Repair of Hydraulic Tubes with HARRISON Elastomerically-Swaged Fittings

TASK 20-23-11-300-002-A
Repair of Hydraulic Tubes with HARRISON Elastomerically-Swaged Fittings

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

NOTE: This procedure is applicable to:

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: This repair procedure is not applicable to:

Hydraulic tubes in the engine area
Hydraulic tubes in the pylon box structure
Hydraulic tubes in the fuel tanks
Coiled tubes
Hydraulic tubes installed on the landing gear legs.

NOTE: It is not permitted to use separable fittings in pressurized areas.

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

REFERENCE	QTY	DESIGNATION
No specific	1	BRUSH - BRISTLED
No specific	1	CAP - BLANKING
No specific	1	CLOTH-EMERY (GRADE 400)
No specific	AR	WARNING NOTICE(S)
No specific	Torque wrench: range to between 3.15 and 2.85 m.daN (23.23 and 21.02 lbf.ft )

B. Consumable Materials

REFERENCE	DESIGNATION
(Material No.03FAB1)	Mineral Oil base Grease-- Vaseline or Petrolatum -
(Material No.04EAC2)	Primer Polyurethane Paint_- Corrosion Inhibiting Structure
(Material No.05ABM1)	Retaining adhesive-Cylindrical fitting High strength High viscosity -
(Material No.05XAB1)	Adhesive Activator-- Anaerobic -
(Material No.08BAA9)	Non Aqueous Cleaner-General - -
(Material No.10ABC1)	Surface Pretreatment-Light Alloys Chemical Conversion Yellow -
(Material No.14SBA1)	Textile-Lint free Cotton -

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 20-21-12-911-001-A	Tightening Torques for Pipe Unions (not for OXYGEN Unions)
TASK 20-23-11-200-001-A	Permitted Damage and Defects on Hydraulic Tubing
TASK 20-23-11-911-001-A	Installation of the Hydraulic Tubes
TASK 20-23-11-917-003-A	Cutting and Deburring of Hydraulic Tubes
TASK 29-00-00-864-001-A	Put the Related Hydraulic System in the Depressurized Configuration before Maintenance Action
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 29-00-00-910-002-A	Safety Procedures of the Hydraulic System
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
Minimum Length of Straight Tube for Swaging
Repair Set-Up
Internal Swaging Tooling
Tool Assembly for Sleeve
Tool Assembly for Union
Part Numbers of the Internal Tooling - Unions
Part Numbers of the Internal Tooling - Sleeves
Part Numbers of the External Swaging Tools
Sleeves and Unions
Tube End Dimension
Swaging Pressure for NSA855010
Swaging Pressure for NSA855034
Inspection of the Swaged Union for NSA855010
Inspection of the Swaged Sleeve for NSA855034

3. Job Set-up
Subtask 20-23-11-941-057-A

A. Safety Precautions
(1) You must obey the hydraulic safety procedures when you do work on the hydraulic system (Ref. AMM TASK 29-00-00-910-002).
(2) Put a WARNING NOTICE(S) in position in the cockpit to tell persons not to operate the hydraulic systems.

Subtask 20-23-11-860-068-A

B. Aircraft Maintenance Configuration
(1) Make sure that the hydraulic systems are depressurized and put them in the maintenance configuration
(Ref. AMM TASK 29-00-00-864-001).

4. Procedure
Subtask 20-23-11-917-061-A

A. Selection of the Repair Procedure
(1) Remove the damaged tube from the aircraft.
(2) Make sure that the length of straight tube after a bend is the minimum necessary for the swaging operation.

Minimum Length of Straight Tube for Swaging

(3) Measure the length of the defect.

Repair Set-Up

(a) Use the single-assembly repair procedure if the length of the defect is less than F.
(b) Use an assembly with one AS21902 union and two sleeves if:

The length of the defect is more than F
The defect is in a bend
The defect is at a distance of less than the minimum values from the end of the bend.

(4) Repair procedures without AS21902 union.
(a) Single-assembly repair procedure
1 Remove (cut out) the damaged part of the tube.
You must remove a length F of tube.
2 Replace the removed part of the tube with:

An NSA855010 union
An NSA855034 sleeve
An MS21921 or AS21921 or ASNA3769 nut.

(5) Repair procedures with AS21902 union.
(a) Assembly with the repair procedure with one AS21902 union and two sleeves.
1 Remove (cut out) the damaged part of the tube.
2 Replace the removed part of the tube with:

An AS21902 union
Two NSA855034 sleeves
Two MS21921 or AS21921 or ASNA3769 nuts.

