W DOC AIRBUS | AMM A320F

Repair of the Tubes Assembly of the Potable Water and the associated Air Supply System to be carried out in the Workshop

TASK 20-23-38-300-001-A
Repair of the Tubes Assembly of the Potable Water and the associated Air Supply System to be carried out in the Workshop

WARNING: BE CAREFUL WHEN YOU USE CONSUMABLE MATERIALS. OBEY THE MATERIAL MANUFACTURER'S INSTRUCTIONS AND YOUR LOCAL REGULATIONS.
NOTE: The procedure is the same for both the potable water and the air supply system.
1. Reason for the Job
Self explanatory
2. Job Set-up Information
 A. Fixtures, Tools, Test and Support Equipment
REFERENCE
QTY
DESIGNATION
No specific
AR
BRUSH - BRISTLED
No specific
AR
CLOTH-EMERY (GRADE 240)
No specific
AR
CUTTER - TUBING
No specific
AR
MARKING TOOL (DLT5302-031-01 TYPE)
No specific
AR
STEM ASSEMBLY
No specific
AR
SWAGING TOOL - ELASTOMERIC SWAGING TOOLS
No specific
AR
TOOL - DEBURRING
No specific
Torque wrench: range to between 3.15 and 2.85 m.daN (23.23 and 21.02 lbf.ft ) T
 B. Consumable Materials
REFERENCE
DESIGNATION
(Material No.03BDB9)
Mineral base Lubricating Oil-General & Water-displacing Preservative Low Temp. -
(Material No.03FAB1)
Mineral Oil base Grease-- Vaseline or Petrolatum -
(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.14SBA1)
Textile-Lint free Cotton -
 C. Referenced Information
REFERENCE
DESIGNATION
TASK 20-23-38-000-001-A
Removal of the Tube of the Potable Water and the associated Air Supply System
TASK 20-23-38-400-003-A
Installation of the Tube Assembly of the Potable Water and the associated Air Supply System
F Connection of a (two) Tube(s) with Fittings
F Repair of a Tube with Fittings
F Chipless Cutter
F Length of the Straight Tube Required for Swaging
F Deburring Tool Operation
F Table and Operation of Deburring Tool
F Squaring, Deburring and Champfering of the Tube End
F Internal Swage Tool
F Components of Internal Swage Tools for Corrosion-Resistant Steel Tubes
F Tool Assembly for Sleeve and Union
F Tube Marking Tool
F Tube Marking Operation
F Swage Principle
F Swage Pressure with Hand Swager Models 5175 and 5720 for 855010 and 855034.
F Dimension Acceptance Criteria for NSA 855012 Sleeves
F Dimension Acceptance Criteria for NSA 855034 Sleeves
F Table of Dimensions Acceptane Criteria for NSA 855034P Unions
F Table of Torque Values for Pressure Test
3. Job Set-up
Subtask 20-23-38-010-050-A
A. Remove the Tube Assembly or Tube Section for Repair (Ref. AMM TASK 20-23-38-000-001)
Subtask 20-23-38-941-053-A
B. General
   (1) Only personnel familiar with the stainless steel tube repair should do the following procedure.
   (2) Use this approved procedure to repair tubes made of 21-6-9 corrosion-resistant steel.
NOTE: This repair procedure uses a tube-expansion swaging method with an elastomeric expander.
   (3) The use of sleeve and union lets you make a connection that you can disassemble between two tubes or between a tube and a system component.
F Connection of a (two) Tube(s) with Fittings
   (4) To repair a tube with sleeve and union, you must:
F Repair of a Tube with Fittings
  • cut the tube with a chipless cutter and remove the damaged section,
  • square and deburr the ends of the tubes,
  • clean the tubes,
  • install the sleeve nut, the sleeve and the union on the tubes,
  • swage the tubes into the sleeve and the union,
  • connect the ends of the tubes with the sleeve, the nut and the union.
   (5) You must use the applicable SWAGING TOOL - ELASTOMERIC SWAGING TOOLS to swage the tube.
4. Procedure
Subtask 20-23-38-320-053-A
A. Procedure
WARNING: MAKE SURE THAT THE EQUIPMENT YOU USE FOR THIS PROCEDURE IS CLEAN AND APPROVED FOR THE POTABLE WATER SYSTEM. IF NOT IT CAN CAUSE CONTAMINATION OF THE POTABLE WATER SYSTEM.
