. Press “NO” to go back to step (e) without changing the fluid type

Store this data? Yes No

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(f) Press “YES” if proper measurement has been displayed

(g) Press “YES” to save measurement and return to step (c)

Measure? Yes Next

OR

(h) Press “NO” not to save and return to step (c) Measure? Yes No

(i) Press “PWR” to turn unit off.

Note: The Pall Water Sensor information has been included in the JOAP Manual with permission from Pall Aerospace.

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SECTION VI

US NAVY DIELECTRIC COOLANT TESTING 6-1. GENERAL.

a. Introduction. This section provides technical information required for dielectric coolant testing. It includes several individual test methods, which are utilized to perform analysis on coolant fluids, used in Naval aircraft. It is an abbreviated manual for use by trained operators and is not intended to replace applicable equipment manuals, test procedures or training. This manual is required reading for all personnel responsible for the installation, operation or support of the equipments described. This section does not constitute a requirement to collect and submit samples; it provides procedures for laboratory testing.

b. Objective. The primary objective of this section is to provide an abbreviated set of instructions for performing dielectric coolant testing at the intermediate level.

c. Application. This section is applicable to dielectric coolant testing utilized at the intermediate level of maintenance, ashore and afloat. The testing is required for maintenance and support of the F-18 APG-65, and AV-8 radar coolant systems and both the F-14 AWG-9 and AIM-54 coolant systems. The intermediate level dielectric coolant test sets are utilized to perform coolant fluid quality tests on site, at the location of the equipment. Two samples (color coded red and green) are taken at 30 day intervals for Support Equipment (SE), at 56 day intervals for the F-14 and at 84 day intervals for the F-18 and AV-8. Sample red is tested at the intermediate level for moisture, flash point and particle contamination (patch test). If sample red passes all three tests, then sample green will be forwarded to a higher capability laboratory where dielectric breakdown, volume resistivity and particle count tests will be performed. However, if sample red fails either of the three tests specified herein, sample green shall be discarded.

d. Coolant Fluid Contamination. Silicate ester fluids (i.e. Coolanol 25R) are very effective in transferring heat

and providing high voltage insulation. However, they have two undesirable properties: a hygroscopic nature and poor hydrolytic stability. Being hygroscopic, the fluids readily absorb any moisture to which they are exposed, atmospheric moisture included. The lack of hydrolytic stability means that the fluid may combine with water to form undesirable by-products. These by-products include gel-like substances that can adversely affect equipment operation, when deposited in a critical area, and affect the flammability of the fluid itself. The fact that these substances, when present, tend to pick up minute amounts of particulate matter and ionic contaminants further creates a problem, in that their presence can also degrade the electrical insulating properties of the fluid. Coolanol fluid is being replaced by polyalphaolefin (PAO) dielectric coolant fluid, which does not exhibit these properties.

e. Fluid Inspection. Fluid inspection consists of the collection and test of fluid samples obtained from

operating equipments. Inspections are performed in accordance with scheduled requirements and when coolant contamination is otherwise suspected. Fluid samples are collected in specially prepared sample bottles using procedures provided in applicable equipment manuals. Samples are tested utilizing the liquid coolant testing procedures provided in this manual.

f. Coolant Fluid Testing Requirements. Liquid coolant contamination control requirements have been established for all F-18, AV-8, and F-14 aircraft and for support equipment (SE) to assure that fluid is maintained within acceptable limits that will preclude its physical deterioration and to assure satisfactory equipment operation. Most important, there is a requirement for the periodic collection and test of fluid samples from all operating equipment, with tests performed to assure that the following physical properties are within the limits specified:

(1) Water content: Not to exceed 150 parts per million (ppm) in aircraft systems or 100 ppm in SE. Not to exceed 150 ppm in EOTS/CASS (AN/USM-629/AN/USM-636) Coolant Unit Assy (P/N 74D740194-1001).

(2) Flash point: Minimum of 275°F (Cleveland Open Cup).

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(3) Particulate level: Not to exceed Navy Standard Class 5 in aircraft systems or Navy Standard Class

3 in SE. Not to exceed Navy Standard Class 5 in EOTS/CASS (AN/USM-629/AN/USM/636) Coolant Unit Assy (P/N 74D740194-1001.)

g. Coolant Fluid Analysis. Coolant fluid testing is generally accomplished at the depot level utilizing laboratory-type test equipment. The testing described in this manual is intended for utilization at the intermediate level to provide an immediate “Go or No Go” indication. More extensive testing will be accomplished at depot level facilities.

h. Decontamination Procedures. Aircraft or SE found to be unacceptably contaminated are decontaminated

using procedures provided in the applicable maintenance manuals. The procedures vary but the basic technique used is to circulate the contaminated fluid through known serviceable fluid conditioners.

i. Related Publications.

(1) NAVAIR 01-1A-17 Aviation Hydraulics Manual. (2) NAVAIR 17-15E-52 Operation and Intermediate Maintenance with Illustrated Parts Breakdown for Hydraulic Fluid Contamination Kit P/N 57L414. (3) ASTM D-92 Test Method for Flash and Fire Points. (4) ASTM D-1533 Test Method for Water in Insulating Liquids (Karl Fischer Reaction Method).

j. Training Description. All of the tests required for testing coolanol are included in the physical properties portion of the JOAP Operator/Evaluator Training School. 6-2. COOLANT TESTING PROCEDURES.

a. Introduction. This section provides general procedures for testing coolant samples. It is intended to assist the operator by providing procedural information relative to incoming inspection of the sample, sequence of testing, general test requirements and data reporting.

b. Incoming Sample Inspection. The bottles are made of polyethylene plastic and hold 8 fluid ounces when

filled. The bottles are intended for one-time use and are discarded upon completion of the fluid analysis. Provided with each sample bottle is a coolant sample identification label (Figure 6-1). This label, when filled in and attached to the sample bottle, identifies the submitting activity and equipment sample.

c. Visual Inspection

(1) Prior to the sample analysis, the unopened sample bottle shall be visually inspected for proper

filling and sealing, as well as evidence of gross contamination. Properly filled bottles will be almost completely filled with fluid extending up to the bottom of the threaded neck section. The purpose of completely filling the bottle is to minimize the quantity of air present, which could contain large amounts of atmospheric moisture, and to assure that adequate fluid is available to perform all of the required tests. Activities submitting coolant fluid samples in improper or inadequately filled bottles shall be advised to resample the equipment.

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COOLANT IDENTIFICATION LABEL

SAMPLE I.D. (SOURCE, BUNO./SERIAL NO.)

FILL OUT ACCURATELY AND COMPLETELY (CIRCLE ONE)

F-14 AIRCRAFT PGSE AND SE AN/USM 629 F-18 AV-8

AWG9 AIM54 RAIL FAIRING LAU93

LCSU FMU HD 957

DSM 130

APM 446

APG 65

SAMPLING DATE PREVIOUS SAMPLING DATE

AIRCRAFT HOURS OR METER HOURS SUBMITTING ACTIVITY PHONE

NO.

Figure 6-1. Coolant Identification Label

(2) Prior to sample analysis, fluid in the sample bottle shall be visually inspected for evidence of free

water, turbidity or visible particles. This inspection is somewhat limited by the is positioned in front of a strong light source. Free water, when present, will collect in the bottom of the bottle and be readily visible. Allowing the bottle to stand stationary for at least 10 minutes prior to inspection will cause any dispersed water droplets to settle out, rendering them more visible. Free water is cause for rejection, and the submitting activity shall be requested to resample the equipment to confirm this indication.

(3) Gross particulate contamination, i.e., particles large enough to be seen with the unaided eye, will

also be most visible when the fluid is allowed to stand motionless for a period of time. Like free water, such particles will generally settle to the bottom of the bottle. Gross particulate contamination is usually indicative of improper sampling technique. If present, the submitting activity shall be so advised and requested to resample the equipment.

(4) Fluid turbidity results in the coolant fluid appearing cloudy as opposed to its normal clear,

transparent appearance. Turbidity is most visible when the fluid is agitated and may be indicative of large amounts of air, free water or suspended foreign matter. Allowing the fluid to stand stationary for a period of time will assist in identifying the probable cause. Turbidity caused by suspended semi-solid matter is of particular concern as it may be indicative of chemical degradation of the Coolanol fluid. The contamination byproducts of such degradation will also show up when performing the test for particulate contaminations using the patch test.

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d. Testing Sequence.

(1) Coolant fluid analysis at the intermediate level consists of three separate tests. It is important that

the individual tests be conducted in a specific sequence to minimize the effects of sample handling upon the test results. Table 6-1 illustrates the required testing sequence in chart form and should be referred to until a normal working routine is established.

The test for particulate contaminations using the patch test. (2) The first test performed on any sample is water measurement utilizing the Photo volt Aquatest VIII.

This test is highly affected by exposure of the sample fluid to the atmosphere, particularly in high humidity environments. The fluid sample bottle shall not have been opened prior to the time that fluid is removed for the water test, thus minimizing the effects of external moisture.

Water measurement is accomplished in accordance with detailed procedures provided in Section 5-3. In performing the test, fluid is removed from the sample bottle using a hypodermic syringe and transferred to the aquatest for analysis. A minimum of 2 analyses per sample, each requiring at least 2 milliliters (ml) of sample fluid, are analyzed to assure adequate repeatability of test results. The total amount of fluid required for the water analysis normally will not exceed 10 ME.

(3) Flash Point Analysis. Analysis for flash point is the second test performed on the coolant fluid

sample. The analysis is accomplished using the Cleveland Open Cup flash point tester. Detailed operating procedures are provided in Section 6-4.

TABLE 6-1. SPECIFIC TESTING SEQUENCE

Testing Sequence Key Requirements

Inspect bottle sample Inspect for: Use of proper sample bottle. Sample bottle completely filled. Identification label properly filled out.

Record identification data Record identification data on: Test data worksheet. Test data report form.

Visually inspect fluid Inspect for: Free water. Visible particles. Turbidity.

Measure water content in performing test: Perform three separate tests (if necessary). Use 2-ml samples for each test. Record test results on worksheet. (Two separate tests with results that do not differ more than 11 pprn are acceptable).

Measure flash point in performing test: Use Cleveland Open Cup test set. Fill cup to fill mark. Record test results on worksheet.

Measure particle level in performing test: Perform Patch Test Analysis using 100 ml samples. Use Con-tamination Analysis Kit. Record test results on worksheet.

Review test data Review test data to: Determine fluid acceptability. Determine need for corrective maintenance advisory.

Prepare test report Prepare test report providing: Numerical test results. Pass/fail notations. Appropriate maintenance advisories.

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(4) Particulate Analysis. Analysis for particulate (solid particles) contamination is the third test

performed on the coolant fluid sample. The analysis is accomplished using the Contamination Analysis Kit, part no. 57L414. Section 6-5 contains the procedures for analyzing coolant samples for particulates.

e. Test Data Reporting.

(1) The recording and reporting of test data resulting from the analysis of fluid samples is of the utmost

importance. The information provided by the testing operator will in effect determine whether corrective maintenance will be performed on the equipment. To facilitate test data reporting, the use of specially prepared coolant analysis record (CAR) forms (Figure 6-2) is required.

Figure 6-2. Coolant Analysis Report005002

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(2) Two copies of the CAR form shall be prepared. One copy shall be provided to the customer; the

second copy shall be retained by the laboratory in designated files or binders. In addition, each laboratory shall maintain a written index that contains the following: (i) list of samples received, (ii) dates received and analyzed, and (iii) the file/binder location of the associated results. When files or binders are maintained by calendar year, the index may be incorporated directly into the front of the file or binder; otherwise, a separate log book shall be used for the index. Test results shall be entered in the service’s computerized database when this capability exists within the database. Entry of results is not required when unsupported by the computerized database. When the laboratory has the capability of entering data into the central service database and does in fact enter the data, the program manager may waive the requirement for a laboratory to maintain (i) the independent file or binder, (ii) index log book of results, or both.

f. Maintenance Advisory. The purpose of the maintenance advisory is to allow the testing operator to provide the activity with the information for corrective action if necessary. Appropriate maintenance advisories from Table 6-5 will be included in the remarks section. The customer activity then will take the appropriate action. 6-3. MOISTURE ANALYSIS.

a. Introduction. The Aquatest VllI uses both the dead stop electrode and the coulometric generation of iodine in a closed vessel system. The coulometric addition of iodine makes the Aquatest an absolute instrument. When sample is added to the vessel reagent, the voltage rises across the sensing electrode to indicate the wet state. This triggers the coulometer and a constant current flow through the generator producing iodine in the vessel reagent. The iodine reacts with the water from the sample and the vessel solution. When all the water has reacted, the voltage at the sensing electrode drops. This signals the coulometer to stop. The electrical charge produced during the titration is measured coulometrically and is displayed as the total water content. Since the reagent in the vessel is returned to an initial state at the end of each sample addition, sequential analysis can be performed until the vessel reagent is exhausted.

b. Instrument Setup.

(1) Place the Aquatest VIll instrument on the laboratory bench in an area away from direct sunlight and sources of heat such as ovens.

(2) Handle the generator assembly (8, Table 6-2) by the Teflon collar. (3) Holding the vessel cover (10) with the thumbscrews facing away from you, feed the generator plugs

and wires through the larger threaded opening. While gently pulling the wires out of the way of the threads, insert the end of the generator that is open into cover.

NOTE

Never risk breaking the generator by over tightening it in the vessel cover. A gentle tightening will be satisfactory.

(4) Lightly and evenly grease the ground glass rim of the Pyrex vessel jar (12, Table 6-2) with the Photo volt special sealant (4). Check to see that the thumbscrew fasteners on the cover are fully unscrewed and extended.

(5) Place the magnetic stir bar (14) into the vessel jar. (6) Carefully join the titration vessel jar and cover with the generator assembly. Twist the cover gently

to spread the sealant. Finger tighten the cover thumbscrews to lock it onto the vessel jar, assuring the pawl on each thumbscrew grasps the lip of the vessel jar securely.

(7) Install a membrane septum. (7, Table 6-2)

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TABLE 6-2. AQUATEST VIII REPLACEMENT PARTS

Item Description Part Number Source

1. Solution, Generator, Pyridine-Free 2712801 Seradyn, Inc (50 ml bottle) 1200 Madison Ave. Indianapolis, IN 46225-1600 (800) 222-5711 2. Solution, Vessel, Pyridine-Free 0890106 Seradyn, Inc (Four 200 ml bottles)

3. Aqua star Coulomat Single Solution (500 ml) EM9255-1 VWR Scientific (Alternate to items 1 and 2) P.O. BOX 626 200 Center Square Road Bridgeport, NJ 08014 (800) 932-5000 4. Grease, Special Sealing 2712205 Seradyn, Inc 5. Electrode, Sensing, Aquatest 8, AC Circuitry 0412201 Seradyn, Inc (Dual platinum loops) 6. Electrode, Sensing, Aquatest, DC Circuitry 0412401 Seradyn, Inc (Single platinum loop) 7. Membranes, Sample Port (20 to a pkg and 3 caps) 0812202 Seradyn, Inc 8. Generator Assembly (one-piece), Aquatest 8 1112801 Seradyn, Inc 9. Three-piece Generator Assembly (complete) 1112813 Seradyn, Inc 10. Vessel Cover (for 1112801) 1212802 Seradyn, Inc 11. Vessel Cover (for 1112813) 1212805 Seradyn, Inc 12. Vessel, Titration (alone) 2612201 Seradyn, Inc 13. Cap, Generator 2612211 Seradyn, Inc 14. Bar, Stir 2612250 Seradyn, Inc 15. Pump; Vacuum (to clean generator) 2612254 Seradyn, Inc 16. Syringe, Hamilton Series 7000, 5 micro liters, 2612255 Seradyn, Inc Gastight, 4-1/2 inch round point needle with Chaney Adapter 17. Needle, nerve block, 19 gauges, 5 inches long 7522 Popper and Sons, Inc P.O. Box 128 300 Denton Ave. New Hyde Park, NY 11040 (516) 248-0300

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18. Syringe, glass multifit, luerlok, B-D (10 ml) BD2132 See address in item 3.

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(8) Lightly grease the ground glass collar area of the sensor electrode (5 or 6, Table 6-2). Insert the

electrode into the small opening of the vessel cover. As you carefully and gently seal the collar into the cover, align the platinum circle rings at the end of the electrode such that they are parallel with the side area of the vessel jar closest to them.

c Pyridine Free Reagent Setup.

(1) In an exhaust hood or well ventilated area, remove the septum holder cap and membrane (7, Table 6-2) from the vessel cover, place the funnel supplied into the septum support, and add the entire contents of a bottle of vessel reagent (2). Remove the funnel and replace the septum and cap.

(2) Remove the generator cap (13). Using a glass syringe (18), add approximately 3-4 ml of

pyridine-free generator solution (1) to the generator. Replace the generator cap.

NOTE

As an alternative, Aqua star Coulomat Single Solution (manufactured by EM Science) can be used in both the generator and vessel in the same amounts as the Photo volt pyridine-free reagents.

(3) Place the vessel jar onto the Aquatest VIll inside the plastic retaining ring.

(4) Plug the two banana plugs from the generator into the two banana jacks on back of the Aquatest VIll, black-to-black and red-to-red for proper polarity. Plug the sensing electrode plugs into the smaller two jacks; the larger of the two sensor plugs goes into the small red jack.

(5) Plug the power cable of the Aquatest VIII into an 110-VAC grounded receptacle.

NOTE

Assure the Aquatest VIII does not share its power line with devices capable of causing power line disturbances such as motors, compressors, refrigerators and ovens.

(6) Dip Switch settings should be 1,2,4,5,7,8 UP and 3,6 DOWN.

(7) Switch on power. The Aquatest will perform internal diagnostics, then display SELECT MODE.

NOTE

When the Aquatest VIII is first turned on, wait 30 minutes before performing a sample assay. This time allows the instrument and vessel assembly to stabilize in its new working environment. Photo volt pyridine-free reagent does not require the use of any neutralizing reagent.

(8) When SELECT MODE is displayed, press MONITOR.

(9) Press the first key on the left of the upper 4 keys that corresponds to SEN.

(10) At this time you will see wet/dry status which will usually show the reagent being at set point or slightly wet; this will be displayed on the Aquatest VIII as follows: WET… !∧ ... DRY.

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(11) When the vessel is at set point, a caret on the dotted line will appear as follows: WET ... ∧ ... DRY.

The instrument is ready to perform assays.

d. PPM Moisture Assay

(1) Press SET-UP. (2) Press the fourth white function key under WT. (3) Press the fourth white function key under NO to enter in a single sample weight. (4) Press the fourth white function key under NO to allow manual entry of sample weight. (5) Press CLR to remove the weight value stored in memory. (6) Key in 1600 for PAO (1800 mg for Coolanol) as the weight of the sample and press ENTER. The

aquatest VIII will beep as it stores the value in memory.

NOTE

In order for the Aquatest microprocessor to compute water content in ppm by weight, it must have the weight of the fluid sample. PAO fluid has a specific gravity of 0.8, weighing 0.8 grams per ml. The sample size of 1 ml represents a sample weight of 0.8 grams or 800 milligrams (mg). A sample size of 2 ml, therefore, represents a sample weight of 1600 mg.

(7) Again press SET-UP and this time press the first function key to choose UNIT. (8) MCG PCT PPM will be displayed. Press the third function key to choose PPM. (9) Press SET-UP. The third option is DLY: press the white pad. Next menu will display MCG TIME.

Press the second pad correlating to TIME. Press the CLR key on the keypad and enter 0.3. This is 0.3 minutes or 18 seconds of a delay in the titration. Finally press ENTER. Now the instrument will delay the start of the titration by 18 seconds after the initial 7-second injection period has elapsed.

CAUTION

If the test set has not been used for 12 hours or more, initial test results may tend to be inaccurate. Perform two or three analyses, using spare coolant fluid, to allow test set to stabilize.

NOTE

Since the weight analysis is to be based on the weight transferred, care must be taken to remove all air bubbles from both the syringe and needle.

Careful wiping of the liquid clinging to the needle is required for precision. Do not draw the tissue all the way over the end of the needle. Wipe to just the edge of the needle tip and then stop. Blot the membrane septum between samples.

(10) Gently invert and swirl the sample bottle, so as to mix contents without generating excessive air bubbles. Remove the cap from the sample bottle. Using a clean, dry (see step (16).)

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e. 10-ml glass hypodermic syringe (18, Table 6-2) fitted with 5-inch needle (17, Table 6-2), slowly draw

approximately 1 ml of sample fluid from the sample bottle into the syringe. Withdraw the plunger past the 8-ml mark. Coat the interior walls of the syringe with the coolant fluid. Depress the plunger and expel the 1 ml of coolant into a waste container. Wipe needle clean.

(11) Using the same 10-ml glass hypodermic syringe fitted with 5-inch needle, slowly draw

approximately 7 ml of sample fluid from sample bottle into syringe. (12) With the needle pointed up, allow the air bubbles to rise to the tip. Place the wiping material above

and over the needle point and slowly expel into wiping material any air trapped in syringe and any fluid in excess of 6 ml. Syringe should now contain exactly 6 ml of sample fluid and no air. Wipe the needle clean with wiping material.

(13) Press START Introduce sample immediately after ADD SAMPLE 7 SEC is displayed as follows:

Insert needle through membrane septum (7, Table 6-2) on sampling port in vessel cover until it is below the level of the vessel solution, and discharge precisely 2 ml of fluid directly into the vessel solution. Remove the needle from sampling port. After 7 seconds, the display will show DELAY for 0.3 minutes and be automatically followed by titration.

(14) At the end of the titration, the weight that is in memory will be displayed as a confirmation test. If it

is the right weight, merely press ENTER, and the result of the assay will be displayed in parts per million water.

NOTE If the sample weight displayed after titration is incorrect, press CLR and enter the correct weight followed by ENTER.If you are assaying a number of samples of the same weight, you will only need to enter this weight once.Results of water analysis should be reported as an average of at least two runs. Results are considered to have good repeatability if they are within 11 ppm of each other. If they are not, perform a third run and report the average of the three runs.

(15) Repeat step d. (13) for the next injection of the same sample. If a different sample is to be injected, repeat step d. (10).

(16) Thoroughly clean the syringe, attached needle and plunger with filtered Dry Cleaning Solvent (2,

Table 6-3) or isopropyl alcohol (3, Table 6-3) and allow it to air dry. If using flammable solvents, use an explosion proof oven and a temperature of 185°F or 85°C. For non-flammable solvents, if a hot air oven is available, place the syringe with plunger out of the barrel into the oven at 212°F or 100°C. After 5 minutes, remove the apparatus from the oven using protection for the hands and insert the plunger into the syringe barrel. Allow it to cool to room temperature (approximately 2 or 3 minutes). Syringe, needle, and plunger may also be cleaned in a solution of 2% Micro Cleaner (1, Table 6-3), rinsed well with hot tap water, and placed on in a hot air oven at 212°F or 100°C.

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TABLE 6-3. SOLVENTS AND CHEMICALS Specification Item Nomenclature or Part Number Unit Issue Source

1. Micro Liquid Laboratory Cleaner H-08790-00 Case of 12 Cole - Parmer

1 qt btls Instrument Company 7425 N Oak Park Niles, IL 60714 (800) 323-4340

2. Solvent, Dry Cleaning P-D-680 1 Gallon Navy Stock Type II 3. Isopropyl Alcohol TT-I-735 1 Gallon Navy Stock 4. Methanol O-M-232 1 Gallon Navy Stock 5. Sodium Hydroxide, 0.5 Normal SS270-4 4 Liters Fisher Scientific (bottle) 711 Forbes Ave Pittsburgh, PA 15219-4785 (800) 766-7000 6. Sodium Hydroxide, Pellets O-C-265 2.5 kg NSN 6810-00-234-8373 (bottle)

f. Cleaning Generator.

(1) The bottom end of the generator assembly consists of a porous Pyrex glass frit. With use, the minute fluid passages in the frit will become clogged, retarding the transfer of generator solution to vessel solution during titration. This condition * may be indicated by the error display GEN OVERVOLTAGE and can be corrected by cleaning the frit. (* This display does not always occur.)

WARNING

Do not get sodium hydroxide (NaOH) solution in eyes on skin or on clothing: it causes severe burns. Do not take it internally. Wear gloves and wear goggles (or face shield) when handling.

When making up solution with NaOH pellets, continuously stir solution while adding compound: add it slowly to the solution to avoid violent splattering. Limit the heat rise to 50°F (10°C) per minute. Do not allow temperature of solution to exceed 194°F (90°C) when mixing.

Do not use on aluminum parts; reaction with aluminum forms large volumes of hydrogen gas. Flush area of spillage or leakage with water spray.

(2) The generator frit is cleaned by soaking it in a sodium hydroxide (caustic) solution (4, Table 6-3) and applying a vacuum to the top of the generator assembly. The vacuum pulls the caustic solution through the frit, opening up the pore structure. To clean frit, proceed as follows:

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(a) Remove power from the Aquatest by switching the power off in back of the test set (power can be left on if so desired). (b) Disconnect the generator and sensing electrode cables from the jacks. (c) Loosen the three thumbscrews on the vessel cover and swing pawls away from the titration vessel. Use gentle twisting motion to loosen grease seal and remove cover. (d) Remove generator cap from generator assembly and pour used generator solution into an approved waste container. (e) Pour used vessel solution into the same waste container used in step e. (2) (d). Be careful not to pour out magnetic stir bar. Seal the waste container. Next transfer the magnetic stir bar from titration vessel onto a clean wiping cloth. Wipe and dry the stir bar with a clean disposable towel. (f) Grasp Teflon mounting collar on generator assembly and remove from vessel cover by carefully unscrewing threaded section. Remove sensing electrode and wipe it clean. (g) Using the empty titration vessel, stand generator assembly to be cleaned in empty vessel. Pour technical grade 0.5 Normal (0.5N) sodium hydroxide (NaOH) solution into the empty vessel jar until a level of approximately 2 inches is reached. To make up 0.5N NaOH, weigh 80g of pellets (6, Table 6-3) and dilute with 4 liters of tap water or deionized water if available. (h) Pour additional solution into top opening of generator assembly, just enough to cover the frit. (i) Allow generator assembly to soak 1 hour in the sodium hydroxide solution. Longer periods of soaking, if required, may be employed without damage to the generator. Periodically observe fluid level inside generator. An increase in level will indicate partial clearing of the frit; the open frit allows fluid to transfer from the vessel into the generator. Upon completion of soaking, discard used NaOH solution into an approved waste container, or dispose by approved methods. (j) Expedite cleaning of porous frit after soaking procedure by the application of a vacuum (not to exceed 15 inches mercury (Hg)) to the generator assembly. Required vacuum can be obtained using the syringe and valve (15, Table 6-4) provided with Contamination Analysis Kit, part no. 57L414. Locally fabricate required adapters to connect vacuum source to generator, using modified rubber or cork stopper to connect vacuum line to open end of generator. (k) Place fresh sodium hydroxide solution in emptied titration vessel, enough to partially cover the generator assembly when it is placed in the titration vessel. Apply vacuum to generator assembly until caustic cleaning solution flows freely from the vessel jar to the inside of the line. If required, pour excess fluid from generator assembly to waste. A filtering flask may be installed as a trap between the generator and the vacuum pump. (l) When frit has been cleaned, remove generator assembly from vessel jar and discard caustic solution into an approved waste container, or dispose by approved methods. Rinse generator assembly and vessel jar using generous amounts of water, preferably hot. (m) Return generator assembly to the vessel jar and partially fill vessel with tap or deionized water. Using vacuum procedure specified in steps (j) and (k), flush frit with water to remove residual caustic solution. (n) Remove generator assembly from vessel jar and discard water.

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TABLE 6-4. CONTAMINATION ANALYSIS KIT REPLACEMENT PARTS

Part Number

Item Description (Millipore) NSN

1. Holder Assembly, Filter XX6300120 Not Listed

2. Funnel, Stainless Steel XX6300121 Not Listed

3. Support, Holder with Screen and XX6504708 6640-00-256-3351 Aluminum Base

4. Support O-Ring, Buna-N (5/pkg) YY4014267 5330-01-207-1482

5. Base O-rings, (2) BUNA-N (1 0/pkg) XX6300123 Not Listed

6. Flask, Vacuum, Stainless Steel XX63000129 6640-00-256-3354

7. Bottle, Solvent Rinse, Plastic XX6504704 8125-01-238-1382 500 ml (mod.)

8. Holder, Swinnex Filter XX6504707 6640-00-476-0682

9. Bottle, Wash, Plastic, 500 ml XX6504701 6640-01-076-5460

10. Bottle, Sample, Plastic, 4 oz. XX6504709 6640-01-193-0568

11. Cylinder, Graduated, TPX, 100 ml XX6504702 6640-01-165-5747

12. Forceps, Stainless Steel XX6200006 6640-00-426-0300

13. Slides, Petri (100/pkg) PD1504700 6640-00-431-6919

14. Filter Membranes, Test, SMWP04700 6640-00-967-0488 47 mm (1 00/pkg)

15. Filter Membranes, Solvent, SMWP02500 6640-00-152-1460 25 mm (1 00/pkg)

16. Syringe and Valve XX6200035 6640-00-086-5326

17. Tube and Adapter, with Clamps XX6504710 6640-00-256-3355

18. Contamination Standards XX6504713 6630-00-102-9187

WARNING

Methanol is flammable - do not use near open flames, near welding area, or on hot surfaces. Do not smoke when using it, and do not use it where others are smoking. Prolonged or repeated inhalation of vapor can cause eye irritation, drowsiness, and headache. Ingestion may be fatal or may cause eye damage. If vapor contacts eyes, immediately flush eyes with large amounts of water. Immediately remove solvent-saturated clothing. If vapors cause drowsiness, go to fresh air. When handling or applying liquid at air-exhausted workbench, wear approved goggles and gloves. When handling or applying liquid at unexhausted workbench, wear approved respirator, goggles and gloves.

(o) Remove residual water from generator assembly by pulling methanol (4, Table 6-3) through generator with vacuum, as described in steps (j) and (k), and then drying in explosion-proof oven (if available) at 150° to 185°F (65° to 85°C) for a period of 2 hours. If no oven is available, allow to air dry before use. Alternatively, generator assembly may be dried in a hot air oven, after step e.(2)(n) at 212°F (100°C), omitting the use of methanol. Store generator in dessicator, if available, until needed.

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(p) In some cases, because of lack of equipment, it may not be possible to clean the frit in shipboard laboratories. In these cases the laboratory should be retained and subsequently taken to a shore-based laboratory where cleaning can be accomplished.

g. Calibration.

NOTE

The Aquatest VIII does not require calibration. However, a calibration check procedure is provided so that the user can quickly confirm that the instrument is indeed triturating water accurately. User calibration check is generally done every 6 months or as needed (whenever erroneous results are suspected).

(1) Set Aquatest to MCG mode (see paragraph d. (7)-(8)).

NOTE

In preparation for the following, fill a beaker or other clean container with a small amount of tap or deionized water. Set adapter on syringe (16, Table 6-2) to 1.0 micro liter mark on syringe barrel. Pump syringe several times while the needle is submerged in water to remove air. Remove septum membrane from sample port to enable needle (shorter length) to be below the vessel solution.

(2) Press START. Introduce sample immediately after ADD SAMPLE 7 SEC is displayed as follows: Insert needle of a gas-tight 5 micro liter syringe (16, Table 6-2) with built-in Chaney adapter directly through the sampling port in the vessel cover until it extends below the level of the vessel solution and discharge precisely 1.0 micro liter of water into the vessel solution. After a brief moment, remove syringe and needle from sampling port and replace membrane. After 7 seconds, the display will show DELAY and be automatically followed by titration. Establish that you obtain 1000 +/-50 micrograms of water. Repeat additions as necessary to determine precision (standard deviation less than or equal to 50 mcg is acceptable). Flush needle several times with water prior to storing to remove chemicals from Aquatest that will cause corrosion.

h. Replacement parts. For replacement parts, refer to table 6-2.

WARNING

Check local/state regulations before disposing of toxic wastes. Most local sewage disposal regulations prohibit the discharge of toxic wastes into natural waterways.

i. Disposal of Wastes. For handling and disposal concerns, refer to the Material Safety Data Sheet of the particular chemical or solvent.

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6-4. FLASH POINT ANALYSIS.

a. Introduction. This section provides procedures used in determining the flash point of coolant fluid samples using the American Standard Test Method for Flash and Fire Points by Cleveland Open Cup (ASTM D 92). For detailed set up and equipment operation, refer to the applicable manual for the test equipment being used.

(1) Flash point is the lowest temperature at which application of a test flame causes the vapor of a specimen to ignite under specified conditions of test.

(2) Fire point is the lowest temperature at which a specimen will sustain burning for 5 seconds.

b. Summary of Method. The test cup is filled to a specified level with the sample. The temperature of the

sample is increased rapidly at first and then at a slow constant rate as the flash point is approached. At specified intervals a small test flame is passed across the cup. The lowest temperature, at which application of the test flame causes the vapors above the surface of the liquid to ignite, is taken as the flash point.

c. Procedure.

CAUTION

The operator must exercise and take appropriate safety precautions during the initial application of the test flame, since samples containing low flash material may give an abnormally strong flash when the test flame is first applied. Assure that all flammables are removed from the immediate area prior to performing this procedure.

(1) Support the test apparatus on a secure level table in a draft-free room or compartment. Shield the top of the apparatus from strong light to permit ready detection of the flash point. Tests made in a laboratory hood, or in any location where drafts occur, cannot be relied upon. During the last 30°F before anticipated flash point, care must be taken to avoid disturbing the vapors in the test cup by careless movements or breathing near the cup.

(2) Wash the test cup with detergent in hot water. i.e., 2% solution of Micro Cleaner (1, Table 6-3) to

remove any oil, traces of gum or residue remaining from a previous test. Rinse well with hot water. Wipe dry with disposable towel. Place on heating element of flash tester to remove last traces of water. Cool to at least 100°F below expected flash point prior to use.

(3) Support the thermometer in a vertical position with the bottom of the bulb ¼ inch from the bottom of

the cup and locate it at a point halfway between the center and side of the cup on a diameter perpendicular to the arc of the sweep of the test flame and on the side opposite the test flame burner arm.

NOTE

The immersion line engraved on the thermometer will be 5/64 inch below the level of the rim of the cup when the thermometer is properly positioned.

(4) Fill the cup so that the top of the meniscus of the sample fluid is exactly at the filling line. If too much sample has been added to the cup, remove the excess with a medicine dropper. If there is sample on the outside of the apparatus, wipe off and clean thoroughly with a disposable towel. Destroy any air bubbles on the surface of the sample.

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CAUTION

Meticulous attention to all details relating to the test flame applicator, size of the test flame, rate of temperature increase and rate of passing the test flame over the sample is necessary for good results and repeatability.

(5) Light the test flame and adjust it to a diameter of 1/8 to 3/16 inch which is the size of the comparison bead if one is mounted on the apparatus.

(6) Apply heat initially so that the rate of temperature rise of the sample is 25° to 30°F per minute. When

the sample temperature is approximately 100°F below the anticipated flash point (275°F), decrease the heat so that the rate of temperature rise of the last 50°F before the flash point is 9° to 11°F per minute.

(7) Starting at least 50°F below the flash point, apply the test flame when the temperature read on the thermometer reaches each successive 5°F mark. Pass the test flame across the center of the cup, at right angles to the diameter, which passes through the thermometer. With a smooth continuous motion, apply the flame either in a straight line or along the circumference of a circle having a radius of at least 6 inches. The center of the test flame must move in a horizontal plane, not more than 5/64 inch above the plane of the upper edge of the cup and pass in one direction only. At the time of the next test flame application (each successive 5°F mark), pass the flame in the opposite direction. The time consumed in passing the test flame across the cup in each case shall be about 1 second. (8) Record as the observed flash point the temperature read on the thermometer when a flash appears at any point on the surface of the oil, but does not confuse the true flash with the bluish halo that sometime surrounds the test flame. (9) After cooling, test cup may be cleaned as in step c. (2). d. For handling and disposal safety concerns, refer to safety summary at front of manual and to the Material Safety Data Sheet of the particular chemical. 6-5. CONTAMINATION ANAYLSIS KIT. a. Introduction. This section provides detailed information on a method utilized to determine the level of particulate contamination in coolant fluid samples. It provides a detailed operating description of Contamination Analysis Kit, part no. 57L414 (08071) and its required operating procedures. Information is also provided that will assist the operator in maintaining the equipment and accomplishing minor repairs.

b. General Description of Equipment.

(1) Contamination Analysis Kit, part no. 57L414 (see Table 6-4) is the principal equipment used for

determining contamination levels in naval aircraft hydraulic systems and related support equipment (SE). The equipment is compatible with the fluids utilized in liquid coolant systems and can be used to determine particulate levels in these fluids as well.

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(2) The analysis kit employs a patch test technique in which a specific volume (100 ml) of sample fluid

is filtered through an analytical filter disk of known porosity. All particulate matter in excess of a size determined by the filter characteristics is retained on the surface of the filter, causing it to discolor in an amount proportional to the particulate level of the sample fluid. The typical color of contamination in any given system will remain fairly uniform, and the degree of filter discoloration may be correlated with a level of particulate contamination. By visually comparing the test filter with the Contamination Standards representative of known contamination levels, a judgement can be made of the contamination level of the system. Free water will appear either as droplets during the fluid sample processing or as a stain on the test filter.

(3) The major component of the analysis kit is a filtration assembly consisting of a stainless steel funnel, filter holder and vacuum flask. The funnel is attached to the upper half of the filter holder, in which the filter disk is installed. The lower part of the filter holder is seated in the top opening of the vacuum flask, and an air-tight seal established by means of an 0-ring. A hand-operated vacuum pump is provided, which can be connected to a port on the vacuum flask and used to evacuate it.

(4) When processing a fluid sample, a new unused filter disk is first installed in the filter holder. One hundred milliliters (100 ml) of sample fluid is then measured out, using a graduated cylinder, and poured into the funnel. Using the hand pump, a vacuum is produced in the flask, pulling the fluid sample through the filter disk.

(5) Upon completion of the filtration process, a quantity of filtered solvent is introduced into the funnel

and serves to rinse the filter disk free of any residual sample fluid, leaving only the particulate matter that is deposited on the filter surface.

(6) The Contamination Analysis Kit contains all the equipment and materials, solvent excepted,

required to perform the test described. In addition to those items described, the kit also includes sufficient filters to perform 200 tests, sample collection bottles, solvent rinse bottles, filter storage slides and a Contamination Standard. The 4 ounce sample collection bottles, intended for use in hydraulic fluid analysis, are not utilized when sampling liquid coolant systems.

c. Unpacking. The Contamination Analysis Kit is a portable self-contained unit. All component parts are supplied in a fitted fiberglass carrying case that serves also as a transportation case. No special unpacking is required.

d. Facility Requirements. The test kit was designed for field use and has no special facility requirements. e. Electrical Requirements. Electrical power is not required for operation of this equipment. f. Preparation for Use.

NOTE

Accurate determination of coolant contamination levels requires proper technique and the use of known clean equipment and materials. Any foreign matter, which is allowed to contaminate the fluid sample or testing equipment, will cause erroneous results. Careful attention to the detailed procedures here in will assure that the effects of external contaminants are minimized.

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WARNING

Dry Cleaning Solvent is combustible - do not use near open flames, near welding areas, or on hot surfaces. Prolonged contact of skin with liquid can cause dermatitis. Repeated inhalation of vapor can irritate nose and throat and can cause dizziness. If any liquid contacts skin or eyes, immediately flush affected area thoroughly with water. Remove solvent-saturated clothing. If vapors cause dizziness, go to fresh air. When handling liquid, wear approved gloves and eye protection. Use in a well-ventilated area and keep containers covered when not in use.

g. Required Materials. In addition to the kit components, a suitable solvent and a waste container are needed to analyze fluid samples. Dry Cleaning Solvent (2, Table 6-3) is the only authorized solvent, but may result in damage to plastic components of the kit. h. Rinse Bottle Preparation.

(1) The solvent rinse bottle is used to dispense filtered solvent material when clearing residual coolant

fluid from the test filter. To prepare the rinse bottle for use, proceed as follows:

NOTE

Two plastic bottles (7, 9, Table 6-4) provided in the analysis kit are identical except that one (7) has a shorter spout to accommodate the Swinnex filter unit (8). One bottle (7) is used to dispense filtered solvent when performing analysis. The other bottle (9) is used to flush fittings at aircraft sampling points to prevent external contamination of the sample fluid.Blue separator disks separate packaged filter membranes. Remove separators before installing the filter membrane in the equipment.

The 25 mm filter membrane does not need to be replaced after every test or usage of the equipment. The filter serves to remove particulates from the solvent being dispensed and may be used until saturated with dirt, as indicated when unusually high pressure is required to dispense fluid.

Should it be observed that fluid is being dispensed with unusually light pressure being applied, immediately disassemble the filter assembly and check for possible filter rupture.

(2) The Swinnex filter assembly consists of two threaded half sections and an internal support screen. Place one 25 mm filter membrane (15, Table 6-4) on the girded plastic surface using forceps (12). Position the perforated support screen on top of the filter membrane and reassemble the two halves of the assembly finger tight.

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WARNING

Dry Cleaning Solvent is combustible - do not use near open flames, near welding areas, or on hot surfaces. Prolonged contact of skin with liquid can cause dermatitis. Repeated inhalation of vapor can irritate nose and throat and can cause dizziness. If any liquid contacts skin or eyes, immediately flush affected area thoroughly with water. Remove solvent-saturated clothing. If vapors cause dizziness, go to fresh air. When handling liquid, wear approved gloves and eye protection. Use in a well-ventilated area and keep containers covered when not in use.

CAUTION

Certain plastic components of the analysis kit, notably the graduate (11, Table 6-4) and the petri slides (13) are damaged by prolonged exposure to Dry Cleaning Solvent (2, Table 6-3). Such exposure therefore should be limited. The tip of the wash bottle may be damaged if the Swinnex filter holder is forced on too tight.

(3) Fill the 500 ml plastic bottle (7, Table 6-4) having the short spout with Dry Cleaning Solvent. Replace the screw cap.

(4) Attach the Swinnex filter unit to the rinse bottle (7, Table 6-4) with the short spout. Close hole in the

cap with a finger, squeeze bottle, and filtered solvent will be dispensed as required. Sufficient drying time must be allowed and the other applicable precautions observed for Dry Cleaning Solvent.

NOTE

When using a Swinnex filter, if air becomes trapped between the filter and the inside nozzle of the rinse bottle, the flow will stop. To eliminate the air-lock, remove the filter from the outlet spout and purge air before filtering. If clogging persists, replace the filter.

If the rinse bottle (7) is damaged, the other plastic bottle may be modified by carefully cutting off the tip with a sharp knife or razor blade so that the Swinnex filter unit will fit. The damaged bottle may then be used for flushing of fittings and sampling points.

i. Fluid Analysis Procedures.