Subtask 20-23-11-917-060-A

B. Selection of Tooling, Unions and Sleeves
(1) Get the applicable tools.

Internal Swaging Tooling

Tool Assembly for Sleeve

Tool Assembly for Union

NOTE: This repair procedure uses a tube-expansion swaging procedure with an elastomeric expander.

(a) Get the applicable tool head:

For tube sizes -04 to -08, use small tool head (5175)
For tube sizes -10 to -24, use large tool head (5720).

(b) Get the applicable components (drawbolt, expander, split ring, bushing, anti-extrusion ring and back-up ring) of the internal tool for unions.

Part Numbers of the Internal Tooling - Unions

(c) Get the applicable components (drawbolt, expander, split ring, bushing, anti-extrusion ring and back-up ring) of the internal tool for sleeves.

Part Numbers of the Internal Tooling - Sleeves

(d) Get the applicable components (jaws, anvil, retainer and adapter) of the external tool.

Part Numbers of the External Swaging Tools

(2) Get the applicable union, sleeve and nut.

Sleeves and Unions

(a) Table of applicable coupling standard codes
Get coupling parts that have the correct standard (finish/material) for the tube you will repair:

Coupling Standard	CRES TUBE ASNA3288	Aluminum Tube ABS5144 or ASNA3410 or DAN40
Sleeve NSA855034	P	-
Union NSA855010	PP or PN	GV
Union MS21902 or AS21902	J or K	W
Union ABS1369	Not applicable	GVC
Nut MS21921 or AS21921	J or K	W
Nut ASNA3769	V	W

Subtask 20-23-11-917-058-A

C. Tube Cutting and Deburring
(1) Cut the damaged part of the tube: (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 20-23-11-917-057-A

D. Preparation for Tubing Repair

Tube End Dimension

(1) Remove the paint at the tube ends.
(a) Remove the paint along a minimum length (J MIN) of tube with a CLOTH-EMERY (GRADE 400).
(b) Make sure that you do not cause scratches on the tube when you remove the paint.

Subtask 20-23-11-917-056-A

E. Preparation of the Swage Tools

Tool Assembly for Sleeve

Tool Assembly for Union

(1) Engage and tighten the adapter in the tool head.
(2) Engage the anvil on the top of the tool head then tighten the attach nut.
(3) Install the internal tool components on the drawbolt:
(a) Make sure that the split ring (or back-up ring) agrees with the tube ID.

NOTE: You must not use a split ring (or back-up ring) with an Outside Diameter (OD) immediately smaller than the tube Inner Diameter (ID). If you do, it will not be easy to remove the tube after the swaging operation.

(b) Install the split ring (or back-up ring), the expander and the bushing (union or sleeve) on the drawbolt.

NOTE: The inner chamfers of the split ring (or back-up ring) must point away from the expander.

NOTE: The shoulder of the sleeve bushing must point to the drawbolt to be against the tube end.

(4) Install the drawbolt on the adapter then tighten it with your hand.
(5) Connect the hose between the pump and the swager of the swage machine.

Subtask 20-23-11-917-095-A

F. Installation of the Sleeve or the Union on the Tube
(1) If applicable, engage the nut on the tube.
(2) Install the union or the sleeve on the tube end:
(a) If bonding is not necessary, engage the union or the sleeve on the tube end.
(b) If bonding of the union or the sleeve on the tube is necessary:

NOTE: If you bond the union or the sleeve on the tube, the time between the installation and the swaging must not be more than 15 minutes.

1 Clean the union or the sleeve with a lint-free cotton cloth Textile-Lint free Cotton - (Material No.14SBA1) made moist with Non Aqueous Cleaner-General - - (Material No.08BAA9) .
2 Put CAP - BLANKING on the tube ends.
3 Apply Adhesive Activator-- Anaerobic - (Material No.05XAB1) or Adhesive Activator-- Anaerobic - (Material No.05XAB1) on the swaging area of the tube and on the inner side of the union or the sleeve.
4 Let it dry:

From 4 to 6 minutes if you used Adhesive Activator-- Anaerobic - (Material No.05XAB1)
For 10 minutes if you used Adhesive Activator-- Anaerobic - (Material No.05XAB1) .