   (1) Cut the Tube
     (a) Remove the damaged parts of the tube and the defective ends with the applicable PERMASWAGE chipless cutting-tool:
F Chipless Cutter
D12531-001, tubes of 1/2", 3/4" and 3/8".
     (b) Put the CUTTER - TUBING into the correct position on the tube.
       1 observe the dimension A between the two tubes
F Repair of a Tube with Fittings
       2 make sure that the length of the straight section of the tube is the minimum necessary for the swaging operation.
F Length of the Straight Tube Required for Swaging
NOTE: If the damaged section is too large or too near the bend, you can replace the damaged section with a new tube. In this case, you must use two HARRISON fittings.
     (c) Tighten the drive screw until the cutter wheel lightly touches the tube. Then give the drive screw a 1/8 to 1/4 turn.
     (d) Turn the ratchet handle through the arc of clearance until it turns loosely.
     (e) Do the steps (b) thru (d) again to cut through the tube.
     (f) Cut the tube slowly and smoothly to make sure that the end of the tube does not change its shape.
NOTE: Lubricate regularly the ratchet, the rollers and the cutter wheel with Mineral base Lubricating Oil-General & Water-displacing Preservative Low Temp. - (Material No.03BDB9) for easy operation.
     (g) Carefully square, deburr and chamfer the ends of the tubes internally and externally. Use a TOOL - DEBURRING.
F Deburring Tool Operation
F Table and Operation of Deburring Tool
F Squaring, Deburring and Champfering of the Tube End
   (2) Clean the tube
WARNING: WHEN YOU USE COMPRESSED AIR:
  • USE THE CORRECT PROTECTION (FACE SHIELD OR GOGGLES)
  • DO NOT POINT THE AIRFLOW AT YOURSELF OR OTHER PERSONS.
LOOSE PARTICLES AND/OR HIGH PRESSURE AIR CAN CAUSE INJURY.
WARNING: WHEN YOU USE COMPRESSED AIR:
  • USE THE CORRECT PROTECTION (FACE SHIELD OR GOGGLES)
  • DO NOT POINT THE AIRFLOW AT YOURSELF OR OTHER PERSONS.
LOOSE PARTICLES AND/OR HIGH PRESSURE AIR CAN CAUSE INJURY.
     (a) Carefully clean the tube with Non Aqueous Cleaner-General - - (Material No.08BAA9) .
     (b) Blow air through the tube to remove all swarf and other foreign material.
Subtask 20-23-38-941-054-A
B. Preparation of the Swage Tools
NOTE: You can use the manual or the automatic power equipment when you swage.
Make sure that each pressure gage used in this procedure is calibrated. If necessary, use a master gage to calibrate the pressure gage.
Mark the date of calibration on the gage.
NOTE: Replace the tool components as soon as they show signs of wear.
   (1) Determine the components of the internal tools to swage the tubes on the sleeve and the union:
  • use the applicable drawbar, expander, split back-up washers, tapered back-up ring and thrust bush.
    F Internal Swage Tool
NOTE: For corrosion-resistant steel tube which are dia. 1/2" ,3/8" and 3/4", two types of tools are available.
F Components of Internal Swage Tools for Corrosion-Resistant Steel Tubes
   (2) Install the internal tool components on the draw bar and obey these precautions:
F Internal Swage Tool
     (a) Solid-type back-up washers
You must use the solid-type back-up washers so that they agree with the I.D. of the tube.
Use a 57.2.19 gage to do this.
Do not use the washers with an O.D. immediately smaller than the I.D. of the tube. If you do, it will be difficult to remove the tube after the swaging operation.
You must keep a clearance of 0.10 mm (0.0039 in.) to 0.15 mm (0.0059 in.) between the washers and the tube.
The inner chamfers must point away from the 57.2.15 expander.
     (b) Split-type back-up washers 57.2.32.
You must replace these washers when:
  • the increase in diameter during each swaging operation becomes permanent
  • it is difficult to install or remove the washers from the tube.
     (c) Expander
You must replace the expander as soon as it is difficult to install or remove the tube.
     (d) Tapered back-up ring
The cone of the tapered back-up ring 57.2.33 must always point to the expander 57.2.31.
     (e) Thrust bush 57.2.17
The shoulder of the thrust bush 57.2.17 must point to the drawbar to go into the end of the tube.