(1) Fluid analysis is accomplished by drawing the fluid sample through a 47 mm diameter, 5 micron filter membrane (disk) (14, Table 6-4), using the vacuum filtration equipment provided. Process the fluid sample as follows:

(a) Remove filter holder assembly (1) from its storage position in the kit. Stainless steel funnel

(2) and holder support (3) are assembled and stored in an inverted position in the stainless steel vacuum flask (6). To prepare for use, the funnel assembly and holder support assembly must be removed fro installed in the flask assembly.

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NOTE

A Thin film of coolant fluid applied to the external O-ring seals (4/5, Table 6-4) on the filter holder will aid in its insertion and subsequent removal. If difficulty is encountered in removing the filter holder assembly from flask, insert the back end of forceps (12) into the slot (present on some assemblies) and pry the holder from the flask.

(b) Using tube and adapter (17, Table 6-4), connect the vacuum port on syringe (16) to the small opening located on the side of the filter holder assembly (1) base. The tube and adapter are normally left connected to the syringe but may be removed for cleaning or replacement.

CAUTION

Evaporation of the filtered solvent may result in the condensation of atmospheric moisture on the funnel surface. This can cause inaccurate indications of free water in the sample. Carefully inspect for condensation. If present, move equipment to an air-conditioned workspace.

(c) Using the filtered solvent dispenser (see step h. (4)), wash down the inside wall of the stainless steel funnel to flush away any surface contamination present. Ensure funnel screen is also cleaned with filtered solvent.

(d) Remove funnel from filter holder by rotating the outer knurled ring in a counterclockwise

direction until disengaged, and lift upward. Using forceps, carefully remove a single 47 mm filter membrane (14, Table 6-4) and place it on top of the wire mesh filter holder assembly. Ensure that the blue separator disks are not installed with the filter membrane. Place the support screen gasket between test filter membrane and stainless steel funnel. Reinstall funnel on filter holder assembly and secure by rotating the outer knurled ring in a clockwise direction until fully seated.

(e) Using the filtered solvent dispenser (see step h.(4)), repeatedly rinse the inside of

graduated cylinder (11, Table 6-4) to remove all possible contaminants. Pour out any residual solvent into an approved waste container. Measure out approximately 15 ml of filtered solvent, using the cleaned graduate, and pour into the stainless steel funnel to prewet the filter membrane.

(f) Shake the bottle of sample fluid to be processed to distribute its particulate content.

Remove cap from sample bottle and pour exactly 100 ml of fluid into graduate (11, Table 6-4). Pour contents of graduate into the stainless steel funnel (2) on top of the previously introduced filtered solvent. Allow contents of the graduate to drain completely into the funnel.

(g) Using the filtered solvent dispenser, wash down the inside surface of the graduated

cylinder with clean solvent until the graduate contains approximately 100 ml of fluid. (h) Operate syringe and valve (16, Table 6-4) in a slow pumping manner, drawing a vacuum,

until sustained filtration of the fluid is indicated by a steady drop of fluid level in the funnel. As soon as the fluid level in the funnel has dropped enough to allow addition of approximately 50 ml of solvent, pour half of the contents of the graduated cylinder into the funnel as filtration continues. If necessary, operate the syringe again to maintain sufficient vacuum for filtration.

(i) Carefully observe the filtration process in the funnel and the decreasing fluid level. When the

fluid level drops to the narrow neck of the funnel, pour the remaining contents of the graduate into the funnel. Pour contents so as to wash down the inside of the funnel, assuring that solvent is not poured directly onto the filter membrane.

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(j) When filtration is complete, inspect the filter surface. If the central area shows a yellowish

color, indicating that the filter membrane still has a residue of coolant fluid, direct a stream of clean solvent from the filtered solvent dispenser against the walls of the funnel until the fluid reaches the top of the tapered portion. Operate the syringe again to initiate filtration and allow all of this fluid to pass though the filter.

NOTE

Free water, when present in the fluid sample, may be seen as droplets on the surface of the test filter membrane immediately after completion of filtration. Immediate observation is essential as the droplets remain on the filter surface for only a short period of time.

(k) Upon completion of filtration, disengage funnel from the filter holder assembly and remove the test filter by grasping the membrane edge with forceps. Deposit the filter in an uncovered petri slide (13, Table 6-4) and allow to dry thoroughly in still air before applying cover to the slide.

NOTE

After using Dry Cleaning Solvent (2, Table 6-3) the filter must be dried thoroughly prior to placing in petri slide. The solvent, or its fumes, will craze and cloud the polystyrene petri slides.

j. Test Filter Evaluation.

(1) After the fluid sample is processed, the resultant test filter membrane should be visually compared with the Contamination Standards (18, Table 6-4). Determine the particulate contamination level by comparing the shade and color of the test patch with those of the Contamination Standards. If the test patches displays a rust or tan color, use the tan standard patch. If the test patch is gray in color, use the gray standard patch.

(2) Follow operating instructions contained in the Contamination Standards. Tan patches occur when

rust or iron chlorides are formed in the system or the system contains abnormal amounts of silica (sand). Gray patches are typical of systems containing normal proportions of common wear materials and external contaminants.

NOTE

Test patches may be encountered that show evidence of a white colored precipitate or deposit. This material is the by-product of chemical reaction between water and the coolant fluid. Contamination standards for determining acceptability of such patches are presently not available and individual judgement must be based on local experience.

(3) Upon completion of test filter evaluation, record test results on the Coolant Analysis Record (Figure

6-2). The maximum acceptable particle level for coolant fluid samples originating from aircraft equipment is Navy Standard Class 5. Fluid samples from related SE shall not exceed Navy Standard Class 3. Visible free water present in either the sample bottle or on the surface of the test filter (at completion of filtration) is cause for rejection of the system under test. A stain on the test filter membrane may be an indication of the presence of free water. Ensure that observed water is not a result of atmospheric condensation during the sample processing. When a stain is seen on the test filter, a second fluid sample from the system under test should be obtained and processed so that water content can be confirmed prior to system rejection.

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TABLE 6-5. MAINTENANCE ADVISORIES

Abnormal Indications Equipment Sampled Corrective Maintenance Excessive Water Aircraft System or Component Decontaminate using SE.

Resample

Ground Support Equipment Replace Hydro pack filter if present. Operate closed loop to decontaminate fluid. Resample.

Excessive Particle Level Aircraft System Component Check condition of contaminate remover (indicator button). Replace if required. Decontaminate using SE. Resample

Ground Support Equipment Check condition of particle filter(s) contaminate (pressure lamp or gage.) Replace filter element if required. Operate closed loop (if capability exists)* to decontaminate. Resample.

Low Flash Point Aircraft System Decontaminate using SE. Resample.

Ground Support Equipment Operate closed loop (if capability exists)* to decontaminate. Resample. Flushing may be required.

*If closed-loop capability does not exist, it may be necessary to flush out old fluid.

k. Maintenance Requirements. Equipment maintenance includes the unscheduled repair or replacement of

defective items. Consult NAVAIR 17-15E-52 Operation and Intermediate Maintenance with Illustrated Parts Breakdown when effecting repairs and for maintenance consisting of cleaning, lubrication, and adjustments.

l. Calibration Requirements. Equipment calibration is provided by the Contamination Standards furnished

with the equipment. To maintain their accuracy, the standards should be protected from stains and handling damage. Procure replacement standards when those provided with the equipment are determined to be no longer serviceable.

m. Related Publications. The following publications provide additional information relative to the operation

and, maintenance of the Contamination Analysis Kit and should be consulted as required:

(1) NAVAIR 17-15E-52 Operation and Intermediate Maintenance with Illustrated Parts Breakdown for Hydraulic Fluid Contamination Analysis Kit Part No. 57L414.

(2) NAVAIR 01-1A-17 Aviation Hydraulics Manual.

n. Replacement Parts. For replacement parts refer to table 6-4.

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o. Disposal of Waste Solvents. For handling and disposal safety concerns, refer to the Material Safety Data

Sheet (MSDS) of the particular chemical or solvent. 6-6. NAVY (SHIPS) PHYSICAL PROPERTIES PROCEDURES.

NAVY (Ships) PHYSICAL PROPERTY TEST LIMITS BY TYPE OIL AND USE

SUBMARINES

USED AS A DIESEL LUBE OIL

M-L-900OG MS-250

Spectrometric Required

Test Limits Water (by Karl-Fisher) 0.02% or 200 PPM Max. Viscosity (at 100°F) report 100 CS Min. 225 Ma. in. Centistokes (CS)

Acidity (Surface and Sub) Blue = Pass, Green or Yellow Fail Fuel Dilution: Always perform when 0 - 2%, Acceptable Viscosity is less than 130 CS, at 2 - 5%, Marginal/Warning 100°F, or odor of fuel is present. Greater than 5.0%, Fail

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USED AS A LUBE OIL

MIL-L-17331 MS-2190 TEP

Spectrometric Required

Test Limits Water (by Karl-Fisher) High Press Air Compressor .017% or 170 PPM Max. Low Pressure Blower (for Subs) 0.05% or 500 PPM Max. Propulsion LUBE Oil 0.05% or 500 PPM Max. Neutralization Number 0.5% Max.

REFRIGERANT COMPRESSOR OIL

VV-L-825 MS RCO-2 (TYPE 11)

R-12. Refrigeration Plants

Spectrometric Required

Test Limits Water (by Karl-Fisher) 0.01 %or 100 PPM Max. Neutralization Number 0. 1 % Max. R-1 14 Air Conditioning Plants Spectrometric Required Water (by Karl-Fisher) 0.01 % or 100 PPM Max. Neutralization Number .07% Max.

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HYDRAULIC FLUIDS

MIL-L.17672 MS 2075TH; MS 211 OTH; MS 2135TH

MIL-L-17331 MS 190 TEP Spectrometric Required ONLY FOR ABOVE WATER LIMITS, to determine SALT or FRESH water contamination.

Particle Count (ISO) Water (Karl-Fisher)

Overhaul Operating Single Reqm’ts Reqm’ts Sample Average

Ship/System Number of Particles Per Milliliter Over 15 m Over 15 m % Volume %Volume AGSS555 80(IS013) 160(IS014) 0.05 0.05 DSRV 1 and 2 80(IS013) 320(IS015) 0.05 0.05 Other Submarines (SS, SSN, SSBN, NR-I, NKTV) Internal (Main, vital 160(IS014) 320(IS015) 0.05 0.05 Ships Service, Independent Steering & Diving Missile Support) Systems External Systems 320(IS015) 640(IS016) 0.10 0.05

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SECTION VII

US AIR FORCE B-2 COOLANT TESTING PROCEDURES

7-1 Introduction. This section defines the procedures, requirements, equipment and material needed for sampling and testing Silicate Ester-Based Dielectric (SEBD) coolant fluid used in operating systems such as radar cooling in the Environmental Control System of the B-2 Bomber. 7-2. General. a. The equipment cooling system of the B-2 aircraft incorporates three liquid cooling subsystems and five circulated air subsystems. The liquid cooling subsystems consist of the Ethylene Glycol-Water Subsystem (EGW), DMS/LC Subsystem and the Liquid Cooling Subsystem (LCS). b. The Liquid Cooling Subsystem (LCS) is composed of two independent closed cooling loops located in the left-hand and right-hand forward center section of the aircraft. The left side LCS loop (normally the transmitting radar side) is identical to the right side LCS loop (normally in standby). Each closed loop circulates liquid coolant through each of the radar packages to maintain the components at a controlled temperature. The fluid is then circulated through a three-fluid (coolant-EGW) heat exchanger for heat dissipation via the EGW coolant loop to the sink heat exchanger. c. Each loop supplies liquid coolant at a flow rate of 4.0 GPM to the liquid cooling passages of 55.0 degrees Fahrenheit and a maximum pressure of 175.0 psig. The maximum volume of fluid in each loop is 4.76 gallons. d. The LCS transports heat from both radar transmitters and antennas. The transmitters require a heat transport fluid with both high dielectric properties and thermal transport characteristics. The heat transfer fluid is a silicate ester-based dielectric (SEBD) coolant fluid, Coolanol 25R or Flocool 180. e. As the fluid cycles throughout the aluminum system lines, metal particles may be generated by the relative motion between metallic parts within the mechanical system. Friction and continuous wearing away of contacting surfaces will increase the amount of particulate contamination. As particulate size and quantity increase, the physical and chemical characteristics of the EGW and Coolanol 25R fluids may also be impacted. This document defines the requirements for sampling and testing coolants such as EGW and SEBD coolants in the operating systems of the vehicle, in filtering and fluid supply service carts, and in other liquid servicing equipment. 7-3. Equipment.. Equipment identified to each specific test shall be maintained per manufacture's requirements. Records of maintenance and calibration of the equipment shall be maintained. Testing facilities shall be free of contaminates detrimental to test performance and shall be cleaned at intervals deemed necessary to maintain the cleanliness of the area. 7.4. Test Sequence. To minimize the quantity of fluid needed to perform the coolant fluid tests and to minimize the effects of sample handling, testing should be conducted in the following sequence: Paragraph

Appearance 7-7 Dielectric Strength 7-8 Particulate Contamination 7-9 Volume Resistivity 7-10 Water Content 7-11

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TABLE 7-1. COOLANT TEST REQUIRMENTS

The SEBD coolant will be tested for the following: A. Appearance B. Dielectric strength C. Particulate contamination per 100 milliliters, particulate size 10 thru 200 microns >200 microns (Including fibers) D. Volume resistivity E. Water content

No evidence of separation, contamination or precipitates 300 volts per mil, minimum Automatic counts 32,000 maximum. Automatic Count 5 maximum 4 X 1010 OHMS per centimeter 150 parts per million maximum.

7-5 Laboratory Safety.

a. Standard lab safety procedures should be followed. All chemicals should be treated as potentially hazardous and handled with care. Petroleum ether and methanol, which will be used to clean the sample containers on the instruments are flammable and should not be exposed to a flame, spark or high heat. Safety goggles and gloves impervious to organic solvents should be worn at all times. An eye wash station, fire blanket and fire extinguisher should be readily accessible at all times. Material Safety Data Sheets (MSDS) for all chemicals should be accessible to lab personnel while working in the lab. Never work in the lab alone-ensure there is someone else within easy calling distance.

b. Waste chemicals should be disposed of in approved marked waste containers. While the waste organic chemicals used in these procedures may be mixed in a single waste container, it may be more convenient to use one container for SEBD waste chemicals and another for EGW wastes. Remove waste chemicals from the lab on a regular basis. 7-6. Testing. 7-7. Appearance.

a. Prior to the sample analysis, the unopened sample bottle shall be visually inspected for proper filling and sealing, as well as evidence of gross contamination. Properly filled bottles will be almost completely filled with fluid extending up to the bottom of the threaded neck section. The purpose of completely filling the bottle is to minimize the quantity of air present, which could contain large amounts of atmospheric moisture, and to assure that adequate fluid is available to perform all of the required tests. Activities submitting SEBD coolant samples in improper or inadequately filled bottles shall be advised to resample the equipment.

b. Gross particulate contamination, i.e., particles large enough to be seen with the unaided eye, will also be

most visible when the fluid is allowed to stand motionless for a period of time. Like free water, such particles will generally settle to the bottom of the bottle. Gross particulate contamination is usually indicative of improper sampling technique. If either is suspected, the submitting activity shall be advised and requested to resample the equipment.

c. Fluid turbidity results in the SEBD fluid appearing cloudy as opposed to its normal clear, transparent

appearance. Turbidity is most visible when the fluid is agitated and may be indicative of large amounts of air, free water or suspended foreign matter.

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Allowing the fluid to stand stationary for a period of time will assist in identifying the probable cause. Turbidity

caused by suspended semi-solid matter is of particular concern as it may be indicative of chemical degradation of the SEBD fluid. The contamination by-products of such degradation will also show up when performing the test for particulate contamination

d. Prior to sample analysis, fluid in the sample bottle shall be visually inspected for evidence of free water,

turbidity or visible particles. This inspection is somewhat limited by translucent plastic bottles but can be remedied by using a glass bottle or positioning the plastic bottle in front of a strong light source. Free water when present, will collect in the bottom of the bottle and be readily visible. Allowing the bottle to stand stationary for at least 10 minutes prior to the inspection will cause any dispersed water droplets to settle out, rendering them more visible. Free water is cause for rejection and the submitting activity shall be requested to resample the equipment to confirm this indication. 7-8. Dielectric Strength.

a. Introduction. This procedure describes the method for performing dielectric strength of silicate ester base dielectric coolant fluid with the Hipotronics Model 0C60D, digital Oil Dielectric Test Set. All personnel should review the manufacture's instruction manual prior to using the equipment.

b. Equipment and Materials. Model 0C60D Oil Dielectric Test Set, Hipotronics Inc. c. Equipment Information and Test Procedures. The referenced test set provides the means of applying,

measuring, and displaying the value of the voltage required to electrically stress insulating liquids such as SEBD to a point where the insulating qualities break down and allow an electrical current to flow between and electrodes applying the voltage. The 0C60D is capable of applying 0 to 60,000 VAC between two electrodes that are spaced 2.5mm or 0.10 inches apart in a test cup that holds the test sample.

NOTE

During testing a safety cover is lowered to protect the test operator. The rate of applied voltage is determined by selecting the 3000 VPS (volts per second) setting on control panel energized by a facility power source of 115 VAC, 50/60 HZ. The breakdown voltage for SEBD is 300 volts per mil (minimum) and will require the test sample to be subjected to 30 kilovolts minimum to be considered sufficiently free of contaminating agents. Specifications Test Voltage: 0 to 60 kilo volts AC (50,000 VAC) Power Rating: 115 VAC, 50/60 HZ, 15 amps

(1) Set-Up Procedures.

(a) Remove packing material, power cord, test cells, and any other components from the test cage. (b) GROUND THE UNIT BEFORE CONNECTING INPUT POWER. The ground lug is located on

the left side of the unit, below the plug receptacles.

(c) Insert the socket end of the power cord into the receptacle on the left side of the unit and connect it to a suitable power source. IF A TWO-PRONG ADAPTER IS USED, BE SURE TO GROUND THE PIGTAIL.

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(2) Operating Procedures. (a) ENSURE THAT THE UNIT IS PROPERLY GROUNDED BEFORE CONNECTING INPUT POWER. The ground lug is located on the left side of the unit, below the plug receptacle.

(b) Ensure that the power cord is properly plugged in as described in step c of the SET-UP PROCEDURE. (c) Check and adjust the spacing of electrodes in the test cell using a 100 mil gage shim. Push electrodes tightly against gage shim. The distance between the two electrodes will be 100 mils (0.1 inches).

NOTE

Do not fill test receptacle inside test chamber. (d) Fill the test cell with sufficient insulating liquid to completely cover the electrodes. (e) Swirl the insulating liquid by rocking the test cell slowly. (Rapid agitation may create an excess of air bubbles in the liquid).

(f) Gently snap the filled test cell in place between the bushing(s) of the transformer and the test cage and close the safety glass cover.

(g) Before testing, allow the sample to stand for a minimum of three minutes to permit any accumulated air bubbles to escape. If a VDE test cell is used, plug the line cord into the receptacle on the left panel of the test cage. (h) Turn the AC power switch ON. (i) If the failure indicator lights, press the reset push-button until the voltmeter reading is zero. (j) With the voltmeter reading zero, set the rate/rise rotary selector to 3000 VPS.

(k) Press the START push-button to activate the output voltage. Voltage is applied automatically at the specified rate until breakdown occurs, at which point the FAILURE indicator lights and the voltage is turned off.

NOTE

The voltage may be terminated before breakdown by releasing the test cage interlock switch (HV OFF ANYTIME). This is accomplished by opening the safety glass cover. Also, voltage may be maintained at any level prior to breakdown by setting the RATE/RISE selector to STOP (manual dwell).

(l) The voltmeter continues to display the breakdown voltage until the reset pushbutton is

pressed. After reading and recording breakdown voltage, press the RESET push-button and allow the voltmeter to return to zero.

.

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NOTE

Clean test cell between each test with methanol.

(m) Perform three (3) breakdown tests beginning with step k. If results are within + 10% of the

average of the sample taken, test is complete. If results are not within + 10%, perform two additional tests. Discard the two- (2) high/low samples and average the remaining three (3) sample results. If results are within + 10% of the average, the test is complete. Five breakdowns may be performed on one cup filling with one-minute interval between breakdowns.

NOTE

Minimum instrument reading shall be 30 kv which is equivalent to the dielectric strength of 300 volts/mil using the prescribed sample volume.

(3) Calculations. Dielectric strength = volts/mil (volts/100mil).

NOTE

"mil" refers to gap between electrodes.

7-9. Particulate Contamination.

a. Introduction. This procedure describes how to perform the counting of particles suspended in SEBD using the Hiac/Royco Model 800A Particle Counter.

b. Equipment and Materials.

Model 8000A Hiac/Royco, Particle Counter with Printer Automatic Bottle Sampler unit (ABS) Methonol or Isopropanol (filter the solution through a 0.45 micron filter) Petroleum Ether (reagent grade)

c. Equipment Information. The referenced particle counting system is comprised of several individual components. A counter, an automatic bottle sampler, and a sensor. Descriptions of each of the components are given below:

(1) The counter is equipped with a keypad, a 40 column 16-line liquid crystal display (LCD), and an internal 40 character per line graphics printer. Although wide ranges of contamination standards are resident in the unit, the operator has the option of storing a different standard, which better describes the desired application. Any of the standards can then be selected with a single keyboard entry. The Model 8000A is capable of acquiring count data for eight particle size ranges. The calibration graph for the sensor being utilized shows the actual values that must be input to the counter to set the size range limits for the test. Whenever a different size range is desired or when a different sensor is utilized the corresponding graph must be entered into the counter. The manufacturer supplies the calibration graph and the counter is calibrated every 5 months. Before a test can be run, the operator must input the number of sample runs to be performed. The counter automatically gives results for each sample data run as well as the average of the selected number of runs. The operator must also input the limit for the counter's audible alarm. After the test has been performed, the results can be displayed in either tabular or histogram format, and a hard copy can be obtained from the printer.

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(2) The automatic bottle sample is a Hiac/Royco model ABS sampler (P/N BS-13). The sampler is

comprised of three components: A sample holder, a volume measuring tube, and a control box. The sample to be analyzed is placed in a container inside the sample holder. This sample holder has a pressure rating of 60 PSI and is equipped with a magnetic stirrer, which keeps the sample particles in a uniform suspension. Positive pressure is then used to transfer the sample, at a constant flow rate, from the sample holder through the sensor (which will be discussed later) to the volume measuring tube. The pressure required for this transfer can be provided by either a facility air supply or by a separate pump. The sampler is equipped with a locking regulator to regulate the supply pressure down to the desired 5 to 60 PSI. Once the sample has passed through the sensor, it goes into the volume measuring tube. This tube is equipped with two moveable light sensors, which generate the "start count" and "stop count" signals to the counter. The volume of sample to be analyzed is determined by the positioning of these two light blocks. Upon completion of a test, the volume measuring tube is drained by means of an automatic valve and drain line.

(3) A ac/Royco mode HRLD-400 sensor (P/N 040 x 300-1) is provided with the particle counting system.

This sensor, which detects particles in the sample by means of the light obscuration method, has the following specifications:

(a) Measurement Range: 2 - 400 microns

(b) Recommended Concentration Limit: 8,000 particles/ml

(c) Flow Rate: 10 - 200 ml/Min

(d) Pressure Limit: 1000 psi

(e) Temperature Limit:: 150 degrees Fahrenheit

(f) Frequency Response: To 250 kHz

(g) Precision: Coefficient of variation less than 1% for mean mounts greater than 1000 particles per ml.

(h) Accuracy: Traceable to NIST Standard Reference Materials. (4) As mentioned previously, a calibration curve is provided with the sensor so that the operator can key the desired size range limits into the Model 8000A Counter. This sensor will be calibrated with glass spheres in oil or water with latex spheres (use the values from the curve). d. Test Procedures.

(1) Turn on the particle counter and the automatic bottle sampler. (2) Press any key on the key pad to access the main function menu. (3) Place a container of the sample to be analyzed into the sample holder. Put a clean stirring rod into

the container and turn the sample holder's magnetic stirrer on.

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NOTE

Be extremely careful that the stir bar is "just" moving to eliminate the counting of bubbles as particles. If a vortex appears in the center of the liquid, it is being stirred too rapidly. Adjust stir speed until vortex is no longer visible.

(4) Position the volume measuring tube light blocks. The volume of sample that is analyzed is determined

by the positioning of these two blocks. Volume should be set for a 100 ml sample size. (5) Set the locking regulator on the sample holder to the desired pressure. Desire pressure will provide a

flow rate of 20 ml in 20 seconds, ≈ 14-20 PSI. (6) Press start key. (7) Once the test is complete obtain results from the display and/or printer. (8) First flush the system with a total of 60 ml of Petroleum Ether, followed by flush with 120 ml of

menthanol. (9) Turn off the particle counter and automatic bottle sampler.

NOTE

If initial set-up data is lost, reenter data using the following calibration procedures.

e. Calibration Procedures.

(1) Turn unit on and press any key. (2) Press the more key on the main function menu. (3) Press the user STD key. (4) Press the alter STD key. (5) Enter the following data:

(a) Standard Name: Latex (b) Number of Classes: 16 (c) Coml/Diff: Cumulative (d) Class Limit Units: Counts (e) Sample Volume: 20.00 ml

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(f) Classify: Runs only

(g) Number of Channels: 3

(h) Class 1 thru 16: N/A

(i) Channel 1: 10

(j) Channel 2: 200

(k) Channel 3: 400

(6) Press exit key. (7) Save standard in storage slot #1. (8) Using exit key return to main menu. (9) From the main menu, press Set-up. (10) Press the global set-up key and enter the following data:

(a) Operator ID: Operators Initials (b) Number of Runs: 3 (c) Delete Time: 00H, 00M, 10S (d) Delay Time: 00H, 00M, 00S (e) Transducer Units: English (f) Quick-Adjust-Rate: 02H, 30M

(11) Press the exit key to return to the parameter set-up function menu.

(12) Press the control set-up key and enter the following data:

(a) Sample ID: 000

(b) Background: OFF

(c) Dilution Factor: 1.00

(d) Standard: Latex in Water

(e) Mode: Volume

(f) Sample Volume: 20.00 ml

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(13) Press the exit key and return to the parameter set-up function menu.

(14) Press the exit key to return to the main menu.

(15) From the main menu, press the cal key.

(16) Press the set cal key.

(17) Press the alter cal key and enter the following data:

(a) Sensor Model: HRLD-400

(b) Serial Number: 9306-003

(c) Calibration Date: dd/mm/yr

(d) Material: Latex in Water

(e) Flow Rate: 60 ml/Min

(f) Sensor Type: Extinction

(g) Algorithm: Interpolation

(h) Noise: 13.5 mV

(i) Extinction: 12

Diameter

2.020 3.020 5.007 9.870

15.000 20.490 32.200 40.100 58.500

112.000 165.000 301.000

MV

41 60

132 309 475 641

1020 1240 1720 3210 4300 7500

(18) Press the exit key to go to the calibration function menu.

(19) Press the bin size and enter the following data:

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Number of Channels 3 Channel Threshold (Micrometers)

1 2 3

10 200 400

(20) Press the exit key to return to the calibration function menu.

(21) Press the exit key and return to the main menu.

NOTE

The tester is now ready for use.

7-10. Volume Resistivity.

a. Introduction. This procedure describes the method for performing volume resistivity of silicate ester based coolant with the JPF-60 test set.

b. Equipment and Materials.

(1) QuadTech 1865

(2) Rosemond JPF-60 Test Cell

(3) Rosemond (PN JPF-60) Model TF-12 Test Fixture

(4) Glass Vials

(5) Petroleum Ether

c. Test Information.

(1) The referenced test set provides technicians and the capability to interface a liquid sample of SEBD with the resistivity test set (test fixture) and the megohmeter in order to perform a volume resistivity test. This test measures the dielectric properties of the fluid that may be degraded by particle contamination.

(2) The test set consists of a pronged end, a three terminal guarded electrode end, and a wire bale

clasping section used to hold the glass vial, which contains the required sample. (3) The pronged end is a three pole male connector that will mate with the resistivity test fixture. The test

fixture is a rectangular box shaped fixture, which includes a hinged cover provided for safety concerns. When the user opens the cover during testing, the test voltage will be curtailed. The back of the test fixture contains a two input hard wire connection.

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The back also contains a hard wire phone jack connection that mates with the ohmmeter rear phone jacks to establish a foot remote control feature. In addition, the back of the test fixture contains a single thin (ground) lead that will run to the ohmmeter's chassis ground terminal. Inside the test fixture cover, a cylindrical receptacle is installed that allows the resistivity test set to be mounted.

(4) A glass vial containing sample fluid will be clamped inside the test set, and at the same time the three terminal electrodes of the test set will become immersed in the vial fluid. The test set containing the sample fluid is put onto the test fixture part of the test set and the test fixture is connected to the megohmeter. When the resistivity test fixture, test cell, and glass vial containing the test sample of SEBD is connected to the megohmeter, a series resistance circuit is formed. The resistance of the sample is connected in series with a known value of resistance (in the megohmeter) selected for the test. These two resistance's (one unknown) form a voltage divider across the regulated power supply. The output of this voltage divider, which is inversely proportional to the value of the unknown resistance (test sample), is applied to an amplifier that drives the megohmeter meter (calibrated in megohms) to display the measured value.

d. Test Procedures.

(1) Preliminary adjustments - Model 1865 Megohmeter

(a) Turn unit on.

(b) Recall setup data. Recall function is found in the utility menu.

(c) Zero the megohmeter at 500 volts after connecting with the test fixture. Zero function is found in the utility menu.

(2) Megohmeter set-up:

(a) Set-Up Menu

1. Voltage: 500 volts 2. Change Time: 10 sec 3. Dwell Time: 1 sec 4. Measure Time: 60 sec 5. Discharge Time: 10 sec 6. Mode: Auto

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7. Range: Auto 8. Limit: 1.52 x 108 ohms 9. Stop on Pass: 60 10. Average: 60

(b) I/O Menu

1. Display Type: Pass/Fail 2. Result Format: Engineering

NOTE

Remainder of I/O Menu is optional.

(c) Utilities Menu

1. Save Set-Up: Optional 2. Recall Set-Up: Optional 3. Zero: Refer to preliminary adjustment above. 4. Lock Out: Optional

NOTE

Remainder of menu is optional.

(3) Operation

(a) Fill a clean test cell vial to the reference mark with a sample. Insert the cell into the vial and

latch the vial in place with the wire holder. Turn the vial (one or two quarter turns) to wet the electrode surfaces and clear any entrained air bubbles.

(b) Insert the test cell with sample into the test fixture receptacle. Close the test fixture lid. Press

the green start key. The megohmeter will display a pass or fail message on the instrument screen.

(4) Calculations

P = R/K (a) In the formula above P = volume resistivity, K = the test cell constant, and R = volume as

indicated on the megohmeter. To determine the volume resistivity of the sample, divide the volume resistance (R) measured by the megohmeter by the test cell constant (K). A volume resistivity equal to or greater than 4 x 1010 ohm per centimeter is acceptable. The cell constant (K) for the JPF-60 test cell is .0038/cm.

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(b) In the event the test cell changes, a new limit (volume resistance) will have to be calculated based on the new test cell constant (usually expressed as K) and entered in the megohmeter set-up screen. Using the JPF-60 test cell constant as a reference, calculate the new limit as follows: P = R/K R = PK = (4 x 1010) (.0038) = 152,000,000 or 1.52 x 108 ohms

(5) Cleaning cell. For routine cell cleaning, rinse with petroleum ether and wipe with a clean cloth, particularly the area between the tip and the sleeve. Unscrew the outer cylindrical electrode from the cell body. Rinse with petroleum ether and wipe the insulator area with a clean cloth, particularly between the inner electrode and the guard ring. 7-11. Water Content.

a. Introduction. This procedure describes the method for measuring the water content of silicate ester based coolant with the Karl Fischer Coulometric Titrator (Aquatest 8). The Aquatest 8 uses both the dead stop electrode and the coulometric generation of iodine in a closed vessel system. The coulometric addition of iodine makes the Aquatest an absolute instrument. When a sample is added to the vessel reagent, the voltage rises across the sensing electrode to indicate the wet state. This triggers the coulometer and a constant current flow through the generator producing iodine in the vessel reagent. The iodine reacts with the water from the sample and the vessel solution. When all the water has reacted, the voltage at the sensing electrode drops. This signals the coulometer to stop. The electrical charge produced during the titration is measured coulometrically and is displayed as the total water content. Since the reagent in the vessel is returned to an initial state at the end of each sample addition, sequential analysis can be performed until the vessel reagent is exhausted. b. Equipment and Materials. (1) Titrator, Karl Fischer Coulometric (P/N 02-128-10) Solvent

(2) Generator Pyridine Free (50 ml) Solution

(3) Vessel Pyridine Free Isopropyl Alcohol TT-I-735

(4) Methanol O-M-232

(5) Sodium Hydroxide, 1 Normal Solution 0S598

c. Test Information.

(1) The referenced Karl Fischer Coulometric Titrator consists of an Aquatest 8 Titrator and a printer. The Aquatest 8 is a microprocessor-controlled, automated Karl Fischer Coulometric Titrator, which is manufactured by Photovolt, a division of Seradyn, Inc. (FSCM 47125). It is comprised of a base unit, which houses the microprocessor, a titration vessel assembly. (2) the sample is inserted into the Titractor by means of a sample syringe. The sample will be taken from the sample container and injected into the Titrator's vent hole or its septum opening. At this point, test parameters and other data are input to the Aquatest 8 Titrator via a spill-resistant keypad on the base. The titration is then initiated, via the keypad, and the Aquatest 8 proceeds to automatically perform the titration.

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Upon detection of the titration end-point, the results are displayed on the base's sixteen character alphanumeric display. This value can be given in terms of micrograms, percent water, or PPM (parts per million). The printer that is provided with the Aquatest 8 can then be used to obtain hard copies of the test results.

(3) The silicate in the SEBD will react with the reagent to produce water over an extended period of time. The addition of water to the solution will give inaccurate results. In order to remedy the situation, new solution and reagent will be used every 48 hours.

(4) Specifications for the Aquatest 8 are as follows:

(a) Accuracy: 1 microgram or 0.05% whichever is greater. (b) Capacity: Readouts to 999,999 micrograms of water. (c) Range: 1 PPM to 100% moisture. (d) Rate: 2540 micrograms of water per minute. (e) Electrical: 110 V, 50/60 Hz, 40 Watts

d. Test Procedures.

(1) Instrument Set-Up

(a) Place the Aquatest 8 instrument on the laboratory bench in an area away from direct sunlight

and sources of heat such as ovens. (b) Handle the generator assembly by the Teflon collar.

(c) Holding the vessel cover with the thumbscrews facing away from you, feed the generator

plugs and wires through the larger threaded opening. While gently pulling the wires out of the way of the threads, insert the end of the generator that is opened into the cover. Carefully screw the generator into cover.

NOTE

Do not overtighten generator in the vessel cover.

(d) Lightly and evenly grease the ground glass rim of the Pyrex vessel jar with the Photovolt special sealant. Check to see that the three thumbscrew fasteners on the cover are fully unscrewed and extended. (e) Place a clean and dry magnetic stir bar into the vessel jar.

(f) Carefully join the titration vessel jar and cover with the generator assembly. Twist the cover gently to spread the sealant. Finger tighten the thumbscrew grasps the lip of the vessel jar securely. (g) Install a membrane septum.

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(h) Lightly grease the ground glass collar area of the sensor electrode. Insert the electrode into the small opening of the vessel cover. Carefully and gently seal the collar into the cover. Assure the two circle platinum rings at the end of the electrode are parallel to each other and to the side area of the vessel jar closest to them. (i) Enter the test parameters into the Aquatest 8 via the keypad.

(2) Pyridine Free Reagent Set-up

(a) In an exhaust hood or well ventilated area, remove the septum holder cap and membrane from the vessel cover, place the funnel supplied into the septum support, and add the entire contents of a bottle of vessel reagent. Remove the funnel and replace the septum and cap.

(b) Remove the generator cap and using a glass syringe, add approximately 3-4 ml of pyridine-

free generator solution to the generator. Replace the generator cap. (c) Place the vessel jar onto the Aquatest 8 inside the plastic retaining ring. (d) Plug the two banana plugs from the generator into the two banana jacks on back of the

Aquatest 8, black-to-black and red-to-red for proper polarity. Plug the sensing electrode plug into the smaller two jacks; the larger sensor plug goes into the small red jack.

(e) Plug the power cable of the Aquatest 8 into a 110-vac grounded receptacle.

NOTE

Assure the Aquatest 8 does not share its power line with devices capable of causing power line disturbances such as motor, compressors, refrigerators and ovens.

(f) Switch on power. The Aquatest 8 will perform internal diagnostics, then display select mode.

NOTE

Once the Aquatest 8 is first turned on, wait 30 minutes before performing a sample assay. This time allow the instrument and vessel assembly to stabilize in its new working environment. Photovolt pyridine-free reagent does not require the use of any neutralizing reagent.

(g) Dipswitch setting should be 1, 2, 4, 8, UP and 3, 5, 6, 7, DOWN.

(h) Turn on the Aquatest 8, and when select mode is displayed press monitor.

(i) Press the first key on the left of the upper 4 keys that correspond to sen.

(j) At this time you will see wet/dry status which will usually show the reagent being at set point or

slightly wet; this will be displayed on the Aquatest 8 as follows: WET….!..^…….DRY.

(k) When the vessel is at set point a caret (^) on the dotted line will appear. The instrument is ready to perform assays.

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(3) PPM Moisture Assay.

(a) Press set-up.

(b) Press the fourth white function key under WT.

(c) Press the fourth white function key under NO to enter in a single sample weight.

(d) Press the fourth white function key under NO to allow manual entry of sample weight.

(e) Press clr to remove the weight value stored in memory.

(f) Key the 1800 mg as the weight of the sample and press enter. The Aquatest VIII will beep as it stores the value in memory.

NOTE

In order for the Aquatest 8 microproccessor to compute water content in ppm by weight, it must know the weight of the fluid sample. SEBD has a specific gravity of 0.9, weighing 0.9 grams per ml. The sample size of 1 ml, therefore, represents a sample weight of 0.9 grams or 900 milligrams (mg). A sample size of 2 ml, therefore, represents a sample weight of 1800 mg.

(g) Again press set-up and this time press the first function key to choose unit.

(h) MCG PCT PPM will be displayed. Press the third function key to choose ppm.

CAUTION

If the test set has not been used for 12 hours or more, initial test results may tend to be inaccurate. Perform two or three analysis, using spare SEBD to allow the test set to stabilize.

NOTE

Since the weight analysis is to be based on the weight transferred, care must be taken to remove all air bubbles from both the syringe and the needle. Careful wiping of the liquid clinging to the needle is required for precision. Do not draw the tissue all the way over the end of the needle. Wipe to just the edge of the needle tip and then stop. Blot the membrane septum between samples.

(i) Remove the cap from the sample bottle. Using a clean, dry 10 ml glass hypodermic syringe

fitted with 4-1/2 inch needle, slowly draw approximately 1 ml of sample fluid from the sample bottle into the syringe. Withdraw the plunger past the 8 ml mark. Coat the interior walls of the syringe with the SEBD. Depress the plunger and expel the 1 ml of SEBD into a waste container. Wipe needle clean.

(j) Using the same 10 ml glass hypodermic syringe fitted with 4-1/2 inch needle, slowly draw

approximately 7 ml of sample of fluid from sample bottle into the syringe.

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(k) With the needle pointed up, allow the air bubbles to rise to the tip. Place the wiping material halfway over the needlepoint and slowly expel into wiping material any air trapped in the syringe and any fluid in excess of 6 ml. Syringe should now contain exactly 6 ml of sample fluid and no air. Clean the needle with wiping material.

(l) Press set-up. The third option is dly; press the white pad. Next menu will display mcg time.

Press the second pad correlating to time. Press the clr key on the keypad and enter 0.3. This is 0.3 minutes or 18 seconds of a delay in the titration. Finally press enter. Now the instrument will delay the start of the titration by 18 seconds after the initial 7-second injection period has elapsed.

(m) Press start. Introduce sample immediately and add sample 7 sec is displayed as follows:

Insert needle through membrane septum on sampling port in vessel cover until it is below the level of the vessel solution and discharge precisely 2 ml of fluid directly into the vessel solution. Remove the needle from sampling port. After 7 seconds, the display will show delay for 0.3 minutes and be automatically followed by titration.

(n) At the end of the titration, the weight that is in memory will be displayed as a confirmation test.

If it is the correct weight, merely press enter and the results of the assay will be displayed in parts per million water.

NOTE If the sample weight displayed after titration is incorrect, press clr and enter the correct weight followed by enter. If you are assaying a number of samples of the same weight, you will only need to enter this weight once. Results of water analysis should be reported as an average of at least three runs. Results are considered to have good repeatability if they are within 11 ppm of each other.

(o) Repeat step m above for next injection of the same sample. If a different sample is to be

injected, repeat step l above. (p) Thoroughly clean the syringe, attached needle and plunger with methanol and allow them to

air dry. If an explosion-proof oven is available, place the syringe with plunger out of the barrel into the oven at 150-185 degrees F or 65-85 degrees C. After 5 minutes, remove the apparatus from the oven using protection for the hands and insert the plunger into the syringe barrel. Allow it to cool to room temperature (approximately 2 to 3 minutes).

e. Cleaning Generator for Silicate Diester.

(1) The bottom end of the generator assembly consists of a porous Pyrex glass frit. With use, the

minute fluid passages in the frit will become clogged, retarding the transfer of generator solution to vessel solution during titration. This condition may be indicated by the error display gen overvoltage and can be corrected by cleaning the frit. (This display does not always occur).

WARNING

Do not get sodium hydroxide (NaOH) solution in eyes, on skin, or on clothing; it causes severe burns. Do not take it internally. Wear gloves and wear goggles (or face shield) when handling. Continuously stir solution while adding compound; add it slowly to surface of solution to avoid violent splattering. Limit the heat rise to 50°F (10°C) per minute. Do not allow temperature of solution to exceed 194°F (90°C) when mixing. Do not use on aluminum parts; reaction with aluminum forms large volumes of hydrogen gas. Flush area of spillage or leakage with water spray.

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(2) The generator frit is cleaned by soaking it in a sodium hydroxide (caustic) solution (5, table 6-3) and

applying a vacuum to the top of the generator assembly. The vacuum pulls the caustic solution through the frit, opening up the pore structure. To clean frit, proceed as follows:

(a) Remove power from the Aquatest 8 by switching the power off in back of the instrument. (b) Disconnect the generator and sensing electrode cables from the jacks.

(c) Loosen the three thumbscrews on the vessel cover and swing pawls away from the titration vessel. Use gentle twisting motion to loosen grease seal and remove cover.

(d) Remove generator cap from generator assembly and pour used generator solution into an approved waste container.

