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MIL-F-8615D
29 March 1976
SUPERSEDING
MIL-F-8615C
26 February 1969

MILITARY SPECIFICATION

FUEL SYSTEM COMPONENTS: GENERAL SPECIFICATION FOR

This specification is approved for use by all Departments

and Agencies of the Department of Defense.

1. SCOPE

1.1 Scope. This specification covers the requirements for aircraft fuel,
vent, and propulsion system functional components.

1.2 Classification. Components shall be identified by class based upon a

-
temperature environment in accordance with table I.

TABLE 1. Temperature classification.

T - High operational fuel temperature

Tt - High fuel test temperature

.
Ta - High ambient temperature

1.2.1 Non-standard environment. Wherever the temperature environment exceeds

the classes of 1.2, or where unusual circumstances exist, the lowest and high-
est fluid, vapor, and ambient temperatures shall be identified. A component
may still belong to one of the above classes if the exposure to a higher ambient
temperature (Ta) is transitory and does not result in heating the component
more than 30°C above the test temperature (Tt) for more than 15 minutes total
during 10 hours of operation.

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MIL-F-8615D

2. APPLICABLE DOCUMENTS

2.1 Issue of documents. The following documents, of the issue in effect on

date of invitation for bids or request for proposal, form a part of this speci-
fication to the extent specified herein:

SPECIFICATIONS

FEDERAL

QQ-C-320 Chromium Plating

QQ-P-416 Plating, Cadmium (Electrodeposited)
TT-S-735 Standard Test Fluids, Hydrocarbon
VV-G-109 Gasoline, Unleaded

MILITARY

MIL-D-1000 Drawings, Engineering and Associated Lists

MIL-S-4040 Solenoid, Electrical, General Specification for
MI -B-5087 Bonding, Electrical and Lightning Protection, Aerospace
Syst ems
MIL-W-5088 Wiring, Aircraft, Selection and Installation of
MIL-P-5315 Packing, Preformed, Hydrocarbon Fuel Resistant
MIL-G-5572 Gasoline, Aviation, Grades 80/87, 100/130, 115/145
MIL-T-5624 Turbine Fuel, Aviation, Grades JP-4 and JP-5
MIL-C-6021 Castings, Classification and Inspection of
MIL-E-6051 Electromagnetic Compatibility Requirements, Systems
MIL-R-6855 Rubber, Synthetic, Sheets, Strips, Molded for Extruded
Shapes
MIL-C-7024 Calibrating, Fluids, for Aircraft Fuel System Components
MIL-E-7080 Electric Equipment, Aircraft, Selection and Installation of
MIL-F-7190 Forging, Steel, for Aircraft and Special Ordnance Applications
MIL-S-7742 Screw Threads, Standard, Optimum Selected Series, General
Specification for
MIL-M-7969 Motor, Alternating Current, 400 Cycle, 115/200-Volt System
Aircraft General Specification for
MIL-M-8609 Motor, DC, 28 Volt System, Aircraft, General Specification
for
MIL-S-8879 Screw Threads, Controlled Radius Root with Increased Minor
Diameter; General Specification for
MIL-A-21180 Aluminum Alloy Castings, High Strength
MIL-E-2S499 Electrical System, Aircraft, Design and Installation of,
General Specification for
MIL-R-25988 Rubber, Fluorosilicone Llastomer, Oil- and Fuel-Rcsistant,
Sheets, Strips, Molded Parts and Extruded Parts
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MIL-F-8615D

MIL-F-27351 Fluid, Calibrating, High Flash Point Aircraft Fuel Systems

Components
MIL-C-38999 Connector, Electrical, Circular, Miniature, High Density
Quick Disconnect, Environment Resistant Removable Crimp
Contacts
MIL-R-83248 Rubber, Fluorocarbon Elastomer, High Temperature, Fluid,
and Compressor Set Resistant

STANDARDS

FEDERAL

FED-STD-151

MIL-STD-100 Engineering Drawing Practices

MIL-STD-129 Marking for Shipment and Storage
MIL-STD-130 Identification Marking for US Military Property
MIL-STD-143 Standards and Specifications, Order of Precedence for the
Selection of
MIL-STD-202 Test Methods for Electronic and Electrical Component Parts
MIL-STD-461 Electromagnetic Interference Requirements
MIL-STD-462 Electromagnetic Interference Characteristics, Measurement of
MIL-STD-471 Maintainability Demonstration
MIL-STD-704 Electric Power, Aircraft, Characteristics and Utilization of
MIL-STD-781 Reliability Tests, Exponential Distribution
MIL-STD-794 Parts and Equipment, Procedures for Packaging and Packing of
MIL-STD-810 Environmental Test Methods
MIL-STD-831 Test Reports, Preparation of
MIL-STD-882 System Safety Program Requirements
MIL-STD-889 Dissimilar Metals
MIL-STD-1523 Age Controls of Elastomeric Items
MS16142 Boss, Gasket Seal, Straight Thread Tube Fitting
MS33649 Bosses, Fluid Connection - Internal Straight Thread
MS33656 fitting End, Standard Dimensions for Flared Tube Connection,
and Gasket Seal
MS33657 Fitting End, Standard Dimensions for Bulkhead Flared Tube
Connections

(Copies of specifications, standards, bulletins and drawings required by con-

tractors in connection with specific procurement functions should be obtained
from the procuring activity or as directed by the contracting officer.)