   (3) Determine the external tool components below, applicable to hold the tube and fitting during the swaging:
F Tool Assembly for Sleeve and Union
  • two jaws and one die (the jaws and the die must match the OD of the tube and the fitting (sleeve or union),
  • one die bolster,
  • one attach nut,
  • one 57.2.10 adapter (to attach the drawbar to the swage machine).
NOTE: Make sure that you can adapt the tool components on the swage machine (manual or automatic).
   (4) Connect the hose between the pump and the swager of the swage machine.
NOTE: You can put the swager in the horizontal or vertical position as necessary.
   (5) Install the drawbar assembly on the die and on the adapter. Tighten the drawbar on the adapter.
   (6) Install the drawbar assembly and the die on the swager. Tighten the drawbar with your hand.
   (7) Install the attach nut of the die.
   (8) Apply a layer of Mineral Oil base Grease-- Vaseline or Petrolatum - (Material No.03FAB1) on the expander.
Subtask 20-23-38-350-050-A
C. Deburr the tube.
   (1) The internal diameter
     (a) Use the TOOL - DEBURRING and the STEM ASSEMBLY that are correct for:
     (b) Make sure that the deburring tool is clean. Lubricate it with Mineral Oil base Grease-- Vaseline or Petrolatum - (Material No.03FAB1) .
     (c) Prepare to deburr the tube:
  • hold the tube,
  • push in the plunger of the tool,
  • put the stem into the end of the tube
  • release the plunger to let the stem become expanded to seal the tube.
    F Table and Operation of Deburring Tool
     (d) Deburr the tube:
  • continue to hold the tube
  • Apply light pressure on the cutter and at the same time turn the knurled body clockwise
  • continue to turn until the tube is deburred.
     (e) Do not push the plunger in, but:
  • carefully and slowly pull the deburring tool from the tube until you can see the first ridge of the stem
  • clean the end of the tube and the stem.
     (f) If the end of the tube is not correctly deburred:
  • push the tool into the tube,
  • repeat the step (d),
  • pull the tool out of the tube.
   (2) The external diameter
     (a) Remove the burrs on the external diameter of the tube with CLOTH-EMERY (GRADE 240).
NOTE: Burrs on the external diameter of the tube can cause damage to the seals in the fittings. This damage can cause external leakage.
The surfaces must be clean and without damage:
  • the swaging area must have no deep scratches and must be clean (no dust, particles of metal etc.).
  • before you swage, clean the end of the tube with a Textile-Lint free Cotton - (Material No.14SBA1) .
   (3) Clean the Tube
WARNING: WHEN YOU USE COMPRESSED AIR:
  • USE THE CORRECT PROTECTION (FACE SHIELD OR GOGGLES)
  • DO NOT POINT THE AIRFLOW AT YOURSELF OR OTHER PERSONS.
LOOSE PARTICLES AND/OR HIGH PRESSURE AIR CAN CAUSE INJURY.
WARNING: WHEN YOU USE COMPRESSED AIR:
  • USE THE CORRECT PROTECTION (FACE SHIELD OR GOGGLES)
  • DO NOT POINT THE AIRFLOW AT YOURSELF OR OTHER PERSONS.
LOOSE PARTICLES AND/OR HIGH PRESSURE AIR CAN CAUSE INJURY.
     (a) (t) Carefully clean the tube with Non Aqueous Cleaner-General - - (Material No.08BAA9) .
     (b) Blow the air through the tube and remove all swarf and other foreign material.
Subtask 20-23-38-930-051-A
D. 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 MARKING TOOL (DLT5302-031-01 TYPE).
   (1) Use a marking tool with the correct dimensions for the tube that you must swage:
tubes of 1/2", 3/4" and 3/8".
   (2) Put the marking tool into 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.
F Tube Marking Tool
NOTE: 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.
F Tube Marking Operation
Subtask 20-23-38-420-051-A
E. Installation of the Sleeve and the Union on the Tube
F Swage Principle
NOTE: Do not cause damage to the seals of the fittings:
  • the tubes must not have external burrs,
  • the tubes must go freely into the fittings.
If a tube does not go freely into a fitting (not circular, out of tolerance), do not install the fitting.
The surfaces must be clean and without damage:
  • the swaging area must have no deep scratches and must be clean (no dust, particles of metal, etc.).
    Before you swage, clean the end of the tube with a Textile-Lint free Cotton - (Material No.14SBA1) .
   (1) Apply a layer of Mineral Oil base Grease-- Vaseline or Petrolatum - (Material No.03FAB1) into the tube end to swage.
NOTE: Put the sleeve nut in position on the tube before you install the sleeve.