(e) Pour used vessel solution into the same waste container used step 4.b.(4). Be careful not to pour out the magnetic stirring bar. Seal the waste container. Next transfer the magnetic stirrer bar from titration vessel onto a clean wiping cloth. Wipe and dry stirring bar.

CAUTION

Do not separate the sensor and generator assembly from the teflon cover. (f) Grasp Teflon mounting collar on generator assembly and remove from vessel cover by carefully unscrewing threaded section. Remove sensing electrode and wipe it clean. (g) Using the empty titration vessel, stand sensor and generator assembly to be cleaned in empty vessel. Pour technical grade one Normal (1N) sodium hydroxide (NaOH) solution into the empty vessel jar until a level of approximately 2 inches is reached. (h) Pour additional solution into top opening of generator assembly, just enough to cover the frit. (i) Allow generator assembly to soak 4 hours, or longer, in the sodium hydroxide solution. Periodically observe fluid level inside generator. An increase in level will indicate partial clearing of the frit; the open frit allows fluid to transfer from the vessel into the generator. Upon completion of soaking, discard used NaOH solution into an approved waste container, or dispose by approved methods. (j) Expedite cleaning of porous frit after soaking procedure by the application of a vacuum (not to exceed 15 inches mercury (Hg)) to the generator assembly. Required vacuum can be obtained using the syringe and valve provided with contamination Analysis Kit, part No. 57L414. Locally fabricate required adapters to connect vacuum source to generator, using modified rubber or cork stopper to connect vacuum line to open end of generator. (k) Place fresh sodium hydroxide solution in emptied titration vessel, enough to partially cover the generator assembly when it is placed in the titration vessel. Apply vacuum to generator assembly until caustic cleaning solution flows freely from the vessel jar to the inside of the generator. Carefully observe fluid level in generator and assure that fluid is not sucked into vacuum line. A filtering flask may be installed as a trap between the generator and the vacuum pump. If required, pour excess fluid from generator assembly to waste.

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(l) When frit has been cleaned, remove sensor and generator assembly from vessel jar and discard caustic solution into an approve waste container, or dispose by approved methods. Rinse generator assembly and vessel jar using generous amounts of water, preferably hot.

(m) Return generator assembly to the vessel jar and partially fill vessel with water (tap or

deionized). Using vacuum procedure specified in steps (j.) and (k.), flush frit with water to remove residual caustic solution.

(n) Remove generator assembly from vessel jar and discard water.

WARNING

Methanol is flammable - Do not use near open flames, near welding area, or on hot surfaces. Do not smoke when using it, and do not use it where others are smoking. Prolonged or repeated inhalation of vapor can cause eye irritation, drowsiness, and headache. Ingestion may be fatal or may cause eye damage. If vapor contacts eyes, immediately flush eyes with large amounts of water. Immediately remove solvent-saturated clothing. If vapor cause drowsiness, remove affected person from area and expose to fresh air. When handling or applying liquid at air-exhausted workbench, wear approved goggles and gloves. When handling or applying liquid at unexhausted workbench, wear approved respirator, goggles and gloves.

(o) Remove residual water from generator assembly by pulling Methanol through generator with

vacuum, as described in steps (j) and (k), and then drying in oven (if available) at 150 to 185°F (65 to 85°C) for a period of 2 hours. If no oven is available, allow to air dry before use. Store generator in desiccator if available, until needed.

(p) In some cases, because of lack of equipment, it may not be possible to clean the frit in

shipboard laboratories. In these cases the laboratory should change the generator assembly. The assemblies which need cleaning of the frits should be retained and subsequently taken to a shore based laboratory where cleaning can be accomplished.

f. Calibration.

NOTE

The Aquatest 8 does not require calibration. However, a user calibration procedure is provided so that the user can quickly confirm that the instrument is indeed titrating water accurately. User calibration is generally done every 6 months or as needed (whenever erroneous results are suspected).

(1) Set Aquatest 8 to mcg mode (see paragraph D (g) and (h)).

NOTE

In preparation for the following, fill beaker or other clean container with small amount of tap or deionized water. Set adapter on syringe to 1.0 microliter mark on syringe barrel. Pump syringe several times while needle is submerged in water to remove air. Remove membrane from sample port to enable needle (shorter length) to be below vessel solution.

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(2) Press start. Introduce sample immediately after add sample 7 sec is displayed as follows: Insert needle of a gas tight 2 microliter syringe (15, table 3-1) with built in Chaney adapter directly through the septum on the sampling port in the vessel cover until it extends below the level of the vessel solution and discharge precisely 1.0 microliter of water into the vessel solution. After a brief moment, remove syringe and needle from sampling port and replace membrane. After 7 seconds, the display will show delay and be automatically followed by titration. Established that; you obtain 1000 + 50 micrograms of water. Repeat additions until you have 5-10 replicates to determine precision (standard deviation less than or equal to 50 mcg is acceptable). Flush needle several times with water prior to storing to remove chemicals from Aquatest that will cause corrosion.

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SECTION VIII

CONTAMINATION TESTING OF COOLANT IN OPERATING SYSTEMS, ETHYLENE GLYCOL/WATER (EGW)

8-1. Introduction. This section defines the procedures, requirements, equipment and material needed for sampling and testing Ethylene Glycol/Water (EGW) used in operating systems such as airborne systems, filtering and fluid supply carts, and other ground servicing equipment. The testing shall provide information on the degradation and contamination of EGW for controlling and monitoring their use. 8-2. General. a. The equipment cooling system of the B-2 aircraft incorporates three liquid cooling subsystems and five circulated air subsystems. The liquid cooling subsystems consist of the Ethylene Glycol-Water Subsystem (EGW), DMS/LC Subsystem and the Liquid Cooling Subsystem (LCS). b. The EGW subsystem is composed of two independent closed cooling loops which use Ethylene Glycol-Water (EGW ) solution as a heat transfer fluid. Each loop circulates coolant from the heat sources and transports the heat to the sink heat exchanger for heat dissipation. The primary heat sources for the EGW loops are the aft bay rack mounted avionics, the forward left avionics, the forward right avionics, the forward left avionics, the forward right avionics, the DMS/LS and the LCS. The Ethylene-Glycol Water subsystem supplies coolant at a flow rate of 85 psig per minute to transport the sink heat from the heat sources to the heat exchangers. The coolant is supplied at a nominal temperature of 47 degrees F with a maximum system pressure of 175 psig. c. The Ethylene Glycol-Water solution is a mixture of 62.8 + 1.0 percent ethylene glycol by weight, distilled water and appropriate corrosion inhibitors. The EGW coolant appears as a clear, light straw colored liquid and has a characteristic odor. The EGW fluid is composed of the following:

MATERIALS SPECIFICATION

MATERIALS OR SOURCE PART BY WEIGHT Ethylene Glycol, Technical Triethanolamine- Phosphate (TEAP) 50 Percent (by weight) Sodium Mercaptobenzothia- Zole (NaMBT) Benzotriazole Di Water

ASTM E 1119-92 Commercial Grade Commercial Grade Commercial Grade Commercial Grade

62.80 + 1.00 1.60 +/- 0.10 0.17 +/- 0.02 0.50 + 0.5 35.00 + 1.00

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TABLE 8-1. EGW COOLANT TEST REQUIRMENTS

Appearance Clear and bright, with no evidence of turbidity,

haze, cloudiness, gelation, sediment, visible particles or fibers, separation, precipitation, or contamination.

Foaming (Optional) - Increase in volume in 5 minutes. - Break Time.

- 350 milliliters, maximum. - 30 seconds, maximum.

Particulate Contamination per 100 milliliters of Aircraft Fluid, microns:

– 5 to 15 microns – 15 to 25 microns – 25 to 50 microns – 50 to 100 microns – over 100 microns

- over 200 microns Particulate Contamination per 100 milliliters of GSE Fluid, microns:

– 5 to 15 microns – 15 to 25 microns – 25 to 50 microns – 50 to 100 microns – over 100 microns – over 200 microns

– 93,000 particles – 15,400 particles – 3,130 particles – 430 particles – 41 particles

– 5 particles

– 27,000 particles – 4,000 particles – 1,300 particles – 180 particles – 17 particles – 2 particles

pH at 60 F

7.80 to 8.50

Refractive Index at 60 F 1.3900 to 1.4030

Specific Gravity at 60 F 1.0850 to 1.0910

Accelerated Stability No turbidity, cloudiness, precipitation, deposit formation, gelation or phase separation after the coolant is heated to 190 F for 24 hours.

Sodium Mercaptobenzothiazole (NaMBT) Content 0.13 to 0.20% by weight 50% NaMBT 8-3. Equipment.. Equipment identified to each specific test shall be maintained per manufacture's requirements. Records of maintenance and calibration of the equipment shall be maintained. Testing facilities shall be free of contaminates detrimental to test performance and shall be cleaned at intervals deemed necessary to maintain the cleanliness of the area.

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8-4. Test Sequence. To minimize the quantity of fluid needed to perform the EGW tests and to minimize the effects of sample handling, testing should be conducted in the following sequence: Paragraph

Appearance 8-7 Dielectric Strength 8-8 Particulate Contamination 8-9 Refractive Index 8-10 Specific Gravity 8-11 Accelerated Stability 8-12 NaMBT Content 8-13

8-5. Laboratory Safety.

a. Standard lab safety procedures should be followed. All chemicals should be treated as potentially hazardous and handled with care. Petroleum ether and methanol, which will be used to clean the sample containers on the instruments are flammable and should not be exposed to a flame, spark or high heat.. Safety goggles and gloves impervious to organic solvents should be worn at all times. An eye wash station, fire blanket and fire extinguisher should be readily accessible at all times. Material Safety Data Sheets (MSDS) for all chemicals should be accessible to lab personnel while working in the lab. Never work in the lab alone-ensure there is someone else within easy calling distance.

b. Waste chemicals should be disposed of in approved marked waste containers. While the waste organic chemicals used in these procedures may be mixed in a single waste container, it may be more convenient to use one container for EGW waste chemicals and another for EGW wastes. Remove waste chemicals from the lab on a regular basis. 8-6. Testing. 8-7. Appearance.

a. Prior to the sample analysis, the unopened sample bottle shall be visually inspected for proper filling and sealing, as well as evidence of gross contamination. Properly filled bottles will be almost completely filled with fluid extending up to the bottom of the threaded neck section. The purpose of completely filling the bottle is to minimize the quantity of air present, which could contain large amounts of atmospheric moisture, and to assure that adequate fluid is available to perform all of the required tests. Activities submitting EGW fluid samples in improper or inadequately filled bottles shall be advised to resample the equipment.

b. Prior to sample analysis, fluid in the sample bottle shall be visually inspected for evidence of turbidity or

visible particles. This inspection is somewhat limited by translucent plastic bottles but can be remedied by using a clean glass bottle or positioning the plastic bottle in front of a strong light source.

c. Gross particulate contamination, i.e., particles large enough to be seen with the unaided eye, will also be

most visible when the fluid is allowed to stand motionless for a period of time. Particles will generally settle to the bottom of the bottle. Gross particulate contamination is usually indicative of improper sampling technique. If this is suspected, the submitting activity shall be advised and requested to resample the equipment.

d. Fluid turbidity results in the EGW fluid appearing cloudy as opposed to its normal clear, transparent

appearance. Turbidity is most visible when the fluid is agitated and may be indicative of large amounts of air, free water or suspended foreign matter.Turbidity caused by suspended semi-solid matter is of particular concern as it may be indicative of chemical degradation of the EGW fluid. The contamination by-products of such degradation shall be cause for sample rejection.

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8-8. Dielectric Strength.

a. Introduction. This procedure describes how to measure the pH content of EGW using the type M-245 pH test meter.

b. Equipment and Materials.

(1) Pyrex Beaker

(2) pH Meter, Corning 245

(3) Glass Electrode

(4) Calomel Electrode, commonly referred to as the reference electrode.

(5) Adapter (if required)

(6) Thermometer - Saybolt Viscosity 14C (Range 19C to 27C, reading to 0.01C)

(7) DI Water

(8) Buffer solution: Buffer solutions can be purchased pre-mixed and certified. (pH 4, pH 7).

c. Equipment Information and Test Procedures. The referenced pH test meter is an upright box design. On the face of the meter is a keypad operated control panel which programs the calibration, temperature, mode selection, and time interval adjustments. The pH test meter has the following capabilities: Range: -2 to 14 pH Resolution: 0.01 pH Relative Accuracy: +/- 0.01 pH Modes: pH Temperature Span: -5 C to 105 C Power Requirements: 90 -127 or 198 -264 VAC, 50/60 HZ

NOTE

In use, the pH test meter is first set up with the calomel electrode and pH electrode attached to the electrode holder. Before beginning the test, standardize instrument with pH and pH7 buffers for maximum accuracy, Sample should be cooled in a water bath to 60°F or 15.6C before pH testing or calibration begins.

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d. Calibration Procedures.

(1) Calibrate the pH meter, Corning Model 245, as follows:

(a) Remove protective caps from electrodes. (b) Remove filler cap from reference electrode.

(c) Set the instrument to pH mode.

(d) Press cal button.

(e) Press right arrow key to select 2 point calibration.

NOTE

Lower display will read "cal 1" and upper display will read "7.00". If the upper display reads "0", press 7.00 on the keypad. Lower display will read "read".

(f) Place the electrodes in the pH 7 buffer solution and press the read button. Instrument will automatically adjust to pH 7 and a beep will be heard. Remove electrodes from buffer solution and clean.

(g) Lower display will read cal 2 and upper display will read 4.00. If the upper display reads 0

press 4.00 on the keypad. Lower display will read "read". (h) Place electrodes in pH 4 buffer solution and press read button. Instrument will automatically

adjust to pH 4 and a beep will be heard. Remove electrodes from the buffer solution and clean. Press exit button. Ensure unit is in pH mode.

(i) Verify calibration by measuring pH 4 and pH 7 buffer solutions as if they were a fluid sample.

e. Test Procedures.

(1) Before beginning the test, measure samples of both pH 4 and pH 7 buffers for maximum accuracy using preceding instructions. If samples do not measure correctly, calibrate instrument..

(a) Transfer sufficient volume of EGW fluid into a marked Pyrex beaker to allow the electrode tips

to be fully immersed without touching the glass container. (b) Remove electrodes from the storage solution and rinse with DI water. Gently blot the

electrodes with clean, soft cloth.

(c) Using a twisting motion, remove the plastic caps from the electrodes.

(d) Pull black plug out of the electrode fill hole.

(e) Measure sample temperature with thermometer.

(f) Place pH electrodes in sample. The tips are fully immersed when 1/2 inch into a sample; they may be immersed further, but, never up to the fill holes.

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(g) Ensure unit is in pH mode.

(h) Press read. Instrument will automatically display pH measurement and a beep will be heard.

f. Care of pH Meter. Remove electrodes from EGW fluid and rinse with DI water. Replace tip protectors and insert black plug into fill hole. The electrodes are stored immersed in pH 7 buffer solution, or distilled water, which is changed after every test setup or weekly at a minimum. Electrodes should be cleaned with DI water and blotted with a clean, soft cloth after each measurement.

CAUTION

Special care should be exercised in handling the electrodes, which are composed of a very fragile glass and may be easily broken.

8-9. Particulate Contamination.

a. Introduction. This procedure describes how to perform the counting of particles suspended in EGW using the Hiac/Royco Model 8000A Particle Counter.

b. Equipment and Materials.

(1) Model 8000A Hiac/Royco Particles Counter with printer

(2) Automatic Bottle Sampler Unit (ABS)

(3) Methanol or Isopropanol (filter the solution through a 0.45 micron filter)

(4) Petroleum Ether (Reagent grade)

c. Equipment Information.

(1) The referenced particle counting system is comprised of several individual components: A counter, an automatic bottle sampler, and a sensor. Descriptions of each of the components are given below.

(a) The counter is equipped with a keypad, a 40 column 16 line liquid crystal display (LCD), and

an internal 40 character per line graphics printer. Although wide ranges of contamination standards are resident in the unit, the operator has the option of storing a different standard, which better describes his application. Any of the standards can then be selected with a single keyboard entry. The Model 8000A is capable of acquiring count data for eight particle size ranges. The calibration graph for the sensor being utilized shows the actual values that must be input to the counter to set the size range limits for the test. Whenever a different size range is desired or when a different sensor is utilized, the corresponding calibration graph must be entered into the counter. The calibration graph is supplied by the manufacturer, and the counter is recalibrated every 6 months. Before a test can be run, the operator must input the number of sample runs to be performed. The counter automatically gives results for each sample data run as well as the average of the selected number of runs. The operator must also input the limit for the counter's audible alarm. After the test has been performed, the results can be displayed in either tabular or histogram format, and a hardcopy can be obtained from the printer.

(b) The automatic bottle sampler is a Hiac/Royco model ABS sampler (P/N BS-313). The

sampler is comprised of three components: A sampler holder, a volume measuring tube, and a control box. The sample to be analyzed is placed in a container inside the sampler holder.

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This sample holder has a pressure rating of 60 PSI and is equipped with a magnetic stirrer, which keeps the sample particles in a uniform suspension. Positive pressure is then used to transfer the sample, at a constant flow rate, from the sample holder through the sensor (which will be discussed later) to the volume measuring tube. The pressure required for this transfer can be provided by either a facility air supply or by a separate pump. The sampler is equipped with a locking regulator to regulate the supply pressure down to the desired 5 to 60 psi. Once the sample has passed through the sensor, it goes into the volume measuring tube. This tube is equipped with two moveable light sensors, which generate the "start count" and "stop count" signals to the counter. The volume of sample to be analyzed is determined by the positioning of these two light blocks. Upon completion of a test, the volume measuring tube is drained by means of an automatic valve and drain line. A Hiac/Royco model HRLD-400 sensor (P/N 040 X 300-01) is provided with the particles in the sample by means of the light obscuration method, has the following specifications:

1. Measurement Range: 2 - 400 microns

2. Recommended Concentration Limit: 8,000 particles/ml

3. Flow Rate: 10 - 200 ml/Min

4. Pressure Limit: 1000 psi

5. Temperature Limit: 150 degrees Fahrenheit

6. Frequency Response: To 250 kHz

7. Precision: Coefficients of variation less than 1% for mean counts greater than 1000

particles per ml 8. Accuracy: Traceable to NIST Standard Reference Materials

d. Test Procedures.

(1) Turn on the particle counter and the automatic bottle sampler.

(2) Press any key on the keypad to access the main function menu.

(3) Place a container of the sample to be analyzed into the sample holder. Put a clean stirring rod into the container and turn the sample holder's magnetic stirrer on.

NOTE

Be extremely careful that the stir bar is "just" moving to eliminate the counting of bubbles as particles.If a vortex appears in the center of the liquid, it is being stirred rapidly. Adjust stir speed until vortex is no longer visible.

(4) Position the volume measuring tube light blocks. The volume of sample that is analyzed is

determined by the positioning of these two blocks. Volume should be set for a 20 ml sample size.

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(5) Set the locking regulator on the sample holder to the desired pressure. Desire pressure will provide a flow rate of 20 ml in 20 seconds, ≈ 14 -20 psi. (6) Press start key.

(7) Once the test is complete obtain results from the display and/or printer. (8) First flush the system with a total of 100 ml of Methanol or IPA, followed by a flush with 120 ml of Petroleum Ether. (9) Turn off the particle counter and automatic bottle sampler.

NOTE

If initial set-up data is lost, reenter data using the following calibration procedures.

e. Calibration Procedures.

(1) Turn unit on and press any key.

(2) Press the more key on the main function menu.

(3) Press the user std key.

(4) Press the alter std key.

(5) Enter the following data:

(a) Standard Name: Latex

(b) Number of Classes: 16

(c) Coml/Diff: Cumulative

(d) Class Limit Units: Counts

(e) Sample Volume: 20.00 ml

(f) Classify: Runs only (g) Number of Runs: 3

(h) Number of Channels: 3

(i) Class 1 thru 16: N/A

(j) Channel 1: 10

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(k) Channel 2: 200

(l) Channel 3: 400

(6) Press exit key.

(7) Save standard in storage slot #1.

(8) Using exit key, return to main menu.

(9) From the main menu, press set-up.

(10) Press the global set-up key and enter the following data:

(a) Operator ID: Operator's Initials

(b) Number of Runs: 3

(c) Delete Time: 00H, 00M, 10S

(d) Delay Time: 00H, 00M, 00S

(e) Transducer Units: English

(f) Quick Adjust Rate: 02H, 30M

(11) Press the exit key to return to the parameter set-up function menu.

(12) Press the control set-up key and enter the following data:

(a) Sample ID: 000 (b) Background: OFF

(c) Dilution Factor: 1.00

(d) Standard: Latex in Water

(e) Mode: volume

(f) Sample Volume: 20.00 ml

(13) Press the exit key and return to the parameter set-up function menu.

(14) Press the exit key to return to the main menu.

(15) From the main menu press the cal key.

(16) Press the set cal key.

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(17) Press the alter cal key and enter the following data:

(a) Sensor Model: HR-LD400 (b) Serial Number: 9306-003

(c) Calibration Date: dd/mm/yr

(d) Material: Latex in Water

(e) Flow Rate: 60 ml/Min

(f) Sensor Type: Extinction

(g) Algorithm: Interpolation

(h) Noise: 13.5 mV

(i) Extinction: 12

(j) Diameter mV

2.020 3.020 5.007 9.870

15.000 20.490 32.200 40.100 58.500

112.000 165.000 301.000

41 60

132 309 475 641

1020 1240 1720 3210 4300 7500

(18) Press the exit key to go to the calibration function menu.

(19) Press the bin size and enter the following data:

Number of Channels 3

Channel 1 2 3

Threshold (micrometers)

10 200 400

(20) Press the exit key to return to the calibration function menu. (21) Press the exit key and return to the main menu.

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NOTE

The tester is now ready for use.

8-10. Refractive Index

a. Introduction. This procedure describes the method for measuring the refractive index of EGW coolant fluid using a refractometer and water bath. b. Equipment and Materials.

(1) Refractometer

(2) Thermometer - Saybolt Viscosity 17C (range 19C to 27C, reading to 0.01C)

(3) Water Bath, Model F3K

(4) Distilled Water

(5) Glass Standard

(6) Lens Tissue Paper

(7) Methanol

(8) Monobromonaphthalene ***Usually supplied with refractometer for calibration. Calibration procedures are found in the manufacturers manual.

c. Equipment Information.

(1) The refractometer is a precision optical instrument, with a focusable eyepiece and dispersion corrective prism, equipped for connection to a water bath for uncompensated measurements. It also has an adjustable built-in illumination system.

(2) The refractometer has the following specifications:

(a) Display: Direct reading LED

(b) Range, Dissolved solids: 0 to 85 degrees Brix, and % solids.

Refractive index 1.3210 to 1.7001 ND.

(c) Accuracy: +/-0.1 Birx, +/-0.0001 ND, +/-0.1% Solids

(d) Temperature Compensation Accuracy: +/- 0.2 degrees Centigrade

(e) Sample Types: Transparent or translucent liquids or solids.

(f) Sample Temperature Control: Refractive index and uncompensated Brix or % solids.

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(3) The circulating heated electric water bath, part number F3-K, NSN 4920-01-096-6405, is used in

conjunction with the refractometer. The circulating water bath is necessary to maintain prism temperature so sample is at the desired temperature (60°F). Calibrate the refract meter with standards such as monobromonaphthalene and a glass standard.

(4) The water bath has the following specifications: (a) Mounting type: stand

(b) Inside dimensions of the reservoir: 295 x 190 x 150 mm

(c) Operating temperature range: 10 to 150 degrees Fahrenheit (-23 to 65 C)

(d) Heating element current type: single

(e) Heating element wattage in watts: 1000

d. Test Procedures.

(1) Instructions for performing Refractive Index (RI) are as follows:

(a) Turn on circulating water bath and adjust controls to allow refractometer prism to reach 60°F +/-0.5°F or 15.6°C +/- 0.2°C.

(b) Place sample container in water bath and allow to come to 60°F +/- 0.5°F or 15.6°C +/- 0.2°C.

(c) Turn the mode selector to measurement mode N.

NOTE

Prism face is easily scratched which will cause inaccurate measurements. Use only lens tissue designed for instrument cleaning on prism surface.

(d) Verify prism temperature is 60 degrees F by pressing temp button.

(e) Open prism assembly and remove lens tissue from prism face (used to protect prism when

instrument is not in use). When adding sample be careful not to touch the eyedropper to the prism face. Never "wipe" sample onto prism. Sample should be added dropwise and when prism is closed it will spread.

(f) Place sample on prism using an eyedropper (the entire surface of the lower prism should be

covered). Do not touch prism face with eyedropper.

(g) Position the illuminator arm and lens for maximum contrast.

NOTE

While viewing through eyepiece, turn the adjustment control knob (located on right hand side of instrument) until the shadow line appears in the reticle field. The adjustment should be counterclockwise when the field appears dark and clockwise when bright.

(h) Press temperature button on front panel for readout of sample temperature. Sample should be

tested at 15.2 - 15.6C.

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(i) When sample reaches correct temperature range, focus on the shadow line. Turn the knob to

precisely intersect the shadow line with the cross hair.

(j) Depress the read button for measurement. Unit will count then display the measurement.

NOTE

If test fails, check accuracy of tester using distilled water. If tester is proven to be accurate, the EGW sample is out of the specification requirement. If test failed, recalibrate the instrument using the calibration procedures.

e. Calibration Procedures.

(1) Calibrate refractometer as follows:

(a) Turn mode selector to refractive index.

(b) Open the prism assembly and insure that the surfaces are clean.

(c) Apply a minute drop of 1-bromonaphthalene to the illuminator end of the refracting prism surface.

(d) Place the test glass standard on the contact liquid with the polished side down (refractive index alue face up), polished end toward the illuminator end of the refracting prism. Do not use an excessive amount of 1-bromonaphthalene, and avoid build-up along the polished front end of the standard.

(e) Gently press down on the test glass to insure there are no bubbles between the test glass and the refracting prism.

(f) Align the illuminator arm and lens so that the front edge face of the test glass is fully illuminated.

NOTE

To achieve the best possible contrast of the liquid field for this measurement, place a sheet of white tissue between the lamp and prism assembly. Diffused lighting will eliminate the black-white fringes (horizontal lines).

(g) Follow the steps in the general operating instructions for focusing the eyepiece, aligning the

shadow line with the cross hair and obtaining a measurement.

NOTE

The alignment of the lamp and color compensation must be accurate. Lamp mispositioning can create a secondary shadow line. The recognition of the proper contrast line can be easily achieved. Move the illuminator slightly up and down; the primary shadow line will not move. The accuracy of the instrument depends on how well the shadow line is set on the cross half.

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(h) Depress the read button; 1.3330 will be instantaneously displayed, followed by counting. When the counting stops, the ND value of the test glass is displayed. Note the value shown. The accuracy of calibration should be within 0.0001 ND of the value stamped on the test glass.

(i) If calibration is necessary, rotate the adjustment control knob and depress the read button, Repeat until the correct value, as indicated on the test glass, is obtained. Insert the allen wrench provided through the access hole in the dispersion control. Turn the adjusting screw carefully to move the reticle up and down until the shadow line is aligned with the center of the crosshair. Remove the test glass; clean and close the prism assembly.

CAUTION

Care should be taken to avoid any contact between the edges or sharp corners of the solid sample and the prism. If the flat surface of the sample is smaller than the refracting prism, place the sample on the far half of the prism surface, toward the illuminator. This will improve the contrast line visibility.

f. Care of Refractometer. - Prism should be cleaned after each sample is removed with a soft cloth or cotton swab dampened with DI water. The prism may be wiped with lens cleaning tissues but it should NOT be wiped with a hard, dry cloth. 8-11. Specific Gravity.

a. Introduction. This procedure describes the method of measuring the specific gravity of EGW using the hydrometer.

b. Equipment and Materials.

(1) Glass Stirrer or Glass Rod (to use with cylinder) (2) Thermometer - Gravity 12 C, (range -20 to +120 C) or 12 F (range -5 to +215 F)

(3) Water Bath

(4) Hydrometers, Numbers 111H to 117H, specific gravity range 1.000 to 1.350, precision 0.050 each

hydrometer.

(5) Hydrometer Cylinder

c. Test Procedures.

NOTE

Assure that the sample temperature is 60 F + 0.5 F, by immersing a thermometer into sample.

(1) Carefully pour the sample into the hydrometer cylinder without splashing. Remove the bubbles

formed after they have collected on the surface of the sample by touching with a clean, dry glass rod. Fill cylinder about 2/3 - 3/4 full.

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(2) Place sample in water bath and allow sample to reach 15C (60F). (3) Lower the hydrometer gently into the sample. Avoid wetting the stem above the level to which it will

be immersed. Stir the sample with glass rod, and record the temperature when a steady temperature has been reached. Remove the thermometer after recording temperature.

(4) Depress the hydrometer about two scale divisions into the sample and then release it, imparting a

slight spin. (5) When the hydrometer has come to rest away from the cylinder walls and with no air bubbles

present, read the density/specific gravity, by placing the eye slightly below the level of the liquid and slowly raising it until the surface of the sample becomes a straight line cutting the hydrometer scale.

(6) Again determine the sample temperature. If this differs from the initial value, repeat the hydrometer

test and then thermometer observations until no more than 1 F difference is obtained.

(7) Report the specific gravity/relative density to the nearest 0.001, and temperature measurement to the nearest 1 F.

8-12. Accelerated Stability.

a. Fill a 100-ml centrifuge tube to the 100 +0, –2 ml mark with coolant or add coolant to an acceptable level in a 100 ml to 500 ml three-neck flask so that a thermometer will have its bulb in the fluid. Cap with a properly sized one-hole rubber or cork stopper.

NOTE Cork stopper particles will float. Rubber particles will not.

b. Insert a 12-inch long glass condenser tube through the stopper. Insert a dry Nichrome or stainless wire into the condenser past the bottom of the condenser but not into the coolant as shown in ASTM D5828 Figure 1. The purpose of the wire is to provide a means of directing condensate back to the centrifuge tube. It is also permissible to have the fluid in a 100 ml to 500 ml three-neck flask and to utilize a 600 mm Vigreux distillation column in the center neck with an appropriate thermometer in one of the side necks and a solid rubber, cork, ground glass or Teflon stopper in the other side neck.

c. Expose the fluid to a target temperature of 200 F for 24 to 30 hours. It is permissible for the fluid temperature to fluctuate between 185 F and 210 F during the test. At the end of the test period, remove the fluid from the heat source and allow to cool to room temperature for at least one hour.

d. Remove the air condenser and stopper and replace with a solid rubber or cork stopper. Balance the centrifuge tube, stopper and fluid sample against another centrifuge tube (with stopper) containing another coolant sample that was not heated 190 F. If a three-neck flask was used, decant 100 ml +0, –2 ml of cooled fluid into a 100 ml centrifuge tube, then balance with another centrifuge tube filled with coolant to 100 ml +0, –2 ml.

8-13. NaMBT Content.

a. Adjust reagent grade deionized water (resistivity > 3,000,000 ohm-cm) to a pH of 5.2 using a pH meter, a small Pasteur pipette and glacial acetic acid that is diluted to 1% acetic acid by volume.

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Stir the water constantly with a magnetic stirrer while adding the diluted acetic acid. Use a Ross combination electrode or other suitable sensing electrode. Adjust at least 500 ml of deionized water that has been freshly boiled and allowed to cool to room temperature while covered.

NOTE

UV-visible measurement of NaMBT in EGW is not feasible because the 310-nm peak for this compound is strongly interfered by other ingredients that absorb at a lower but close frequency. If NaMBT is converted to MBT by adjusting the pH to near 5.2, the analytical peak changes to 322nm where the interference is slight.

b. Adjust a 100 ml sample of the coolant to a pH of 5.2 using reagent grade or better glacial acetic acid, a small Pasteur pipette, a magnetic stirrer, and a pH meter with Ross or other suitable electrode. Stir the sample constantly while adding the acid drop wise.

c. If available, use reagent grade ethylene glycol, benzotriazole, deionized water, triethanolamine, and phosphoric acid to formulate EGW fluid in accordance with MS-139, omitting the 50% NaMBT. Standards cannot be made using water alone, since the NaMBT is converted to the MBT form at pH 5.2, and is insoluble in water. Adjust the pH of the fluid to 5.2 as per step 2, then add known amounts of 50% NaMBT (R.T. Vanderbilt “NACAP”) to the fluid (weighing to the nearest 0.1 mg) to provide the desired standard (suggested approximate values of weight % of 50% NaMBT added to the fluid are 0.05, 0.10, 0.15, 0.20, and 0.25). Store the standards in a dark place in carefully sealed bottles (amber glass preferred).

d. Use pH 5.2 water or pH 5.2 EGW with no NaMBT to fill both cells and perform a baseline analysis.

Perform a zero analysis as well, operating the instrument in accordance with the manufacturer’s instructions. After completion of the baseline analysis, remove the cell from the sample beam, and leave the cell in the reference beam.

e. Dilute a 1 ml aliquot of each standard with pH 5.2 water to 1% standard by volume for a 1 cm cell or 10% standard by volume for a 1 mm cell. Use a Class A glass pipette or a Gilmont Micrometer Buret to obtain the 1 ml sample for the Cary 400 spectrophotometer. Other spectrophotometers may require different dilutions. Rinse the cell down with the diluted sample, then fill, and place in the sample beam. Scan the sample from 500 nm to 200 nm or other desired wavelengths, as long as there is sufficient distance on either side of the 322 nm peak. Multiple scans may be performed if the instrument does not demonstrate sufficient repeatability (the Cary 400 typically will not vary more than 0.001 absorbance unit from run to run, and does not normally required more than one analysis). Print the results, making note of the absorbance at 322 nm, and determine the absorbance of the valley just to the left of the 322 nm peak, and of the baseline to the right. Add the two absorbances on either side of the 322 nm peak, divide by two, and subtract from the 322 nm absorbance. Repeat for all of the standards, so as to have a reference range for all analyses. Use only Class A glass volumetric flasks for all dilutions.

f. Use a Class A glass pipette or a Gilmont micrometer buret to obtain a 1 ml aliquot of the sample, and dilute as specified in step 5. Perform the analysis per step 5, and determine the 50% NaMBT content by computing the ratio of the net absorbance of the sample (calculated as in step 5) to the standard closest in net absorbance to the sample, and multiplying by the amount of NaMBT in the standard. Alternatively, the absorption coefficient may be determined using Beer’s law (A = axbxc; b= pathlength of the cell, c is the concentration in whatever desired units, and a is the absorption coefficient) and at least two of the known concentration standards. The method of known additions may be used when NACAP and only used MS-139 are available. Add a known amount of NACAP to the EGW fluid after analysis, dilute as in step 5, and analyze.Use the 2 net absorbances to determine your absorption coefficient via subtraction and division into the remaining net absorption. The weight % of 50% NaMBT = net absorbance divided by response factor.

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NOTES Do not calculate concentration based on just the maximum peak values of the samples and the standard or use nonscanning UV-visible spectrometers that measure fixed wavelengths. Do not determine concentration based on the area of the 322 nm peak rather than the peak height. Samples with lower concentrations of NaMBT give slightly higher values when analyzed by UV-visible spectroscopy because the interference is relatively greater for these samples.

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SECTION IX

FLUID CONTAMINATION

9.1. Introduction

This section discusses the contamination of lubricating and hydraulic fluids, how it occurs, how it is identified, what its impacts are, and what to do when contamination is suspected.

9.2. Types of contamination Essentially, anything that is not supposed to be in the oil sump is a contaminant, regardless of its source. Contaminants may enter the system as a result of environmental exposure, normal operation, normal or abnormal wear, or human error (wrong fluid type). 9.2.1. Environmental. Environmental contamination occurs when materials normally

present in the environment enter the oil. Environmental contamination can occur when fluid is transferred or when any reservoir (cart, pre-oiler, can, drum) is open to the environment. Environmental contaminants include (1) finely divided, airborne and windborne soil, dust, sand, or clay, (2) large particles of debris from contaminated surfaces, such as corroded cans, and (3) water from rain, snow, or other sources. Environmental contamination is largely a function of the environmental conditions under which fluids are stored and transferred and the care taken by personnel to ensure cleanliness and to protect transfer. Environmental contamination occurs when (1) bottles, cans, pre-oilers, or oil carts are left open or in unprotected conditions for extended periods, (2) closures malfunction or seals/gaskets have degraded, (3) drum or can surfaces are allowed to corrode and debris enters the oil as the container is opened, (4) dirty can openers, church keys, pour spouts, funnels, or nozzles are used, or (5) contaminants enter through the component air intake (or other exposure) as a result of normal operation. Improvements in personnel training and material handling equipment have reduced much of the environmental contamination.

9.2.2. Wrong fluid type. This results from human error (such as putting the wrong fluid in

a pre-oiler) or sloppy handling (such as reusing a pre-oiler for a different type of fluid without proper cleaning). Contamination with the wrong fluid type most commonly occurs when an oil cart or pre-oiler (for example, PON-6) is filled with the wrong material at the maintenance site. However, it is also possible for mix-ups to happen in the supply system. Any time fluid is transferred between containers or to a vehicle’s oil sump, there is an opportunity for contamination. There are three general types of fluids used in aircraft: hydraulic fluids (MIL-PRF-83282 and MIL-PRF-5606), mineral lubricants [SAE J1899 (formerly MIL-L-22851D) and SAE J1966 (formerly MIL-L-6802E)], and synthetic lubricants (MIL-PRF-7808 and MIL-PRF-23699). However, there are many types of vehicles and components (engines, transmissions, gearboxes) enrolled in the JOAP. There are also many types of fluids used in servicing mechanical equipment (antifreezes or coolants, fuels, additives, lubricants, and hydraulic fluids). Any of these types of fluid

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may be inadvertently added to the oil sump or to an intermediate container (i.e., between the manufacturer’s container and the sump).

9.2.3. Wear debris. Friction from moving parts and abrasion from environmental

debris causes small fragments of metal to slough off into the oil. Excessive wear debris indicates poor engine health. For aeronautical equipment, nearly the entire oil analysis program is directed towards wear debris and engine health.

9.2.4. Operational byproducts. Chemical reactions that take place during combustion

yield products that reduce oil quality and effectiveness. Soot is formed from the incomplete combustion of hydrocarbon fuels. Water formed by combustion and fuel vaporized during combustion may enter the oil. Sulfur and phosphorus compounds may occur as impurities in diesel fuel and will burn to produce acids that attack metallic parts. Heat and mechanical stress break down the long hydrocarbon chains of the compounds that make up the oil itself.

9.3. Identifying and measuring contamination. Much of the JOAP Manual is dedicated to

detecting and quantitating wear debris contamination and/or operational byproduct contamination.

9.3.1. Water. Although water is an environmental contaminant, it is also an operational

byproduct that forms as a result of combustion of hydrocarbon fuels; therefore, it is already addressed when it represents a significant threat to a component or to oil performance. Water is measured via the crackle test, Karl Fischer titrimetry, and infrared spectrometry. These topics are covered in Volume II Section V of the JOAP Manual and are a part of routine analysis for many samples.

9.3.2. Particulate debris. This includes environmental particulate debris and soot. Dust,

sand, grit, clay, and soil can be encountered as environmental particulate debris. Silicon is present in sand (silicon dioxide). When silicon is found with aluminum, that suggests the presence of aluminosilicates found in soils and clays. High levels of iron, inconsistent with engine composition, may be from rust on a can, can opener, pour spout, or church key. Many aircraft engine oils contain low concentrations of silicon in the form of silicone pour point depressants that allow the oil to be dispensed easily in cold weather. Therefore, it is normal to see silicon concentrations around 3-4 ppm and occasionally as high as 5-6 ppm. Silicon, aluminum, and iron are all quantitated via rotrode atomic emission spectroscopy, which is covered heavily in Volume II Section III, and to which the wear limit tables in Volumes III and IV are dedicated. In addition, particle counting is used for hydraulic fluids and covered in Volume II Section V.

9.3.3. Wrong fluid type. Wrong fluid type is normally found by identifying additives that

would be absent in the correct fluid.

9.3.3.1. Zinc. High levels of zinc are consistent with MIL-PRF-2104 or other automotive lubricants. As of 2005, zinc dialkyldithiophosphate (ZDDP)

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compounds are still added as antiwear agents to engine oils. These compounds form protective zinc phosphate glasses on engine parts. ZDDP compounds are not used in turbojet oils.

9.3.3.2. Molybdenum. Although not routinely found in MIL-PRF-2104, many

commercial automotive (e.g., 5W30, 10W40) and truck (e.g., 15W40, 20W50) oil formulations incorporate suspensions of molybdenum disulfide. Molybdenum disulfide is a solid lubricant, and it is found in both engine oils and anti-seizing compounds. Unfortunately, molybdenum is also used in many aircraft engine bearings (such as 4.0-4.5% in M50 steel). The presence of molybdenum alone is not diagnostic for wrong fluid type. When detected in the oil of a component that does not contain molybdenum, this finding does point to contamination with automotive/truck engine oil.

9.3.3.3. Boron. Historically, the presence of boron has suggested the presence

of coolant in the oil since borates are used as buffers to control pH in cooling systems. Nevertheless, boron additives, such as boron nitride, are found as solid lubricants, especially in heavy weight (e.g., 20W50) commercial oils. As of 2005, boron compounds were not used in any qualified product under MIL-PRF-2104 in the Defense supply system, and the presence of boron should initially suggest contamination with antifreeze coolant.

9.3.3.4. Magnesium. Historically, the presence of magnesium has suggested the

presence of coolant in the oil since magnesium compounds are used as detergents in cooling systems. However, it has become increasingly common for the same detergents to be used in automotive/truck engine oils. When detected in the oil of a component that does not contain magnesium, this finding points to contamination with either automotive/truck engine oil or antifreeze coolant.

9.3.3.5. Glycol. Most antifreeze coolant formulas are based on ethylene glycol, but

environmentally friendly formulations contain propylene glycol. The alcohol functional groups are observed by infrared spectroscopy. Contamination with antifreeze coolant occurs mostly in ground equipment and rarely in aircraft. Glycol contamination usually occurs simultaneously with water contamination.

9.3.3.6. Analytical techniques. Zinc, molybdenum, and boron are determined via

rotrode atomic emission spectrometry. Glycol and some other additives can be determined by infrared spectrometry. Some services and some laboratories may not have all techniques available.

9.3.4. Operational byproducts. In addition to water, various acidic species may be

formed by the partial combustion of hydrocarbon fuels or impurities in them; these

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are measured collectively as the total acid number. Though not a byproduct, vaporized fuel may enter the oil during operation, and so it is included here. Fuel contamination can be determined by decrease in the flash point or fuel sniffer (Volume II Section V) as well as a decrease in viscosity when severe. Decreases in viscosity are also associated with the degradation of the oil itself resulting from exposure to heat and mechanical shearing action.