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MIL-F-8615D

2.2 Other publications. The following documents form a part of this specifi-
cation to the extent specified herein. Unless otherwise indicated, the issue
in effect on date of invitation for bids or request for proposal shall apply.

Society of Automotive Engineers

ARP 868 Pressure Drop Test for Fuel System Components

(Copies of the above publication may be obtained from the Society of Automotive
Engineers, Two Pennsylvania Plaza, New York, New York 10001.)

American Society for Testing and Materials

ASTM-D1655 Aviation Turbine Fuels

ASTM-E380-74 Metric Practice Guide

(Copies of the above documents may be obtained from the American Societ for
Testing and Materials, 1916 Race Street, Philadelphia, PA 19106.)

3. REQUIREMENTS

3.1 First article. Unless otherwise specified, the assemblies furnished. under
this specification shall have been inspected and passed the first artic
inspection specified herein.

3.2 Item specification. A specification providing all design and performance

details shall be submitted by the contractor to the procuring agency for ap-
proval. The item specification shall reiterate all applicable requirements of
this specification inserting the necessary specific and special requirements.
The item specification shall include a specification control drawing.

3.2.1 Drawings. The installation and outline drawings shall be in accordance

with MIL-D-1OOO. At the time and place of first article approval, the data
shall include the detailed assembly drawing(s) with the parts list showing
the material, coating, temper, special finishes for all parts and applicable
processes and assembly procedures, as applicable.

3.2.2 Weight. The allowable wet and dry weights of the component shall be
stated in the item specification.

3.3 Selection of standards and specifications. Standards and specificat ions

for commodities and services not specified herein, shall be selected in accord-
ance with MIL-STD-143.
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MIL-F-8615D

3.4 Materials. Materials and processes shall conform to applicable Govern-

ment specifications. Materials conforming to contractor’s specifications
may be used after approval by the procuring activity. All materials shall
be resistant to the fuels, fuel vapors, humidity, salt fog, and other environ-
mental factors encountered in service.

3.4.1 Fungus proof. Materials that are nutrients for fungi shall not be used
where it is practical to avoid them. Where used and not hermetically sealed,
they shall be treated with fungicidal agent acceptable to the procuring acti-
vity; however, if used in a hermetically sealed enclosure, fungicidal treatment
will not be necessary.

3.4.2 Metals. Metals shall be of the corrosion-resistant type or suitably

treated to resist corrosion due to contact with materials or exposure to
environments likely to be met in storage or normal service. Metals shall
be inspected in accordance with FED-STD-151.

3.4.2.1 Dissimilar metals. Unless suitably protected against electrolytic

corrosion, dissimilar metals shall not be used in intimate contact with each
other. Dissimilar metals are defined in MIL-STD-889.

3.4.2.2 Magnesium and copper. Magnesium and copper or alloys thereof shall
not be used in contact with fuel.

3.4.2.3 Castings and forgings. Castings shall be in accordance with MIL-C-6021,

or MIL-A-21180. The minimum acceptable elongation shall be 3 percent. Steel
forgings shall satisfy the applicable requirements of MIL-F-7190.

3.4.3 Rubber. Rubber materials shall conform to MIL-P-5315, MIL-R-6855,

Class I, MIL-R-25988 or MIL-R-83248. All other elastomeric materials are
required to have specific approval from the procuring activity for the
particular application.

3.4.4 Finishes and coatings. All finishes and protective treatments shall
be in accordance with applicable Government specifications. The use of any
protective coating that will crack, chip, peel, or scale because of age or
the aircraft operational environment is prohibited. Paint shall not be used
on surfaces normally in contact with fuel.

3.4.4.1 Cadmium plating. Cadmium plating shall conform to QQ-P-416, Class 2,

Type II. Cadmium plating shall not be used on surfaces which would normally
be in contact with fuel, unless specifically approved by the procuring activity.

3.4.4.2 Chromium plating. Chromium plating shall conform to QQ-C-320,

Class 2.

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3.5 Fluids. The item specification shall state the principal fluid and
other fluids expected to be encountered in use. Fuel system components shall
normally be compatible with MIL-G-5572, MIL-T-5624, MIL-C-7024, MIL-F-27351,
TT-S-735, VV-G-109, ASTM D-1655, Types A, A-1, and B and other comparable
fuels. In normal aircraft operation, these fuels may contain various quan-
tities of dissolved and free water, salts, gases, some solid contaminants,
such as sand, dirt and metal chips.

3.6 Design and construction

3.6.1 Pressure. Fuel system components shall be compatible with the pressure
schedules of table II, or higher pressures in accordance with the item specifi-
cation.

TABLE II (Metric)

ALTERNATE TABLE II (Customary Units)

3.6.2 Leakage

3.6.2.1 External. The item specification shall state the permissible external
leakage from less than atmospheric pressure up to the ultimate pressure.
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3.6.2.2 Internal. The item specification shall state the permissible internal
leakage for all operating conditions.

3.6.2.3 Plug-in units. When applicable, the item specification shall state
the maximum allowable fuel loss when plug-in units are removed and reinstalled.

3.6.3 Strength. The specific requirements of each of the following para-

meters shall be stated in the item specification as applicable.

