W DOC AIRBUS | AMM A320F

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

TASK 20-23-38-300-002-A
Repair of the Tubes of the Potable Water and the associated Air Supply System to be carried out in the Aircraft

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
CLOTH-EMERY (GRADE 240)
No specific
1
CONTAINER 1 L (1/4 USGAL)
No specific
AR
CUTTER - ROLLER TYPE, CHIPLESS
No specific
AR
REPAIR KIT PERMSWAGE DLT OR D1200 - HYDRAULIC TUBES
No specific
AR
STEM SUBASSEMBLY
No specific
AR
TOOL - DEBURRING
No specific
AR
WARNING NOTICE(S)
 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.14SBA1)
Textile-Lint free Cotton -
 C. Referenced Information
REFERENCE
DESIGNATION
TASK 12-15-38-613-001-A
Fill the Potable Water Tank System (Aircraft Electrical Power Available)
TASK 12-24-38-680-001-A
Draining of the Potable Water System (with Electrical Power)
TASK 24-42-00-861-001-A
Energize the Ground Service Network from the External Power
TASK 24-42-00-862-001-A
De-energize the Ground Service Network Supplied from the External Power
TASK 30-73-53-000-001-A
Removal of the Potable-Water De-icing Heater Elements
TASK 30-73-53-400-001-A
Installation of the Potable-Water De-icing Heater Elements
TASK 38-10-00-614-001-A
Pressurization of the Potable Water System from a Ground Air Supply
TASK 38-10-00-614-002-A
Depressurization of the Potable Water System
TASK 38-10-00-670-002-A
Disinfection of Potable Water System and Discard of Water Filter Elements, if Installed
F Swage Principle
F Tube Marking Tool
F Swage Tool Installation (Series DLT)
F Table of Series DLT Repair Kits
F Table of Series D12000 Repair Kits
F Chipless Cutter
F Table and Operation of Deburring Tool
F Deburring Tool Operation
F Squaring, Deburring and Champfering of the Tube End
F Tube Marking Operation
F Swaged Fitting Installation
F Fitting Installation
F Table of Swage Tools
F Swage Tool Installation (Series D12000)
F Table and Inspection Gage
3. Job Set-up
Subtask 20-23-38-861-054-A
A. Energize the ground service network
(Ref. AMM TASK 24-42-00-861-001)
Subtask 20-23-38-010-053-A
B. Get Access
   (1) Remove/open the relevant access panels/doors to get access to the repair area.
Subtask 20-23-38-860-056-A
C. Drain the Potable Water System
   (1) Drain the Potable Water System (Ref. AMM TASK 12-24-38-680-001).
   (2) Depressurize the Potable Water System (Ref. AMM TASK 38-10-00-614-002).
Subtask 20-23-38-941-052-A
D. Safety Precautions
WARNING: MAKE SURE THAT THE POTABLE WATER SYSTEM IS DEPRESSURIZED. A PRESSURIZED SYSTEM CAN CAUSE INJURY TO PERSONS WHEN THEY DO WORK ON IT.
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) Put a WARNING NOTICE(S) in position to tell the personnel not to fill or pressurize the potable water system.
4. Procedure
Subtask 20-23-38-320-051-A
WARNING: MAKE SURE THAT THE POTABLE WATER SYSTEM IS DEPRESSURIZED. A PRESSURIZED SYSTEM CAN CAUSE INJURY TO PERSONS WHEN THEY DO WORK ON IT.
A. Repair of the Tube Assembly
F Swage Principle
Use this approved procedure to repair tubes made of 21.6.9 corrosion-resistant steel.
NOTE: You can use the PERMASWAGE repair procedure to repair the 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
ABS0450 ASNA3757
ASNA3758
ABS0477
ABS0464 ASNA3765
NSA855022
ABS0566
ABS0534 ASNA3767
NSA855024
ASNA3752
ABS0542 ASNA3768
NSA855027
ASNA3753
ABS0544 NSA855011
NSA855036
ASNA3756
ABS0545 NSA855020