9.3.5. Wear debris. Like environmental particulate debris, wear debris is determined

primarily by rotrode atomic emission spectrometry. Most wear debris is too large to remain suspended in the oil so that it cannot be estimated by the oil’s opaqueness to infrared light (unlike soot). Volume II Section III is devoted to rotrode atomic emission spectrometry.

9.4. Consequences of contamination

9.4.1. Water. Small amounts of water are dispersed by the surfactants in the oil; however, large amounts of water lead to the formation of sludge, which clogs the filter and increases the viscosity. As sludge forms, the oil becomes less effective at lubricating surfaces and less effective at conducting heat energy. This makes the engine work harder and wear out faster. Water also speeds corrosion.

9.4.2. Environmental particulate debris and soot. Depending on the particle size, these

contaminants either interfere with the proper function of the dispersants and surfactants in the oil (leading to sludge formation) or they abrade the moving parts of the engine. In most aircraft, large debris is removed by the oil filter so that the presence of individually visible particles (i.e., turnings, chunks, flakes, needles) suggests improper filter function. Even in ground equipment, individually visible particles suggest substantial engine wear and/or poor air/oil filtration.

9.4.3. Wrong fluid type. For aircraft, wrong fluid type can be an extremely serious

problem. Aircraft consume oil at a rate such that any noncombustible or involatile compounds are rapidly concentrated and can clog filters or deprive the system of needed lubrication and heat transference. Furthermore, aircraft components are not designed for exposure to some of the additives present in automotive/truck engine oils. Because aircraft lubricants are relatively free of additives, it is difficult to identify contamination of automotive/truck oil with aircraft oil, but it is also less serious.

9.4.4. Operational byproducts. Acidic compounds produced from the burning of

sulfur or phosphorus impurities in fuel, incomplete combustion of hydrocarbon fuels, or nitrogen oxides formed from air at operating temperatures all attack metallic engine parts, corroding them. They also react with seals and gaskets, reducing their lifetimes.

9.4.5. Fuel. Excessive levels of fuel (about 5% by weight or higher) pose a safety risk by

making the oil combustible or even flammable. Fuel incursion lowers viscosity,

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which, in turn, reduces lubricity. It also decreases thermal conductivity. Fuel incursion is primarily a concern for ground equipment and diesel engines.

9.4.6. Wear debris. Depending on the level of debris and the component, the debris may be

normal or abnormal. In precision gas turbine engines, even small amounts of wear debris can signal an impending engine failure. The wear debris limits for aeronautical equipment are given in JOAP Manual Volume III. The wear debris limits for ground equipment are given in JOAP Manual Volume IV. Safety of flight dictates that special attention is given to aircraft. As a rule, limits for aircraft are much lower than limits for ground equipment or diesel engines on ships. Wear debris results should ideally be diagnostic (identifying what part is failing) and prognostic (how long that part will last). When coupled with knowledge of the engine composition and design, wear debris analysis is an important aspect to a condition-based maintenance program.

9.5. Mandatory actions for addressing contamination

9.5.1. Environmental debris and water. Recommend resampling and retesting when

dust, dirt, sand, soil, clay, or water is suspected. Confirm proper instrument function with appropriate check standards. Recommend continual flushing, sampling, and testing until contamination is undetectable (< 8.0 ppm Si if no limit given) or nearly so. Consult program manager if further information is needed. Compare results with reported limits in JOAP Manual Volumes III and IV limit tables.

9.5.2. Visible particulate debris. When visible debris is present, regardless of the nature of

the debris (wear or environmental), the sample fails automatically. Confer with mechanic or maintenance chief if appropriate to ensure sample was not contaminated during/after collection. Recommend resampling or draining/flushing if evidence indicates. Test to identify and quantitate wear debris in original sample and any additional samples.

9.5.3. Wrong fluid type. Report results suggesting wrong fluid type as soon as practical;

recommend resampling and retesting. Confirm proper instrument function with appropriate check standards. When wrong fluid type has been verified, notify local chain of command, oil analysis program manager, maintenance chief, cognizant engineering authority (Army and Navy only), and other personnel as required by local written procedures. When contamination has been identified in sealed materials procured through the Defense supply system, initiate action through the Defense supply deficiency reporting system. Recommend continual flushing, sampling, and testing until contamination is undetectable (< 8.0 ppm Zn and B) or nearly so. Consult program manager if further information is needed.

9.5.4. Operational byproducts. Report results as required for individual components or

equipment. Report recommendations for additional sampling and testing or maintenance as required. Further detail is provided elsewhere in the manual.

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9.5.5. Wear debris. When metallic debris consistent with component wear is confirmed by

rotrode atomic emission spectrometry, take action consistent with the wear limit tables in JOAP Manual Volumes III and IV.

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APPENDIX A

NON-AUTOMATED LABORATORY DATA SUBMISSION

The following instructions apply to non-automated Air Force laboratories, but may be directed for use by other Service Program Managers for their non-automated laboratories or for automated laboratories experiencing ADP equipment malfunctions, to transmit manually accumulated data into the JOAP Data Base. Laboratories shall use DD Form 2026 as a source document for completing 80 column detail records. The resulting data will be forwarded to the JOAP-TSC via e-mail on or about the 15th and last day of each month. Data will be transmitted in accordance with instructions provided by the JOAP-TSC. The JOAP Data System will require submission of six different types of inputs which are described in detail in this section. These inputs were established to provide for independent sample and feedback records and to permit data deletion/correction actions as required. See Appendix E for data index codes. A-1. Control Data. Data in record columns 1 through 24 and 80, as applicable, are designated as control data fields. These columns must be completed on all source documents and all 80 column record cards.

a. JOAP Laboratory Codes. Record columns 1-3.

(1) Designation: JOAP Laboratory Code.

(2) Entry: Alpha/Numeric.

(3) Instructions: JOAP laboratory codes consist of three digit alpha/numeric codes listed in the JOAP Directory.

b. Major Command Codes. Record column 4.

(1) Designation: Major Command.

(2) Entry: Alpha/Numeric.

(3) Instructions: Major Command codes consist of two digit alpha/numeric codes to identify the major command, foreign government, contractor, etc., which owns the unit from which the sample was taken. Non-automated laboratories will use only the last digit of the command code. These codes are listed in Appendix

c. Operating Activity Codes. Record columns 5-10.

(1) Designation: Operating Activity.

(2) Entry: Alpha - Left justified.

(3) Instructions: Enter base location codes in record columns 5-8 (Air Force). Base location codes (also known as geographical location codes or GEOLOC's) consist of four digit alphanumeric codes as reflected on the following Scott AFB hosted website: https://tmds03.scott.af.mil/ap_info.shtml Enter the base location in the "AP NAME" block, click on "Find AP Name Data", and the GEOLOC will be displayed.

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d. Equipment/End Item Model Codes. Record columns 11-14.

(1) Designation: Equipment/End Item Model Codes.

(2) Entry: Alpha/Numeric.

(3) Instructions: Equipment model field will reflect codes established in Appendix B to identify the engine type, model and series and the end item mission, design and series for engine samples. Samples from accessory equipment such as CSD, main transmission, etc., will be reported by entering the first three digits of appropriate end item code and entering the appropriate accessory equipment code as the last digit.

e. Equipment Serial Number. Record columns 15-20.

(1) Designation: Equipment Serial Number.

(2) Entry: Alpha/Numeric - Left justified.

(3) Instructions: Enter last six digits of the equipment serial number from which the oil sample was taken, e.g., engine, transmission, CSD, etc. Dashes and slashes will be excluded.

f. Date. Record columns 21-24.

(1) Designation: Julian Date Sample Taken.

(2) Entry: Numerics.

(3) Instructions: Enter Julian date sample was taken, e.g., YDDD. Y will be the last position of the year and DDD will be the Julian Day. A-2. Analytical Sample Record. Analytical sample record is required to report all sample identification data and analytical results. Analytical sample record will contain control data (record columns 1-24 and 80 as applicable) and the following data (see table A-1).

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TABLE A-1. ANALYTICAL SAMPLE RECORD

Record Columns Data Elements 1* L Instrument A B O R 2 * A Command T O R 3 * Y Laboratory 4 * Major Command 5-10 * Operating Activity 11-14* Equipment/End Item Model 15-20* Equipment Serial Number 21-24* Julian Date (YDDD) 25-29 Hours/Miles Since Overhaul 30-33 Hours/Miles Since Oil Change 34 Reason for Sample 35-36 Oil Added Since Last Sample 37-38 Type Oil 39-40 Sample Response Time 41-76 Sample Analytical Results

41-43 44-46 47-49 50-52 53-55 56-58 Fe Ag Al Cr Cu Mg 59-61 62-64 65-67 68-70 71-73 74-76 Ni Pb Si Sn TI Mo

77-78 Laboratory Recommendation 79 File Maintenance Action Code 80* Data Sequence

*Control Data

a. Hours/Miles Since Overhaul. Record columns 25-29.

(1) Designation: Hours/Miles Since Overhaul.

(2) Entry: Numerics.

(3) Instructions: Total hours/miles since overhaul will be reported as five digit numerics reflecting

nearest whole hours/miles. Total hours/miles which do not complete the field (5 digits) will be preceded with zeros, e.g., 21 = 00021.

b. Hours/Miles Since Oil Change. Record columns 30-33.

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(1) Designation: Hours/Miles Since Oil Change.

(2) Entry: Numerics.

(3) Instructions: Total hours/miles since oil change will be reported as four digit numerics reflecting

nearest whole hours/miles. Total hours/miles which do not complete the field (4 digits) will be preceded with zeros, e.g., 245 = 0245.

c. Reason for Sample. Record column 34.

(1) Designation: Reason for Sample Code.

(2) Entry: Alpha.

(3) Instructions: Reason for sample code is established to identify specific reason for sample submission. Reason for sample codes are listed in Appendix F.

d. Oil Added Since Last Sample. Record columns 35-36.

(1) Designation: Quantity Oil Added Since Last Sample.

(2) Entry: Alpha/Numeric.

(3) Instructions: Instructions: This two digit data field must be completed to allow the AETC program to proceed with the sample analysis. The first digit must be alpha and the second digit will be numeric. The first digit must be O, C, P, Q, or G, which indicates measurement in ounces, cups, pints, quarts or gallons respectively, e.g., 5 pints = P5. Quantities greater than 9 gallons will be entered as 9 gallons = G9.

e. Type Oil Code. Leave blank.

f. Sample Response Time. Record columns 39-40.

(1) Designation: Sample Response Time in Hours.

(2) Entry: Alpha/Numeric - right justified.

(3) Instructions: Compute and enter the sample response time to nearest whole hour. Interval will be the elapsed hours between time sample is taken to time laboratory issues recommendation or determines that a recommendation is not required. If the interval is less than 10, precede entry with (0) zero. If the interval is greater than 96 hours (4 days), time will be reported as whole days by entering 5D, 6D, 7D, 8D and 9D, which indicates 5 days, 6 days, 7 days, 8 days and 9 days, respectively. Time greater than 9 days will be reported as 9 days or 9D.

g. Sample Analytical Results. Record columns 41-76.

(1) Designation: Sample Analytical Wear-metal Results in parts per million (PPM).

(2) Entry: Numerics.

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(3) Instructions: Oil analysis results will be reflected as 12 segregated fields containing three digits

each for specified wear-metal elements. Each element will be reflected in whole numerics. Readings, which do not complete the field, will be preceded by zeros. Entire field will be skipped for elements which are not analyzed. Results from instruments which read-out In tenths will be converted to the nearest whole number as follows: Results with five tenths or greater will be converted to the next higher whole number. Tenths results of four tenths or less will be dropped. Examples: Fe=129, Ag=0.4, AI=49.7, Cr=3.5, Cu=13.2, Mg=97.8, Ni=0.2, Pb=6.6, Si=236.9, Sn=1.3, Ti=9.8, Mo=1.7.

Record Columns 41-43 44-46 47-49 50-52 53-55 56-58 Fe Ag Al Cr Cu Mg OAP Results (PPM) 129 000 050 004 013 098 Record Columns 59-61 62-64 65-67 68-70 71-73 74-76 NI Pb Si Sn Ti Mo OAP Results (PPM) 000 007 237 001 010 002

h. Laboratory Recommendation Code. Record columns 77-78.

(1) Designation: Laboratory Recommendation.

(2) Entry: Alpha - Right justified.

(3) Instructions: Laboratory recommendation codes consist of one digit alpha codes to identify

specific action recommended by OAP laboratory based on wear-metal trends. Applicable code will be entered in card column 78. Card column 77 will be blank and is reserved for future use. Laboratory Recommendation codes are listed in Appendix G.

i. File Maintenance Action Codes. Record column 79.

(1) Designation: File Maintenance Action.

(2) Entry: None.

(3) Instructions: Skip this field when inputting analytical sample record.

j. Data Sequence. Record column 80.

(1) Designation: Data Sequence.

(2) Entry: Numeric.

(3) Instructions: Data sequence field is established to reflect sequence of samples taken on the same day from the same equipment. Blank field will signify initial sample of the day and subsequent samples will be sequentially numbered 2 through 9, e.g., initial sample of the day from same equipment, leave field blank; second sample of the day from same equipment, enter numeric 2, etc. A-3. Analytical Sample Record Deletion. (See table A-2.)

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TABLE A-2. ANALYTICAL SAMPLE RECORD DELETION

Record Columns Data Elements 1* L Instrument A B O 2* R A T O 3 * R Laboratory Y 4 * Major Command 5-10 * Operating Activity 11-14* Equipment/End Item Model 15-20* Equipment Serial Number 21-24* Julian Date (YDDD) 25-78 Blank 79 File Maintenance Action Code "N" 8 0 Data Sequence

*Control Data

a. Errors in the Control Data fields (Columns 1-24 and 80) on a previously submitted Analytical Sample Record which is in the computer data bank, can only be corrected by deletion of entire record and resubmittal of corrected record. To effect an Analytical Sample Record Deletion, the deletion record must contain identical control data (record columns 1-24 and 80) as the erroneous sample record requiring deletion, coupled with File Maintenance Action Code.

NOTE

Errors listed on the OAP DATA EXCEPTIONS Report have been rejected by computer and are not in computer data base. Such errors will be corrected by resubmission of correct data and will not require Change or Delete action.

b. Analytical Sample Record Deletion requires submittal of a deletion record as described above with an

alpha "N" entry in Record Column 79. Record Columns 25-78 will be left blank on deletion record. This input will automatically delete the erroneous record and a corrected record must be resubmitted.

c. Record Columns 1-24 and 80.

(1) Designation: Analytical Sample Record Deletion.

(2) Entry: As detailed in paragraphs A-1,a. through f and A-2,j.

d. Record Column 79. (File Maintenance Action Code.)

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(1) Designation: File Maintenance Action (Deletion).

(2) Entry: Alpha Code "N".

A-4. Analytical Sample Record Change. (See table A-3.)

a. Errors in Record Columns 25-78 on a previously submitted JOAP Analytical Sample Record which is in the computer data base, may be corrected by changing erroneous data. To effect an Analytical Sample Record Change, the change record must contain identical control data (Record Columns 1-24 and 80) as the erroneous sample record requiring change, coupled with appropriate File Maintenance Action Code.

b. Analytical Sample Record Change requires submittal of a change record as described above with an alpha R entry in Record Column 79. Data in change fields (Record Columns 25-78) will only be entered for data which requires change. A change field with all asterisks will automatically blank that field, e.g., if laboratory does not have nickel (Ni) analysis capability, and Ni results are inadvertently reported, this erroneous entry may be deleted by submitting change record with asterisks in Ni field. A change field with data will automatically update that field with new data, e.g., if laboratory erroneously reports 800 in iron (Fe) field and it should have read 080, this erroneous entry may be changed to 080 by submitting change record with correct data in Fe field.

c. Record Columns 1-24 and 80.

(1) Designation: Analytical Sample Record Change.

(2) Entry: As detailed in paragraphs A-1,a. through f and A-2j.

d Record Column 79. (File Maintenance Action Code.)

(1) Designation: File Maintenance Action (Change).

(2) Entry: Alpha Code "R". A-5. Maintenance Feedback Record. Maintenance Feedback Record is required to report all maintenance actions to oil wetted components. Maintenance Feedback Record will contain control data (Record Columns 1-24 and 80) and the following data. (See table A-4.)

a. Hours/Miles Since Overhaul. Record columns 25-29.

(1) Designation: Hours/Miles Since Overhaul.

(2) Entry: Numeric.

(3) Instructions: Total hours/miles since overhaul will be reported as five digit numerics reflecting nearest whole hours/miles. Total hours/miles which do not complete the field (5 digits) will be preceded with zeros, e.g., 148 =, 00148.

b. Action Taken Code. Record column 30.

(1) Designation: Maintenance Action Taken.

(2) Entry: Alpha.

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TABLE A-3. ANALYTICAL SAMPLE RECORD CHANGE

Record Columns Data Elements 1 * L Instrument A B O 2 * R Command A T O R 3 * Y Laboratory 4 * Major Command 5-10 * Operating Activity 11-14* Equipment/End Item Model 15-20* Equipment Serial Number 21-24* Julian Date (YDDD) 25-29 Hours/Miles Since Overhaul 30-33 Hours/Miles Since Oil Change 34 Reason for Sample 35-36 Oil Added Since Last Sample 37-38 Type Oil 39-40 Sample Response Time 41-76 Sample Analytical Results

41-43 44-46 47-49 50-52 53-55 56-58 Fe Ag Al Cr Cu Mg 59-61 62-64 65-67 68-70 71-73 74-76 Ni Pb Si Sn Ti Mo

77-78 Laboratory Recommendation 79 File Maintenance Action Code "R" 80* Data Sequence

*Control Data

(3) Instructions: Action Taken Codes are established to identify the corrective maintenance accomplished to remedy a suspected discrepancy. Codes are listed in Appendix H.

c. Discrepant Item Codes. Record columns 31-32.

(1) Designation: Discrepant Item.

(2) Entry: Alpha.

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TABLE A-4. MAINTENANCE FEEDBACK RECORD

Record Columns Data Elements 1 * L Instrument A B O 2 * R Command A T O R 3 * Y Laboratory 4 * Major Command 5-10 * Operating Activity 11-14* Equipment/End Item Model 15-20* Equipment Serial Number 21-24* Julian Date (YDDD) 25-29 Hours/Miles Since Overhaul 30 Action Taken . 31-32 Discrepant Item 33 How Malfunctioned 34 How Found 35-78 Blank 79 File Maintenance Action Code "F" 80* Data Sequence

*Control Data

(3) Instructions: Discrepant Item Codes are established to identify the item which has malfunctioned or which was examined for discrepancy. If a discrepant item is not coded, use the coded Item which is most directly related to the failed part. Discrepant Item Codes are listed in Appendix I.

d. How Malfunctioned Codes. Record column 33.

(1) Designation: How Malfunctioned.

(2) Entry: Alpha/Numeric.

(3) Instructions: How Malfunctioned Codes are established to identify the nature of the defect that existed on the item identified in Discrepant Item block. How malfunctioned codes are being kept to a minimum to simplify reporting. Therefore, established codes do not specifically describe all possible conditions, which may be encountered. A code, which best describes or most nearly describes the defect, will be used. How Malfunctioned Codes are listed In Appendix J.

e. How Found Codes. Record column 34.

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(1) Designation: How Found.

(2) Entry: Alpha.

(3) Instructions: How Found Codes are established to indicate how the necessity for maintenance

action was determined. How Found Codes are listed in Appendix K.

f. File Maintenance for Reporting Maintenance Feedback Data. Record column 79.

(1) Designation: File Maintenance Action (Feedback).

(2) Entry: Alpha.

(3) Instructions: Enter an alpha "F" to indicate that this record is a Maintenance Feedback Record.

g. Data Sequence. Record column 80.

(1) Designation: Data Sequence.

(2) Entry: Numeric.

(3) Instructions: Data sequence field is established to reflect sequence of JOAP maintenance feedback data submitted on same day from the same equipment. Blank field will signify Initial feedback data submittal. Subsequent data on same day will be sequentially numbered 2 through 9. A-6. Maintenance Feedback Record Deletion. (See table A-5.)

a. Errors in the Control Data Fields (Columns 1-24 and 80) on a previously submitted JOAP Maintenance Feedback Record, which is in the computer database, can only be corrected by deletion of entire record and resubmittal of corrected record. To affect a Maintenance Feedback Record Deletion, the deletion record must contain identical control data (Columns 1-24 and 80) as the erroneous feedback record requiring deletion, coupled with File Maintenance Action Code.

b. Maintenance Feedback Record deletion requires submittal of a deletion record as described in paragraphs c and d below with an alpha "J" entry in Record Column 79. Record Columns 25-78 will be left blank on deletion record. This input will automatically delete the erroneous record and a corrected record must be submitted.

c. Record Columns 1-24 and 80.

(1) Designation: Maintenance Feedback Record Deletion.

(2) Entry: As detailed in paragraphs A-1,a. through f. and A-2,,j.

d. Record Column 79. (Maintenance Record Feedback Deletion Code.)

(1) Designation: File Maintenance Action (Feedback Deletion).

(2) Entry: Alpha Code "J".

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TABLE A-5. MAINTENANCE FEEDBACK DELETION

Record Columns Data Elements 1 * L Instrument A B O R 2 * A Command T O R 3 * Y Laboratory 4 * Major Command 5-10 * Operating Activity 11-14* Equipment/End Item Model 15-20* Equipment Serial Number 21-24* Julian Date (YDDD) 25-78 Blank 79 File Maintenance Action Code "J" 80* Data Sequence

*Control Data

A-7. Maintenance Feedback Record Change. (See table A-6.)

a. Errors in Record Columns 25-34 on a previously submitted JOAP Maintenance Feedback Record, which is in the computer data bank, may be corrected by changing erroneous data. To affect a Maintenance Feedback Record Change, the change record must contain identical control data (Record columns 1-24 and 80) as the erroneous feedback record requiring change, coupled with appropriate File Maintenance Action Code.

b. Maintenance Feedback Record Change requires submittal of a change record as described in paragraphs c and d below with an alpha "T" entry in Record Column 79. Data in change fields (Record Columns 25-34) will only be entered for data, which requires change. A change field with data will automatically update that field with new data, e.g., if laboratory erroneously reports wrong How Malfunctioned Code, the erroneous entry may be changed by submitting a change record with correct How Malfunctioned Code in How Malfunctioned field.

c. Record Columns 1-24 and 80.

(1) Designation: Maintenance Feedback Record Change.

(2) Entry is as detailed in paragraph A-1,a. through f. and A-2,j.

d. Record Column 79. (Maintenance Feedback Record Change Code.)

(1) Designation: File Maintenance Action (Feedback Change).

(2) Entry: Alpha Code "T".

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TABLE A-6. MAINTENANCE FEEDBACK RECORD CHANGE

Record Columns Data Elements

1 * L Instrument A B O R 2 * A Command T O R 3 * Y Laboratory 4 * Major Command 5-10 * Operating Activity 11-14* Equipment/End Item Model 15-20 * Equipment Serial Number 21-24 * Julian Date (YDDD) 25-29 Hours/Miles Since Overhaul 30 Action Taken 31-32 Discrepant Item 33 How Malfunctioned 34 How Found 35-78 Blank 79 File Maintenance Action Code "T" 80* Data Sequence

*Control Data

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APPENDIX B

TYPE EQUIPMENT CODES

CONTENTS Page No. AERONAUTICAL CRITERIA RESTRICTION ................................................................................................... B-2 CRITERIA RESTRICTION (sorted by TEC) ........................................................................ B-10

CR = CRITERIA RESTRICTION

CR EXPLANATION

AO ARMY ONLY CE ARMY CORP OF ENGINEERS FA AIR FORCE AND ARMY FN AIR FORCE AND NAVY FO AIR FORCE ONLY NC NAVY AND COAST GUARD NO NAVY ONLY SO NASA ONLY

NONAERONAUTICAL MARINE CORPS COMPONENTS ....................................................................................... B-18 ARMY COMPONENTS . ........................................................................................................ B-20 ARMY CORPS OF ENGINEERS .......................................................................................... B-32 U.S. AIR FORCE ................................................................................................................... B-34 FLIGHT SIMULATORS ......................................................................................................... B-34

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AERONAUTICAL TYPE EQUIPMENT CODES

CRITERIA RESTRICTION

END ITEM COMPONENT TEC CR 5220 Hyd-PU DXBA 05-7014-1200 Hyd-PU DXBB 05-7008 Hyd-PU DXBC A/M32A-95 GTCP 85-180 DJBC A-10 GTCP36-50 DCBA A-10 TF34-GE-100 KDAA FO A-37 J85-GE-17 ERFA A-4 CSD DSAA NO A-4 J52-P-408 EECA NO A-4 J52-P-6C EEDA A-4 J52-P-8B EEBA NO A-6 CSD DSBA NO A-6 J52-P-408 Gbx EECB A-6 J52-P-408 Tank EECC A-6 J52-P-8B EEBB NO AH-1E 42/Int Gbx GAIE AH-1E Main Xmsn GAME AH-1E 90/Tail Gbx GATE AH-1G 42/Int Gbx GAIG FA AH-1G 90/Tail Gbx GATC FA AH-1G Hyd Sys 1 HA1G FA AH-1G Hyd Sys 2 HA2G FA AH-1G Hyd Sys 3 HA31 AH-1G Main Xmsn GAMG FA AH-1G T53-L-13B SBEA AO AH-1S 42/Int Gbx GAIS AH-6C 90/Tail Gbx GHTC AH-6C Hyd Sys HHA1 AH-6C Main Xmsn GHMCAH-6C T63-A720 SFCB AO AH-6J 90/Tail Gbx GHTJ AO AH-6J Hyd Sys HHA2 AH-6J Main Xmsn GHMJ AO AH-6N 90/Tail Gbx GHTN AO AH-6N Hyd Sys HHA3 AH-6N Main Xmsn GHMN AO AH-64A T700-GE-701 SHCB AH-64A Int Gbx GMIA

END ITEM COMPONENT TEC CR AH-64A Tail Gbx GMTA AH-64A #1 Nose Gbx GM1A AH-64A #2 Nose Gbx GM2A AH-64A APU DQAA AH-64A Hyd Sys 1 HM11 AH-64A Hyd Sys 2 HM21 AH-64A Main Xmsn GMMAAH-64A PTO Clutch GMPA AH-64D Hyd Sys HMAD AH-64D Hyd Sys 2 HM22 AH-64D PTO Clutch GMPD AH-64D T700-GE-701 SHCA AH-64D APU DQAD Aircraft Hydraulic Oil HHYD AO Aircraft Synthetic Oil ASYN AO AV-8 F402-RR-402 FMAA AV-8 F402-RR-404 FMCA AV-8 ING DR GEN DPAA NO AV-8B F402-RR-406 FMEA AV-8B F402-RR-408 FMFA B-1 F101-GE-102 FBAA B-111 TF30-P-107 KAEA B-111 TF30-P-7 KABA B-1B GTCP165-9 DLBA B-2 F118-GE-100 FKAA FO B-52 J57-P-19 EFGA B-52 J57-P-43 KFCA B-52 TF33-P-103 KCGA B-52 TF33-P-3 KCAA BE-65 IO-720-A1B RHBA BIO-RAD FT-IR AIRA C-10 FI 03-G E- 101 FDBA C-12 PT5A-41 SPHA C-12 PT6A-27 SPCC C-12 PT6A-34 SPFA C-12 PT6A-38 SPGA C-12 PT6A-42 SPJA C-12C PT6A-41 SPHB

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END ITEM COMPONENT TEC CR C-12D PT6A-41 SPHC C-12J PT6A-65B SPPA C-12U PT6A-42 SPJC C-130 GTCP85-180 DJBA C-130 GTC85-71 DGEA C-130 Nose Gear GTNK C-130 T56-A-15 SDFA FN C-130 T56-A-15 Gbx GTMF C-130 T56-A7 SDAA FN C-130 T56-A-9 SDCA FN C-130 T56-A-9 Gbx GTMC C-135 F108-CF-100 FFAA C-135 GTC70-15 DFAA C-135 J57-P-43 EFCB C-135 J57-P-59 EFDA C-135 T41 M-9 DAAA C-135 TF33-P-5 KCBA C-135 TF33-P-9 KCDA C-135 TF33-PW-102 KCFA C-135 TF33-PW-102/JT3D–3B KCFC C-137 GTCP 85-97 DJDA C-137 GTCP85-98 DJEA C-137 JT-3D-3 KJAA C-137 TF33-PW-102/JT3D-3B KGBA C-140 J60-P-5 EHCA FO C-141 GTCP85-106 DJAA C-141 TF33-P-7 KCCA C-17 F117-PW-100 FLAA C-18 TF33-PW-102 KCFB C-2 GTCP36-201C DCAA NO C-20 F113-RR-100 FJAA C-20 GTCP36-100 DCCA C-21 TFE731-2 KMAA C-22 JT-8D-7 KKAA FO C-23 PT6A-45 SPKA C-23C PT6A-65AR SPRA C-27 CTCP36-16A DCGA C-27 T64-P4D SPLA C-5 GTCP165-1 DLAA C-5 TF39-GE-1 KGAA C-6 PT6A-20 SPAA C-9 JT-8D-9 KKBA FO C-9 JT-8D-9 KKBB NO

END ITEM COMPONENT TEC CR CH-47A Hdy Sys 3 HE3A CH-47A Hyd Sys 1 HE1A CH-47A Hyd Sys 2 HE2A CH-47A T55-L-7C SCBA CH-47A Fwd Xmsn GEFA CH-47A Aft Xmsn GEAA CH-47A Eng Comb Xmsn GEEA CH-47A 1eng Mec Zmsn GEGA CH-47A 2eng Mec Xmsn GEHA CH-47B Hdy Sys 3 HE3B CH-47B Hyd Sys 1 HE1B CH-47B Hyd Sys 2 HE2B CH-47C Hyd Sys 1 HE1C CH-47C Hyd Sys 2 HE2C CH-47C Hyd Sys 3 HE3C CH-47C T55-L-712 SCDA CH-47D 1 EngMecXmsn GEGD CH-47D APU DQAF CH-47D 2 EngMecXmsn GEHD CH-47D Aft Xmsn GEAD CH-47D Engcombxmsn GEED CH-47D Fwdxmsn GEFD CH-47D Hyd Sys 1 HE1D CH-47D Hyd Sys 2 HE2D CH-47D Hyd Sys 3 HE3D CH-47D T55-GA-714A SCFA CH-47D T55-L-712 SCDB CH-47D T55-L-714 SCED CH-47F Aft Xmsn GEAF CH-47F Fwd Xmsn GEFF CH-47F APU DQAG CH-47F 1 Eng Mec Xmsn GEGF CH-47F 2 Eng Mec Xmsn GEHF CH-47F Eng Comb Xmsn GEEF CH-47F Hyd Sys 1 HE1F CH-47F Hyd Sys 2 HE2F CH-47F Hyd Sys 3 HE3F CH-47F T55-L-712 SCDD CH-47F T55-L-714 SCEE CH-47FS Hyd Pump HEAD CH-54 T73-P-1 SSAA CH-54A Hyd Sys 1 HG1A CH-54A Hyd Sys 2 HG2A

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END ITEM COMPONENT TEC CR CH-54A Hyd Sys 3 HG3A CH-54B Hyd Sys 1 HG1B CH-54B Hyd Sys 2 HG2B CH-54B Hyd Sys 3 HG3B Cruise Missile F107-WR-402 KEAA Cruise Missile F112-WR-100 KEBA CV-22 Emer Lube Res DVAC CV-22 Mid-Wing Gbx GVBC CV-22 Prop Rotor Gbx GVDC CV-22 T406-AD-400 SWAA CV-22 Tilt Axis Gbx GVJC E-3 GTCP165-1 DLAB E-3 TF33-PW-100 KCEA E-4 CSD DSFA E-4 JT-9D-7 KNAA E-4B GTCP660-4 DMAA E-6A CFM56-2A-2 FFAB E-6A GTCP165-1 DLAC E-8 TF33-PW-102/JT3D-3B KCFD EA-6B CSD DSBB NO EH-60A APU DXAC EH-60A 42/INT GBX GLID EH-60A 90/Tail Gbx GLTD EH-60A Main Xmsn GLMM EH-60A Main Xmsn (3u) GLMC EH-60A T62T-40-1 DBEB EH-60A T700-GE-701 SHCJ EH-60L APU DQAB EH-60L Main Xmsn GLML EH-60L T700-GE-701 SHCK EH-60L Int Gbx GLIJ EH-60L Tgb GLTJ EMU-30 T62T-32 DBDA EMU-36 T62T-32 DBDB EO-5B PT6A-50 SPNB AO F-111 CSD DSGA F-111 TF30-P-100 KAJA F-111 TF30-P-103 KADA F-111 TF30-P-109 KAFA F-111 TF30-P-3 KAAA F-111 TF30-P-9 KACA

END ITEM COMPONENT TEC CR F-14 CSD DSEA NO F-14 F110-GE-400 FHBA F-14A TF30-P-414A KAHA F-15 F100-PW-100 FAAA F-15 F100-PW-220 FACA F-15 F100-PW-229 FADA F-16 F100-B FAEA F-16 F100-PW-200 FABA F-16 F100-PW-220 FACB F-16 F100-PW-229 FADB F-16 F110-GE-100 FHAA F-16 F110-GE-100B FHDA F-16 F110-GE-129 FHCA FO F-16 T62T40-8 DBFA F-16N F110-GE-100 FHAB F-18 F404-GE-400 PPAA NO F-18 GTCP36-200 DCDA NO F-21 J79-JIE EPFA F-22 F119-PW-100A FRAA F-4 J79-GE-10 EPCA F-4 J79-GE-15 EPDA F-4 J79-GE-17 EPEA F-4 J79-GE-8 EPAA F-5 J85-GE-13 EREA F-5 J85-GE-21 ERGA G-159 MK-529-8X SQAA SO GSE GTC 85-16 DGBA NO GSE GTC 85-116 DGJA NO GSE GTC 85-180L DGHA NO GSE GTC 85-56 DGCA NO GSE GTC 85-72 DGFA NO GSE GTC 85-76 DGGA NO H-1 42/Int Gbx GAIA NO H-1 90/Tail Gbx GATA NO H-1 Main Xmsn GAMA NO H-1 T400-CP-400 SRAA NO H-1 T400-WV-402 SRCA NO H-1 T53-L-11-D SBCD NO H-1 T53-L-13 SBDA FO H-1 T58-GE-3 SEAA H-2 42/Int Gbx GBIA NO

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B-5

END ITEM COMPONENT TEC CR H-2 90/Tail Gbx GBTA NO H-2 Main Xmsn GBMA NO H-2 T58-GE-8F SEDA NC H-3 42/Int Gbx GCIA NO H-3 90/Tail Gbx GCTA NO H-3 Main Xmsn GCMA NO H-3 T58-GE-10 SEEA NC H-3 T58-GE-402 SEJA NC H-3 T58-GE-5 SEBA H-3 T58-GE-8F SEDB NC H-3 T62T-16 DBBB H-46 T58-GE-402 SEJB H-46 Aft Xmsn GDAA NO H-46 Fwd Xmsn GDFA NO H-46 T58-GE-10 SEEB NC H-46 T58-GE-16 SEFA NC H-46 T62T-l 1 DBAA NO H-52 42/Int Gbx GRIA NC H-52 90/Tail Gbx GRTA NC H-52 Main Xmsn GRMA NC H-52 T58-GE-8 SECA NC H-53 #1 Nose Gbx GF1A NO H-53 #2 Nose Gbx GF2A NO H-53 42/Int Gbx GFIA NO H-53 90/Tail Gbx GFTA NO H-53 Acesory Gbx GFCA NO H-53 Main Xmsn GFMA NO H-53 T62T-27 DBCA H-53 T64-GE-100 SGGA H-53 T64-GE-413 SGFA H-53 T64-GE-6B SGBA H-53 T64-GE-7 SGCA H-53D T64-GE-415 SGDA H-53E T64-GE-416 SGEA H-53E #1 Nose Gbx GF1E H-53E #2 Nose Gbx GF2E H-53E Acessory Gbx GFCE H-53E Main Xmsn GFME H-53E 90/TAIL GBX GFTE H-60 T400-GE-401 SRBB H-60 T700-GE-700 SHBA HH-1H 42/Int Gbx GAID FA HH-1H 90/Tail Gbx GATID FA

END ITEM COMPONENT TEC CR HH-1H Main Xmsn GAMD FA HH-60A T700-GE-701 SHCI HH-60A APU DXAD HH-60A T62T-40-1 DBEH HH-60A Int Gbx GLIL HH-60A Main Xmsn GLMP HH-60A MAIN XMSN-3u GLMS HH-60A Tail Gbx GLTL HH-60A Hyd Sys 1 HL1E HH-60A Hyd Sys 2 HL2E HH-60A Hyd Sys 3 HL3E HH-60J Int Gbx GLIK HH-60J Tail Gbx GLTK HH-60L GRCP36-15BH DCHB HH-60L Hyd Sys 1 HL1D HH-60L Hyd Sys 2 HL2D HH-60L Int Gbx GLII HH-60L Main Xmsn GLMI HH-60L T62T-40-1 DBEG HH-60L Tail Gbx GLTI HH-60L T700-GE-701 SHCL HH-65 90/Tail Gbx GPTA HH-65 LTS-101-750 STAA HH-65 Main Xrnsn GPMA HM-60L Main Xmsn GLMJ HU-25 CSD DSJA HU-25 Hyd Sys 1 HT1A HU-25 Hyd Sys 2 HT2A KC-135 T62T-40LC DBGA M32A-60 GTCP 85-180 DJBB M32A-60 GTCP 85-397 DJCA MA-1 GTC 85-70 DGDA MH-47D 1eng Mec Xmsn GEGG MH-47D 2eng Mec Xmsn GEHG MH-47D Aft SP GESG MH-47D Eng Comb Xmsn GEEG MH-47D Fwdsp GERG MH-47D Hyd Sys 1 HE1G MH-47D Hyd Sys 2 HE2G MH-47D Hyd Sys 3 HE3G MH-47D T55-L-712 SCDE MH-47D Aft Xmsn GEAG MH-47D Fwd Xmsn GEFG

TM 38-301-2 - [PDF Document] (187)

NAVAIR 17-15-50.2 TM 38-301-2 T.O. 33-1-37-2 CGTO 33-1-37-2

B-6

END ITEM COMPONENT TEC CR MH-47D T55-L-714 SCEG MH-47E 1EngMecXmsn GEGE MH-47E 2EngMecXmsn GEHE3MH-47E Aft Xmsn GEAF MH-47E Eng CombXmsn GEEE MH-47E Fwd Xmsn GEFE MH-47E Hyd Sys 1 HE1E

MH-47E Hyd Sys 2 HE2E MH-47E Hyd Sys 3 HE3E MH-47E T55-GA-714A SCFB MH-47E T55-L-714 SCDC MH-47E Aft Xmsn GEAE MH-47E Fwd Swplte Brg GERA MH-47E Aft Swplte Brg GESA MH-47E APU DXAF MH-47G Fwd Swplte Brg GERH MH-47G Aft Swplte Brg GESH MH-47G APU DXAG MH-47G Aft Xmsn GEAH MH-47G Fwd Xmsn GEFH MH-47G Comb Xmsn GEEH MH-47G Eng Mec Xmsn 1 GEGH MH-47G Eng Mec Xmsn 2 GEHH MH-47G Hyd Sys 1 HE1H MH-47G Hyd Sys 2 HE2H MH-47G Hyd Sys 3 HE3H MH-47G T55-L-714 SCEH MH-53E T64-GE-419 SGHA MH-6C 90/Tail Gbx GHTD MH-6C Hyd Sys HHAD MH-6C Main Xmsn GHMDMH-6C T63-A-720 SFCH MH-6H 90/Tail Gbx GHTH AO MH-6H HYD SYS HHA4 MH-6H Main Xmsn GHMHMH-6J 90/TailGbx GHTK AO MH-6J Hyd Sys HHA5 MH-6J Main Xmsn GHMK AO MH-6M 250-C-30-R3 SVBA MH-6M Main Xmsn GHMMMH-6M 90/Tail Gbx GHTM

END ITEM COMPONENT TEC CR MH-6M Hyd Sys HHA8 MH-6N 90/TailGbx GHTP AO MH-6N Hyd Sys HHA6 MH-6N Main Xmsn GHMP AO MH-60K Hyd Sys 1 HL1F MH-60K Hyd Sys 2 HL2F MH-60K Hyd Sys 3 HL3F MH-60K T700-GE-701 SHCF MH-60L T700-GE-701 SHCG MH-60L GTCP36-150H DCHA MH-60L Hyd Sys 1 HL1B MH-60L Hyd Sys 2 HL2B MH-60L Hyd Sys 3 HL3B MH-60L Int Gbx GLIG MH-60L Main Xmsn GLMG MH-60L T62T-40-1 DBED MH-60L Tail Gbx GLTG MH-60L APU DXAE MH-60M APU DQAE MH-60M Int Gbx GLIR MH-60M Main Xmsn GLMR MH-60M Tail Gbx GLTR MH-60M T700-GE-701 SHCH MH-60R Int Gbx GLIF MH-60R Main Xmsn GLMF MH-60R Tail Gbx GLTF MH-60S Int Gbx GLIE MH-60S Main Xmsn GLME MH-60S Tail Gbx GLTE MQ-5B Heavy Fuel Engine RPAA MQ-5B Heavy Fuel Engine RPAB Multiple GTCP36-50H DCJX MV-22 Emer Lube Res DVAM MV-22 Mid-Wing Gbx GVBM MV-22 Prop Rotor Gbx GVDM MV-22 Tilt Axis Gbx GVJM O-2 IO-360 RBAA O-5A PT6A-50 SPNA AO OH-58A 90/Tail Gbx GKTA OH-58A Hyd Sys HKAA OH-58A Main Xrnsn GKMA

TM 38-301-2 - [PDF Document] (188)

NAVAIR 17-15-50.2 TM 38-301-2

T.O. 33-1-37-2 CGTO 33-1-37-2

B-7

END ITEM COMPONENT TEC CR OH-58A T63-A 700 SFBA AO OH-58A T63-A-720 SFCG OH-58C Main Xmsn GKMC OH-58C T63-A-720 SFCF OH-58C 90/TAIL GBX GKTC OH-58C Hyd Sys HKAC OH-58D Main Xmsn GKMD OH-58D Tail Gbx GKTD OH-58D T63-A-730 SFDA OH-6A Hyd Sys HHA7 OH-6A T63-A-700 SFBB OH-6A Main Xmsn GHMA OH-6A 90/TAIL GBX GHTA Oil Cart PON-6 DRAA Oil-Lube MIL-H-5606 A007 Oil-Lube MIL-H-83282 A006 Oil-Lube MIL-L-23699 A001 Oil-Lube MIL-L-7808 A003 Oil-Lube MIL-L-85734 A005 Oil-Lube MIL-PRF23699 A002 Oil-Lube MIL-PRF85734 A004 OV-10 T76-G-10 SMAA OV-10 T76-G-12 SMBA OV-10 T76-G-418 SMCA OV-10 T76-G-419 SMDA OV-10 T76-G-420 SMEA OV-10 T76-G-421 SMFA P-3 GTCP 95-2 DKAA NO Predator TPE331-10 SJAA QF-86F J47-GE-27 ECAA RC-12D PT6A-41 SPHD RC-12G PT6A-41 SPHE RC-12K PT6A-67 SPMA RC-12P PT6A-41 SPHG RC-12Q PT6A-41 SPHH RQ-5A Main Gbx GNMA RQ-5A V-75 RNAA RU-9D O-480-B1A6 RDEA S-3 GTCP36-201A DCAB NO S-3 TF34-GE-400B KDBA NO SH-2G #1 Nose Gbx GB1G NO SH-2G #2 Nose Gbx GB2G NO SH-2G 42/Int Gbx GBIG NO