3.6.3.1 Mechanical load. The component shall be capable of withstanding

normal operating maintenance loads without distortion or failure. The minimum
design value of torque for installation and removal of fittings, fasteners,
etc., shall be at least 125 percent of the normal maximum.

3.6.3.2 Shock resistance. The component mounting shall assure safe retention
in place and not be a cause for leakage of fuel in the event of a shock load
within the envelope of the applicable structural design criteria.

3.6.3.3 Fatigue resistance. The component shall be capable of withstanding

the vibrations and acoustical noise of its installed environment as well as
any other external force input that causes repeated stress in any portion of
the component. The vibration and acoustical noise environment shall be speci-
fied in accordance with MIL-STD-810.

3.6.4 Bonding. Bonding for electrical requirements and lightning protection

shall be in accordance with MIL-B-5087.

3.6.5 Electrical. Electrical devices shall be compatible with the aircraft

electrical system as well as power in accordance with MIL-STD-704 and shall
satisfy the applicable requirements of MIL-E-7080 and MIL-E-25499.

3.6.5.1 Electrical connector. Electrical connectors shall be in accordance

with MIL-C-38999, or in accordance with the applicable aircraft specification.

3.6.5.2 Wiring. Electrical wiring shall be in accordance with MIL-W-5088.

3.6.5.3 Solenoids. Solenoids in fuel system components shall be continuous

duty in accordance with MIL-S-4040.

3.6.5.4 Motors. Electrical motors shall satisfy the applicable requirements

of MIL-M-7969 and MIL-M-8609.

3.6.5.5 Electrical fault containment. The assembly housing shall be completely

capable of containing any internal fault without failure of the housing. In no
case shall an electrical short or internal explosion propagate to the outside
of the housing or generate an unsafe condition.

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3.6.5.6 Electrical insulation requirements. The electrical components shall

withstand, without damage, breakdown, or excessive leakage current, applications
of test voltages in accordance with the test procedure of Section 4. The AC
dielectric current shall not exceed 2 milliamperes. Insulation resistance
shall not be less than 100 megohms for motors, or 200 megohms for other elec-
trical components.

3.6.5.7 Electromagnetic interference. The electrical components shall meet

the applicable requirements of MIL-STD-461 and shall be capable of satisfying
the requirements of MIL-E-6051 when installed in the aircraft.

3.6.6 Thermal protection. If normal operation of the equipment or if an

electrical fault can generate high temperatures, thermal protection shall
be incorporated to assure that the assembly is maintained within safe tem-
perature limits under all operating or nonoperating conditions. The peak
temperature, from any heat source, of any portion of the assembly in contact
with fuel or fuel vapors, shall not exceed 200°C or a lower temperature in
accordance with the item specification.

3.6.7 Shaft seals, drains, and vents. Motor operated fuel system components
shall provide shaft seals and a suitable drain chamber between the motor and
the component unless the rotating element of the motor is immersed in fuel.
A vent connected to an electrical motor chamber shall not be connected to
the seal drain chamber and shall incorporate a flame arrestor.

3.6.8 Traps and voids. Fuel system components shall not contain traps,
pockets, or voids in which moisture may freeze or contaminants may collect
that affects performance or reliability.

3.6.9 Threaded connections. Threaded connections shall comply with MIL-S-7742,

MIL-S-8879, MS16142, MS33649, MS33656, or MS33657, as applicable.

3.6.9.1 Pipe threads. Pipe threads shall not be used except for permanent
closures.

3.6.9.2 Threaded safety. All threaded parts shall be positively locked

or safetied in accordance with applicable military standards or other accepted
practice. Wherever loosening of a self-locking nut could possibly result in
the nut or other parts entering the fuel system plumbing, approval of the
installation shall be obtained from the procuring activity. The use of
cotter pins on studs, or the use of lockwashers or staking is prohibited.
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3.6.10 Lubrication. Fuel system components shall function satisfactorily

without the need for lubrication other than the fuel in which it operates
during its useful service life. Wherever a lubricant is required (such as a
gear assembly) it shall be a sealed unit and shall not require relubrication
between overhaul periods.

3.6.11 Overspeed. Components containing rotating members which can over-

speed for any reason shall have a self-contained speed regulator and shall
also be designed to prevent propagation of any failure outside of the housing.

3.7 Performance. All necessary specific performance requirements must be

provided by the item specification. The following paragraphs shall be used
as guides in preparing the item specification requirements, but they do not
necessarily contain all the required performance parameters.

3.7.1 Calibration. All critical calibration points shall be specified, such

as, flow rates, pressure schedules, pressure drop (or rise), fluid level,
response adjustments, or power requirements.

3.7.2 Altitude. Fuel system components shall deliver full required perform-
ance at all altitude levels, and during changes in altitude. If performance
is required to be insensitive to altitude, the specification shall so state.

3.7.3 Acceleration. The required performance during changes in speed or

changes in direction shall be specified.

3.7.4 Gravity force. The component performance during periods of inverted

flight or changes in the effective gravity force, shall be in accordance with
system requirements as stated in the detail specification.

3.7.5 Endurance. In general, components whose operational life is time

dependent shall have a minimum endurance of 1,200 hours between overhaul
periods. For components whose operation is intermittent, and are operated
10 times or more per flight or a component whose failure can impose a hazard
shall have a minimum endurance of 100,000 cycles. For components that operate
less frequently, and are not safety critical, the required endurance shall be
10,000 cycles. The endurance test shall encompass all operational conditions
from sea level to maximum altitude, including high and low temperature exposure
as well as dry operation (without fuel).