ASNA3764
ABS0650 NSA855025

ASNA3766
ABS0658 NSA855026

ASNA3772
ABS0669 NSA855030

NSA855006 and 008
ABS0675 NSA855032
ABS0711 NSA855033
NSA855037
NSA855033
NSA855037

You can swage PERMASWAGE fittings on the aircraft.
NOTE: The separable fittings have MS33514 or MS33515 threaded end or a sleeve with a nut.
   (1) Remove the potable-water de-icing heater elements as necessary:
   (2) Put a CONTAINER 1 L (1/4 USGAL) below the potable water line to collect the unwanted water.
   (3) Cut the Tube
     (a) Remove the damaged parts of the tube and the defective ends with the applicable PERMASWAGE CUTTER - ROLLER TYPE, CHIPLESS:
To repair the tubing with the PERMASWAGE system, you must:
     (b) Remove the damaged parts of the tube and the defective ends with the applicable PERMASWAGE chipless cutting-tool:
-D12531-001, tubes 1/2", 3/4" and 3/8".
     (c) Put the tubing cutter into the correct position on the tube.
F Chipless Cutter
     (d) Tighten the drive screw until the cutter wheel lightly touches the the tube. Then give the drive screw a 1/8 to 1/4 turn.
     (e) Turn the ratchet handle through the arc of the clearance until it turns loosely.
     (f) Do step (d) and (e) again to cut through the tube.
     (g) Cut the tube slowly and smoothly to make sure that the end of the tube does not change its shape.
     (h) Lubricate regularly the ratchet, the rollers and cutter wheels with Mineral base Lubricating Oil-General & Water-displacing Preservative Low Temp. - (Material No.03BDB9) for easy operation.
Subtask 20-23-38-350-051-A
B. Deburr the Tube
F Table and Operation of Deburring Tool
F Deburring Tool Operation
F Squaring, Deburring and Champfering of the Tube End
   (1) The internal diameter
     (a) Use the TOOL - DEBURRING and the STEM SUBASSEMBLY that are correct for:
  • the diameter of the tube,
  • the thickness of the wall.
     (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 and seal to tube.
     (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: 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.
     (b) 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)
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.
   (3) Clean the Tube
Subtask 20-23-38-930-050-A
C. 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.
   (1) Use a marking tool with the correct dimensions for the tube that you must swage:
F Tube Marking Tool
DLT5302-031-01, 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.
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 20-23-38-320-052-A
D. Swage the fitting on the tube
F Swaged Fitting Installation
   (1) Install the fitting on the tube.
NOTE: Do not cause damage to the seals or the fittings:
  • the tubes must have no external burrs,
  • the tubes must go freely into the fittings.
    If a tube does not go freely into the fitting (not circular, out of tolerance), do not install the fittings.
    The surface must be clean and without a damage:
  • the swaging area must have no deep scratches and must be clean ( no dust, particles or metal etc.).
    Before you swage, clean the end of the tube with a clean cloth.
NOTE: The end of the fitting must be in the area of the mark.
F Fitting Installation
   (2) Use a swage tool assembly and power unit which are correct for the dimensions of the tube.
F Table of Swage Tools
CAUTION: MAKE SURE THAT ONLY APPROVED PERSONNEL USE THIS TOOL. THIS TOOL OPERATES AT VERY HIGH PRESSURE AND CAN BE DANGEROUS.
   (3) Swage with the Tool Series DLT
F Swage Tool Installation (Series DLT)
F Table of Series DLT Repair Kits
NOTE: If you swage with the tool series D12000 ref. to step (5) (a) thru (d).
     (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) Position the head assembly on the fitting and the water 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.
F Fitting Installation
     (i) Apply a hydraulic pressure 690 +17 -17 bar (10000 +250 -250 psi) to the power unit in order to swage the fitting.
     (j) Release the pressure.
     (k) Remove the power unit and the head assembly.
   (4) Swage with the Tool Series D12000
F Swage Tool Installation (Series D12000)
F Table of Series D12000 Repair Kits
CAUTION: MAKE SURE THAT ONLY APPROVED PERSONNEL USE THIS TOOL. THIS TOOL OPERATES AT VERY HIGH PRESSURE AND CAN BE DANGEROUS.
     (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.
     (c) Install the power unit:
  • 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
    F 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).
NOTE: 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 20-23-38-220-050-A
E. Do a 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.
F Table and Inspection Gage
F 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 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 20-23-38-790-053-A
F. Do the Leak Check of the Repaired Tube.
   (1) Do the leak test of the potable water lines.
     (a) Remove the WARNING NOTICE(S).
     (b) Fill the potable water system with water (Ref. AMM TASK 12-15-38-613-001).
     (c) Pressurize the potable water system (Ref. AMM TASK 38-10-00-614-001).
     (d) Examine the repaired tubing for leaks.
   (2) If there is leakage, slowly and continuously increase the torque value to the maximum authorized (maximum test value) until you stop the leak.
NOTE: Leaks are not permitted.
     (a) Remove the container.
     (b) Install the potable-water de-icing heater elements as necessary:
   (3) Do the leak check of the air supply lines.
     (a) Examine the repaired air tubing for leaks (Ref. AMM TASK 38-10-00-614-001).
     (b) If there is leakage, slowly and continuously increase the torque value to the maximum authorized (maximum test value) until you stop the leak.
NOTE: Leaks are not permitted.
Subtask 20-23-38-410-061-A
G. Close Access
   (1) Make sure that the work area is clean and clear of tools and other items.
   (2) Install/close the removed/opened access panels/doors.
5. Close-up
Subtask 20-23-38-670-052-A
A. Do the Sterilization of the Potable Water Tank and Distribution System (Ref. AMM TASK 38-10-00-670-002) .
Subtask 20-23-38-410-053-A
B. Close Access
   (1) Install/close the removed/opened access panels/doors.
Subtask 20-23-38-862-052-A
C. De-energize the ground service network
(Ref. AMM TASK 24-42-00-862-001)
[Rev.10 from 2021] 2026.04.01 04:49:38 UTC
"Aviabrain" 2025