5 Apply Retaining adhesive-Cylindrical fitting High strength High viscosity - (Material No.05ABM1) on the tube end.
6 Install the union or the sleeve on the tube end.
Lightly turn the union or the sleeve when you engage it on the the tube to equally apply Retaining adhesive-Cylindrical fitting High strength High viscosity - (Material No.05ABM1) .
7 Use a lint-free cotton cloth Textile-Lint free Cotton - (Material No.14SBA1) to remove the unwanted material.
8 Remove CAP - BLANKING from the tube ends.

Subtask 20-23-11-917-096-A

G. Swaging of the Union or the Sleeve on the Tube
(1) Apply a thin layer of Mineral Oil base Grease-- Vaseline or Petrolatum - (Material No.03FAB1) on the expander.
(2) Put the tube assembly (with the union or the sleeve) on the drawbolt.
Make sure that the tube assembly is against the anvil.
(3) Install the two jaws on the anvil.
(4) Install the retainer on the jaws.
(5) If you do work on size -10 to size -24 tubes:
(a) Install the retainer bolts on the retainer.
(b) Tighten the retainer bolts with your hand.
Be careful not to cross-thread the retainer bolts.
(c) TORQUE the retainer bolts to between 3.15 and 2.85 m.daN (23.23 and 21.02 lbf.ft )

.
(6) On the pump, tighten the valve installed on the right side of the gage.
(7) Slowly operate the pump until you get the specified value.

Swaging Pressure for NSA855010

Swaging Pressure for NSA855034

(8) On the pump, loosen the valve to release the pressure.
(9) If applicable, loosen and remove the retainer bolts from the retainer.
(10) Remove the retainer and the two jaws from the anvil.
(11) Remove the tube assembly from the drawbolt.
(12) Clean the tube with a lint-free cotton cloth Textile-Lint free Cotton - (Material No.14SBA1) made moist with Non Aqueous Cleaner-General - - (Material No.08BAA9) .

Subtask 20-23-11-917-097-A

H. Inspection of the Swaged Union or Sleeve
(1) Do a check of the tube for damage.
(2) If you find damage, make sure that it is in the limits (Ref. AMM TASK 20-23-11-200-001).
(3) Measure the deformations of the tube after swaging.

Inspection of the Swaged Union for NSA855010

Inspection of the Swaged Sleeve for NSA855034

(a) Tube protrusion out of the sleeve
1 Measure the tube protrusion B out of the sleeve.
2 Make sure that the tube protrusion B is in the limits.
3 If necessary, cut the tube end to decrease the tube protrusion.

NOTE: You must not decrease the tube protrusion to less than 0.5 mm (0.0197 in.).

(b) Deformations of the tube, sleeve and union
1 Measure the diameters D1 and D2 and calculate the wave deformation 2A (with 2A=D1-D2).

NOTE: Measure D1 only at the second groove.

NOTE: To measure D2, you must use the smallest diameter in the reference area.

2 Make sure that the wave deformation 2A is in the limits.
3 Measure the diameter D3.
4 Make sure that the diameter D3 is in the limits.
(4) Reject the assembly if:

The diameter D3 is more than the maximum tolerance
The wave deformation 2A is more than the maximum tolerance
The tube protrusion B is less than the minimum tolerance.

(5) If the wave deformation 2A is less than the minimum tolerance, do step G again.

NOTE: To swage again, you can increase the swaging pressure by 5%.

NOTE: If the sleeve or the union is bonded to the tube, there must be less than 30 minutes between the two swaging operations.

NOTE: You can do the swaging operation again one time.

Subtask 20-23-11-917-098-A

I. Protection of the Tubes
(1) Apply Surface Pretreatment-Light Alloys Chemical Conversion Yellow - (Material No.10ABC1) on the bare metal area with a BRUSH - BRISTLED.
(2) Complete the protection with Primer Polyurethane Paint_- Corrosion Inhibiting Structure (Material No.04EAC2) .

Subtask 20-23-11-917-099-A

J. Pressure Test of the Repaired Tube
(1) Install the repaired tube on the aircraft (Ref. AMM TASK 20-23-11-911-001).
(2) Connect the union and sleeve (Ref. AMM TASK 20-21-12-911-001).
(3) Pressurize the hydraulic reservoirs (Ref. AMM TASK 29-14-00-614-002).
(4) 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).

(5) 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).

(6) Do a check for leaks.
(7) 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).

5. Close-up
Subtask 20-23-11-860-062-A

A. Put the aircraft back to its initial configuration.
(1) Remove the WARNING NOTICE(S).
(2) Make sure that the work area is clean and clear of tools and other items.

[Rev.10 from 2021] 2026.03.31 22:59:30 UTC