3.7.6 Water and ice. Water (or ice) shall not be a cause of a fuel system
component failure. The water may come from any available source, such as
free or dissolved water in the fuel, vapor in a bleed air system, clouds,
rain, etc. Any fuel system component whose failure, due to water (or ice)
could prevent transfer of fuel, or could cause a buildup of pressure, either
positive or negative, in excess of design allowances, shall demonstrate its
capability to satisfy aircraft system requirements in the presence of water,
either in the fuel or in the surrounding atmosphere.

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3.7.6.1 Above freezing. The component shall demonstrate its ability to

perform in the presence of water when the temperature is above freezing.

3.7.6.2 Icing conditions. The minimum endurance and required performance

under icing conditions shall be specified.

3.7.7 Speed. Where applicable, the duration of time for a valve opening
and closing shall be specified. Whenever a component contains a speed
control device, or whenever a variation in the amount of fluid in a component
will allow a speed change, the minimum performance requirements shall be
specified.

3.7.8 Dust (fine sand). Components installed in exposed locations shall be

capable of withstanding the damaging effects of sand and dust in the atmo-
sphere without excessive deterioration in performance.

3.7.9 Pressure surge. Fuel system components shall not cause pressure surges
in the fuel tubing greater than the proof pressure of table II. If this
requirement cannot be satisfied, a specific approval of the deviation must
be obtained, and the proof and burst pressure test requirements shall be
increased accordingly. Surge pressures are transient pressure peaks above
the normal system pressure, caused by component actuation.

3.7.10 Thermal shock. The component shall be capable of withstanding the

thermal cycling effects of its environment and fluid temperature changes
without deterioration in either performance or endurance, and without any
other failure. Where applicable, thermal shock performance requirements
shall be specified.

3.8 Safety analysis. Where applicable, all possible failure modes and
their impacts shall be examined in accordance with the applicable paragraphs
of MIL-STD-882, and in accordance with the system safety requirements of
the air vehicle.

3.8.1 Proof-of-safety tests. Tests shall be conducted to verify the safety

analysis. The requirements of MIL-STD-882 shall be applied to the verifica-
tion tests.

3.9 Reliability.
— . — The reliability of the component to perform shall be stated
in the item specification, as needed to satisfy system requirements. A test
plan shall be prepared for demonstrating the required reliability in accordance
with MIL-STD-781.

3.10 Maintainability. The maintainability plan shall provide an estimate

of maintenance manhours, total clock-hours, and special tools needed for
intermediate shop and overhaul maintenance of the component, in accordance
with MIL-STD-471.
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3.10.1 Accessibility. Fuel system components which require routine service

checking, adjustment, or parts replacement, shall provide accessibility for
this routine maintenance without requiring teardown, or disassembly of the
housing from the airframe, fluid lines or electrical components.

3.10.2 Seal replacement. Wherever seals are partially exposed and subject
to possible damage, the seal unit shall be readily replaceable and preferably
without removal of the main housing from its mounted position.

3.10.3 Error-free maintenance. The following general requirements will

reduce the possibility of human errors during assembly and maintenance of
system components, if applicable:

a. Stacked assemblies shall use arrangements which prevent improper assembly,

such as the use of indicator markings which are exposed if parts are omitted.

b. Similar components shall either be identical and interchangeable, or shall

have some design feature to prevent their interchange. The use of right and
left hand parts shall be avoided.

c. When bolts of different sizes are used near the same location, widely
differing sizes shall be specified. Two bolts identical except for length
shall not be used in the same location. Design shall protect against damage
to parts caused by accidental use of screws or bolts which are too long.

) d. Where reversed or rotated mounting of a part cannot be tolerated, non-

symmetrical mounting arrangements (including key ways or pins) shall be used,
Parts that are capable of proper operation when mounted in any orientation
are more desirable.

e. Identical cable receptacles shall not be used side-by-side unless internal

functions are identical and interchangeable.

3.11 Interchangeability. All component part.; shall be governed by the part

numbering system of MIL-STD-1OO.

3.12 Identification. All assemblies and parts shall be marked in accordance

with MIL-STD-130. The information may be etched, engraved, embossed, or
stamped in a suitable location on the assembly or on a corrosion resistant-
nameplate securely attached to the component. The information shall be
located where it can be read with the component mounted in place, insofar
as practical.
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3.12.1 Color identification. The component shall be color coded to indicate

fuel use by means of a red color. The color shall be permanent and shall not
deteriorate, loosen or fade due to contact with fuel or the operational environ-
ment. The marking may consist of a red band 1/4 inch or wider around the
component body or a stripe at least 1 inch long on opposite sides of the
component or by coloring the entire outer surface of the principal body, or
by use of an embossed nameplate with a red background color.

3.13 AGE Control. The assembly date marking shall be in accordance with
MIL-STD-1523.

3.14 Workmanship. Workmanship shall be in accordance with all applicable

specifications, drawings, and quality control plans.