END ITEM COMPONENT TEC CR SH-2G 90/Tail Gbx GBTG NO SH-2G Acesory Gbx GBCG NO SH-2G Main Xmsn GBMG NO SH-60B 42/Int Gbx GLIB SH-60B 90/Tail Gbx GLTB SH-60B Main Xmsn GLMB T-1A JT15D-5B KPAA T-2 J85-GE-4 ERBA T-2C J85-GE-4A ERCA T-34 PT6A-42 SPJB T-34B O-470 RCAA NO T-34C Brake Sys HNBC T-34C PT6A-25 SPBA NO T-37 J69-T-25 EKAA T-38 J85-GE-5 ERDA T-39 J60-P-3 EHAA FO T-39 J60-P-3A EHBA NO T-39 JT-12A-8 KLAA NO T-41 IO-360 RBAB T-41 O-300D RLAA T-41B IO-360-D RBCA T-41C IO-360-C RBBA T-41C IO-360-D RBCB T-41D IO-360-D RBCC T-43 JT-8D-9 KKBC FO T-44A PT6A-34B SPFB NO T-45A F405-RR-400 FQAA T-46 F109-GA-100 FGAA T-6A PT6A-68 SPQA Test Cell GTCP 95-3 DKBA NO Test Cell T56-A-10 SDDX FN Test Cell T56-A-14 SDEX FN Test Cell T56-A-16 SDGX FN Test Cell T56-A-425 SDHX FN Test Cell T56-A-426 SDJX FN Test Cell T56-A-7B SDBX FN Test Cell T62T-16 DBBA Test Cell T700-GE-401 SHAX TG-7 O-235 RAAA TH-1G Hyd Sys 3 HA32 TH-57B 90/Tail Gbx GSTB NO TH-57B Main Xmsn GSMB NO TH-57B T63-A-720 SFCA NO

TM 38-301-2 - [PDF Document] (189)

NAVAIR 17-15-50.2 TM 38-301-2 T.O. 33-1-37-2 CGTO 33-1-37-2

B-8

END ITEM COMPONENT TEC CR TH-67 250-C-30 SVAA TH-67 90/TAIL GBX GUTA TH-67 Hyd Sys HUAA TH-67 Main Xmsn GUMA U-10 GO-480-G1D6 RDHA U-2 J57-P-31 EFBA U-2 J75-P-17 EMAB U-21F PT6A-28 SPDA U-21G T74-CP-700 SUAF U-2S F118-GE-101 EMAC UH-1B 42/Int Gbx GAIB FA UH-1B 90/Tail Gbx GATB FA UH-1B Hyd Sys HAAB FA UH-1B Main Xmsn GAMB FA UH-1B T53-L-11 SBCA AO UH-1C 42/Int Gbx GAIC FA UH-1C 90/Tail Gbx GATC FA UH-1C Hyd Sys HAAC FA UH-1C Main Xmsn GAMC FA UH-1C T53-L-11 SBCB AO UH-1FS Hyd Pump HAA1 UH-1H 42/Int Gbx GAIH FA UH-1H 90/Tail Gbx GATH FA UH-1H Hyd Sys HAAH FA UH-1H Main Xmsn GAMH FA UH-1H T53-L-13B SBEE AO UH-1M 42/Int Gbx GAIM FA UH-1M 90/Tail Gbx GATM FA UH-1M Hyd Sys 1 HA1M FA UH-1M Hyd Sys 2 HA2M FA UH-1M Main Xmsn GAMM FA UH-1M T53-L-13B SBEF AO UH-1N 42/Int Gbx GAIN FA UH-1N 90/Tail Gbx GATN FA UH-1N Eng Comb Gbx GAEN FN UH-1N Hyd Sys HAA4 UH-1N Main Xmsn GAMN FA UH-1N T400-CP-400 SRAB UH-1V 42/Int Gbx GAIV FA UH-1V 90/Tail Gbx GATN FA UH-1V Hyd Sys HAAV FA

END ITEM COMPONENT TEC CR UH-1V Main Xmsn GAMV FA UH-1V T53-L-11 SBCC AO UH-1V T53-L-13B SBEG AO UH-1X 42/Int Gbx GAIX FA UH-1X 90/Tail Gbx GATX FA UH-1X Hyd Sys HAAX FA UH-1X Main Xmsn GAMX FA UH-60 Hyd-Pump HLPA UH-60A T700-GE-701 SHCC UH-60A 90/Tail Gbx GLTI UH-60A Main Xmsn GLMK UH-60A Main Xmsn (3u) GLMA UH-60A T62T-40-1 DBEA UH-60A Int Gbx GLIA UH-60A 90/Tail Gbx GLTA UH-60A APU DXAA UH-60FS Hyd Pump HLAA UH-60L T700-GE-701 SHCD UH-60L GTC36-150 DCEA UH-60L 42/Int Gbx GLIC UH-60L Hyd Sys 1 HL12 UH-60L T62T-40-1 DBEC UH-60L T700-GE-701C SHDA UH-60L Main Xmsn GLMD UH-60L Main Gbx GLMD UH-60L 90/Tail Gbx GLTC UH-60L APU DXAB UH-60L Hyd Sys GLTC UH-60M APU DQAC UH-60M Int Gbx GLIM UH-60M Main Xmsn GLMQ UH-60M Tail Gbx GLTM UH-60M T700-GE-701 SHCE UH-60Q Hyd Sys 1 HL1C UH-60Q Hyd Sys 2 HL2C UH-60Q Hyd Sys 3 HL3C UH-60Q Main Xmsn (3u) GLMH UH-60Q Tail Gbx GLTH UV-18 PT6A-27 SPCA UV-18A PT6A-27 SPCB VC-140 GTCP 30-92 DNAA

TM 38-301-2 - [PDF Document] (190)

NAVAIR 17-15-50.2 TM 38-301-2

T.O. 33-1-37-2 CGTO 33-1-37-2

B-9

END ITEM COMPONENT TEC CR VH-3D 42/Int Gbx GCID NO VH-3D 90/Tail Gbx GCTD NO VH-3D Hyd Sys HCA1 VH-3D Main Xmsn GCMD NO VH-3D T58-GE-400 SEGA NC VH-3D T58-GE-400B SEHA NC VH-60N Main Xmsn GLMT VH-60N Int Gbx GLTT VH-60N Tail Gbx GLIT X-32 F119-PW-614C FRCA X-35 F119-PW-611C FRBA X-35 F135-PW-100 FSAA X-35 F235-PW-600 FSAB

END ITEM COMPONENT TEC CR

TM 38-301-2 - [PDF Document] (191)

NAVAIR 17-15-50.2 TM 38-301-2 T.O. 33-1-37-2 CGTO 33-1-37-2

B-10

AERONAUTICAL TYPE EQUIPMENT CODES Sorted by TEC

CRITERIA RESTRICTION

END ITEM COMPONENT TEC CR Oil-Lube MIL-L-23699 A001 Oil-Lube MIL-PRF23699 A002 Oil-Lube MIL-L-7808 A003 Oil-Lube MIL-PRF85734 A004 Oil-Lube MIL-L-85734 A005 Oil-Lube MIL-H-83282 A006 Oil-Lube MIL-H-5606 A007 BIO-RAD FT-IR AIRA Aircraft Synthetic Oil ASYN AO C-135 T41 M-9 DAAA H-46 T62T-l 1 DBAA NO Test Cell T62T-16 DBBA H-3 T62T-16 DBBB H-53 T62T-27 DBCA EMU-30 T62T-32 DBDA EMU-36 T62T-32 DBDB UH-60A T62T-40-1 DBEA EH-60A T62T-40-1 DBEB UH-60L T62T-40-1 DBEC MH-60L T62T-40-1 DBED HH-60L T62T-40-1 DBEG HH-60A T62T-40-1 DBEH F-16 T62T40-8 DBFA KC-135 T62T-40LC DBGA C-2 GTCP36-201C DCAA NO S-3 GTCP36-201A DCAB NO A-10 GTCP36-50 DCBA C-20 GTCP36-100 DCCA F-18 GTCP36-200 DCDA NO UH-60L GTC36-150 DCEA C-27 CTCP36-16A DCGA MH-60L GTCP36-150H DCHA HH-60L GRCP36-15BH DCHB Multiple GTCP36-50H DCJX C-135 GTC70-15 DFAA GSE GTC 85-16 DGBA NO GSE GTC 85-56 DGCA NO

END ITEM COMPONENT TEC CR MA-1 GTC 85-70 DGDA C-130 GTC85-71 DGEA GSE GTC 85-72 DGFA NO GSE GTC 85-76 DGGA NO GSE GTC 85-180L DGHA NO GSE GTC 85-116 DGJA NO C-141 GTCP85-106 DJAA C-130 GTCP85-180 DJBA M32A-60 GTCP 85-180 DJBB A/M32A-95 GTCP 85-180 DJBC M32A-60 GTCP 85-397 DJCA C-137 GTCP 85-97 DJDA C-137 GTCP85-98 DJEA P-3 GTCP 95-2 DKAA NO Test Cell GTCP 95-3 DKBA NO C-5 GTCP165-1 DLAA E-3 GTCP165-1 DLAB E-6A GTCP165-1 DLAC B-1B GTCP165-9 DLBA E-4B GTCP660-4 DMAA VC-140 GTCP 30-92 DNAA AV-8 ING DR GEN DPAA NO AH-64A APU DQAA EH-60L APU DQAB UH-60M APU DQAC AH-64D APU DQAD MH-60M APU DQAE CH-47D APU DQAF CH-47F APU DQAG Oil Cart PON-6 DRAA A-4 CSD DSAA NO A-6 CSD DSBA NO EA-6B CSD DSBB NO F-14 CSD DSEA NO E-4 CSD DSFA F-111 CSD DSGA HU-25 CSD DSJA

TM 38-301-2 - [PDF Document] (192)

NAVAIR 17-15-50.2 TM 38-301-2

T.O. 33-1-37-2 CGTO 33-1-37-2

B-11

END ITEM COMPONENT TEC CR CV-22 Emer Lube Res DVAC MV-22 Emer Lube Res DVAM UH-60A APU DXAA UH-60L APU DXAB EH-60A APU DXAC HH-60A APU DXAD MH-60L APU DXAE MH-47E APU DXAF MH-47G APU DXAG 5220 Hyd-PU DXBA 05-7014-1200 Hyd-PU DXBB May-08 Hyd-PU DXBC QF-86F J47-GE-27 ECAA A-4 J52-P-8B EEBA NO A-6 J52-P-8B EEBB NO A-4 J52-P-408 EECA NO A-6 J52-P-408 Gbx EECB A-6 J52-P-408 Tank EECC A-4 J52-P-6C EEDA U-2 J57-P-31 EFBA C-135 J57-P-43 EFCB C-135 J57-P-59 EFDA B-52 J57-P-19 EFGA T-39 J60-P-3 EHAA FO T-39 J60-P-3A EHBA NO C-140 J60-P-5 EHCA FO T-37 J69-T-25 EKAA U-2 J75-P-17 EMAB U-2S F118-GE-101 EMAC F-4 J79-GE-8 EPAA F-4 J79-GE-10 EPCA F-4 J79-GE-15 EPDA F-4 J79-GE-17 EPEA F-21 J79-JIE EPFA T-2 J85-GE-4 ERBA T-2C J85-GE-4A ERCA T-38 J85-GE-5 ERDA F-5 J85-GE-13 EREA A-37 J85-GE-17 ERFA F-5 J85-GE-21 ERGA F-15 F100-PW-100 FAAA

END ITEM COMPONENT TEC CR F-16 F100-PW-200 FABA F-15 F100-PW-220 FACA F-16 F100-PW-220 FACB F-15 F100-PW-229 FADA F-16 F100-PW-229 FADB F-16 F100-B FAEA B-1 F101-GE-102 FBAA C-10 FI 03-G E- 101 FDBA C-135 F108-CF-100 FFAA E-6A CFM56-2A-2 FFAB T-46 F109-GA-100 FGAA F-16 F110-GE-100 FHAA F-16N F110-GE-100 FHAB F-14 F110-GE-400 FHBA F-16 F110-GE-129 FHCA FO F-16 F110-GE-100B FHDA C-20 F113-RR-100 FJAA B-2 F118-GE-100 FKAA FO C-17 F117-PW-100 FLAA AV-8 F402-RR-402 FMAA AV-8 F402-RR-404 FMCA AV-8B F402-RR-406 FMEA AV-8B F402-RR-408 FMFA T-45A F405-RR-400 FQAA F-22 F119-PW-100A FRAA X-35 F119-PW-611C FRBA X-32 F119-PW-614C FRCA X-35 F135-PW-100 FSAA X-35 F235-PW-600 FSAB UH-1N Eng Comb Gbx GAEN FN H-1 42/Int Gbx GAIA NO UH-1B 42/Int Gbx GAIB FA UH-1C 42/Int Gbx GAIC FA HH-1H 42/Int Gbx GAID FA AH-1E 42/Int Gbx GAIE AH-1G 42/Int Gbx GAIG FA UH-1H 42/Int Gbx GAIH FA UH-1M 42/Int Gbx GAIM FA UH-1N 42/Int Gbx GAIN FA AH-1S 42/Int Gbx GAIS UH-1V 42/Int Gbx GAIV FA

TM 38-301-2 - [PDF Document] (193)

NAVAIR 17-15-50.2 TM 38-301-2 T.O. 33-1-37-2 CGTO 33-1-37-2

B-12

END ITEM COMPONENT TEC CR UH-1X 42/Int Gbx GAIX FA H-1 Main Xmsn GAMA NO UH-1B Main Xmsn GAMB FA UH-1C Main Xmsn GAMC FA HH-1H Main Xmsn GAMD FA AH-1E Main Xmsn GAME AH-1G Main Xmsn GAMG FA UH-1H Main Xmsn GAMH FA UH-1M Main Xmsn GAMM FA UH-1N Main Xmsn GAMN FA UH-1V Main Xmsn GAMV FA UH-1X Main Xmsn GAMX FA H-1 90/Tail Gbx GATA NO UH-1B 90/Tail Gbx GATB FA AH-1G 90/Tail Gbx GATC FA UH-1C 90/Tail Gbx GATC FA AH-1E 90/Tail Gbx GATE UH-1H 90/Tail Gbx GATH FA HH-1H 90/Tail Gbx GATID FA UH-1M 90/Tail Gbx GATM FA UH-1N 90/Tail Gbx GATN FA UH-1V 90/Tail Gbx GATN FA UH-1X 90/Tail Gbx GATX FA SH-2G #1 Nose Gbx GB1G NO SH-2G #2 Nose Gbx GB2G NO SH-2G Acesory Gbx GBCG NO H-2 42/Int Gbx GBIA NO SH-2G 42/Int Gbx GBIG NO H-2 Main Xmsn GBMA NO SH-2G Main Xmsn GBMG NO H-2 90/Tail Gbx GBTA NO SH-2G 90/Tail Gbx GBTG NO H-3 42/Int Gbx GCIA NO VH-3D 42/Int Gbx GCID NO H-3 Main Xmsn GCMA NO VH-3D Main Xmsn GCMD NO H-3 90/Tail Gbx GCTA NO VH-3D 90/Tail Gbx GCTD NO H-46 Aft Xmsn GDAA NO H-46 Fwd Xmsn GDFA NO

END ITEM COMPONENT TEC CR CH-47A Aft Xmsn GEAA CH-47D Aft Xmsn GEAD MH-47E Aft Xmsn GEAE CH-47F Aft Xmsn GEAF MH-47E Aft Xmsn GEAF MH-47D Aft Xmsn GEAG MH-47G Aft Xmsn GEAH CH-47A Eng Comb Xmsn GEEA CH-47D Engcombxmsn GEED MH-47E Eng CombXmsn GEEE CH-47F Eng Comb Xmsn GEEF MH-47D Eng Comb Xmsn GEEG MH-47G Comb Xmsn GEEH CH-47A Fwd Xmsn GEFA CH-47D Fwdxmsn GEFD MH-47E Fwd Xmsn GEFE CH-47F Fwd Xmsn GEFF MH-47D Fwd Xmsn GEFG MH-47G Fwd Xmsn GEFH CH-47A 1eng Mec Zmsn GEGA CH-47D 1 EngMecXmsn GEGD MH-47E 1EngMecXmsn GEGE CH-47F 1 Eng Mec Xmsn GEGF MH-47D 1eng Mec Xmsn GEGG MH-47G Eng Mec Xmsn 1 GEGH CH-47A 2eng Mec Xmsn GEHA CH-47D 2 EngMecXmsn GEHD MH-47E 2EngMecXmsn GEHE3 CH-47F 2 Eng Mec Xmsn GEHF MH-47D 2eng Mec Xmsn GEHG MH-47G Eng Mec Xmsn 2 GEHH MH-47E Fwd Swplte Brg GERA MH-47D Fwdsp GERG MH-47G Fwd Swplte Brg GERH MH-47E Aft Swplte Brg GESA MH-47D Aft SP GESG MH-47G Aft Swplte Brg GESH H-53 #1 Nose Gbx GF1A NO H-53E #1 Nose Gbx GF1E H-53 #2 Nose Gbx GF2A NO

TM 38-301-2 - [PDF Document] (194)

NAVAIR 17-15-50.2 TM 38-301-2

T.O. 33-1-37-2 CGTO 33-1-37-2

B-13

END ITEM COMPONENT TEC CR H-53E #2 Nose Gbx GF2E H-53 Acesory Gbx GFCA NO H-53E Acessory Gbx GFCE H-53 42/Int Gbx GFIA NO H-53 Main Xmsn GFMA NO H-53E Main Xmsn GFME H-53 90/Tail Gbx GFTA NO H-53E 90/TAIL GBX GFTE OH-6A Main Xmsn GHMA AH-6C Main Xmsn GHMC MH-6C Main Xmsn GHMD MH-6H Main Xmsn GHMH AH-6J Main Xmsn GHMJ AO MH-6J Main Xmsn GHMK AO MH-6M Main Xmsn GHMM AH-6N Main Xmsn GHMN AO MH-6N Main Xmsn GHMP AO OH-6A 90/TAIL GBX GHTA AH-6C 90/Tail Gbx GHTC MH-6C 90/Tail Gbx GHTD MH-6H 90/Tail Gbx GHTH AO AH-6J 90/Tail Gbx GHTJ AO MH-6J 90/TailGbx GHTK AO MH-6M 90/Tail Gbx GHTM AH-6N 90/Tail Gbx GHTN AO MH-6N 90/TailGbx GHTP AO OH-58A Main Xrnsn GKMA OH-58C Main Xmsn GKMC OH-58D Main Xmsn GKMD OH-58A 90/Tail Gbx GKTA OH-58C 90/TAIL GBX GKTC OH-58D Tail Gbx GKTD UH-60A Int Gbx GLIA SH-60B 42/Int Gbx GLIB UH-60L 42/Int Gbx GLIC EH-60A 42/INT GBX GLID MH-60S Int Gbx GLIE MH-60R Int Gbx GLIF MH-60L Int Gbx GLIG HH-60L Int Gbx GLII EH-60L Int Gbx GLIJ

END ITEM COMPONENT TEC CR HH-60J Int Gbx GLIK HH-60A Int Gbx GLIL UH-60M Int Gbx GLIM MH-60M Int Gbx GLIR VH-60N Tail Gbx GLIT UH-60A Main Xmsn (3u) GLMA SH-60B Main Xmsn GLMB EH-60A Main Xmsn (3u) GLMC UH-60L Main Xmsn GLMD UH-60L Main Gbx GLMD MH-60S Main Xmsn GLME MH-60R Main Xmsn GLMF MH-60L Main Xmsn GLMG UH-60Q Main Xmsn (3u) GLMH HH-60L Main Xmsn GLMI HM-60L Main Xmsn GLMJ UH-60A Main Xmsn GLMK EH-60L Main Xmsn GLML EH-60A Main Xmsn GLMM HH-60A Main Xmsn GLMP UH-60M Main Xmsn GLMQ MH-60M Main Xmsn GLMR HH-60A MAIN XMSN-3u GLMS VH-60N Main Xmsn GLMT UH-60A 90/Tail Gbx GLTA SH-60B 90/Tail Gbx GLTB UH-60L 90/Tail Gbx GLTC UH-60L Hyd Sys GLTC EH-60A 90/Tail Gbx GLTD MH-60S Tail Gbx GLTE MH-60R Tail Gbx GLTF MH-60L Tail Gbx GLTG UH-60Q Tail Gbx GLTH HH-60L Tail Gbx GLTI UH-60A 90/Tail Gbx GLTI EH-60L Tgb GLTJ HH-60J Tail Gbx GLTK HH-60A Tail Gbx GLTL UH-60M Tail Gbx GLTM MH-60M Tail Gbx GLTR VH-60N Int Gbx GLTT

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B-14

END ITEM COMPONENT TEC CR AH-64A #1 Nose Gbx GM1A AH-64A #2 Nose Gbx GM2A AH-64A Int Gbx GMIA AH-64A Main Xmsn GMMA AH-64A PTO Clutch GMPA AH-64D PTO Clutch GMPD AH-64A Tail Gbx GMTA RQ-5A Main Gbx GNMA HH-65 Main Xrnsn GPMA HH-65 90/Tail Gbx GPTA H-52 42/Int Gbx GRIA NC H-52 Main Xmsn GRMA NC H-52 90/Tail Gbx GRTA NC TH-57B Main Xmsn GSMB NO TH-57B 90/Tail Gbx GSTB NO C-130 T56-A-9 Gbx GTMC C-130 T56-A-15 Gbx GTMF C-130 Nose Gear GTNK TH-67 Main Xmsn GUMA TH-67 90/TAIL GBX GUTA CV-22 Mid-Wing Gbx GVBC MV-22 Mid-Wing Gbx GVBM CV-22 Prop Rotor Gbx GVDC MV-22 Prop Rotor Gbx GVDM CV-22 Tilt Axis Gbx GVJC MV-22 Tilt Axis Gbx GVJM AH-1G Hyd Sys 1 HA1G FA UH-1M Hyd Sys 1 HA1M FA AH-1G Hyd Sys 2 HA2G FA UH-1M Hyd Sys 2 HA2M FA AH-1G Hyd Sys 3 HA31 TH-1G Hyd Sys 3 HA32 UH-1FS Hyd Pump HAA1 UH-1N Hyd Sys HAA4 UH-1B Hyd Sys HAAB FA UH-1C Hyd Sys HAAC FA UH-1H Hyd Sys HAAH FA UH-1V Hyd Sys HAAV FA UH-1X Hyd Sys HAAX FA VH-3D Hyd Sys HCA1

END ITEM COMPONENT TEC CR CH-47A Hyd Sys 1 HE1A CH-47B Hyd Sys 1 HE1B CH-47C Hyd Sys 1 HE1C CH-47D Hyd Sys 1 HE1D MH-47E Hyd Sys 1 HE1E CH-47F Hyd Sys 1 HE1F MH-47D Hyd Sys 1 HE1G MH-47G Hyd Sys 1 HE1H CH-47A Hyd Sys 2 HE2A CH-47B Hyd Sys 2 HE2B CH-47C Hyd Sys 2 HE2C CH-47D Hyd Sys 2 HE2D MH-47E Hyd Sys 2 HE2E CH-47F Hyd Sys 2 HE2F MH-47D Hyd Sys 2 HE2G MH-47G Hyd Sys 2 HE2H CH-47A Hdy Sys 3 HE3A CH-47B Hdy Sys 3 HE3B CH-47C Hyd Sys 3 HE3C CH-47D Hyd Sys 3 HE3D MH-47E Hyd Sys 3 HE3E CH-47F Hyd Sys 3 HE3F MH-47D Hyd Sys 3 HE3G MH-47G Hyd Sys 3 HE3H CH-47FS Hyd Pump HEAD CH-54A Hyd Sys 1 HG1A CH-54B Hyd Sys 1 HG1B CH-54A Hyd Sys 2 HG2A CH-54B Hyd Sys 2 HG2B CH-54A Hyd Sys 3 HG3A CH-54B Hyd Sys 3 HG3B AH-6C Hyd Sys HHA1 AH-6J Hyd Sys HHA2 AH-6N Hyd Sys HHA3 MH-6H HYD SYS HHA4 MH-6J Hyd Sys HHA5 MH-6N Hyd Sys HHA6 OH-6A Hyd Sys HHA7 MH-6M Hyd Sys HHA8 MH-6C Hyd Sys HHAD

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T.O. 33-1-37-2 CGTO 33-1-37-2

B-15

END ITEM COMPONENT TEC CR Aircraft Hydraulic Oil HHYD AO OH-58A Hyd Sys HKAA OH-58C Hyd Sys HKAC UH-60L Hyd Sys 1 HL12 MH-60L Hyd Sys 1 HL1B UH-60Q Hyd Sys 1 HL1C HH-60L Hyd Sys 1 HL1D HH-60A Hyd Sys 1 HL1E MH-60K Hyd Sys 1 HL1F MH-60L Hyd Sys 2 HL2B UH-60Q Hyd Sys 2 HL2C HH-60L Hyd Sys 2 HL2D HH-60A Hyd Sys 2 HL2E MH-60K Hyd Sys 2 HL2F MH-60L Hyd Sys 3 HL3B UH-60Q Hyd Sys 3 HL3C HH-60A Hyd Sys 3 HL3E MH-60K Hyd Sys 3 HL3F UH-60FS Hyd Pump HLAA UH-60 Hyd-Pump HLPA AH-64A Hyd Sys 1 HM11 AH-64A Hyd Sys 2 HM21 AH-64D Hyd Sys 2 HM22 AH-64D Hyd Sys HMAD T-34C Brake Sys HNBC HU-25 Hyd Sys 1 HT1A HU-25 Hyd Sys 2 HT2A TH-67 Hyd Sys HUAA F-111 TF30-P-3 KAAA B-111 TF30-P-7 KABA F-111 TF30-P-9 KACA F-111 TF30-P-103 KADA B-111 TF30-P-107 KAEA F-111 TF30-P-109 KAFA F-14A TF30-P-414A KAHA F-111 TF30-P-100 KAJA B-52 TF33-P-3 KCAA C-135 TF33-P-5 KCBA C-141 TF33-P-7 KCCA C-135 TF33-P-9 KCDA E-3 TF33-PW-100 KCEA

END ITEM COMPONENT TEC CR C-135 TF33-PW-102 KCFA C-18 TF33-PW-102 KCFB C-135 TF33-PW-102/JT3D–3B KCFC E-8 TF33-PW-102/JT3D-3B KCFD B-52 TF33-P-103 KCGA A-10 TF34-GE-100 KDAA FO S-3 TF34-GE-400B KDBA NO Cruise Missile F107-WR-402 KEAA Cruise Missile F112-WR-100 KEBA B-52 J57-P-43 KFCA C-5 TF39-GE-1 KGAA C-137 TF33-PW-102/JT3D-3B KGBA C-137 JT-3D-3 KJAA C-22 JT-8D-7 KKAA FO C-9 JT-8D-9 KKBA FO C-9 JT-8D-9 KKBB NO T-43 JT-8D-9 KKBC FO T-39 JT-12A-8 KLAA NO C-21 TFE731-2 KMAA E-4 JT-9D-7 KNAA T-1A JT15D-5B KPAA F-18 F404-GE-400 PPAA NO TG-7 O-235 RAAA O-2 IO-360 RBAA T-41 IO-360 RBAB T-41C IO-360-C RBBA T-41B IO-360-D RBCA T-41C IO-360-D RBCB T-41D IO-360-D RBCC T-34B O-470 RCAA NO RU-9D O-480-B1A6 RDEA U-10 GO-480-G1D6 RDHA BE-65 IO-720-A1B RHBA T-41 O-300D RLAA RQ-5A V-75 RNAA MQ-5B Heavy Fuel Engine RPAA MQ-5B Heavy Fuel Engine RPAB UH-1B T53-L-11 SBCA AO UH-1C T53-L-11 SBCB AO UH-1V T53-L-11 SBCC AO H-1 T53-L-11-D SBCD NO

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B-16

END ITEM COMPONENT TEC CR H-1 T53-L-13 SBDA FO AH-1G T53-L-13B SBEA AO UH-1H T53-L-13B SBEE AO UH-1M T53-L-13B SBEF AO UH-1V T53-L-13B SBEG AO CH-47A T55-L-7C SCBA CH-47C T55-L-712 SCDA CH-47D T55-L-712 SCDB MH-47E T55-L-714 SCDC CH-47F T55-L-712 SCDD MH-47D T55-L-712 SCDE CH-47D T55-L-714 SCED CH-47F T55-L-714 SCEE MH-47D T55-L-714 SCEG MH-47G T55-L-714 SCEH CH-47D T55-GA-714A SCFA MH-47E T55-GA-714A SCFB C-130 T56-A7 SDAA FN Test Cell T56-A-7B SDBX FN C-130 T56-A-9 SDCA FN Test Cell T56-A-10 SDDX FN Test Cell T56-A-14 SDEX FN C-130 T56-A-15 SDFA FN Test Cell T56-A-16 SDGX FN Test Cell T56-A-425 SDHX FN Test Cell T56-A-426 SDJX FN H-1 T58-GE-3 SEAA H-3 T58-GE-5 SEBA H-52 T58-GE-8 SECA NC H-2 T58-GE-8F SEDA NC H-3 T58-GE-8F SEDB NC H-3 T58-GE-10 SEEA NC H-46 T58-GE-10 SEEB NC H-46 T58-GE-16 SEFA NC VH-3D T58-GE-400 SEGA NC VH-3D T58-GE-400B SEHA NC H-3 T58-GE-402 SEJA NC H-46 T58-GE-402 SEJB OH-58A T63-A 700 SFBA AO OH-6A T63-A-700 SFBB

END ITEM COMPONENT TEC CR TH-57B T63-A-720 SFCA NO AH-6C T63-A720 SFCB AO OH-58C T63-A-720 SFCF OH-58A T63-A-720 SFCG MH-6C T63-A-720 SFCH OH-58D T63-A-730 SFDA H-53 T64-GE-6B SGBA H-53 T64-GE-7 SGCA H-53D T64-GE-415 SGDA H-53E T64-GE-416 SGEA H-53 T64-GE-413 SGFA H-53 T64-GE-100 SGGA MH-53E T64-GE-419 SGHA Test Cell T700-GE-401 SHAX H-60 T700-GE-700 SHBA AH-64D T700-GE-701 SHCA AH-64A T700-GE-701 SHCB UH-60A T700-GE-701 SHCC UH-60L T700-GE-701 SHCD UH-60M T700-GE-701 SHCE MH-60K T700-GE-701 SHCF MH-60L T700-GE-701 SHCG MH-60M T700-GE-701 SHCH HH-60A T700-GE-701 SHCI EH-60A T700-GE-701 SHCJ EH-60L T700-GE-701 SHCK HH-60L T700-GE-701 SHCL UH-60L T700-GE-701C SHDA Predator TPE331-10 SJAA OV-10 T76-G-10 SMAA OV-10 T76-G-12 SMBA OV-10 T76-G-418 SMCA OV-10 T76-G-419 SMDA OV-10 T76-G-420 SMEA OV-10 T76-G-421 SMFA C-6 PT6A-20 SPAA T-34C PT6A-25 SPBA NO UV-18 PT6A-27 SPCA UV-18A PT6A-27 SPCB C-12 PT6A-27 SPCC

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T.O. 33-1-37-2 CGTO 33-1-37-2

B-17

END ITEM COMPONENT TEC CR U-21F PT6A-28 SPDA C-12 PT6A-34 SPFA T-44A PT6A-34B SPFB NO C-12 PT6A-38 SPGA C-12 PT5A-41 SPHA C-12C PT6A-41 SPHB C-12D PT6A-41 SPHC RC-12D PT6A-41 SPHD RC-12G PT6A-41 SPHE RC-12P PT6A-41 SPHG RC-12Q PT6A-41 SPHH C-12 PT6A-42 SPJA T-34 PT6A-42 SPJB C-12U PT6A-42 SPJC C-23 PT6A-45 SPKA C-27 T64-P4D SPLA RC-12K PT6A-67 SPMA O-5A PT6A-50 SPNA AO EO-5B PT6A-50 SPNB AO C-12J PT6A-65B SPPA T-6A PT6A-68 SPQA C-23C PT6A-65AR SPRA G-159 MK-529-8X SQAA SO H-1 T400-CP-400 SRAA NO UH-1N T400-CP-400 SRAB H-60 T400-GE-401 SRBB H-1 T400-WV-402 SRCA NO CH-54 T73-P-1 SSAA HH-65 LTS-101-750 STAA U-21G T74-CP-700 SUAF TH-67 250-C-30 SVAA MH-6M 250-C-30-R3 SVBA CV-22 T406-AD-400 SWAA

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B-18

NONAERONAUTICAL TYPE EQUIPMENT CODES

U.S. MARINE CORPS COMPONENT EIMOD COMPMOD TEC EIMOD COMPMOD TEC 1150-MC A38714 MEDH 1150-MC DD453 MEGC 1150-MC HYD SYS MEDN 4000K-MC 18314-2 MJBG 4000K-MC 4BT3.9 MJBA 4000-MC DD353 MEBC 4000-MC HYD SYS MEBN 4000-MC TTB2221-1 MEBJ 420-C-MC DD353 MECB 420-C-MC HMD2315CB MECH 48MC-MC DD453 MEBB 48MC-MC HR18325 MEBH 580-MC A38714 MEFH 580-MC CASE-G188D MEFB 6000K-MC 6359T MKZA 6000K-MC FUNK-1724 MKZG 6000RTL-MC A3331-1 MDBJ 6000RLT-MC A38714 MDAG 6000RLT-MC DD453 MDBB 6000RLT-MC HYD SYS MDBN 6000RLT-MC MHR18325 MDAH UH-60L HYD SYS 3 HL32 600GPM-MC DD353 MEDC 621B-MC 3406 MECA 621B-MC 7G2780 MECG 621B-MC HYD SYS MECN 72-31-MC CRT 3333-1 MEEH 72-31-MC DD471 MEEC 72-31-MC HYD SYS MEEN AAVC7A1-MC HS400-3A1 MWAG AAVC7A1-MC VT-400 MWAA AAVP7A1-MC HS400-3A1 MWBG AAVP7A1-MC VT-400 MWBA AAVR7A1-MC HS400-3A1 MWCG AAVR7A1-MC HYD SYS NWCN AAVR7A1-MC VT-400 MWCA AIRCOMP-MC DEUTZ-F4L912 META AVLB-MC 1790-2DA MAGB AVLB-MC CD850-6A MAGH AVLB-MC HYD SYS MAJN BRIDGE-MC SABRE 212 MXJA CAT-130G-MC 5R6172 MEMH CAT-130G-MC CAT-3304 MEMC CAT-130G-MC HYD SYS MEMN CAT-D7G-MC 9R5382 MENG CAT-D7G-MC CAT-3306 MENA CAT-D7G-MC HYD SYS MENN CAUSEWAY-MC CMD-2A-221 MWFN CAUSEWAY-MC DD8V71T MWDC

CAUSEWAY-MC F301HY1PCNTB MWQN CAUSEWAY-MC MH30L MWDH CAUSEWAY-MC PAVC38RA MWEN CAUSEWAY-MC RSA 04K MWDN COMPACTO-MC DD4534 MVPA COMPACTO-MC HMD2315CB MVPG CONMIXER-MC TRI-02 MEMB CRANE-MC 4133.9 MEKA CRANE-MC CAT-3208T MXBA CRANE-MC CLARK-28000 MXBG CRANE-MC FUNK-17243E MEKG DECONAPP-MC 4A084-3 MBQA DRCH2500-MC DD6V53 MEAB DRCH2500-MC R28621-12 MEAH EXCAVATO-MC 5043-7000 MEJA EXCAVATO-MC FUNK-17243E MEJG GRADER-MC CAT-3304 MEGA GRADER-MC POWESHIFT MEGG HOSEREEL-MC AT5CC MDCN HOSEREEL-MC DD371 MDCB LAV-25-MC DD6V53T MWGA LAV-25-MC MT653 MWGG LAV-AT-MC DD6V53T MWHA LAV-AT-MC MT653DR MWHG LAV-C2-MC DD6V53T MWJA LAV-C2-MC MT653DR MWJG LAV-L-MC DD6V53T MWKA LAV-L-MC MT653DR MWKG LAV-M-MC DD6V53T MWLA LAV-M-MC MT653DR MWLG LAV-R-MC DD6V53T MWMA LAV-R-MC MT653DR MWMG M109A3-MC DD8V71T MAAA M109A3-MC XTG-411-2A MAAG M110A2-MC DD8V71T MABA M110A2-MC XTG-411-2A MABG M123A1C-MC V8-300 MBCC M123E2-MC V8-300 MBDC M1A1-MC AGT-1500 MACA M1A1-MC HYD SYS MAVN M1A1-MC X1100-3B MACG M35A2C-MC LD-465-1 MBAC M45A2-MC LD-465-1 MBFC

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T.O. 33-1-37-2 CGTO 33-1-37-2

B-19

EIMOD COMPMOD TEC EIMOD COMPMOD TEC M49A2C-MC LD-465-1 MBEC M50A2-MC LD-465-1 MBGC M543A2-MC LD-465-1 MBLC M578-MC DD8V71T MADA M578-MC XTG-411-2A MADG M60A1-MC 1790-2CA MAEA M60A1-MC CD850-6A MAEG M813A1-MC NHC-250 MBAA M814-MC NHC-250 MBBA M816-MC HYD SYS MBCN M816-MC NHC-250 MBCA M817-MC HYD SYS MBDN M817-MC NHC-250 MBDA M818-MC NHC-250 MBEA M88A1-MC 1790-2DR MAFA M88A1-MC XT-1410-4 MAFG M893-MC LD-465-1 MBDB M923A1-MC NHC-250 MCFA M923-MC NHC-250 MBFA M925A1-MC HYD SYS MCGN M925A1-MC NHC-250 MCGA M925-MC HYD SYS MBGN M925-MC NHC-250 MBGA M927A1-MC NHC-250 MCHA M927-MC NHC-250 MBHA M928A1-MC HYD SYS MCJN M928A1-MC NHC-250 MCJA M928-MC HYD SYS MBJN M928-MC NHC-250 MBJA M929A1-MC HYD SYS MCKN M929A1-MC NHC-250 MCKA M929-MC HYD SYS MBKN M929-MC NHC-250 MBKA M930A1-MC NHC-250 MCLA M930-MC NHC-250 MBLA M931A1-MC NHC-250 MCMA M931-MC NHC-250 MBMA M934 HYD SYS BTBM M934A1-MC NHC-250 MCMB M935 HYD SYS BTCM M936A1-MC HYD SYS MCMN M936A1-MC NHC-250 MCNA M936-MC HYD SYS MBMN M936-MC NHC-250 MBNA M970-MC ONAN MBNC M9-MC CLARK-1345 MHPH M9-MC CUMMINSV903C MHPB MEP-003-MC ONAN/DJC MVCB MEP-005A-MC D298ERX37 MVMC MEP-006A-MC AC3500 MVDC MEP-007A-MC CAT-D333CT MVEC MEP-021A-MC 42032 MVBA MEP-112A-MC ONAN/DJC MVDB

MEP-113A-MC D198ERX51 MVLC MEP-114A-MC D298ERX37 MVMC MEP-115A-MC AC3500 MVHC MEP-16A-MC 42032 MVAB MEP-208A-MC KTA-2300G MVNC MEP-208A-MC ONAN MVPC MK-23 ENGINE MBPB MK-23 XMSN MBPH MK-23 HYD SYST MBPP MK-25 ENGINE MBPC MK-25 XMSN MBPJ MK-25 HYD SYST MBPQ MK-27 ENGINE PBCA MK-27 XMSN PBCG MK-27 HYD SYST PBCN MK-28 ENGINE PBDA MK-28 XMSN PBDG MK-28 HYD SYST PBDN MK48 4X4-MC DD8V92TA MBPA MK48 4X4-MC HT740D MBPG MK48 4X4-MC HYD SYS MBPN P19A-MC ALLIS750DRD MBRH P19A-MC NHC-250 MBRB P250WDN-MC F2L511 MEMA RTCH-MC 3P9094 MDAW RTCH-MC CAT-3408T MDAC RTCH-MC CAT-5R3855 MDAJ RTCH-MC HYD SYS MDAN SCRAPER-MC 3406 MEHA SCRAPER-MC POWERSHIFT MEHG SLWT-4-MC 70823300 MAEB SLWT-4-MC CMD-2A-221 MAGN SLWT-4-MC DD8V71T MAEC SLWT-4-MC F301HY1PCNTB MAHN SLWT-4-MC MH30L MAEH SLWT-4-MC PAVC38RA MAFN SLWT-4-MC RSA 04K MAEN SWEEPER-MC 4239D MSEA SWEEPER-MC ALLISON-540 MSEG TRACTOR-MC 4WG-200 MJCG TRACTOR-MC 6076ADW02 MJCA TRACTOR-MC BENZ-320 MEDA TRACTOR-MC BENZ-MECH MEDG TRACTOR-MC CASE-6T590 MHPA TRACTOR-MC CASE-G107561 MHPG TRK FIRE-MC NTC-400 MTCA WINCH-MC 1489 MDDN WINCH-MC 50438301 MDDB WINCH-MC DD453 MDDC WLDTLMTD-MC PERKINS4236 MEFC

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B-20

NONAERONAUTICAL TYPE EQUIPMENT CODES

ARMY COMPONENTS EIMOD COMPMOD TEC EIMOD COMPMOD TEC 10000M 6BT5.9 DJFA 10000M FUNK-1723M DJFG 10000M HYD SYS DJFN 1200 CSG649 NC4A 1200 C-6 NC4G 1500M DD6V53 TVAA 140H CAT-3306 EHAB 140H CAT-1442234 EHAG 140H HYD SYS EHAM 175B CLK4000 EFBG 175B DD8V71N EFBF 175B HYD SYS EFBN 175B NT-855-C EFBB 1854 9.0L180F NB2A 1854 CM-5552D NB2G 1854 HYD SYS NB2N 2500L DD6V92 TCWA 2500L HT750DRD TCWG 250DCMS1 JD403 DWSA 250RPV DD453 DWLA 270-9 DD353 EU5A 3000 KW-N CB LSV16T PVDA 3000M 2067761 DJ8G 3000M C-180 DJ8A 35KVA GPT 30-150E TVYA 4200 3TNE78A NB5A 4200 4200HST NB5G 4200 HYD SYS NB5M 444C 6329 NA5A 444C NOII NA5G 444C HYD SYS NA5M 450D 4219 NA7A 450D NOII NA7G 450D HYD SYS NA7M 450E TO4276 NC3A 450E JD4SPD NC3G 450E HYD SYS NC3M 4700 T444E NA4A 4700 AT545 NA4G 4700 HYD SYS NA4M 4800 DT466 NB9A 4800 MT643 NB9G 4800 HYD SYS NB9M 5060 DD23010052 EMKG 5060 DD471T EMKA 515 D-359N NC2A