   (2) Bond the sleeve or the union on the tube.
     (a) Clean the external surface of the tube end with Non Aqueous Cleaner-General - - (Material No.08BAA9) .
     (b) Application of activator
       1 Mask the tube ends to prevent contamination.
       2 Apply Adhesive Activator-- Anaerobic - (Material No.05XAB1) with a BRUSH - BRISTLED in the area where you swage.
NOTE: If the product is supplied in an aerosol can, spray it on.
       3 Apply Adhesive Activator-- Anaerobic - (Material No.05XAB1) to the internal side of the union that you must swage.
       4 Remove the unwanted material.
       5 Stop for 10 minutes.
     (c) Apply Retaining adhesive-Cylindrical fitting High strength High viscosity - (Material No.05ABM1) to the end of the tube that you must swage and make sure it does not go into the tube.
NOTE: Apply sufficient material to the surfaces that you must seal.
     (d) Use force to install the union on the tube and turn the tube.
     (e) Equally apply Retaining adhesive-Cylindrical fitting High strength High viscosity - (Material No.05ABM1) .
     (f) Remove the unwanted material when the union is fully installed on the tube.
NOTE: Swage the tube before the bonding and adhesive compounds are dry.
Subtask 20-23-38-320-054-A
F. Swage the Tube
   (1) Put the tube assembly with the sleeve (or the union) on the drawbar and the die.
Fully push the tube and the sleeve (or the union) into the swage tool.
F Tool Assembly for Sleeve and Union
   (2) Install the two jaws on the die and the tube assembly.
   (3) Lock the attach nut.
   (4) Tighten the two nuts and make sure that the threads do not cross. TORQUE the nuts to to between 3.15 and 2.85 m.daN (23.23 and 21.02 lbf.ft ) T.
   (5) Tighten the valve installed on the right side of the gage.
   (6) Slowly operate the pump until you obtain the specified pressure:
F Swage Pressure with Hand Swager Models 5175 and 5720 for 855010 and 855034.
   (7) Loosen the valve installed on the right side of the gage.
   (8) Remove the tube from the swage tool.
NOTE: Wait for 24 hours before you do the pressure test or degrease the tube.
   (9) Clean the tube.
     (a) Carefully clean the tube with Non Aqueous Cleaner-General - - (Material No.08BAA9) .
Subtask 20-23-38-220-051-A
G. Do the Check of the Swage
   (1) Make sure that the swage obeys the dimension acceptance criteria.
F Dimension Acceptance Criteria for NSA 855012 Sleeves
F Dimension Acceptance Criteria for NSA 855034 Sleeves
F Table of Dimensions Acceptane Criteria for NSA 855034P Unions
     (a) You must reject the swage if:
  • the diameters D1, D2 or D3 are higher than the maximum tolerance
  • the wave deformations A2 are higher than the maximum tolerance
  • the dimension B is lower than the minimum tolerance.
     (b) You can re-swage the tube if:
  • the wave deformations A or the diameters D1, D2 or D3 are lower than the minimum tolerance.
NOTE: To re-swage, you can increase the maximum swaging pressure to plus 10 %.
     (c) You can remove material from the end of the tube if:
  • the tube is too long and you cannot install it.
NOTE: Do not decrease the dimension B more than 0.5 +0 +0.5 mm (0.02 +0.00 +0.02 in.).
   (2) If there are marks on the tube, measure the depth of these marks.
NOTE: You can possibly see two types of marks on the tube after the swaging:
  • circular marks behind the sleeve thimble-end
  • contact marks along the jaw of the die.
     (a) Make sure that the circular marks are not more than 0.05 mm (0.0020 in.).
     (b) Make sure that the contact marks are not more than 10 % of the thickness of the wall.
Subtask 20-23-38-780-050-A
H. Do the Pressure Test of the Tube
   (1) Connect the HARRISON sleeve and union of the tube and TORQUE it to the normal value.
F Table of Torque Values for Pressure Test
   (2) Pressurize the tube to an operational pressure.
   (3) If there is leakage, slowly and continuously increase the torque value to the maximum authorized (maximum test value) until you stop the leak.
   (4) Make sure that there is no leakage.
NOTE: Leakage is not permitted.
5. Close-up
Subtask 20-23-38-410-052-A
A. Install the Repaired/New Tube (Ref. AMM TASK 20-23-38-400-003)
[Rev.10 from 2021] 2026.03.31 22:59:44 UTC
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