4. QUALITY ASSURANCE PROVISIONS

4.1 Responsibility for inspection. Unless otherwise specified in the contract,

the contractor is responsible for the performance of all inspection requirements
as specified herein. The contractor may use his own or other suitable facilities
unless disapproved by the Government. The Government reserves the right to per-
form any of the inspections set forth in the specification where such inspections
are deemed necessary to assure supplies and services conform to prescribed
requirements.

4.2 Classification of inspections. The inspection and testing of the componen

shall be classified as follows:

a. First article inspection

b. Quality conformance inspection.

4.3 First article inspection. The first article inspection shall consist of
all applicable inspections and tests herein, and any additional tests shall be
in accordance with the item specification. The number of test articles and
the order of tests shall be in accordance with table 111.

4.3.1 Test report. The test report, covering all details of the first
article inspection shall be prepared in accordance with MIL-STD-831. The
report shall include the assembly and cross-section drawings of the component,
copies of test log sheets and other applicable sketches and photographs. The
description of the test apparatus may be abbreviated by including sketches
and photographs to provide a clear understanding of each test set-up.
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TABLE III. First article inspection program.

NOTES: A. Inspections 2, 3, 4, and 5 shall be repeated at the end of the tests

for each test article, prior to disassembly.
B. Inspections 7, 8 and 9 shall be conducted in the order listed.
c . Inspection 6 shall be conducted prior to any other lower number
in the list.
D. A simple mechanical device without electrical equipment may only
require two test articles. A 4th test article is optional for sharing the
inspections of test article 3.
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4.3.2 Disposition of test articles. All items subjected to test shall be

available for the first article inspection and thereafter shall be retained
or delivered to the procuring agency in accordance with the contract require-
ments.

4.4 Quality conformance inspections. The quality conformance inspections

shall consist of individual tests.

4.4.1 Individual tests. Each assembly shall be subjected to individual

tests prior to delivery in accordance with the detail specification. This
will normally consist of at least the following.

a. Examination

b. Break-in-run

c. Leakage

d. Calibration

e. Electrical insulation tests.

accordance with the item specification. These will consist of at least the
following:

a. Calibration (4.5.5)

b. Strength (4.5.15).

4.5 Inspection methods. Unless otherwise specified, the atmospheric pressure

and temperature shall be the local ambient.

4.5.1 Test fluid. Unless otherwise specified, the test fluid shall be the
principal fluid the component shall experience in use. For quality conform-
ance inspections, the test fluid shall be in accordance with the item
specification.

4.5.2 Examination of product. All component assemblies shall be inspected

and certified to be in accordance with the applicable drawings and specifi-
cations, including all requirements of Section 3 for which tests are not
appropriate. The units shall be of satisfactory workmanship, within the
weight allowance, clean and free of contaminants, oil, grease, preservatives
or any other material not specified on the assembly drawings.

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4.5.3 Break-in run. Where applicable, a break-in run (either dry or wet)
shall be conducted in accordance with the item specification.

4.5.4 Leakage. All leak tests shall be performed at a variety of pressure

levels from the minimum up to the maximum pressure. Wherever slight leaks
are critical, the pressure at each level shall be held for a sufficient
length of time (5 to 30 minutes or more) to provide an accurate assessment.
Leak detection by pressure gage drop is not permitted for first article or
sampling inspections. Leak checks for individual tests may be conducted
at fewer pressure levels and for a shorter duration of time.

4.5.4.1 Internal. Internal leakage tests are normally conducted from

minimum up to proof pressure or maximum operating pressure, and back down
again to minimum. The pressure levels and allowable leakage rate shall
be specified.

4.5.4.2 External. There shall be no visible external leakage except as

permitted by the item specification from minimum pressure up to ultimate
pressure.

4.5.4.3 Plug-in units. The quantity of fuel loss resulting from engagement
and disengagement of plug-in units shall satisfy specification requirements.

4.5.5 Calibration. Calibration tests shall be conducted to demonstrate

compliance with 3.7.1. For first article and sampling inspections, sufficient
data points shall be taken to thoroughly demonstrate the complete performance
characteristics of the component. For individual tests, the number of data
points may be limited to only one or two critical points, as specified.

4.5.6 Altitude. Altitude tests shall be conducted to demonstrate as speci-

fied in 3.7.2. These tests may be conducted concurrently with the endurance
requirements as specified in 3.7.5.

4.5.7 Speed. Tests shall be conducted to demonstrate as specified in

3.7.7.

4.5.8 Acceleration. Tests shall be conducted in accordance with MIL-STD-81O,

Method 513.2 to demonstrate as specified in 3.7.3.

4.5.9 Gravity. Tests shall be conducted to demonstrate as specified in

3*7.4.

4.5.10 Pressure surge. Tests shall be conducted to demonstrate as specified

in 3.7.9 as applicable.

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4.5.11 Fuel resistance. This test is applicable to all components having

any parts whose physical properties are affected by contact with fuel. The
test shall be conducted in a continuous manner in accordance with the schedule
of table IV. Each period shall follow the preceding one in the order noted
with a minimum of delay. The soak periods shall be conducted with a body
of fluid in continuous contact with all affected parts. For the dry periods,
the component shall be drained, without disassembly, and blown dry with the
ports open and placed in a test chamber having air continuously circulating
around the component at the test temperature.