515 S710 NC2G 515 HYD SYS NC2M 530B LDS-465-1 TEDA 530BAM LDS-465-1 TEEA 544E HYD SYS TDBN 544E JD6059TDW04 TDBA 544E WG-120 TDBG 609-C F6L912B ZTCA 6000M 6BT5.9 TDHA 6000M FUNK-1723 TDHG 6000M HYD SYS TDHN 600TV75 T-1010 S-39 TVFA 613BSNS 8S3543 EHZG 613BSNS CAT-3208 EHZA 613BSNS HYD SYS EHZN 613BSNSI 8S3543 EJLG 613BSNSI CAT-3208 EJLA 613BSNSI HYD SYS EJLN 613BSS 8S3543 EH2G 613BSS CAT-3208 EH2A 613BSS HYD SYS EH2N 613BSSI 8S3543 EJKG 613BSSI CAT-3208 EJKA 613BSSI HYD SYS EJKN 613BWDNS 8S3543 EVGG 613BWDNS CAT-3208 EVGA 613BWDNS HYD SYS EVGN 613BWDS 8S3543 EVFG 613BWDS CAT-3208 EVFA 613BWDS HYD SYS EVFN 621B 3406 EH3A 621B 7G2780 EH3G 621B HYD SYS EH3N 645M AC3500 EFLA 645M HYD SYS EFLN 645M TT2420-1 EFLG 6M125 D2000X16 TVGA 750PQ DD6V71N TVJA 75TPH EAGLE N855-P235 TFAA 780T T4.236 E47A 950BNS 7G4851 EFWG 950BNS CAT-3304 EGEA 950BNS HYD SYS EFWN 950BNSCE 7G4851 EGEG 950BNSCE CAT-3304 EGEA 950BMSCE HYD SYS EGEN

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T.O. 33-1-37-2 CGTO 33-1-37-2

B-21

950BS 7G4851 EFVG 950BS CAT-3304 EFVA 950BS HYD SYS EFVN 950BSCE 7G4851 EGFG 950BSCE CAT-3304 EGFA 950BSCE HYD SYS EGFN AMTC HYD SYS TMTN AN/MJQ-10A D298ERX37 VCOA AN/MJQ-11A CAT-D343TA VENA AN/MJQ-12A AC3500 VELA AN/MJQ-15 D198ERX51 VLOA AN/MJQ-18 D198ERX51 VLAA AN/MJQ-18 100-1345 VLAB AN/MJQ-21 T62T32A VIHA AN/MJQ-24 A04043B02 VICA AN/MJQ-35 DN2M VICD AN/MJQ-35A DN2M VICE AN/MJQ-36 DN2M VICF AN/MJQ-37 DN4M-1 VIDA AN/MJQ-38 DN4M-1 VIDB AN/MJQ-39 ISUZU-C240 VICJ AN/MJQ-40 JD4039T VICB AN/MJQ-41 JD6059T VICC AP308 4B3.96 DXLA AP308 FORD C-6 DXLG APP-1 GTCP85-127 VAFC ARTFT6 ALS 3331-1 DJCG ARTFT6 DD453N DJCF ARTFT6 HYD SYS DJCN AT422T 13.9LFHR ELTG AT422T 6BTA5.9 ELTA AT422T HYD SYS ELTM B413 RTG3600C-S1 TVPB B8 4-53T NA9A B8 13.3HR28420 NA9G B8 HYD SYS NA9M BBBUESCSBMK1 10-18-002 XJGG BBBUESCSBMK1 SABRE 212 XJGA BBBUESCSBMK2 10-18-002 TWVG BBBUESCSBMK2 SAVE 212 TWVA BD 264B CO-5EN668 WACE BD 264B CO-6EN68 WACB BD 264B CO-DSM-6 WACC BD 264B CO-GAB4 WACA BD 264B FM-316A6 WACD BD-6802 NTA-855-63 WB1A BD-6802 KTA38-G2 WB1B BD-6802 HYD SYS WB1M BD-6802 HYD SYS ANC1 WB1N BD-6802 HYD SYS ANC2 WB2N BD-6802 HYD SYS ANC3 WB3N BIO-RAD FT-IR GRDA

BP 4002 WAHA BP 4003 WAFA BRIDGE-MA DD8V71 TWDA BRIDGE-MA HT70 TWDG BSF-400 DD353 EXEA BSF-400 HYD SYS EXEN C350B DD353 TEHA C350B HYD SYS TEHN C350B-D DD353 TEWA C3508-D HYD SYS TEWN C530A 393303 EURG C530A DD353 EURA CAT-12 CAT-D333 EHKA CAT-120ROPS 3R9859 EHKG CAT-130G 5R6192 EHFG CAT-130G CAT-330DIT EHFA CAT-130G HYD SYS EHFN CAT-130GNS CAT-3304 EHNA CAT-130GNS 5R6192 EHNG CAT-130GNS HYD SYS EHNN CAT-130GNSC 5R6192 EJJG CAT-130GNSC CAT-3304DIT EJJA CAT-130GNSC HYD SYS EJJN CAT-130GNSE 5R6192 TAAG CAT-130GNSE CAT-3304 TAAA CAT-130GNSE HYD SYS TAAN CAT-130GS 5R6192 EHPG CAT-130GS CAT-3304 EHPA CAT-130GS HYD SYS EHPN CAT-130GSCE 5R6192 TABG CAT-130GSCE CAT-3304 TABA CAT-130GSCE HYD SYS TABN CAT-814F 1223774 E5DG CAT-814F CAT-3306B E5DA CAT-814F HYD SYS E5DM CAT-815F 1223774 E5EG CAT-815F CAT-3306B E5EA CAT-815F HYD SYS E5EM CAT-816F 1223774 E5FG CAT-816F CAT-3306B E5FA CAT-816F HYD SYS E5FM CAT-D5 3S7094 EAPG CAT-D5 CAT-3306 E5FA CAT-D5 HYD SYS E5FM CAT-D5A 3S7094 EAPG CAT-D5A CAT-3306 EAPA CAT-D5A HYD SYS EANN CAT-D5B 3S7094 TEKG CAT-D5B 9P4905 TEKH CAT-D5B CAT-2WA1/UP TEKI CAT-D5B CAT-3306 TEKA CAT-D5B D5/3T3394 TEKJ

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B-22

CAT-D5B HYD SYS TEKN CAT-D7E CAT-D333 EA3G CAT-D7F 5R82 EA2G CAT-D7F CAT-3306 EA2A CAT-D7F CAT-6CYL638C EA2B CAT-D7F HYD SYS EA2N CAT-D7G 9P5382 TELG CAT-D7G CAT-3306 TELA CAT-D7G HYD SYS TELN CAT-D7H 9P5382 TELH CAT-D7H CAT-3306 TELB CAT-D7H HYD SYS TELM CAT-D7R CAT-3306 TEMA CAT-D7R CAT-9TXI-UP TEMG CAT-D7R HYD SYS TEMN CAT-D8K 3N1869 EADG CAT-D8K CAT-D342 EADA CAT-D8K HYD SYS EADN CB-534B CAT-3054 E5BA CB-534B HYD SYS E5BN CS433C HYD SYS E5HM CS433C CAT-3054 E5KA CS563D CAT-3114 E5JA CS563D CAT-3116 E5JB CS563D CAT-3126 E5JC CS563D HYD SYS E5JM D424A A0403B02 TVPA D5 HYD SYS EAPM D5 ENG TS HYD SYS TB3N D5BNS CAT-2WA1/UP EBAH D5BNS CAT-3306 EBAA D5BNS D5/3T3394 EBAG D5BS CAT-2WA1/UP EBBH D5BS CAT-3306 EBBA D5BS D5/3T3394 EBBG D5BS HYD SYS EBBN D5BS1 CAT-2WA1/UP TFBA D5BS1 CAT-3306 TFBG D5BS1 D5/3394 TFBH D5BS1 HYD SYS TFBN D6 HYD SYS TCMM DV43 CAT-2408T DJNA DV43 CAT-3408 DJNB DV43 CAT-3P9094 DJNH DV43 CAT-5R3855 DJNG DV43 HYD SYS DJNN DV-100 HYD SYS EBCM DV-100 POWER SHIFT JCCG DV-100 CAT-3126 JCCA EMD12567 16-567-C TVQA EPPIII BF8L513 VCAA F5070 HT750CRD EZYH F5070 HYD SYS EZYN F5070 NTC-290 EZYA

FLU419 BENZ-OM352 TEYA FLU419 HYD SYS 1 TEYN FLU419 HYD SYS 2 TEYM FT750 LDT-465-1 ZMAA GTGE709-2 GPT 70-52 VLVA H100C HYD SYS EFRN H100C IHDT817C EFRA H100C P-2004 EFRG H100C GPB HYD SYS EFSN H100C GPB IHDT817C EFSA H100C GPB P-2004 EFSG H40XL-MIL 360311 TDEG H40XL-MIL HYD SYS TDEN H40XL-MIL ISUZU-C240 TDEA H446 DD353 EKTA H60XL-MIL 360311 TDFG H60XL-MIL HYD SYS TDFN H60XL-MIL ISUZU-C240 TDFA HC-238A DD671N DSFA HC-283A DD6V92TC DSFB HC-238A HYD SYS EFJN HMMH BENZ-OM352 TEXA HMMH HYD SYS 1 TEXN HMMH HYD SYS 2 TEXM HSPB 400MERLIN WCRA JD230LC-RD JD6068 AKXA JD230LC-RD JD4045 AKXB JD230LC-RD HYD SYS AKXM JD230LCR JD6068 AKXC JD230LCR HYD SYS AKXN JD330LCR JD6081 AKYD JD330LCR HYD SYS AKYM JD410 4-2-19DT-03 EDHA JD410 DP23981 EDHG JD410 HYD SYS EDHN JD550 4276TT01 TEQA JD550 AT49678 TEQG JD550 HYD SYS TEQN JD644G 6081HDW04 TERG JD644G 609T TERA JD644G HYD SYS TERM JD770C 6081HDW03 TEQB JD770C DF1888E00WA TEQH JD770C HYD SYS TEQM JD862B 6101AT012 TERB JD862B AT59822 TERH JD862B HYD SYS TERN JEEP77 JAM4.0T5ND1 NA2A JEEP77 AX5 NA2G JHTWX1096 GTCP85-127 TVUA K300 CAT-3208 EXBA K300 CLK28000 EXBG K300 HYD SYS EXBN KTA50GS KTA50GS NB7A

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B-23

LARC-LX 6080RA WANB LARC-LX 6081RC WANA LARC-XV 300 WARA LCM8 671LB63A WASA LCM8 671LD63A WAEA LCM8 671RB63A WAZA LCM8 671RD63A WAYA LCM8 DD12V71T WAEB LCM8MOD1 DD12V71T WASB LCM8MOD1SL DD12V71T WASC LCM8-SLEP 7000 WGDA LCMB-SLEP 7122 WGCA LCM8-SLEP 7000 WGDA LCM8-SLEP 7122 WGCA LCU1646 1033-7005 WAAD LCU1646 GM1043-7000 WAAB LCU1646 GM7122-7000 WAAC LCU1646 MG514 WAAG LCU2000 4B3.9 WBSC LCU2000 KTA-50M WBSA LCU2000 NT-855-M WBSD LCU2000 NTA-855 WBSB LCU2000 WAV850PT WBSG LCU2000 WAV850SB WBSH LOCO100T AMER 539 XCUA LOCO100T EMD8-567B XCIA LOCO10T DD3080 TXAA LOCO115T AMER 539S XCAA LOCO120T 38D-81/8 TXDA LOCO120T AMER 244F XCPA LOCO120T BALDWING 606A TXBA LOCO120T EMD16-567B XCKA LOCO120T EMD16-645E XCQA LOCO120T FM-H12-44 XCCA LOCO25T HBI-600 XCWA LOCO44T CAT-D17000 XCLB LOCO45T HBI-600 XDFA LOCO60T CAT-3508 XCTA LOCO60T CAT-D397 XCSA LOCO80T LI-600 XCVA LOCO80T NTA-855L4 XC3A LOCO80T-470 NHBIS-600 XCMA LOCO80T-550 NHBIS-600 XCNA LPU-71 GTCP85-127 VAFB LPU-71W GTCP85-127 VAAA LRT-110 17243E EKZG LRT-110 4B3.9 EKZA LRT-110 HYD SYS EKZN LSV 3304-B WAXC LSV 3306-B WAXD LSV 3406-B WAXB LSV EMD16-645E6 WAXA LSV MG509 WAXG LSV WAV630-2240 WAXH

LT 3408DITAJW WGEB LT CAT-3304NA WGEC LT CAT-3306TA WGED LT EMD12645F7B WGEA LT HS400-3 WAMG LT LS6DRT WAMA LT9500 CAT-C10 NB3A LT9500 RM0131454 NB3G LT9500 HYD SYS NB3M LT9513 CAT-C10 NC6A LT9513 RTLO12713A NC6G LT9513 HYD SYS NC6M LVTC-7 DD8V53T TWNA LVTC-7 HS400-3 TWNG LVTC-7A1 HS400-3 TWPG LVTC-7A1 VT-400 TWPA LVTP-7 DD8V53T TWRA LVTP-7 HS-400-3 TWRG LVTP-7A1 HS400-3 TWSG LVTP-7A1 VT-400 TWSA LVTR-7 DD8V53T TWTA LVTR-7 HS400-3 TWTG LVTR-7A1 HS400-3 TWUG LVTR-7A1 V903 TWUB LVTR-7A1 VT-400 TWUA M1 AGT-1500 AAAA M1 HYD SYS AAAN M1 X1100-3B AACG M1 IP AGT-1500 AACA M1 IP HYD SYS AACN M1 IP X1100-3B AAAG M1000 HYD SYS CXUN M1025 6.2 L DIESEL BBFA M1025 6.5 L DIESEL BBFC M1025 THM-3L80 BBFG M1025A1 6.2 L DIESEL BBFD M1025A1 6.5 L DIESEL BBFB M1025A1 THM-3L80 BBFH M1025A2 6.5 L DIESEL BCLB M1025A2 THM-4L80E BCFG M1026 6.2 L DIESEL BBGA M1026 6.5 L DIESEL BBGC M1026 THM-3L80 BBGG M1026A1 6.2 L DIESEL BBGB M1026A1 6.5 L DIESEL BBGD M1026A1 THM-3L80 BBGH M1035 6.2 L DIESEL BBLA M1035 6.5 L DIESEL BBLC M1035 THM-3L80 BBLG M1035A2 6.5 L DIESEL BCLB M1035A2 THM-4L80E BCLG M1036 6.2 L DIESEL BBHA M1036 6.5 L DIESEL BBHC M1036 THM-3L80 BBHG

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B-24

M1037 6.2 L DIESEL BBKA M1037 6.5 L DIESEL BBKC M1037 THM-3L80 BBKG M1038 6.2 L DIESEL BBEA M1038 6.5 L DIESEL BBEC M1038 THM-3L80 BBEG M1038A1 6.2 L DIESEL BBEB M1038A1 6.5 L DIESEL BBED M1038A1 THM-3L80 BBEH M1042 6.2 L DIESEL TCTA M1042 6.5 L DIESEL TCTC M1042 THM-3L80 TCTG M1043 6.2 L DIESEL BBJA M1043 6.5 L DIESEL BBJC M1043 THM-3L80 BBJG M1043A2 6.5 L DIESEL BCJB M1043A2 THM-4L80E BCJG M1044 6.2 L DIESEL BBNA M1044 6.5 L DIESEL BBNC M1044 THM-3L80 BBNG M1046 6.2 L DIESEL TCSA M1046 6.5 L DIESEL TCSC M1046 THM-3L80 TCSG M1059 DD6V53 AESA M1059 TX-100-1 AESG M1059A3 DD6V53T AFAA M1059A3 X200-4 Afa*g M1064 DD6V53 AE4A M1064 TX-100-1 AE4G M1064A3 DD6V53T AE8A M1064A3 X200-4 AE8G M1065 OM603.950 TCPA M1065 W4A040 TCPG M1066 OM603.950 TCPA M1066 W4A040 TCQG M1067 OM603.950 TCRA M1067 W4A040 TCRG M1068 DD6V53 AE5A M1068 TX-100 AE5G M1068A3 DD6V53T AFCA M1068A3 X200-4 AFCG M1069 6.2 L DIESEL AKZA M1069 6.5 L DIESEL AKZB M1069 THM-3L80 AKZG M106A1 DD6V53 AEFA M106A1 TX-100-1 AEFG M106A2 DD6V53 AERA M106A2 TX-100-1 AERG M1070 CLT-754 B5CG M1070 DD8V92TA B5CA M1070 HYD SYS B5CM M1074 CLT-755 B4GG M1074 DD8V92TA B4GA M1074 HYD SYS B4GM

M1075 CLT-755 B4HG M1075 DD8V92TA B4HA M1075 HYD SYS B4HM M1078 CAT-3116-225 BHDA M1078 HYD SYS BHHM M1078 MD3070PT BHDG M1078A1 CAT-3126 BHRA M1078A1 MD3070PT BHRG M1078A1 HYD SYS BHRM M1079 CAT-3116-225 BHEA M1079 MD3070PT BHEG M1079A1 CAT-3126 BHSA M1079A1 MD3070PT BHSG M1079A1 HYD SYS BHSM M1080 CAT-3116-290 BHCA M1080 MD3070PT BHCG M1081 CAT-3116-225 BHFA M1081 MD3070PT BHFG M1080A1 CAT-3126 BHTB M1080A1 MD3070PT BHTH M1081A1 CAT-3126 BHUA M1081A1 MD3070PT BHUG M1081A1 HYD SYS BHUM M1083 CAT-3116-290 BR2A M1083 MD3070PT BR2G M1083A1 CAT-3126 BT9A M1083A1 MD3070PT BT9G M1083A1 HYD SYS BT9M M1084 CAT-3116-290 BR3A M1084 HYD SYS BR3N M1084 MD3070PT BR3G M1084A1 CAT-3126 BUBA M1084A1 MD3070PT BUBG M1084A1 HYD SYS BUBM M1085 CAT-3116-290 BR7A M1085 MD3070PT BR7G M1085A1 CAT-3126 BUGA M1085A1 MD3070PT BUGG M1085A1 HYD SYS BUGM M1086 CAT-3116-290 BR8A M1086 HYD SYS BR8N M1086 MD3070PT BR8G M1086A1 CAT-3126 BUHA M1086A1 MD3070PT BUHG M1086A1 HYD SYS BUHM M1087 CAT-3116-290 BT3A M1087 MD3070PT BT3G M1087A1 CAT-3126 BUTA M1087A1 MD3070PT BUTG M1088 CAT-3116-290 BTJA M1088 MD3070PT BTJG M1088A1 CAT-3126 BUCA M1088A1 MD3070PT BUCG M1088A1 HYD SYS BUCM

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B-25

M1089 CAT-3116-290 BR4A M1089 HYD SYS BR4N M1089 MD3070PT BR4G M1089A1 CAT-3126 BUDA M1089A1 MD3070PT BUDG M1089A1 HYD SYS BUDM M1090 CAT-3116-290 BR5A M1090 HYD SYS BR5N M1090 MD3070PT BR5G M1090A1 CAT-3126 BUEA M1090A1 MD3070PT BUEG M1090A1 HYD SYS BUEM M1091 CAT-3116-290 BT2A M1091 MD3070PT BT2G M1091A1 CAT-3126 BUSA M1091A1 MD3070PT BUSG M1092 CAT-3116-290 BRZA M1092 MD3070PT BRZG M1092A1 CAT-3126 BT8A M1092A1 MD3070PT BT8G M1093 CAT-3116-290 BR9A M1093 MD3070PT BR9G M1093A1 CAT-3126 BUAA M1093A1 MD3070PT BUAG M1093A1 HYD SYS BUAM M1094 CAT-3116-290 BTKA M1094 HYD SYS BTKN M1094 MD3070PT BTKG M1094A1 CAT-3126 BUFA M1094A1 MD3070PT BUFG M1094A1 HYD SYS BUFM M1096 CAT-3116-290 BR6A M1096 HYD SYS BR6N M1096 MD3070PT BR6G M1097 6.2 L DIESEL BBMA M1097 THM-3L80 BBMG M1097 6.5 L DIESEL BBMC M1097A1 6.2 L DIESEL BBUA M1097A1 THM-3L80 BBUG M1097A2 6.5 L DIESEL BCMB M1097A2 THM-4L80E BCMG M109A3 LDT-465-1C BMJC M10A HYD SYS DJUN M10A IHCDT-466B DJUA M10A IHCS-700 DJUG M1109 6.2 L DIESEL B6AA M1109 THM-3L80 B6AG M1109 6.5 L DIESEL B6AC M1113 6.5 L DIESEL B6BA M1113 THM-4L80E B6BG M1114 6.5 L DIESEL B6CA M1114 THM-4L80E B6CG

M1123 6.5 L DIESEL B6GA M1123 THM-4L80E B6GG M113A2 DD6V53 AENA M113A2 TX-100-1 AENG M113A3 DD6V53 AEYB M113A3 DD6V53T AEYA M113A3 TX-100-1 AEYH M113A3 X200-4 AEYG M113A3BMP-2 DD6V53T AEZA M113A3BMP-2 X200-4 AEZG M150 CSWP 4BT3.9C TBCF M150 CSWP 6CT8.3G TBCB M150 CSWP 6CTA8.3-C#1 TBCD M150 CSWP 6CTA8.3-C#2 TBCE M150 CSWP M11-C TBCC M1977 DD8V92TA DV4A M1977 HT740D DV4G M1977 HYD SYS DV4M M1A1 AGT-1500 AABA M1A1 HYD SYS AABN M1A1 X1100-3B AABG M1A2 AGT-1500 TAUA M1A2 HYD SYS TAUM M1A2 X1100-3B TAUG M2A3 VTA-903T APGA M2A3 HMPT-500 APGH M2 HMPT-500 APAG M2 HMPT-500-3 APAH M2 HMPT-500-3E APAJ M2 HMPT-500-B APAK M2 VTA903T APAA M270 HMPT-500-3EC QBDG M270 HYD SYS QBDM M270 VTA-903T QBDA M291A1 ENDT-673 BRPA M291A1 LD-465-1C BRPD M291A1 LDS-427-2 BRPC M291A1 LDS-465-1 BRPB M291A1 LDT-465-1C BRPF M291A1 LDT-465-1D BRPE M291A2 LDS-465-1 TBCA M292A1 LD-465-1C BGMB M292A1 LDS-427-2 BGMA M292A1 LDT-465-1C BGMD M292A1 LDT-465-1D BGMC M292A2 LD-465-1 BGLA M292A2 LD-465-1C BGLB M292A2 LDS-427-2 BGLE M292A2 LDT-465-1C BGLD M292A2 LDT-465-1D BGLC M292A4 LD-465-1C TBDB M292A4 LDS-427-2 TBDA

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B-26

M292A4 LDT-465-1C TBDD M292A4 LDT-465-1D TBDC M292A5 LD-465-1 BGNA M292A5 LD-465-1C BGNB M292A5 LDS-427-2 BGNE M292A5 LDT-465-1C BGND M292A5 LDT-465-1D BGNC M2A1 HMPT-500 ALEG M2A1 HMPT-500-3 ALEH M2A1 HMPT-500-3E ALEJ M2A1 HMPT-500-B ALEK M2A1 VTA-903T ALEA M2A2 HMPT-500 TARG M2A2 HMPT-500-3 TARH M2A2 HMPT-500-3E TARJ M2A2 HMPT-500-3TE TARK M2A2 VTA-903T TARA M3 HMPT-500 APBG M3 HMPT-500-3 APBH M3 HMPT-500-3E APBJ M3 HMPT-500-B APBK M3 VTA-903T APBA M34A2 LD-465-1 TBEA M34A2 LD-465-1C TBEB M34A2 LDS-427-2 TBEE M34A2 LDT-465-1C TBED M34A2 LDT-465-1D TBEC M35A2 LD-465-1 BMAA M35A2 LD-465-1C BMAB M35A2 LDS-427-2 BMAE M35A2 LDT-465-1C BMAD M35A2 LDT-465-1D BMAC M35A2C LD-465-1 BMRA M35A2C LD-465-1C BMRB M35A2 LDS-427-2 BMRE M35A2 LDT-465-1C BMRD M35A2 LDT-465-1D BMRC M35A2C LD-465-1 BMRA M35A3 3116ATAAC BM6A M35A3 AT1545 BM6G M35A3C AT1545 BHQG M35A3C CAT-3116 BHQA M36A2 LD-465-1 BMCA M36A2 LD-465-1C BMCB M36A2 LDS-427-2 BMCE M36A2 LDT-465-1C BMCD M36A2 LDT-465-1D BMCC M36A3 AT1545 BHNG M36A3 CAT-3116 BHNA M3A1 HMPT-500 ALFG M3A1 HMPT-500-3 ALFH M3A1 HMPT-500-3E ALFJ M3A1 HMPT-500-B ALFK M3A1 VTA-903T ALFA

M3A2 HMPT-500 TASG M3A2 HMPT-500-3 TASH M3A2 HMPT-500-3E TASJ M3A2 HMPT-500-3TE TASK M3A2 VTA-903T TASA M3A3 VTA-903T APHA M3A3 HMPT-500 APHG M4 6BT5.9 APCA M4 VTA-903T APCB M4 HMPT-500-3E APCG M44A1 LDT-465-1C TCFB M487 A413 DXJG M487 TMD27 DXJA M48A5 1790-2A ABCB M48A5 1790-2DA ABCD M48A5 HYD SYS ABCM M48A5AVLB 1790-2DA AREA M48A5AVLB CD850-6A AREG M48A5AVLB CD850-6A1 AREH M48A5AVLB HYD SYS AREN M49A1C LD-465-1C BMXB M49A1C LDS-427-2 BMXA M49A1C LDT-465-1C BMXD M49A1C LDT-465-1D BMXC M49A2C LD-465-1 BMEA M49A2C LD-465-1C BMEB M49A2C LDS-427-2 BMEE M49A2C LDT-465-1C BMED M49A2C LDT-465-1D BMEC M4K CASE-207D DJVA M4K CLK18340 DJVG M4K HYD SYS DJVN M51A2 HYD SYS BQEN M5142 LDS-465-1 BQEA M548 DD6V53 AEGA M548 TX-100-1 AEGG M548A1 DD6V53 AEUA M548A1 TX-100-1 AEUG M548A3 DD6V53T AEUB M548A3 X200-4 AEUH M551A1 DD6V53 ALBB M551A1 DD6V53T ALBA M551A1 G250-1A ALBG M551OPFOR DD6V453T ALDA M551OPFOR G250-1A ALDG M577A2 DD6V53 AEQA M577A2 TX-100-1 AEQG M577A3 DD6V53T AEQB M577A3 X200-4 AEQH M58 DD6V53T AE8B M58 X200-4A AE8H M6 VTA-903T600 AP6A M6 HMPT-500-3EC AP6G M60A1 CD850-6A1 ABHG

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B-27

M60A1AVLB 1790-2DA ARCA M60A1AVLB CD850-6A ARCG M60A1AVLB CD850-6A1 ARCH M60A1AVLB HYD SYS ARCN M60A3 1790-2C ABBA M60A3 CD850-6A ABBG M60A3 CD850-6A1 ABBH M60A3 HYD SYS ABBN M7 VTA-903T AP7A M7 HMPT-500-3EC AP7G M764 LD-465-1 BMVA M792 DD353 BFAA M809 NHC-250 TBNA M809A1 NHC-250 TBPA M810 NHC-250 TBQA M811 NHC-250 BRNA M811A1 NHC-250 TBRA M811A2 NHC-250 TBSA M812 NHC-250 TBTA M812A1 NHC-250 TBUA M813 NHC-250 BSBA M813A1 NHC-250 BSDA M814 NHC-250 BSKA M815 NHC-250 BSEA M816 HYD SYS BSQN M816 NHC-250 BSQA M817 HYD SYS BSRN M817 NHC-250 BSRA M818 NHC-250 BSHA M819 HYD SYS BSLN M819 NHC-250 BSLA M820 NHC-250 BSMA M820A1 NHC-250 TBVA M820A2 NHC-250 BSNA M821 NHC-250 BSPA M876 HYD SYS BHAN M876 IHD190 BHAA M876 MT650 BHAG M877 CAT-11614457 B3GH M877 CAT-D333 B3GB M878 DD6V53 BTAA M877 PS4R219 B3GG M878 MT653 BTAG M878A1 DD6V53T BTLA M878A1 MT653 BTLG M88A1 1790-2DR AQAA M88A1 HYD SYS AQAN M88A2 1790-8CR AQAB M88A2 HYD SYS AQAM M88A2 XT-1410-5A AQAH M9 HYD SYS ASAN M9 13.5HR3610-2 ASAG M9 V903 ASAA

M901 DD6V53 AEMA M901A1 DD6V53 AEVA M901A1 TX-100-1 AEVG M911 CLBT750 B5BG M911 DD8V92T B5BA M911 DD8V92TA B5BB M911 HYD SYS B5BN M915 CAT-D7155 B4AG M915 NTC-400 B4AA M915A1 HT754CRD B4BG M915A1 NTC-400 B4BA M915A2 DD12.7L B4EA M915A2 DDHT740 B4EG M915A3 DDEC IV B4LA M915A3 HD4560P B4LG M915A4 BIG CAM I B4MA M915A4 HD4560P B4MG M916 CAT-D7155 B4CG M916 HYD SYS B4CN M916 NTC400 B4CA M916A1 DD12.7L B4FA M916A1 DDHT740 B4FG M916A1 HYD SYS B4FN M916A2 DDEC III B4JA M916A2 HT740 B4JG M916A2 HYD SYS B4JN M917 CAT-D7155 EZZG M917 HYD SYS EZZN M917 NTC-400 EZZA M917A1 DDC III E5CA M917A1 HT740 E5CG M917A1 HYD SYS E5CN M917A1MCS DDEC III E5CB M917A1MCS HD456P E5CH M918 CAT-D7155 EXCG M918 HYD SYS EXCN M918 NTC-400 EXCA M919 CAT-D7155 EXDG M919 HYD SYS B4DN M919 NTC-400 EXDA M920 CAT-D7155 B4DG M920 HYD SYS B4DN M920 NTC-400 B4DA M923 MT654 BRYG M923 NHC-250 BRYA M923A1 MT654 BSSG M923A1 NHC-250 BSSA M923A2 6CTA0-8.3 BS7A M923A2 MT654 BS7G M924 MT654 BRXG M924 NHC-250 BRXA M924A1 MT654 BSUG M924A1 NHC-250 BSUA

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B-28

M925 HYD SYS BRTN M925 MT654 BRTG M925 NHC-250 BRTA M925A1 HYD SYS BSTN M925A1 MT654 BSTG M925A1 NHC-250 BSTA M925A2 6CTA-8.3 BS8A M925A2 MT654 BS8G M926 HYD SYS BRWN M926 MT654 BRWG M926 NHC-250 BRWA M926A1 HYD SYS BSVN M926A1 MT654 BSVG M926A1 NHC-250 BSVA M927 MT654 BRVG M927 NHC-250 BRVA M927A1 MT654 BSWG M927A1 NHC-250 BSWA M927A2 6CTA-8.3 BS9A M927A2 MT654 BS9G M928 HYD SYS BRUN M928 MT654 BRUG M928 NHC-250 BSUA M928A1 HYD SYS TCHN M928A1 MT654 TCHG M928A1 NHC-250 TCHA M928A2 6CTA-8.3 BTMA M928A2 HYD SYS BTMN M928A2 MT654 BTMG M929 HYD SYS BTHN M929 MT654 BTHG M929 NHC-250 BTHA M929A1 HYD SYS BSYN M929A1 MT654 BSYG M929A1 NHC-250 BSYA M926A1 HYD SYS BSVN M929A2 6CTA-8.3 BTNA M929A2 HYD SYS BTGN M929A2 MT654 BTNG M930 HYD SYS BTGN M930 MT654 BTGG M930 NHC-250 BTGA M930A1 HYD SYS BSZN M930A1 MT6654 BSZG M930A1 NHC-250 BSZA M93A1FOX OM402A 559B M93A1FOX HP500 TYPE 6 559H M93A1FOX HYD SYS 559M M930A2 6CTA-8.3 BTOA M930A2 HYD SYS BTON M930A2 MT654 BTOG M931 MT654 BTEG M931 NHC-250 BTEA

M931A1 MT654 BS2G M931A1 NHC-250 BS2A M931A2 6CTA-8.3 BTPA M931A2 MT654 BTPG M932 HYD SYS BTDN M932 MT654 BTPG M932 NHC-250 BTDG M932A1 HYD SYS BS3N M932A1 MT654 BS3G M932A1 NHC-250 BS3A M932A2 6CTA-8.3 BTQA M932A2 HYD SYS BTQN M932A2 MT654 BTQG M934 MT654 BTBG M934 NHC-250 BTBA M934A1 MT654 BS4G M934A1 NHC-250 BS4A M931A2 6CTA-8.3 BTRA M931A2 MT654 BTRG M935 MT654 BTCG M935 NHC-250 BTCA M935A1 HYD SYS BS5M M935A1 MT654 BS5G M935A1 NHC-250 BS5A M935A2 6CTA-8.3 BTSA M935A2 MT654 BTSG M936 HYD SYS BTFN M936 MT654 BTFG M936 NHC-250 BTFA M936A1 HYD SYS BS6N M936A1 MT654 BS6G M936A1 NHC-250 BS6A M936A2 6CTA-8.3 BTTA M936A2 HYD SYS BTTN M936A2 MT654 BTTG M939 MT654 BRSG M939 NHC-250 BRSA M939A2 6CTA8.3 BRSB M939A2 MT654 BRSH M940 MT654 TBXG M940 NHC-250 TBXA M941 MT654 TBYG M941 NHC-250 TBYA M942 MT654 TBZG M942 NHC-250 TBZA M943 MT654 TCAG M943 NHC-250 TCAA M944 MT654 TCBG M944 NHC-250 TCBA M945 MT654 TCCG M945 NHC-250 TCCA M966 6.2 L DIESEL BBCA M966 THM-3L80 BBCG

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B-29

M966 6.5 L DIESEL BBCC M966A1 6.2 L DIESEL BBCB M966A1 THM-3L80 BBCH M966A1 6.5 L DIESEL BBCD M973 OM617952 BXAA M973 W4A018 BXAG M973A1 OM603.950 BXBA M973A1 W4A040 BXBG M977 DD8V92TA B2GA M977 DDA-HT740D B2GG M977 HYD SYS B2GN M978 DD8V92TA B2HA M978 DDA-HT740D B2HG M978 HYD SYS B2HN M981 DD6V53 AETA M981 TX-100-1 AETG M981A1 DD6V53T TAQA M981A1 TX-100-1 TAQG M981A3 DD6V53T TAQB M981A3 X200-4 TAQH M983 DD8V92TA B2AA M983 DDA-HT740D B2AG M983 HYD SYS B2AN M984 DD8V92TA B2BA M984 DDA-HT740D B2BG M984 HYD SYS B2BN M984A1 DD8V92TA TCDA M984A1 DDA-HT740D TCDG M984A1 HYD SYS TCDN M985 DD8V92TA B2JA M985 DDA-HT740D B2JG M985 HYD SYS B2JN M985E1 DD8V92TA TCJA M985E1 DDA-HT740D TCJG M985E1 HYD SYS TCJN M992A2 DD8V71TLHR TAWB M992A2 HYD SYS TAWN M992A2 XTG-411-4 TAWH M993 HMPT-500 TANG M993 HMPT-500-3 TANH M993 HMPT-500-3E TANJ M993 HMPT-500-B TANK M993 VTA-903T TANA M996 6.2 L DIESEL BBBA M996 THM-3L80 BBBG M996 6.5 L DIESEL BBBC M996A1 6.2 L DIESEL BBBB M996A1 THM-3L80 BBBH M996A1 6.5 L DIESEL BBBD M997 6.2 L DIESEL BBAA M997 THM-3L80 BBAG M997 6.5 L DIESEL BBAC M997A1 6.2 L DIESEL BBAB M997A1 THM-3L80 BBAH

M997A1 6.5 L DIESEL BBAD M997A2 6.5 L DIESEL BCAC M997A2 THM-4L80E BCAG M998 6.2 L DIESEL BBDA M998 THM-3L80 BBDG M998 6.5 L DIESEL BBDD M998A1 6.2 L DIESEL BBDB M998A1 THM-3L80 BBDH M998A1 6.5 L DIESEL BBDE M998A2 6.5 L DIESEL BCDC M998A2 THM-4L80E BCDG MCD 4.236 NA6A MCD 542-L1 NA6G MCD HYD SYS NA6M MEMP, TN COE LVEA MEMP, TN COE LVFA MEMP, TN COE LVGA MEP-003A D198ERX51 VCDB MEP-003A 100-1345 VCDD MEP-003 100-345 VCDC MEP-004A D198ERX51 VCDA MEP-005A D298ERX37 VCCA MEP-006A AC3500 VECA MEP-007A CAT-D333CT VCGA MEP-007B CAT-76-4106 VDSA MEP-009A CAT-D343TA VEGA MEP-009B CAT-D3434TA TVCA MEP-012A KTA-2300G VEPB MEP-029A VTA-1710G VFJA MEP-029A VTA-28G1 VFJB MEP-103A D198ERX51 VCEA MEP-104A D298ERX37 VCFA MEP-105A AC3500 VEDA MEP-106A CAT-D333CT VCHA MEP-108A CAT-D343TA VEVA MEP-113A D198ERX51 VLFA MEP-114A D298ERX37 VLGA MEP-115A AC3500 VLHA MEP-116A CAT-D333CT TVBA MEP-208A KTA-2300G VEPA MEP-360A GTCP36-50(H) UAGA MEP-360A HYD SYS UAGN MEP-362A TT10-1 VKEA MEP-36A 16-567-E4 TUSA MEP-36A50 16-567-E4 VEIA MEP-36A60 CAT-D398A VEHA MEP-404B T62T32A VIBA MEP-802A DN2M-1 VG2A MEP-803A DN4M VG3A MEP-804A C-240PW-28 VG4A MEP-805A JD4039T VG5A MEP-806A JD6059T VG7A MEP-812A DN2M-1 VG2B MEP-813A DN4M VG3B

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B-30

MEP-814A C-240PW-28 VN4B MEP-815A JD4039T VN5A MEP-816A JD6059T VN6A MEP-903A D722TB-11 VCJA MEP-903B D722TB-11 VCJB MEP-903C D722TB-11 VCJC MHE-269 A38714 DJ4A MHE-269 MHR18325 DJ4G MHE-270 1102T1236210 DJ6G MHE-270 4B3.9 DJ6A MHE-270 HYD SYS DJ6N MHE-271 1102T1236210 DJ5G MHE-271 4B3.9 DJ5A MHE-271 HYD SYS DJ5N MLT6 ALS 3331-1 DJJG MLT6 DD453N DJJA MLT6 HYD SYS DJJN MLT6-2 DD453N DJBF MLT6-2 HYD SYS DJBN MLT6-2 R28422-1 DJBG MLT6CH ALS 3331-1 DJLG MLT6CH DD453N DJLA MLT6CH HYD SYS DJLN MT250 DD6V53N ELAA MT250 HYD SYS ELAN MW24C CASE-504BD EFQA MW24C CASE-A504BDT EFQB MW24C HYD SYS EFQN MW24C TT2421-1 EFQG OH-58D HYD SYS HKAD P250WDMH268 DEUTZ DWTA PACAR9999 NHC-250 XMAA PPU85-4 GTCP85-127 VAAB PPU85-5 GTCP85-127 VAFA PU405A/M D198ERX51 VCNA PU406B/M D298ERX37 VCMA PU495A/G CAT-D333CT VCLA PU495B/G CAT-76-4106 VDTA PU650B/G AC3500 VEMA PU699A/M AC3500 VFBA PU700A/M AC3500 VFCA PU707A/M AC3500 VLMA PU732M 100-1345 VLLA PU753M 100-1345 VLNF PU760M D298ERX37 VLNA PU797 DN2M VLPA PU797A DN2M VLPB PU798 DN4M-1 VLPC PU798A DN4M-1 VLPD PU799 DN4M-1 VLPE PU799A DN4M-1 VLPF PU800 C-240PW-28 VLLD PU801 C-240PW-28 VLLB PU801A C-240PW-28 VLLE

PU802 C-240PW-28 VLLC PU803 JD4039T VLNB PU804 JD4039T VLNC PU805 JD6059T VLND PU806 JD6059T VLNE R60SL-DC F4L912W TDCA R60SL-DC HYD SYS TDCN R60SL-DC PR-2 TDCG RAIL C 25T D13,000 XDGA RAIL C 40T DD671 TXCA RMS-250 DD6V53N TVRA RS28 DD453 EVPA RS28 HYD SYS EVPN RT41AA 126HR183278 ELLG RT41AA D3400X289 ELLA RT41AA HYD SYS ELLM RT875CC 6CTA-8.3 DKDA RT875CC CLARK-C273.5 DKDG RT875CC HYD SYS DKDN RTFL 6BT5.9 DJWA RTFL FUNK-1723 DJWH RTFL HYD SYS DJWN RTL10 CRT 3531-1 DJHG RTL10 DD6V53 DJHA RTL10 HYD SYS DJHN RTL10-1 CRT 3531-1 DJDG RTL10-1 DD6V53 DJDF RTL10-1 HYD SYS DJDN SM50068003 D398A 3AC VEJA SM50068004 CAT-D398A VEKA SM54A DEUTZ-F2L51 TETA SP848 DD353 EUUA SP848 HYD SYS EUUN ST 320 WAKB ST-TUG-200 6DCMR 1879 WAKA ST-TUG-600 3004 WALA SU252G CSG64916001H NA8A SU252G C-6 NA8G T449 180DAC TWWB T449 CAT-D375 TWWA TC6DO42 350LIDV85.7L NB4A TC6DO42 AT545 NB4G TC6DO42 3043LE NA3G TC6DO42 HYD SYS NB4M TMS-300-5 DD671 ELHA TMS-300-5 HYD SYS ELHN TO730HKEG 6BT5.9 E45A TO730HKEG HYD SYS E45N TUG-900 6B5.9-G1 WA2A TUG-900 KTA19-M3 WA2B UNKNOWN HYDRAULIC XXHN UNKNOWN MINERAL XXMX UNKNOWN SYNTHETIC XXSX US612ACD1 DEUTZ-91213 ZD8A

