Repair of Hydraulic Tubes with PERMASWAGE Unions

TASK 20-23-11-300-001-A
Repair of Hydraulic Tubes with PERMASWAGE Unions

1. Reason for the Job
This is an approved repair procedure for hydraulic tubes.

NOTE: This repair procedure is applicable to:

Titanium-alloy (Ti-3Al-2.5V) tubes ref. ABS5004, sizes -04 to -16
Corrosion-resistant steel (21-6-9) tubes ref. ASNA3288, sizes -04 to -24
Aluminum-alloy (6061-T6) tubes ref. ASNA3410 and DAN40, sizes -04 to -16 and -24.

NOTE: For hydraulic tubes installed in the fuel tanks, in the pylon box structure (between RIB 5 and RIB 10) and in the pressurized area, only permanent fittings repair solution is permitted.

NOTE: This repair procedure is not applicable to:

Hydraulic tubes of the engines
Coiled tubes
Hydraulic tubes installed on the landing gear legs.

2. Job Set-up Information
A. Fixtures, Tools, Test and Support Equipment

REFERENCE	QTY	DESIGNATION
No specific	1	CLOTH-EMERY (GRADE 240)
No specific	AR	PAD - ABRASIVE
DLTFRPSKT3028A	1	REPAIR KIT FIELD - SIZE 04 TO 24

B. Consumable Materials

REFERENCE	DESIGNATION
(Material No.04CMA2)	Wash Primer_- - Structure
(Material No.04EAC2)	Primer Polyurethane Paint_- Corrosion Inhibiting Structure
(Material No.08BAA9)	Non Aqueous Cleaner-General - -
(Material No.10ABC1)	Surface Pretreatment-Light Alloys Chemical Conversion Yellow -

C. Referenced Information

REFERENCE	DESIGNATION
TASK 12-12-29-611-001-A	Fill the Hydraulic Fluid Reservoir with a Hand Pump
TASK 12-12-29-611-002-A	Fill the Hydraulic Fluid Reservoir with a Hydraulic Service Cart
TASK 20-23-11-200-001-A	Permitted Damage and Defects on Hydraulic Tubing
TASK 20-23-11-917-003-A	Cutting and Deburring of Hydraulic Tubes
TASK 29-00-00-870-001-A	Bleeding Procedure of the Green Hydraulic System Upstream of the Engine Pump
TASK 29-00-00-870-002-A	Bleeding Procedure of the Green Hydraulic System Upstream of the PTU
TASK 29-00-00-870-003-A	Bleeding Procedure of the Green Hydraulic System Downstream of the Engine Pump
TASK 29-00-00-870-004-A	Bleeding Procedure of the Yellow Hydraulic System Upstream of the Engine Pump
TASK 29-00-00-870-005-A	Bleeding Procedure of the Yellow Hydraulic System Upstream of the PTU
TASK 29-00-00-870-006-A	Bleeding Procedure of the Yellow Hydraulic System Upstream of the Yellow E-Pump
TASK 29-00-00-870-007-A	Bleeding Procedure of the Yellow Hydraulic System Downstream of the Engine Pump
TASK 29-00-00-870-008-A	Bleeding Procedure of the Blue Hydraulic System Upstream of the Blue E-Pump
TASK 29-00-00-870-009-A	Bleeding Procedure of the Blue Hydraulic System Downstream of the Blue E-Pump
TASK 29-10-00-863-001-A	Pressurize the Green Hydraulic System with a Hydraulic Ground Power-Cart
TASK 29-10-00-863-002-A	Pressurize the Yellow Hydraulic System with a Hydraulic Ground Power-Cart
TASK 29-10-00-863-003-A	Pressurize the Blue Hydraulic System with a Hydraulic Ground Power-Cart
TASK 29-10-00-863-003-A-01	Pressurize the Blue Hydraulic System with the Blue Electric Pump
TASK 29-14-00-614-002-A	Pressurization of the Hydraulic Reservoirs through the Ground Connector
TASK 29-14-00-614-002-A-01	Pressurization of the Hydraulic Reservoirs with the Auxiliary Power Unit (APU)
TASK 29-23-00-863-001-A	Pressurize the Green Hydraulic System from the Yellow Hydraulic System through the PTU with the Electric Pump
TASK 29-23-00-863-002-A	Pressurize the Yellow Hydraulic System from the Green Hydraulic System through the PTU with the Ground Service Cart
TASK 32-42-00-870-001-A	Bleeding of the Normal Braking at the Brake Units
TASK 32-43-00-612-001-A	Filling and Bleeding of the Low Pressure Control System of the Alternate Braking
TASK 32-43-00-612-001-A-01	Filling and Bleeding of the Low Pressure Control System of the Alternate Braking using Green Reservoir fluid
TASK 32-43-00-870-002-A	Bleeding of the High Pressure Alternate Braking System
PERMASWAGE - Swaging Principle
PERMASWAGE Installation Tooling
PERMASWAGE Repair Kit Series DLT
PERMASWAGE Repair Kit Series D12000
Union Assemblies
Material Code Table
Tubing Repairs
Tube Marking Operation
Tube Marking Operation
Fitting Installation
Swage Tools
Swaging Tool Installation (Series DLT)
Swaging Tool Installation (series D12000)
Inspection Gage
Swaged Fitting Installation