4.5.11.1 Test fluids. The test fluids for the fuel resistance test shall
be in accordance with TT-S-735, Types I and III and MIL-T-5624, JP-4 and
JP-5. For the high temperature soak periods, it is advisable to perform
the soak in a closed container with a pressure not to exceed 15 psi to
prevent boiling. For Class B components, MIL-T-S624 fuel may be used in
lieu of Type III if permitted by the item specification.

TABLE IV
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4.5.11.2 Fuctional operation during tests. At least once each day during
the soak periods, components with moving parts shall be actuated. Intermittent
duty components shall be actuated through a minimum of 4 cycles. Continuous
duty or motor operated components shall be operated for 1 hour or a minimum
of 25 cycles. During dry periods, actuation shall be accomplished if the
component may be operated in the dry condition when installed. The item
specification shall provide the specific actuation requirements.

4.5.11.3 Tests after each period. At the conclusion of each soak or dry
period, the component shall be actuated through 4 cycles or operated for
5 to 10 minutes and subjected to a leakage test. Following the Phase I and
II periods, the tests shall be conducted at room temperature. The fluid to
be used following the soak periods shall be Type III and following the dry
periods, Type I. Following the Phase III period the test shall be conducted
at -57° *4°C (-70” 2 S°F) using Type I fluid, and repeated at room temperature.
The component actuation and leakage shall satisfy the specification, except
that following the dry periods, some increased leakage may be permitted for
no more than 15 minutes.

4.5.12 Endurance. The endurance test is applicable to nearly all fuel

system components in order to demonstrate as specified in 3.7.5. The test
shall be a simulation of the operating conditions of the component for its
design operational life between overhauls. It shall be accomplished without
disassembly, lubricative adjustment, or other maintenance, except as pro-
vialed by the specification. Calibration and leakage tests shall be accom-
plished following each phase to verify performance. For power operated
components, which are subjected to variations in power input, the test should
be conducted with these variations. The test set-up shall not provide for
surge pressure relief and should simulate the aircraft installation insofar
as practical. If operation of the unit causes pressure surges, the instru-
mentation shall automatically record the rate of pressure change and the
pressure peaks and valleys.

4.5.12.1 Altitude. When applicable, this test shall be conducted at the

various critical operating conditions occurring at altitude. If operation
at altitude produces some special effect, such as slow start-up, overspeed,
or heating, the test should include a reasonable number of these cycles or
duration of time for the special effect. This test shall comprise at least
20 percent of the total endurance test.

4.5.12.2 High temperature. The high temperature endurance test is applicable

to all components and shall consist of 20 percent of the total required endur-
ance test. The fluid and ambient temperature shall be in accordance with the
appropriate class.
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MIL-F-8615D

4.5.12.3 Low temperature. The low temperature endurance test is applicable

to all components and shall consist of at least 10 percent of the total required
endurance test.

4.5.12.4 Dry. The dry-endurance test is applicable to all components which

may be operated dry when installed in aircraft. The test is applicable,
whether the operation occurs by design or is inadvertent. If the unit contains
an automatic dry shut-off feature, the dry endurance test shall demonstrate
the operation of this feature. The dry endurance shall consist of at least
5 percent of the total endurance test. The test shall consist of at least
four periods of dry operation between periods of wet operation. The test
chamber temperature shall be the high ambient temperature of the component
class.

4.5.12.5 Room temperature. The room temperature endurance test shall consist
of the remaining portion of the unassigned endurance hours or cycles after the
other phases have been assigned their share. The room temperature endurance
test may normally be conducted first.

4.5.12.6 Combining of tests. Half of the high temperature and low tempera-
ture endurance runs may be combined with the altitude test; especially when
the combinations simulate a realistic operating environment.

4.5.13 Contaminated fuel test. This test is applicable to all components

required to perform the endurance test as specified in 4.5.12.

4.5.13.1 Contaminated test fluid. The test fluid shall contain the types
and concentration of the contaminant mixture as specified in.table V. The
fluid circuit shall insure that the contaminants remain in suspension in the
fluid and enter the component under test. The contaminant shall normally not
be recirculated.

4.5.13.2 Test method. The component shall be subjected to rated flow and
pressure for 2-1/2 hours or 500 cycles and to 10 to 25 percent rated flow
for 2-1/2 hours or 500 cycles. The operation of the component during this
time shall be in accordance with the specification. For components with no
moving parts, the above test shall be sufficient. For components with opera-
ting parts, the above test shall be repeated once. If fuel flows in both
directions when installed in a system, then the test shall be conducted with
flow in both directions.

4.5.13.3 Tests following contaminated fuel endurance. Following the above

tests, the component may be flushed with fuel to loosen contaminant, but it
may not be disassembled for cleaning. The component shall satisfy a func-
tional and leakage test in accordance with the item specification.

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TABLE V. Contaminant mixture.

4.5.14 Corrosion resistance. The corrosion resistance tests shall consist

of both accelerated corrosion and salt fog, unless otherwise specified. There
shall be no evidence of corrosion beyond superficial. These tests may be
abbreviated or deleted when it can be demonstrated that all materials indi-
vidually and in contact in the assembly, are not subject to any manner of
corrosive deterioration, whether chemical, electrolytic or stress accelerated.
Following each test, leakage and calibration tests shall be conducted. There
shall not be any excessive leakage or deterioration nor any malfunction due
to the tests.