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B-31

US90CCD1 DD353 ZHCA W150Y 28265 DJ7A W150Y AUTO79410 DJ7G W150Y HYD SYS DJ7M W15A ENDT-673 TEVA WC17 TMD NB6A WC17 W410TT NB6G WF1700/1000 DD8V92T ZM3A WF1700/1000 TD61-1168 ZM3G WPS6006 JD4039T VG6A XJJL72 RCR4.078GAEA NA3A XJJL72 3043LE NA3G XJJL72 TCR4.01BGFEK NB3B XM104 AGT-1500 ARDA XM104 X1100-3B ARDG XM104 HYD SYS ARDM

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B-32

NONAERONAUTICAL TYPE EQUIPMENT CODES

ARMY CORPS OF ENGINEERS

EIMOD COMPMOD TEC EIMOD COMPMOD TEC 10235100 DD2A102916 852A 10245102 DD2A0105034 854A 10245102 DD2A0105612 853A 10245102 DD2A0106018 656A 10245102 DD2A0106038 855A 10245102 DD2A0106177 857A 175DG1803 NT-855 858A 22BM JN61 831A 250D33 CAT-D353 85DA 4031C DD4A171904 819A 500FD63D47A MT865PG270 85AA 599C DD471 81BA 67110431 LCN8 822A 71637305 DD16VA019218 85CA 71637305 DD16VA019219 85BA 76SX9E CAT-3304PC 85GA 80623400 DD6VF079684 8F1A 80827400 DD6VF079688 8F2A 80827402 DD80827402 EF3A ALEXANDER 271 893B ALEXANDER DD12V71 893A ALEXANDER MG512 893G B-40FT DD453 811A B-40FT HYD SYS 811N BAYFIELD DD671 8D7A BIENBILLE 371 8A2B BIENBILLE DD12V71 8A2A BIENBILLE MG514 8A2G BRAY DD692 81CA BRETON 15MOL3J1A 899B BRETON DD8V71 899A BRETON MH20L 899G BURRWOOD 271 898B BURRWOOD DD12V71T 898A BURRWOOD MG514 898G C-1303-24 AI45MSX8 8D3A CAT-130G 5R6192 861G CAT-130G 5R6192 862G CAT-130G CAT-3304 85HA CAT-130G CAT-3304DI 862A CAT-130G CAT-3304DIT 861A CAT-130G HYD SYS 861N CAT-130G HYD SYS 862N CAT-D4 CAT-3306 8B1A CAT-D4 CAT-7R559 8B7G CAT-D4 HYD SYS 8B1N

CAT-D5 CAT-3306 8B3A CAT-D5 3S7094 8B3G CAT-D5 HYD SYS 8B3N CAT-D7E CAT-3R2211 8B2G CAT-D7E HYD SYS 8B2N CHALMETTE 8.0MDKD3CR 897B CHALMETTE DD8V71 897A CHALMETTE M20L 897G D6 CAT-D333 8B4A D7H CAT-3306B 8B6A DAVID BOYD DD8V92 89EA DULUTH AI45M5X8 8D8A DULUTH GM271G3 8D8B F800 C8.3 8C5A FAIRCHILD DD671 8D6A FORNEY DD371 8DAA FREDERICK DD271 8DBA G-1 DD353 851A GRANADA 271 896B GRANADA DD12V71T 896A GRANADA MG514 896G H60XL-MIL 360311 841G H60XL-MIL HYD SYS 841N H60XL-MIL ISUZU-C240 841A HAMMOND BAY DD671 8D4A HARVEY DD371 814A HODGE DD8V92 89CA HURON DD453 817A JD550 HYD SYS 8B5N JD550 JD4276TT01 8B5A JD550 JDAT49678 8B5G JOHN BOPP 8.0614D 895B JOHN BOPP DD8V92 895A JOHN BOPP MH20L 895G KENT 16V1499 8A3A KENT DD671 8A1A KENT DD671 8A3B KENT MG540 8A3G L9000 CAT-3406C 8C4A LABORDE 11.0KWD 89BA LABORDE DD8V71 894A LABORDE MH20L 894G LB-1 DD453 8E2A LB-1 HYD SYS 8E2N LT-18 GM3906 8D1A LUDINGTON GM371R641 8DCA

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B-33

EIMOD COMPMOD TEC EIMOD COMPMOD TEC M109A5 DD8V71T 3E7A M109A5 HYD SYS 3E7N M109A5 XTG-411-2A 3E7G M109A6 DD8V71T 3FCA M109A6 HYD SYS 3FCN M109A6 XTG-411-4 3FCG M4K CASE-207D 8C1A M4K CLK18340 8C1G M4K HYD SYS 8C1N M50A1 DD671 8C2A M578 DD8V71T 3LAA M578 HYD SYS 3LAN M578 XTG-411-2A 3LAG MANITOWAC DD353 812A MT250 HYD SYS 831N MW24C CASE-504BD 871A MW24C HYD SYS 871N MW24C TT24211 871G N CENTRAL DD8V71 89FA NI9752 DD671 83CA NICOLET DD471 818A P38 DD853 891A PAJ DD8V92 89DA PB-1 GMC871 881A PU406A/M D298ERX37 85FA RACINE DD353 8D2A RG4031C DD4A171903 81AA RT855B CAT-3116 832A RT855B HYD SYS 832M RT855B R32620-4 832G RTCH-MC 3P9094 MDAW RTCH-MC CAT-3408T MDAC RTCH-MC CAT-5R3855 MDAJ RTCH-MC HYD SYS MDAN S2200 NTC-240 8C3B S2200 NTC-300 8C3C S2200 NTC-855 8C3A

SCOW #31 DD6068 815A SCOW #32 DD671 816A SHOALHUNTER CAT-3406B 824A SPD-1 DD371 8E4A SPD-1 DD6V71 8E4B SR-4 CAT-3304 85EA TAWAS BAY DDD671 8D9A TBCL4 DD16V149 8A4A TBCL4 DD671 8A4B TBCL4 MG540 8A4G TD-15C IHDT-466B 8B8A UPS-8 DD671 81DA USCCBMK1 363CI 821A VELER DD371 813A W-38 DDC671 892A W-38 MG509 892G W-46 8.0MKDB/1 89AB W-46 M20L 89AG W-48 DD8V71 89AA WHITEFISH DD12V71 8D5A XM93FOX HP500 TYPE 6 559G XM93FOX HYD SYS 559N XM93FOX OM402A 559A YF-865 DD371 8E6A YF-865 DD6V149 8E6B YSD-22 DD12V71 8E3A YSD-22 DD471 8E3B YSD-59 DD12V71 8E5A YSD-59 DD471 8E5B YSD-67 DD671 823B YSD-67 NTA855M 823A YSD-78 DD353 8E7A YSD-78 DD371 8E7B YSD-78 DD671 8E7C YSD-78 DD6V53 8E7D

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B-34

NONAERONAUTICAL TYPE EQUPMENT CODES

US AIR FORCE

EIMOD COMPMOD TEC EIMOD COMPMOD TEC 100KW-AF NTC-380-1 LVAA PWR GEN-AF DSK38 VJAA 1750KW-AF DSR38 LVBA PWR GEN-AF S-12NPTA VJBA 87H-AF AIR-COMP LVCA SF256128-AF AIR COMP LVHA FS136SC-AF NORDBERG LVDA

NONAERONAUTICAL TYPE EQUIPEMENT CODES

FLIGHT SIMULATORS END ITEM COMPONENT TEC END ITEM COMPONENT TEC UH-60FS Hydraulic Pump HLAA UH-1FS Hydraulic Pump HAA1 CH-47FS Hydraulic Pump HEAD PON-6 OILCART DRAA

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B-35

PAGES 25 THRU END OF THIS APPENDIX ARE ON SEPERATE DOCUMENT. REMOVE THIS PAGE WITHIN ADOBE

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NONAERONAUTICAL

TYPE EQUIPMENT CODES US NAVY SHIPS EQUIPMENT

End Item Component TEC ANCHORS ALL ANCHOR HYDRAULIC 1A01 ALL ANCHOR 80-90 1A02 CRANES ALL CRANE 80-90 2A01 ALL CRANE HYDRAULIC 2A02 ALL CRANE 9250 2A03 Hydraulic Equipment ALL HYDRAULIC POWER UNIT 3A01 AIR CONDITIONING AND REFRIGERATION ALL AIR CONDITIONING/REFRIGERATION SW 68 4001 ALL AIR CONDITIONING/REFRIGERATION RC02 4002 ALL AIR CONDITIONING/REFRIGERATION RC04 4003 ALL AIR CONDITIONING/REFRIGERATION POE 48 4004 MISCELLANEOUS EQUIPMENT ALL MISCELLANEOUS EQUIPMENT 2190 5A01 ALL MISCELLANEOUS EQUIPMENT 9250 5A02 ALL MISCELLANEOUS EQUIPMENT 23699 5A03 ALL MISCELLANEOUS EQUIPMENT HYDRAULIC 5A04 ALL MISCELLANEOUS EQUIPMENT 80-90 5A05 BLOWERS ALL BLOWER 2190 6A0Y TURBO CHARGERS

ALL TURBO CHARGERS 9250 7001

MISC GENERATORS ALL MISC GENERATORS 9250 8001 ALL MISC GENERATORS 2190 8002 AIR COMPRESSORS ALL AIR COMPRESSORS 2190 AA01 ALL AIR COMPRESSORS 9250 AA02 ALL AIR COMPRESSORS 23699 AA03 ALL AIR COMPRESSORS HYDRAULIC AA04

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NAVAIR 17-15-50.2 TM 38-301-2 T.O. 33-1-37-2 CGTO 33-1-37-2 End Item Component TEC BEARINGS ALL BEARINGS 2190 B001 CONTROLLABLE PITCH PROPELLERS AOE 6 Class ROLLS ROYCE NAVY MARINES 245-6361975 C41M ARS 50 Class ROLLS ROYCE NAVY MARINES 7309 C50M CG 47 Class ROLLS ROYCE NAVY MARINES 115652102 C80M CG 66 Class ROLLS ROYCE NAVY MARINES 115652103 C8AM DD 963 Class ROLLS ROYCE NAVY MARINES 7309 CF0M DDG 51 Class ROLLS ROYCE NAVY MARINES 7309 CF1M DDG 993 Class ROLLS ROYCE NAVY MARINES 115657001 CF2M FFG 7 Class ROLLS ROYCE NAVY MARINES 7309 CG0M LCAC Class DOWDY CO. LTD. CH0N LHD 1 Class ROLLS ROYCE NAVY MARINES 80-3S-CP CI1M LSD 41 Class ROLLS ROYCE NAVY MARINES 112152001 CN0M LSD 49 Class ROLLS ROYCE NAVY MARINES 112157071 CP0M LST 1179 Class ROLLS ROYCE NAVY MARINES DWG110251003PORT CQ0M MCM 1 Class ROLLS ROYCE NAVY MARINES 7309 CR0M MISC Class MISC CPP CH5M WAGB 10 Class ROLLS ROYCE NAVY MARINES CU0M WHEC 715 Class ROLLS ROYCE NAVY MARINES CV0M WLB 200 Class ROLLS ROYCE NAVY MARINES CW0M WMEC 620 Class ROLLS ROYCE NAVY MARINES DWG620WPC4301-51 CX0M GUIDED MISSLE SYSTEMS ALL GUIDED MISSILE HYDRAULIC D001 EMERGENCY DIESEL GENERATORS AE 26 Class DETROIT DIESEL CORP. 7124-320212V71LC E101 AE 26 Class DETROIT DIESEL CORP. 7124-320212V71RC E1A1 AGF 11 Class COLTEC INDUSTRIES INC. 38F5 1/4 E213 AGF 3 Class CATERPILLER INC. D334TA E202 AGSS Class EDG 555 E221 AO 177 Class COLTEC INDUSTRIES INC. 6-38D8 1/8 E303 AO 177 Class COLTEC INDUSTRIES INC. 6-38ND8 1/8 E3A3 AOE 1 Class COLTEC INDUSTRIES INC. 38ND8 D3051/8 E403 AOE 1 Class GENERAL MOTORS CORP. 16-567C E408 AOE 1 Class COLTEC INDUSTRIES INC. 38ND8-1/8 E4A3 AOE 6 Class CATERPILLER INC. 3608 E412 ARDM 5 Class ARDM 5 EDG E510 AS 33 Class COLTEC INDUSTRIES INC. 8-38D8 1/8 E603 AS 33 Class GENERAL MOTORS CORP. 12-645E2 E608 AS 39 Class COLTEC INDUSTRIES INC.38 D8 1/8AR3 E703 AS 39 Class COLTEC INDUSTRIES INC. 38ND8 1/8 E7A3 CGN 36 Class COLTEC INDUSTRIES INC. 38D8 1/8 E003 CGN 38 Class COLTEC INDUSTRIES INC. 38D8 1/8 E9A3 CV 59 Class COLTEC INDUSTRIES INC. 38ND8 1/8 EA03 CV 63 Class COLTEC INDUSTRIES INC. 12-38D8 1/8 EB03 CV 63 Class GENERAL MOTORS CORP. 16-567C EB08

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NAVAIR 17-15-50.2 TM 38-301-2

T.O. 33-1-37-2 CGTO 33-1-37-2

End Item Component TEC CV 63 Class COOPER CAMERON CORP. FVAM8T EB0L CV 63 Class COLTEC INDUSTRIES INC. 38ND8 1/8 EBA3 CVN 65 Class GENERAL MOTORS CORP. 16-567C ED08 CVN 68 Class GENERAL MOTORS CORP. LL16-645E5 EE08 CVN 68 Class GENERAL MOTORS CORP. LL16-645E5N EEA8 LCC 19 Class COLTEC INDUSTRIES INC. 6-38D8 1/8 EH13 LHA 1 Class COLTEC INDUSRIES INC. 251C EI03 LHD 1 Class COLTEC INDUSTRIES INC. 251C EI13 LPD 1 Class COLTEC INDUSTRIES INC. 38F5 1/4 EJ03 LPD 14 Class DETROIT DIESEL CORP. 7123-730012V71RC EL01 LPD 7 Class COLTEC INDUSTRIES INC. 38F5 1/4 EK03 LSD 36 Class DETROIT DIESEL CORP. 7123-730012V71RC EM01 MCM Class MCM EDG ER00 MCS 12 Class COLTEC INDUSTRIES INC. 12-38D8 1/8 ER13 ALL MISC EDG EH50 SSBN 726 Class COLTEC INDUSTRIES INC. 38ND8 1/8 ET03 SSN 21 Class COLTEC INDUSTRIES INC. 38ND8 1/8 ET13 SSN 637 Class COLTEC INDUSTRIES INC. 38F5 1/4 ET23 SSN 640 Class COLTEC INDUSTRIES INC. 38F5 1/4 ET33 SSN 671 Class COLTEC INDUSTRIES INC. 38F5 1/4 ET43 SSN 688 Class COLTEC INDUSTRIES INC. 38ND8 1/8 ET53 WAGB 10 Class DETROIT DIESEL CORP. 16V149 EU01 WLB 200 Class CATERPILLER INC. 3406TA EW02 WLB 277 Class DETROIT DIESEL CORP. 8V-71 EW11 WLB 277 Class CATERPILLER INC. 3306DI EW12 WLIC 298 Class DETROIT DIESEL CORP. #6-71 EW51 WLIC 75301 Class DETROIT DIESEL CORP. #4-71 EW61 WLIC 75301 Class DETROIT DIESEL CORP. #6-71 EWB1 WLM 540 Class CATERPILLER INC. 406T EW82 WLR 311 Class DETROIT DIESEL CORP. #3-53 EW91 WLR 75401 Class DETROIT DIESEL CORP. #4-71 EWY1 WMEC Class CATERPILLER INC. 3306 EX02 WMEC Class CATERPILLER INC. D348TA EXA2 FIN STABLIZIERS ALL FIN STABILIZER HYDRAULIC F001 GAS TURBINE ENGINES AOE 6 Class GENERAL ELECTRIC CO LM2500 G41O CG 47 Class STEWART & STEVENSON SERVICES INC 139A200 G80J CG 47 Class GENERAL ELECTRIC CO LM2500 G80O DD 963 Class ROLLS ROYCE NAVY MARINES 501-K17 GF0M DD 963 Class GENERAL ELECTRIC CO LM2500 GF0O DDG 51 Class ROLLS ROYCE NAVY MARINES 501-K34 GF1M DDG 51 Class ALLIED SIGNAL GTCP 100-82 GF1P DDG 993 Class GENERAL ELECTRIC CO LM2500 GF2O FFG 7 Class GENERAL ELECTRIC CO LM2500 GG0O LCAC Class AVCO-LYCOMING TF40B GH0Q LCAC Class SUNDSTRAND T-62T-40-7 GH0R MCM 1 Class SOLAR T-1000S-28AA GR0B

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NAVAIR 17-15-50.2 TM 38-301-2 T.O. 33-1-37-2 CGTO 33-1-37-2 End Item Component TEC MCM 1 Class SOLAR T-1302S-28AA GRAB WHEC Class WHEC GTE GV0M GAS TURBINE GENERATORS AOE 6 Class ALLISON 501 2190 H41Y AOE 6 Class ALLISON 501 23699 H41Z CG 47 Class ALLISON 501 2190 H80Y CG 47 Class ALLISON 501 23699 H80Z DD 963 Class ALLISON 501 2190 HF0Y DD 963 Class ALLISON 501 23699 HF0Z DDG 51 Class ALLISON 501 2190 HF1Y DDG 51 Class ALLISON 501 23699 HF1Z DDG 993 Class ALLISON 501 2190 HF2Y DDG 993 Class ALLISON 501 23699 HF2Z FFG 7 Class ALLISON 501 2190 HG0Y FFG 7 Class ALLISON 501 23699 HG0Z LCAC Class ALLISON 501 2190 HH0Y LCAC Class ALLISON 501 23699 HH0Z MCM 1 Class ALLISON 501 2190 HR0Y MCM 1 Class ALLISON 501 23699 HR0Z WHEC WHEC GTG HV00 FANS ALL SCAVENGER FAN HYDRAULIC I001 GEARS ALL GEARS 2190 J001 ALL GEARS 80-90 J002 ALL GEARS 23699 J003 ALL GEARS HYDRAULIC J004 ALL GEARS 9250 J005 ROCKER ARMS LSD 36 CLASS COLTEC IND. INC. DIESEL ENG ROCKER ARMS KM03 LSD 41 CLASS COLTEC IND. INC. DIESEL ENG ROCKER ARMS KN03 LSD 49 CLASS COLTEC IND. INC. DIESEL ENG ROCKER ARMS KP03 ELEVATORS NON HYDRAULIC CG 47 CLASS CG 47 ELEVATOR-NON HYDRAULIC L800 CV 63 CLASS WESTINGHOUSE LB07 CV 63 CLASS JARED INDUSTRIES INC LB0A CV 63 CLASS OTIS ELEVATOR CO LB0D CVN 65 WESTINGHOUSE LD07 CVN 68 CLASS JARED INDUSTRIES INC LE0A CVN 68 CLASS RUCKER LE0E DD 963 CLASS DD 963 ELEVATOR NON HYDRAULIC LF00 FFG 7 CLASS FFG7 ELEVATOR NON HYDRAULIC LG00

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T.O. 33-1-37-2 CGTO 33-1-37-2

End Item Component TEC LHA 1 CLASS JARED INDUSTRIES INC LI0A LHA 1 CLASS LHA1 ELEVATOR NON HYDRUALIC LI00 LHD 1 CLASS SCHINDLER ELEVATOR CORP LI0S LPD 7 CLASS LPD 7 ELEVATOR-NON HYDRAULIC LK00 MCS 12 CLASS JARED INDUSTRIES INC LR1A ELEVATORS HYDRAULIC CG 47 CLASS CG 47 ELEVATOR HYDARULIC L8A0 CV 63 CLASS WESTINGHOUSE LBA7 CV 63 CLASS OTIS ELEVATOR CO LBAA CV 63 CLASS JARED INDUSTRIED INC LBAD CVN 65 WESTINGHOUSE LDA7 CVN 68 CLASS RUCKER LEAA CVN 68 CLASS JARED INDUSTRIED INC LEAE DD 963 DD 963 ELEVATOR HYDRAULI LFA0 FFG 7 FFG 7 ELEVATOR HYDRAULIC LGA0 LHA 1 CLASS JARED INDUSTRIED INC LIAA LHD 1 CLASS SCHINDLER ELEVATOR CORP LIBS LPD 7 LPD 7 ELEVATOR HYDRAULIC LKA0 MSC 12 JARED INDUSTRIED INC LRAS MAIN DIESEL ENGINES AE 26 CLASS CATERPILLER INC. D398 M102 AGSS 555 CLASS DETROIT DIESEL CORP. 7124-3202-12V71 M221 AOE 1 CLASS AOE 1 MDE M400 ARS 50 CLASS CATERPILLER INC. D399B-TA M502 CG 47 CLASS CG 47 MDE M800 DD 963 CLASS DD 963 MDE MF00 LCU CLASS LCU MDE MH20 LHA 1 CLASS LHA 1 MDE MI00 LHD 1 CLASS LHD 1 MDE MI10 LPD 1 CLASS LPD 1 MDE MJ00 LPD 7 CLASS LPD 7 MDE MK00 LSD 36 CLASS DETROIT DIESEL CORP. 7123-7305-12V71T MM01 LSD 41 CLASS COLTEC INDUSTRIES INC. PC2.5V-LL1 MN03 LSD 41 CLASS COLTEC INDUSTRIES INC. PC2.5V-LR1 MNA3 LSD 41 CLASS COLTEC INDUSTRIES INC. PC2.5V-RL1 MNB3 LSD 41 CLASS COLTEC INDUSTRIES INC. PC2.5V-RR1 MNC3 LST 1179 CLASS ALCO PRODUCTS INC. 16-251C MQ00 LST 1179 CLASS ALCO PRODUCTS INC. 8-251E MQA0 MCM 1 CLASS ISOTTA FRASCHINI SPA. 36SS6V-AM MR0F MCM 1 CLASS WAUKESHA L1616DSIN MR0G MHC 51 CLASS ISOTTA FRASCHINI SPA. ID36SS8V-AM MS0F TWR CLASS CATERPILLAR INC. 3512 MT62 MISC MISC MDE MH50 PC PC MDE MH30 WAGB 10 CLASS ALCO PRODUCTS INC. 16-251-F MU00 WAGB 10 CLASS DETROIT DIESEL CORP. 6V53 MU01 WAGB 10 CLASS CUMMINS ENGINE CO. INC. 4BT3.9M MU04 WAGB 10 CLASS FAIRBANKS MORRIS 12-38D8-1/8 MU09 WAGB 10 CLASS SULZER 12ZA40S MU0H WHEC 715 CLASS CUMMINS ENGINE CO. INC. 4BT3.9M MV04

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NAVAIR 17-15-50.2 TM 38-301-2 T.O. 33-1-37-2 CGTO 33-1-37-2 End Item Component TEC WHEC 715 CLASS VOLVO PENTA OF AMERICA INC. B31B MV06 WHEC 715 CLASS FAIRBANKS MORRIS 12-38TD8-1/8 MV09 WHEC 716 CLASS DETROIT DIESEL CORP. #3-53 MV01 WLB 200 CLASS CATERPILLER INC. 3608 MW02 WLB 200 CLASS CUMMINS ENGINE CO. INC. 6BT5.9M MW04 WLB 277 CLASS DETROIT DIESEL CORP. #3-53 MW11 WLB 277 CLASS VOLVO PENTA OF AMERICA INC. B31B MW16 WLB 277 CLASS GENERAL MOTORS CORP. R8645E6 MW18 WLI 313 CLASS CATERPILLER INC. D-353 MW32 WLI 65303 CLASS DETROIT DIESEL CORP. 8V-71N MW41 WLIC 298 CLASS CATERPILLER INC. D-353D MW52 WLIC 75301 CLASS CATERPILLER INC. D-353E MW62 WLIC 800 CLASS CATERPILLER INC. D-379 MW72 WLM 540 CLASS CATERPILLER INC. D-353 MW82 WLM 540 CLASS CATERPILLER INC. D398LH MWB2 WLM 540 CLASS CATERPILLER INC. D398RH MWC2 WLM 685 CLASS CATERPILLER INC. 3508 MWA2 WLR 311 CLASS CATERPILLER INC. D-379 MW92 WLR 65501 CLASS CATERPILLER INC. D-353 MWX2 WLR 75401 CLASS CATERPILLER INC. D-353 MWY2 WMEC CLASS ALCO PRODUCTS INC. 16MS-251CE MX00 WMEC CLASS CUMMINS ENGINE CO. INC. 4BT3.9M MX04 WMEC CLASS VOLVO PENTA OF AMERICA INC. B31B MX06 WMEC CLASS GENERAL MOTORS CORP. 645 MX08 WMEC CLASS FAIRBANKS MORRIS 38D8-1/8 MX09 WMEC CLASS ALCO PRODUCTS INC. 251F18MS MXA0 WPB 1301 CLASS CATERPILLER INC. 3516 MY02 WPB 1301 CLASS PAXMAN 16RP200M MY0I WPB 82333 CLASS CATERPILLER INC. 3412 MY12 WTGB 101 CLASS FAIRBANKS MORRIS 8-38D8-1/8 MZ09 WYTL 65601 CLASS CATERPILLER INC. 3412 MZ12 YTB YTB MDE MH40 NITROGEN GENERATION PLANT ALL NITRO PLANT 2190 N001 SMALL BOYS DIESEL ENGINES AE 26 CLASS DETROIT DIESEL CORP. 5042-40004-53LD O101 AE 26 CLASS CUMMINS ENGINE CO. INC. 6BTA5.9-M O104 AE 26 CLASS WESTERBEKE CORP. 108O-14088 O105 AE 26 CLASS DETROIT DIESEL CORP. 5062-70006V53N O1A1 AE 26 CLASS WESTERBEKE CORP.4 –107 O1A5 AE 26 CLASS DETROIT DIESEL CORP. 6087M-ALUM O1B1 AE 26 CLASS DETROIT DIESEL CORP. 6-71RD706087M O1C1 AGF 11 CLASS DETROIT DIESEL CORP. 6121T6-71LC O211 AGF 11 CLASS WESTERBEKE CORP. 108U-14088 O215 AGF 3 CLASS DETROIT DIESEL CORP. 1062-7000 O201 AGF 3 CLASS WESTERBEKE CORP. 108O-14088 O205 AGF 3 CLASS DETROIT DIESEL CORP. 6072M6-71RC O2A1 AGF 3 CLASS DETROIT DIESEL CORP. 7082-7399 O2B1 AO 177 CLASS DETROIT DIESEL CORP. 1062-7000 O301

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T.O. 33-1-37-2 CGTO 33-1-37-2

End Item Component TEC AO 177 CLASS CUMMINS ENGINE CO. INC. 6BTA5.9-M O304 AO 177 CLASS VOLVO PENTA OF AMERICA INC AQAD41A-DP290A O306 AO 177 CLASS DETROIT DIESEL CORP. 6072M6-71RC O3A1 AOE 1 CLASS DETROIT DIESEL CORP. 1062-7000 O401 AOE 1 CLASS CUMMINS ENGINE CO. INC. 6BTA5 9-M O404 AOE 1 CLASS WESTERBEKE CORP. 108U-14088 O405 AOE 1 CLASS DETROIT DIESEL CORP. 5062-70006V53N O4A1 AOE 1 CLASS CUMMINS ENGINE CO. INC. 6BTA5 9-M2 O4A4 AOE 1 CLASS WESTERBEKE CORP. 14088 SPEC B O4A5 AOE 1 CLASS DETROIT DIESEL CORP. 64HN9HTEXCH O4B1 AOE 1 CLASS DETROIT DIESEL CORP. 64HN9KCLG O4C1 AOE 6 CLASS DETROIT DIESEL CORP. 1062-7000 O411 AOE 6 CLASS CUMMINS ENGINE CO. INC. 4B3.9-M O414 AOE 6 CLASS VOLVO PENTA OF AMERICA INC AQAD41A-DP290A O416 AOE 6 CLASS CUMMINS ENGINE CO. INC. 6BTA5.9-M O4B4 AOE 6 CLASS CUMMINS ENGINE CO. INC. 6BTA5.9-M2 O4C4 AOE 6 CLASS DETROIT DIESEL CORP. 6072M6-71RC O4D1 ARS 50 CLASS DETROIT DIESEL CORP. 5042-40004-53LD O501 ARS 50 CLASS DETROIT DIESEL CORP. 5042-40004-53RB O5A1 AS 33 CLASS DETROIT DIESEL CORP. 1062-5000 O601 AS 33 CLASS CUMMINS ENGINE CO. INC. 6BTA5.9-M2 O604 AS 33 CLASS WESTERBEKE CORP. 4-107 O605 AS 33 CLASS ONAN CORP. 1.5OMDJF4R4686D O60C AS 33 CLASS DETROIT DIESEL CORP. 1062-5099 O6A1 AS 33 CLASS ONAN CORP. DJC-MS/2450V O6AC AS 33 CLASS DETROIT DIESEL CORP. 1062-7000 O6B1 AS 33 CLASS DETROIT DIESEL CORP. 6072M6-71RC O6C1 AS 33 CLASS DETROIT DIESEL CORP. 64HN9HTEXCH O6D1 AS 39 CLASS DETROIT DIESEL CORP. 1043-7005 O701 AS 39 CLASS COLTEC INDUSTRIES INC. 38D8 1/8AR3 O703 AS 39 CLASS WESTERBEKE CORP. 14088 SPEC B O705 AS 39 CLASS DETROIT DIESEL CORP. 1043-7005-4-71N O7A1 AS 39 CLASS WESTERBEKE CORP. 4-107 O7A5 AS 39 CLASS DETROIT DIESEL CORP. 1062-5099 O7B1 AS 39 CLASS DETROIT DIESEL CORP. 1062-6001 O7C1 AS 39 CLASS DETROIT DIESEL CORP. 5062-7000 O7D1 AS 39 CLASS DETROIT DIESEL CORP. 5062-70006V53N O7E1 AS 39 CLASS DETROIT DIESEL CORP. 6072M6-71RC O7F1 AS 39 CLASS DETROIT DIESEL CORP. 6088M O7G1 CG 47 CLASS DETROIT DIESEL CORP. 5062-3000 O801 CG 47 CLASS CUMMINS ENGINE CO. INC. 6BTA5.9-M O804 CG 47 CLASS VOLVO PENTA OF AMERICA INC AQAD41A-DP290A O806 CG 47 CLASS DETROIT DIESEL CORP. 5062-70006V53N O8A1 CGN 36 CLASS DETROIT DIESEL CORP. 1062-7000 O901 CGN 36 CLASS CUMMINS ENGINE CO. INC. 8BTA5.9-M O904 CGN 36 CLASS WESTERBEKE CORP. 108D-14088 O905 CGN 36 CLASS DETROIT DIESEL CORP. 5062-70006V53N O9A1 CGN 36 CLASS WESTERBEKE CORP. 14088 SPEC B O9A5 CGN 38 CLASS DETROIT DIESEL CORP. 5042-3000 O001 CGN 38 CLASS WESTERBEKE CORP. 4-107 O005 CGN 38 CLASS DETROIT DIESEL CORP. 5042-40004-53LD O0A1 CV 59 CLASS DETROIT DIESEL CORP. 6087M-STBD OA01 CV 59 CLASS WESTERBEKE CORP. 108U-14088 OA05

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NAVAIR 17-15-50.2 TM 38-301-2 T.O. 33-1-37-2 CGTO 33-1-37-2 End Item Component TEC CV 59 CLASS VOLVO PENTA OF AMERICA INC AQAD41A-DP290A OA06 CV 59 CLASS DETROIT DIESEL CORP 6088M PORT OAA1 CV 59 CLASS WESTERBEKE CORP. 4-107 OAA5 CV 59 CLASS DETROIT DIESEL CORP. 64HNTEXCH OAB1 CV 59 CLASS DETROIT DIESEL CORP. 6-71RA6071MB OAC1 CV 63 CLASS DETROIT DIESEL CORP. 1062-7000 OB01 CV 63 CLASS WESTERBEKE CORP. 4-107 OB05 CV 63 CLASS VOLVO PENTA OF AMERICA INC AQAD41A-DP290A OB06 CV 63 CLASS DETROIT DIESEL CORP. 5033-60023-53 OBA1 CV 63 CLASS DETROIT DIESEL CORP. 6072M6-71LC OBB1 CV 63 CLASS DETROIT DIESEL CORP. 6072M6-71RA OBC1 CV 63 CLASS DETROIT DIESEL CORP. 6072M6-71RC OBD1 CV 63 CLASS DETROIT DIESEL CORP. 6088M-ALUM-6-71 OBE1 CV 63 CLASS DETROIT DIESEL CORP. 6088MCI OBF1 CV 63 CLASS DETROIT DIESEL CORP. 6088MPORT OBG1 CV 63 CLASS DETROIT DIESEL CORP. 64HN9HTEXCH OBH1 CV 63 CLASS DETROIT DIESEL CORP. 6-71RD706087M OBI1 CVN 65 DETROIT DIESEL CORP. 6072M6-71RC OD01 CVN 65 WESTERBEKE CORP. 4-107 OD05 CVN 65 DETROIT DIESEL CORP. 64HN106-71RC19H ODA1 CVN 65 DETROIT DIESEL CORP. 64HN9KCLG ODB1 CVN 68 CLASS DETROIT DIESEL CORP. 1062-6001 OE01 CVN 68 CLASS CUMMINS ENGINE CO. INC. 6BTA5.9-M OE04 CVN 68 CLASS WESTERBEKE CORP. 10488 SPEC B OE05 CVN 68 CLASS DETROIT DIESEL CORP. 1062-7000 OEA1 CVN 68 CLASS CUMMINS ENGINE CO. INC. 6BTA5.9-M2 OEA4 CVN 68 CLASS WESTERBEKE CORP. 108U-14088 OEA5 CVN 68 CLASS DETROIT DIESEL CORP. 6072M6-71LC OEB1 CVN 68 CLASS DETROIT DIESEL CORP. 6072M6-71RC OEC1 CVN 68 CLASS DETROIT DIESEL CORP. 64HN9HTEXCH OED1 CVN 68 CLASS DETROIT DIESEL CORP. 64HN9KCLG OEE1 DD 963 CLASS DETROIT DIESEL CORP. 1062-6001 OF01 DD 963 CLASS CUMMINS ENGINE CO. INC. 6BTA5.9-M OF04 DD 963 CLASS WESTERBEKE CORP. 4-107 OF05 DD 963 CLASS DETROIT DIESEL CORP. 5062-3000 OFA1 DD 963 CLASS DETROIT DIESEL CORP. 5062-7000 OFB1 DD 963 CLASS DETROIT DIESEL CORP. 5062-70006V53N OFC1 DDG 51 CLASS CUMMINS ENGINE CO. INC. 6BTA5.9-M OF14 DDG 51 CLASS VOLVO PENTA OF AMERICA INC AQAD41A-DP290A OF16 DDG 993 CLASS DETROIT DIESEL CORP. 1062-6001 OF21 DDG 993 CLASS CUMMINS ENGINE CO. INC. 6BTA5.9-M OF24 DDG 993 CLASS VOLVO PENTA OF AMERICA INC AQAD41A-DP290A OF26 FFG 7 CLASS CUMMINS ENGINE CO. INC. 6BTA5.9-M OG04 FFG 7 CLASS WESTERBEKE CORP. 108U-14088 OG05 FFG 7 CLASS VOLVO PENTA OF AMERICA INC 6AQAD40-867734 OG06 FFG 7 CLASS WESTERBEKE CORP. 4-107 OGA5 FFG 7 CLASS VOLVO PENTA OF AMERICA INC AQAD41A-DP290A OGA6 LCC 19 CLASS DETROIT DIESEL CORP. 5042-40004-53LD OH11 LCC 19 CLASS DETROIT DIESEL CORP. 6088M OHA1 LCC 19 CLASS DETROIT DIESEL CORP. 6088M-ALUM-6-71 OHB1 LCC 19 CLASS DETROIT DIESEL CORP. 6121T6-71LC OHC1 LCC 19 CLASS DETROIT DIESEL CORP. 64HN9KCLG OHD1 LHA 1 CLASS DETROIT DIESEL CORP. 7082-7399-8V71TI OI01

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T.O. 33-1-37-2 CGTO 33-1-37-2

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End Item Component TEC LHA 1 CLASS DETROIT DIESEL CORP. 7082-7399RC-8V71TI OIA1 LHA 1 CLASS DETROIT DIESEL CORP. 7082-7399TI-8V71RC OIB1 LHD 1 CLASS CUMMINS ENGINE CO. INC. 6BTA5.9-M OI14 LHD 1 CLASS VOLVO PENTA OF AMERICA INC 6AQAD40-867734 OI16 LHD 1 CLASS VOLVO PENTA OF AMERICA 6AQAD40B-867936 OIA6 LHD 1 CLASS DETROIT DIESEL CORP. 1062-7000 OIC1 LHD 1 CLASS DETROIT DIESEL CORP. 7082-7399RC-8V71TI OID1 LHD 1 CLASS DETROIT DIESEL CORP. 8062-7403RC OIE1 LPD 1 CLASS DETROIT DIESEL CORP. 5042-40004-53LD OJ01 LPD 1 CLASS WESTERBEKE CORP. 108U-14088 OJ05 LPD 1 CLASS DETROIT DIESEL CORP. 64HN9KCLG OJA1 LPD 1 CLASS WESTERBEKE CORP. 4-107 OJA5 LPD 1 CLASS DETROIT DIESEL CORP. 6-71LC6121T OJB1 LPD 1 CLASS DETROIT DIESEL CORP. 7082-7399RC-8V71TI OJC1 LPD 14 CLASS WESTERBEKE CORP. 4-107 OL05 LPD 14 CLASS DETROIT DIESEL CORP. 7082-7399-8V71TI OL01 LPD 14 CLASS CUMMINS ENGINE CO. INC. 6B5.9-M OL04 LPD 14 CLASS DETROIT DIESEL CORP. 7082-7399RC-8V71TI OLA1 LPD 7 CLASS DETROIT DIESEL CORP. 5042-40004-53LD OK01 LPD 7 CLASS CUMMINS ENGINE CO. INC. 6B5.9-M OK04 LPD 7 CLASS WESTERBEKE CORP. 4-107 OK05 LPD 7 CLASS DETROIT DIESEL CORP. 4HN9KCLG OKA1 LPD 7 CLASS DETROIT DIESEL CORP. 7082-7399RC-8V71TI OKB1 LPD 7 CLASS DETROIT DIESEL CORP. 7082-7399TI-8V71RC OKC1 LSD 36 CLASS DETROIT DIESEL CORP. 64HN9KCLG OM01 LSD 36 CLASS DETROIT DIESEL CORP. 7082-30008V71 OMA1 LSD 36 CLASS DETROIT DIESEL CORP. 7082-7399RC-8V71TI OMB1 LSD 41 CLASS DETROIT DIESEL CORP. 1062+D417-7000 ON01 LSD 41 CLASS CUMMINS ENGINE CO. INC. 6BTA5.9-M ON04 LSD 41 CLASS DETROIT DIESEL CORP. 6072M6-71RC ONA1 LSD 41 CLASS DETROIT DIESEL CORP. 7082-7399-8V71TI ONB1 LSD 41 CLASS DETROIT DIESEL CORP. 7082-7399RC-8V71TI ONC1 LSD 41 CLASS DETROIT DIESEL CORP. 7122-7000 OND1 LSD 41 CLASS DETROIT DIESEL CORP. 8062-7403RC ONE1 LST 1179 CLASS DETROIT DIESEL CORP. 64HN9KCLG OQ01 LST 1179 CLASS DETROIT DIESEL CORP. 7082-7399RC-8V71TI OQA1 MCS 12 CUMMINS ENGINE CO. INC. 4B3.9-M OR14 MCS 12 CUMMINS ENGINE CO. INC. 6BTA5.9-M ORA4 ALL MISC DIESEL ENGINE OH50 PUMPS ALL PUMP 2190 LUBE P001 ALL PUMP 2190 P002 ALL PUMP 9250 P003 DAVIT ALL DAVIT 2190 LUBE Q001 ALL DAVIT HYDRAULIC Q002

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NAVAIR 17-15-50.2 TM 38-301-2 T.O. 33-1-37-2 CGTO 33-1-37-2 End Item Component TEC REDUCTION GEAR AGF 11 CLASS REDUCTION GEAR 9250 R21W AOE 6 CLASS REDUCTION GEAR 2190 R41Y ARS 50 CLASS REDUCTION GEAR 9250 R50W CG 47 CLASS REDUCTION GEAR 2190 R80Y CG 47 CLASS REDUCTION GEAR 23699 R80Z CV 63 CLASS REDUCTION GEAR 9250 RB0W CVN 65 CLASS REDUCTION GEAR 2190 RD0Y DD 963 CLASS REDUCTION GEAR 2190 RF0Y DD 963 CLASS REDUCTION GEAR 23699 RF0Z DDG 51 CLASS REDUCTION GEAR 23699 RF1Z DDG 993 CLASS REDUCTION GEAR 2190 RF2Y FFG 7 CLASS REDUCTION GEAR 2190 RG0Y FFG 7 CLASS REDUCTION GEAR 23699 RG0Z LCAC REDUCTION GEAR 23699 RH0Z LCC 19 CLASS REDUCTION GEAR 2190 RH1Y LCU CLASS REDUCTION GEAR 9250 RH2W LHA 1 CLASS REDUCTION GEAR 2190 RI0Y LHD 1 CLASS REDUCTION GEAR 2190 RI1Y LPD 1 CLASS REDUCTION GEAR 2190 RJ0Y LPD 7 CLASS REDUCTION GEAR 2190 RK0Y LSD 36 CLASS REDUCTION GEAR 2190 RM0Y LSD 41 CLASS REDUCTION GEAR 2190 RN0Y LSD 49 CLASS REDUCTION GEAR 2190 RP0Y LST 1179 CLASS REDUCTION GEAR 9250 RQ0W MCM 1 CLASS REDUCTION GEAR 9250 RR0W MCM 1 CLASS REDUCTION GEAR 23699 RR0Z MHC 51 CLASS REDUCTION GEAR 2190 RS0Y TWR CLASS REDUCTION GEAR 7241 RT62 ALL REDUCTION GEAR 2190 R50Y ALL REDUCTION GEAR 23699 R50Z ALL REDUCTION GEAR 9250 R50W PC CLASS REDUCTION GEAR 9250 RH3W SSN 688 CLASS REDUCTION GEAR RT50 WAGB CLASS REDUCTION GEAR 9250 R40W WAGB 10CLASS REDUCTION GEAR 9250 RU0W WHEC CLASS REDUCTION GEAR 9250 RV0W WHEC 715 CLASS REDUCTION GEAR 23699 RV0Z WIX CLASS REDUCTION GEAR 9250 RV1W WLB 200 CLASS REDUCTION GEAR 9250 RW0W WLB 277 CLASS REDUCTION GEAR 9250 RW1W WLIC 75401 CLASS REDUCTION GEAR 9250 RW6W WLM 540 CLASS REDUCTION GEAR 9250 RW8W WLR 311 CLASS REDUCTION GEAR 9250 RW9W WLR 65501 CLASS REDUCTION GEAR 9250 RWXW WMEC CLASS REDUCTION GEAR 9250 RX0W WPB 1301 CLASS REDUCTION GEAR 9250 RY0W WPB 82312 CLASS REDUCTION GEAR 9250 RY1W WYTL 65501 CLASS REDUCTION GEAR 9250 RZ1W YTB CLASS REDUCTION GEAR 9250 RH4W