3. Job Set-up
Subtask 20-23-11-917-055-A

A. General

PERMASWAGE - Swaging Principle

Use this approved repair procedure to repair hydraulic tubes made of 21.6.9 corrosion-resistant steel, 6061-T6 aluminum alloy or Ti 3AL 2.5V titanium alloy.

Use aluminum union assemblies to repair light alloy tubes (ASNA3410) or (DAN40).
Use stainless-steel union assemblies to repair corrosion-resistant steel tubes (ASNA3288) and titanium tubes (ABS5004).

NOTE: You can use the PERMASWAGE repair procedure to repair tubes installed with HARRISON fittings.

There are two types of PERMASWAGE fittings:

Permanent,
Separable (that you can remove).
The table below gives the standards for the swaged fittings that are available.

PERMANENT FITTINGS	SEPARABLE FITTINGS	SLEEVE AND NUT
ABS0335	ABS0138 ASNA3750	ASNA3758
ABS0451	ABS0272 ASNA3757	ASNA3771
ABS0452	ABS0450 ASNA3765	ASNA3773
ABS0477	ABS0453 ASNA3767	ASNA3774
ABS0478	ABS0464 ASNA3768	NSA855022
ABS0566	ABS0527 NSA855011	NSA855023
ABS0567	ABS0534 NSA855016	NSA855024
ABS0568	ABS0535 NSA855019	NSA855027
ASNA3752	ABS0542 NSA855020	NSA855031
ASNA3753	ABS0544 NSA855025	NSA855036
ASNA3756	ABS0545 NSA855026
ASNA3764	ABS0564 NSA855028
ASNA3766	ABS0565 NSA855029
ASNA3772	ABS0650 NSA855030
NSA855006 up	ABS0658 NSA855032
to NSA855009	ABS0669 NSA855033
NSA855014	ABS0675 NSA855035
NSA855015	ABS0711 NSA855037
	NSA855039

You can swage PERMASWAGE fittings on the aircraft.

NOTE: The separable fittings have a MS33514 or MS33515 threaded end or a sleeve with a nut.

To repair the tubing with the PERMASWAGE system, you must:

Cut the tube,
Deburr the tube,
Make the marks for tube insertion,
Put the swaging tool into position,
Swage the tube,
Do a check of the tube joint.

You must use the applicable PERMASWAGE DLTFRPSKT3028A REPAIR KIT FIELD - SIZE 04 TO 24, DLT series or D12000 series tools (vendor code F6087) (D12000 series is the previous generation).

PERMASWAGE Installation Tooling

PERMASWAGE Repair Kit Series DLT

PERMASWAGE Repair Kit Series D12000

4. Procedure
Subtask 20-23-11-917-106-A

A. Selection of PERMASWAGE Tooling and Unions
(1) Get the DLTFRPSKT3028A REPAIR KIT FIELD - SIZE 04 TO 24, DLT series or D12000 series).

PERMASWAGE Installation Tooling

PERMASWAGE Repair Kit Series DLT

PERMASWAGE Repair Kit Series D12000

This kit includes:

Head assemblies
Power units
Cutting tools
Deburring tools
Inspection gages
Marking Tools
A manual pump assembly.