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4.5.14.1 Accelerated corrosion. The component (except for open electrical

connectors) with all fuel ports open, shall be submerged and, if practical,
operated manually or otherwise for 3 cycles in a saturated salt solution.
The unit shall then be drained for 30 seconds and operated as necessary to
remove trapped salt solution. The component shall be placed immediately in
a test chamber maintained at a temperature of 30° t 2°C with a relative humid-
ity of 100 percent for a period of 20 minutes. Upon completion of the
humidity exposure period, the unit shall be placed in an air oven maintained
at a temperature of 55° to 60°C for a period of 20 minutes. The component
shall not be operated again until a total of 50 immersions, high humidity,
and drying cycles have been completed. Immediately after completion, the
component shall be washed with warm water, dried, wetted with fuel, and
actuated as in normal service.

4.5.14.2 Salt fog. The component shall be subjected to salt fog in accord-
ance with MIL-STD-810, Method 509.1. At the end of the test period, the
component shall be washed with warm water to remove the deposits, dried,
wetted with fuel, and actuated as in normal service.

4.5.15 Strength. The following strength tests shall be conducted for first
article and sampling inspections in accordance with the item specification.
Following each test, leakage and calibration tests shall be conducted.

4.5.15.1 Mechanical shock. The component shall be subjected to a crash

safety test in accordance with the requirements of the shock tests of
MIL-STD-810, Method 516.2. The mounting shall simulate the aircraft instal-
lation with tubing and electrical wiring. Fluid cavities may be filled with
water, and pressure may be applied, if required. The component shall demon-
strate as specified in 3.6.3.2 and the item specification.

4.5.15.2 Mechanical load. With the component mounted in the normal manner,
it shall be subjected to the most severe tension, compression, bending, or
torsional loads that would be expected to occur in service to demonstrate
as specified in 3.6.3.1 and with the item specification. There shall be no
evidence of failure, permanent distortion, excessive leakage or deterioration
in performance.

4.5.15.3 Overspeed. Overspeed tests shall be conducted to demonstrate as

specified in item specification requirements and 3.6.17.

4.5.16 Electrical. The following tests are applicable to components incor-

porating electrical equipment.

4.5.16.1 Electrical actuators. Tests shall be conducted to demonstrate in

accordance with MIL-S-4040 and MIL-M-7969 as applicable.

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4.5.16.2 Electrical insulation tests

4.5.16.2.1 Dielectric withstanding voltage. A test shall be conducted in

accordance with MIL-STD-202, Method 301, and table VI. There shall be no dis-
ruptive discharge, flashover, or breakdown. Leakage current shall not exceed
the requirements as specified in 3.6.5.6.

TABLE VI. Dielectric test voltages (AC).

* If not specified, use 20 mm Hg pressure.

4.5.16.2.2 Insulation resistance. The insulation resistance test shall be

conducted in accordance with MIL-STD-202. For equipment operating
at less than 250 volts rms, the test potential shall be 500 volts. For equip-
ment operating at voltages between 250 and 500 volts rms, the test potential
shall be 1,000 volts. The insulation resistance shall not be less than as
specified in 3.6.5.6.

4.5.16.3 Explosion proof. The test shall be conducted in accordance with

MIL-STD-810, Method 511.1, Procedure II or IV, as applicable, and with the
following modifications:

a. The fuel to be used shall be the principal fuel to be used in service.

If a different fuel is used, additional tests shall be conducted to demon-
strate that the explosive vapor possesses the same rate of pressure rise
and peak pressure as the fuel to be used in service.

b. The chamber temperature shall be the high vapor temperature (Ta) of

table I unless it can be shown that a lower temperature provides equivalent
results.

c. The electrical equipment shall be operated for sufficient time for the
temperature of the equipment to stabilize and demonstrate that no external
hot spot exists to cause a fire or explosion.

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4.5.16.4 Electromagnetic compatibility. The electrical equipment shall be

tested in accordance with MIL-STD-462 for Class A1 equipment. The minimum
test shall be in accordance with method CE03. Additional tests shall be
in accordance with the item specification.

4.5.16.5 Thermal protectors. Tests shall be conducted to demonstrate

that the thermal protectors are capable of repeated cycles of heating and
cooling without causing deterioration in their capability to operate in
accordance with specification requirements.

4.5.17 Water. Tests shall be accomplished to demonstrate as specified in

3.7.6 through 3.7.6.2 and tests as specified in 4.5. 17.1 through 4.5.17.3,
as applicable, in accordance with the item specification. The test require-
ments for components using bleed air or subject to externally applied water
shall be in accordance with the item specification.

4.5.17.1 Fuel-water mixture. The fuel for this test shall be without anti-
icing additives and may contain up to 30 percent aromatics. While maintain-
ing the fuel at 30° to 40°C temperature, pump a fine spray of water into
the fuel (approximately 0.26 ml water per liter of fuel) while continuously
agitating the mixture. The atmosphere above the fuel shall be above 60 per-
cent relative humidity at the same temperature as the fuel in order to
minimize loss of water by evaporation. The entire quantity of the mixture
should be circulated through an agitating pumping system at least four times
for 2 hours. Three samples from different locations in the bulk of the mix-
ture shall be analyzed and shall indicate an average of at least 90 ppm up
to supersaturated level.