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End Item Component TEC SHIP SERVICE DIESEL GENERATORS AOE 6 CLASS AOE 6 SSDG S410 ARS 50 CLASS CATERPILLER INC. D399-TA S502 FFG 7 CLASS STEWART & STEVENSON SERVICE 114D001 SG0J LCC 19 CLASS COLTEC INDUSTRIES INC. 6-38D8 1/8 SH13 LCU CLASS LCU SSDG SH20 LHD 1 CLASS LHD1 SSDG SI10 LSD 41 CLASS COLTEC INDUSTRIES INC. 38ND8 1/8 SN03 LST 1179 CLASS ALCO PRODUCTS INC. 8-251-E SQ00 MCM CLASS MCM SSDG SR00 TWR CLASS CATERPILLAR INC. 3304 ST62 ALL MISC SSDG S500 PC CLASS PC SSDG SH30 WAGB 10 CLASS ALCO PRODUCTS INC. 8-251-E SU00 WAGB 10 CLASS CATERPILLER INC. D-379 SU02 WHEC 715 CLASS GENERAL MOTORS CORP. 8-645-E2 SV08 WHEC 715 CLASS GENERAL MOTORS CORP. 8-645-E2 SVA8 WHEC 715 CLASS GENERAL MOTORS CORP. 8-645-E2 SVB8 WHEC 715 CLASS GENERAL MOTORS CORP. 8-645-E2 SVC8 WLB 225 CLASS CATERPILLER INC. 3508 SW02 WLB 277 CLASS DETROIT DIESEL CORP. 6V-92 SW11 WLB 297 CLASS DETROIT DIESEL CORP. #6-71 SWA1 WLI 313 CLASS DETROIT DIESEL CORP. #3-71 SW31 WLI 65303 CLASS DETROIT DIESEL CORP. #2-71 SW41 WLIC 298 CLASS DETROIT DIESEL CORP. #3-71 SW51 WLIC 298 CLASS CATERPILLER INC. 3304 SW52 WLIC 800 CLASS DETROIT DIESEL CORP. #4-71 SW71 WLM 540 CLASS DETROIT DIESEL CORP. #6-71 SW81 WLM 540 CLASS CATERPILLER INC.340TA SW82 WLR 311 CLASS DETROIT DIESEL CORP. #4-71 SW91 WLR 65501 CLASS DETROIT DIESEL CORP. #3-71 SWX1 WLR 65501 CLASS CATERPILLER INC. 3304 SWX2 WLR 75401 CLASS DETROIT DIESEL CORP. #3-71 SWY1 WLR 75401 CLASS CATERPILLER INC. 3304 SWY2 WMEC CLASS CATERPILLER INC. 3406BDT SX02 WMEC CLASS CATERPILLER INC. D398B(TA) SXA2 WPB 1301 CLASS CATERPILLER INC. D3304BT SY02 WPB 82333 CLASS CUMMINS ENGINE CO. INC. 4B3.9GM SY14 WTGB 101 CLASS CATERPILLER INC. 3306B SZ02 WTGB 101 CLASS CUMMINS ENGINE CO. INC. 6BTA5.9-M2 SZ04 WTGB 101 CLASS MURPHY MP-24T SZ0K WYTL 65601 CLASS CATERPILLER INC. D-311 SZ12 YTB CLASS YTB SSDG SH40 TANKS ALL TANK 9250 T001 ALL TANK 2190 T002 ALL TANK 23699 T003 ALL TANK HYDRAULIC T004

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NAVAIR 17-15-50.2 TM 38-301-2 T.O. 33-1-37-2 CGTO 33-1-37-2 End Item Component TEC GUN MOUNT ALL GUN MOUNT HYDRAULIC U001 BOW THRUSTERS ALL BOW THRUSTER HYDRAULIC V001 WINCHES ALL WINCH HYDRAULIC W001 ALL WINCH 80-90 W002 ALL WINCH 23699 W003 STEAM TURBINE GENERATORS AE 26 CLASS AE 26 STEAM TURBINE GENERATORS Y101 AGF 11 CLASS AGF 11 STEAM TURBINE GENERATORS Y211 AO 177 CLASS AO 177 STEAM TURBINE GENERATORS Y301 AOE 1 CLASS AOE 1 STEAM TURBINE GENERATORS Y401 AS 33 CLASS S33 STEAM TURBINE GENERATORS Y601 AS 39 CLASS AS 39 STEAM TURBINE GENERATORS Y701 CGN 36 CLASS CGN 36 STEAM TURBINE GENERATORS Y901 CGN 38 CLASS CG 38 STEAM TURBINE GENERATORS Y001 CV 63 CLASS CV 63 STEAM TURBINE GENERATORS YB01 CVN 65 CV 65 STEAM TURBINE GENERATORS YD00 CVN 68 CLASS CV68 STEAM TURBINE GENERATORS YE01 LCC 19 CLASS LCC 19 STEAM TURBINE GENERATORS YH11 LHA 1 CLASS LHA 1 STEAM TURBINE GENERATORS YI01 LHD 1 CLASS LHD 1 STEAM TURBINE GENERATORS YI11 LPD 1 CLASS LPD1 STEAM TURBINE GENERATORS YJ01 LPD 7 CLASS LPD7 STEAM TURBINE GENERATORS YK01 LSD 36 CLASS LSD 36 STEAM TURBINE GENERATORS YM01 MCS 12 MCS 12 STEAM TURBINE GENERATORS YR11 SSBN 726 CLASS SSBN 726 STEAM TURBINE GENERATORS YT01 SSN 640 CLASS SSN 640 STEAM TURBINE GENERATORS YT31 SSN 671 CLASS SSN 671 STEAM TURBINE GENERATORS YT41 SSN 688 CLASS SSN 688 STEAM TURBINE GENERATORS YT51 AIR SUPPLY SYSTEMS ALL AIR SUPPLY SYTEM 2190 Z001

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APPENDIX C

MAJOR COMMAND CODES CODE ACRONYM COMMAND NAME AC IOC Industrial Operations Command AB AMCOM U.S. Army Aviation and Missile Command A7 USAREUR U.S. Army Europe A4 FORSCOM U.S. Army Forces Command AD USAJ U.S. Army Japan A1 AMC U.S. Army Materiel Command A5 USANGB U.S. Army National Guard A6 USAR U.S. Army Reserves AK TACOM U.S. Army Tank-Automotive and Armaments Command

A3 TRADOC U.S. Army Training and Doctrine Command AY CECOM U.S. Army Communication and Electronic Command A8 USARPAC U.S. Army Pacific Command A2 EUSA U.S. Eighth Army Korea A9 USARSO U.S. Army South AG USACE U.S. Army Corps of Engineers FF AFMC Air Force Materiel Command FZ AFNGB Air Force National Guard FU AFRES Air Force Reserves FJ AETC Air Education and Training Command FQ AMC Air Mobility Command FR PACAF Pacific Air Force FT ACC Air Combat Command FD USAFE U.S. Air Force Europe FP AFSPC Air Force Space Command FS AFSOC Air Force Special Operations Command NH MSC Military Sealift Command NF AIRLANT Naval Air Forces Atlantic Fleet NR AIRPAC Naval Air Forces Pacific Fleet NN NAVAIR Naval Air Systems Command NX NAVSEA Naval Sea Systems Command NA SUBLANT Naval Submarine Forces Atlantic Fleet NB SUBPAC Naval Submarine Forces Pacific Fleet NC SURFLANT Naval Surface Forces Atlantic Fleet ND SURFPAC Naval Surface Forces Pacific Fleet NG CGAIR U.S. Coast Guard (Aeronautical) NL CGCUTTER U.S. Coast Guard (Cutters) NM USMC U.S. Marine Corps NJ USMCR U.S. Marine Corps Reserves XW CONTRAC Contractor XV FOREIGN Foreign XE OTHER Other

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APPENDIX D

JOAP LABORATORY CODES / SPECTROMETER CODES

This information changes often. Refer to the most recent JOAP directory. If a directory is needed, send a request by e-mail to [emailprotected]

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APPENDIX E DATA INDEX CODES

CODE FILE MAINTENANCE ACTION (Blank) Detail Input R Sample Detail Revision N Sample Detail Deletion T Maintenance Feedback Revision J Maintenance Feedback Deletion F Maintenance Feedback

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APPENDIX F

REASON FOR SAMPLE CODES CODE REASON SAMPLE SUBMITTED A Accident/Incident C Customer Requested J Equipment Failure F Functional Check Flight L Lab Request H Metal in Sump/Screen/Filter P Physical Test (Not for Air Force use) M Post Maintenance Check I Pre-Shop Inspection (Not for Air Force use) K Prior to Maintenance - Removal R Routine D Sample Prior to Deployment T Test Cell E Test Cell - Reconditioned (Not for Air Force use) U Test Track (for Army depot use) G Test Track - Reconditioned (Not for Air Force use) V Vibration W Warning Light or Abnormal Gage Indication

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APPENDIX G

STANDARD LAB RECOMMENDATION CODES - AERONAUTICAL FOR SPECTROMETRIC ANALYSIS

CODE GENERAL LAB RECOMMENDATIONS

A Sample results Normal, continue routine sampling. X Analysis results supplied to customer; no recommendation required. Z Previous recommendation still applies.

CODE INSPECTION RECOMMENDATIONS (Requires Feedback)

H** Inspect unit and advise lab of finding. Abnormal wear indicated by *** PPM (element). R** Do not fly or operate; inspect filters, screens, chip detector and sumps; advise laboratory

of results. T** Do not fly or operate. Examine for discrepancy and advise laboratory of results and

disposition. If discrepancy found and corrected, continue operation and submit resample after *** hours of operation. If discrepancy is not found, recommend remove component from service and send to maintenance.

CODE OIL CHANGE RECOMMENDATIONS (Requires Resample)

J Contamination confirmed. Change oil, sample after *** minute run-up and after *** operating hours.

NOTE: Contamination is defined as water, coolant, silicon, etc. and not wear metals.

Use the appropriate recommendation codes for increasing treads or elevated wear metal conditions.

W Contamination suspected. Change oil; run for *** additional hours, take samples hourly.

(This code for Air Force ALC Depot use only.)

CODE LAB REQUESTED RESAMPLES (Requires Resample)

B* Resample ASAP, do not change oil. C* Resample after *** hours, do not change oil. E* Do not change oil. Restrict operations to local flights or reduced load operation, maintain

close surveillance and submit check samples after each flight or *** operating hours until further notice.

F* Do not change oil. Submit resample after ground or test run. Do not operate until after

receipt of laboratory result or advice.

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G* Contamination suspected, do not change oil, resample unit and submit sample from new

oil servicing this unit. P* Do not fly or operate; do not change oil; submit resample ASAP. Q* Normal PPM reading was obtained from test cell run after complete P.E. where oil

lubricated parts were changed/removed/replaced. Monitor engine closely after installation to ensure a normal trend before release to routine sampling.

NOTES:

* Resample (red cap) required ** Maintenance feedback required, advise laboratory of findings

*** Laboratory will specify time limit

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STANDARD LAB RECOMMENDATION CODES - NOT AERONAUTICAL FOR SPECTROMETRIC ANALYSIS

(Not For Air Force Use) CODE GENERAL LAB RECOMMENDATIONS

A Sample results Normal, continue routine sampling. X Analysis results supplied to customer, no recommendation required. Z Previous recommendation still applies.

CODE INSPECTION RECOMMENDATIONS (Required Feedback)

H** Inspect unit and advise lab of findings. Abnormal wear indicated by (element) (PPM). Resample after (maintenance/***hours/etc.).

K** Impending failure, critical wear indicated by (element). Inspect unit and advise lab of

findings. Resample after (maintenance/***hours/etc.). L** Inspect brake and clutch plate adjustments, change oil service filters, resample after ***

hours of operation. M** Perform engine coast-down check. If engine fails test, examine for discrepancy and

advise lab of results, else resample after*** hours of operation. U** Cooling system leak indicated by (Mg/Cr/Na/B). Inspect unit and advise lab of findings.

Resample after (maintenance/***hours/etc.).

CODE OIL CAHNGE RECOMMENDATIONS (Requires Resample)

D Change oil and service filters. Resample after *** hours of operation.

CODE LAB REQUESTED RESAMPLES (Requires Resample)

B* Resample ASAP, do NOT change oil. C* Resample after *** hours. F* Do not change oil, submit special sample after test run. Do not operate until after receipt

of laboratory results or advice. G* Contamination suspected, do not change oil resample unit and submit sample from new

oil servicing this unit. I* Stop purification, resample each engine after 4 hours of operation. N* Unit 'wear-in' indicated, resample in accordance with break-in schedule or after *** hours. P* Do not operate; do not change oil; submit resample ASAP.

NOTES: * Resample (red cap) required

** Maintenance feedback required, advise laboratory of findings *** Laboratory will specify time limit

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STANDARD LAB RECOMMENDATION CODES - PHYSICAL TEST RECOMMENDATIONS

(Not For Air Force Use)

CODE RECOMMENDATION

AA Oil condition normal, continue routine sampling. DN Do not operate. ER Evaluate and repair component. TS Check oil type and source. ZZ Previous recommendation still applies XX Analysis results supplied to customer; no recommendation required.

CODE OIL CONDITION STATEMENTS

FD Fuel Dilution. NN Neutralization or acid number. PC Particle count excessive. PN Precipitation number. SA Solid or abrasive material. VS Viscosity (high/low/change). WA Water

CODE OIL CHANGE RECOMMENDATIONS

CS Change oil and service filter. CP Purify, renovate or change oil and service filters.

CODE LAB REQUESTED SAMPLES (Requires Resample).

RB* Resample ASAP. RC* Resample after *** hours. RH* Submit hot sample. RI* Resample, insufficient amount of sample received. RS* Submit sample of new oil servicing this unit.

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CODE INSPECTION RECOMMENDATIONS (Requires Feedback)

IA** Inspect and repair air induction system. IC** Inspect and repair cooling system. IF** Inspect and repair fuel system, change/service filters and oil. IW** Inspect for source of water.

NOTES:

* Resample (red cap) required ** Maintenance feedback required, advise laboratory of findings

*** Laboratory will specify time limit

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APPENDIX H

ACTION TAKEN CODES

CODE DESCRIPTIONS

D Removed and Returned to Depot E Complied with Oil Lab Recommendation G Repair/Replace Minor Parts, Hardware and Softgoods H Equipment Checked - No Repair Required R Removed and Replaced S Removed, Repaired and Reinstalled

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APPENDIX I

DISCREPANT ITEM CODES

NOTE

The Discrepant Item Codes shown are general in nature and are designed to be applicable to all equipment entered in the oil analysis program. Due to the general nature of these codes, descriptions may not always be precise. Select the description that most closely fits for the discrepant item being reported. These codes are intended for use on oil analysis documentation only. Report errors or omissions on this listing to the JOAP-TSC, Pensacola, FL.

CODE DISCREPANT ITEM

AA A-Sump Scavenge Pump Rotor Vanes and liners AB Accessory Gearbox Bearing Housing AC Adapter Cover AD Air Filter AE Bands AF Basic Engine (no other item applies) AG Bearings (no other bearings apply) AH Block AI Brake Plates AJ Bushings AK Camshaft AL Camshaft Bearing AM Case/Main Housing AN Center and Counter Shafts AO Clutch Plates AP Connecting Rod AQ Connecting Rod Bearings AR Constant Speed Drive AS Core Engine Module AT Core Engine Module Number 2 Bearing AU Core Engine Module Number 3 Bearing AV Core engine Module Number 4 Bearing AW Crankshaft AX Crankshaft Bearing AY Cylinder AZ Cylinder Head BA Cylinder Liners BB Ducting/Hoses BC Fan Drive Turbine Module BD Fan Drive Turbine Module Number 5 Bearing BE Fittings BF Fuel Connectors BG Fuel Injectors

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CODE DISCREPANT ITEM

BH Fuel/Injector Pump BI Fuel Lines BJ Gasket BK Gears BL Inlet Fan Module BM Inlet Fan Module Number 1 Bearing BN Lifter BO Number 0 Bearing and Housing BP Number 1 Bearing and Housing BQ Number 2 Bearing and Housing BR Number 3 Bearing and Housing BS Number 4 Bearing and Housing BT Number 5 Bearing and Housing BU Number 6 Bearing and Housing BV Number 7 Bearing and Housing BW "O" Ring BX Oil Cooler/Heat Exchanger BY Oil Filter BZ Oil Pump CA Piston CB Piston Rings CC Planetary Gears CD Power Take-Off CE Pump CF Reservoir CG Rocker Arm CH Rocker Arm Bushing CI Seals CJ Servo CK Starter Retainer CL Support Bushing CM Thrust Washer CN Timing Gear CO Torque Converter CP Turbo Charger/Blower CQ Valve CR Wrist Pin CS Wrist Pin Bushing

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APPENDIX J

HOW MALFUNCTIONED CODES

CODE HOW MALFUNCTIONED A Accident B Adjustment of Alignment Improper C Backlash Excessive D Bearing Failure or Faulty E Bent, Buckled, Collapsed, Dented, Distorted or Twisted F Binding, Stuck or Jammed G Broken H Broken, Faulty or Missing Safety Wire or Key J Bushing Worn or Damaged K Chipped L Corroded - Mild to Moderate M Corroded - Severe N Cracked P Defects Unknown Q Defects Unknown - Unit shipped to SRA - Depot R Dirty, Contaminated or Saturated by Foreign Material S Improper or Faulty Maintenance T Keyway or Spline Damage or Worn U Loose V Loose or Damaged Bolts, Nuts, Screws, Rivets, Fasteners or Clamps W Missing Bolts, Nuts, Screws, Rivets, Fasteners, Clamps, other Hardware X Nicked Y No Defects Z Pitted 3 Removal Not Associated with OAP 4 Scored or Scratched 5 Sheared 6 Worn Beyond Limits 7 Leaking, Internal or External 8 Low Compression

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APPENDIX K

HOW FOUND CODES

CODE HOW FOUND

A Air or Ground Crew Unscheduled Maintenance G Air/Ground Crew Scheduled Maintenance S Impending/Incipient Failure Indicated by OAP

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APPENDIX L

SAMPLE MESSAGE FORMAT DIAGNOSITC DATA AND REQUEST FOR ASSISTANCE

FROM: LABORATORY TO: DIRJOAP TSC PENSACOLA FL (Army only) APPROPRIATE NATEC DET (Navy only) INFO: (as required by paragraph 3-10 and parent commands) UNCLAS SUBJ: SPECTROIL M/N SPECTROMETER REF: (a) SPECTROMETRIC LABORATORY MANUAL NAVAIR 17-15-50/TM 38-301/T.O. 33-1-37

(b) NAVAIR 17-15BF-95 1. Brief narrative of problem. 2. Is the Mercury lamp lit with the spectrometer in the ready mode and the sample stand door open? (Refer to paragraph 4-31 of reference (b).) YES/NO (as applicable). 3. Is there an indication on the optical alignment meter with the sample stand door open? YES/NO (as applicable). 4. Perform the optical alignment adjustment and record the counter setting (refer to paragraph 4-35 of reference (b)) NA/185 (use NA only when paragraph 3 is 'NO'). 5. Is the optical alignment meter reading zero microamps with the sample stand door closed? YES/NO/NA (use NA only when paragraph 3 is 'NO'). 6. (Complete only if answer to paragraph 5 is 'NO', use NA if paragraph 5 is 'YES'.) Is the optical alignment meter reading zero microamps with a piece of cardboard in front of the quartz window? YES/NO/NA 7. Are the readings for all elements within the tolerance of 50.1 + 0.1 upon two completions of the PREOPERATIONAL CHECK? (Refer to paragraph 4-32 of reference (b).) If the answer is 'NO', identify the elements and reading. YES/NO - AL-47.3. 8. Identify the values and corresponding test points for any voltage check not within tolerances specified in table 3-7 of reference (b). +14.2 at TP 2 and 11; -460 at TP 9 and 11.

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9. Record the burn cycle duration time required to analyze one sample of zero oil. (Refer to paragraph 4-45 of reference (b).) 29 seconds 10. List the standardization points for Fe, Ag, Al, Cr, Cu, Mg, Na, Ni, Pb, Si, Sn, Ti, Mo, Zn for the spectrometer in #1. Fe Ag Al Cr Cu Mg Na Ni Pb Si Sn Ti Mo Zn 100 60 70 99 96 94 68 100 106 100 59 90 71 45 11. Record the results and burn time of five analyses of zero oil for the OFFSET CHECK AND ADJUSTMENT for Fe, Ag, Al, Cr, Cu, Mg, Na, Ni, Pb, Si, Sn, Ti, Mo, Zn. Perform the adjustments as required (refer to paragraph 4-46 of reference (b)). Fe Ag Al Cr Cu Mg Na Ni Pb Si Sn Ti Mo Zn TIME A 49.9 49.9 49.3 53.1 51.4 50.1 50.8 49.8 49.9 50.2 50.5 50.1 43.7 50.3 29 B 49.9 50.0 49.4 53.1 49.5 50.0 55.4 49.4 29 C 50.1 50.0 49.4 53.1 RECORD READOUT IN TENTHS 49.9 50.1 55.1 50.1 30 D 49.4 49.8 48.6 53.0 49.7 49.5 54.0 49.9 29 E 50.3 50.0 49.5 53.1 51.4 50.2 50.9 50.5 50.0 50.2 50.7 50.0 56.1 49.9 29 * 12. Record the results and burn time of five analyses of 100 PPM oil for ADJUSTMENT AT 100 PPM for Fe, Ag, Al, Cr, cu, Mg, Na, Ni Pb, Si, Sn, Ti, Mo, Zn. Perform adjustments as required (refer to paragraph 4-47 of reference (b)). Fe Ag Al Cr Cu Mg Na Ni Pb Si Sn Ti Mo Zn TIME A 102 64 73 101 94 91 68 102 106 100 59 89 78 41 30 B 100 62 71 89 76 45 30 C 103 63 74 RECORD READOUT IN WHOLE NUMBERS 88 77 42 30 D 101 62 69 89 76 44 30 E 99 64 72 99 92 90 67 103 105 101 56 87 78 43 30 13. Record the results and burn time of five analyses of a 50 PPM standard for Fe, Ag, Al, Cr, Cu, Mg, Na, Ni, Pb, Si, Sn, Ti, Mo, Zn. First record the results in "0-100" range with the CALIBRATE switch off and in the PPM NORM mode, (1) then in the PPM OFF mode (2). Then record the results in the "0-1000" range first in the PPM NORM mode (3) and finally in the PPM OFF mode (4). (Readouts for each of the four switch positions can be obtained from a single analysis using the reset switch thus only a total of five analyses is requried.) Fe Ag Al Cr Cu Mg Na Ni Pb Si Sn Ti Mo Zn TIME A (1)54.1 53.1 49.1 47.6 52.3 50.0 51.3 49.3 49.0 51.3 50.4 49.8 54.2 52.3 30 (2)54.0 35.0 48.3 RECORD (1) & (2) IN TENTHS 48.9 53.2 51.4 (3)54 53 37 RECORD (3) & (4) IN WHOLE NUMBERS 47 44 34 (4)54 35 31 48 52 50 40 49 49 51 26 50 42 30

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Fe Ag Al Cr Cu Mg Na Ni Pb Si Sn Ti Mo Zn TIME B (1)51.1 52.3 49.9 49.1 50.2 49.2 50.1 52.1 50.9 52.6 51.1 53.6 52.2 50.9 30 (2)51.1 34.6 48.7 RECORD (1) & (2) IN TENTHS 52.9 51.3 50.7 (3)51 52 34 RECORD (3) & (4) IN WHOLE NUMBERS 47 44 34 (4)51 31 31 49 50 49 39 52 51 52 26 54 40 29 C (1)53.8 51.1 41.6 49.9 51.3 52.1 50.6 50.9 51.2 50.9 49.0 50.3 53.8 51.1 30 (2)53.8 33.5 40.1 RECORD (1) & (2) IN TENTHS 51.2 52.7 50.9 (3)53 51 32 RECORD (3) & (4) IN WHOLE NUMBERS 51 43 27 (4)54 33 30 50 52 52 39 50 51 51 25 50 42 29 D (1)52.2 50.9 48.6 50.9 49.9 48.9 51.8 48.7 49.9 49.9 51.6 47.2 51.1 52.3 30 (2)52.2 32.6 31.1 RECORD (1) & (2) IN TENTHS 46.8 50.2 51.1 (3)52 51 49 RECORD (3) & (4) IN WHOLE NUMBERS 48 38 32 (4)52 33 30 51 50 49 41 48 50 50 26 47 39 30 E (1)54.2 52.3 48.6 48.6 52.2 50.3 50.3 48.9 51.5 49.2 49.9 54.3 54.1 53.1 30 (2)54.2 34.6 47.2 RECORD (1) & (2) IN TENTHS 51.1 52.1 51.2 (3)54 52 32 RECORD (3) & (4) IN WHOLE NUMBERS 53 44 31 (4)54 33 31 48 52 50 39 49 52 49 25 54 42 32 14. Record the results and burn time of five analyses of 100 PPM standard for Fe, Ag, Al, Cr, Cu, Mg, Na, Ni, Pb, Si, Sn, Ti, Mo, Zn. Record the results in the 0-1000 range first in the PPM OFF mode then in the PPM NORM mode. (Readouts for both the PPM OFF mode and the PPM NORM mode can be obtained on a single analysis thus only a total of five analyses is requried.) Fe Ag Al Cr Cu Mg Na Ni Pb Si Sn Ti Mo Zn TIME A (1)97 101 102 93 105 91 31 (2)97 60 61 RECORD RESULTS IN WHOLE NUMBERS 94 72 41 B (1)105 103 101 98 107 109 31 (2)105 61 60 RECORD RESULTS IN WHOLE NUMBERS 96 76 47 C (1)101 102 101 97 96 110 31 (2)101 61 60 RECORD RESULTS IN WHOLE NUMBERS 95 67 47 D (1)104 106 100 103 111 93 31 (2)104 63 70 RECORD RESULTS IN WHOLE NUMBERS 97 76 42 E (1)103 106 101 101 106 102 31 (2)103 63 71 RECORD RESULTS IN WHOLE NUMBERS 91 72 45 15. Record the results and burn time of five analyses for Fe, Ag, Al Cr, Cu, Mg, Na, Ni, Pb, Si, Sn, Ti, Mo, Zn in the unmodulated mode. (Refer to paragraph 4-73 of reference (b).)

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Fe Ag Al Cr Cu Mg Na Ni Pb Si Sn Ti Mo Zn TIME A 53.3 50.7 52.1 51.4 52.4 52.7 54.8 51.2 51.6 54.0 52.3 52.8 52.5 53.8 32 B 53.2 51.3 50.1 51.1 52.7 53.1 32 C 53.3 51.1 RECORD RESULTS IN TENTHS 52.1 52.1 53.2 53.0 32 D 52.7 50.8 51.2 51.3 53.8 54.4 32 E 53.0 51.3 52.2 51.3 52.1 53.0 54.4 51.0 51.3 53.8 52.3 52.5 53.3 54.0 32 16 Record the results and burn time of five analyses for Fe, Ag, al, Cr, Cu, Mg, Na, Ni, Pb, Si, Sn, Ti, Mo, Zn in the MODULATED mode. (Refer to paragraph 5-73 of reference (b).) Fe Ag Al Cr Cu Mg Na Ni Pb Si Sn Ti Mo Zn TIME A 641 671 557 392 477 538 657 785 844 680 814 650 305 420 30 B 641 671 648 305 419 30 C 641 670 RECORD RESULTS IN WHOLE NUMBERS 649 304 417 30 D 641 671 650 305 420 30 E 641 671 557 391 477 537 657 785 844 680 814 650 305 420 30 17. REMARKS/ADDITIONAL INFORMATION. (Report any other symptoms you consider abnormal during the other phase of the operation.) 18. REQUEST ASSISTANCE. POINT OF CONTACT IS (name/telephone #).

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NAVAIR 17-15-50.2 TM 38-301-2

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M-1

APPENDIX M

PREPARATION INSTRUCTIONS - DA FORM 3254-R OIL ANALYSIS RECOMMENDATION AND FEEDBACK

M-1. DA 3254-R will be produced locally on 8 1/2 x 11 inch paper. The laboratory will complete blocks 1 through 11.

a. Enter the filed unit's name, address and telephone number.

b. Enter the name and address of the laboratory making the recommendation.

c. Enter lab recommendation number. Example: 04-1 for year 04 and first recommendation of the year.

d. Enter end-item model number. Example: UH-1H, OH-58A, etc.

e. Enter complete end-item serial number.

f. Enter component type. Example: Main transmission, 90 degree gearbox, engine, etc.

g. Enter complete serial number of component.

h. Enter hours/miles on component.

i. Enter the recommendation and reason for action.

j. Laboratory personnel making recommendation will sign in block 10 and enter title.

k. Enter date. Example: 17 Feb 04. M-2. The laboratory will prepare and forward one copy to the field activity, one copy to: Army Oil Analysis Program Office (AMXLS LA) USAMC SUPPORT ACTIVITY BLDG 3661 REDSTONE ARSENAL AL 35898-7466 and for aeronautical equipment, one copy to: COMMANDER ATTN SDSCC QTM STOP 270 CORPUS CHRISTI ARMY DEPOT 308 CRECY STREET CORPUS CHRISTI TX 78419-5260

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M-2

OIL ANALYSIS RECOMMENDATION AND FEEDBACK For use of this form, see TB 43-0106 and TB 43-0210; the proponent agency is DARCOM.

REQUIREMENT CONTROL SYMBOL CSGLD-1818

1. TO: FIELD (Include ZIP Code and Telephone Number) 3. LAB RECOMMENDATION NUMBER

4. END ITEM MODEL

5. END ITEM SERIAL NUMBER

2. FROM: LABORATORY (Include ZIP code) 6. COMPONENT TYPE

7. COMPONENT SERIAL NUMBER

8. COMPONENT TIME (Hours/Miles)

9. RECOMMENDATION AND REASON FOR ACTION

10. SIGNATURE AND TITLE OF INIATOR 11. DATE (Day/Month/Year)

12. NOTE FOR ARMY AVIATION ONLY: Quality Deficiency Report (QDR). SF 368 will be submitted when maintenance is performed due to impending or incipient failure indicated by oil analysis, Failure Code 916.

13. QDR NUMBER

14. FEEDBACK (Maintenance Performed/Action taken) 15. FROM: FIELD DEPOT MAINTENANCE PERSONNEL 16. DATE (Day/Month/Year)

17. TO: LABORATORY NOTE FOR ARMY AVIATION ONLY:

Copy of this form with SF 368 (QDR) attached will be sent to: Commander, CCAD ATTN: DRSTS-MER Stop 55 Corpus Christi, TX 78419

NOTE: AMSAV-MRAT IS NEW ATTN ADDRESS

DA FORM 3254-R EDITION OF JUN 78 IS OBSOLETE. NOV 80

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N-1

APPENDIX N

ARMY LABORATORY EVALUATOR CERTIFICATION REQUIREMENTS

N-1. GENERAL. The role of the evaluator in Army oil analysis laboratories is to serve as the single determining authority for all analyses, which indicate the potential for a maintenance problem or concern for the continued reliability of a tested component. PM AOAP must certify all evaluators serving in Army laboratories. N-2. CERTIFICATION. To be certified as an Army laboratory evaluator, an individual must be actively employed in a single Army Oil Analysis Program (AOAP) laboratory (see paragraph N-3). a. Request for evaluator certification must: (1) Be processed through the government office at installation responsible for the laboratory. The request must be signed by the person for whom certification is being requested, the laboratory chief, and the Contracting Officer's Representative (COR)/Installation Monitor. Signatures attest that the individual has received adequate training and acknowledges that those signing believe the individual is proficient in all areas required for certification as an Army oil analysis evaluator. (2) Include a copy of the training completed by the applicant and any related information such as previous analytical experience and/or chemistry/petroleum background. b. Requirements for evaluator certification are: (1) Applicant must have the ability to be certified for both aeronautical and nonaeronautical equipment. Individuals in laboratories that analyze only nonaeronautical samples or only aeronautical samples will receive limited evaluator certification. (2) Applicant must successfully pass a written test and a performance test administered by the AOAP Program Management Office or its designated representatives. If the applicant fails either test, the individual must wait at least 2 months before requesting certification again. The additional time will permit the applicant to receive additional training in those areas where additional knowledge is required. c. When an applicant has successfully passed the evaluator written and performance examinations, PM AOAP will evaluate the outcome, applicant’s experience, and award the evaluator certification, if appropriate. d. Requirements for evaluator certification in ferrography: (1) In addition to the requirements outlined in paragraphs N-2 above, the following are applicable to Army laboratory personnel who are to be certified to evaluate grease samples through the use of ferrography. (2) Must be a certified aeronautical AOAP evaluator and; (a) Should have completed the ferrographic instrument manufacturer's 1 week Introduction to Ferrography Course and least 3 months on-the-job training preparing and evaluating ferrograms under the supervision of a certified ferrograph evaluator. (b) Requests for attendance at either of the ferrography courses will be coordinated through the Program Manager. Expenses associated with attendance and completion of these training courses will be at the expense of the applicant or the applicant’s company. Written tests are not required for ferrography certification, however, the applicant will be required to successfully pass a performance test. e. Test administration:

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(1) Written test: (a) Will normally be given during Laboratory Assistance and Assessment Review (LAAR) visits. (b) Will be given at Redstone Arsenal, AL, or at the contract laboratory site. If certification testing is required at a time other than during a LAAR visit, the contractor is responsible for all travel costs of the testing representative to the laboratory site or for the applicant’s to travel to Redstone Arsenal. In the case of government-operated laboratories, the installation will be responsible for all travel costs. ( c) The test will examine the applicant’s capabilities and knowledge of Army oil analysis publications and procedures/protocols involved in the documentation and processing of lubricant samples and test finding data. (2) Performance test. Will be given at the Redstone Arsenal, AL, or at the contract laboratory site. In the case of contractor-operated laboratories, the contractor is responsible for all travel costs of the testing representative or for employees to travel to Redstone Arsenal. In the case of government-operated laboratories, the installation will be responsible for all travel costs. ( a) The test will examine the applicant’s capabilities and knowledge of Army oil analysis laboratory instruments, testing methodology, and laboratory procedures. (b) Each applicant will be evaluated to determine their ability to arrive at a single and correct conclusion after reviewing the findings from each tests conducted on an oil sample. The applicant should be able to achieve a high level of accuracy on each oil sample analyzed. N-3. Recommended Training or Experience. a. Knowledge of AOAP publications, to include: (1) AR 750-1, Army Material Maintenance Policies, published in the Maintenance Management UPDATE (Chapter 7, Army Oil Analysis Program). (2) AR 700-132 Joint Oil Analysis Program (JOAP). (3) TM 38-301, Joint Oil Analysis Program Manual, Volumes 1-4. (4) TB 43-0106, Aeronautical Equipment Army Oil Analysis Program (AOAP). (5) TB 43-0211, AOAP Guide for Leaders and Users. (6) DA Pam 738-750, the Army Maintenance Management System, published in the Maintenance Management UPDATE (Chapter 4, Army Oil Analysis Program). (7) DA Pam 738-751, the Army Maintenance Management System - Aviation, (Army Oil Analysis Program). b. Training may be accomplished by general study of the manuals, research of questions posed by trainer, and daily application of procedures outlined in the publications. c. Complete familiarity with the function of wear-metal parts per million evaluation criteria in the Oil Analysis Standard Interservice System (OASIS) or TM 38-301. This may be accomplished by review of the table but the information is best retained when used as a daily reference during evaluator training. d. Physical Property Test Training. One month working closely with a laboratory technician on the performance of physical property tests and an additional 3 months performance of physical property tests.

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Training should include standardization of the viscometer and procedures for adjustment when the viscometer requires calibration as well as procedures and basic principles behind each test. e. Spectrometer Training. Two months working closely with a trained spectrometer operator and an additional 4 months of spectrometer operation. Training is to include proper sample and electrode handling, complete manual and automated spectrometer standardization, procedures for cleaning the sample stand, proper electrode sharpening, operator maintenance services and frequency required, procedures for calibration checks and frequency required, cleaning of quartz window and frequency required, and basic principles of spectrometer operation. f. Evaluator Training. Three or more months working with a certified evaluator. This is to include techniques in evaluation of nonaeronautical and aeronautical samples. These techniques must include a study of trend development, interpretation of changes in individual elements as well as combinations of elements, and discussion of factors influencing evaluation. Certification is not to be requested until the individual is qualified to evaluate without supervision. g. Individual may request a waiver from PM AOAP on the length of recommended training requirements if an individual has previous experience within the AOAP, or has experience acquired elsewhere. A minimum 2 months training in an AOAP laboratory is recommended to ensure familiarization with AOAP tests and evaluation techniques. However, the length and type of training required by PM, AOAP, will be based on the qualifications provided in the applicant’s request for training waiver. N-4. DECERTIFICATION. a. Decertification shall automatically occur if any of the following conditions exists: (1) If an evaluator is employed/contracted to serve full-time in a single AOAP laboratory and is serving as an evaluator at multiple AOAP laboratories. (2) If an evaluator is employed/contracted to serve full-time in a single AOAP laboratory and fails to accomplish laboratory evaluator duties 90 percent of the employment period. Normal absences for personal time off, jury duty, medical or military leave will not count against the individual.

NOTE Contractor management officers, who hold evaluator status and serve to supplement or replace evaluators on temporary medical absence or military leave, etc, are not included in rules N-3a and N-3b. However, individuals in this status must refresh or supplement their experience by performing evaluator duties in an AOAP laboratory every three months. (3) If an evaluator is not employed, full-time, in an AOAP laboratory for 6 consecutive months. b. May be directed by the Program Manager, AOAP, based on, but not limited to, the following reasons: (1) Evaluator's willful disregard of AOAP policies or procedures. (2) Evaluator's removal from the laboratory or military installation for cause, by any authorized government official. (3) Evaluator's willful entry of false test or analytical data into the AOAP computer. (4) Evaluator's willful falsification of any AOAP sample record. (5) Evaluator's willful communication of false information concerning the processing or evaluation of a sample.

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N-4

N-5. RECERTIFICATION: Shall be required for all individuals who were certified evaluators at one time, were decertified, and desire to be certified again. a. Applicants requesting recertification must meet the requirements outlined in paragraph N-2. b. For those whose decertification was directed by the Program Manager, AOAP: (1) Recertification may not be requested until 1 year after decertification. (2) The reason for decertification must be mitigated and satisfactorily resolved. (3) Applicant must meet the requirements outlined in paragraph N-2. c. Request for recertification (for all individuals) must: (1) Be processed through the government office at installation responsible for the laboratory where the applicant will be employed and be signed by the person for whom certification is being requested, the laboratory chief, and the COR/Installation Monitor. (2) Include a copy of the initial certification letter, along with a description of recent training or experience and any other pertinent information. N-6. GENERAL NOTES: a. If an evaluator originally receives limited certification (to evaluate only nonaeronautical samples or only aeronautical samples) and later wants to be fully certified, he/she must take written and performance tests to qualify for full certification (both aeronautical and nonaeronautical evaluation). Procedures for requesting the administering the tests are the same as those for initial certification described in this appendix. b. If an evaluator originally receives full certification to evaluate both nonaeronautical and aeronautical samples, and continues to be employed as an evaluator but evaluates either only nonaeronautical or only aeronautical samples, he/she does not lose full certification. He/she previously demonstrated his/her proficiency in full evaluation capabilities, continued to use evaluator skills on a daily basis, and remained familiar with laboratory test procedures and manuals. It is the responsibility of the evaluator to hone his/her skills as necessary when the occasion to evaluate the type of samples not routinely evaluated arises.

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APPENDIX O

FERROGRAM ANALYSIS REPORT SHEET Ferrogram Number: Organization: Equipment Type: Sample Date:

D.R. Reading (per mL)

L:

S:

Date: Sample No.: Equipment Serial No.: Total Operating Hours: Oil Type: Time on Oil:

Volume of Undiluted Sample to Make Ferrogram:

TYPES OF PARTICLES NONE FEW MODERATE HEAVY

Normal Rubbing Wear Particles

Severe Wear Particles

Cutting Wear Particles

Chunks

Laminar Particles

Spheres

Dark Metallo-Oxide Particles

Red Oxide Particles

Corrosive Wear Debris

Non-Ferrous Metal Particles

Non-Metallic Birefringent } Inorganic

Organic Non-Metallic, Amorphous

Friction Polymers

Fibers

Other, Specify Considered Judgement of Wear Situation:

Normal Caution Very High (Red Alert)

COMMENTS:

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APPENDIX O

DIRECT READ ANALYSIS REPORT REGISTER DR NUMBER:

ORGANIZATION:

EQUIPMENT TYPE:

SAMPLE DATE:

REASON FOR D/R:

FERRO DONE: YES NO

DR READING L:

(PER ML) S:

DATE:

SAMPLE #:

TAIL NUMBER:

TOTAL OVERHAUL HRS:

TIME ON OIL:

OIL TYPE:

RECOMMENDATION/COMMENTS:

DIRECT READ ANALYSIS REPORT REGISTER DR NUMBER:

ORGANIZATION:

EQUIPMENT TYPE:

SAMPLE DATE:

REASON FOR D/R:

FERRO DONE: YES NO

DR READING L:

(PER ML) S:

DATE:

SAMPLE #:

TAIL NUMBER:

TOTAL OVERHAUL HRS:

TIME ON OIL:

OIL TYPE:

RECOMMENDATION/COMMENTS:

DIRECT READ ANALYSIS REPORT REGISTER DR NUMBER:

ORGANIZATION:

EQUIPMENT TYPE:

SAMPLE DATE:

REASON FOR D/R:

FERRO DONE: YES NO

DR READING L:

(PER ML) S:

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DATE:

SAMPLE #:

TAIL NUMBER:

TOTAL OVERHAUL HRS:

TIME ON OIL:

OIL TYPE:

RECOMMENDATION/COMMENTS:

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