NOTE: You can use the TOOL, MARKING (TPE016) as an alternative to the DLT marking tools that are included in the DLTFRPSKT3028A REPAIR KIT FIELD - SIZE 04 TO 24.

NOTE: You can use the PUMP-PERMASWAGE AIR DRIVEN (DLT02MAPP1000) as an alternative to the manual pump assembly that is included in the DLTFRPSKT3028A REPAIR KIT FIELD - SIZE 04 TO 24.

(2) Get the correct union assemblies:

Union Assemblies

Material Code Table

Use aluminum union assemblies to repair light alloy tubes (ASNA3410) or (DAN40).
Use stainless-steel union assemblies to repair corrosion-resistant steel tubes (ASNA3288) and titanium tubes (ABS5004).

Subtask 20-23-11-917-107-A

B. Selection of the Repair Procedure

Tubing Repairs

(1) Measure the length L of the defect on the damaged tube.
(a) Use the single-union repair procedure if:

The length L of the defect is less than the maximum value (L MAX.).

(b) Use the two-union repair procedure if:

The length L of the defect is more than the maximum value (L MAX).
The defect is in a bend.
The defect is less than the minimum distance (N MIN.) from the end of a bend.

(2) Single-union repair procedure
(a) Remove (cut out) the damaged part of the tube or cut the tube through the defect.
(b) Use a PERMASWAGE union to connect the two parts of the tube.
(3) Two-union repair procedure
(a) Remove (cut out) the damaged part of the tube.
You must remove a minimum length (M MIN.) of tube.
(b) Replace the removed part of the tube with:

An equal or smaller (but almost the same) length of equivalent tube.
Two PERMASWAGE unions.

Subtask 20-23-11-917-051-A

C. Tube Cutting and Deburring
(1) For the single-union repair procedure
(a) Cut the damaged part of the tube with the applicable cutting tool (included in the DLTFRPSKT3028A REPAIR KIT FIELD - SIZE 04 TO 24).
There are two procedures to cut the tube for a single-union repair.

Remove (cut out) the damaged part of the tube.
Cut through the center of the defect: (Ref. AMM TASK 20-23-11-917-003)
Make sure that the tube ends have no burrs (inner and outer side).
Deburr if necessary.

NOTE: This is not the best procedure because the defect can cause damage to the sealing surface of the union.
If you use this procedure, you must be careful:

To cut the tube in the center of the defect
To put the union in the center between the installation marks.

(2) For the two-union repair procedure
(a) You must remove a minimum length (M MIN.) of tube to do this procedure correctly: (Ref. AMM TASK 20-23-11-917-003).

Make sure that the tube ends have no burrs (inner and outer side).
Deburr if necessary.

Subtask 20-23-11-917-053-A

D. Paint Removal (if applicable)

NOTE: You can do the installation on parts that are treated with Alodine. You must not do the installation on parts that are painted.

(1) Remove the paint, with CLOTH-EMERY (GRADE 240), on a sufficient length so that you swage the union on a bare area. Make sure that you do not make scratches on the tubes when you remove the paint.
(2) Make sure that all the tube ends are in the correct condition and agree with the tube dimension specifications (Ref. AMM TASK 20-23-11-200-001).
(3) Clean all the tube ends with Non Aqueous Cleaner-General - - (Material No.08BAA9) .

Subtask 20-23-11-917-054-A

E. Mark the Tube Insertion
(1) Make the marks for tube insertion.

NOTE: These marks give an indication of the depth of the tube in the fitting before and after swaging.

(2) Use a marking tool with the correct dimensions for the tube that you must swage:
DLT5302-013-01, tubes from 1/4" thru 3/8"
DLT5302-031-01, tubes from 1/2" thru 3/4"
DLT5302-040-01, tubes from 1" thru 1-1/2"
(3) Put the marking tool in position on the tube. The lip of the marking tool must be against the end of the tube. Make a mark on the tube with the marking pen D10058.

Tube Marking Operation

(4) You can make the marks on the tube without the special tool. But you must keep to the specified high and low limits for the insertion of the end of the tube.