4.5.17.2 Above freezing test. The unit shall be functionally operated

using the above fuel mixture. The duration in time shall be 2 hours or
100 cycles of operation. There shall be no indication of incorrect opera-
tion, disruptive electric discharge or other failure. If the item speci-
fication does not require an icing test, this test may be accomplished
using plain water.

4.5.17.3 Icing test. While agitating or circulating the above fuel-water

mixture, begin atomizing water above the surface of the fuel at a rate of
approximately 100 ml per minute per square meter of fuel mixture surface.
Continue atomizing to insure at least 0.25 ml of water per liter of fuel.
During this time, circulate the fuel-water mixture through the component
while cooling the mixture to the test temperature. To avoid complete freeze-
up of the heat exchanger, the difference in the temperatures of the refri-
gerant and the fuel-water mixture should not exceed 6°C at the test tempera-
ture. Immediately upon reaching the test temperature, begin the test run.
The component shall be functionally operated for a length of time and number
of cycles in accordance with the item specification. The test temperatures

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MIL-F-8615D

shall be -2”C, -10”C, and -20”C (+1°C, -4°C). Upon completion of each run,
the fuel-water mixture shall contain not less than 0.12 ml of water per liter
of fuel above the quantity required to saturate the fuel.

4.5.18 Environmental. The following environmental inspections and tests,

as applicable, shall be conducted in accordance with the item specification.
There shall be no degradation in performance except as permitted in the
specification.

4.5.18.1 Humidity. This test applies to all components containing electri-

cal equipment and shall be conducted in accordance with MIL-STD-810, Method
507.1, Procedure II or III. Component operation during the test shall be
in accordance with the item specification. Within 2 hours of the completion
of the last cycle, a calibration shall be conducted in fuel at -S7° t4°C.

4.5.18.2 Fungus resistance. This test applies to all components containing

any material that can be a nutrient or be damaged by fungi. The test shall
be performed in accordance with MIL-STD-810, Method 508.1, except that sub-
stitution of a specified fungus may be made, if authorized by the procuring
agency.

4.5.18.3 Dust. This test applies to all components installed in vent systems
or external to fuel tanks. The test shall be performed in accordance with
MIL-STD-810, Method 510.1.

4.5.18.4 Vibration. This test is applicable to all fuel system components

and shall be accomplished in accordance with MIL-STD-810, Method 514.2 and
the item specification. Components containing electrical switches shall
be monitored for contact bounce and contact resistance variations.

4.5.18.5 Acoustical noise. The acoustical noise test is applicable to all

components located near a jet engine exhaust and other high noise level
areas. It shall be conducted in accordance with MIL-STD-810, Method 515.2.

4.5.18.6 Thermal shock. The thermal shock test shall be performed in

accordance with MIL-STD-810, Method 516.2.

4.5.19 Bonding and lightning protection. Tests shall be conducted to demon-

strate as specified in 3.6.4.

4.5.20 Disassembly and inspection. Following completion of all tests,

including repetition of inspections 2, 3, 4, and 5 of table III, each com-
ponent submitted to test shall be disassembled for inspection. There shall
be no evidence of any problem that will affect safety, performance, or cause
premature wearout. Photographs shall be taken of all parts and of any cri-
tical area discussed in the test report, as needed.

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4.6 Safety analysis report. The safety analysis and proof-of-safety test
report shall be prepared as required by the specification, and the procure-
ment documents.

4.7 Reliability and maintainability. The reliability and maintainability

demonstration plans shall be delivered as required by the procurement
document.

s. PACKAGING

5.1 Preservation and packaging. Unless otherwise specified in the item

specification, preservation, packaging, and packing shall be in accordance
with MIL-STD-794 (see 6.2).

5.2 Marking for shipment. In addition to any special marking required by

the contract or order, marking of individual packages and shipping containers
shall be in accordance with MIL-STD-129. .

6. NOTES

6.1 Intended use. Components covered by this specification are intended

for use in fuel and fuel vapor systems.
6.2 Ordering data. Procurement documents should specify:

a. Title, number and date of item specification, and of specification control

drawing (3.1).

b. instructions concerning delivery of test reports and the test articles

to the procuring agency or the responsible engineering office (4.3).

c. Preparation for delivery instructions (5.1 and 5.2).

d. Instructions concerning delivery of sampling test data (4.4.2).

e. Instructions concerning delivery of reliability and maintainability

demonstration plans (4.7).

6.3 International standardization agreement. Certain provisions of this

specification regarding fuel pressures (3.6.1) and fuel compatibility (3.5)
are the subject of international standardization agreement ASCCAS 11/3B
and STANAG 3105. When amendment, revision, or cancellation of this speci-
fication is proposed which will affect or violate the international] agreement ,
concerned, the preparing activity will take appropriate reconciliation action
through international standardization channels, including departmental stand-
ardization offices, if required.

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6.4 Metric units. The metric units are in accordance with the ASTM Metric
Practice Guide E-380-74.

6.5 Identification of changes. Asterisks are not used in this revision

to identify changes with respect to the previous issue, due to the exten-
siveness of the changes.

Custodians: Preparing activity:

Army - AV Air Force - 11
Navy - AS
Air Force - 11 Project No. 2915-0082

Reviewer activity:
Army - AV
Navy - AS
Air Force - 11, 82

User activity.
Air Force - 79

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