Tube Marking Operation

Subtask 20-23-11-917-052-A

F. Swage the Fitting on the Tube
(1) Install the fitting on the tube. The end of the fitting must be in the area of the mark.

Fitting Installation

(2) Make sure that you do not cause damage to the seals in the fitting when you install it.
(3) Use a swage tool assembly and power unit which are correct for the dimensions of the tube.

Swage Tools

CAUTION: MAKE SURE THAT ONLY APPROVED PERSONNEL USE THIS TOOL. THIS TOOL OPERATES AT VERY HIGH PRESSURE AND CAN BE DANGEROUS.

(4) Swage with the tool series DLT.

Swaging Tool Installation (Series DLT)

NOTE: If you swage with the tool series D12000, refer to the farther step.

(a) Push the die block assembly out of the head assembly.
(b) Make sure that the upper and lower dies have the same serial number.
(c) Put the lower die block on the top of the power unit.
(d) Connect the power unit to the hydraulic pump.
(e) Put the head assembly on the fitting and the hydraulic tube. Make sure that the bevelled end of the die is towards the center of the fitting.
(f) Put the knurled surface of the power unit and of the head assembly on the same side and engage the power unit on the head assembly.
Make sure that the balls in the lower die block engage with a "click" on the head assembly.
(g) Move the power unit toward the center of the fitting until the stop plate touches the fitting.
(h) Make sure that the end of the fitting is on the reference mark.

Fitting Installation

(i) Apply a hydraulic pressure of 690 +17 bar or -17 bar (10007.6013 +246.5641 psi or -246.5641 psi) to the power unit in order to swage the fitting.
(j) Release the pressure.
(k) Remove the power unit and the head assembly.

CAUTION: MAKE SURE THAT ONLY APPROVED PERSONNEL USE THIS TOOL. THIS TOOL OPERATES AT VERY HIGH PRESSURE AND CAN BE DANGEROUS.

(5) Swage with the tool series D12000

Swaging Tool Installation (series D12000)

(a) Make sure that you install the dies correctly in the yoke and in the die holder assembly. You must install the tapered end of the dies on the black side of the yoke and die holder assembly.
(b) Move the yoke into position on top of the fitting:

The silver side of the yoke assembly must be nearest to the end of the fitting that you must swage,
The silver side of the yoke must be aligned with the end of the fitting.
Push the die holder into the yoke assembly:
The silver faces of the die holder assembly and the yoke must be on the same side,
The silver sides of the yoke and the die holder must be aligned with the end of the fitting.

Install the square connector of the power unit in the swage head assembly,
Tighten the knurled nut of the power unit with your hand,
Connect the hose and coupling half-assembly of the hydraulic power supply (D12025-001) to the nipple valve of the power unit.

Make sure that:

The end of the fitting is above the area of the insertion mark on the tube,
Fitting Installation
You can see a piece of the mark,
The silver sides of the yoke and the die holder are aligned with the end of the fitting.
Carefully move the tool back until the end stops are approximately 0.8 mm (0.0315 in.) from the end of the fitting.

(d) Make sure that the pressure relief valve of the swaging tool is set to open at 380 +17 -17 bar (5500 +250 -250 psi).
Do not pressurize too high or too low.
Operate the swaging tool with a hydraulic handpump or a hydraulic power source (push the remote air ON button). Keep the swaging tool in this position while you apply a hydraulic pressure of 380 +17 -17 bar (5500 +250 -250 psi).
Remove the swaging tool from the fitting:

Release the pressure,

NOTE: If you do not release the pressure, the dies stay closed and you cannot remove them.

Loosen the knurled nut and remove the power unit,
Remove the die holder and yoke assembly.

Subtask 20-23-11-917-050-A

G. Check of the Tube Joint
(1) You must reject the joint if the tube:

Goes too far into the fitting,
Does not go sufficiently far into the fitting.

(2) Look at the joint:

Make sure that you can see a piece of the insertion mark.

(3) Do an inspection of the joint with the applicable inspection gage.

Inspection Gage

Swaged Fitting Installation

The inspection gage must:

Contain all the segments around the diameter of the fitting,
Touch the end of the fitting with its shoulder.
If the swaging is not correct, it is possible to swage the joint again, but not always.

INDICATION	POSSIBLE PROBLEM	CORRECTIVE ACTION
The fitting does not swage correctly.	The swaging pressure is out of tolerances: FOR TOOLS SERIES DLT: - 10000 +250 -250 psi FOR TOOL SERIES D12000: - 5500 +250 -250 psi	Make sure that the hydraulic power supply and connections to the tool are correct.
	The swaging head is too large.	Use the correct swaging head.
The gage does not go on top of the external diameter of the swaged fitting.	The swaging pressure is not correct.	Do the swage again.
	The gage is on top of the flash marks. The dies and the walls of the yoke and the die holder must be clean.	Turn the gage away from the flash marks. Carefully remove the dies from the head and clean the dies and all parts of the head assembly.
The shoulder of the gage does not touch the end of the fitting.	You did not push the fitting sufficiently far into the swaging head.	Do the swage again.
You cannot see the insertion mark or you can see all the mark.	The insertion mark on the tube was not aligned with the end of the fitting du- ring swaging.	Cut out the fitting.

NOTE: For any other malfunctions, contact your PERMASWAGE S.A. supplier.

Subtask 20-23-11-860-065-A

H. Put the Aircraft back to its Initial Configuration
(1) Pressurize the hydraulic reservoirs (Ref. AMM TASK 29-14-00-614-002).
(2) If necessary, fill the hydraulic reservoirs:

With a hand pump (Ref. AMM TASK 12-12-29-611-001) or
With a hydraulic cart (Ref. AMM TASK 12-12-29-611-002).

(3) Pressurize the hydraulic systems for 15 minutes:

For the Green system (Ref. AMM TASK 29-10-00-863-001) or (Ref. AMM TASK 29-23-00-863-001)
For the Yellow system (Ref. AMM TASK 29-10-00-863-002) or (Ref. AMM TASK 29-23-00-863-002)
For the Blue system (Ref. AMM TASK 29-10-00-863-003).

(4) Make sure that there is no leakage in the repaired area.
(5) Bleed the related hydraulic system:
(a) For the Green system:

Upstream of the engine pump (Ref. AMM TASK 29-00-00-870-001)
Upstream of the Power Transfer Unit (PTU) (Ref. AMM TASK 29-00-00-870-002)
Downstream of the engine pump (Ref. AMM TASK 29-00-00-870-003).

(b) For the Yellow system:

Upstream of the engine pump (Ref. AMM TASK 29-00-00-870-004)
Upstream of the PTU (Ref. AMM TASK 29-00-00-870-005)
Upstream of the Yellow E-pump (Ref. AMM TASK 29-00-00-870-006)
Downstream of the engine pump (Ref. AMM TASK 29-00-00-870-007).

Upstream of the Blue E-pump (Ref. AMM TASK 29-00-00-870-008)
Downstream of the Blue E-pump (Ref. AMM TASK 29-00-00-870-009).

(d) For the normal braking system (Ref. AMM TASK 32-42-00-870-001).
(e) For the alternate braking system:

Low pressure (if installed) (Ref. AMM TASK 32-43-00-612-001)
High pressure (Ref. AMM TASK 32-43-00-870-002).

(6) Make sure that the work area is clean and clear of tools and other items.

Subtask 20-23-11-917-077-A

I. Apply the Protection on the Repaired Tubes (if applicable)
(1) After the applicable leak test and bleeding procedure, apply the protection on the repaired tubes (if applicable).
(a) For aluminum tubes:

Apply Surface Pretreatment-Light Alloys Chemical Conversion Yellow - (Material No.10ABC1) on the bare metal area of the tube with a brush.
Complete the protection with Primer Polyurethane Paint_- Corrosion Inhibiting Structure (Material No.04EAC2) .

(b) For CRES tubes (if painted):

Rub the bare metal area with PAD - ABRASIVE.
Apply Wash Primer_- - Structure (Material No.04CMA2) on the bare metal area of the tube.
Complete the protection with Primer Polyurethane Paint_- Corrosion Inhibiting Structure (Material No.04EAC2) .

[Rev.10 from 2021] 2026.04.01 04:47:11 UTC